ABB HT565892, Operation Manual

Page 1: ... Systems Ltd CH 5401 Baden Type TPL65VA33 HT565892 nMmax 503 t Mmax 650 nBmax 486 t Bmax 620 1 s C 01210 35 50 50 Year 2016 made in Switzerland Application according to the Operation Manual kg HZTL2464 English TPL65VA33 Original Operation Manual ...

Page 2: ...Replacement 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 is considered to be normal for the cur rent application it is recommended to contact ABB for a re calculation of replacement intervals Frequent load alterations high temperatures and high speed lowe...

Page 3: ...Contact information 2 Safety 2 1 Introduction 2 2 CE conformity 2 3 Definition of mandatory signs 2 4 Definition of Safety instructions 2 5 Warning plates on the turbocharger 2 6 Safe operation and maintenance 2 7 Hazards during operation and maintenance 2 8 Periodic checking of the pressure vessel 2 9 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commissioning after taking ...

Page 4: ...d installation 7 1 Turbocharger weights 7 2 Removing the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Removing and fitting turbine diffuser 8 7 Removing variable turbine geometry module with gas inlet casing 8 8 Fitting t...

Page 5: ...2464_EN Revision C 10 1 Taking the engine out of operation for up to 12 months 10 2 Taking the engine out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers 12 3 View of cartridge group with part numbers ...

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Page 7: ...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 existing national regulations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the ...

Page 8: ...served September 2015 HZTL2464_EN Revision C Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Air outlet casing 07 Gas inlet casing 1 2 ...

Page 9: ...el 12 It then passes through the diffuser 11 and leaves the turbocharger through the air outlet casing 13 The rotor runs in two radial plain bearings 02 05 One plain bearing is in the bearing bush 04 and the second one is in the axial thrust bearing 03 at the compressor end The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine s lubricating oil ci...

Page 10: ...y remarks 1 Layout and function 1 2 Page 8 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Additional function TPL V These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring ...

Page 11: ...nufacturer accepts no liability for other applications If it is used otherwise ABB Turbo Systems reserves the right to reject all warranty claims This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or ...

Page 12: ...th when handling VCIs VCI products are not hazardous in the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs Ensure good room ventilation Do not eat drink or keep food at the workplace while working with VCIs Wear safety gloves Clean hands and face after working with VCIs For further information refer to www branopac com Wear safet...

Page 13: ...B Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the turbocharger or cartridge group must be inspected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOTICE Repl...

Page 14: ...s also applies to the provision and wearing of personnel protection equipment NOTICE The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual The turbocharger must be shut down immediately by stopping the engine in the event of alterations affecting safety or of corresponding operating behaviour The fault must b...

Page 15: ...original parts Operation of the turbocharger with non original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel Only use original parts from ABB Turbo Systems ABB Turbo Systems accepts no liability for any damage resulting from the use of non original parts and corresponding accessories Competence of personnel The turbocharger must on...

Page 16: ... are not relevant for a specific turbocharger variant ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Registered tra...

Page 17: ... 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 caution warning The caution and warning signs are described in the chapter Safety ABB Turbo Systems In this document ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems Official ABB Turbo Systems Service...

Page 18: ...rwise agreed with the enginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1...

Page 19: ...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 test bed These limits can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals can increase the risk of unpredictable compon...

Page 20: ...served September 2015 HZTL2464_EN Revision C Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

Page 21: ...rger itself and its accessories originate from the operating and auxiliary materials used are the consequence of insufficient observance of the safety instructions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operator is responsible for access to the turbocharger as well as the organisational measures which regulate the safe handling of the tu...

Page 22: ...2 2 Page 20 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C CE conformity 2 2 Information ABB turbochargers fulfil Directive 2006 42 EC on machinery and are considered partly completed machinery in the sense of Article 2 g 2 2 ...

Page 23: ...EN Revision C Definition of mandatory signs 2 3 To be worn at all times Protective clothing Safety footwear against mechanical hazards To be worn according to the specific work Safety glasses Safety goggles Safety gloves against mechanical hazards chemical hazards heat hazards Respiratory mask against dust gases Safety helmet Ear protection 2 3 ...

Page 24: ...of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed precisely Warning signs must be observed at all times CAUTION Definition of caution Serious machine or property damage may occur if work and operating instructions marked with this symbol an...

Page 25: ...attached to turbochargers by ABB Turbo Systems must not be removed Illegible warnings must be replaced with new ones Further information is available from ABB Turbocharging service stations Part number Size mm Product 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the responsibilit...

Page 26: ...neral regulations for the prevention of accidents Do not work on the turbocharger if you are under physical or mental stress Work only with suitable tools as well as equipment and working materials that are in perfect condition Electric tools must be solidly earthed and connecting cables may not be damaged Keep the workplace clean clear away loose objects and remove obstacles on the floor Keep the...

Page 27: ...t any damage or changes in operational performance to person responsible If damage is discovered immediately shut down turbocharger and secure it against inadvertent or unauthorized use 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 It is possible that detergents ...

Page 28: ... must be switched off and the turbocharger must have come to a standstill Ensure that the supply of oil is interrupted especially with an external oil supply Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger Perform only those tasks that are described in this...

Page 29: ...se of stack draught Operate the turbocharger in accordance with instructions During maintenance work secure the rotor against unintentional rotation Mechanical hazards when working on the turbocharger During maintenance work various risks can occur through the improper handling of components through the non observance of work instructions due to inadequate care or as a consequence of insufficient ...

Page 30: ...ssure level is above 85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating oil become hot The surface temperature is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burn...

Page 31: ...hot turbocharger surfaces must be observed in every case Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work Oils greases coolants cleaning agents and solvents acids etc can be regarded as hazardous materials Operating and auxiliary materials can be combustible and easily ignited WARNING Handling ...

Page 32: ... contamination of the ground and water due to improper disposal can lead to environmental damage Handle operating and auxiliary materials carefully Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials Wear appropriate protective clothing Avoid inhalation and contact with the skin Ensure that the work space is adequately vent...

Page 33: ...ials only in the work area Take particular care when removing old insulating materials Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against chemical risks Use only suitable non combustible insulating materials Ensure that t...

Page 34: ...ved September 2015 HZTL2464_EN Revision C Hazards due to electrical components WARNING Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans All work on or with electrical components may only be performed by trained specialists Heed any country specific regulations ...

Page 35: ... so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is responsible for the safe operation of the pressure vessel WARNING Hazards from pressure vessels The operator must keep the pressure vessel in a proper condition and monitor it Necessary repair or maintenance work must be carried out without delay and the ...

Page 36: ...e stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet In the case of two or more suspension points the slinging angle must not exceed 45 This avoids excessive loading due to inclined tensile loading Fasten turbocharger assemblies components as described in respective handling steps Before attaching slings allow turbocharger components to cool down maximum ...

Page 37: ...conditions is an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s specifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter system with a fi...

Page 38: ...tion on the turbocharger are listed below Status for operation Oil pressure in front of the turbocharger bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily permissible 1h alarm 1 1 1 3 Not permissible emergency stop 0 0 1 1 Permissible during pre and post lubrication engine stopped 0 2 2 5 NOTICE Oil orifice To make sure these oil pressures are obtai...

Page 39: ...e oil 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 Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbochar...

Page 40: ...oroughly with warm oil using a bypass pipe before starting up the first time commissioning and after all service work on the lubricating system It is urgently recommended that a running in filter is used when running in the engine and after all service work on the lubricating system Check the oil pressure in the oil supply lines Check that variable turbine geometry module can be adjusted TPL65 Ver...

Page 41: ...e air temperature in front of and behind the compressor Check the functioning of the variable turbine geometry module The measured values must be compared with the values in the acceptance test report while taking different operating conditions into account NOTICE Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few ...

Page 42: ... gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and remove Inspect air supply line or filter silencer for any foreign matter Clean and remove Start up turbocharger oil circulation system at engine end Prepare turbocharger for operation as instructed in section Inspection work before start up commissioning of chapter headed Start up co...

Page 43: ...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 the turbocharger in order to observe this limit value Fitted air inlet system All standard noise reducing measures have been taken2 The bellows at the air outlet have been perfectly insulated acoustic...

Page 44: ...2 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C 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 scavenging air line 06 Sheet metal cover ...

Page 45: ...vals CAUTION Shortened service intervals Despite observance of the service intervals unusual loads such as several start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lead to premature machine damage A shortened service interval must be arranged with ABB Turbo Systems NOTICE Service inspection after 5 years To prevent age and stoppage related machine...

Page 46: ... 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 Lubricating oil pressure and lubricating oil temperature Air temperature behind compressor and charge air cooler Turbocharger speed Pressure loss in air filter Servicing work according to the engine m...

Page 47: ...rrosion Clean bearing casing and blow air through oil ports Inspect and assess sealing air lines Inspect and assess rotor and bearing parts Have the variable turbine geometry module overhauled by ABB Turbo Systems ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX Customer Part Exchange programme Service work every 30000 hour...

Page 48: ...ponents and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections are carried out the individual components are inspected for wear and tear and replaced if necessary In this way trouble free operation is ensured The following parameters influence the replacement intervals for turbocharger components Parame...

Page 49: ...ing 50000 100000 Variable turbine geometry module The variable turbine geometry module can be replaced with a CPEX variable turbine geometry module by an ABB Turbocharging service station 15000 Turbine diffuser cover ring 35000 50000 Other casings 100000 Axial bearing components 24000 36000 Radial bearing components 24000 36000 Turbine blades due to wear Rotor components See the data on the rating...

Page 50: ...peed measuring system permits continuous monitoring of the turbocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out Do not tension the speed measurement cables Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer 4 4 ...

Page 51: ...ded the following steps must be carried out Reduce engine performance immediately until the highest turbocharger speed no longer exceeds 70 of nBmax If the engine cannot be stopped continue to run at this reduced engine performance or turbocharger speed If the turbocharger surges continuously engine performance must be reduced further Measure the temperatures in the air and gas lines to and from t...

Page 52: ...dopted to fit it Engine and turbocharger are not running The turbocharger lubricating system is switched off Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for measuring the speed is marked n on the bearing casing Screw in speed sensor 86505 as far as it will go and tighten to torque specified in table See chapter Table of tightening torques Connect...

Page 53: ...n stop the engine Switch off the lubricating oil supply to the turbocharger Disconnect the cable connector from the speed sensor Screw out defective speed sensor Screw in a new speed sensor up to the limit block Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing the speed sensor The speed sensor is designed with a seali...

Page 54: ...mergency operation TPL VA 4 5 In the event of failure of the control system or the drive the variable turbine geometry module can be fixed by clamping the ring lever B using at least 3 washers C spaced around the circumference When fixing the position of the variable turbine geometry module and or the blades must be specified by the enginebuilder 4 5 Detail A ...

Page 55: ...All rights reserved September 2015 HZTL2464_EN Revision C Stopping the engine 4 6 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 6 ...

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Page 57: ... visual checks and cleaning 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 established by visual checks at the specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter sile...

Page 58: ...15 HZTL2464_EN Revision C Cleaning the filter silencer 5 2 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering 5 2 5 2 1 ...

Page 59: ...n air is Clean filter strip every 500 hours of service or more frequently if necessary Unscrew and remove lock nuts 81273 Unscrew and remove screws 81272 for connecting rods 81269 Remove connecting rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cleaning ...

Page 60: ...81137 Bend sheet metal coverings 81137 back to original shape Insert the insert units E into slot guides in filter silencer unit 81135 Uniformly place cover grids 81266 in correct position Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their recesses on the filter silencer unit 81135 the cover grid 81266 can twist a...

Page 61: ...s 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now tighten screws 81272 alternately until the following maximum torque is reached Screw Tightening torque Nm 81272 20 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 Fit filter strip 81265 If provid...

Page 62: ...Various kinds of dust Contamination of the compressor stage has a negative influence on the compressor efficiency and the charging pressure This results in higher exhaust gas temperatures and higher fuel consumption by the engine Contamination of the compressor can also increase rotor unbalance Under no circumstances is periodic cleaning of the compressor during operation a substitute for the serv...

Page 63: ... injection pipe fitted in the filter silencer or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provided that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additive...

Page 64: ...aning operation with XC2 Compressor wet cleaning operation with XC2 Maintain water pressure before connection to turbocharger during water injection time must be maintained as shown in table Cleaning parameters After cleaning wait at least 5 minutes to allow turbocharger to dry NOTICE If the cleaning process is unsatisfactory it can be repeated up to 2 times If the cleaning result is still not sat...

Page 65: ...ing process which has been tested and is recommended by ABB Turbo Systems the following prerequisites must be fulfilled Engine load 50 85 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Compressor wet cleaning procedure with XC3 It is mandatory to fulfil the operating condition prerequisites before cleaning compressors with XC3 Remove the sealin...

Page 66: ...een injected After cleaning wait at least 5 minutes to allow the turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service St...

Page 67: ...ight 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Cleaning turbines and guide vanes during operation 5 4 NOTICE HFO applications The TPL65VA has not been released for HFO applications Wet cleaning of the turbine blades and guide vanes during operation is thus neither required nor planned 5 4 ...

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Page 69: ...bo charger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbo charger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permissible The compressor blades and turbine blades are then shortened somewhat Certain tole...

Page 70: ...ed or periodic surging Possible damage to components such as the compressor wheel turbine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging service station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Sporadic surge blows Surging of the turbocharger can occur during certain operat...

Page 71: ... Turbo charger 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 the enginebuilder Turbo charger Heavy contamination of the turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the exh...

Page 72: ...air it or contact the manufacturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine contaminated Exhaust counterpressure too high Clean or repair the boiler or exhaust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry ...

Page 73: ...ong Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pressure Clean it Compressor turbine contaminated Damaged compressor turbine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or exhaust silencer Charge air pressure too high Engine performance and engine speed unchanged ...

Page 74: ...ing run down Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharg...

Page 75: ...n cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus attract metal particles As a result the distance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to fa...

Page 76: ... 2015 HZTL2464_EN Revision C Variable Turbine Geometry 6 6 Variable Turbine Geometry VTG not adjustable Possible causes Elimination Turbocharger Heavy turbine contamination Contact an ABB Turbocharging Service Station VTG bearing damaged Drive unit electrical components No drive energy Contact an ABB Turbocharging Service Station 6 6 ...

Page 77: ...64_EN Revision C Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest possibility This guide value can differ from data on the rating plate depending on the specification TPL65VA32 33 1210 7 7 1 Weight kg ...

Page 78: ...g 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 Check correct installation of oil orifice plates Unplug the cable connector on the speed sensor Remove the insulation at the suspension ribs TPL65 Version with compressor wheel ...

Page 79: ...place a sling around the bearing casing Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate the turbocharger could tip over during installation or removal and cause a serious or even fatal injury Support the turbocharger at a suitable point If possible secure...

Page 80: ...earing 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 Check correct installation of oil orifice plates Adapt turbocharger to suit engine Tighten fixing screws in foot in accordance with engine builder s instructions Fas...

Page 81: ...itions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Visually c...

Page 82: ...ttach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves against mechanical risks Wear safety helmet Definition of terms Suspension point Defined load carrying point on a compone...

Page 83: ...ights of individual parts or assemblies are guides rounded off to the next highest value Assemblies Description TPL65VA32 33 01 Radial air suction branch 50 02 Axial air suction branch 35 03 Filter silencer 130 04 Compressor casing 180 05 Wall insert 40 06 Diffuser 19 07 Cartridge group 290 08 Turbine diffuser 30 09 Variable turbine geometry module 55 10 Radial gas inlet casing 50 8 2 Weights kg ...

Page 84: ...e 82 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Complete compressor casing TPL65VA32 33 240 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing the diffuser and the wall insert Weight kg ...

Page 85: ...C Removing and fitting filter silencer or air suction branch 8 3 Remove insulation where necessary Pass lifting gear through rib on filter silencer Pass lifting gear through lugs on back Unscrew nuts 72027 and remove them together with washers 72018 Remove filter silencer and set it down to one side Install filter silencer in reverse order 8 3 Removing the filter silencer Installing the filter sil...

Page 86: ... builder s instructions Dismantle the insulation where necessary Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to improve stability Unscrew the nuts 72027 and remove them together with the washers 72018 Remove the air suction branch and set it down to one side Fit the air suction branch in reverse order Remo...

Page 87: ...ult in injury Wear safety gloves Wear safety gloves against mechanical risks The axial clearance A must be measured before removing and after fitting the cartridge group Measure and note the axial clearance A TPL65VA32 33 0 31 0 49 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have compon...

Page 88: ...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 Check correct installation of oil orifice plates Loosen and remove sealing air line 56501 between compressor casing 72000 and variable...

Page 89: ... with the wall 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 Allow the compressor casing to rest only on surface F Check the underlay and adjust it if necessary Remove the screws 72002 Remove the diffuser 79000 Remove the wall insert 77000 using swivel lifting eyes 90235 Remove the O ring 77005 from t...

Page 90: ... 86506 Remove the O ring 42012 Remove the three screws 61059 and Verbus Ripp washers 61058 Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose Uniformly press off the cartridge group using the press off screws 90900 in the holes provided CAUTION If the rotor blades have insufficient or no clearance the blades and casing could be damaged Turn the rot...

Page 91: ...2 33 Disassembly and assembly 8 Removing cartridge group 8 5 Page 89 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Withdraw the cartridge group and fit the supports 90450 Cover the oil connections ...

Page 92: ...turbine diffuser 8 6 Replace two screws 61032 with two studs 90903 in upper section of turbine diffuser Screw out the remaining screws 61032 press off the turbine diffuser 63000 using the press off screws 90901 then withdraw and remove it Fitting the turbine diffuser Fit the turbine diffuser in reverse order of removal NOTICE Brush high temperature grease on all screws at and in the gas outlet cas...

Page 93: ...let casing 51001 together with variable turbine geometry module 56100 CAUTION After removing screws 56122 and retaining clips 56121 gas inlet casing 51001 is no longer secured Loosen screws 56122 together with retaining clips 56121 and remove with clamping ring 56112 Remove clamping ring 56112 Carefully separate gas inlet casing 51001 from variable turbine geometry module 56100 and remove it CAUTI...

Page 94: ...TL2464_EN Revision C Fitting the variable turbine geometry module and the gas inlet casing 8 8 Push variable turbine geometry module 56100 over studs Push gas inlet casing 56001 over studs Slide clamping ring 56112 onto studs Tighten nuts 61042 to specified torque Fit retaining clips 56121 using screws 56122 Fit semi circular section of sealing air line A to variable turbine geometry module 8 8 ...

Page 95: ...bly and assembly 8 Fitting the variable turbine geometry module and the gas inlet casing 8 8 Page 93 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Fit sealing air line 56501 to semi circular section of line A ...

Page 96: ...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 Check correct installation of oil orifice plates Remove the cover from the oil connection Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this p...

Page 97: ...be damaged Turn the rotor to check that the blades do not rub against the turbine diffuser Remove the lifting gear Fit the O ring 42012 Screw in the speed sensor 86505 along with the O ring 86506 and plug in the cable connector 86515 Fit the O ring 77005 to the wall insert 77000 Fit the lifting gear and the swivel lifting eye 90235 Align and fit the wall insert 77000 using the centring screw 90187...

Page 98: ...ess off nuts 61090 onto bearing casing studs equally spaced around circumference and up to end of thread Push compressor casing 72000 onto cartridge group to fit snugly and fasten it using nuts 61037 Secure three press off nuts 61090 against compressor casing 72000 by tightening them to specified torque See chapter Table of tightening torques Remove lifting device 90190 Fit sealing air line 56501 ...

Page 99: ...ances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property Have components assessed and if necessary replaced by an ABB Turbocharging Service Station Connect oil pipes and all air lines in accordance with engine builder s instructions Version with compressor wheel cooling system Fit the air supply line Also see the chapter Preliminary remark...

Page 100: ...tion Manual TPL65VA32 33 Disassembly and assembly 8 Table of tightening torques 8 10 Page 98 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Table of tightening torques 8 10 8 10 ...

Page 101: ... C Part number TPL65VA32 33 01 82005 M16x1 5 50 03 72027 With washer M14 100 04 72002 M10 50 06 61037 M14 80 07 61090 M14 10 08 61036 61041 72029 M14 50 09 61059 M14 160 13 42059 42064 M12 50 17 61056 M14 150 18 51075 56110 56114 M8 25 19 61042 M14 130 24 56122 M10 50 30 86505 M18x1 5 160 Part number TPL65VA32 33 29 56501 M26x1 5 30 Tightening torques Nm Tightening angle ...

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Page 103: ... Sound an alarm and depending on the situation stop the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directives ...

Page 104: ...vision C Fitting the cover plate 9 2 NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL65 13 325 30 30 8 10 6 70 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 616 694 660 16 22 15 Product α 1 α 2 α 3 TPL65 4 x 90 37 5 24 x 15 9 2 Cover plate dimensions mm ...

Page 105: ... of operation at short notice 9 Fitting the cover plate 9 2 Page 103 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 106: ...he cover plate 9 2 Page 104 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Close off opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 107: ...ngine builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and exhaust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The engine...

Page 108: ...t 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C Blocking the inlets and outlets 9 3 CAUTION Shut off the lubricating oil supply to the turbocharger 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 3 ...

Page 109: ... September 2015 HZTL2464_EN Revision C Turbocharger bypass CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around turbocharger NOTICE In this respect refer to the engine manufacturer s instructions 9 4 ...

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Page 111: ...d by preserving oil before taking the engine out of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies...

Page 112: ...are necessary after taking an engine out of operation Dismantle the turbocharger The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards Clean all parts Machined bright surfaces of steel and cast parts must be oiled with anticorrosive oil Reassemble complete turbocharger Rotor turning in stack draught If the rotor turns as a result o...

Page 113: ...r in individual parts See the section Taking out of operation for up to 12 months under Mothballing measures for the measures always necessary when mothballing turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out of operation for up to 12 months under Rotating the rotor in stack draught If the entire turbocharger is removed or if the turbocharger is ...

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Page 115: ...oves made of leather Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metalli...

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Page 117: ...ken into consideration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in a professional and environmentally compatible way Required customer spare parts s...

Page 118: ...anual TPL65VA32 33 Spare parts 12 View of turbocharger with part numbers 12 2 Page 116 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C View of turbocharger with part numbers 12 2 12 2 ...

Page 119: ...gon nut 61043 in customer spare parts set Verbus Ripp Washer 61044 in customer spare parts set Hexagon head screw 61056 in customer spare parts set Hexagon head screw 61057 in customer spare parts set Verbus Ripp Washer 61058 in customer spare parts set Verbus Ripp Washer 61059 in customer spare parts set Hexagon head screw 63000 Turbine diffuser 68000 Foot 72000 Compressor casing 72018 Washer 720...

Page 120: ...al TPL65VA32 33 Spare parts 12 View of cartridge group with part numbers 12 3 Page 118 Copyright 2015 ABB All rights reserved September 2015 HZTL2464_EN Revision C View of cartridge group with part numbers 12 3 12 3 ...

Page 121: ...iary bearing 32105 Floating disc 32106 Axial bearing 32107 Bearing bush 42001 Bearing casing 42002 Hood 42011 O ring 42015 Sealing cover 42041 in customer spare part set Gasket 42045 in customer spare part set Gasket 42058 in customer spare part set Verbus Ripp Washer 42059 in customer spare part set Hexagon head screw 42063 Verbus Ripp Washer 42064 Hexagon head screw 43002 option with compressor ...

Page 122: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...