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Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.1 Purpose of this manual

© Copyright 2018 . All rights reserved.

HZTL2499_EN

Revision F

December 2018

1 Preliminary remarks

1.1 Purpose of this manual

This Operation Manual belongs to the turbocharger with the identical
serial number (01), see the cover sheet of the Operation Manual and the
turbocharger rating plate.

Operation Manual

The Operation Manual explains the turbocharger and contains instruc-
tions for safe operation.

The Operation Manual is a complement to and expansion of existing na-
tional regulations for occupational safety, accident prevention and envir-
onmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics re-
sponsible for the proper operation of the engine and for the turbochar-
ger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read
and fully understood the Operation Manual.

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Summary of Contents for XAC25847

Page 1: ...al ABB Turbocharging Type TPR56 F XAC25847 nMmax 700 t Mmax 680 nBmax 686 t Bmax 650 1 s C 00360 15 40 40 Year 2022 Application according to the Operation Manual kg HZTL2499 English TPR56 F Original Operation Manual ...

Page 2: ...Replacement intervals of components depends on the load profile turbine inlet temperature suction air temperature and turbocharger speed In case the operation conditions differs significantly from what is considered to be normal for the cur rent application it is recommended to contact ABB for a re calculation of replacement intervals Frequent load alterations high temperatures and high speed lowe...

Page 3: ...2 4 Definition of Safety instructions 15 2 5 Warning plates on the turbocharger 16 2 6 Safe operation and maintenance 17 2 7 Hazards during operation and maintenance 20 2 8 Periodic checking of the pressure vessel 25 2 9 Lifting loads 26 3 Start up commissioning 27 3 1 Oil supply 27 3 2 Inspection work 30 3 3 Commissioning after taking out of operation 32 4 Operation 33 4 1 Noise emissions 33 4 2 ...

Page 4: ...Removal and installation 49 6 1 Turbocharger weights 49 6 2 Removing the turbocharger 49 6 3 Installing the turbocharger 52 7 Mothballing the turbocharger 54 7 1 Taking the engine out of operation for up to 12 months 54 7 2 Taking the engine out of operation for more than 12 months 55 8 Disposing of turbocharger components 56 ...

Page 5: ...turbocharger and contains instruc tions for safe operation The Operation Manual is a complement to and expansion of existing na tional regulations for occupational safety accident prevention and envir onmental protection Target group The Operation Manual is aimed at engineers and trained mechanics re sponsible for the proper operation of the engine and for the turbochar ger connected to it Availab...

Page 6: ...ght 2018 All rights reserved HZTL2499_EN Revision F December 2018 1 2 Layout and function 01 Suction branch filter silencer 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush 09 Bearing casing 05 Gas outlet casing 10 Compressor casing Page 4 56 ...

Page 7: ... exhaust gases then escape into the open air through the gas outlet casing 05 and the exhaust gas pipe connected to it The rotor runs in two radial plain bearings which are located between the compressor and the turbine in the bearing bush 04 The axial bear ing is also a plain bearing The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating o...

Page 8: ...serves the right to reject all warranty claims State of the art This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties In addition im proper use may cause damage to the machine u The mach...

Page 9: ...s in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves t...

Page 10: ...idge group must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Tur bocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Replace the desiccant ag...

Page 11: ...n and wearing of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u The turbocharger must be shut down immediately in the event of modifications affecting safety or of corresponding operating beha viour by stopping the engine The fault sho...

Page 12: ...tence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rel evant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy t...

Page 13: ...oduct Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be com plied with Definition of caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo Systems S...

Page 14: ...e agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in...

Page 15: ...nd tMmax normally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals increases the risk of unpredictable component failures 1 7 2 Positions of the rating plates A rating plate is attached to the turbocharger foot one on the left and one on the right On turbochargers w...

Page 16: ...ence of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel All instructions contained in this chapter must be observed for safe...

Page 17: ...Ear protection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed pre cisely u Warning s...

Page 18: ...rning plates that must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Part number Size mm Product 81080 105 x 74 TPR When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the responsibility of the engine builder Page 16 56 ...

Page 19: ...k on the turbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cables may not be damaged u Keep the workplace clean clear away loose objects and remove obstacles on the floor u Keep the floor equipment and the turbocharger clean u Have ...

Page 20: ...damage or changes in operational perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u When switching on auxiliary power sources hydraulics pneumatics electricity water keep an eye open for any hazards resulting from supplying these power sources Safety during cleaning If cleaning agents or solvents ...

Page 21: ...hat the supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger u Perform only those tasks that are described in this manual u Perform work only for which training has been carried out Safety whe...

Page 22: ...rbocharger in accordance with instructions u During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various risks can occur through the improper handling of components through the non observance of work instruc tions due to inadequate care or as a consequence of insufficient train ing WARNING Mechanical h...

Page 23: ...ve 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating oil become hot The surface temperat ure is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burns are possible WA...

Page 24: ...ocharger surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operating and auxiliary materials can be combustible and ea...

Page 25: ...ontamination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials u Wear appropriate protective clothing u Avoid inhalation and contact with the skin u Ensure that the work space is adequat...

Page 26: ...k area u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that the ...

Page 27: ...cking of the pressure vessel The pressure vessels used by ABB such as those for wet or dry cleaning are so called simple pressure vessels The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make ...

Page 28: ...uspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet In the case of two or more suspension points the slinging angle must not exceed 45 This avoids excessive loading due to inclined tensile loading u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 8...

Page 29: ... regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Pre and post lubrication The pre lubrication time must not be less than 5 minutes The post lubrication time is 10 minutes If the engine is allowed to idle for 10 minutes before it is shut down no additional post lubrication...

Page 30: ...ec tion on the turbocharger are listed below Status for operation Oil pressure bar Admissible for normal operation 1 0 2 5 Admissible during engine warm up 1 0 5 0 Temporarily admissible 1 h alarm 0 8 1 0 Not admissible emergency stop 0 0 0 8 Admissible during pre lubrication and post lub rication engine stopped 0 2 2 5 Oil orifice A metering orifice is installed in the oil inlet of the turbocharg...

Page 31: ...start preheat oil 30 Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for ...

Page 32: ...TION Contaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil u When running in the engine and after all service work on the lubricat ing system special running in filters must be used u Check oil pressure in oi...

Page 33: ...ust gas temperature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hour...

Page 34: ... air duct before gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Ins...

Page 35: ...e turbocharger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the air inlet and over the entire speed range The following prerequisites must be fulfilled on the turbocharger in or der to observe this limit value Fitted air inlet system All standard noise reducing measures have been taken2 The bellows at the air outlet have been perfectly insulated acoustic ally b...

Page 36: ...yright 2018 All rights reserved HZTL2499_EN Revision F December 2018 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover Page 34 56 ...

Page 37: ...hortened service intervals Despite observance of the service intervals unusual loads such as sev eral start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage u A shortened service interval must be arranged with ABB Turbo Sys tems NOTICE Service inspection after 5 years To prevent age and stoppage related machine damage an...

Page 38: ...bocharger speed Pressure loss in air filter 4 2 3 Servicing work according to the engine manufacturer s instructions Oil filter u Clean or replace oil filter in supply line to turbocharger when engine is not running 4 2 4 Service work every 24000 36000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station u...

Page 39: ...vals for non rotating components and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections are carried out the individual components are inspected for wear and tear and replaced if necessary In this way trouble free operation is ensured Influencing parameters The following parameters influence the replacem...

Page 40: ...Service hours h Gas inlet casing 50000 100000 Gas outlet casing 50000 100000 Nozzle ring 35000 75000 Turbine diffuser cover ring 35000 75000 Other casings 100000 Axial bearing components 24000 36000 Radial bearing components 24000 36000 Recommended replace ment intervals h Rotor components See rating plate information NOTICE The specified values are guides and not guaranteed See Influencing parame...

Page 41: ...ring system permits continuous monitoring of the tur bocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer Page 39 56 ...

Page 42: ...ontinuously engine performance must be reduced further u Measure the temperatures in the air and gas lines to and from the tur bochargers and compare them with standard values If the engine can be stopped for a short time u Inspect the air and gas lines as well as the turbocharger and eliminate any problems u In any event it is recommended that you contact the nearest ABB Tur bocharging Service St...

Page 43: ... stop the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to the stop u Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing of the speed sensor The speed sensor is designed with a sea...

Page 44: ...ts reserved HZTL2499_EN Revision F December 2018 4 5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Allow the engine to continue running at idling speed for a further 10 minutes before stopping Page 42 56 ...

Page 45: ...er Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine blades are then shortened somewhat Certain tolerances...

Page 46: ...ic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified u Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain operating co...

Page 47: ...r ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbochar ger Heavy contamination of the turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the ex haust gas...

Page 48: ...arvation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Enlarged flow cross section of the nozzle ring due to de formed blade trailing edges Contact an ABB Turbocharging Service Station Damaged or eroded turbine Charge air cooler Cooler contaminated Clean it Cooling water volum...

Page 49: ...Clean it Compressor turbine contam inated Damaged compressor tur bine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged air intake condition normal Possible causes Elimination Engine Malfunctioning injection sys tem Repair it or contact the manu fac...

Page 50: ...aling disc increases As a result the voltage amplitude of the speed signal decreases which can cause prob lems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliar...

Page 51: ...m the data on the rating plate depending on the specification Weight kg TPR56 F TPR56 F28 with support TPR61 F TPR61 F66 with support 360 430 700 800 6 2 Removing the turbocharger Oil orifice plate There is an orifice in each of the two oil inlet channels of the bearing cas ing The diameter of this orifice has been individually adapted by the en ginebuilder for the purpose of adjusting the oil pre...

Page 52: ...ear u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Loosen the fixing screws 01 at the foot u Remove the sliding blocks 02 WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the turbocharger could tip over during installation or removal and cause a serious or even fatal injury u Wear personal protective equipm...

Page 53: ...ring casing provided for this purpose Only TPR56 F28 u Unscrew and remove nut 03 Only TPR61 F66 u Undo and remove fastening 01 as per the enginebuilder s instruc tions u Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the turbocharger could tip over during installation or removal and cause a...

Page 54: ... the oil feeding oil inlet channel u Reuse the same orifice that was installed before 6 3 1 TPR56 F28 TPR61 F66 with support u Remove the cover from the oil connection Product Tightening torque of nuts 03 TPR56 F28 415 Nm TPR61 F66 Enginebuilder s specifications u Inspect the lifting gear u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Align turboch...

Page 55: ... TPR61 F 205 Nm First tighten the inner screws crosswise Then tighten the outer screws crosswise u Inspect the lifting gear u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Align turbocharger on bracket The fixing screws and nuts must be compliant with ISO strength class 8 8 u Fit sliding blocks 02 and tighten fixing screws 01 in accordance with the ...

Page 56: ...n and this is circulated by the pre lubrica tion pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health u Do not bre...

Page 57: ...onths If the engine is taken out of operation the following variants are pos sible with regard to the turbocharger The turbocharger remains mounted on the engine The turbocharger is removed completely See the section Taking out of operation for up to 12 months under Mothballing measures for the measures always necessary when moth balling turbocharger parts If the turbocharger remains mounted on th...

Page 58: ...espiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic materials filter components of felt a...

Page 59: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland ...

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