ABB TPS44-F33 Operation Manual Download

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Operation Manual

ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden

Type

TPS44-F33

HT842296

Mmax

1203

Mmax

750

Bmax

1142

Bmax

710

1/s

°C

00120

Year

2016

made in Switzerland

Application according to

the Operation Manual

HZTL2412 English

TPS44-F33

Original Operation Manual

Summary of Contents for TPS44-F33

Page 1: ...ystems Ltd CH 5401 Baden Type TPS44 F33 HT842296 nMmax 1203 t Mmax 750 nBmax 1142 t Bmax 710 1 s C 00120 10 25 25 Year 2016 made in Switzerland Application according to the Operation Manual kg HZTL241...

Page 2: ...eplacement 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...

Page 3: ...ng plate 1 8 Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe ope...

Page 4: ...ransport 7 2 Turbocharger weights 7 3 Remove the turbocharger 7 4 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Disassembling and assembling turbocharg...

Page 5: ...Turbo Systems and to use it as intended It provides important information in order that the turbocharger can be op erated safely correctly and efficiently This Operation Manual complements and expands...

Page 6: ...412_EN Revision F Layout and function 1 2 1 Suction branch filter silencer 8 Gas outlet flange 2 Compressor casing 9 Nozzle ring 3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine end bearing fl...

Page 7: ...ders The exhaust gases escape into the ambient air through the exhaust gas pipe which is connected to the gas outlet flange 8 The air which is necessary for operation of the diesel or gas engine and i...

Page 8: ...ufacturer accepts no liability for other applications If it is used otherwise ABB Turbo Sys tems reserves the right to reject all warranty claims This turbocharger was built according to state of the...

Page 9: ...handling VCIs VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs Ensure good room ventilation D...

Page 10: ...Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Turbo charging Service Station and...

Page 11: ...also applies to the provision and wearing of personnel protection equipment NOTICE The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly wit...

Page 12: ...original parts Operation of the turbocharger with non original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel Only use original parts...

Page 13: ...are not rele vant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant see Contact information at www ab...

Page 14: ...he product 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 complied with Definition of...

Page 15: ...e agreed with the enginebuilder 02 Turbocharger operating limits during operation 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement inte...

Page 16: ...bly shorten the recommended replacement intervals In such cases we recommend that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at...

Page 17: ...served September 2016 HZTL2412_EN Revision F Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code...

Page 18: ......

Page 19: ...ger itself and its accessories originate from the operating and auxiliary materials used are the consequence of insufficient observance of the safety instruc tions are the consequence of unsatisfactor...

Page 20: ...2 2 Page 18 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F CE conformity 2 2 Information ABB turbochargers fulfil Directive 2006 42 EC on machinery and are con sidered pa...

Page 21: ...f mandatory signs 2 3 To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling To be worn according to the specific work Safety glasses Safe...

Page 22: ...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 no...

Page 23: ...ng plates are not present at the intended places or are not legible then proceed as follows Order new warning plates from ABB Turbocharging Service Stations Remove unreadable warning plates Clean and...

Page 24: ...Do not work on the turbocharger if you are under physical or mental stress Work only with suitable tools as well as equipment and working mate rials that are in perfect condition Electric tools must b...

Page 25: ...e separate burst pro tection 57200 must be fitted before operation See View of tur bocharger showing part numbers 126 Before starting work carry out visual inspection of working area Remove any obstac...

Page 26: ...harger the engine must be switched off and the turbocharger must have come to a standstill Ensure that the supply of oil is interrupted especially with an external oil supply Put the engine into opera...

Page 27: ...Operate the turbocharger in accordance with instructions During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance...

Page 28: ...evel is above 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 op erating material...

Page 29: ...ainst hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances us...

Page 30: ...atmosphere or contamination of the ground and water due to improper disposal can lead to environmental damage Handle operating and auxiliary materials carefully Heed the instructions for use safety d...

Page 31: ...only in the work area Take particular care when removing old insulating materials Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local...

Page 32: ...rved September 2016 HZTL2412_EN Revision F Hazards due to electrical components WARNING Hazards due to electrical components Electrical components operate with voltages which can present hazards to hu...

Page 33: ...rbo Systems recommends verifying the following points on the turbocharger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket...

Page 34: ...so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is responsible for the safe operation of the pressure ves...

Page 35: ...d beneath a suspended 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 ex...

Page 36: ......

Page 37: ...ion CAUTION Depending on the turbine specifications and bearings used varying amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts The st...

Page 38: ...ssible oil inlet vis cosities and oil inlet temperatures are shown in the following chart 1 Kinematic viscosity mm2 s cSt 2 Oil inlet temperature C A Permissible range CAUTION Falling below the minimu...

Page 39: ...sure trouble free operation Status for operation Oil pressure in front of turbocharger bar Normal operation 2 0 4 5 Engine start cold oil permissible for maximum 15 minutes 8 0 Engine idling 0 2 Pre a...

Page 40: ...tlet The oil temperature at the outlet depends mainly on lubricating oil temperature and pressure at the oil inlet engine load and turbocharger speed exhaust gas temperature The maximum permissible oi...

Page 41: ...matter in the oil can cause serious damage to the machine or property During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil W...

Page 42: ...mperature in front of and behind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the acceptance test report while taking diffe...

Page 43: ...duct before gas inlet and after gas outlet Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move Inspect air supply...

Page 44: ......

Page 45: ...the turbocharger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on...

Page 46: ...44 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at l...

Page 47: ...vals CAUTION Shortened service intervals Despite observance of the service intervals unusual loads such as several start stops a day harsh environmental factors poor fuel quality or heavy installation...

Page 48: ...h instructions on rating plate In general after 8000 12000 hours of operation Rotor and bearing parts must be inspected and assessed by an ABB Turbo charging Service Station The following work can be...

Page 49: ...following operating data and measured values must be entered regu larly in the engine manufacturer s engine logbook Engine performance and speed Air intake temperature Exhaust gas temperature in fron...

Page 50: ...nd the replacement interval for those non rotating components that are exposed to hot gases Decisive in this respect are various influencing parameters which can drastically shorten the replacement in...

Page 51: ...following influences Fuel quality and preparation Load profile thermal load cycles also starts stops emergency shut downs Gas inlet temperature Frequency and execution of turbine and compressor clean...

Page 52: ...monitoring of the turbo charger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out Do not tension the speed measurement cabl...

Page 53: ...ded the following steps must be carried out Reduce engine performance immediately until the highest turbo charger speed no longer exceeds 70 of nBmax If the engine cannot be stopped continue to run at...

Page 54: ...tures exceeding 100 C Wear safety gloves when removing the cable connector and speed sensor Wear safety gloves to protect against thermal hazards Reduce engine performance to the idling speed then sto...

Page 55: ...Sealing the speed sensor The speed sensor is designed with a sealing lip and does not require an additional gasket when fitted Connect cable connector to speed sensor Switch on lubricating oil supply...

Page 56: ...be dissipated by the further circulating lubricating oil Post lubricate for 15 20 minutes Maintain oil pressure of 0 5 1 0 bar for post lubrication CAUTION Stopping the engine of water cooled turbocha...

Page 57: ...aning If mechanical cleaning is carried out too often this can lead to damage and corrosion on the components If cleaning during operation is not sufficient to achieve acceptable values regarding ther...

Page 58: ...nsumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the...

Page 59: ...ot too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives Don t use salt water for cleaning but only clean fres...

Page 60: ...externally mounted water vessel is suitable only for those applications where a negative pressure exists in front of the compressor wheel not used for blowers connected in front of the compressor or h...

Page 61: ...he cleaning cycle until a stabilisation period of at least 10 minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the charging or flushing pressure and also from th...

Page 62: ...come stuck in contamination deposits Experience with turbocharger operation shows that the intervals between overhauls can be extended if cleaning while in operation is carried out pe riodically Wet c...

Page 63: ...g method NOTICE Approval by engine manufacturer The prerequisite for wet cleaning is that the engine manufacturer ap proves the method and his instructions are followed Wet cleaning methods Process wi...

Page 64: ...n cleaning the temperature in front of the turbine will rise and can heavily stress the material of turbine components The temperature at the turbine inlet can be up to 100 C higher than the exhaust g...

Page 65: ...d and is approved by ABB Turbo Systems Characteristic component Conditions short water injection time long water injection time Engine load guide value 20 40 Turbine inlet temperature TTE before water...

Page 66: ...ng phase before increasing engine load again This completes the turbine cleaning process Cleaning parameters during the process TPS Temperature in front of the turbine during cleaning C Water volume f...

Page 67: ...bine cleaning process Cleaning parameters during the process TPS Temperature in front of the turbine during cleaning C Water volume flow 1 dm3 min Injection time min Stabilising phase before after wat...

Page 68: ...he specification nozzle rings and turbine casings have protective coatings which can also be damaged Only use soft tools such as cloths brushes or wire brushes In the event of heavy contamination the...

Page 69: ...itled Disassembly and Assembly Cleaning the filter ring if provided Remove filter ring 81265 Clean filter ring 81265 as required or every 500 operating hours and replace after the fifth cleaning opera...

Page 70: ...rption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Se...

Page 71: ...nal protective equipment PPE according to the material safety data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mas...

Page 72: ...ent PPE according to the material safety data sheet Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against...

Page 73: ...operation again immediately after cleaning parts may corrode Re install and use the cartridge group immediately after cleaning Compressor wheels or turbines may be heavily contaminated due to heavy f...

Page 74: ...ontamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter into the car...

Page 75: ...aning of the turbine are described below Product A mm B mm C mm TPS44 91 15 173 TPS48 108 17 205 TPS52 128 20 245 TPS57 157 25 300 TPS61 187 30 357 To soak the layers of dirt on the turbine the cartri...

Page 76: ...va pours can be produced which are hazardous to health Observe the information in the material safety data sheet Wear a respiratory mask according to material safety data sheet CAUTION Water and dirt...

Page 77: ...piratory tract this can be harmful to health Avoid the formation of dust Vacuum up dust with a suitable vacuum cleaner Wear a respiratory mask to protect against particles P1 or P2 mask Wear safety go...

Page 78: ...ation deposits lead to rotor un balance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank 02 with...

Page 79: ...bocharger Rotor unbalance Contact an ABB Turbocharg ing Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbocharger Minor unifo...

Page 80: ...ed or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice sta...

Page 81: ...er Turbocharger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylin ders when pulse charging C...

Page 82: ...ir it or contact the manu facturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine contami nated Exhaust counterpressure too high Clean or repair...

Page 83: ...ng Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer caus ing excessive loss of pressure Clean it Compressor turbine contamina ted Damaged compressor turbine...

Page 84: ...ne performance losses Possible causes Remedy Turbocharger Heavy fouling of the com pressor components Clean compressor Optimize oil separation Increased vibrations com pressor blade damage Correct the...

Page 85: ...ring run down Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharg ing Service Station Rubbing rotor Foreign object in turbocharger Run...

Page 86: ...cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turbocharging Service Sta tion Measured speeds too high Contaminated sen...

Page 87: ...r 2016 HZTL2412_EN Revision F Removal and installation Transport 7 1 Suspension of uninsulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas outlet casing Sus...

Page 88: ...Turbocharger weights 7 2 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest possibility This guide...

Page 89: ...e hard insulation as follows Remove screws and sheet metal B from the bearing casing insula tion Remove the remaining screws from the bearing casing insulation A Pull the bearing casing insulation up...

Page 90: ...0 12 for tightening torque Product Through hole in bearing casing mm Thread size mm Tightening torque Nm Strength class in acc with DIN ISO 898 TPS44 17 M16 230 10 9 12 9 TPS48 17 M16 230 10 9 12 9 T...

Page 91: ...2016 HZTL2412_EN Revision F If present Fit speed sensor and plug in cable connector Adapt and fit bearing casing insulation A Adapt and fit sheet metal B of bearing casing insulation Version with wate...

Page 92: ......

Page 93: ...oup can lead to serious machine damage ABB Turbo Systems recommends having further work carried out on ly by trained personnel from an ABB Turbocharging Service Station NOTICE Marking casing positions...

Page 94: ...ng else is described the screws and nuts of the assembly devices must be tightened down firmly WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal injury o...

Page 95: ...r the applications described Lifting gear Equipment for lifting and transporting loads ropes chain hoists cranes Lifting gear is not supplied by ABB Turbo Systems Swivel lifting eye to be used A swive...

Page 96: ...48 kg TPS52 kg TPS57 kg TPS61 kg 1 Filter silencer 15 19 30 40 65 2 Radial air suction branch 5 6 8 11 21 3 Axial air suction branch 3 4 4 6 9 4 Compressor casing 17 24 35 55 90 5 Wall insert 4 7 10 1...

Page 97: ...ials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down b...

Page 98: ...8 3 Page 96 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F Removing the insulation Loosen and remove the screws for the insulation plates 1 2 If provided Remove the insul...

Page 99: ...ff tool 90042 against the turbine casing To do this the two cover plates 1 2 must be removed from the hard insula tion on the turbine casing CAUTION Axial force The press off tool can generate a high...

Page 100: ...September 2016 HZTL2412_EN Revision F TPS61 wall insert removal Fasten lifting beam 90258 to wall insert Fasten swivel lifting eye a to lifting beam Remove wall insert 77000 using lifting gear Loosen...

Page 101: ...Installing compressor casing Refit wall insert 77000 and O ring 77005 in the reverse order NOTICE O rings Used O rings must always be replaced with new ones O rings are only available as a set see ch...

Page 102: ...ntact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbo charger Wear heat resistant safety gloves and protective clothing Allow t...

Page 103: ...nozzle ring 56001 using two extraction devices 90070 and withdraw bottom part of service support 90012 Remove C ring 51105 Mount the cartridge group on the service support 90012 and bolt it down firml...

