ABB HT841994, Operation Manual

Page 1: ...ABB Turbo Systems Ltd CH 5401 Baden Type TPS 48E01 HT841994 nMmax 1003 t Mmax 680 nBmax 953 t Bmax 650 1 s C 00180 16 50 50 Year 2013 made in Switzerland Application according to the Operation Manual kg HZTL2410 English TPS 48E01 Original Operation Manual ...

Page 2: ...stes or at a specialised collecting centre ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland Operating condition and replacement intervals The operational limits for the turbocharger nBmax tBmax nMmax tMmax inspection and replacement intervals for the compon ents concerned on the rating plate are valid for the operational mode and compressor inlet condition which has been agreed up...

Page 3: ...afety 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 Use of ABB turbochargers on gas engines 2 9 Periodic checking of the pressure vessel 2 10 Lifting loads 3 Commissioning 3 1 Oil supply 3 2 Inspection work 3 3 Commi...

Page 4: ...Remove the turbocharger 7 4 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Disassembling and assembling turbocharger 8 4 Axial clearance A and radial clearance B 8 5 Radial clearances N and R 8 6 Table of tightening torques 9 Taking out of operation 9 1 Shutting down the turbocharger 10 Mothballing the turbocharger 10 1 Taking the engine out of opera...

Page 5: ...d 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 engine and the turbocharger installed ...

Page 6: ...1 2 1 Suction branch filter silencer 8 Gas outlet flange 2 Compressor casing 9 Nozzle ring 3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine end bearing flange 5 Axial thrust bearing 12 Compressor end bearing flange 6 Radial plain bearing visible only at turbine end 13 Compressor wheel 7 Turbine 1 2 Copyright 2015 ABB All rights reserved ...

Page 7: ... 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 drawn into the compressor wheel 13 through the suction branch or filter silencer 1 It then passes through the diffuser 3 and leaves the turbocharger through the outlet on the compressor casing 2 The rot...

Page 8: ...her 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 third parties In addition improper use...

Page 9: ... 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 safety gloves against chemical risks The fo...

Page 10: ... an opening 1 in the wooden crate which allows this check to be carried out When the display field has changed colour at the 70 level the maximum permissible humidity has been exceeded In this case the turbocharger or rotor must be inspected by an ABB Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the turbocharger or cartridge group must be insp...

Page 11: ... is undamaged the replacement turbocharger or replacement cartridge group can be placed into operation without any prior testing by an ABB Turbocharging Service Station Unpacking replacement turbochargers or spare parts The corrosion protection effect ends after the material is unpacked from the VCI package To avoid the formation of condensation the surroundings and the content of the package must...

Page 12: ...arly 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 be reported to the person or department responsible NOTICE Additions and alterations to and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sy...

Page 13: ...y influenced by using non original parts It must be noted that improper use such as this can be hazardous to persons and the engine Always use original parts from ABB Turbo Systems ABB Turbo Systems accepts no liability whatsoever for any damage caused by the use of non original parts and accessories Qualification of personnel The turbocharger may be operated and maintained only by trained and aut...

Page 14: ...B Turbocharging Service Stations are at your disposal for questions concerning the design version of the supplied turbocharger see chapter Contact address and after sales service 16 Accuracy of illustrations The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instructions Differences may exist in certain details Regist...

Page 15: ...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 Stations In this document official service sta...

Page 16: ...bocharger operating limits during operation 3 Inspection interval for plain bearings in 1000 h 4 Replacement interval for compressor in 1000 h 5 Replacement interval for turbine in 1000 h 6 Part number for customer 7 Designation of special design 8 Turbocharger weight in kg 9 Turbocharger type 10 Serial number 11 Year of turbocharger construction 1 7 Operating limits Recommended inspection and rep...

Page 17: ...ment intervals In such cases we recommend that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during trials on the engine 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...

Page 18: ...015 HZTL2410_EN Revision D Contact address and after sales service 1 8 Contact address ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging After sales service A list of the official ABB Turbo Systems service stations is available online 1 8 Copyright 2015 ABB All rights reserved ...

