ABB HT596419, Operation Manual

Page 1: ... ABB Turbocharging Type TPL65VA32 HT596419 nMmax 499 t Mmax 680 nBmax 475 t Bmax 650 1 s C 01210 35 50 50 Year 2020 Application according to the Operation Manual kg HZTL2464 English TPL65VA32 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: ...ns 17 2 5 Warning plates on the turbocharger 18 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vessel 27 2 9 Lifting loads 27 3 Commissioning 29 3 1 Oil supply 29 3 2 Inspection work 32 3 3 Commissioning after taking out of operation 33 4 Operation 35 4 1 Noise emissions 35 4 2 Servicing work 36 4 3 Replacement intervals ...

Page 4: ...8 4 Axial clearance 79 8 5 Removing cartridge group 79 8 6 Removing and fitting turbine diffuser 84 8 7 Removing variable turbine geometry module with gas inlet casing 85 8 8 Fitting the variable turbine geometry module and the gas inlet casing 86 8 9 Installing cartridge group 87 8 10 Table of tightening torques 93 9 Taking out of operation at short notice 95 9 1 Possibilities for emergency repai...

Page 5: ...w 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 reg ulations 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...

Page 6: ... reserved HZTL2464_EN Rev E March 2020 1 2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radial plain bearing 12Compressor wheel 06Gas outlet casing 13Air outlet casing 07Gas inlet casing Page 4 108 ...

Page 7: ...ses through the diffuser 11 and leaves the turbocharger through the air outlet cas ing 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 circuit The oil ou...

Page 8: ...liminary remarks 1 2 Layout and function Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Additional function TPL V These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring Page 6 108 ...

Page 9: ...her type of use If the 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 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 10: ...rotection of health when 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 ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer t...

Page 11: ...d In this case the turbochar 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 Turbocharging Service Sta tion and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant ...

Page 12: ...of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Operation Manual u If the turbocharger shows modifications affecting safety or any cor responding operating behaviour it must be shut down immediately by stopping the engine The malfunction must be report...

Page 13: ...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 u Only use original parts from ABB ABB accepts no liability for any damage resulting from the use of non original parts and corresponding accessories Competence of personnel The turbocharger must only be operated and serviced by trai...

Page 14: ...nt 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 trademarks Registe...

Page 15: ...cilitate the work on the 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 of caution warning The caution and warning signs are described in the chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this...

Page 16: ...eed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 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 Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 0...

Page 17: ...rmally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals increases the risk of unpredictable component failures 1 7 2 Positions of the rating plates A rating plate is attached to the turbocharger foot one on the left and one on the right On turbochargers with insulat...

Page 18: ...of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel All instructions contained in this chapter must be observed for safe and ...

Page 19: ...rotection 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 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 pre cisely u Warning signs ...

Page 20: ...d maintenance The instructions specified in this section are for the safety of personnel Together with the instructions in the Hazards during operation and maintenance section they allow the user to safely use the turbocharger Work safety and work area safety WARNING Risk of falling There is the risk that someone can fall when working on the turbochar ger u Do not climb on the turbocharger or on p...

Page 21: ... protective equipment PPE for welding operations 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 abo...

Page 22: ...s reserved HZTL2464_EN Rev E March 2020 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 Page 20 108 ...

Page 23: ...o 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 u Perform only those tasks that are described in this manual u Perform work only for which training has been carried out Safety when taking out of operation or preparing for mothballing u Secure the rotor so it cannot turn The ...

Page 24: ...tional ro tation 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 instruc tions due to inadequate care or as a consequence of insufficient train ing WARNING Mechanical hazard Severe injuries to personnel or fatal accidents can be caused by mech anical influences as a co...

Page 25: ... 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 temperat ure is dependent on the effectiveness of the insulation being used The temperature can become high enough so that it falls into ranges where burns are possible WARNING...

Page 26: ...ger surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for 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 ...

Page 27: ...ination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and hazard notices on the containers of the operating and auxiliary materials u Wear appropriate protective clothing u Avoid inhalation and contact with the skin u Ensure that the work space is adequately v...

Page 28: ...a u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against chemical hazards u Use only suitable non combustible insulating materials u Ensure that the work ...

Page 29: ...must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure 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 u Pressure equipment must not be...

Page 30: ...ading 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 sharp edges u Completely screw in assembly fitting devices without fail so that they cannot work loose during use u Use assembly fitting devices only for applications described u Make sure removed...

Page 31: ...s an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubricating oil filter system with a filter mesh ...

Page 32: ...ocharger are listed below Status for operation Oil pressure at measuring point M poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1 h 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 Oil orifice A metering orifice is installed in the oil inlet of the turbochar...

Page 33: ...ing 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 fol lowing table The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation an...

Page 34: ...that the entire lubricating system be flushed thoroughly with warm oil using a bypass pipe before starting up the first time commissioning and after all service work on the lub ricating system It is urgently recommended that a running in filter is used when run ning in the engine and after all service work on the lubricating system u Check oil pressure in oil supply pipes TPL VA u Check that varia...

Page 35: ... of the variable turbine geometry module The measured values must be compared with the values in the accept ance test report while taking different operating conditions into ac count NOTICE Lubricants and pastes used during assembly of the turbocharger li quefy or vaporise and might escape as an oily liquid in the first few hours after commissioning If oily liquid continues to escape after this pe...

Page 36: ... water Clean and re move u Inspect air supply line or filter silencer for any foreign matter Clean and remove u Start up turbocharger oil circulation system at engine end u Prepare turbocharger for operation as instructed in section Inspec tion work before start up commissioning of chapter headed Start up commissioning u Start up turbocharger TPL65 Version with compressor wheel cooling system u Re...

Page 37: ...harger 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 or der 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 ally by ...

Page 38: ...nges 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 is neglected or 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 interv...

Page 39: ...ave unknown causes clarified by an ABB Turbocharging service sta tion 4 2 2 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 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 ...

Page 40: ...etry module overhauled by ABB Tur bocharging ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX Customer Part Exchange programme 4 2 5 Service work every 30000 32000 hours The replacement of bearing parts as well as the inspection and assess ment of the rotor must be carried out by an ABB Turbocharging Service Station u Disas...

Page 41: ...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 Influencing parameters The following parameters influence the replacement intervals for tur bocharger components Parameters influencing bearing parts Poor quality of the lubricating oil lubrication oil filter system condi tion of lubricating ...

Page 42: ...e variable turbine geometry module can be re placed with a CPEX variable turbine geometry mod ule 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 Recommended replace ment intervals h Rotor components See the data on the rating plate GAS Ga...

Page 43: ... March 2020 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 Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F I converter 86528 Tachometer Page 41 108 ...

Page 44: ... steps must be carried 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 or turbocharger speed u If the turbocharger surges continuously engine performance must be reduced further u Measure the temperatures in the air and gas lines to and from the tur ...

Page 45: ...it w Engine and turbocharger are not running w The turbocharger lubricating system is switched off u 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 u Screw in speed sensor 86505 as far as it will go and tighten to torque specified in table See chapter Table of tightening torques u Connect spe...

Page 46: ...itch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor up to the limit block u Observe the tightening torque see the table of tightening torques in the chapter entitled Disassembly and assembly NOTICE Sealing of the speed sensor The speed sensor is designed with a sealing lip an...

Page 47: ... 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 6 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Allow the engine to continue running at idling spee...

Page 48: ...Operation Manual TPL65VA32 VA33 4 Operation 4 6 Stopping the engine Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Page 46 108 ...

Page 49: ...s and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established by visual checks at the spe cified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Filter silencer Compre...

Page 50: ...ev E March 2020 5 2 Cleaning the filter silencer 5 2 1 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screw 81273 Lock nut E Insert unit absorption segment sheetmetal covering Page 48 108 ...

Page 51: ...r is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove connecting rods 81269 u Carefully remove cover grids 81266 u Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 u Clean absorption segments 81136 When cleanin...

Page 52: ...metal coverings 81137 back to original shape u Insert the insert units E into slot guides in filter silencer unit 81135 u Install cover grids 81266 uniformly and in the correct position u Push connecting rods 81269 through the lugs of cover grids 81266 CAUTION If connecting rods 81269 are not correctly positioned in their recesses on filter silencer body 81135 cover grid 81266 can twist and shift ...

