ABB TPL67-C80, Operation Manual

Page 1: ...ABB Turbocharging Type TPL67 C80 HT847101 nMmax 495 t Mmax 650 nBmax 472 t Bmax 620 1 s C 01330 36 75 75 Year 2022 Application according to the Operation Manual kg HZTL2488 English TPL67 C80 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: ...ructions 16 2 5 Warning plates on the turbocharger 17 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vessel 26 2 9 Lifting...

Page 4: ...Removing cartridge group 87 8 6 Dismantling and installing the turbine diffuser and nozzle ring 92 8 7 Installing cartridge group 95 8 8 Dismantling and fitting nozzle ring at turbine end 100 8 9 Tab...

Page 5: ...w to use it as intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existing nationa...

Page 6: ...ved HZTL2488_EN Rev G March 2020 1 2 Layout and function TPL67 71 C 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 0...

Page 7: ...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 seco...

Page 8: ...specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB Turbocharging is no...

Page 9: ...ger is designed and built according to the state of the art and is safe to operate Perfect condition The turbocharger must be operated in technically perfect condition and in accordance with its inten...

Page 10: ...otection of health when handling VCIs VCI products are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Ensu...

Page 11: ...d In this case the turbochar ger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the tur bocharger must be inspected b...

Page 12: ...f personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance with the Opera...

Page 13: ...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...

Page 14: ...ilitate the work on the product Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be com pl...

Page 15: ...eed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Rep...

Page 16: ...mally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals increases t...

Page 17: ...of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for access t...

Page 18: ...rotection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuries...

Page 19: ...t must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Fig 1 Warning plate Part number Size mm Product 81080 105 x...

Page 20: ...he turbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidly ea...

Page 21: ...or changes in operational perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u When switching on au...

Page 22: ...e supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger Possi...

Page 23: ...arger 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 ris...

Page 24: ...dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating oil...

Page 25: ...er surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or...

Page 26: ...ination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and ha...

Page 27: ...u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations Wear...

Page 28: ...must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels are...

Page 29: ...ading u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protection...

Page 30: ...bocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please observe the engine builder s spe cifications for lubricating oil selection oil change...

Page 31: ...charger are listed below Status for operation Oil pressure at measuring point M poil in bar Permissible for normal operation 1 3 2 5 Permissible during engine warm up 1 3 5 0 Temporarily admissible 1...

Page 32: ...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...

Page 33: ...minated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating system...

Page 34: ...mperature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking di...

Page 35: ...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 or residual water Clean and re move u Inspect air supply...

Page 36: ...harger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the turboc...

Page 37: ...opyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03 Cha...

Page 38: ...ned service intervals Despite observance of the service intervals unusual loads such as sev eral start stops a day harsh environmental factors poor fuel quality or heavy installation vibration can lea...

Page 39: ...rer 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 Lubricatin...

Page 40: ...through oil ports u Clean nozzle ring and check for cracks and erosion u Inspect and assess bearing parts and rotor 4 2 5 Service work every 24000 36000 hours The replacement of bearing parts and the...

Page 41: ...intervals for non rotating components and bearing parts are extremely dependent upon system specific operating conditions see Influencing parameters When the specified periodic inspections are carried...

Page 42: ...O HFO Gas inlet 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...

Page 43: ...system permits continuous monitoring of the tur bocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tensio...

Page 44: ...steps must be carried out u Reduce engine performance immediately until the highest turbochar ger speed no longer exceeds 70 of nBmax u If the engine cannot be stopped continue to run at this reduced...

Page 45: ...t w Engine and turbocharger are not running w The turbocharger lubricating system is switched off u Remove screw plug 42047 from bearing casing NOTICE Part position The position of the screw plug for...

Page 46: ...the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to the s...

Page 47: ...ghts reserved HZTL2488_EN Rev G March 2020 4 5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil u Allow the engine...

Page 48: ...s and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be established...

Page 49: ...v G March 2020 5 2 Cleaning the filter silencer 5 2 1 Filter silencer and connecting rod 81265 Filter ring if provided 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81266 C...

Page 50: ...is Clean filter strip every 500 hours of service or more frequently if necessary u Unscrew and remove lock nuts 81273 u Unscrew and remove screws 81272 for connecting rods 81269 u Remove connecting r...

Page 51: ...he lugs of cover grids 81266 CAUTION If connecting rods 81269 are not correctly positioned in their recesses on filter silencer body 81135 cover grid 81266 can twist and shift There is then a risk of...

Page 52: ...nnels if salt oil mist exhaust gas or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased...

Page 53: ...amination is not too high CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives u Don t use salt water for cleaning but...

Page 54: ...in the vicinity of the tur bocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning procedure for compressor with XC2 u Trigger water inj...

Page 55: ...If despite correct settings surging of the compressor stage occurs while cleaning the compressor as a remedial measure the engine load can be reduced further while cleaning the compressor The reductio...

Page 56: ...en tested and is recommended by ABB Turbocharging the following pre requisites must be fulfilled u Engine load 50 85 u Start of cleaning cycle in accordance with following description for wet cleaning...

Page 57: ...Water temperat ure C Contents of wa ter vessel dm3 TPL67 C 71 C 50 85 5 50 0 4 or 1 Surging of the compressor stage Should repeated surging of the compressor stage occur during com pressor cleaning fi...

Page 58: ...drop in turbine efficiency and the engine tem peratures downstream of the cylinder can increase The engine perform ance must therefore be reduced if necessary The contamination of the turbine also ca...

Page 59: ...en started or the engine load reduced The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions see section PrerequisitesTPL A C Operating state prerequis...

Page 60: ...erating state and prerequisites have been tested and approved by ABB Turbocharging for the cleaning process u The engine has just been started or the engine load has been reduced as far as possible be...

Page 61: ...ater sup ply u Set the required volume of water on the flowmeter as shown in the table see table Cleaning parameters u Shut off the water supply again by switching the 3 way valve 04 to scavenging air...

Page 62: ...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 clarified by the operator Points to rem...

Page 63: ...itive to mechanical damage The use of needle guns or other impact tools for example damages the components Depending on the specification nozzle rings have pro tective coatings which can also be damag...

Page 64: ...ta sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases CAUTION Damage to coated nozzle rin...

Page 65: ...r Removal and in stallation u Remove cartridge group see chapter Disassembly and assembly First clean the compressor end and then the turbine end in accordance with the following description 5 5 4 Cle...

Page 66: ...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 soak t...

Page 67: ...ing 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 horizon...

Page 68: ...must not touch the compressor wheel at any time dur ing rotation u Choose appropriate lifting gear length 1 Suspend cartridge group from the two side suspension points on the crane using two lifting...

Page 69: ...til entire cartridge group is suspended from first crane 6 Remove loop from second crane CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neut...

Page 70: ...If water or contamination gets into the cartridge group the turbochar ger function may be impaired and parts in the cartridge group may be damaged u Place cartridge group on suitable wooden or metal...

Page 71: ...nation deposits lead to rotor unbalance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the tank wit...

Page 72: ...or unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear arou...

Page 73: ...ging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rectifi...

Page 74: ...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 engin...

Page 75: ...on for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Enlarged flow cross section...

Page 76: ...ometer 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 T...

Page 77: ...ossible 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...

Page 78: ...s for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor tip...

Page 79: ...l and installation 7 1 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger The following weight specification is the heaviest varia...

Page 80: ...en the cartridge group the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes...

Page 81: ...pose w Ribs 01 not in the middle at the top u Completely remove the bearing casing insulation 02 and place a sling around the bearing casing u Loosen the fixing screws at the foot u Lift the turbochar...

Page 82: ...the bear ing casing or the turbocharger is being fitted to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil o...

Page 83: ...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 an...

Page 84: ...the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined load attachm...

Page 85: ...or assemblies are guides roun ded off to the next highest value Assemblies Weights kg Description TPL67 C TPL71 C 1 Filter silencer 130 180 2 Radial air suction branch 50 70 3 Compressor casing 180 26...

Page 86: ...pyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 Complete compressor casing Weight kg TPL67 C TPL71 C 240 360 NOTICE The total weight of the complete compressor casing is an addition of t...

Page 87: ...ll air lines in accordance with the engine builder s instruc tions u Dismantle the insulation where necessary u Pass a lifting gear around the air suction branch It is permissible to pass the lifting...

Page 88: ...v G March 2020 Removing filter silencer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer u Pass lifting gear through lugs on back u Unscrew nuts 72027 and remove...

Page 89: ...protect against mechanical hazards The axial clearance A must be measured before removing and after fit ting the cartridge group u Measure and note the axial clearance A Clearance A mm TPL67 C TPL71 C...

Page 90: ...nctionality u Disconnect oil pipes in accordance with enginebuilder s instructions CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the be...

Page 91: ...ee studs 72029 at top u Attach lifting device 90190 to compressor casing 72000 then fasten and secure it to crane using lifting gear u Unscrew and remove nuts 61037 u Uniformly press off compressor ca...

Page 92: ...ll insert and dif fuser and put them down with surface F on underlay WARNING Make sure that the underlay does not slip u Allow compressor casing to rest only on surface F u Check underlay and adjust i...

Page 93: ...gether with the Verbus Ripp washers 61058 u Evenly press off cartridge group by screwing press off screws 90900 into the designated holes CAUTION If the blades have insufficient or no clearance betwee...

Page 94: ...arch 2020 8 6 Dismantling and installing the turbine diffuser and nozzle ring Loosening the turbine dif fuser u Put clamp 90921 over stud 61036 until it rests on inner radius of gas outlet casing u Pa...

Page 95: ...amps 90921 over guide studs 90320 and fit studs 61036 u To secure the work screw nuts 61037 onto start of stud threads 61036 u Remove the remaining screws 61056 and Verbus Ripp washers 61057 u Press t...

Page 96: ...6001 is released and can fall down u Pull nozzle ring 56001 forward and remove Qualitative requirements for the nozzle ring area in HFO operation Coverage of one or more nozzle ring blade pitches by m...

Page 97: ...il orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing When the cartridge group the bear ing casing or the turbocharger is being fitte...

Page 98: ...bearing casing provided for this purpose u Remove supports 90450 and carefully insert cartridge group CAUTION If the rotor blades have insufficient or no clearance the blades and cas ing could be dam...

Page 99: ...Rev G March 2020 u Fit the O ring 77005 to the wall insert 77000 u Fit the swivel lifting eyes 90235 and attach lifting gear u Align the wall insert 77000 using the centering screw 90187 and fit it u...

Page 100: ...n the compressor casing 72000 u Screw three press off nuts 61090 onto bearing casing studs equally distributed around circumference and screw up to end of thread by hand u Push compressor casing 72000...

Page 101: ...arance CAUTION If the axial clearance A is out of tolerance an ABB Turbocharging Ser vice Station must be contacted u Connect oil pipes and all air lines in accordance with enginebuilder specification...

Page 102: ...sket 61050 may be used only once u Make ready a new spiral wound gasket 61050 Disassembly u Remove insulation from gas inlet casing 51001 and disconnect clean ing pipe if provided u Secure gas inlet c...

Page 103: ...easure u Loosen and remove remaining screws 61044 and segments 51012 Flange connection u Remove two screws 61044 in lower section u Fit two guide studs 90320 as a safety measure u Loosen and remove re...

Page 104: ...act surfaces in on casing and keep free from metal chips u Keep grooves and spiral wound gasket free from oil and grease 1 If provided u Fix a new spiral wound gasket 61050 using a little instant adhe...

Page 105: ...screw positioning numbers must be marked on the component This enables simple and efficient tightening Tightening torques for screws 61044 Nm with spiral wound gasket Tightening TPL67 C TPL71 C Step 1...

Page 106: ...Operation Manual TPL67 C TPL71 C 8 Disassembly and assembly 8 9 Table of tightening torques Copyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 8 9 Table of tightening torques Page 104 125...

Page 107: ...rques Nm Part number TPL67 C TPL71 C 1 82005 M16x1 5 45 M16x1 5 45 3 72002 M10 50 M12 80 4 72027 with washer M14 95 M16 125 5 72029 with washer M14 30 M16 30 6 61037 M16 110 M18 160 6a 61090 M16 10 M1...

Page 108: ...ge in emergency operation The assembly of the locking device on the turbocharger is only permiss ible in emergencies It is not permitted to lock the rotor for an engine test Serious damage to engine o...

Page 109: ...mes requested by customers As operation with a locked rotor is only brief and the loads are low in these cases subsequent removal of the rotor is not necessary CAUTION During operation of the engine w...

Page 110: ...chapter Disassembly and As sembly u Insert locking flange 94003 into compressor wheel u Put screws 94007 into unoccupied threaded holes in compressor wheel and tighten to values shown in Table of tig...

Page 111: ...reserved HZTL2488_EN Rev G March 2020 u Secure assembly disassembly device 90020 to compressor casing by screwing nuts 72027 complete with washers 72018 onto studs 72026 and then tightening to values...

Page 112: ...ocharger must be 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 turbo...

Page 113: ...of ABB and must be provided by the user as per the il lustration Parts required 1 cover plate 01 recommended material 1 4541 1 4571 1 gasket 02 temperature resistant up to 650 C 24 sleeves 03 Cover p...

Page 114: ...t of operation at short notice 9 3 Fitting the cover plate Copyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 NOTICE Carry out the work as described in the chapter Disassembly and As semb...

Page 115: ...Fitting the cover plate Copyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 u Close opening in gas outlet casing using cover plate u Secure cover plate using spacer sleeves and nuts 61037...

Page 116: ...structions 4 stroke engine with several turbochargers Separate receivers No further measures are necessary on engines with separate air and ex haust gas receivers The engine can be operated as a natur...

Page 117: ...t off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions 9 5 Bypass the turbocharger CAUTION Shut off the...

Page 118: ...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 Mothbal...

Page 119: ...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 120: ...ask 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 Th...

Page 121: ...pare parts All spare parts ordered with the turbocharger must be kept complete and ready for use u Parts showing signs of rust should be carefully cleaned and greased u Dispose of replaced and unusabl...

Page 122: ...should be carried out only by an ABB Turbocharging service station Axial gas inlet casing Quantity Description Part number 6 Locking plate 51255 3 Gasket 52200 2 Hexagon head screw 52204 2 Hexagon hea...

Page 123: ...Operation Manual TPL67 C TPL71 C 12 Spare parts 12 1 Ordering spare parts Copyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 Page 121 125...

Page 124: ...ion Manual TPL67 C TPL71 C 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 All rights reserved HZTL2488_EN Rev G March 2020 12 2 View of turbocharger with part numbers Page 1...

Page 125: ...1044 Hexagon head screw 61050 if provided Gasket 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 Wa...

Page 126: ...of turbine cleaning system with part numbers optional Axial gas inlet casing Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare pa...

Page 127: ...52249 Holder complete 51255 in spare parts set Locking plate 52200 in spare part set Gasket 52204 in spare part set Hexagon head screw 52205 in spare part set Hexagon head screw 52208 in spare part se...

Page 128: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland...