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ABB TPS 50B01, Руководство по эксплуатации

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Operation Manual / TPS50

5 Maintenance / 5.1 Foreword to Maintenance

© Copyright 2021 . All rights reserved.

HZTL2401_EN

Rev.A

September 2021

5 Maintenance

5.1 Foreword to Maintenance

General maintenance work involves regular visual checks and cleaning
tasks which are intended to ensure the trouble-free functioning of the
turbocharger.

5.2 Cleaning the compressor during operation

General

The contamination of the compressor stage (compressor wheel, wall in-
sert and diffuser) depends on the degree of purity of the air that is
drawn in.

Deposits can form in the 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

¡

Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays
any major increase in contamination. It does not, however, replace the
regular service work, during which the turbocharger is completely dis-
mantled and the compressor is cleaned mechanically.

NOTICE

If the coating of dirt is very thick and hard, the compressor can only be
cleaned manually when disassembled. This cleaning must be carried out
by an ABB Turbocharging Service Station.

Cleaning interval

The interval between periodic cleaning is very dependent on the operat-
ing conditions. In general, cleaning should be carried out every 25 ... 100
operating hours.

Should the specified cleaning intervals prove incompatible with engine
operation, please contact ABB Turbocharging.

Page 

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Содержание TPS 50B01

Страница 1: ...ABB Turbocharging Type TPS 50B01 HT846529 nMmax 840 t Mmax 750 nBmax 800 t Bmax 710 1 s C 00270 10 50 50 Year 2021 Application according to the Operation Manual kg HZTL2401 English TPS 50B01 Original...

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: ...rger 13 2 4 Safe operation and maintenance 14 2 5 Hazards during operation and maintenance 17 2 6 Deflagration on gas engines 22 2 7 Lifting loads 22 3 Commissioning 24 3 1 Oil supply 24 3 2 Inspectio...

Страница 4: ...5 Radial clearances N and R 56 8 6 Table of tightening torques 58 9 Taking out of operation 59 9 1 Shut down turbocharger 59 10 Mothballing the turbocharger 62 10 1 Taking out of operation for up to 1...

Страница 5: ...ons concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the engine and the turbocharg...

Страница 6: ...ight 2021 All rights reserved HZTL2401_EN Rev A September 2021 1 2 Layout and function 1Compressor casing 7Turbine 2Diffuser 8Nozzle ring 3Axial thrust bearing 9Gas inlet casing 4Radial bearing 10Bear...

Страница 7: ...e ambient air through the exhaust gas pipe which is connected to the gas outlet flange 6 The air which is necessary for operation of the diesel or gas engine and which is compressed in the turbocharge...

Страница 8: ...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 Improp...

Страница 9: ...iour it must be shut down immediately by stopping the engine The malfunction must be reported to the per son or department responsible NOTICE Any modifications additions or conversions made to the tur...

Страница 10: ...rbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Storage of new turboc...

Страница 11: ...e number Definition of notes NOTICE Note A note provides suggestions which facilitate the work on the product Definition of caution warning The caution and warning signs are described in the chapter S...

Страница 12: ...ise agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended inspec tion replacement inter vals for turbocharger components 3 Inspection interval for plain bearings...

Страница 13: ...tervals In such cases we recommend that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during trials on the engine t...

Страница 14: ...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...

Страница 15: ...t all times 2 3 Warning plates on the turbocharger Fig 1 Fig 2 Table of warning plates Part number Size mm Product 72080 175 x 22 TPS 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivere...

Страница 16: ...ipment in perfect condition u Obey mandatory signs u Observe the general rules for occupational safety and prevention of accidents u Only perform operations that are described in this chapter u Only p...

Страница 17: ...ing and operation u Before starting work carry out visual inspection of working area u Remove any obstacles and objects lying around u Before start up commissioning check all pipes from and to tur boc...

Страница 18: ...be switched off and the turbocharger must have come to a standstill u Ensure that the supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after al...

Страница 19: ...er 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...

Страница 20: ...uenced by the installa tion and operating conditions Noise with a sound pressure level exceed ing 85 dB A is harmful WARNING Hazards due to noise Noise can cause impaired hearing damage to health ment...

Страница 21: ...afety gloves to protect against thermal hazards WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries burns The turbocharger is supplied with...

Страница 22: ...ect against gases WARNING Risk of fire explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion u Observe the details in the ma...

Страница 23: ...materials signify a fire hazard u Use only suitable non combustible insulating materials u Ensure that the work area is well ventilated u Avoid stirring up dust u Use tools and processes which keep du...

Страница 24: ...of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomalies are found or if a partic...

Страница 25: ...ng 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 protection at...

Страница 26: ...ions 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 standard oil filter specification for the turboch...

Страница 27: ...es are shown in the following chart 1 Kinematic viscosity mm2 s cSt 2 Oil inlet temperature C A Permissible range CAUTION Falling below the minimum oil inlet temperature Serious machine or property da...

Страница 28: ...engine 3 2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning Inspections help de tect changes to the turbocharger M...

Страница 29: ...y or recom mended Too frequent tightening can lead to wear on the connection 3 2 3 Check when running up engine u Measure the oil pressure and charging pressure at various engine per formance levels u...

Страница 30: ...s between compressor casing out let and charge 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 o...

Страница 31: ...ger 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 the turbochar...

Страница 32: ...s to the turbocharger to be identified and rectified In this way it can be ensured that the turbocharger remains in full work ing order CAUTION Service intervals Service work on the turbocharger that...

Страница 33: ...e work every 25 50 hours u Visual inspection for air exhaust gas water and oil leaks u Record operating data and enter it in the engine logbook u Clarify the cause of any variances CAUTION Unknown cha...

Страница 34: ...check for cracks and erosion 4 2 4 Entries in engine logbook By monitoring the engine conclusions can be drawn about the tur bocharger performance The following operating data and measured values must...

Страница 35: ...aired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major incre...

Страница 36: ...d directly via a cock to a water pipe or a dosing vessel larger than the one supplied This prevents uncontrolled volumes of water entering the turbocharger and engine which can lead to serious damage...

Страница 37: ...state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging the following pre req...

Страница 38: ...rights reserved HZTL2401_EN Rev A September 2021 Procedure for compressor wet cleaning with XC1 X Screw plug D Pressurized air Y Valve activator W Water Z Container Operating the water pres sure vess...

Страница 39: ...minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the char ging or flushing pressure and also from the exhaust gas temperatures If the cleaning operation is not...

Страница 40: ...our 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 bla...

Страница 41: ...the same time the flow direction in the compressor is mo mentarily reversed Such sporadic surge blows do not impair the safe operation of the turbocharger A surge blow is accompanied by a loud bang a...

Страница 42: ...njection system Repair it or contact the manu facturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too h...

Страница 43: ...eter 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 Contact an ABB Tur...

Страница 44: ...sible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too sh...

Страница 45: ...rbocharger suspension 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 stand...

Страница 46: ...g the turbocharger u Disconnect all gas and air lines in accordance with the engine builder s instructions Turbocharger without an exhaust gas pipe Fig 3 u Secure the lifting gear to the bearing casin...

Страница 47: ...gaskets of the oil supply and drain pipe O ring gaskets for the engine are not delivered by ABB Turbocharging u Inspect the lifting gear Turbocharger without a gas outlet bend Fig 4 u Attach lifting...

Страница 48: ...bed in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station u Unqualified work on the cartridge group can lead to total system failure and voi...

Страница 49: ...itting WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal injury or accidents with fatal consequences u Attach turbochargers assemblies or individual comp...

Страница 50: ...ghts The specified weights of individual parts or assemblies are guides roun ded off to the next highest value Assemblies Weights kg Description TPS 50 1 Compressor casing 55 2 Wall insert 13 3 Diffus...

Страница 51: ...bling and assembling turbochargers Removing the compressor casing u Disconnect all air lines in accordance with engine builder s instruc tions u Loosen the V clamp 72020 and remove the filter silencer...

Страница 52: ...September 2021 u Loosen the V clamp 72030 and horizontally move away the com pressor casing 72000 with the wall insert 77000 u Tap the wall insert 77000 out of the compressor casing using a nylon hamm...

Страница 53: ...the V clamps 72020 72030 before assembly u Lubricate the V clamp threads and the inner part of the profile with high temperature grease If removed u Install wall insert 77000 77006 with O ring 77005 i...

Страница 54: ...apter If provided u Treat the screw thread of the V clamp 52410 with rust remover and allow it to act u Check the lifting gear and secure it to the bearing casing 10900 u Loosen the V clamp 52410 and...

Страница 55: ...wall u Check lifting gear and attach to bearing casing 42001 u Lubricate the centring seats inner part of the V clamp profile and screw threads with high temperature grease u Remove temporary covers f...

Страница 56: ...y lightly striking the cover clamp with a plastic tip hammer u Fit bearing casing 42001 using the fixing screws C u Tighten the fixing screws to the tightening torques specified in the following table...

Страница 57: ...arance A and radial clearance B must be measured and noted NOTICE In order to correctly measure the axial clearance A the turbine must be raised slightly Axial clearance and pos sible radial movement...

Страница 58: ...inimum and maximum values result from the manufacturing toler ances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange Feeler gauge N1 and N2 as well as R1 and R2 are e...

Страница 59: ...must be within the permissible values of the radial clearance N and R Radial clearances N and R mm N R TPS 50 0 66 0 92 0 65 0 93 CAUTION Clearances out of tolerance Clearances out of tolerance and ex...

Страница 60: ...assembly 8 6 Table of tightening torques Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 8 6 Table of tightening torques Fig 7 Item Part number Tightening torques Nm 1 72020 72030...

Страница 61: ...gency repairs proceed as follows u Fit the cover plate CAUTION Always precisely obey the engine builder s instructions in case of engine operation with a blocked throttled turbocharger Dismantling the...

Страница 62: ...01_EN Rev A September 2021 Fitting the cover plate u Close the opening in the gas outlet casing with the cover plate 91000 u Secure the cover plate on the gas inlet casing 51000 with the V clamp 52410...

Страница 63: ...drawing The cover is not supplied by ABB Turbocharging and must be manufac tured by the operator according to the following drawing Material Common structural steel in compliance with DIN EN 10025 2...

Страница 64: ...d this is circulated by the prelubrica tion pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protec ted against corrosion Mothb...

Страница 65: ...for up to 12 months under Mothballing measures for the measures always necessary when moth balling turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out...

Страница 66: ...presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazard ou...

Страница 67: ...nts engine oil electronic components speed sensor and associated components thermal insulation u Dispose of metals as old metal for recycling u Dispose of non metallic materials as waste u Dispose of...

Страница 68: ...mber Spare parts can be ordered from an official ABB Turbocharging service station u If different design versions have not been taken into consideration in this document please contact an ABB Turbocha...

Страница 69: ...re available only as a complete set Spare parts kit 97070 Quantity Description Part number 2 O ring 32222 42011 1 O ring 42012 2 O ring 77006 79005 2 O ring 77005 82010 83010 CAUTION All spare parts t...

Страница 70: ...tion Manual TPS50 12 Spare parts 12 2 View of turbocharger showing part numbers Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 12 2 View of turbocharger showing part numbers Page...

Страница 71: ...ZTL2401_EN Rev A September 2021 Part number Description 51000 Turbine casing 52400 Gas outlet flange 52410 V clamp 52420 V clamp 72000 Compressor casing 72020 V clamp 72030 V clamp 77000 Wall insert 7...

Страница 72: ...n Manual TPS50 12 Spare parts 12 3 View of cartridge group showing part numbers Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 12 3 View of cartridge group showing part numbers Pa...

Страница 73: ...Compressor wheel 32101 Plain bearing bush 32103 Safety ring 32105 Thrust ring 32106 Thrust bearing 32107 Bearing bush 32108 Piston ring 32221 Bearing cover 32222 in spare parts kit O ring 42001 Beari...

Страница 74: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland...

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