Page 19: ...nate 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 turbocharger by his personnel All instr...

Page 20: ...mity 2 2 Page 18 April 2015 HZTL2410_EN Revision D 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 Copyright 2015 ABB All rights reserved ...

Page 21: ...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 Copyright 2015 ABB All rights reserved ...

Page 22: ...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 and the word CAUTION are either not fol...

Page 23: ...ded places or are not legible then proceed as follows Order new warning plates from ABB Turbocharging Service Stations Remove unreadable warning plates Clean and degrease surfaces provided for warning plates Attach new warning plates Uninsulated turbochargers When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This i...

Page 24: ...f 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 floor equipment and the turbocharger ...

Page 25: ...l 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 or solvents will be used for cleaning...

Page 26: ...arger 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 manual Perform work only for which t...

Page 27: ...harger 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 training WARNING Mechanical hazards Se...

Page 28: ...ction 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 burns are possible WARNING Risk of burning Touching ho...

Page 29: ...erved 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 operating and auxiliary materials Ing...

Page 30: ...r 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 ventilated Seal containers tightly immedi...

Page 31: ...ular 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 the work area is well ventilated Wear s...

Page 32: ...on D 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 Copyright 2015 ABB All rights reserved ...

Page 33: ...as engines reinforces this value Damage to ABB turbochargers during deflagration events has not been determined in the past ABB Turbo Systems recommends that following a deflagration event the turbocharger undergo a visual inspection Items to check during this inspection are the position of the turbine casing of the compressor casing to the bearing casing as well as a shifting of the bearing casin...

Page 34: ...e 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 required safety precautions must be t...

Page 35: ... 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 80 C Use suitable protection at sharp...

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Page 37: ...e 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 for the turbocharger is 34 µm This means that contaminants larger than 0 034 mm must be filtered out of the oil with a separation efficiency 99 Fit an accessory filter if engine oil filter is not efficie...

Page 38: ...l 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 machine or property damage can be caused by excessively high oil viscosity and the resulting lack of oil in the bearings Do not allow the oil inlet temperature to fall below the minimum 30 ºC when startin...

Page 39: ...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 1 0 CAUTION Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting Activate prelubrication device before starting engin...

Page 40: ...let 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 listed in the following table The specified oil outlet temperature must be regarded as an alarm value for turbocharger operation and be monitored in accordance with standard regulations Status for operati...

Page 41: ...ticles of dirt and solid matter in the oil can cause serious damage to the machine or property During initial commissioning and after all service work the complete lubricating system must be flushed thoroughly with warm oil When running in the engine and after all service work on the lubricating system special running in filters must be used Check the oil pressure in the oil supply lines CAUTION P...

Page 42: ...rbine Measure air temperature in front of and behind compressor 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 hours after commissioning If oily liquid continues to ...

Page 43: ...outlet Inspect exhaust 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 chap...

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Page 45: ...e 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 acoustically by the engine builder He is also resp...

Page 46: ...Page 44 April 2015 HZTL2410_EN Revision D Suggestion for noise insulation of the bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air line 04 Insulation pads 05 Insulation mat at least 15 mm 06 Sheet metal cover Copyright 2015 ABB All rights reserved ...

Page 47: ...carried out too late can lead to excessive contamination and wear as well as operating failures Carry out service work at specified time intervals 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 shortene...

Page 48: ...turer s instructions Clean or replace oil filter in supply line to turbocharger when engine is not running Service work in accordance with instructions on rating plate In general after 8000 12000 hours of operation Rotor and bearing parts must be inspected and assessed by an ABB Turbocharging Service Station The following work can be carried in preparation Remove cartridge group as described in ch...

Page 49: ... values must be entered regularly in the engine 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 ...

Page 50: ...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 cases During the specified periodic service work the individual components are inspected for wear and if necessary replaced Expected replacement intervals h GAS MDO HFO Turbine casing 25000 50000 25000 50...

