ABB Turbocharger

Turbocharging

Operation Manual TPL85-B15 ABB Turbo Systems Ltd CH 5401 Baden Type

TPL85-B15

HT489493

n Mmax 200

t

Mmax

550

Bmax

520

1/s n Bmax 190

10620kg Year

°C t

36

100

100

Application according to the Operation Manual

2008

HZTL2491 English

made in Switzerland

ABB Turbo Systems Ltd

Operating condition and replacement intervals The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the components concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon between the engine builder and ABB.

Note:

Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the current application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components. Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to the „European Machinery Directives“. We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.

© Copyright by ABB TURBO SYSTEMS Ltd 2004 Design and specifications are subject to change without notice.

Printed on naturally white paper, bleached free from chlorine and environmentally acceptable. The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of recycled cardboard. These materials may be disposed with the domestic wastes or at a specialised collecting centre.

ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland

Operation Manual / TPL85-B14/-B15/-B16

Version 5

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January 2008

List of contents

Page 1

List of contents 1

Preliminary remarks

1.1

Purpose of manual

1.2

Layout and function

1.3

Correct use of the turbocharger

1.4

Essential information

1.5

Abbreviations and symbols

1.6

Turbocharger rating plate

2

Safety

2.1

Basic safety instructions

2.2

General safety instructions

2.3

Special safety instructions

2.4

Safety instructions and hazard protection

2.5

Warnings on the turbocharger

3

Commissioning

3.1

Oil supply

3.2

Inspection work

3.3

Putting into operation after laying up

4

Operation

4.1

Servicing work

4.2

Expected exchange intervals

4.3

Monitoring

4.4

Surging of turbocharger

4.5

Contact with rotating parts

4.6

Shutting the engine down

5

Maintenance

5.1

Foreword to Maintenance

5.2

Cleaning the filter silencer

5.3

Cleaning the compressor during operation

5.4

Cleaning turbine blades and nozzle ring in operation

5.5

Suppliers of materials for dry cleaning


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6.1

Possible remedies for failures

7

Removal and installation

7.1

Turbocharger weights

7.2

Remove the turbocharger

7.3

Installing the turbocharger

8

Disassembly and assembly

8.1

Module weights

8.2

Removing and fitting filter silencer or air suction branch

8.3

Axial clearance

8.4

Dismantling the internal part of the compressor casing

8.5

Dismantling gas inlet casing

8.6

Fitting gas inlet casing

8.7

Fitting the internal part of the compressor casing

8.8

Table of tightening torques

9

Taking out of operation temporarily

9.1

Possibilities for emergency repair

9.2

Locking the rotor

9.3

Blocking the inlets and outlets

9.4

Bypass the turbocharger

10

Mothballing the turbocharger

10.1

Taking out of operation for up to 12 months

10.2

Taking out of operation for more than 12 months

11

Disposal

11.1

Environmentally compatible disposal of turbocharger components

12

Reserve and spare parts

12.1

Ordering spare parts

12.2

Directory of part numbers

12.3

General view of turbocharger

12.4

General view of cartridge group


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Troubleshooting

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6

Page 2

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List of contents

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Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks

1

Purpose of manual

1.1

Page 1

January 2008

1 Preliminary remarks 1.1 Purpose of manual Operating manual

This operation manual will help you to become familiar with your ABB Turbo Systems 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.

Content of operating manual

This operation manual includes helpful information on the following topics: Information on the operation of the turbocharger and ways to prolong

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the turbocharger's service life. Early identification and avoidance of hazards. Minimizing repair costs and downtime.

This operating manual complements and extends existing national regulations on protection against accidents and accident prevention.

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. Anyone who works only occasionally on the machine, e.g. during installation and maintenance, must also read and fully understand the operating manual before beginning work.

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The instructions included in this operating manual must be followed without fail.

WARNING

This applies especially to the general and special safety instructions preceding the respective chapters and in them. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. If in doubt, consult the safety officer responsible and the person accountable for protection against accidents in your domain.


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1

Layout and function

1.2

Page 2

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January 2008

1.2 Layout and function

1.2.

Filter silencer

7

Nozzle ring

2

Radial plain bearing

8

Turbine wheel

3

Thrust bearing

9

Bearing casing

4

Radial plain bearing

10

Diffuser

5

Gas outlet casing

11

Compressor wheel

6

Gas inlet casing

12

Compressor casing Version 5

1


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1

Layout and function

1.2

Page 3

January 2008

Working principle The turbocharger is a turbo-machine and consists of the following main components: Turbine Compressor

These are both mounted on a common shaft.

Exhaust gases from the diesel engine flow through the gas inlet casing (6) and the nozzle ring (7) to impinge on the turbine wheel (8). The turbine wheel (8) uses the energy contained in the exhaust gas to drive the compressor wheel (11). The compressor draws in fresh air, compresses it and then forces it into the engine cylinders. HZTL2491_EN

The exhaust gas escapes to free air through the exhaust manifold which is connected to the gas outlet casing (5). The air, which is necessary for the operation of the diesel engine and compressed in the turbocharger, is drawn through the suction branch or the filter silencer (1) into the compressor wheel (11). This air then passes through the diffuser (10) and leaves the turbocharger through the compressor casing (12). The rotor runs in two radial plain bearings (2/4), which are located in the bearing casing (9) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side. The plain bearings are connected to a central lubricating oil feed which is normally supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (9).

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The turbocharger is equipped with an emergency lubrication oil tank, which is integrated in the bearing casing. During an emergency stop caused by a failure of the lubrication oil system, this emergency lubrication unit supplies oil to the bearings until the rotor comes to a standstill.


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1

Correct use of the turbocharger

1.3

Page 4

This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine. NOTE

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1.3 Correct use of the turbocharger

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

This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations. Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine. The machine may only be operated by trained personnel.

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Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty.

Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed. The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual. X Malfunctions / defects which could affect safety must be eliminated

immediately.

The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.


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Perfect condition


1


1.4

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January 2008

1.4 Essential information Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed. This also applies to the provision and wearing of personnel protection equipment. The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual. NOTE

X The turbocharger must be shut down immediately by stopping the enHZTL2491_EN

gine in the event of alterations affecting safety or of corresponding operating behaviour. The fault must be reported to the person or department responsible.

Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems.

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NOTE


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1


1.4

Page 6

January 2008

Original parts and safety Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us. NOTE

If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger. Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine. ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories.

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WARNING

Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel. Work on mechanical components, such as bearings or rotors, may only be performed by qualified fitters from an official service station of ABB Turbo Systems. CAUTION


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It must be ensured that only authorised personnel work on the turbocharger.

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1


1.4

Page 7

January 2008

After-sales service The Contact Information brochure contains an overview of official ABB Turbo Systems. service stations worldwide. Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger. Our service stations and agencies will gladly answer your questions relating specifically to your model.

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Accuracy of illustrations The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details. Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the delivery date. Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form. X After expiry of the 6 months, all surfaces and accessible areas of the

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turbocharger should be sprayed with anticorrosive agent. X To do this, the insulating materials must be removed.

Repeat the described measures every 6 months to keep your turbocharger free from rust. NOTE


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1

Abbreviations and symbols

1.5

Page 8

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1.5 Abbreviations and symbols The following abbreviations are used in this document: Z Prerequisite X Work step D Result

9 Positive checkpoint (activity that must be carried out without fail) U Negative checkpoint (activity that must not be carried out under any circumstances)

Basic Instructions HZTL2491_EN

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 note provides further essential information.

Reference to safety instructions The warnings and cautions are described in the chapter Safety . CAUTION

ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Systems. Official ABB Turbo Systems service station The term Official ABB Turbo Systems service station used in this manual signifies ABB turbocharger service stations, that have been tested and certified by ABB Turbo Systems.


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1


1.6

Page 9

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January 2008

1.6 Turbocharger rating plate

L_00012

Operational limits

1

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2

Recommended replacement periods / exchange intervals for turbocharger components


3 4 5

Turbocharger operational limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer. Turbocharger operational limits in service.

Replacement interval for the plain bearings in 1000 h Exchange interval for the compressor in 1000 h (no data for 100,000 h) Exchange interval for the turbine in 1000 h (no data for 100,000 h)

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Operation Manual / TPL85-B14/-B15/-B16 1


1.6

6 7 8 9 10 11 12

Page 10

Customer part number Field for special design designation Weight of the turbocharger in kg CE = Conformité Européenne Turbocharger type Series number Year of construction of the turbocharger

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Additional specifications:

Preliminary remarks

Explanations of the rating plate

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. 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.

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The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific.

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Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.


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Operation Manual / TPL85-B14/-B15/-B16 Safety

2

Basic safety instructions

2.1

Page 1

2 Safety January 2008

2.1 Basic safety instructions The following symbols and terms are used for the safety instructions in this manual: Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents. WARNING

Warning signs must be strictly observed at all times.

CAUTION

Caution signs must be strictly observed at all times.

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Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed.


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2

General safety instructions

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.

January 2008

2.2 General safety instructions

The following safety instructions must be followed when operating and when working on the turbocharger. WARNING

Do not work on the turbocharger if you are under physical or mental

stress.

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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.

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Wear protective clothing at all times.


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2


2.3

Page 3

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2.3 Special safety instructions Safety when connecting Work only on those connections for which you are qualified.

Safety when commissioning and during operation Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working with the turbocharger. Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. Report any damage or changes in operational performance to the person/department responsible immediately. In the event of damage, shut down the turbocharger immediately and secure it against inadvertent or unauthorized use.

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Safety when cleaning When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Follow directions regarding the environmentally compatible collection, storage and disposal of these liquids. Explosion hazard

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WARNING


Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.

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2


2.3

Page 4

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.

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Before cleaning, protect the floor against unintended leaks of oil and

Safety during disassembly, assembly, maintenance and troubleshooting

Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.

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CAUTION

justment, maintenance and inspection work. Inform operating personnel about special work and repairs before starting. 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.

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Follow the prescribed maintenance and inspection schedules for all ad-


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2


2.3

Page 5

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Safety when taking out of operation or putting into storage Secure the rotor against turning. Clean the turbocharger before mothballing. Wear protective clothing when mothballing the turbocharger. Keep the work area clean and free of oil and operating materials. Remove any obstacles lying around on the floor.

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2.4

Page 6

Associated hazards may arise during operation of and work on the turbocharger:

from the turbocharger and its accessories. from the operating materials used. due to failure to comply with the safety instructions. from inadequate performance of maintenance and inspection work.

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2.4 Safety instructions and hazard protection

Mechanical influences

Mechanical influences can cause serious injury or even fatal injury.

Unconsciousness and injury due to:


crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling

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Personal injury

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WARNING


2


2.4

Page 7

sharp edges, pointed parts crush, shear and winding areas fragmentation / ejection of parts fracture or rupture of parts due to overload Elastic elements (springs), liquids and / or gases under pressure/in a vacuum slippery, oily work area, obstacles on the floor

Protective measures

9 9 9 9 9 9 9

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Causes

Wear leather protective gloves Wear close-fitting protective clothing Tie up long hair and beards (wear hair protection) Wear face and eye protection Wear protective shoes Keep floor, equipment and the turbocharger clean Ensure the availability of oil absorbing materials and have oil collector basins ready or in position 9 Eliminate leaks

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Operation and process materials Operation and process materials refer to chemical and hazardous substances:

Oils Grease Coolants Detergents and solvents Acids Note that operation and process materials are harmful to the environment if they penetrate soil or water.

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CAUTION


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2.4

Page 8

The following injuries can be caused by operation and process materials: Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation

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Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids Clothing wet or soaked with hazardous substances Spilling and tipping over of vessels containing substances used during operation Escape due to leakage Tanks and collectors which are not gas-tight and which do not comply with the regulations on hazardous substances Burning cigarettes or open flame in the proximity of operation materials

Causes

Protective measures

9 9 9 9 9 9 9

9

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9

Utmost caution when handling process and operation materials Protective clothing must be worn Avoid skin contact and inhalation Ensure that the workroom is properly ventilated Observe the hazard indications on the containers for operation and process materials Seal the hazardous substance container tight immediately after use Used operation materials must be collected safely in accordance with the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in an environmentally compatible manner Ensure that containers with new / used operation materials are sealed tight In the event of leaks or spills, immediately apply a suitable absorbent material and dispose of this in a technically and environmentally compatible manner as special waste

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Personal injury

Safety


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2


2.4

Page 9

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Handling insulating materials 9 9 9 9 9 9 9 9 9 9 9

Ensure that the work area is well ventilated Keep the work area clean Avoid disturbing dust Dust-suppressing tools and processing steps Remove from packaging only in the work area Exercise particular care when removing old insulating materials Dispose of insulating materials in a technically and environmentally compatible manner If large quantities of dust are created, wear protective glasses Use half or quarter masks Wear suitable work clothing and gloves For sensitive skin, apply moisturising, protective barrier cream

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Noise The effects of noise above a legally permitted level can cause personal injury. Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances

Personal injury

Causes

Machine noise level above 85 dB (A)

Protective measures

9 Wear ear protection Heat hazard

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When the turbocharger is operated, surfaces become very hot. Personal injury

Burns

Causes

Missing or incorrectly fitted insulation.

Protective measures

9 Wear leather protective gloves.


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2

Warnings on the turbocharger

2.5

Page 10

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Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.

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2.5 Warnings on the turbocharger

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.

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NOTE


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Operation Manual / TPL85-B14/-B15/-B16 Commissioning

3

Oil supply

3.1

Page 1

3 Commissioning January 2008

3.1 Oil supply A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger. Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit. Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature. NOTE

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Oil filtration A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for TPL ..-B turbochargers. Oil pressure The oil pressure in front of the bearings must be maintained precisely to ensure trouble-free operation.

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The permissible oil pressures are specified in the following tables dependent on the lubrication (engine lubrication or separate lubricating system).


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Separate lubricating system

NOTE

3

Oil supply

3.1

Page 2

Oil pressure [bar]

Inadmissible oil pressure range -> Emergency shutdown (without time lag)

0.0 - 0.6

Oil pressure range permissible in short term (<1h) -> Alarm

0.6 - 0.8

Permissible oil pressure range for normal operation

0.8 - 2.5

Permissible oil pressure range during engine warmup phase

0.8 - 4.0

Kinetic viscosity 12 - 170 cST

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Kinetic viscosity 45 - 170 cST

Oil pressure [bar]

Inadmissible oil pressure range -> Emergency shutdown (without time lag)

0.0 - 0.9

Oil pressure range permissible in short term (<1h) -> Alarm

0.9 - 1.1

Permissible oil pressure range for normal operation

1.1 - 2.5

Permissible oil pressure range during engine warmup phase

1.1 - 4.0

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Engine lubrication

Commissioning

If a separate lubricating system has been designed for operation in the viscosity range of the engine lubrication system, i.e. 45 – 170 cSt, the oil pressure limits according to the engine lubrication information may be used for this system.

Engine lubrication


Oil entry temperature [ °C ]

Engine load [%]

Oil entry pressure [bar]

Oil exit temperature [ °C ]

45

100

1.5 - 2

70 - 90

70

100

1.5 - 2

90 - 110

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Oil temperature during normal operation


3

Inspection work

3.2

Page 3

3.2 Inspection work January 2008

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. The safety instructions must be followed before and during all inspec-

tion work.

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3.2.1

Inspection before commissioning

Monitoring equipment

X Check for correct functioning.

Air filter mat

X Inspect for damage.

Lubrication system

X Check that the oil filter is clean before commissioning.

It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system. CAUTION

We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.

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X Check oil pressure in oil supply lines.


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Inspection work

3.2

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Inspection after commissioning

Lubrication system

X Check oil pressure in oil supply lines.

Charger speed

X Measure

Charger pressure

X Measuring

Measure temperatures

X upstream/downstream from turbine, compressor and oil feed for vari-

Gas, air, and oil lines

X Check all gas, air, and oil lines for leaks after the engine has been star-

ous engine speeds

ted up.

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3.2.2

Commissioning

Further must be observed:

Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours after commissioning. If further oily liquid continues to appear after this period, an oil leak must be suspected. Then, the first step is to check for leakage of the oil supply to the turbocharger. If something wrong is detected, contact an official ABB Turbo Systems service station.

NOTE

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.

3.2.3

Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.


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X Measure the speed, oil pressure, charging pressure and temperatures


3

Putting into operation after laying up

3.3

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3.3 Putting into operation after laying up If they are present

X Remove the cover plates (blind flanges) between the compressor cas-

ing outlet and the charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.

X Inspect the exhaust-gas duct before and after the turbine for any comX X X

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X

bustion residue, clean / remove foreign bodies or residual water. Inspect air supply line or filter silencer for any foreign bodies, clean / remove. Start up the turbocharger's engine end oil circulation system. Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning. Commission the turbocharger.


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Operation Manual / TPL85-B14/-B15/-B16 Operation

4

Servicing work

4.1

Page 1

4 Operation January 2008

4.1 Servicing work Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be carried out at the intervals indicated. The pertinent safety instructions must be observed during all servicing work.

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WARNING

Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger. CAUTION

4.1.1 Operation data

Servicing work every 25 to 50 hours X Record X Record in the machine logbook X In the event of significant deviations, establish the cause.

If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.

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CAUTION


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Servicing work

4.1

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Entries in the machine logbook Monitoring of the machine plant provides information about the performance of the turbocharger.

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4.1.2

Operation

The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book: Output and speed of the engine Air intake temperature Exhaust temperature before and after the turbine Pressure of the charge-air Pressure drop in the charge-air cooler Lubricating oil pressure, lubricating oil temperature

Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter

If provided

4.1.3

X With the engine at standstill clean or replace oil filters

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Oil filters

Servicing work according to the engine manufacturer's instructions

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Servicing work

4.1

Page 3

Inspection work every 18,000 hours Remove filter silencer or air suction branch Clean filter silencer as far as accessible, and inspect for damage Remove internal part of compressor casing Check clearance A (axial bearing play). Clean accessible parts (compressor wheel, diffusor, wall insert), and inspect for damage X Without removing turbine parts and using an endoscope, carry out a visual check for possible soiling and damage (nozzle ring, turbine diffusor/cover ring, turbine blades). As an option, this inspection can be carried out after removal of gas inlet casing. X Refit internal part of compressor casing X Re-install filter silencer or air suction branch. X X X X X

This inspection work and checks must be carried out by an official service station of ABB Turbo Systems. NOTE

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January 2008

4.1.4

Operation


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Servicing work

4.1

Page 4

Servicing work every 36,000 hours Remove filter silencer or air suction branch Clean filter silencer as far as accessible, and inspect for damage Remove internal part of compressor casing Check clearance A (axial bearing play). Clean accessible parts (diffusor, wall insert), and inspect for damage. Take apart gas inlet casing and remove nozzle ring. Clean nozzle ring and check for damage or wear. Clean turbine diffusor / cover ring and check for damage or wear. Replace radial bearing and thrust bearing with original parts from ABB Turbo Systems. X Inspect and assess rotor.

X X X X X X X X X

Replacement of the bearing parts as well as inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.

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NOTE

January 2008

4

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4.1.5

Operation


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4

Expected exchange intervals

4.2

Page 5

January 2008

4.2 Expected exchange intervals Expected replacement intervals [h]

Turbocharger part

HFO

Gas inlet casing

50'000 … 100’000

Gas outlet casing

50'000 … 100’000

Nozzle ring

35'000 … 50’000

Turbine diffusor / cover ring

25'000 … 50’000

Other housings

100’000

Rotor components

See rating plate for information

Bearings

See rating plate for information

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HFO

The values indicated are for guidance only and are not guaranteed values. These values may vary significantly for example due to inadequate servicing, frequent emergency stoppages as well as through the use of fuel or lubricating oil of inferior quality.

Version 5

NOTE

= Heavy Fuel Oil


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4

Monitoring

4.3

Page 6

4.3.1

January 2008

4.3 Monitoring Measuring speed 1 9

2 11

3 10

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6 7

8 L_01246

1

Bearing casing

7

Line amplifier (optional)

2

Thrust bearing

8

Speed transmitter

3

Guide in axial bearing

9

Auxiliary bearing

-

-

10

Alternative for fitting speed transmitter

5

Screw plug

11

Tachometer (option)

6

Connecting cable (with voltage limiting module)

-

-

The speed transmitter system for measuring the turbocharger speed also permits continuous remote monitoring of the turbocharger speed when it is used in conjunction with the corresponding measuring instruments and / or monitoring systems (not included in the scope of delivery). If the machine installation is monitored continuously, the turbocharger speed can be used as a suitable control parameter. The line amplifier (7) can be purchased as an option to the described speed measuring system.


