ABB TPS 50B01, Operation Manual

Page 1: ...ABB Turbocharging Type TPS 50B01 HT846529 nMmax 840 t Mmax 750 nBmax 800 t Bmax 710 1 s C 00270 10 50 50 Year 2021 Application according to the Operation Manual kg HZTL2401 English TPS 50B01 Original...

Page 2: ...eplacement 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...

Page 3: ...rger 13 2 4 Safe operation and maintenance 14 2 5 Hazards during operation and maintenance 17 2 6 Deflagration on gas engines 22 2 7 Lifting loads 22 3 Commissioning 24 3 1 Oil supply 24 3 2 Inspectio...

Page 4: ...5 Radial clearances N and R 56 8 6 Table of tightening torques 58 9 Taking out of operation 59 9 1 Shut down turbocharger 59 10 Mothballing the turbocharger 62 10 1 Taking out of operation for up to 1...

Page 5: ...ons concerning work safety and accident prevention Target group This Operation Manual is intended for engineers and qualified mechan ics who are responsible for operating the engine and the turbocharg...

Page 6: ...ight 2021 All rights reserved HZTL2401_EN Rev A September 2021 1 2 Layout and function 1Compressor casing 7Turbine 2Diffuser 8Nozzle ring 3Axial thrust bearing 9Gas inlet casing 4Radial bearing 10Bear...

Page 7: ...e ambient air through the exhaust gas pipe which is connected to the gas outlet flange 6 The air which is necessary for operation of the diesel or gas engine and which is compressed in the turbocharge...

Page 8: ...to reject all warranty claims State of the art This turbocharger was built according to state of the art technology and is operationally safe according to recognised safety regulations WARNING Improp...

Page 9: ...iour it must be shut down immediately by stopping the engine The malfunction must be reported to the per son or department responsible NOTICE Any modifications additions or conversions made to the tur...

Page 10: ...rbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible Storage of new turboc...

Page 11: ...e number Definition of notes NOTICE Note A note provides suggestions which facilitate the work on the product Definition of caution warning The caution and warning signs are described in the chapter S...

Page 12: ...ise agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended inspec tion replacement inter vals for turbocharger components 3 Inspection interval for plain bearings...

Page 13: ...tervals 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 t...

Page 14: ...and inspection work The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel All...

Page 15: ...t all times 2 3 Warning plates on the turbocharger Fig 1 Fig 2 Table of warning plates Part number Size mm Product 72080 175 x 22 TPS 81080 105 x 74 TPL TPR When uninsulated turbochargers are delivere...

Page 16: ...ipment in perfect condition u Obey mandatory signs u Observe the general rules for occupational safety and prevention of accidents u Only perform operations that are described in this chapter u Only p...

Page 17: ...ing and operation u Before starting work carry out visual inspection of working area u Remove any obstacles and objects lying around u Before start up commissioning check all pipes from and to tur boc...

Page 18: ...be switched off and the turbocharger must have come to a standstill u Ensure that the supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after al...

Page 19: ...er in accordance with instructions u During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various risks...

Page 20: ...uenced by the installa tion and operating conditions Noise with a sound pressure level exceed ing 85 dB A is harmful WARNING Hazards due to noise Noise can cause impaired hearing damage to health ment...

Page 21: ...afety gloves to protect against thermal hazards WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries burns The turbocharger is supplied with...

Page 22: ...ect against gases WARNING Risk of fire explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion u Observe the details in the ma...

Page 23: ...materials signify a fire hazard u Use only suitable non combustible insulating materials u Ensure that the work area is well ventilated u Avoid stirring up dust u Use tools and processes which keep du...

Page 24: ...of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomalies are found or if a partic...

Page 25: ...ng u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection at...

Page 26: ...ions 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 turboch...

Page 27: ...es 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 da...

Page 28: ...engine 3 2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning Inspections help de tect changes to the turbocharger M...

Page 29: ...y or recom mended Too frequent tightening can lead to wear on the connection 3 2 3 Check when running up engine u Measure the oil pressure and charging pressure at various engine per formance levels u...

Page 30: ...s between compressor casing out let and charge air duct before gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter o...

Page 31: ...ger 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 turbochar...

Page 32: ...s to the turbocharger to be identified and rectified In this way it can be ensured that the turbocharger remains in full work ing order CAUTION Service intervals Service work on the turbocharger that...

Page 33: ...e work every 25 50 hours u Visual inspection for air exhaust gas water and oil leaks u Record operating data and enter it in the engine logbook u Clarify the cause of any variances CAUTION Unknown cha...

Page 34: ...check for cracks and erosion 4 2 4 Entries in engine logbook By monitoring the engine conclusions can be drawn about the tur bocharger performance The following operating data and measured values must...

Page 35: ...aired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major incre...

Page 36: ...d 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 can lead to serious damage...

Page 37: ...state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging the following pre req...

Page 38: ...rights reserved HZTL2401_EN Rev A September 2021 Procedure for compressor wet cleaning with XC1 X Screw plug D Pressurized air Y Valve activator W Water Z Container Operating the water pres sure vess...

Page 39: ...minutes has elapsed NOTICE Whether or not cleaning has been successful can be seen from the char ging or flushing pressure and also from the exhaust gas temperatures If the cleaning operation is not...

Page 40: ...our no malfunction Turbochar ger Minor uniform wear around the periphery of rotor components caused by slight local rubbing of adjacent components is per missible The compressor blades and turbine bla...

Page 41: ...the same time the flow direction in the compressor is mo mentarily reversed Such sporadic surge blows do not impair the safe operation of the turbocharger A surge blow is accompanied by a loud bang a...

Page 42: ...njection system Repair it or contact the manu facturer Turbocharger Air starvation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too h...

Page 43: ...eter Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine Contact an ABB Tur...

Page 44: ...sible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time too sh...

Page 45: ...rbocharger suspension Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest variant possible This stand...

Page 46: ...g the turbocharger u Disconnect all gas and air lines in accordance with the engine builder s instructions Turbocharger without an exhaust gas pipe Fig 3 u Secure the lifting gear to the bearing casin...

Page 47: ...gaskets of the oil supply and drain pipe O ring gaskets for the engine are not delivered by ABB Turbocharging u Inspect the lifting gear Turbocharger without a gas outlet bend Fig 4 u Attach lifting...

Page 48: ...bed in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station u Unqualified work on the cartridge group can lead to total system failure and voi...

Page 49: ...itting WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per sonal injury or accidents with fatal consequences u Attach turbochargers assemblies or individual comp...

Page 50: ...ghts The specified weights of individual parts or assemblies are guides roun ded off to the next highest value Assemblies Weights kg Description TPS 50 1 Compressor casing 55 2 Wall insert 13 3 Diffus...

Page 51: ...bling and assembling turbochargers Removing the compressor casing u Disconnect all air lines in accordance with engine builder s instruc tions u Loosen the V clamp 72020 and remove the filter silencer...

Page 52: ...September 2021 u Loosen the V clamp 72030 and horizontally move away the com pressor casing 72000 with the wall insert 77000 u Tap the wall insert 77000 out of the compressor casing using a nylon hamm...

Page 53: ...the V clamps 72020 72030 before assembly u Lubricate the V clamp threads and the inner part of the profile with high temperature grease If removed u Install wall insert 77000 77006 with O ring 77005 i...

Page 54: ...apter If provided u Treat the screw thread of the V clamp 52410 with rust remover and allow it to act u Check the lifting gear and secure it to the bearing casing 10900 u Loosen the V clamp 52410 and...

Page 55: ...wall u Check lifting gear and attach to bearing casing 42001 u Lubricate the centring seats inner part of the V clamp profile and screw threads with high temperature grease u Remove temporary covers f...

Page 56: ...y lightly striking the cover clamp with a plastic tip hammer u Fit bearing casing 42001 using the fixing screws C u Tighten the fixing screws to the tightening torques specified in the following table...

Page 57: ...arance A and radial clearance B must be measured and noted NOTICE In order to correctly measure the axial clearance A the turbine must be raised slightly Axial clearance and pos sible radial movement...

Page 58: ...inimum and maximum values result from the manufacturing toler ances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange Feeler gauge N1 and N2 as well as R1 and R2 are e...

Page 59: ...must be within the permissible values of the radial clearance N and R Radial clearances N and R mm N R TPS 50 0 66 0 92 0 65 0 93 CAUTION Clearances out of tolerance Clearances out of tolerance and ex...

Page 60: ...assembly 8 6 Table of tightening torques Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 8 6 Table of tightening torques Fig 7 Item Part number Tightening torques Nm 1 72020 72030...

Page 61: ...gency repairs proceed as follows u Fit the cover plate CAUTION Always precisely obey the engine builder s instructions in case of engine operation with a blocked throttled turbocharger Dismantling the...

Page 62: ...01_EN Rev A September 2021 Fitting the cover plate u Close the opening in the gas outlet casing with the cover plate 91000 u Secure the cover plate on the gas inlet casing 51000 with the V clamp 52410...

Page 63: ...drawing The cover is not supplied by ABB Turbocharging and must be manufac tured by the operator according to the following drawing Material Common structural steel in compliance with DIN EN 10025 2...

Page 64: ...d this is circulated by the prelubrica tion pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protec ted against corrosion Mothb...

Page 65: ...for up to 12 months under Mothballing measures for the measures always necessary when moth balling turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking out...

Page 66: ...presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazard ou...

Page 67: ...nts engine oil electronic components speed sensor and associated components thermal insulation u Dispose of metals as old metal for recycling u Dispose of non metallic materials as waste u Dispose of...

Page 68: ...mber Spare parts can be ordered from an official ABB Turbocharging service station u If different design versions have not been taken into consideration in this document please contact an ABB Turbocha...

Page 69: ...re available only as a complete set Spare parts kit 97070 Quantity Description Part number 2 O ring 32222 42011 1 O ring 42012 2 O ring 77006 79005 2 O ring 77005 82010 83010 CAUTION All spare parts t...

Page 70: ...tion Manual TPS50 12 Spare parts 12 2 View of turbocharger showing part numbers Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 12 2 View of turbocharger showing part numbers Page...

Page 71: ...ZTL2401_EN Rev A September 2021 Part number Description 51000 Turbine casing 52400 Gas outlet flange 52410 V clamp 52420 V clamp 72000 Compressor casing 72020 V clamp 72030 V clamp 77000 Wall insert 7...

Page 72: ...n Manual TPS50 12 Spare parts 12 3 View of cartridge group showing part numbers Copyright 2021 All rights reserved HZTL2401_EN Rev A September 2021 12 3 View of cartridge group showing part numbers Pa...

Page 73: ...Compressor wheel 32101 Plain bearing bush 32103 Safety ring 32105 Thrust ring 32106 Thrust bearing 32107 Bearing bush 32108 Piston ring 32221 Bearing cover 32222 in spare parts kit O ring 42001 Beari...

Page 74: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland...