Version 2.0
May 2006
Table of Contents
Page 1
Table of Contents
1
Preliminary remarks
1.1
1.2
1.3
1.4
Essential information
1.5
1.6
Safety
2.1
2.2
2.3
2.4
2.5
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Operation
4.1
Servicing work
4.2
Monitoring
4.3
Surging of turbocharger
4.4
4.5
Maintenance
5.1
Foreword to Maintenance
5.2
5.3
5.4
ABB
Operation Manual
6.1
7.1
Turbocharger weights
7.2
7.3
8.1
Module weights
8.2
8.3
8.4
Axial clearance
8.5
8.6
8.7
8.8
9.1
9.2
9.3
9.4
9.5
10
10.1
10.2
11
11.1
11.2
11.3
11.4
May 2006
Troubleshooting
Page 2
Version 2.0
Table of Contents
ABB
Operation Manual
Preliminary remarks
1.1
Page 1
This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
May 2006
1 Preliminary remarks
NOTE
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully understood the operating manual before beginning work.
Version 2.0
WARNING
ABB
Operation Manual
Preliminary remarks
1.2
Page 2
May 2006
Filter silencer
Nozzle ring
Turbine wheel
Thrust bearing
10
Bearing casing
Bearing bush
11
Diffuser
12
Compressor wheel
13
Version 2.0
00000_001
ABB
Operation Manual
Preliminary remarks
1.2
Page 3
Mode of operation
May 2006
The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel.
The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). It then
passes through the diffuser (11) and leaves the turbocharger through the
compressor outlet on the air outlet casing (13).
The rotor runs in two radial plain bearings (2/5) which are located in the
bearing bush (4) between the compressor and the turbine. The axial thrust
bearing (3) is on the compressor side.
Version 2.0
The plain bearings are connected to a central lubricating oil feed which is
supplied by the oil lubrication circuit of the engine. The oil outlet is always
at the lowest point of the bearing casing (10).
ABB
Operation Manual
Preliminary remarks
1.3
Page 4
May 2006
The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
Latest technology
WARNING
If it is used in conjunction with a gas engine, the engine must not be installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive.
Perfect condition
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
ABB
Version 2.0
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.
Operation Manual
Preliminary remarks
Essential information
1.4
Page 5
May 2006
NOTE
Version 2.0
ABB
Operation Manual
Preliminary remarks
Essential information
1.4
Page 6
May 2006
WARNING
Version 2.0
ABB
Operation Manual
Preliminary remarks
Essential information
1.4
Page 7
After-sales service
May 2006
Our service stations and agencies will gladly answer your questions relating specifically to your model.
Accuracy of illustrations
The graphics and images shown in this operation manual are of a general
nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
ABB
Operation Manual
Preliminary remarks
1.5
Page 8
Basic Instructions
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
The term used in this manual Official ABB Turbo Systems service station
signifies ABB Turbocharger service stations, that have been tested and
certified by ABB Turbo Systems Ltd.
ABB
Version 2.0
Operation Manual
Preliminary remarks
1.6
Page 9
May 2006
L_00012
Operational limits
Version 2.0
3
4
5
ABB
Operation Manual
1
1.6
6
7
8
9
10
11
12
Page 10
May 2006
Additional specifications:
Preliminary remarks
CAUTION
Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Version 2.0
Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
ABB
Operation Manual
Safety
2.1
Page 1
2 Safety
May 2006
Version 2.0
WARNING
ABB
Operation Manual
Safety
2.2
Page 2
The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating
materials.
May 2006
stress.
Version 2.0
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
ABB
Operation Manual
Safety
2.3
Page 3
May 2006
Version 2.0
ABB
Operation Manual
Safety
2.3
Page 4
May 2006
Explosion hazard
WARNING
Before cleaning, protect the floor against unintended leaks of oil and
Version 2.0
operation materials.
You must wear protective clothing (see section General safety instructions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the following rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
ABB
Operation Manual
Safety
2.3
Page 5
Follow the prescribed maintenance and inspection schedules for all ad-
Inform operating personnel about special work and repairs before start-
CAUTION
Version 2.0
ing.
Ensure that absorbent materials are available to clean up any operation materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
ABB
Operation Manual
Safety
2.4
Page 6
Associated hazards may arise during operation of and work on the turbocharger:
May 2006
Mechanical influences
Personal injury
Causes
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
ABB
Version 2.0
WARNING
Operation Manual
May 2006
Protective measures
Safety
2.4
Page 7
9
9
9
9
9
9
9
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environment if they penetrate soil or water.
CAUTION
Personal injury
Version 2.0
Causes
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
ABB
Operation Manual
2.4
9
9
9
9
9
9
9
9
9
Page 8
Version 2.0
9
9
9
9
May 2006
Protective measures
Safety
ABB
Operation Manual
Safety
2.4
Page 9
Noise
Loss of hearing
Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Personal injury
Causes
Protective measures
Personal injury
Burns
Causes
Protective measures
Version 2.0
May 2006
The effects of noise above a legally permitted level can cause personal injury.
ABB
Operation Manual
Safety
2.5
Page 10
L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
May 2006
Version 2.0
NOTE
ABB
Operation Manual
Commissioning
Oil supply
3.1
Page 1
3 Commissioning
May 2006
NOTE
Version 2.0
The oil pressure before the bearings (measuring point in blind connection)
must be exactly maintained to ensure fault-free operation.
ABB
Operation Manual
Commissioning
Inspection work
3.2
Page 2
This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
May 2006
The safety instructions must be followed before and during all inspec-
tion work.
Monitoring equipment
Lubricating system
Version 2.0
ABB
Operation Manual
Commissioning
Inspection work
3.2
Page 3
May 2006
Charger speed
X Measuring
Charger pressure
X Measuring
Temperatures
X After the engine has been started up, check all gas, air and oil lines for
leaks.
NOTE
Version 2.0
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, taking into account the different operating conditions.
ABB
Operation Manual
Commissioning
3.3
Page 4
If provided
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
May 2006
X
X
X
Version 2.0
X Inspect the exhaust pipe before and after the turbine for any combus-
ABB
Operation Manual
Operation
Servicing work
4.1
Page 1
4 Operation
May 2006
WARNING
X must be recorded
X Enter in the machine logbook
X In the event of significant anomalies, establish the cause
Version 2.0
CAUTION
ABB
Operation Manual
4
Servicing work
4.1
Page 2
May 2006
Operation
If provided
Version 2.0
Oil filters
ABB
Operation Manual
Operation
Servicing work
4.1
Page 3
May 2006
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor and bearing parts
The inspection and assessment of the rotor and bearing parts must be
performed by an official ABB Turbo Systems service station.
NOTE
erosion / corrosion.
Clean bearing casing, blow through oil ports
Clean nozzle ring and check for cracks and erosion
Inspection and assessment of the rotor
Replacement of the plain bearings with original parts from ABB Turbo
Systems
Version 2.0
The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
NOTE
ABB
Operation Manual
Operation
Monitoring
4.2
Page 4
May 2006
4.2 Monitoring
Bearing casing
Connecting cable
Axial bearing
Speed transmitter
Gasket ring
Screw plug
ABB
Version 2.0
L_278
Operation Manual
Operation
Monitoring
4.2
Page 5
May 2006
Turbocharger damage.
Version 2.0
ABB
Operation Manual
Operation
Surging of turbocharger
4.3
Page 6
Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbocharger.
May 2006
Action to be taken:
Version 2.0
The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.
CAUTION
ABB
Operation Manual
Operation
4.4
Page 7
Version 2.0
ABB
Operation Manual
Operation
4.5
Page 8
Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
May 2006
Version 2.0
CAUTION
ABB
Operation Manual
Maintenance
Foreword to Maintenance
5.1
Page 1
May 2006
5 Maintenance
5.1 Foreword to Maintenance
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
Version 2.0
Filter silencer
Compressor
Turbine and nozzle ring
ABB
Operation Manual
Maintenance
5.2
Page 2
May 2006
81265
81266
Cover grids
81270
Tension ring
81136
Fleece segment
38271
Trap cover
81137
Cover panel
81268
Connecting strip
81135
Version 2.0
L_00210
ABB
Operation Manual
Maintenance
5.2
Page 3
May 2006
If provided
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
NOTE
X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
Version 2.0
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo
Systems.
NOTE
ABB
Operation Manual
Maintenance
5.2
Page 4
May 2006
(81135).
X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).
Version 2.0
If provided
NOTE
ABB
Operation Manual
Maintenance
5.2
Page 5
May 2006
Version 2.0
L_00185
81265
81136
Fleece segment
81269
Connecting rods
81137
Cover panel
81266
Cover grids
81135
Screw
Locknut
ABB
Operation Manual
Maintenance
5.2
Page 6
If provided
Rinse filter ring (81265) with water using detergent or, if very dirty, soak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
May 2006
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
X
X
X
X
NOTE
NOTE
X Withdraw the slide-in modules (E), bend open the cover panels
Heavily soiled fleece segments and filter ring as well as damaged connecting rods should be replaced with original parts from ABB Turbo
Systems.
NOTE
ABB
Version 2.0
Operation Manual
Maintenance
5.2
Page 7
(81135).
(81266).
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grid (81266) can twist and
shift. This can allow foreign bodies and dirt to get into the compressor.
CAUTION
Version 2.0
NOTE
L_00232
ABB
Operation Manual
5
5.2
Page 8
May 2006
Maintenance
X Connect the connecting rods (81269) with screws (B). While tightening
the screws (B), ensure that the connecting rods (81269) are located
correctly in the recesses in the filter silencer body (81135). Now tighten
screws (B) alternately to the following max. tightening torque:
Screw
Tightening torque
20 Nm
L_00234
X Fit locknuts (N) on screw (B) and tighten to the following torque:
Tightening torque
40 Nm
If provided
Locknut
ABB
Operation Manual
Maintenance
5.2
Page 9
May 2006
L_00192
Injection pipe
Guide tube
Pipe
ABB
Operation Manual
Maintenance
5.2
Page 10
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
May 2006
Version 2.0
NOTE
ABB
Operation Manual
Maintenance
5.2
Page 11
May 2006
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
Version 2.0
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
ABB
Operation Manual
Maintenance
5.3
Page 12
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
May 2006
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point.
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers.
This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the
rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.
NOTE
ABB
Version 2.0
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Operation Manual
Maintenance
5.3
Page 13
Cleaning method
May 2006
The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
Version 2.0
The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
V-engines
Register supercharging
ABB
Operation Manual
Maintenance
5.3
Page 14
NOTE
The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage
charging).
May 2006
5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)
Z Engine warm from running (engine under full loading as far as possi-
Version 2.0
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.
ABB
Operation Manual
Maintenance
5.3
Page 15
May 2006
L_00198
Version 2.0
Screw plug
Valve lever
ABB
Operation Manual
Maintenance
5.3
Page 16
NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
May 2006
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL65-A
If possible
nBmax
0.4
415
TPL69-A
1.0
TPL77-A
1.0
TPL80-A
2.0
Version 2.0
TPL73-A
Turbocharger type
ABB
Operation Manual
Maintenance
5.3
Page 17
May 2006
Z Engine warm from running (engine under full loading as far as possi-
Version 2.0
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.
ABB
Operation Manual
Maintenance
5.3
Page 18
May 2006
L_00197
Cleaning container
2 Pipe
Injection pipe
4 Cleaning instructions
Cover
6 Valve
If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer
should be followed.
ABB
Version 2.0
NOTE
Operation Manual
Maintenance
5.3
Page 19
May 2006
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL65-A
If possible
nBmax
0.4
415
TPL69-A
TPL73-A
TPL77-A
3
Version 2.0
TPL80-A
ABB
Operation Manual
Maintenance
5.4
Page 20
Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. The deposits on the
turbine components are caused by the following products of combustion:
Soot
Molten ash
Cinders
Incompletely burned fuel
Sodium vanadyl vanadate
Therefore, it is advantageous to use fuels with a low content of ash, sulphur, sodium and vanadium. The fuel must also be stored, prepared and
handled correctly.
We recommend the use of fuels with a mass ratio of vanadium to sodium less than 3:1, so that the melting point of the sodium vanadyl vanadate is as high as possible.
NOTE
Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits.
May 2006
The charging pressure can rise somewhat if the turbine profile is constricted due to fouled turbine components. Contamination causes loss of
performance in the turbine and the engine temperature after the cylinders
can increase. This may mean that the engine output has to be reduced.
ABB
Version 2.0
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Operation Manual
5
5.4
Page 21
May 2006
Maintenance
Cleaning method
The turbine and nozzle ring are cleaned while operating using the cleaning method described in the following. This method has been tested and is
approved by ABB Turbo Systems:
Wet cleaning
The dry cleaning method may be used as an alternative to wet cleaning. However, this is not the preferred method, and must be approved
by an official ABB Turbo Systems service station.
NOTE
Principle of wet cleaning
During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
Version 2.0
CAUTION
ABB
Operation Manual
Maintenance
5.4
Page 22
CAUTION
V-engines
Version 2.0
Register supercharging
NOTE
May 2006
ABB
Operation Manual
Maintenance
5.4
Page 23
May 2006
5.4.1 Wet cleaning the turbine and nozzle ring during operation
The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
Operating state preconditions for wet cleaning the turbine and nozzle ring
Z After the engine is started up or the engine load has been reduced to
Version 2.0
during operation
ABB
Operation Manual
Maintenance
5.4
Page 24
Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)
May 2006
L_00203
Version 2.0
L_00204
ABB
May 2006
Operation Manual
Maintenance
5.4
Other turbochargers
Regulating valve
Injection pipe
Manometer
Drainage line
Drain cock
10
Outflow
11
Page 25
X
X
X
X
X
X
cleaning is begun!
Check that the water supply (1) is connected, open and reliable.
Open the drain pipe (8, 9) on the gas outlet casing.
Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.
Slowly open the 3-way-valve (4) first, then the regulating valve (2) until
the manometer (3) shows a pressure of 2 0.2 bar.
Inject water for 10 minutes.
Check whether the exhaust-gas temperature after the turbine drops.
Close the regulating valve (2) and the 3-way-valve (4).
Close the drain pipe (8, 9) on the gas outlet casing.
The water supply connection (1) must be isolated at the regulating valve (2).
After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.
The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
Version 2.0
NOTE
If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.
ABB
Operation Manual
5
5.4
Page 26
when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these case, washing must be
stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.
May 2006
The gas outlet casing must be drained of water via the drain pipe (8)
Version 2.0
Maintenance
ABB
Operation Manual
Maintenance
5.4
Page 27
L_00252
In V-engines with two
turbochargers (TL 1 and
2)
Version 2.0
May 2006
Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)
L_00253
ABB
Operation Manual
5.4
Other turbochargers
Regulating valve
Injection pipe
Manometer
Drainage line
Drain cock
10
Outflow
11
Page 28
May 2006
cleaning is begun!
Check that the water supply (1) is connected, open and reliable.
Open the drain pipe (8, 9) on the gas outlet casing.
Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.
Slowly open the 3-way-valve (4) first, then the regulating valve (2) until
the manometer (3) shows a pressure of 2 0.2 bar.
Inject water for 10 minutes.
Check whether the exhaust-gas temperature after the turbine drops.
Close the regulating valve (2) and the 3-way-valve (4).
Close the drain pipe (8, 9) on the gas outlet casing.
The water supply connection (1) must be isolated at the regulating valve (2).
After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.
Maintenance
NOTE
If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.
ABB
Version 2.0
The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
Operation Manual
5
5.4
Page 29
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these case, washing must be
stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.
Version 2.0
May 2006
Maintenance
ABB
Operation Manual
Maintenance
5.4
Page 30
Operating state preconditions for wet cleaning the turbine and nozzle ring
May 2006
(3 nozzles)
Version 2.0
ABB
Operation Manual
Maintenance
5.4
Page 31
May 2006
Procedure for wet cleaning the turbine and nozzle ring (3 nozzles)
L_00200
Version 2.0
L_00201
ABB
Operation Manual
5.4
other turbochargers
Regulating valve
3 injection nozzles
Manometer
Drainage line
Drain cock
Page 32
May 2006
Outflow
begin!
Ensure that the water supply (1) is connected, turned on and constant.
Open the drainage line (8,9).
First open the 3-way valve (4), then open the regulating valve (2) slowly until the pressure gauge (3) indicates a pressure of 2.5 bar.
Inject water for 10 minutes. Check whether the exhaust gas temperature falls after the turbine.
Close the regulating valve (2).
This completes the cleaning process. The water supply must be disconnected from the gas inlet casing.
Switching the 3-way-valve (4) for the water supply to blow-out mode
with compressed air.
Close drain hole (at 8) above drainage line (8,9).
After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.
Maintenance
NOTE
If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.
ABB
Version 2.0
The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
Operation Manual
5
5.4
Page 33
The gas outlet casing should be drained via the drainage line (8) during
cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the washing operation must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
Version 2.0
May 2006
Maintenance
ABB
Operation Manual
Troubleshooting
6.1
Page 1
6 Troubleshooting
May 2006
Engine
Turbocharger
Charge-air cooler
Z Cooler soiled
X Clean
Z Insufficient coolant water quantity
X Replenish
Version 2.0
ABB
Operation Manual
Troubleshooting
6.1
Page 2
Engine
Z Injection misadjusted
X Correct adjustment
Z Valve control misadjusted
X Correct adjustment
Turbocharger
Version 2.0
ABB
Operation Manual
Troubleshooting
6.1
Page 3
Engine
Z Injection misadjusted
X Correct adjustment
Turbocharger
Vibrations
Turbocharger
Z
Z
Z
X
Version 2.0
Turbocharger
Z Turbocharger dirty
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
ABB
Operation Manual
Troubleshooting
6.1
Page 4
May 2006
Turbocharger
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
Sluggish start-up
Z Turbocharger dirty
X Clean
Z
Z
Z
X
Turbocharger
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
Version 2.0
Turbocharger
ABB
Operation Manual
Troubleshooting
6.1
Page 5
May 2006
Engine
silencer is dirty
Z Trap dirty
X Clean
Version 2.0
Turbocharger
ABB
Operation Manual
Removal and installation
Turbocharger weights
7.1
Page 1
charger parts.
Version 2.0
L_00082
For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration.
WARNING
ABB
Operation Manual
Removal and installation
Turbocharger weights
7.1
Page 2
Weights [kg]
TPL 73
TPL 77
TPL 80
2080
3200
4920
May 2006
TPL 73
TPL 77
TPL 80
2324
3604
5496
TPL 73
TPL 77
TPL 80
2220
3355
5162
Version 2.0
Weights [kg]
ABB
Operation Manual
Removal and installation
7.2
Page 3
May 2006
nufacturers instructions.
Version 2.0
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the of this orifice has been individually adjusted by the engine builder. Whenever
these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the
correct is fitted into the oil-conducting oil-inlet channel.
ABB
Operation Manual
Removal and installation
7.2
Page 4
May 2006
Turbocharger without
reinforced suspension lug
L_00052
WARNING
(lugs are flush with external diameter of the flange), the complete
charger must be secured by the air outlet casing and gas inlet casing. See following illustration.
X Select a suitable rope taking into account the weight of the turbocharger.
ABB
Version 2.0
Operation Manual
Removal and installation
7.2
Page 5
May 2006
L_00051
If the support for the turbocharger is missing or defective, the turbocharger may tip over during installation and removal and can cause serious or even fatal injury.
WARNING
Version 2.0
ABB
Operation Manual
Removal and installation
7.3
Page 6
lug, the complete charger must be secured by the air outlet casing
and gas inlet casing.
X Select a suitable rope taking into account the weight of the turbocharger.
X Suspend the complete turbocharger using the two ribs provided for
this purpose.
If provided
X Secure the lifting equipment to the suspension lugs on the gas inlet ca-
WARNING
May 2006
manufacturer's instructions.
X Mate the insulating shell with the bearing casing and secure.
X Secure all gas, air, and oil lines in accordance with the engine manufacturers instructions.
ABB
Version 2.0
Operation Manual
Disassembly and assembly
Module weights
8.1
Page 1
charger parts.
Version 2.0
L_00082
For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration.
WARNING
ABB
Operation Manual
Disassembly and assembly
Module weights
8.1
Page 2
May 2006
Modules
Weights [kg]
Description
TPL 73
TPL 77
TPL 80
140
155
242
Filter silencer
244
404
576
148
260
355
Wall insert
134
276
431
Diffuser
57
80
125
290
475
680
Cartridge group
546
950
1356
Turbine diffuser
72
150
250
10
Nozzle ring
25
44
63
ABB
Version 2.0
L_00048
Operation Manual
Disassembly and assembly
Module weights
8.1
Page 3
May 2006
Weights [kg]
TPL 73
TPL 77
TPL 80
339
616
911
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.
Version 2.0
NOTE
ABB
Operation Manual
Disassembly and assembly
Page 4
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
May 2006
NOTE
instructions.
TPL 69 - 73
81000_003
Version 2.0
ABB
Operation Manual
Disassembly and assembly
Page 5
L_00011
X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.
TPL 77 85
Version 2.0
May 2006
TPL 77 - 85
L_00226
ABB
Operation Manual
8
Page 6
X Sling lifting gear through the loops at the rear and secure to the
X The filter silencer or air suction branch is installed in the reverse se-
May 2006
Version 2.0
quence.
ABB
Operation Manual
Disassembly and assembly
8.3
Page 7
May 2006
X Remove insulation
X Disconnect the oil lines in accordance with the engine manufacturer's
instructions.
If provided:
Position of the safety
segments before disassembly
X Take nuts (90458) out of the toolbox and fit them on the threaded pins
of the safety segments (Y) on the internal part of the compressor casing (76000).
Version 2.0
L_00269
ABB
Operation Manual
8
8.3
Page 8
Dimension
TPL73-A
TPL77-A
TPL80-A
18.6
19.0
19.6
May 2006
L_00266
bolts (90320).
X
X
X
X
screws (90900) until the lifting device (90190) can be attached with
shackle (90195) and secured to the crane.
Raise internal part of compressor casing slightly with wall insert and
diffuser, remove guide bolts (90320) and then withdraw.
Fit support angle (90025).
Place internal part of compressor casing with wall insert and diffuser on
support bracket and shim.
Remove O-ring gasket (76040).
ABB
Version 2.0
Operation Manual
Disassembly and assembly
8.3
Page 9
May 2006
L_00047
X Refit the lifting device on the other side of the flange (F).
X Turn the internal part of the compressor casing with wall insert and dif-
Version 2.0
fuser carefully over the support bracket (90025) and set down with the
front side of the flange (F) on the shim.
ABB
Operation Manual
Disassembly and assembly
8.3
Page 10
May 2006
Diffuser
For the turbocharger sizes up to and including TPL 73-A, the diffuser is
positioned by hand and therefore has no threaded holes in the diffuser
for the safety ring bolt 90230.
NOTE
ABB
Version 2.0
L_00053
8.3
Page 11
May 2006
Operation Manual
74000_002
Version 2.0
ABB
Operation Manual
Disassembly and assembly
8.3
Page 12
May 2006
Cartridge group
L_00054
Version 2.0
If provided:
ABB
Operation Manual
Disassembly and assembly
8.3
Page 13
May 2006
X Select a suitable rope taking into account the weight of the cartridge
group.
X Press cartridge group down evenly with jack screws (90900) into the
holes provided.
If the turbine blades on the rotor have too little or no clearance, this may
damage the blades and the casing.
CAUTION
X By turning the rotor, check that the turbine blades do not touch the
turbine diffuser.
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
Version 2.0
CAUTION
ABB
Operation Manual
Disassembly and assembly
Axial clearance
8.4
Page 14
01000_001
May 2006
Clearance A [mm]
TPL 73
TPL 77
TPL 80
0.36 - 0.53
0.39 - 0.57
0.42 - 0.65
ABB
Version 2.0
Operation Manual
Disassembly and assembly
8.5
Page 15
May 2006
L_00055
X Place clamp (90921) over stud (61036) until it lies flush with the inner
Version 2.0
ABB
Operation Manual
Disassembly and assembly
8.5
Page 16
56001_001
X In the upper section of the turbine diffuser (63000), replace the two
Version 2.0
screws (61056) and Verbus washers (61057) with two guide bolts
(90320). Pass the guide bolts through the holes in clamps (90921).
X To secure, fit hexagon nuts (90178).
May 2006
ABB
Operation Manual
Disassembly and assembly
8.5
Page 17
May 2006
Secure diffuser
61000_002
Version 2.0
ABB
Operation Manual
Disassembly and assembly
8.5
Page 18
May 2006
Remove diffuser
56001_002
Version 2.0
ABB
Operation Manual
8
8.5
Page 19
May 2006
56001_003
X Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting
Version 2.0
ABB
Operation Manual
Disassembly and assembly
8.5
Page 20
X Fit the nozzle ring and the turbine diffuser by reversing the sequence
Fitting
for removal.
X Align the nozzle ring with the holes in the gas inlet casing and assem-
May 2006
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
Version 2.0
CAUTION
NOTE
ABB
Operation Manual
Disassembly and assembly
8.6
Page 21
May 2006
L_00054
Version 2.0
ABB
Operation Manual
Disassembly and assembly
8.6
Page 22
CAUTION
X By turning the rotor, check that the turbine blades do not touch the
turbine diffuser.
May 2006
If the blades on the rotor have too little or no clearance, this may damage the blades and the casing.
If provided:
ABB
Version 2.0
74000_002
Operation Manual
8
8.6
Page 23
May 2006
L_00053
Version 2.0
For the turbocharger sizes up to and including TPL 73-A, the diffuser is
positioned by hand and therefore has no threaded holes in the diffuser
for the safety ring bolt 90230.
NOTE
If provided
X Transport diffuser (79000) with the fitted safety ring bolts (90230).
X Mount diffuser (79000) and align. Remove safety ring bolts.
X Fit the diffuser with the screws (76002).
ABB
Operation Manual
8
8.6
Page 24
May 2006
L_00047
X Attach the lifting device (90190) and shackle (90195) securely to the
Version 2.0
ABB
Operation Manual
8
8.6
Page 25
May 2006
L_00266
X Check that the nuts (90348) on the three safety segments are all tight-
ened.
X Attach the lifting device (90190) and shackle (90195) securely to the
Version 2.0
X
X
X
X
If provided:
Position of the safety
segments after assembly
X Loosen nuts (90458) on the threaded pins of the safety segments (Y)
on the internal part of the compressor casing (76000) and push the
threaded pins together with safety segment (Y) as far as they will go
against the external part of the compressor casing (74000).
ABB
Operation Manual
8
8.6
Page 26
May 2006
L_00276
NOTE
Control dimension s [mm]
Dimension
TPL73-A
TPL77-A
TPL80-A
12.1
12.9
11.9
X Replace the nuts (90458) that were taken from the toolbox.
TPL 73
TPL 77
TPL 80
0.36 - 0.53
0.39 - 0.60
0.42 - 0.65
X Connect the oil lines and all air lines in accordance with the engine
manufacturers instructions.
X Mount filter silencer or air suction branch and secure with nuts (72027)
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
ABB
Version 2.0
CAUTION
Operation Manual
Disassembly and assembly
8.7
Page 27
May 2006
NOTE
L_00290
Version 2.0
X
X
X
pe.
Remove the two hexagon head screws (61044) and Verbus washers
(61043) from the lower section and replace them with two studs
(90177).
To secure, fit hexagon nuts (90178) onto the studs (90177).
Loosen and remove the remaining screws (61044) and Verbus washers (61043) on the gas inlet casing flange (61001).
Withdraw the gas inlet casing with the nozzle ring from the gas outlet
casing until holder (90175) can be fitted from outside with screws
(61044) and Verbus washers (61043).
Release the hexagon nuts (90178) from the studs.
ABB
Operation Manual
Disassembly and assembly
8.7
Page 28
When positioning the gas inlet casing, use suitable shims and take care
to avoid damaging the brackets for the insulation.
CAUTION
May 2006
X Release holder (90175) and remove the nozzle ring with gasket
(61050).
X Fit nozzle ring and place the holder (90175) over the nozzle ring.
X Tighten holder (90175) with screw (61044) and Verbus washer
X
X
X
X
X
X
X
X
(61043).
Insert gasket (61050) in the groove in the gas inlet casing (61001).
Align the gas inlet casing and secure by fitting hexagon nuts (90178)
on the studs (90177).
Remove holder (90175) and screw (61044) and Verbus washers
(61043).
Fit and tighten the gas inlet casing flange to the gas outlet casing with
screws (61044) and Verbus washers (61043).
Remove hexagon nuts (90178) from studs (90177).
Replace the studs (91077) with hexagon head screws (61044) and
Verbus washers (61043).
Remove shackle (90195) and suspension rope from gas inlet casing
(51001).
Secure the insulation on the gas inlet casing (51001).
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
Version 2.0
CAUTION
ABB
Operation Manual
Disassembly and assembly
8.8
Page 29
May 2006
L_00044
Version 2.0
ABB
Operation Manual
8.8
Page 30
Part no.
TPL 73
TPL 77
TPL 80
42059
M16
105
M20
240
M20
240
61036
M18
80
M20
80
M22
80
61037
M18
160
M20
210
M22
280
61044
M18
370
M20
480
M22
480
61056
M18
370
M20
480
M22
480
61059
M18
370
M20
480
M22
480
74026
M18
80
M20
80
M22
80
74027
M18
135
M20
175
M22
235
76002
M14
1)
M16
1)
M18
1)
82005
M16 x 1.5
50
M16 x 1.5
50
M16 x 1.5
50
86505
M18 x 1.5
150
M18 x 1.5
150
M22 x 1.5
220
90458
M10
30
M10
30
M10
30
Version 2.0
1)
May 2006
L_00228
ABB
Operation Manual
Taking out of operation temporarily
9.1
Page 1
CAUTION
If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following
possibilities are available:
Lock the turbocharger rotor
Fitting the cover plate
Blocking the inlets and outlets
Bypass the turbocharger
Version 2.0
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 2
May 2006
CAUTION
NOTE
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
NOTE
CAUTION
Various intermediate rings are provided with the locking device for different compressor wheels. The compressor wheel type CV (for the
balancing screw holes) must be noted. The space between the locking
flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.
During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures
and information for operation with a locked rotor for 4-stroke engines).
Otherwise components that are still intact can be damaged by overheating.
Version 2.0
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 3
May 2006
L_00225
Version 2.0
Part no.
TPL73-A
TPL77-A
TPL80-A
74027
M18
135
M20
175
M22
235
94006
M8
25
M8
25
M10
45
94007
M8
15
M8
15
M10
35
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 4
Version 2.0
May 2006
casing.
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 5
May 2006
L_00046
Version 2.0
Part no.
TPL73-A
TPL77-A
TPL80-A
74027
M18
135
M20
175
M22
235
94006
M8
25
M8
25
M10
45
94007
M8
15
M8
15
M10
35
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 6
internal part together with the wall insert and the diffuser.
X Fit partition wall clamp (94005) with screws (90442).
X Fit locking flange (94003) with the nuts (74027) and then with the
screws (94007 / 94006) according to the Table of tightening torques.
May 2006
X Remove the silencer or air suction branch and the compressor casing
D For engines with one or two turbochargers, eight screws are sufficient
Version 2.0
94000_002
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 7
May 2006
Compressor type CV 20
94000_003
It must be ensured that all components are clean and free from grease.
CAUTION
Version 2.0
disassembly device (90020) onto the locking flange (94003) in the correct sequence.
X Now push on the other remaining intermediate rings (94001 and/or
94002).
X Tighten intermediate rings, assembly-disassembly device (90020) and
locking flange (94003) with the screws (94006) according to the values
shown in the preceding Table of tightening torques.
X Now tighten the assembly-/disassembly device (74027) to the compressor casing with the nuts (74027) and the studs to the values shown
in the preceding Tightening torques table.
ABB
Operation Manual
Taking out of operation temporarily
9.2
Page 8
Further measures and information for operation with a locked rotor for 4May 2006
stroke engines
Separate receivers
No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
If the engine is equipped with a common air receiver and separate exhaust-gas receivers, the compensator at the compressor outlet of the damaged turbocharger must be dismantled and the air line on the engine side must be isolated. Otherwise the undamaged turbocharger can spin
"unloaded" and overspeed.
More or less powerful pulses from the exhaust-gas system are applied to
the locked rotor, depending on the engine turbocharging system. Particularly with pulse supercharging (turbine casing with more than one gas inlet) the locking device is then subjected to heavy loading. The following
operating limits should therefore not be exceeded:
In systems similar to those with constant pressure (1 gas inlet) the en-
ABB
Version 2.0
gine can be operated up to a maximum of 25% engine load. The pressure in the charge-air receiver must not exceed 0.9 bar overpressure.
With pulse supercharging (2...4 gas inlets) the engine can be operated
up to a maximum of 20% engine load. The pressure in the charge-air
receiver must not exceed 0.5 bar overpressure.
Operation Manual
Taking out of operation temporarily
9.3
Page 9
May 2006
NOTE
90000_001
Version 2.0
Type
B3
B4
B5
B6
B7
B8
50
50
12
94
TPL 77
12
107
TPL 80
11
15
136
TPL 73
B1
B2
ABB
Operation Manual
Taking out of operation temporarily
9.3
Page 10
TPL 73
844
948
905
20
28
20
TPL 77
1003
1124
1075
22
30
TPL 80
1164
1300
1248
24
32
May 2006
Type
TPL 73 - 80
4 x 90
37.5
24 x 15
Type
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
ABB
Version 2.0
20000_003
Operation Manual
9
9.3
Page 11
May 2006
61000_003
X Block the opening in the gas outlet casing with the cover plate.
X Secure cover plate with spacer sleeves and nuts (61037).
Version 2.0
CAUTION
ABB
Operation Manual
Taking out of operation temporarily
9.3
Page 12
May 2006
Separate receivers
No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
Common receiver
The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.
Version 2.0
CAUTION
ABB
Operation Manual
Taking out of operation temporarily
9.4
Page 13
May 2006
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
Version 2.0
NOTE
ABB
Operation Manual
Taking out of operation temporarily
9.5
Page 14
May 2006
Version 2.0
NOTE
ABB
Operation Manual
Mothballing the turbocharger
10
10.1
Page 1
May 2006
If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
Version 2.0
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
ABB
Operation Manual
Mothballing the turbocharger
10
Page 2
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station.
May 2006
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
Check mothballed turbochargers yearly for corrosion.
In the event of rust, clean and renew the corrosion protection.
Version 2.0
NOTE
ABB
Operation Manual
Reserve and spare parts
11
11.1
Page 1
Our service stations and agents accept orders for spare parts.
X If special variants/cases are not addressed in these general instruc-
Spare-parts set
Spare-parts set (97070) is required for the work described in this manual. The parts included in the spare-parts set are only available as part
of the complete set.
NOTE
Version 2.0
TPL73-A
Quantity
Description
Part number
Hexagon head
screw
42059 / 42064
Verbus washer
42058 / 42063
15
Hexagon head
screw
15
Verbus washer
Hexagon nut
61037
Gasket
42041
Gasket
42045
O-ring gasket
42012 / 76040
O-ring gasket
77005 / 77006
O-ring gasket
86506
O-ring gasket
25011
ABB
Operation Manual
11.1
Page 2
Quantity
Description
Part number
15
Hexagon head
screw
15
Verbus washer
Hexagon nut
61037
Gasket
42041
Gasket
42045
O-ring gasket
42012 / 76040
O-ring gasket
77005 / 77006
O-ring gasket
86506
O-ring gasket
25011
Quantity
Description
Part number
Hexagon head
screw
42059 / 42064
Verbus washer
42058 / 42063
15
Hexagon head
screw
15
Verbus washer
Hexagon nut
61037
Gasket
42041
Gasket
42045
O-ring gasket
42012 / 76040
O-ring gasket
77005 / 77006
O-ring gasket
86506
O-ring gasket
25011
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
CAUTION
May 2006
TPL80-A
11
ABB
Version 2.0
TPL77-A
Operation Manual
Reserve and spare parts
11
11.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Version 2.0
May 2006
Part number
Description
Cartridge group
51001
56001
Nozzle ring
61001
Verbus washer
61050
Gasket
Verbus washer
Verbus washer
Hex.-headed nut
63000
Turbine diffuser
68000
Foot
74027
Hex.-headed nut
74000
76000
O-ring gasket
76080
Safety segment
77000
Wall insert
O-ring gasket
O-ring gasket
79000
Diffuser
81000
Silencer
82000
82000
ABB
Operation Manual
11.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25005
Screw plug
32001
Cam bearing
32101
32102
32104
Auxiliary bearing
32105
Float disc
32106
Axial bearing
32107
Bearing bush
42001
Bearing casing
42002
Cowling
42011
O-ring gasket
O-ring gasket
42015
Gasket cover
Gasket
Gasket
Verbus washer
Verbus washer
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
O-ring gasket
Page 4
May 2006
11
Version 2.0
ABB
Operation Manual
11
11.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25008
Threaded pin
25009
Ring nut
32001
Cam bearing
32101
32102
32104
Auxiliary bearing
32105
Float disc
32106
Axial bearing
32107
Bearing bush
42001
Bearing casing
42002
Cowling
42011
O-ring gasket
O-ring gasket
42015
Gasket cover
Gasket
Gasket
Verbus washer
Verbus washer
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
O-ring gasket
Page 5
Version 2.0
May 2006
ABB
Operation Manual
Reserve and spare parts
11
11.3
Page 6
Version 2.0
May 2006
L_00291
ABB
Operation Manual
Reserve and spare parts
11
11.4
Page 7
Version 2.0
May 2006
L_00039
ABB