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Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

7 Removal and installation / 7.1 Turbocharger weights

© Copyright 2018 . All rights reserved.

HZTL2498_EN

Revision C

April 2018

7 Removal and installation

7.1 Turbocharger weights

Lifting gear with a sufficient load limit must be used for removing and
installing the turbocharger. The following weight specification is the
heaviest variant possible. This standard value may deviate from the data
on the rating plate depending on the specification.

Weights [kg]

TPL65-A32/-A33/ -A36

TPL69-A32 / -A33

1230

1780

7.2 Removing the turbocharger

u

Disconnect all gas, air and oil lines in accordance with engine manu-
facturer’s instructions.

CAUTION

Oil orifice plates

An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.

u

Check correct installation of oil orifice plates.

u

Unplug the cable connector on the speed sensor.

u

Remove the insulation at the suspension ribs.

TPL65: Version with compressor wheel cooling system

u

Remove air supply line. (See also chapter entitled Preliminary re-
marks / Layout and functionality)

u

Inspect the lifting gear.

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Содержание HT576419

Страница 1: ...Systems Ltd CH 5401 Baden Type TPL65 A33 HT576419 nMmax 499 t Mmax 600 nBmax 474 t Bmax 600 1 s C 01230 36 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2498...

Страница 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...

Страница 3: ...ition 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 ve...

Страница 4: ...5 Removing cartridge group 83 8 6 Dismantling and installing the turbine diffuser and nozzle ring 87 8 7 Installing cartridge group 90 8 8 Dismantling and fitting nozzle ring at turbine end 93 8 9 Ta...

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

Страница 6: ...ights reserved HZTL2498_EN Revision C April 2018 1 2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffu...

Страница 7: ...is air then passes through the diffuser 11 and leaves the turbocharger through the com pressor casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 a...

Страница 8: ...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 operatio...

Страница 9: ...s 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 u Ensure good room ventilation u Do not ea...

Страница 10: ...charging Service Sta tion 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 re...

Страница 11: ...vision 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...

Страница 12: ...Competence 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...

Страница 13: ...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 com plied with Definition o...

Страница 14: ...erwise 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 100...

Страница 15: ...nning at overload 110 during trials on the engine test bed These limits can also be permitted during op eration for special applications Operation above nMmax and tMmax is not per mitted Non observanc...

Страница 16: ...nsequence 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 fo...

Страница 17: ...lmet 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...

Страница 18: ...Warning 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 7...

Страница 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 soli...

Страница 20: ...any 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 swit...

Страница 21: ...ure that 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 turboch...

Страница 22: ...he turbocharger 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 v...

Страница 23: ...s 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 operating materials lubri...

Страница 24: ...turbocharger 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 o...

Страница 25: ...or contamination 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 she...

Страница 26: ...e work 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 regula...

Страница 27: ...e 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 sure the pressure v...

Страница 28: ...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 80 C u Use suitable...

Страница 29: ...nditions is an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please...

Страница 30: ...n the turbocharger are listed below Status for operation Oil pressure at measuring point M poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily ad...

Страница 31: ...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 Exhau...

Страница 32: ...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 runni...

Страница 33: ...e u Measure speed oil pressure and charging pressure at various engine performance levels u Measure exhaust gas temperature in front of and behind turbine u Measure air temperature in front of and beh...

Страница 34: ...haust 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 Cle...

Страница 35: ...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...

Страница 36: ...ions Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 1...

Страница 37: ...ION Shortened 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 vibrati...

Страница 38: ...manufacturer s engine logbook Engine performance and speed Air intake temperature Exhaust gas temperature in front of and behind the turbine Pressure of charge air Pressure drop in charge air cooler...

Страница 39: ...nd blow air through oil ports u Clean nozzle ring and check for cracks and erosion u Inspect and assess bearing parts and rotor 4 2 5 Service work every 24000 36000 hours The replacement of bearing pa...

Страница 40: ...eplacement intervals for non rotating components and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections...

Страница 41: ...ent GAS MDO HFO Gas inlet casing 50000 100000 25000 50000 Gas outlet casing 50000 100000 35000 100000 Nozzle ring 35000 50000 25000 50000 Turbine diffuser cover ring 35000 50000 25000 50000 Other casi...

Страница 42: ...o 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 8...

Страница 43: ...res 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 turbochar...

Страница 44: ...then 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 senso...

Страница 45: ...All rights reserved HZTL2498_EN Revision C April 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...

Страница 46: ...isual checks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be e...

Страница 47: ...Revision C April 2018 5 2 Cleaning the filter silencer 5 2 1 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering...

Страница 48: ...n in air is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove conn...

Страница 49: ...through the lugs of cover grids 81266 CAUTION If connecting rods 81269 are not correctly positioned in their recesses on filter silencer body 81135 cover grid 81266 can twist and shift There is then...

Страница 50: ...he flow channels if salt oil mist exhaust gas or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption...

Страница 51: ...heel through an injection pipe fitted in the fil ter silencer or the suction branch The water does not act as a solvent but the contamination deposit is re moved by the mechanical impact of the drople...

Страница 52: ...be present in the vicinity of the tur bocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning procedure for compressor with XC2 u Trigg...

Страница 53: ...hich has been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled Engine load 50 85 u Start of cleaning cycle in accordance with following description for wet...

Страница 54: ...at least 5 minutes to allow turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning result is still not satisfactory after three at...

Страница 55: ...auses a drop in turbine efficiency and the engine tem peratures downstream of the cylinder can increase The engine perform ance must therefore be reduced if necessary The contamination of the turbine...

Страница 56: ...ine has been started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see section PrerequisitesTPL A C Operating state...

Страница 57: ...ollowing operating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process u The engine has just been started or the engine load has been reduced as far as...

Страница 58: ...mode to water sup ply u Set the required volume of water on the flowmeter as shown in the table see table Cleaning parameters u Shut off the water supply again by switching the 3 way valve 04 to scav...

Страница 59: ...l cases must be determined together with an ABB Turbocharging Service Station The influence of the cleaning water on peripheral equipment such as a boiler must be clarified by the operator Points to r...

Страница 60: ...s are sensitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have pro tective coatings which can als...

Страница 61: ...fety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked on layers of contamination for example from heavy fuel oil or coked oil occur...

Страница 62: ...h contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contami...

Страница 63: ...d The cartridge group must be rotated to do this u Two cranes or chain blocks must be used for the rotating operation Suspending the chain block directly from the crane and rotating the cart ridge gro...

Страница 64: ...served HZTL2498_EN Revision C April 2018 4 When the cartridge group is horizontal secure one chain block to one of the upper push off threads using a swivel lifting eye and suspend from the second cra...

Страница 65: ...ifting gear must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using t...

Страница 66: ...in block until entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use o...

Страница 67: ...r ger function may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal supports u Allow the layers of contamination on the turbine to soak f...

Страница 68: ...o rotor unbalance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank with clean water not salt...

Страница 69: ...har ger 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 unifor...

Страница 70: ...eriodic 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...

Страница 71: ...bochar 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...

Страница 72: ...ir starvation 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 cro...

Страница 73: ...ace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine Conta...

Страница 74: ...run down Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run dow...

Страница 75: ...se 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...

Страница 76: ...all gas air and oil lines in accordance with engine manu facturer s instructions CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet chan...

Страница 77: ...ril 2018 u Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose w Ribs 01 not in the middle at the top u Completely remove the bearing casing insulation...

Страница 78: ...casing ribs provided for this purpose CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridg...

Страница 79: ...described in this chapter u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This li...

Страница 80: ...rbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has suffi cient load capacity u Make sure the load is suspended properly on the crane...

Страница 81: ...PL69 A32 A33 01 Radial air suction branch 50 70 02 Axial air suction branch 35 03 Filter silencer 130 220 04 Compressor casing 180 260 05 Wall insert 40 65 06 Diffuser 19 35 07 Cartridge group 290 360...

Страница 82: ...sconnect all air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u Pass a lifting gear around the air suction branch It is permissible to pass th...

Страница 83: ...Revision C April 2018 Removing the filter silen cer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer u Pass lifting gear through lugs on back u Unscrew nuts 7202...

Страница 84: ...loves Wear safety gloves to protect against mechanical hazards w The axial clearance A must be measured before removing and after fitting the cartridge group u Measure and note the axial clearance A C...

Страница 85: ...the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that t...

Страница 86: ...all insert and diffuser and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift u Allow the compressor casing to rest only on surfac...

Страница 87: ...p washers 61058 TPL69 A32 33 u Unscrew and remove two nuts 61037 Undo screw 61059 and re move together with Verbus Ripp washer 61058 u Fasten separate lifting gear to each of the two ribs on the beari...

Страница 88: ...ssembly 8 5 Removing cartridge group Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 u Withdraw cartridge group and fit supports 90450 u Remove screws 42064 flange 42044 and gaske...

Страница 89: ...C April 2018 8 6 Dismantling and installing the turbine diffuser and nozzle ring CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins u Before removing the turbine d...

Страница 90: ...right 2018 All rights reserved HZTL2498_EN Revision C April 2018 u Position clamp 90921 over stud 61036 until it lies flat against inner radius of gas outlet casing u Insert extension A of torque span...

Страница 91: ...the remaining screws 61056 and Verbus Ripp washers 61057 u Press the turbine diffuser 63000 free using the press off screws 90901 and pull it out it until the clamp 90921 is up against the nut 61037 u...

Страница 92: ...e specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Fig 2 u Remove cover from oil connection u Secure separate lifting...

Страница 93: ...ck that blades do not rub against turbine diffuser u Remove the lifting gear u Screw in the speed sensor 86505 along with the O ring 86506 and plug in the cable connector 86515 u Fit the O ring 77005...

Страница 94: ...compressor casing 72000 by tightening to specified torque See chapter Table of tight ening torques u Remove lifting device 90190 u Measure and note the axial clearance A see the section on axial clear...

Страница 95: ...ne end Removing nozzle ring u Remove insulation from gas inlet casing 51001 u Loop rope around gas inlet casing and secure with lifting gear CAUTION When looping the securing line around the casing ma...

Страница 96: ...sing to one side use suitable under lays and take care not to damage the angles of the insulation u Remove optional gasket 61050 Fitting the nozzle ring If provided u Insert optional gasket 61050 into...

Страница 97: ...ion Manual TPL65 A32 A33 A36 TPL69 A32 A33 8 Disassembly and assembly 8 8 Dismantling and fitting nozzle ring at turbine end Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 Page 9...

Страница 98: ...Manual TPL65 A32 A33 A36 TPL69 A32 A33 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 8 9 Table of tightening torques P...

Страница 99: ...Tightening torques Nm Position Part number TPL65 A32 A33 A36 TPL69 A32 A33 01 82005 M16x1 5 45 M16x1 5 45 04 72027 with washer M14 95 M16 125 05 72029 M14 30 M16 30 06 61044 61059 61071 TPL69 A32 33...

Страница 100: ...ending on the situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directive...

Страница 101: ...s is sometimes requested by customers As operation with a locked rotor is only brief and the loads are low in these cases subsequent removal of the rotor is not necessary CAUTION During operation of t...

Страница 102: ...of compressor wheel and tighten them as specified in following Table of tightening torques CAUTION Do not remove any balancing screws from compressor wheel Use only unoccupied threaded holes to fit l...

Страница 103: ...h NOTICE Carry out work as described in chapter Removing and fitting u Insert locking flange 94003 into compressor wheel u Position screws 94007 in unused threaded holes of compressor wheel and tighte...

Страница 104: ...htening torques tighten inter mediate ring assembly disassembly device 90020 and locking flange 94003 using screws 94006 u Tighten nuts 74027 complete with washers 72018 on compressor casing as specif...

Страница 105: ...m aged turbocharger must be removed and the air duct on the engine side must be closed off If this is not done the undamaged turbocharger can race under no load and run at overspeed Depending on the e...

Страница 106: ...te NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Cover plate dimensions mm Product B1 B2 B3 B4 B5 B6...

Страница 107: ...33 9 Taking out of operation at short notice 9 3 Fit cover plate Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 NOTICE Carry out the work as described in the chapter Removal and...

Страница 108: ...ce 9 3 Fit cover plate Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nut...

Страница 109: ...er s instructions 4 stroke engine with several turbochargers Separate receivers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as...

Страница 110: ...arger u Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 9 5 Bypass the turbocharger CAUTION Sh...

Страница 111: ...peration 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...

Страница 112: ...y after taking an engine out of opera tion u Dismantle the turbocharger u The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards u Cle...

Страница 113: ...in indi vidual parts 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...

Страница 114: ...ar a respiratory 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 applica...

Страница 115: ...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 u Parts showing signs of rust...

Страница 116: ...42064 61044 61056 61059 3 Hexagon nut 61037 1 Gasket 77005 1 O ring speed sensor 86506 Spare parts set 97078 for turbine cleaning system if provided CAUTION Leaks Improper assembly of the cleaning pip...

Страница 117: ...Operation Manual TPL65 A32 A33 A36 TPL69 A32 A33 12 Spare parts 12 1 Ordering spare parts Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 Page 115 118...

Страница 118: ...5 A32 A33 A36 TPL69 A32 A33 12 Spare parts 12 2 View of the turbocharger with part numbers Copyright 2018 All rights reserved HZTL2498_EN Revision C April 2018 12 2 View of the turbocharger with part...

Страница 119: ...stomer spare part set Verbus Ripp Washer 61044 in customer spare part set Hexagon head screw 61050 only TPL65 A32 A33 Spiral gasket 61056 in customer spare part set Hexagon head screw 61057 in custome...

Страница 120: ...EN Revision C April 2018 12 3 View of turbine cleaning system with part numbers optional Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52208...

Страница 121: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB...

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