Page 104: ...side This can be pushed back in with a screw driver Fit the lamellar sealing ring 56005 if present in the correct slot see detail A When doing this pay attention to correct winding of the la mellar se...

Page 105: ...e nozzle ring is held in place during operation it must be clamped between the partition wall and the turbine casing Calculate the press fit PD as shown NOTICE If the calculated value PD is less than...

Page 106: ...s reserved September 2016 HZTL2412_EN Revision F Calculate the press fit PD as shown NOTICE If the calculated value PD is outside 0 2 mm an official ABB Turbo charging Service Station must be contacte...

Page 107: ...rew 42008 Check lifting gear and fasten to bearing casing 42001 Unscrew the cartridge group and lift it out of the service support 90012 Apply high temperature grease to the centering points and screw...

Page 108: ...aring casing Fasten the cartridge group using fastening strips 51002 Verbus Ripp washers 51003 and nuts 51007 also see the chapter enti tled Table of tightening torques Fasten the bearing casing 42001...

Page 109: ...and if provided fit the insulation plates 1 2 Removing gas outlet bend and gas outlet flange Disconnect all lines in accordance with engine builder s instructions and remove insulation See also preced...

Page 110: ...C ring 52408 Fit the gas outlet flange 52400 In the case of gas outlet bends 51100 from ABB Turbo Systems always replace the gasket 52406 see the chapter entitled Spare parts Apply high temperature gr...

Page 111: ...arp edges on the compressor wheel The compressor wheel has sharp edges which can cause injuries Wear safety gloves Wear safety gloves to protect against mechanical hazards TPS44 TPS48 TPS52 TPS57 TPS6...

Page 112: ...clockwise rotations and then compared With standard radial bearings the run out time for anticlockwise and clockwise rotating rotors is the same If one run out time is at least 1 5 times longer than...

Page 113: ...flange The minimum and maximum values result from the manufacturing toler ances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange N1 and N2 as well as R1 and R2 are ea...

Page 114: ...earance N and R Product N mm R mm TPS44 0 15 0 49 0 36 0 67 TPS48 0 22 0 58 0 47 0 77 TPS52 0 30 0 67 0 59 0 92 TPS57 0 40 0 86 0 75 1 11 TPS61 0 50 0 94 0 90 1 32 CAUTION Clearances out of tolerance...

Page 115: ...ZTL2412_EN Revision F Table of tightening torques 8 6 The following tightening torques must be observed for the specified screw connections Position Part number TPS44 TPS48 TPS52 TPS57 TPS61 1 72020 6...

Page 116: ......

Page 117: ...9 1 If the turbocharger is damaged and the engine can be shut down for only a short time for emergency repairs proceed as follows Fit the cover plate CAUTION Always heed precisely the engine builder...

Page 118: ...the cover plate Close the opening in the turbine casing using the cover plate A Fasten the cover plate on the turbine casing 51000 using the fas tening strips 51002 Verbus Ripp Verbusripp washers 510...

Page 119: ...ording to the following drawing Material Common structural steel according to DIN EN 10025 2 Product B1 0 5 B2 B3 B4 0 2 B5 B6 TPS44 62 6 54 110 11 0 1 144 TPS48 65 7 60 130 11 7 1 5 150 TPS52 79 6 78...

Page 120: ...1 Page 118 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F Diameter for turbine casing designs for optional C ring sealing NOTICE Information about the turbine casing des...

Page 121: ...t of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected ag...

Page 122: ...are necessary after taking an engine out of operation Dismantle the turbocharger The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwar...

Page 123: ...in indi vidual parts See the section Taking out of operation for up to 12 months under Moth balling measures for the measures always necessary when mothballing turbocharger parts If the turbocharger...

Page 124: ......

Page 125: ...made of leather Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional...

Page 126: ......

Page 127: ...his document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing sign...

Page 128: ...TPS44 F TPS61 F Spare parts 12 View of turbocharger showing part numbers 12 2 Page 126 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F View of turbocharger showing part n...

Page 129: ...Metal C ring 56001 Nozzle ring 57200 Burst protection 57210 Burst ring 72000 Compressor casing 72011 Socket screw 72012 Fastening strips 72020 V clamp 72041 in customer spare part set Counter sunk sc...

Page 130: ...44 F TPS61 F Spare parts 12 View of cartridge group showing part numbers 12 3 Page 128 Copyright 2016 ABB All rights reserved September 2016 HZTL2412_EN Revision F View of cartridge group showing part...

Page 131: ...002 Piston ring 25000 Compressor wheel 32101 Plain bearing bush 32103 Locking ring 32105 Thrust ring 32106 Thrust bearing 32108 Piston ring 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bear...

Page 132: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB...

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