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ABB Switzerland Ltd, Turbocharging

Operation Manual

TPS48-H32

HT601539 English

Original Operation Manual

Chapter

Document-ID

Introduction

HZTL4005_EN_G

Safety

HZTL4026_EN_D

Safety data sheet

HT601539

Product description

HZTL4037_EN_E

Содержание HT601539

Страница 1: ...Turbocharging Operation Manual TPS48 H32 HT601539 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4026_EN_D 3 Safety data sheet HT601539 4 Product descr...

Страница 2: ...ls and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals an...

Страница 3: ...f contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and...

Страница 4: ...lains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention...

Страница 5: ...the work 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 C...

Страница 6: ...ctogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply oth...

Страница 7: ...the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation...

Страница 8: ...the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turboch...

Страница 9: ...reserved HZTL4005_EN Rev G March 2020 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Switzerla...

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Страница 11: ...datory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check...

Страница 12: ...f insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining...

Страница 13: ...sk to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition...

Страница 14: ...required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were...

Страница 15: ...bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo Systems...

Страница 16: ...always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new warni...

Страница 17: ...eed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 10...

Страница 18: ...ve nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The loc...

Страница 19: ...nst mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded...

Страница 20: ...ked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engi...

Страница 21: ...nning always wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts an...

Страница 22: ...s to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter s...

Страница 23: ...installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operatio...

Страница 24: ...e received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger the...

Страница 25: ...uring disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service...

Страница 26: ...previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the...

Страница 27: ...the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials D...

Страница 28: ......

Страница 29: ...on Manual TPS48 H32 Safety data sheet Page 1 1 Safety data sheet Copyright 2021 ABB All rights reserved HT601539 April 2021 TPS48 H32 HT601539 TPS48 H32 HT601539 1035 680 1014 650 12453729 180 16 60 6...

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Страница 31: ...er 10 3 Commissioning 13 3 1 Oil supply 13 3 2 Inspection procedures 14 3 3 Commissioning after taking out of operation 16 4 Monitoring operation 17 4 1 Oil pressure oil temperature 17 4 2 Exhaust gas...

Страница 32: ...ser 61 9 11 Installing the cartridge group 62 9 12 Installing nozzle ring 64 9 13 Fitting the turbine casing 65 9 14 Rotating the turbocharger 66 9 15 Radial clearances N and R 67 9 16 Installing the...

Страница 33: ...y questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of...

Страница 34: ...s reserved HZTL4037_EN Revision E July 2017 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Air suction branch filter silencer 06 Plain bearing bush 02 Com...

Страница 35: ...in air or a mixture of gas and air through the air suction branch 01 or the filter silencer In the compressor wheel 10 the energy required for build ing up the pressure is transferred to the air By fl...

Страница 36: ...o the enginebuilder without insulation must be equipped later with warning plates on the insulation This is the responsibility of the enginebuilder If warning plates are not present in the designated...

Страница 37: ...to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg TPS44 120 TPS48 180 TP...

Страница 38: ...cool down before carrying out any work Wear safety gloves to protect against thermal hazards CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out u...

Страница 39: ...urbocharger This protects the plug from being crushed 4 Install the swivel lifting eye S and attach the lifting gear to it 5 Lift the turbocharger away from the support vertically The bracket turbocha...

Страница 40: ...askets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot The oil is supplied 02 and drained 03 through t...

Страница 41: ...cknuts 01 3 Remove nuts 01 again Requirements for the threaded rods 02 Fig 8 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of t...

Страница 42: ...ater connections are removed 2 Make sure that the gaskets are not damaged and are positioned correctly in the slots 3 Install the swivel lifting eye S and attach the lifting gear to it 4 Align the tur...

Страница 43: ...election of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure see Table 6 Lubricating o...

Страница 44: ...Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all serv...

Страница 45: ...ssible values Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with t...

Страница 46: ...he locking screws on the water connections and fit the water pipe General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any f...

Страница 47: ...tur bocharger bar Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for maximal 15 minutes 8 0 Engine idling admissible for maximal 1 hour 0 5 poil 2 5 Pre lubrication and post lubricatio...

Страница 48: ...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...

Страница 49: ...plate 4 3 Turbocharger speed 4 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not strain cables If you pull the speed measurement cable...

Страница 50: ...ZTL4037_EN Revision E July 2017 4 3 2 Layout and overview Fig 10 Layout and overview of the speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I co...

Страница 51: ...t be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the tempera...

Страница 52: ...lip and an O ring No additional gasket is required during assembly Fig 11 Fitting the speed sensor Part number TPS44 TPS48 TPS52 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 9 Tightenin...

Страница 53: ...t a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfill...

Страница 54: ...pyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 Suggestion for noise insulation bellows Fig 12 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scaveng...

Страница 55: ...erformed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses su...

Страница 56: ...asured values must be entered every 24 48 hours in the engine logbook of the enginebuilder Performance and speed of the engine Air intake temperature Charging pressure Pressure loss in the charge air...

Страница 57: ...sassembly of the cartridge group and assessment of the ro tor and bearing parts requires the specialist knowledge of an ABB Tur bocharging Service Station The rotor parts turn very fast and are very s...

Страница 58: ...ed with the aid of the safety concept for rotating parts SIKO and dependent on the operating conditions Influencing parameters The specified values are guideline values and are not guaranteed The actu...

Страница 59: ...re while performing post lubrication 0 5 poil 1 0 u Switch off post lubrication as soon as the rotor is stationary or after no more than two minutes Deviating procedures must be coordinated with ABB T...

Страница 60: ...nd corrosion If mechanical cleaning is carried out incorrectly this can lead to damage and corrosion on the components u Pay attention to the specifications in this chapter pertaining to mechan ical c...

Страница 61: ...ilter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the f...

Страница 62: ...ption segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Servic...

Страница 63: ...E according to the material safety data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gase...

Страница 64: ...omply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from...

Страница 65: ...emove cartridge group see chapter Dismantling and fitting 46 First clean the compressor end and then the turbine end according to the following descrip tion 7 2 6 Cleaning the cartridge group on compr...

Страница 66: ...ll as for cleaning the turbine are described in the following Fig 16 Soaking contamination of the turbine Product A mm B mm C mm TPS44 115 20 155 TPS48 115 29 180 TPS52 135 35 215 Table 12 Dimensions...

Страница 67: ...rger and damage parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not...

Страница 68: ...amination deposits lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02...

Страница 69: ...Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 14 Malfunctions when starting Vibrations Rotating parts rubbing N...

Страница 70: ...ing oil pressure too low Speed reduces Possible causes Remedy Turbocharger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic maintenance work 30 Rotor components or bearing...

Страница 71: ...ing water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 19 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine pe...

Страница 72: ...A severely contaminated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with t...

Страница 73: ...cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Rem...

Страница 74: ...ble 25 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always...

Страница 75: ...r to chapter Ordering spare parts 75 Replacing the speed sensor 22 Table 27 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remed...

Страница 76: ...u Wait for the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the...

Страница 77: ...ult Docu mentKind Catalogue QueryText spare parts set SortBy Score CountryCode CH Addition alLanguage Identification of the assembly devices Not all assembly devices are marked with a part number Iden...

Страница 78: ...n the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point...

Страница 79: ...ms scope of delivery Swivel lifting eye S to be used Product Thread Length H mm Diameter D mm Minimum load limit kg TPS44 M8 12 25 300 TPS48 M8 12 25 300 TPS52 M10 15 25 400 Table 30 Swivel lifting ey...

Страница 80: ...hts of the individual parts or assemblies are rounded up standard values Fig 17 Overview of assemblies Designation TPS44 TPS48 TPS52 01 Radial air suction branch 5 6 8 02 Axial air suction branch 3 4...

Страница 81: ...ision E July 2017 9 3 Removing the gas outlet casing u Mark the casing position for assembly Note Gas outlet casings which are not from ABB may also be secured with studs and nuts Fig 18 Removing the...

Страница 82: ...2017 9 4 Removing air inlets u Mark the casing position for assembly Fig 19 Removing the air inlets 1 Manually secure the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp...

Страница 83: ...ng Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 5 Removing the compressor casing Fig 20 Removing the compressor casing 1 2 1 Place the turbocharger in a vertical position...

Страница 84: ...for assembly Fig 21 Removing the compressor casing 2 2 1 Secure lifting gear to compressor casing 72000 2 Remove the compressor casing 72000 vertically 3 Rotate the compressor casing 72000 through 18...

Страница 85: ...he admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casi...

Страница 86: ...ghts reserved HZTL4037_EN Revision E July 2017 Removing the turbine end fastening strips u Mark the casing position for assembly Fig 23 Removing the cartridge group 1 1 Loosen the hexagon nuts 51007 2...

Страница 87: ...h washers 3 Secure the lifting gear to the ring nuts and swivel lifting eye as shown 4 Remove the cartridge group vertically from the turbine casing Fig 25 Rotating the cartridge group and fitting the...

Страница 88: ...ling and fitting 9 7 Removing nozzle ring Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 7 Removing nozzle ring Fig 26 Removing the nozzle ring 1 Remove the nozzle ring 5600...

Страница 89: ...86 1 52 TPS52 0 13 0 22 0 98 1 68 Table 33 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure c...

Страница 90: ...1 and the turbine casing 51000 Fig 28 Measuring nozzle ring compression 42001 Bearing casing 51000 Turbine casing 56001 Nozzle ring 1 Measure dimensions A B and C on cleaned surfaces 2 Calculate the c...

Страница 91: ...Revision E July 2017 9 10 Fitting the diffuser Fig 29 Fitting the diffuser Part number TPS44 TPS48 TPS52 72041 M5 5 Nm M5 5 Nm M6 10 Nm Table 35 Tightening torque 72041 1 Position the diffuser 79000 i...

Страница 92: ...ing it by 90 1 Fit a new high temperature resisting O ring 42012 red or green see Customer spare part set 97070 47 2 Loosen and remove nuts 3 Lift the cartridge group out of the service support 90012...

Страница 93: ...ridge group Fig 31 Fitting the cartridge group Part number TPS44 TPS48 TPS52 72011 M8 40 Nm M8 40 Nm M10 80 Nm Table 36 Tightening torque 72011 1 Lower cartridge group carefully into the compressor ca...

Страница 94: ...2017 9 12 Installing nozzle ring Fig 32 Installing the nozzle ring 1 Fit lamellar sealing ring 56005 in the slot of the nozzle ring When doing this pay atten tion to correct winding of the lamellar s...

Страница 95: ...PS52 51007 M8 30 Nm M8 30 Nm M10 60 Nm Table 37 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Turn the turbine casing 51000 by 180 3 Fit two swivel lifti...

Страница 96: ...7_EN Revision E July 2017 9 14 Rotating the turbocharger Rotating the turbocharger Fig 34 Rotating the turbocharger 1 Fit swivel lifting eye S 2 Insert screws from the service support 3 Fit ring nuts...

Страница 97: ...ce The upper direc tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the ga...

Страница 98: ...Nm M10 50 Nm Table 39 Tightening torque 51101 1 Coat the threads of the hexagon head screws or studs 51008 with high temperature grease 2 Align the casing position of the gas outlet casing 61001 to th...

Страница 99: ...44 TPS48 TPS52 72020 M10 30 Nm M10 30 Nm M10 30 Nm Table 40 Tightening torque 72020 1 Fit the new O ring 81010 82010 to the filter silencer 81000 or the air suction branch 82000 2 Manually position th...

Страница 100: ...50 Nm 03 72020 M10 30 Nm M10 30 Nm M10 30 Nm 04 72041 M5 5 Nm M5 5 Nm M6 10 Nm 05 72011 M8 40 Nm M8 40 Nm M10 80 Nm 06 42188 M12 x 1 5 35 Nm M12 x 1 5 35 Nm M12 x 1 5 35 Nm 07 51007 M8 30 Nm M8 30 Nm...

Страница 101: ...hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine u Follow t...

Страница 102: ...ected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be h...

Страница 103: ...the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the m...

Страница 104: ...es Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally app...

Страница 105: ...harger must be kept intact and ready for use u Carefully clean any rusted parts and grease them Please quote the following data when making queries and ordering spare parts Turbocharger type Serial nu...

Страница 106: ...e casing mechanically 34 Fig 16 Soaking contamination of the turbine 36 Fig 17 Overview of assemblies 50 Fig 18 Removing the gas outlet casing 51 Fig 19 Removing the air inlets 52 Fig 20 Removing the...

Страница 107: ...40 Table 19 Malfunctions during operation Exhaust gas temperature too high 41 Table 20 Malfunctions during operation Charge air pressure too low 41 Table 21 Malfunctions during operation Charge air p...

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