ABB TPL-B Series, Assembly Instructions Manual

Page 1: ...o the engine correctly and without any health and safety risks Target group The assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine TPL B turbocharger Taking on two stroke for large marine applications ASSEMBLY INSTRUCTIONS Turbocharger TPL B Original assembly instructions English ...

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Page 3: ... 2 1 3 Symbols and definitions 2 1 4 Definition of warning caution note 3 1 5 Definition of mandatory signs 4 1 6 Definition of pictograms 4 2 Safety 5 2 1 Introduction 5 2 2 Lifting loads 6 2 3 Occupational safety 7 3 Weight and transportation of the turbocharger 9 4 Installing the turbocharger 10 4 1 Steps for fastening the turbocharger 11 4 2 Completion work if required 12 5 Storage of new turb...

Page 4: ...turbocharger on the engine Basic mechanical training is a prerequisite All persons who are involved in the transportation and installation of the turbocharger have read and understood the assembly instructions 1 3 Symbols and definitions The following symbols are used in the documents w Prerequisite u Work step Enumeration first level Enumeration second level Refers to a page number The trademarks...

Page 5: ... 1 4 Definition of warning caution note 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 u Warning signs must be observed at all times CAUTION Definition of caution Serious machine or property damage may occur ...

Page 6: ...ases Safety helmet Ear protection Table 2 1 6 Definition of pictograms The following pictograms can occur in this document These point out actions that must be taken in accordance with the meaning of the relevant pictogram Pictogram Meaning Pictogram Meaning Tighten with specified torque Oil free grease free and dry Tighten over specified tightening angle Affix Hand tight tighten without tools Mea...

Page 7: ...bocharger itself or its accessories Are caused by the operating and auxiliary materials used Are a consequence of insufficient compliance with safety instructions All instructions contained in this chapter must be observed during all work on the turbochar ger Responsibility of the operating company In awareness of its responsibility the operating company must ensure that only authorised personnel ...

Page 8: ...r with sufficient loading capacity u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Use a suitable edge guard if t...

Page 9: ...ns for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work...

Page 10: ...operations that are described in this chapter u Only perform operations for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies can include Oils greases coolants cleaning agents and solvents acids or similar substances WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operatin...

Page 11: ...r with a sufficient load limit must be used for installing the turbocharger The fol lowing weight specification applies to the heaviest variant possible Depending on the spe cification the weight specified on the rating plate may be lower than the standard value specified here u Remove insulation jacket from bearing casing u Fit lifting gear to turbocharger Product Weight kg TPL85 B14 15 16 12000 ...

Page 12: ... casing provided for this pur pose Ensure that the transport ropes are not touching the emergency oil tank CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bearing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger a...

Page 13: ...5 nominal thread diameter Dimension a compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Dimension b Hole in bracket Dimension c Thread length 1 5 times the nominal thread diameter Coefficient of friction 0 12 lightly oiled Table 5 NOTICE Strength classes of screws In order to install the turbocharger screws with a higher strength...

Page 14: ...ation TPL B Table of tightening torques for feet 12 TPL B Table of tightening angles 12 Torque controlled tightening Product Thread size Tightening torque Nm Pre tightening torque Nm Height a of the ten sioned turbocharger foot mm TPL85 B14 15 16 M42 3100 850 148 TPL91 B M42 3100 850 145 Table 6 Angle controlled tightening Product Thread size Tightening angle for tensioned height a DEG Additional ...

Page 15: ...oducts are not hazardous in the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to protec...

Page 16: ...cted by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant agent Repackage the component NOTICE Turbocharg...

Page 17: ...Assembly Instructions TPL85 B14 B15 B16 TPL91 B 5 Storage of new turbochargers and spare parts Copyright 2020 ABB All rights reserved HZTL455311P0020_EN Rev A July 2020 Page 15 17 ...

Page 18: ...al for the turbocharger with the relevant serial number is available on line on our website www abb com turbocharging A rating plate is attached to the turbocharger foot one on the left and one on the right On turbochargers with insulation from ABB at least one additional rating plate is attached to the insulation of the gas outlet casing 1 Read the serial number 02 on the rating plate 01 of the t...

Page 19: ...Assembly Instructions TPL85 B14 B15 B16 TPL91 B 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0020_EN Rev A July 2020 Page 17 17 ...

Page 20: ...product on our website see Operation Manuals Copyright 2020 ABB All rights reserved Operation Manual Contact information ABB Switzerland Ltd Turbocharging Bruggerstrasse 71 a CH 5401 Baden Switzerland Phone 41 58 585 7777 Fax 41 58 585 5144 E mail turbocharging ch abb com www abb com turbocharging Visit our website by scanning the QR code HZTL455311P0020 ...