Page 51: ... 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 specific operating conditions operating point combustion quality composition of exhaust gas For bearing parts Lubricating oil quality oil filtration condition of lubricating oil oil monitoring Load pr...

Page 52: ...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 86505 A Speed sensor cable not integrated 86526 F I converter 86505 B Speed sensor cable integrated 86528 Tachometer 86515 A Cable connector for 86505 A 1 Screw plug 86515 B Cable connector for 86505 B 2 Gasket 4 4 Copyright 2015 ABB A...

Page 53: ...ed 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 the turbochargers and compare them wit...

Page 54: ...r safety gloves when removing the cable connector and speed sensor Wear safety gloves against thermal risks Reduce engine performance to the idling speed then 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 Adhere to tightening torque Par...

Page 55: ...sor is designed with a sealing lip and does not require an additional gasket when fitted Connect cable connector to speed sensor Switch on lubricating oil supply to turbocharger Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting 4 4 3 Copyright 2015 ABB All rights reserved ...

Page 56: ...ng lubricating oil Post lubricate for 15 20 minutes Maintain oil pressure of 0 5 1 0 bar for post lubrication CAUTION Stopping the engine of water cooled turbocharger version Heat in the turbocharger must be dissipated Allow turbocharger cooling water to run for 15 20 minutes after stopping engine Allow oil lubrication to continue running until rotor comes to a stop Further post lubrication is not...

Page 57: ...ed out too often this can lead to damage and corrosion on the components If cleaning during operation is not sufficient to achieve acceptable values regarding thermal load and engine performance mechanical cleaning of certain spots can be carried out Perform mechanical cleaning especially of the cartridge group only once within the service interval NOTICE Cleaning method To allow you to observe th...

Page 58: ... 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 service work carried out when the turbocharger is completely dismantled and the compressor is cleaned mechanically NOTICE If the coating of dirt is very thick and hard the compressor can only be cleaned manu...

Page 59: ...its when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives Don t use salt water for cleaning but only clean fresh water CAUTION The injection pipe must on no account be connected directly via a cock to a water pipe or a dosing vessel larger than the one supplied This prevents uncontrolled volumes of water entering the turbocharger and engine which c...

Page 60: ...uitable 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 pressure compressor stages with two stage charging Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Sy...

Page 61: ...on period of at least 10 minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the charging or flushing pressure and also from the exhaust gas temperatures If the cleaning process is unsatisfactory it can be repeated up to 2 times If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that y...

Page 62: ...rformance After stopping the engine the rotor can become stuck in contamination deposits Experience with turbocharger operation shows that the intervals between overhauls can be extended if cleaning while in operation is carried out periodically Wet cleaning the turbine as described below should be used for 4 stroke applications when there are heavy deposits from for example HFO Under no circumsta...

Page 63: ...als prove incompatible with engine operation please contact ABB Turbo Systems Cleaning method Turbine components are cleaned during operation using the wet cleaning processes described in the following These have been tested and are approved by ABB Turbo Systems The turbine casing design and the type of turbine casing sealing are decisive for the choice of cleaning method NOTICE Approval by engine...

Page 64: ...hermal 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 turbocharger designs with additional sealing by means of C rings Based on a 10 minute injection phase this cleaning process utilises the water solubility of the dirty deposits NOTICE Choice of cleaning method If yo...

Page 65: ...ture at the turbine inlet can be up to 100 C higher than the exhaust gas temperature after the cylinder This should be taken into consideration when setting the operating point before cleaning Don t exceed maximum temperature in front of turbine when cleaning CAUTION Impermissible thermal stressing and flooding of the turbine Smaller volumes of water can result in poor cleaning Larger volumes of w...

Page 66: ...s Characteristic component 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 supply ensured Water pressure overpressure over atmosphere pWT 2 0 bar 1 5 bar If necessary engine performance must be reduced to maintain these conditions The cleaning cycle can now be started based ...

Page 67: ... load again This completes the turbine cleaning process Cleaning parameters during the process TPS Temperature in front of the turbine during cleaning C Water volume flow 1 dm3 min Injection time min Pause between injections min 48 450 6 0 5 3x 3 52 8 57 11 61 17 5 1 corresponds to a water pressure pWT of 2 0 bar overpressure over atmosphere CAUTION Maximum temperature in front of turbine during c...

Page 68: ...rameters during the process TPS Temperature in front of the turbine during cleaning C Water volume flow 1 dm3 min Injection time min Stabilising phase before after water injection min 48 530 4 10 10 52 5 5 57 8 5 61 12 1 corresponds to a water pressure pWT of 1 5 bar overpressure over atmosphere CAUTION Maximum temperature in front of turbine during cleaning When cleaning the temperature in front ...

Page 69: ...bine casings have protective coatings which can also be damaged Only use soft tools such as cloths brushes or wire brushes In the event of heavy contamination the cleaning methods that have been described such as soaking can be repeated until a satisfactory result has been achieved Dispose of dirty water and cleaning agents in an environmentally compatible manner professionally and in accordance w...

Page 70: ...g the filter ring if provided Remove filter ring 81265 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 cleanliness of the air that is drawn in Wash filter ring 81265 using water containing light duty detergent or if very heavily contaminated soak it while sque...

Page 71: ... with a mild jet of compressed air soft brush or a damp cloth Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station Fitting the filter silencer Insert the absorption segments 81136 into the sheet metal coverings 81137 Bend the sheet metal coverings 81137 back into their original shape and insert them into the slot guides in the silencer b...

Page 72: ...omply with local legislation Wear safety goggles Wear safety gloves against mechanical risks Wear a respiratory mask to protect against gases The following performance relevant parts can be cleaned according to the following description 72000 Compressor casing 77000 Wall insert 79000 Diffuser Clean the components specified above with steam or allow to soak in diesel oil or water with household det...

Page 73: ...lies Comply with local legislation Wear safety goggles Wear safety gloves against mechanical risks Wear a respiratory mask to protect against gases Baked on layers of dirt for example from heavy fuel oil or coked oil occur at the turbine end The following performance relevant parts can be cleaned according to the following description 51000 Turbine casing 56001 Nozzle ring 52400 Gas outlet flange ...

Page 74: ...er cleaning parts may corrode Re install and use 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 removed through cleaning during operation and must be cleaned mechanically during the standard service intervals see chapter entitled Service work Remove tu...

Page 75: ... group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter into the cartridge group Clean compressor wheel with a cloth or soft brush soaked in water with household detergent Do not use any wire brushes Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of com...

Page 76: ...ibed below Product A mm B mm C mm 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 submerged vertically in a tank 02 with liquid Place the tank 02 in a larger container 03 so that the excess liquid can be collected CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals Use ...

Page 77: ...ardous to health Observe the information in the material safety data sheet Wear a respiratory mask according to material safety data sheet CAUTION Water and dirt in the cartridge group If water or dirt gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be damaged Place the cartridge group on suitable wooden or metal supports 01 Maintain dim...

Page 78: ...l to health Avoid the formation of dust Vacuum up dust with a suitable vacuum cleaner Wear a respiratory mask to protect against particles P1 or P2 mask Wear safety goggles Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Raise the cartridge group and align horizontally Remove dirt manually with a soft brush or wire brush Removing...

Page 79: ...e This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank 02 with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of dirt detach completely Raise the cartridge group and align horizontally Clamp the partition wall with the bearing casing Dry...

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Page 81: ...B 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 tolerances must be observed to avoid a signi...

Page 82: ...e 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 operating conditions such as when reducing ...

Page 83: ...oo 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 exhaust gas pipes or charge air ducts Mak...

Page 84: ...n it Cooling water volume too small Top up water Entry temperature of cooling water too high Inspect clean cooling system Inadequate ventilation Improve ventilation Charge air pressure too low Engine output and engine speed unchanged air intake condition normal Possible causes Elimination Engine Air receiver leaky Repair it Gas line between engine and turbine leaky Maladjusted injection system Cor...

Page 85: ...e Replace manometer Fouling of the compressor due to the feeding in of ventilation gases Reduced compressor performance efficiency hence engine performance losses Possible causes Remedy Turbo charger Heavy fouling of the compressor components Clean compressor Optimize oil separation Increased vibrations compressor blade damage Correct the feed of ventilation gases according to instructions of engi...

Page 86: ...ion 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 turbocharger 6 4 Copyright 2015 ABB All rights ...

Page 87: ...ectronics This problem is eliminated by removing the gasket Defective sensor Contact an ABB Turbocharging Service Station Measured speeds too high Contaminated sensor tip The sensor tip is magnetic and can thus attract metal particles As a result the distance to the signal generating sealing disc is reduced which can lead to amplification of the noise component and consequently to faulty triggerin...

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Page 89: ...and installation Transport 7 1 Suspension of uninsulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas outlet casing Suspension of insulated turbocharger Turbocharger with oil cooled bearing casing Complete turbocharger with gas outlet casing 7 7 1 Copyright 2015 ABB All rights reserved ...

Page 90: ...s 7 2 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 TPS48 kg TPS52 kg TPS57 kg TPS61 kg 180 250 410 650 7 2 Copyright 2015 ABB All rights reserved ...

Page 91: ... Remove screws and plate B of bearing casing insulation Remove remaining screws of bearing casing insulation A Pull bearing casing insulation up and off Squeeze bearing casing insulation together so that it can be removed more easily Unplug cable connector of speed sensor Fasten lifting gear to bearing casing If a gas outlet pipe elbow is provided sling lifting gear around it additionally or faste...

Page 92: ... swivel lifting eye C See also section Transport Weights Adapt turbocharger to suit engine Tighten fixing screws D on bearing casing Plug in cable connector of speed sensor and variable compressor intake VCI If provided fasten hard insulation as follows Adapt bearing casing insulation to suit Tighten screws of bearing casing insulation A Adapt screws and plate B of bearing casing insulation to sui...

Page 93: ... ABB Turbo Systems recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Station NOTICE Marking casing positions 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...

Page 94: ...ice When disassembling the turbocharger a fitted oil orifice must not be removed Tightening torques for turbocharger components The specified tightening torques of screw connections for turbocharger components must be observed See section Table of tightening torques Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described the screws and nuts of the assembly devices...

Page 95: ... 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 component or an assembly blind hole thread eye lug Assembly device Devices mounted on the turbocharger to create a suspension point Assembly devices are calculated and designed especially for the defined application They...

Page 96: ...on D 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 capacity TPS48 M10 17 mm 250 kg TPS52 M10 17 mm 250 kg TPS57 M12 21 mm 350 kg TPS61 M12 21 mm 500 kg Copyright 2015 ABB All rights reserved ...

Page 97: ...61 kg 1 Filter silencer 19 30 40 65 2 Radial air suction branch 6 8 11 21 3 Axial air suction branch 4 4 6 9 4 Compressor casing 24 35 55 90 5 Wall insert 7 10 13 30 6 Diffuser 2 3 6 10 7 Cartridge group 35 50 85 140 8 Nozzle ring 1 2 3 6 9 Burst ring 2 3 5 12 10 Turbine casing with external burst protection 1 inlet 35 50 80 130 2 inlets 35 50 86 150 3 inlets 53 95 170 4 inlets 95 170 11 Gas outle...

Page 98: ... Do not touch hot surfaces and heed the warning plate on the turbocharger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down before carrying out any work Wear safety gloves against thermal risks Disconnect all air lines in accordance with the enginebuilder s instructions Remove the screws for the compressor casing insulation and dismantle the insulation U...

Page 99: ...ing the insulation Loosen and remove the screws for the insulation plates 1 2 Remove the insulation plates 1 2 Slightly loosen the screws 72011 and turn the compressor casing 72000 until the swivel lifting eye can be fastened to the lifting gear 77006 only provided with the wall insert with acceleration aid If provided Copyright 2015 ABB All rights reserved ...

Page 100: ...nd if it is not used properly too much pressure on one side it can damage the rotor It should thus be used alternately on both sides while avoiding excessive pressure on either side Loosen the screws 72011 and remove them together with the fastening strips 72012 Move the compressor casing 72000 with the wall insert 77000 carefully away doing so horizontally Tap the wall insert 77000 out of the com...

Page 101: ...ssor casing together with the filter silencer also see the previous chapter WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns Do not touch hot surfaces and heed the warning plate on the turbocharger Wear heat resistant safety gloves and protective clothing Allow the turbocharger to cool down before carrying out any work Wear safety glov...

Page 102: ...and assembling turbocharger 8 3 Page 100 April 2015 HZTL2410_EN Revision D Withdraw nozzle ring 56001 using two extraction devices 90070 and withdraw bottom part of service support 90012 Remove C ring 51105 If provided Removing the diffuser Copyright 2015 ABB All rights reserved ...

Page 103: ...8 3 Page 101 April 2015 HZTL2410_EN Revision D Put cartridge group 42001 on service support 90012 and secure using bolts Remove screw 42008 and remove diffuser 79000 complete with O ring 42012 Measure axial and radial clearances See section Axial and radial clearances Copyright 2015 ABB All rights reserved ...

Page 104: ...new ones O rings are only available as a set see chapter Spare parts NOTICE Protruding insulation The insulation on the turbine casing may protrude at the gas outlet side This can be pushed back in with a screw driver Push the nozzle ring 56001 into the turbine casing 51000 as far as it will go Insert the C ring 51105 into the turbine casing and hold it in place using high vacuum grease If provide...

Page 105: ... operation it must be clamped between the partition wall and the turbine casing Calculate the press fit PD as shown NOTICE If the calculated value PD is less than 0 1 mm an official ABB Turbocharging Service Station must be contacted Measure the axial and radial clearances see the section Axial and radial clearances Nozzle ring press fit for single inlet turbine casing Copyright 2015 ABB All right...

Page 106: ... Revision D Calculate the press fit PD as shown NOTICE If the calculated value PD is outside 0 2 mm an official ABB Turbocharging Service Station must be contacted Measure the axial and radial clearances see the section Axial and radial clearances Nozzle ring press fit for multiple inlet turbine casing Copyright 2015 ABB All rights reserved ...

Page 107: ... fasten to bearing casing 42001 Unscrew the cartridge group and lift it out of the service support 90012 Apply high temperature grease to the centering points and screw threads Remove temporary covers from oil connections CAUTION Don t damage or shift gasket rings A in the mounting support when fitting the cartridge group The gasket rings A are supplied by the engine builder Fitting diffuser Copyr...

Page 108: ...group using fastening strips 51002 Verbus Ripp washers 51003 and nuts 51007 also see the chapter entitled Table of tightening torques Fasten the bearing casing 42001 using the fixing screws C Tighten the fixing screws C to the torques listed in the following table For the assembly of the turbocharger on the engine support the threads of the screws and screw heads must be lightly oiled assumed coef...

Page 109: ...2 Removing gas outlet bend and gas outlet flange Disconnect all lines in accordance with engine builder s instructions and remove insulation See also preceding chapter Loop lifting gear around gas outlet bend 51100 Remove gas outlet bend 51100 and gasket 52406 Only gas outlet bends from ABB Turbo Systems have the gasket 52406 Remove gas outlet flange 52400 and if fitted C ring 52408 If provided If...

Page 110: ... 52400 In the case of gas outlet bends 51100 from ABB Turbo Systems always replace the gasket 52406 see the chapter entitled Spare parts Apply high temperature grease to contacting surfaces and threads Fit the turbine casing using the nuts 52433 while observing tightening torques specified in the table of tightening torques Fasten the insulation Attach pipes in accordance with the enginebuilder s ...

Page 111: ...ury due to sharp edges on the compressor wheel The compressor wheel has sharp edges which can cause injuries Wear safety gloves Wear safety gloves against mechanical risks TPS48 TPS52 TPS57 TPS61 A minimum 0 08 0 10 0 12 0 15 A maximum 0 16 0 18 0 21 0 25 B minimum 0 50 0 61 0 72 0 81 B maximum 1 00 1 15 1 31 1 55 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn...

Page 112: ...s result from the manufacturing tolerances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange N1 and N2 as well as R1 and R2 are each measured at the same time using two feeler gauges To measure N1 and N2 the feeler gauges must be pushed between the wall insert and the compressor wheel free of play in each case above and below To measure R1 and R2 the feeler gauges ...

Page 113: ...1 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 tolerance Clearances 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 Measuring N and R Radial clear...

Page 114: ...able of tightening torques 8 6 The following tightening torques must be used for the specified screw connections Item Part number TPS48 TPS52 TPS57 TPS61 1 72020 60 60 60 60 2 42008 10 10 20 40 5 52433 20 40 65 65 6 51007 25 45 75 75 9 72011 35 70 105 105 10 86505 15 15 15 15 8 6 Tightening torques Nm Copyright 2015 ABB All rights reserved ...

Page 115: ...nd the engine can be shut down for only a short time for emergency repairs proceed as follows Fit the cover plate CAUTION Always heed precisely the engine builder s instructions in case of engine operation with a blocked throttled turbocharger Dismantling the turbocharger Dismantle the turbocharger see the section Dismantling and fitting the turbocharger Do not dismantle the nozzle ring 9 9 1 Copy...

Page 116: ... the turbine casing using the cover plate A Fasten the cover plate on the turbine casing 51000 using the fastening strips 51002 Verbus Ripp Verbusripp washers 51003 and nuts 51007 and screw it down securely on the support NOTICE Thoroughly clean the fastening strips 51002 before fitting them Apply high temperature grease to the stud threads 51006 Copyright 2015 ABB All rights reserved ...

Page 117: ...e following drawing Material Common structural steel according to 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 2 100 190 17 2 2 220 TPS61 116 8 120 226 20 5 2 4 260 Product B7 ØD1 0 2 ØD1 0 2 ØD2 R1 M TPS48 35 7 222 7 227 7 17 105 M8 TPS52 39 6 265 7 271 7 21 125 M8 TPS57 48 2 325 7 332 5 21 153 M10 TPS61 56 8 387 7 395 9 2...

Page 118: ...ger 9 1 Page 116 April 2015 HZTL2410_EN Revision D Diameter for turbine casing designs for optional C ring sealing NOTICE Information about the turbine casing design with without C ring sealing can be requested from an ABB Turbocharging Service Station Copyright 2015 ABB All rights reserved ...

Page 119: ...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 or contact with them may be harmful t...

Page 120: ...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 of the stack draught Install blind fla...

Page 121: ... 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 re assembled from the individual comp...

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Page 123: ...les 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 metallic materials filter components of felt...

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Page 125: ...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 Customer spare part set 97070 The customer spare part set 97070 is required for the work ...

Page 126: ...l TPS48 D E TPS61 D E Spare parts 12 View of turbocharger showing part numbers 12 2 Page 124 April 2015 HZTL2410_EN Revision D View of turbocharger showing part numbers 12 2 12 2 Copyright 2015 ABB All rights reserved ...

Page 127: ...56001 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 79000 Diffuser 81000 Filter silencer 81010 in customer spare part set O ring 82000 Axial air suction branch 82010 in customer spare part set O ring 86505 A Speed sensor cable not integrated 86505 B ...

Page 128: ...PS48 D E TPS61 D E Spare parts 12 View of cartridge group showing part numbers 12 3 Page 126 April 2015 HZTL2410_EN Revision D View of cartridge group showing part numbers 12 3 12 3 Copyright 2015 ABB All rights reserved ...

Page 129: ...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 32114 Turbine end socket screw 32221 Bearing cover 32222 O ring 42001 Bearing casing 42002 Socket screw 42008 in customer spare part set Socket screw 43001 Partition wall 43012 Metal C ring depends on...

Page 130: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...