Page 53: ...he enginebuilder approves the process 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 fue...

Page 54: ...n injection pipe fitted in the fil ter silencer or the suction branch The water does not act as a solvent but the contamination deposit is re moved by the mechanical impact of the 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 wa...

Page 55: ...be present in the vicinity of the tur bocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning procedure for compressor with XC2 u Trigger water injection according to the specifications of the en ginebuilder u The specified water pressure upstream of the connection to the tur bocharger must be maintained u Operate engine for at least ...

Page 56: ...en tested and is recommended by ABB Turbocharging the following pre requisites must be fulfilled u Engine load 50 85 u Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Operating procedure for compressor wet cleaning with XC3 Operating the water pres sure vessel u The operating state prerequisites for compressor cleaning with XC3 must be fulfilled...

Page 57: ...rameters per turbocharger compressor Product Engine load Contents of water ves sel dm3 TPL65 50 85 0 4 5 4 Cleaning turbines and guide vanes during operation NOTICE HFO applications The TPL65VA has not been released for HFO applications Wet clean ing of the turbine blades and guide vanes during operation is thus neither required nor planned 5 5 Cleaning components mechanically 5 5 1 Introduction C...

Page 58: ...n chapter Fitting and dismantling u Dispose of contaminated water and cleaning agents in an environ mentally compatible manner professionally and in accordance with valid local regulations CAUTION Risk of damage during mechanical cleaning If mechanical cleaning is carried out too often this can lead to damage and corrosion on the components u Perform mechanical cleaning especially of the cartridge...

Page 59: ...not use any wire brushes u Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of compressed air u Lightly spray the gap between the compressor and the bearing casing with penetrating oil u Dispose of contaminated water and cleaning agent in accordance with the safety data sheet 5 5 4 Cleaning the cartridge group on the turbine end Soaking the contami...

Page 60: ...ifting gear length 1 Suspend cartridge group from normal suspension point and suspend from first crane 2 Secure two lifting loops with swivel lifting eyes in the lower push off threads and suspend from a second crane 3 Rotate cartridge group horizontally by lifting the second crane 4 When the cartridge group is horizontal secure one chain block to one of the upper push off threads using a swivel l...

Page 61: ...Operation Manual TPL65VA32 VA33 5 Maintenance 5 5 Cleaning components mechanically Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 6 Remove loop from first crane Page 59 108 ...

Page 62: ...r must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting loops or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops 2 Attach third lifting loop with swivel lifting eye to thread of oil outlet ...

Page 63: ...til entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neutral cleaning agents that do not corrode metals u Observe the material safety data sheet u Observe country specific regulations regarding banned and restric ted substances u Fill the tank with soaking ...

Page 64: ...p If water or contamination gets into the cartridge group the turbochar ger function may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal supports u Allow the layers of contamination on the turbine to soak for at least four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or resp...

Page 65: ...nation deposits lead to rotor unbalance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank with clean water not salt water u Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely u Lift the cartridge group u Dry turbine and gap be...

Page 66: ...aviour 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 blades are then shortened somewhat Certain tolerances must be observed to avoid a significant loss of efficiency If there is any doubt about the extent of rubbing then an ABB Turbocharging Service Sta...

Page 67: ...larified immediately by an ABB Turbocharging ser vice station and rectified u 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 operating condi tions such as when reducing the engine performance quickly when man oeuvring At the same time the flow direction in the compresso...

Page 68: ... 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 Turbochar ger 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 ex haust gas pipe...

Page 69: ...ion for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Enlarged flow cross section of the nozzle ring due to de formed blade trailing edges Contact an ABB Turbocharging Service Station Damaged or eroded turbine Charge air cooler Cooler contaminated Clean it Cooling water volume too...

Page 70: ... it Compressor turbine contam inated Damaged compressor tur bine Contact an ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Charge air pressure too high Engine performance and engine speed unchanged air intake condition normal Possible causes Elimination Engine Malfunctioning injection sys tem Repair it or contact the manu facturer...

Page 71: ... for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus at tract metal particles As a result the dis tance to the auxiliary bearing decreases which can lead to amplification of the noise component and consequently to faulty triggeri...

Page 72: ...bleshooting 6 6 Variable Turbine Geometry Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Possible causes Elimination Drive unit electrical com ponents No drive energy Contact an ABB Turbocharging Service Station Page 70 108 ...

Page 73: ...ir and oil lines in accordance with engine manu facturer s instructions CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pi...

Page 74: ... Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose w Ribs 01 not in the middle at the top u Completely remove the bearing casing insulation 02 and place a sling around the bearing casing u Loosen the fixing screws at the foot u Lift the turbocharger off the engine and set it down to one side Page 72 108 ...

Page 75: ...g casing ribs provided for this purpose CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifice...

Page 76: ...k on the cartridge group can lead to total system failure and void the warranty u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use u Check visual...

Page 77: ...echnically perfect condition and has a suffi cient load limit u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachment point on a component or an assembly blind hole thread eye lug Assembly device Devices tha...

Page 78: ... Rev E March 2020 Weights kg 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 geo metry module 55 10 Radial gas inlet casing 50 Page 76 108 ...

Page 79: ...mplete compressor casing Weight kg 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 8 3 Removing and fitting filter silencer or air suction branch Removing the filter silen cer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer Page 77 108 ...

Page 80: ...nstall filter silencer in reverse order Removing the air suction branch u Disconnect all air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u Pass a lifting gear around the air suction branch It is permissible to pass the lifting gear through holes possibly provided in the ribs to im prove stability u Unscrew the nuts 72027 and remove them to...

Page 81: ... be measured before removing and after fitting the cartridge group u Measure and note the axial clearance A Clearance A mm 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 u Have components assessed and if necessary replaced by an ABB Turbocharging Service Station 8 5 ...

Page 82: ...ing fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Loosen and remove sealing air line 56501 between compressor cas ing 72000 and variable turbine geometry module 56100 u Remove three studs 72029 at top u Attach lifting device 90190 to compressor casing 7200...

Page 83: ... and diffuser and set them down with surface F on an underlay WARNING Tipping the compressor casing Make sure the underlay does not shift u Allow the compressor casing to rest only on surface F u Check the underlay and adjust it if necessary u Remove the screws 72002 u Remove the diffuser 79000 u Remove the wall insert 77000 using swivel lifting eyes 90235 u Remove the O ring 77005 from the wall i...

Page 84: ...Remove the three screws 61059 together with their Verbus Ripp washers 61058 u Attach one lifting gear each to the two fins of the bearing casing provided for this purpose u Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be damaged u Check that the blades do not ...

Page 85: ...artridge group Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 u Withdraw cartridge group and fit supports 90450 u Remove screws 42054 together with flange 42044 and also remove possible contamination behind the flange u Cover the oil connections Page 83 108 ...

Page 86: ...ser u Replace two screws 61032 with two studs 90903 in upper section of turbine diffuser u Screw out the remaining screws 61032 press off the turbine diffuser 63000 using the press off screws 90901 then withdraw and re move it Fitting the turbine diffuser u Fit the turbine diffuser in reverse order of removal NOTICE Brush high temperature grease on all screws at and in the gas outlet casing Page 8...

Page 87: ...1 together with variable turbine geo metry module 56100 CAUTION After removing screws 56122 and retaining clips 56121 gas inlet cas ing 51001 is no longer secured u Loosen screws 56122 together with retaining clips 56121 and re move with clamping ring 56112 u Remove clamping ring 56112 u Carefully separate gas inlet casing 51001 from variable turbine geo metry module 56100 and remove it CAUTION Ha...

Page 88: ... 8 8 Fitting the variable turbine geometry module and the gas inlet casing u Push variable turbine geometry module 56100 over studs u Push gas inlet casing 56001 over studs u Slide clamping ring 56112 onto studs u Tighten nuts 61042 to specified torque u Fit retaining clips 56121 using screws 56122 u Fit semi circular section of sealing air line A to variable turbine geo metry module Page 86 108 ...

Page 89: ...talling cartridge group CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been corr...

Page 90: ...e u Remove supports 90450 and carefully insert cartridge group u Uniformly tighten the screws 61059 together with the Verbus Ripp washers 61058 CAUTION If there is no or insufficient clearance between the rotor turbine blades and the turbine diffuser the blades and the turbine diffuser casing can be damaged u Check that the blades do not rub on the turbine diffuser by rotating the rotor u Remove t...

Page 91: ... Rev E March 2020 u Fit the O ring 77005 to the wall insert 77000 u Fit the lifting gear and the swivel lifting eye 90235 u Align and fit the wall insert 77000 using the centring screw 90187 u Place the diffuser 79000 in position using the swivel lifting eye 90235 u Remove the swivel lifting eye 90235 u Fit the screws 72002 Page 89 108 ...

Page 92: ...0 onto bearing casing studs equally spaced around circumference and up to end of thread u Push compressor casing 72000 onto cartridge group to fit snugly and fasten it using nuts 61037 u Secure three press off nuts 61090 against compressor casing 72000 by tightening them to specified torque See chapter Table of tightening torques u Remove lifting device 90190 u Fit sealing air line 56501 between c...

Page 93: ...ce and excessively worn components can be the cause of serious damage to machinery and property u Have components assessed and if necessary replaced by an ABB Turbocharging Service Station u Connect oil lines and all air lines in accordance with engine builder s instructions Version with compressor wheel cooling system u Fit the air supply line Also see the chapter Preliminary remarks Lay out and ...

Page 94: ...Operation Manual TPL65VA32 VA33 8 Disassembly and assembly 8 9 Installing cartridge group Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Page 92 108 ...

Page 95: ...Operation Manual TPL65VA32 VA33 8 Disassembly and assembly 8 10 Table of tightening torques Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 8 10 Table of tightening torques Page 93 108 ...

Page 96: ...orques Nm 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 Tightening angle Part number TPL65VA32 33 29 56501 M26x1 5 30 Page 94 108 ...

Page 97: ... Machine damage in emergency operation The assembly of the locking device on the turbocharger is only permiss ible in emergencies It is not permitted to lock the rotor for an engine test Serious damage to engine or property can be caused by non com pliance with the regulations in the event of an emergency u The permissible turbocharger speed for the unlocked turbocharger may not exceed 45 of nBmax...

Page 98: ...it cover plate NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Cover plate dimensions mm Product B1 B2 B3 B4 B5 B6 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 Page 96 108 ...

Page 99: ... Taking out of operation at short notice 9 2 Fit cover plate Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 NOTICE Carry out the work as described in the chapter Removal and fitting u Remove cartridge group Page 97 108 ...

Page 100: ... 2 Fit cover plate Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger Page 98 108 ...

Page 101: ... builder s instructions Common receiver The air line must be closed off at the engine end because the undam aged turbochargers build up a receiver pressure CAUTION The engine can be operated according to the engine builder s instruc tions Attention must always be paid to the speed of the undamaged turbocharger The speed limit nBmax given on the rating plate must not be exceeded 9 3 Blocking the in...

Page 102: ...32 VA33 9 Taking out of operation at short notice 9 4 Bypass the turbochar ger Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 NOTICE In this respect refer to the engine manufacturer s instructions Page 100 108 ...

Page 103: ...nd this is circulated by the pre lubrica tion pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health u Do not breath...

Page 104: ...han 12 months If the engine is taken out of operation the following variants are pos sible with regard to the turbocharger The turbocharger remains mounted on the engine The turbocharger casing remains mounted on the engine but the ro tor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station The turbocharger is removed completely either as a whole or in in...

Page 105: ... for more than 12 months Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Condition of the mothballed turbocharger u Check the mothballed turbocharger parts for corrosion once per an num u If there are signs of rust Clean parts thoroughly and renew protection against corrosion Page 103 108 ...

Page 106: ...mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic materials filter components of felt and polyethy...

Page 107: ...sideration 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 u Parts showing signs of rust should be carefully cleaned and greased u Dispose of replaced and unusable parts in a professional and environ mentally compatible way Required customer spare part set 97070...

Page 108: ...Operation Manual TPL65VA32 VA33 12 Spare parts 12 1 Ordering spare parts Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 Page 106 108 ...

Page 109: ...tion Manual TPL65VA32 VA33 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 All rights reserved HZTL2464_EN Rev E March 2020 12 2 View of turbocharger with part numbers Page 107 108 ...

Page 110: ...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 72029 Stud 72027 Hex...

Page 111: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland ...