ABB HT842691, Operation Manual

Page 1: ... Systems Ltd CH 5401 Baden Type TPL69 A10 HT842691 nMmax 426 t Mmax 650 nBmax 405 t Bmax 620 1 s C 01780 36 50 50 Year 2017 made in Switzerland Application according to the Operation Manual kg HZTL2481 English TPL69 A10 Original Operation Manual ...

Page 2: ...Replacement intervals of components depends on the load profile turbine inlet temperature suction air temperature and turbocharger speed In case the operation conditions differs significantly from what is considered to be normal for the cur rent application it is recommended to contact ABB for a re calculation of replacement intervals Frequent load alterations high temperatures and high speed lowe...

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

Page 4: ...ed measurement system 7 Removal and installation 7 1 Turbocharger weights 7 2 Removing the turbocharger 7 3 Installing the turbocharger 8 Disassembly and assembly 8 1 Introduction 8 2 Module weights 8 3 Removing and fitting filter silencer or air suction branch 8 4 Axial clearance 8 5 Removing cartridge group 8 6 Dismantling and installing the turbine diffuser and nozzle ring 8 7 Installing cartri...

Page 5: ...481_EN Revision B 10 1 Taking the engine out of operation for up to 12 months 10 2 Taking the engine out of operation for more than 12 months 11 Disposing of turbocharger components 12 Spare parts 12 1 Ordering spare parts 12 2 View of turbocharger with part numbers 12 3 View of turbine cleaning system with part numbers optional ...

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Page 7: ...d by ABB Turbo Systems and to use it as intended It provides important information in order that the turbocharger can be op erated safely correctly and efficiently This Operation Manual complements and expands existing national regu lations concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechanics who are responsible for ope...

Page 8: ...ights reserved December 2016 HZTL2481_EN Revision B Layout and function 1 2 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing 1 2 ...

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

Page 10: ...The manufacturer accepts no liability for other applications If it is used otherwise ABB Turbo Sys tems 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 u...

Page 11: ...h 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 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 safe...

Page 12: ... an ABB Turbocharging Service Station and repacked Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Turbo charging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOT...

Page 13: ...d This also applies to the provision and wearing of personnel protection equipment NOTICE The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual The turbocharger must be shut down immediately by stopping the en gine in the event of alterations affecting safety or of corresponding op erating behaviour The fault...

Page 14: ...s and corresponding accessories Competence of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not rele vant for a specific turbocharger variant ABB Turbochar...

Page 15: ...rk 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 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 Turb...

Page 16: ...greed with the en ginebuilder 02 Turbocharger operating limits during operation 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h 06 Customer part number 07 Designation of the special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 M...

Page 17: ...ommend that you contact the nearest official ABB Turbocharging service station nMmaxand tMmax normally apply only when running at overload 110 during tri als on the engine test bed These limits can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals can increase the risk of unpredictabl...

Page 18: ...ghts reserved December 2016 HZTL2481_EN Revision B Contact information 1 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging 1 8 ...

Page 19: ...erials used are the consequence of insufficient observance of the safety instruc tions 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 turbo charger by his personnel All instructions in this chapter must be observe...

Page 20: ...Ear protection Definition of Safety instructions 2 4 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 precisely Warning sign...

Page 21: ...e been attached to turbochargers by ABB Turbo Sys tems must not be removed Illegible warnings must be replaced with new ones Further information is available from ABB Turbocharging service stations Part number Size mm Product 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivered to the engine builder the warning plates must be subsequently attached to the insulation This is the respo...

Page 22: ...all general regulations for the prevention of accidents Do not work on the turbocharger if you are under physical or mental stress Work only with suitable tools as well as equipment and working mate rials 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 ob stacles on the floor ...

Page 23: ...y report any damage or changes in operational perfor mance to person responsible If damage is discovered immediately shut down turbocharger and se cure 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 de...

Page 24: ...e engine must be switched off and the turbocharger must have come to a standstill Ensure that the supply of oil is interrupted especially with an external oil supply Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger Perform only those tasks that are described...

Page 25: ...raught Operate the turbocharger in accordance with instructions During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various risks can occur through the improper handling of components through the non observance of work instructions due to inadequate care or as a consequence of insufficient training WAR...

Page 26: ...s dependent on the effectiveness of the insulation being used The tem perature can become high enough so that it falls into ranges where burns are possible 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 turbo charger Wear heat resistant safety gloves and protective clothing ...

Page 27: ... the skin Ensure good ventilation Observe details in the safety data sheets of the operating and auxil iary materials Observe local laws Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases WARNING Risk of fire explosion Combustible or easily ignited operating and auxiliary materials can burst into flame or vapours from them ca...

Page 28: ...tible manner in accordance with statutory regulations Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations Unsuitable combustible insulating materials signify a fire hazard Use only suitable non combustible insulating materials Ensure that the work area is well ventilated Avoid sti...

Page 29: ...n or with electrical components may only be performed by trained specialists Heed any country specific regulations Periodic checking of the pressure vessel 2 8 The pressure vessels used by ABB Turbo Systems such as those for wet or dry cleaning are so called simple pressure vessels The local statutory regulations covering periodic checks of pressure vessels must be observed The operator is respons...

Page 30: ...e stand beneath a suspended load Wear safety gloves to protect against mechanical hazards 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 respec tive handling steps Before attaching slings allow turbocharger components to cool...

Page 31: ...al conditions is an important prerequisite for trouble free tur bocharger operation The turbocharger is normally lubricated with oil from the engine oil circuit NOTICE With regard to the oil supply please observe the engine builder s speci fications for lubricating oil selection oil change intervals oil filtration oil pressure and oil temperature Oil filtration A lubrication oil filter system with...

Page 32: ...on the turbocharger are listed below Status for operation Oil pressure in front of the turbo charger 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 NOTICE Oil orifice A metering orifice is installed in the...

Page 33: ...he oil 30 30 Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the fol lowing table The specified oil outlet temperature is to be considered as alarm value for the turb...

Page 34: ...k oil filter for cleanliness before commissioning CAUTION Contaminated oil Particles 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 lubricat ing system special running i...

Page 35: ...as temperature in front of and behind turbine Measure air temperature in front of and behind compressor The measured values must be compared with the values in the ac ceptance test report while taking different operating conditions into ac count 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 ...

Page 36: ...e air duct before gas inlet and after gas outlet Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move 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...

Page 37: ...e from the turbocharger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the turbocharger in order to observe this limit value Fitted air inlet system All standard noise reducing measures have been taken2 The bellows at the air outlet have been perfectly insulated a...

Page 38: ...1 Page 36 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Charge air duct scavenging air line 06 Sheet metal cover ...

Page 39: ... 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 shortened service interval must be arranged with ABB Turbo Sys tems NOTICE Service inspection after 5 years To prevent age and stoppage related ...

Page 40: ...e 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 filter Servicing work according to the ...

Page 41: ...ring casing and blow air through oil ports Clean nozzle ring and check for cracks and erosion Inspect and assess bearing parts and rotor Service work every 24000 36000 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 Disassemble turbocharger Measure clearances Clean the turbine and compressor w...

Page 42: ...ating components and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections are carried out the individual components are inspected for wear and tear and replaced if necessary In this way trouble free operation is ensured The following parameters influence the replacement intervals for turbo charger compone...

Page 43: ...et casing 50000 100000 25000 50000 Gas outlet casing 50000 100000 35000 100000 Nozzle ring 35000 50000 25000 50000 Turbine diffuser cover ring 35000 50000 25000 50000 Other casings 100000 100000 Axial bearing components 24000 36000 24000 36000 Radial bearing components 24000 36000 24000 36000 Turbine blades due to wear 12000 Rotor components See the data on the rating plate GAS Gas Engine MDO Mari...

Page 44: ...ed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out 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 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine ...

Page 45: ...re the temperatures in the air and gas lines to and from the tur bochargers and compare them with standard values If the engine can be stopped for a short time Inspect the air and gas lines as well as the turbocharger and eliminate any problems In any event it is recommended that you contact the nearest ABB Turbocharging Service Station Assembly If the speed sensor is not fitted on the turbocharge...

Page 46: ...g 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 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 designe...

Page 47: ...mat on the filter silencer can cause a loss of pres sure A significant pressure loss indicates an increase in dirt build up in the filter material U tube manometer on filter silencer if present 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss Pressure difference With a clean filter silencer and clean filter mat if provided the maximum pressure loss A is 120 mm H2O at full load W...

Page 48: ...016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Stopping the engine 4 6 CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil Allow the engine to continue running at idling speed for a further 10 minutes before stopping 4 6 ...

Page 49: ...regular visual checks 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 specified intervals The safety precautions must be observed during all maintenance and servicing work The cleaning points described in the following are Fil...

Page 50: ...er 2016 HZTL2481_EN Revision B Cleaning the filter silencer 5 2 Filter silencer with tension band 81265 Filter ring if provided 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Sheet metal covering 81268 Connecting strip 81135 Filter silencer body E Insert unit absorption segment sheet metal covering fitted 5 2 5 2 1 ...

Page 51: ...nsert units E bend open sheet metal coverings 81137 then take out absorption segments 81136 Clean the absorption segments 81136 During cleaning ensure that the absorption segments 81136 are only cleaned with a mild jet of compressed air soft brush or a damp cloth Otherwise there is a risk of damage or deformation NOTICE Replace heavily contaminated absorption segments filter ring and damaged conne...

Page 52: ...ghts reserved December 2016 HZTL2481_EN Revision B Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut E Insert unit absorption segment sheet metal covering 5 2 2 ...

Page 53: ...drawn in air is Clean filter strip every 500 hours of service or more frequently if necessary Unscrew and remove lock nuts 81273 Unscrew and remove screws 81272 for connecting rods 81269 Remove connecting rods 81269 Carefully remove cover grids 81266 Pull out insert units E bend open sheet metal coverings 81137 and then remove absorption segments 81136 Clean the absorption segments 81136 During cl...

Page 54: ...erings 81137 Bend sheet metal coverings 81137 back to original shape Insert the insert units E into slot guides in filter silencer unit 81135 Uniformly place cover grids 81266 in correct position Push connecting rods 81269 through lugs of cover grids 81266 CAUTION If the connecting rods 81269 are not correctly positioned in their re cesses on the filter silencer unit 81135 the cover grid 81266 can...

Page 55: ...g screws 81272 When tightening the screws 81272 ensure that connecting rods 81269 are located correctly in recesses in filter silencer body 81135 Now tighten screws 81272 alternately until the following maximum torque is reached Screw Tightening torque Nm 81272 20 Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 81273 40 Fit filter strip 81265 If...

Page 56: ...oil mist or dust are in the intake air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays a severe increase of the contamination It does not however replace the regular service work during which the turbocharger is completely disman ...

Page 57: ...ough an injection pipe fitted in the filter silenc er or the suction branch The water does not act as a solvent but the dirt deposit is removed by the mechanical impact of the droplets This is a very suitable process provid ed that the degree of contamination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water...

Page 58: ...ger must be maintained Operate engine for at least five additional minutes after cleaning The cleaning process can be repeated up to two times How successful the cleaning was can be seen from the charging pres sure or the exhaust gas temperature If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory it is recommended to have the turbo charger ...

Page 59: ...tory cleaning process which has been tested and is recommended by ABB Turbo Systems the following pre requisites must be fulfilled Engine load 50 85 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3 Operating procedure for compressor wet cleaning with XC3 The operating state prerequisites for compressor cleaning with XC3 must be fulfilled Remove s...

Page 60: ...ed After cleaning wait at least 5 minutes to allow turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station Cleaning p...

Page 61: ... is why regular and correctly performed cleaning is important in order to remove the de posits that have formed Contaminated turbine components can cause a slight increase in charging pressure because of narrowing of the turbine cross section The contami nation causes a drop in turbine efficiency and the engine temperatures downstream of the cylinder can increase The engine performance must theref...

Page 62: ...o salt water and cooling water additives Don t use salt water for cleaning but only clean fresh water Components at the turbine end are not cleaned until the engine has been started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see section Prerequisites 61 CAUTION Exhaust gas temperature stabilising and drying tim...

Page 63: ...cleaning The following operating state and prerequisites have been tested and ap proved by ABB Turbo Systems for the cleaning process The engine has just been started or the engine load has been reduced as far as possible best cleaning is achieved at a load level of roughly 10 15 As soon as the turbine inlet temperature is stable and below 430 C wait at least another 10 minutes for the charger par...

Page 64: ...ed Open drain pipe 08 09 if provided Switch over 3 way valve 04 from scavenging air mode to water sup ply Set the required volume of water on the flowmeter as shown in the ta ble see table Cleaning parametersTPL C 3 nozzles Cleaning pa rameters for wet cleaning of turbine and nozzle ring After injecting required volume of water shut off water supply again by switching over 3 way valve 04 to scaven...

Page 65: ...ing process If a drainage system is not provided the injected vol ume of water can be controlled by a flowmeter in the water supply The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station The influence of the cleaning water on peripheral equipment such as a boiler must be clari fied by the operator The following must be observed...

Page 66: ...t 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Wet cleaning parameters for turbine and nozzle ring Product Maximum temper ature at start of cleaning process TTI C Injection time t i min Water flow rate per turbo charger at pWater 2 bar MW l min TPL69 A 430 10 18 TPL73 A 24 TPL77 A 37 Table of cleaning parameters ...

Page 67: ...sitive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have protec tive coatings which can also be damaged Only use soft tools such as scouring cloths brushes or wire brushes In the event of heavy contamination the cleaning methods described in this chapter such as soaking can be repeated until a satis...

Page 68: ... erating materials and supplies Comply with local legislation Wear safety goggles Wear safety gloves to protect against mechanical hazards Wear a respiratory mask to protect against gases Baked on layers of contamination 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 56001 Nozzle r...

Page 69: ...ely after cleaning Remove turbocharger from the engine see chapter Removal and in stallation Remove cartridge group see chapter Disassembly and assembly First clean the compressor end and then the turbine end in accordance with the following description Cleaning the cartridge group on the compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals Us...

Page 70: ...g the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end The contamination can be removed by soaking and brushing The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following To soften the layers of contamination on the turbine the cartridge group can be submerged vertically in a tank w...

Page 71: ...ane 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 from one of the upper push off threads using a swivel lifting eye and sus pend from the second crane 5 Tighten chain block until entire cartridge group ...

Page 72: ...or wheel The lifting gear must not touch the compressor wheel at any time during rotation 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 ...

Page 73: ...e swivel lifting eye and attach to the first crane 5 Tighten chain block until entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals Use only pH neutral cleaning agents which do not attack metals Observe safety data sheet Fill the tank with soaking liquid Only immerse the car...

Page 74: ...nation in the cartridge group If water or contamination gets into the cartridge group the turbocharger function may be impaired and parts in the cartridge group may be dam aged Place cartridge group on suitable wooden or metal supports 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 particle...

Page 75: ...y distributed residual contamination deposits lead to rotor unbalance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the contamination fill the tank with clean water not salt water Submerge the turbine of the cartridge group in clean water so that loose particles of contamination detach completely Lift the cartridge group Dr...

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Page 77: ...on Turbo charger Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or compressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbo charger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is permis sible The compressor blades and turbine blades are then short ened somewhat Cert...

Page 78: ...rolonged or periodic surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser vice 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 certai...

Page 79: ...ometer Turbo charger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbo charger Heavy contamination of the tur bine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in ...

Page 80: ...em Repair it or contact the manufac turer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine conta minated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Damaged or eroded turbine Contact an ABB Turbocharging Service Station Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the wat...

Page 81: ...ay wrong Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contami nated Damaged compressor turbine 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 un...

Page 82: ...ses during run down Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too short Possible causes Elimination Turbo charger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in tur...

Page 83: ...ich can cause problems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service station Measured speeds too high Dirty sensor tip The sensor tip is magnetic and can thus 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 consequent...

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Page 85: ...ion B Removal and installation Turbocharger weights 7 1 Lifting gear with a sufficient load limit must be used for removing and in stalling the turbocharger The following weight specification is the heaviest variant possible This standard value may deviate from the data on the rating plate depending on the specification TPL69 A TPL73 A TPL77 A 1780 3070 4840 7 7 1 Weights kg ...

Page 86: ... in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Unplug the cable connector on the speed sensor Remove the insulation...

Page 87: ...lace a sling around the bearing casing Attach one lifting gear each to the two fins of the bearing casing pro vided for this purpose Loosen the fixing screws at the foot Lift the turbocharger off the engine and set it down to one side WARNING If support for the turbocharger is missing or defective the turbocharger can tip over during installation and removal and cause serious injuries or even fata...

Page 88: ...s in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Adapt turbocharger to suit engine Tighten fixing screws at foot in accordance with engine builder s in st...

Page 89: ...ing 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 list This list is enclosed in the toolbox WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use Vis...

Page 90: ...ttach turbochargers assemblies or individual components only to lifting gear which is in technically perfect condition and has sufficient load capacity Make sure the load is suspended properly on the crane hook Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load carrying point...

Page 91: ...es are guides round ed off to the next highest value Description TPL69 A TPL73 A TPL77 A 01 Radial air suction branch 80 140 160 02 Filter silencer 140 250 410 03 Compressor casing internal part 85 150 260 04 Wall insert 85 140 280 05 Diffuser 40 60 80 06 Compressor casing external part 180 290 480 07 Cartridge group 360 550 950 08 Turbine diffuser 50 75 150 09 Nozzle ring 17 25 45 10 Gas inlet ca...

Page 92: ...6 ABB All rights reserved December 2016 HZTL2481_EN Revision B Complete compressor casing internal part TPL69 A TPL73 A TPL77 A 210 350 620 NOTICE The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing the diffuser and the wall insert Weights kg ...

Page 93: ...ncer or air suc tion branch 8 3 Disconnect all air lines ducts in accordance with engine builder s in structions Remove insulation where necessary Loop lifting gear around air suction branch Pass lifting gear through possibly provided holes in ribs to improve stability Unscrew nuts 74027 and remove together with washers 74018 Remove air suction branch and set down to one side Install air suction b...

Page 94: ...HZTL2481_EN Revision B Remove insulation where necessary Fit swivel lifting eye 90231 to filter silencer Or Pass lifting gear through rib on filter silencer Pass lifting gear through lugs at back Unscrew nuts 74027 and remove them together with their washers 74018 Remove filter silencer and set down to one side Fit filter silencer in reverse order Removing filter silencer Fitting filter silencer ...

Page 95: ...protect against mechanical hazards Screw on at least four nuts 74027 together with washers 74018 equally spaced around the circumference and tighten them to secure the partition wall axially Measure and note the axial clearance A Axial clearance TPL69 A TPL73 A TPL77 A Clearance A mm 0 33 0 50 0 36 0 53 0 39 0 57 CAUTION Clearances out of tolerance Clearances out of tolerance and excessively worn ...

Page 96: ...27 complete with washers 74018 equally spaced around circumference and tighten Remove insulation Take nuts 90458 out of toolbox and screw onto threaded studs of safety segments 76080 on compressor casing internal part 76000 Tighten nuts 90458 to specified torque see Table of tightening tor ques Tightening torque for nut 90458 TPL69 A TPL73 A TPL77 A 20 Nm 30 Nm NOTICE Note the control dimension u ...

Page 97: ...uds 90320 Leave two holes free for lifting device 90190 Using press off screws 90900 press off the compressor casing in ternal part 76000 until the lifting device 90190 with shackle 90195 can be attached and secured to the crane Slightly lift compressor casing internal part complete with wall insert and diffuser remove guide studs 90320 and then withdraw Fit support angle 90025 Set down compressor...

Page 98: ...ber 2016 HZTL2481_EN Revision B Loop the lifting device around the rear of the flange F Carefully rotate the compressor casing internal part with wall insert and diffuser over the support bracket 90025 and set it down with the front side of the flange F on the underlay CAUTION Make sure that underlay does not shift Check underlay and adjust if necessary ...

Page 99: ...Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Remove screws 76002 Loop lifting gear around diffuser 79000 and remove diffuser Carefully press off the wall insert 77000 using the press off screws 90900 and remove it using the swivel lifting eye 90230 Remove O rings 77005 and 77006 ...

Page 100: ...BB All rights reserved December 2016 HZTL2481_EN Revision B Fasten the lifting device 90190 with shackle 90195 to the compres sor casing external part 74000 and secure it to the crane Loosen nuts 61037 Uniformly press off compressor casing external part 74000 using three press off nuts 61090 remove it and set down to one side ...

Page 101: ...amination behind the flange CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check...

Page 102: ...wo fins of the bearing casing pro vided for this purpose Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the blades on the rotor have insufficient or no clearance this might cause damage to the blades and the casing Check that the blades do not rub on the turbine diffuser by rotating the rotor Withdraw cartridge group and fit supports 90450 ...

Page 103: ...016 HZTL2481_EN Revision B Dismantling and installing the turbine diffuser and nozzle ring 8 6 CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins Before removing the turbine diffuser secure the nozzle to prevent it from falling Before disassembling the turbine diffuser if possible secure the nozzle ring against falling with a lashing strap and a wooden block 8 6...

Page 104: ...02 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Position clamp 90921 over stud 61036 until it lies flat against inner radius of gas outlet casing Insert extension A of torque spanner B through hole in clamp and loosen screws 61056 61057 one after other Do not yet remove the screws 61056 and Verbus Ripp washers 61057 ...

Page 105: ...clamps 90921 over guide studs 90320 and studs 61036 To secure the work screw the nuts 61037 onto the start of stud threads 61036 Remove the remaining screws 61056 and Verbus Ripp washers 61057 Press the turbine diffuser 63000 free using the press off screws 90901 and pull it out it until the clamp 90921 is up against the nut 61037 Loop the lifting gear around the turbine diffuser 63000 and secure ...

Page 106: ...HZTL2481_EN Revision B Fasten the holder 90490 to the gas outlet casing Pull the nozzle ring 56001 in the forward direction fasten it to the lift ing gear and remove it Installing the turbine diffuser and nozzle ring Install the nozzle ring and turbine diffuser in the reverse order of re moval Coat the screw threads with high temperature grease Align nozzle ring with holes or cams in gas inlet cas...

Page 107: ... cartridge group the bearing casing or the turbocharger is fitted to the engine it must be en sured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Remove the cover from the oil connection Fit flange 42044 with screws 42064 and new gasket 42045 Attach one lifting gear each to the two ...

Page 108: ...ance the blades and cas ing could be damaged Check that the blades do not rub on the turbine diffuser by rotating the rotor Remove the lifting gear Fit O ring 42012 Screw in the speed sensor 86505 together with the O ring 86506 and plug in the cable connector 86515 Reconnect oil pipes Version with compressor wheel cooling system Fit the O ring 42124 Fit the air supply line See also chapter entitle...

Page 109: ...ernal part 74000 to crane us ing lifting device 90190 and shackle 90195 Screw three press off nuts 61090 onto bearing casing studs equally distributed around circumference and screw up to end of thread by hand Fit the compressor casing external part 74000 and secure with nuts 61037 Secure three press off nuts 61090 against compressor casing 74000 by tightening them to specified torque see chapter ...

Page 110: ...insert 77000 Fit lifting gear and swivel lifting eyes 90230 Align wall insert 77000 with threaded holes in compressor casing in ternal part 76000 using spigots on swivel lifting eyes and lower it Loop the lifting gear around the diffuser 79000 align it with the holes and lower it into position Screw in the screw 76002 as far as it will go and then unscrew it by turn The screw must be loose and the...

Page 111: ...016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Secure the lifting device 90190 and the shackle 90195 to the rear of the flange F Carefully turn compressor casing internal part complete with wall insert and diffuser about support angle 90025 into vertical position and set down on underlay and support angle ...

Page 112: ...y segments have been tight ened Fasten lifting device 90190 complete with shackle 90195 to front side of flange F Fit O ring 76040 Remove support angle 90025 Fit four guide studs 90320 Carefully put compressor casing internal part complete with wall insert and diffuser over guide studs Remove the guide studs 90320 and fit the studs 74026 74029 Use studs 10x 74029 and 2x 74026 each screwed in at to...

Page 113: ...segments 76080 on compressor casing internal part 76000 The compressor casing internal part 76000 is now secure relative to the compressor casing external part 74000 NOTICE Note control dimension s The safety segments 76080 are again in the operating state Dimension mm TPL69 A TPL73 A TPL77 A s 11 3 12 1 12 9 Put the nuts 90458 back in the toolbox Measure and note axial clearance see section Axial...

Page 114: ...gasket 61050 may only be used once Provide a new spiral wound gasket 61050 Disassembly Remove the insulation from the gas inlet casing 51001 and discon nect the cleaning pipe if provided Secure the gas inlet casing using a lifting gear CAUTION When looping the rope around the casing make sure that no cleaning pipes are crushed or damaged Do not under any circumstances fasten the lifting gear to th...

Page 115: ...ing screws 61044 and Verbus Ripp washers 61043 Pull gas inlet casing 51001 together with nozzle ring 56001 away from gas outlet casing 61001 until the nozzle ring can be lifted out Pull the gas inlet casing together with nozzle ring away from the gas outlet casing until holder 90175 can be fitted from the outside using screws 61044 and Verbus Ripp washers 61043 Loosen the hexagon nuts 90178 on the...

Page 116: ...hen nozzle ring 56001 Segment connection disassembly Figure 1 Remove screws 61044 and segments 51012 Fit two studs 90177 in the bottom section Pull gas inlet casing 51001 together with nozzle ring 56001 away from gas outlet casing 61001 until the nozzle ring can be lifted out Fully withdraw the gas inlet casing and remove it CAUTION When setting down gas inlet casing use suitable underlays Remove ...

Page 117: ...hree equally spaced points in the groove Fit nozzle ring and place holder 90175 over the nozzle ring Then tighten holder 90175 using screw 61044 and Verbus Ripp washer 61043 Align gas inlet casing and secure using hexagon nuts 90178 on studs 90177 Insert and position nozzle ring Remove holder 90175 and screw 61044 together with Verbus Ripp washers 61043 Coat thread of screws 61044 with high temper...

Page 118: ...s inlet casing with segments the segments are po sitioned with the aid of recesses and cams on the casing Coat the screw threads with high temperature grease Fix a new spiral wound gasket 61050 in the slot using a little super glue for example Loctite 454 gel applied at three evenly distribut ed points Position gas inlet casing complete with nozzle ring on gas outlet cas ing 61001 Remove the two s...

Page 119: ...TPL77 A10 A30 Disassembly and assembly 8 Dismantling and fitting nozzle ring at turbine end 8 8 Page 117 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Collars C of segments 51012 must be in slot S Check ...

Page 120: ...e marked on the component This enables simple and efficient tightening Tightening TPL69 A TPL73 A TPL77 A Step 1 Screw in all screws hand tight Step 2 130 190 240 Step 3 260 370 480 Tightening TPL69 A TPL73 A TPL77 A Step 1 Screw in all screws hand tight Step 3 260 370 480 Beginning with screw 1 tighten all screws in a clockwise direction with tightening torque from step 3 Remove lifting gear from...

Page 121: ...tion Manual TPL69 A10 A30 TPL77 A10 A30 Disassembly and assembly 8 Dismantling and fitting nozzle ring at turbine end 8 8 Page 119 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B ...

Page 122: ...anual TPL69 A10 A30 TPL77 A10 A30 Disassembly and assembly 8 Table of tightening torques 8 9 Page 120 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Table of tightening torques 8 9 8 9 ...

Page 123: ...16 04 74027 With washer M16 125 M18 170 M20 220 05 61036 74026 74029 M16 30 M18 80 M20 80 06 61044 61056 61059 M16 260 M18 370 M20 480 06b 61077 If provided M16 20 07 42059 42064 M16 105 M16 105 M20 240 10 61037 M16 105 M18 160 M20 210 11 61090 M16 10 M18 15 M20 20 14 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 21 90458 M8 20 M10 30 M10 30 1 Tighten the screw 76002 as far as it will go and then unsc...

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Page 125: ...rm and depending on the situation stop the engine Seal the oil leak Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for locking blanking off the turbocharger on the engine Follow the directiv...

Page 126: ...gain NOTICE Various intermediate rings are provided with the locking device for dif ferent compressor wheels Attention must be paid to the compressor wheel type CV for the balancing screw holes The distance between the locking flange 94003 and the assembly disassembly device 90020 must be compensated using the intermediate rings 94001 and or 94002 depending on the compressor wheel version CAUTION ...

Page 127: ...on B Part number TPL69 A TPL73 A TPL77 A 74027 M16 105 M18 135 M20 175 94006 M8 25 M8 25 M8 25 94007 M8 15 M8 15 M8 15 NOTICE Carried out work as described in the chapter Disassembly and assem bly Remove silencer or air suction branch and compressor casing internal part complete with wall insert and diffuser Fit partition wall clamp 94005 using screws 90442 Table of tightening tor ques Nm ...

Page 128: ...locking flange 94003 using nuts 74027 and then screws 94007 94006 and tighten according to Table of tightening torques In the case of engines with three or four turbochargers the balancing screws should be removed from the compressor wheel concerned In the case of engines with one or two turbochargers eight screws are enough to securely fasten the locking flange Locking rotor Compressor type CV10 ...

Page 129: ...94002 and assembly disassembly device 90020 onto locking flange 94003 in correct or der Now push on remaining intermediate rings 94001 and or 94002 Tighten intermediate rings assembly disassembly device 90020 and locking flange 94003 using screws 94006 according to values shown in preceding Table of tightening torques Now tighten assembly disassembly device to compressor casing using nuts 74027 an...

Page 130: ... removed and the air duct on the engine side must be closed off If this is not done the undamaged turbocharger can race under no load and run at overspeed Depending on the engine turbocharging system more or less powerful pulses from the exhaust gas system act on the locked rotor The locking device is then heavily stressed particularly in the case of pulse charging turbine casing with more than on...

Page 131: ...aterial General structural steel in accordance with DIN EN 10025 2 must be manufactured in house according to the drawing Product B1 B2 B3 B4 B5 B6 B7 B8 TPL69 A 13 385 30 30 8 10 6 84 TPL73 A 450 50 50 9 12 8 94 TPL77 A 535 9 12 107 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL69 A 726 818 779 18 25 15 TPL73 A 844 948 905 20 28 20 TPL77 A 1003 1124 1075 22 30 Product α 1 α 2 α 3 TPL69 A TPL77 A 4 x 90 37 5...

Page 132: ...0 Taking out of operation at short notice 9 Fit cover plate 9 3 Page 130 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B NOTICE Carry out the work as described in the chapter Removal and fitting Remove cartridge group ...

Page 133: ... 9 Fit cover plate 9 3 Page 131 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B Close off opening in gas outlet casing using cover plate Fasten cover plate using spacer sleeves and nuts 61037 CAUTION Shut off the supply of lubricating oil to the turbocharger ...

Page 134: ... engine builder s instructions 4 stroke engine with several turbochargers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as a naturally aspirated engine according to the engine builder s instructions The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure CAUTION The eng...

Page 135: ...o the turbocharger Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions Bypass the turbocharger 9 5 CAUTION Shut off the lubricating oil supply to the turbocharger This applies to engines with one turbocharger only The connections are ready and pipes for the bypass are available Fit bypass around t...

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Page 137: ...d by preserving oil before taking the engine out of operation and this is circulated by the pre lubrication pump no measures have to be taken Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion Mothballing measures WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies...

Page 138: ...asures are necessary after taking an engine out of opera tion 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 ...

Page 139: ...ole or in indi vidual parts See the section Taking out of operation for up to 12 months under Moth balling 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 turbochar...

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Page 141: ...oves made of leather Wear safety goggles Wear a respiratory 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 N...

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Page 143: ...een taken into consideration in this document please contact an ABB Turbocharging Service Station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use Parts showing signs of rust should be carefully cleaned and greased Dispose of replaced and unusable parts in a professional and envi ronmentally compatible way Required customer spare ...

Page 144: ...2012 76040 2 O ring 77005 77006 1 O ring 86506 Quantity Description Part number 15 Hexagon head screw 42059 42064 61044 61056 61059 15 Verbus Ripp washer 42058 42063 61043 61057 61058 3 Hexagon nut 61037 1 Gasket 42041 2 Gasket 42045 2 O ring 42012 76040 2 O ring 77005 77006 1 O ring 86506 Quantity Description Part number 15 Hexagon head screw 42059 42064 61044 61056 61059 15 Verbus Ripp washer 42...

Page 145: ...rbine cleaning system if provided CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system Work on turbine cleaning system should be carried out only by an ABB Turbocharging service station Quantity Description Part number 2 Locking plate 51255 3 Nozzle 52208 6 Sleeve 52212 1 Locking plate 52213 6 Strain bolt 52217 6 Nut 5221...

Page 146: ...PL69 A10 A30 TPL77 A10 A30 Spare parts 12 View of turbocharger with part numbers 12 2 Page 144 Copyright 2016 ABB All rights reserved December 2016 HZTL2481_EN Revision B View of turbocharger with part numbers 12 2 12 2 ...

Page 147: ...sket 61056 in customer spare part set Hexagon head screw 61057 in customer spare part set Verbus Ripp Washer 61058 in customer spare part set Verbus Ripp Washer 61059 in customer spare part set Hexagon head screw 61037 in customer spare part set Hexagon nut 61976 1 if present Centering bolt 61077 1 if present Hexagon nut 63000 Turbine diffuser 68000 Foot 74018 Washer 74026 74029 Stud 74027 Hexagon...

Page 148: ...cember 2016 HZTL2481_EN Revision B View of turbine cleaning system with part numbers optional 12 3 Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52208 in spare parts set Nozzle 52212 in spare parts set Bush 52213 in spare parts set Locking plate 52217 in spare parts set Strain bolt 52218 in spare parts set Nut 12 3 ...

Page 149: ...ABB Turbo Systems AG Bruggerstrasse 71a CH 5400 Baden Switzerland ABB ...