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Operation Manual / TPS48-D/E.. - TPS61-D/E..

2 Safety / 2.6 Safe operation and maintenance

© Copyright 2020 . All rights reserved.

HZTL2410_EN

Rev.F

March 2020

Safety during start-up / commissioning 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-
bocharger for damage and leaks.

u

Don't work in any way that could impair safety when working on tur-
bocharger.

u

After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.

u

Immediately report 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 switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
supplying these power sources.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding
material safety data sheet and the safety instructions in section "Haz-
ards due to operating and auxiliary materials" must be observed.

u

Observe the material safety data sheet for the cleaning agent or
solvent.

u

Wear personal protective equipment (PPE) according to the material
safety data sheet.

u

Inspect the electric cables for abrasion and damage before and after
your cleaning work.

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Содержание TRS 61D01

Страница 1: ...TPS 61D01 HT846638 nMmax 587 t Mmax 650 nBmax 558 t Bmax 620 1 s C 00650 8 50 50 Year 2021 Application according to the Operation Manual kg HZTL2410 English TPS 61D01 Original Operation Manual All ma...

Страница 2: ...components depends on the load profile turbine inlet temperature suction air temperature and turbocharger speed In case the operation conditions differs significantly from what is considered to be no...

Страница 3: ...fety 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 Deflagration on gas engines 25 2 9 Periodic che...

Страница 4: ...8 1 Introduction 78 8 2 Module weights 81 8 3 Disassembling and assembling turbocharger 82 8 4 Axial clearance A and radial clearance B 95 8 5 Radial clearances N and R 96 8 6 Table of tightening torq...

Страница 5: ...It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing national reg ulations concerni...

Страница 6: ...and function 1Suction branch filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing 4Bearing casing 11Turbine end bearing flange 5Axial thrust bearing 12Compres...

Страница 7: ...e 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 is compressed in the turbocharger is d...

Страница 8: ...e equipment is used for any other purpose ABB Turbocharging reserves the right to reject all warranty claims State of the art This turbocharger was built according to state of the art technology and i...

Страница 9: ...en 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 u Ensure good room ventilat...

Страница 10: ...rbochar ger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the tur bocharger must be inspected by an ABB Turbochargin...

Страница 11: ...e equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u If the...

Страница 12: ...bocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of tu...

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: ...2 Turbocharger operating limits during operation Recommended inspection and replacement intervals for turbocharger compon ents 03 Inspection interval for plain bearings in 1000 h 04 Replacement interv...

Страница 15: ...ally apply only when running 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 p...

Страница 16: ...vance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to the turbocharger as...

Страница 17: ...2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries and even a...

Страница 18: ...ed places or are not legible then proceed as follows u Order new warning plates from ABB Turbocharging Service Stations u Remove unreadable warning plates u Clean and degrease surfaces provided for wa...

Страница 19: ...e under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly earthed and connecting cabl...

Страница 20: ...ional perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u When switching on auxiliary power sources...

Страница 21: ...terrupted especially with an external oil supply u Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or dest...

Страница 22: ...ith instructions u During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various risks can occur through...

Страница 23: ...protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating oil become hot The surfa...

Страница 24: ...s ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of mai...

Страница 25: ...and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the c...

Страница 26: ...re when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a...

Страница 27: ...tand a deflagration with a transient pres sure increase of 12 bar ABB Turbocharging recommends that following a deflagration event the turbocharger undergoes an inspection of the following points Posi...

Страница 28: ...ake sure the pressure vessels are in proper working condition and monitor them Necessary repair or main tenance work must be carried out without delay and the required safety precautions must be taken...

Страница 29: ...harger 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 sharp edges u Com...

Страница 30: ...rbine 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 standard oil filter specification...

Страница 31: ...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 minimum oil inlet temperature Serious machi...

Страница 32: ...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 and post lubrication engine stopped...

Страница 33: ...outlet depends mainly on lubricating oil temperature and pressure at the oil inlet engine load and turbocharger speed exhaust gas temperature The maximum permissible oil temperature at the outlet is...

Страница 34: ...of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system must be flushed thoro...

Страница 35: ...and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking different operating con...

Страница 36: ...after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air supply line or filter silenc...

Страница 37: ...und 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 turbocharger in or der to o...

Страница 38: ...hts reserved HZTL2410_EN Rev F March 2020 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavengi...

Страница 39: ...carried out too late can lead to excessive contamination and wear as well as operating failures u Carry out service work at specified time intervals CAUTION Shortened service intervals Despite observa...

Страница 40: ...e manufacturer s instructions Oil filter u Clean or replace oil filter in supply line to turbocharger when engine is not running 4 2 3 Service work in accordance with instructions on rating plate In g...

Страница 41: ...easured values must be entered reg ularly in the engine manufacturer s engine logbook Engine performance and speed Air intake temperature Exhaust gas temperature in front of and behind the turbine Pre...

Страница 42: ...hose non rotating components that are exposed to hot gases Decisive in this respect are various influencing parameters which can drastically shorten the replacement intervals of these parts in extreme...

Страница 43: ...d preparation Load profile thermal load cycles also starts stops emergency shut downs Gas inlet temperature Frequency and execution of turbine and compressor cleaning Turbocharger specification System...

Страница 44: ...ed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables 86505 A Speed sensor cable not...

Страница 45: ...out u Reduce engine performance immediately until the highest turbochar ger speed no longer exceeds 70 of nBmax u If the engine cannot be stopped continue to run at this reduced en gine performance o...

Страница 46: ...ety gloves when removing the cable connector and speed sensor Wear safety gloves to protect against thermal hazards u Reduce engine performance to the idling speed then stop the engine u Switch off th...

Страница 47: ...in the chapter Troubleshooting 4 5 Stopping the engine CAUTION Stopping the engine of oil cooled turbocharger version Heat in the turbocharger must be dissipated by the further circulating lubricatin...

Страница 48: ...ning is carried out too often this can lead to damage and corrosion on the components u If cleaning during operation is not sufficient to achieve acceptable values regarding thermal load and engine pe...

Страница 49: ...nbalance 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 turbocharger is completely...

Страница 50: ...ION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives u Don t use salt water for cleaning but only clean fresh water CAUTIO...

Страница 51: ...y 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 high press...

Страница 52: ...the 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 char ging or flushing pressure and also from...

Страница 53: ...performance After stopping the engine the rotor can become stuck in contamina tion deposits Experience with turbocharger operation shows that the intervals between overhauls can be extended if cleani...

Страница 54: ...ntervals prove incompatible with engine operation please contact ABB Turbocharging Cleaning method Turbine components are cleaned during operation by using the wet cleaning method described below This...

Страница 55: ...e of thermal shock in combination with a subsequent flushing phase Process with long water injection time 10 minutes cleaning The cleaning process with a long water injection time is used for tur boch...

Страница 56: ...emperature at the turbine inlet can be up to 100 C higher than the exhaust gas tem perature after the cylinder This should be taken into consideration when setting the operating point before cleaning...

Страница 57: ...racteristic com ponent Conditions short Water injection time long Water injection time Engine load guide value 20 40 Turbine inlet temperature TTE before water injection 350 400 C 350 430 C Water supp...

Страница 58: ...ing engine load again This completes the turbine cleaning process Cleaning parameters during the process TPS Temperature in front of the tur bine during clean ing C Water volume flow 1 dm3 min Injecti...

Страница 59: ...eaning parameters during the process TPS Temperature in front of the tur bine during cleaning C Water volume flow 1 dm3 min Injection time min Stabilising phase before after wa ter injection min 48 53...

Страница 60: ...d turbine casings have protective coatings which can also be damaged u Only use soft tools such as cloths brushes or wire brushes u In the event of heavy contamination the cleaning methods that have b...

Страница 61: ...81265 u Clean filter ring 81265 as required or every 500 operating hours and replace after the fifth cleaning operation at the latest The degree of contamination of the filter ring depends on the cle...

Страница 62: ...damp cloth u Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station Fitting the filter silencer u Insert the absorption segments 81136 into t...

Страница 63: ...ording 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 gases The...

Страница 64: ...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 heavy fuel oil or coked oil...

Страница 65: ...the cartridge group immediately after cleaning Compressor wheels or turbines may be heavily contaminated due to heavy fuel oil operation or coked oil Such contamination may possibly no longer be remo...

Страница 66: ...p this can im pair the function of the turbocharger and damage parts inside the cart ridge group u Make sure that no water or contamination can enter into the cart ridge group u Clean compressor wheel...

Страница 67: ...m 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 cartridge group can be sub merged vertically in a tank 02 with liquid u Place the ta...

Страница 68: ...u Place the cartridge group on suitable wooden or metal supports 01 u Maintain dimension B for the supports 01 so that the cartridge group does not submerge too deep u Allow the layers of dirt on the...

Страница 69: ...an result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank 02 with clean wa ter not salt water u Submerge th...

Страница 70: ...an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear around the periphery of r...

Страница 71: ...to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectified u Have components...

Страница 72: ...e too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbochar ge...

Страница 73: ...contaminated Clean it Cooling water volume too low Top up the water Entry temperature of cool ing water too high Inspect clean the cooling sys tem Inadequate ventilation Improve the ventilation Charg...

Страница 74: ...rformance efficiency hence engine perform ance losses Possible causes Remedy Turbochar ger Heavy fouling of the com pressor components Clean compressor Optimize oil separation Increased vibrations com...

Страница 75: ...sult the voltage amplitude of the speed signal decreases which can cause problems for the evaluation elec tronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turb...

Страница 76: ...val and installation 7 1 Transport Suspension of uninsulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas out let casing Suspension of insulated turbocharger...

Страница 77: ...ines according to the instructions of the enginebuilder Version with water cooled bearing casing u Disconnect the water pipes according to the instructions of the en ginebuilder If present remove hard...

Страница 78: ...be lightly oiled assumed friction coeffi cient 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 TPS48 17...

Страница 79: ...it speed sensor and plug in cable connector u Adapt and fit bearing casing insulation A u Adapt and fit sheet metal B of bearing casing insulation Version with water cooled bearing casing u Remove the...

Страница 80: ...charging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Sta tion u Mark the casing position for assembly Identifying assembly devices Not all as...

Страница 81: ...Attach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has a suffi cient load limit u Make sure the load is suspended properly on t...

Страница 82: ...2020 Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely not supplied by ABB Swivel lifting eye Product Thread M Length L Minimum load limit loading ca pacity TPS48 M10...

Страница 83: ...57 kg TPS61 kg 1Filter silencer 19 30 40 65 2Radial air suction branch 6 8 11 21 3Axial air suction branch 4 4 6 9 4Compressor casing 24 35 55 90 5Wall insert 7 10 13 30 6Diffuser 2 3 6 10 7Cartridge...

Страница 84: ...the tur bocharger u Wear heat resistant safety gloves and protective clothing u Allow the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards u...

Страница 85: ...ts reserved HZTL2410_EN Rev F March 2020 u Remove the insulation plates 1 2 u Slightly loosen the screws 72011 and turn the compressor casing 72000 until the swivel lifting eye can be fastened to the...

Страница 86: ...one side it can damage the rotor u It should thus be used alternately on both sides while avoiding ex cessive pressure on either side u Loosen the screws 72011 and remove them together with the fasten...

Страница 87: ...lencer also see the previous chapter WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns u Do not touch hot surfaces and heed the warning pl...

Страница 88: ...mbling tur bocharger Copyright 2020 All rights reserved HZTL2410_EN Rev F March 2020 u Withdraw nozzle ring 56001 using two extraction devices 90070 and withdraw bottom part of service support 90012 I...

Страница 89: ...ved HZTL2410_EN Rev F March 2020 Removing the diffuser u Put cartridge group 42001 on service support 90012 and secure us ing bolts u Remove screw 42008 and remove diffuser 79000 complete with O ring...

Страница 90: ...rew driver u 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 lamellar sealing ring see detail B u Secure the lam...

Страница 91: ...peration it must be clamped between the partition wall and the turbine casing Nozzle ring press fit for single inlet turbine casing u Calculate the press fit PD as shown NOTICE If the calculated value...

Страница 92: ...rch 2020 Nozzle ring press fit for multiple inlet turbine cas ing u Calculate the press fit PD as shown NOTICE If the calculated value PD is outside 0 2 mm an official ABB Tur bocharging Service Stati...

Страница 93: ...temperature grease to the centering points and screw threads u Remove temporary covers from oil connections CAUTION Don t damage or shift gasket rings A in the mounting support when fitting the cartr...

Страница 94: ...es u Fasten the bearing casing 42001 using the fixing screws C u Tighten the fixing screws C to the torques listed in the following table For the assembly of the turbocharger on the engine support the...

Страница 95: ...plates 1 2 Removing gas outlet manifold and gas outlet flange If provided u Disconnect all lines in accordance with enginebuilder s instructions and remove insulation see also preceding chapter u Loop...

Страница 96: ...et flange 52400 u For gas outlet manifolds 51100 from ABB always replace the gasket 52406 see the chapter entitled Spare parts u Apply high temperature grease to contacting surfaces and threads u Fit...

Страница 97: ...e to sharp edges on the compressor wheel The compressor wheel has sharp edges which can cause injuries u Wear safety gloves Wear safety gloves to protect against mechanical hazards Axial clearance A a...

Страница 98: ...ues 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 each measured at the sa...

Страница 99: ...l clearances N and R mm TPS48 TPS52 TPS57 TPS61 N minimum 0 22 0 30 0 40 0 50 N maximum 0 58 0 67 0 86 0 94 R minimum 0 47 0 59 0 75 0 90 R maximum 0 77 0 92 1 11 1 32 CAUTION Clearances out of tolera...

Страница 100: ...6 Table of tightening torques The following tightening torques must be observed for the designated screw fittings Tightening torques Nm Position Part number TPS48 TPS52 TPS57 TPS61 1 72020 60 60 60 60...

Страница 101: ...nd the engine can be shut down for only a short time for emergency repairs proceed as follows u Fit the cover plate CAUTION Always heed precisely the engine builder s instructions in case of en gine o...

Страница 102: ...the turbine casing using the cover plate A u Fasten the cover plate on the turbine casing 51000 using the fasten ing strips 51002 Verbus Ripp Verbusripp washers 51003 and nuts 51007 and screw it down...

Страница 103: ...o the following drawing Material Common structural steel in compliance with DIN EN 10025 2 Product B1 0 5 B2 B3 B4 0 2 B5 B6 TPS48 65 7 60 130 11 7 1 5 150 TPS52 79 6 78 155 14 2 1 5 180 TPS57 98 2 10...

Страница 104: ...0 All rights reserved HZTL2410_EN Rev F March 2020 Diameter for turbine casing designs for optional C ring sealing NOTICE Information about the turbine casing design with without C ring sealing can be...

Страница 105: ...by the pre lubrica tion pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures...

Страница 106: ...ng the engine out of operation for more than 12 months If the engine is taken out of service the following alternatives are pos sible with the turbocharger The turbocharger remains mounted on the engi...

Страница 107: ...h 2020 Suitable storage locations are only dry rooms where the relative humid ity is between 40 70 and no condensation can form Condition of the mothballed turbocharger u Check the mothballed turbocha...

Страница 108: ...against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger...

Страница 109: ...ntact 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 should be...

Страница 110: ...E 12 Spare parts 12 2 View of turbocharger showing part numbers Copyright 2020 All rights reserved HZTL2410_EN Rev F March 2020 12 2 View of turbocharger showing part numbers Page 108 111 All manuals...

Страница 111: ...6001 Nozzle ring 57200 Burst protection 57210 Burst ring 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strips 72020 V clamp 77000 Wall insert 77005 in customer spare part set O ring...

Страница 112: ...12 Spare parts 12 3 View of cartridge group showing part numbers Copyright 2020 All rights reserved HZTL2410_EN Rev F March 2020 12 3 View of cartridge group showing part numbers Page 110 111 All manu...

Страница 113: ...05 Thrust ring 32106 Thrust bearing 32108 Piston ring 32109 Sealing disc 32110 Compressor end bearing flange 32111 Auxiliary bearing 32112 Turbine end bearing flange 32113 Compressor end socket screw...

Страница 114: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland All manuals and user guides at all guides com...

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