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Version 5

5


4

Monitoring

4.3

Page 7

Possible reasons for failure of speed transmitter system: Defects of the speed transmitter (8), connecting cable (6) and connect-

January 2008

ing plug for the measuring unit or on the measuring unit or power supply. Turbocharger breakdown. Failure of speed indicator CAUTION

If the speed indicator fails, it is recommended that the engine output be reduced to idling and the engine then stopped. X Investigate cause of failure and eliminate problem.

Fitting speed transmitter system

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NOTE

It is recommended that fitting or replacing a speed transmitter system on an in-place turbocharger be carried out only by an official ABB Turbo Systems service station.

A reduction in turbocharger speed can signify:

Version 5

Damaged turbine or bearing Severe soiling of the turbine


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Monitoring

4.3

Page 8

Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for measuring the negative pressure at the filter silencer.

January 2008

4.3.2

Operation

This measuring can be used for the following purposes: Measuring the correction factor for calculating the turbocharger effi-

ciency during engine acceptance The use of a filter mat on the filter silencer can cause a loss of pressure. More significant pressure loss is an indication of increased soiling of the filter material.


Version 5

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U-tube manometer

L_00003

L_00004

1

Felt discs

A [mm H2O]

Pressure differential / pressure loss

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4

Monitoring

4.3

Page 9

January 2008

All parts required for assembly are supplied in a separate package. Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1). The U-tube manometer must be exposed to minimum possible mechanical shock or vibration. NOTE

X Fit U-tube manometer to filter silencer as shown in preceding illustra-

tion.

X Fill U-tube manometer with slightly coloured water to obtain best legibil-

ity.

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Under as-new conditions (new or clean filter silencer and filter mat), the maximum pressure loss (A) is 120 mm H2O under full loading. X Clean filter at latest as soon as loss of pressure (A) reaches a value of

200 mm H2O.

For better legibility of the pressure differential (A) on the U-tube manometer, the measuring rod can be withdrawn to the level of the bottom water level.

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NOTE


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4

Surging of turbocharger

4.4

Page 10

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.

January 2008

4.4 Surging of turbocharger

Prolonged or periodic surging

Action to be taken:

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NOTE

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.

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CAUTION

If surging is prolonged or occurs periodically, the following components may be damaged: - Compressor wheel (vibration fractures, ...) - Turbine blades (cracks) - Bearing (overheating) - Filter silencer


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4

Contact with rotating parts

4.5

Page 11

4.5 Contact with rotating parts January 2008

Slight, uniform wear around the periphery of rotor components, caused by their just touching adjacent components locally, is not hazardous and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid a significant loss of efficiency. X A check on dimensions must be carried out by an official ABB Turbo

Version 5

HZTL2491_EN

Systems service station.


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4

Shutting the engine down

4.6

Page 12

Before shutting down the engine, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can take away heat from the turbocharger bearings.

January 2008

4.6 Shutting the engine down

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CAUTION


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Operation Manual / TPL85-B14/-B15/-B16 Maintenance

5

Foreword to Maintenance

5.1

Page 1

January 2008

5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and cleaning to ensure that the turbocharger and its attached units function troublefree.

The external condition and how dirty the cleaning points specified in

this chapter are, must be established by visual checks at the specified intervals. The safety precautions must be observed during all maintenance and servicing work.

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The cleaning points described in the following are:

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Filter silencer Compressor Turbine and nozzle ring


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5


5.2

Page 2

5.2.1

January 2008

5.2 Cleaning the filter silencer Filter silencer with tension band 81137

81136

81266 81268 81271 L

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81270

81135

81266

81268

81270

Version 5

81265

L_01158


81265

Filter ring (if provided)

81266

Cover grids

81270

Tension ring

81136

Fleece segment

38271

Trap cover

81137

Cover panel

81268

Connecting strip

81135

Filter silencer body

E

Slide-in module = fleece segment + cover plate installed

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January 2008


5


5.2

Page 3

Disassembling and cleaning filter silencer X Remove filter ring (81265). X Rinse filter ring (81265) with water using detergent or, if very dirty, soak

If provided

it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).

The dirt in the filter ring (81265) depends on how clean the drawn-in air is. Wash or replace the filter ring as necessary or every 500 service hours. NOTE

X Loosen clamping straps (81270) at tightening point (81271) and re-

HZTL2491_EN

move together with mesh covers (81266) and connecting bars (81268).

NOTE

In the case of a slide-in module (E) when a cleaning container is attached to the filter silencer (available as option depending on turbocharger type), the water injection line must first be removed (see also following section Disassembling cleaning line).

X Withdraw slide-in modules (E), bend open cover plates (81137) and

then take out fleece segments (81136).

X Clean fleece segments (81136).

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When cleaning, ensure that fleece segments (81136) are cleaned only with a weak 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 bars should be replaced with original parts from ABB Turbo Systems. NOTE


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5


5.2

Page 4

X Assemble slide-in modules (E) by inserting fleece segments (81136) in

cover plates (81137).

X Bend cover plates back to their original shape. X Insert slide-in modules (E) in grooves in filter silencer body (81135).

January 2008

Mounting filter silencer

When the cleaning container is fitted to the filter silencer (available as option depending on turbocharger type), the water injection line must be re-installed (see also following section Assembling cleaning line). NOTE

lencer body (81135). X Pass clamping straps (81270) through eyelets in connecting bars (see detail L in illustration L_01158). X Tension all clamping straps at tightening points (81271).

X Fit filter ring (81265).

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If provided

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X Fit mesh covers (81266) and connecting bars (81268) onto filter si-


ABB

5.2.2

Maintenance

5


5.2

Page 5

Removing / installing the cleaning line

HZTL2491_EN

January 2008


L_00192

Injection pipe

3

Guide tube

2

Pipe

Version 5

1


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5


5.2

Page 6

X Disconnect the line (2) at the injection pipe (1) and remove the screw

coupling from the pipe.

X Pull line (2) out of the guide tube(3).

January 2008

Disassembling the cleaning line

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Punching out the guide tube

L_00193

X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16

mm) and pull it out.

Version 5

Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems. NOTE


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5


5.2

Page 7

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January 2008

Installing the cleaning line

L_00194

X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-

Version 5

caulk it. X Fit line (2) and screw it to the injection pipe (1).


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5


5.3

Page 8

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.

January 2008

5.3 Cleaning the compressor during operation

NOTE

The contamination of the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in. A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air:

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.

HZTL2491_EN

Oil or saline mist Solid combustion residues Dust of various kinds

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.

The interval between periodic cleaning depends considerably on the operating conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Should the prescribed cleaning intervals prove incompatible with the operation of the engine, please contact ABB Turbo Systems.

NOTE


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Version 5

Interval between cleanings


5


5.3

Page 9

January 2008

Cleaning method 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

Principle of 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.

HZTL2491_EN

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.

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Cleaning more than one turbocharger compressor


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NOTE

5


5.3

Page 10

Wet cleaning the compressor with external pressurised water container (XC3) The supply of water with the externally fitted dosing vessel is only suitable for applications with underpressure before the compressor wheel (not applicable for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).

January 2008

5.3.1

Maintenance

Operating state preconditions for cleaning compressors with XC3

NOTE

Z Engine loading as full as possible Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-

Version 5

cedure for wet cleaning with XC3.

HZTL2491_EN

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met:


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5


5.3

Page 11

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January 2008

Procedure for compressor wet cleaning with XC3

L_00198

Operating the pressurised water container

Version 5

Screw plug

Y

Valve activator

X The Operating state preconditions for cleaning the compressor with X X X X X


X

XC3 must be met before cleaning can begin. Remove screw plug (X). Fill container with clean water. Screw screw plug (X) back in. Actuate valve lever (Y) against the spring and hold for 10 to 15 seconds, until all the water has been injected. After cleaning, the turbocharger must be allowed to dry for at least 5 minutes before any further activity.

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5.3

Page 12

If the cleaning operation was not successful, it can be repeated up to 2 times. NOTE

If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.

January 2008

Maintenance

Cleaning parameters for each turbocharger compressor Turbocharger type

Turbocharger speed

Contents of the dosing vessel [dm3]

Water injection time t1 [s]

TPL 69BA

Possible nBmax

0.4

4 ... 15

TPL 73-B

1

TPL 77-B 2

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TPL 80-B TPL 85-B

Version 5

TPL 91-B


ABB


January 2008

5.3.2

Maintenance

5


5.3

Page 13

Wet cleaning compressors using water vessel (XC4) Operating state preconditions for cleaning compressors with XC4

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met: NOTE

Z Engine loading as full as possible Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-

cedure for wet cleaning with XC4.

Version 5

HZTL2491_EN

Procedure for compressor wet cleaning with XC34

L_00197


1

Cleaning container

2 Pipe

3

Injection pipe

4 Cleaning instructions

5

Cover

6 Valve

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5.3

Page 14

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. NOTE

X The Operating state preconditions for cleaning compressors with XC4 X X X X X X

must be met before cleaning can begin. Open lid (5) of the cleaning container (1). Fill with clean water. Screw lid (5) closed. Open valve (6) for about 3 minutes. Close valve (6) and check that all the water has been sucked out. After cleaning, the turbocharger must be allowed to dry for at least 5 minutes with the engine running before any further activity.



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Operation of the cleaning container

January 2008

Maintenance

Cleaning parameters for each turbocharger compressor Turbocharger type

Turbocharger speed

Contents of the dosing vessel [dm3]

Water injection time t1 [s]

TPL 69BA

Possible nBmax

2

4 ... 15

TPL 73-B TPL 80-B

Version 5

TPL 77-B 3

TPL 85-B TPL 91-B


ABB

January 2008


5


5.4

Page 15

5.4 Cleaning turbine blades and nozzle ring in operation Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits. The exhaust gas temperature downstream of the cylinders can rise and the charging pressure at the air receiver can fall if turbine components become soiled.

Experience in operation has shown that despite periodic cleaning during operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended. Wet cleaning interval

The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours.

Interval for dry cleaning

The interval between periodic cleaning depends considerably on the operating conditions. In general, cleaning should be carried out every 20 to 50 operating hours.

Version 5

HZTL2491_EN

A soiled turbine also results in rotor unbalance. Severe soiling can lead to impermissibly high rotor imbalance.


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5


5.4

Page 16

Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the following have been tested and are recommended by ABB Turbo Systems:

January 2008

Cleaning methods

Wet cleaning Dry 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 risk of corrosion, only clean water may be used and on no account salt water. Furthermore, the water should contain no cooling additives, which could form deposits in the flow ducts. CAUTION Principle of dry cleaning

During dry cleaning using dry solid particles in granulate form, the deposit is removed by the mechanical impact of the grains hitting the surface.

HZTL2491_EN

Principle of wet cleaning

Wet and dry cleaning are equally effective. However, it may be useful to apply both methods together.

Version 5

NOTE


ABB

January 2008


NOTE

Cleaning more than one turbocharger turbine

5


5.4

Page 17

Components at the turbine end are not cleaned until the engine has been started or the engine load reduced. The exhaust temperature must not exceed the value specified in the pertaining cleaning instructions (see respective section Operating state prerequisites).

Failure to maintain the specified exhaust temperature in front of the turbine, the minimum stabilising time before as well as between cleaning operations and the drying time after cleaning in accordance with the pertaining cleaning instructions will drastically shorten the expected service life of the components.

If several turbochargers are installed on one engine, we recommend cleaning the turbocharger turbines with nozzle rings one after the other.

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CAUTION

Maintenance


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5.4

Page 18

Wet cleaning turbine and nozzle ring during operation The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature shown on the turbocharger rating plate must not be exceeded under any circumstances. During wet cleaning the turbine delivers less power to the shaft and the turbocharger speed sinks. As a result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.

January 2008

5.4.1

Maintenance

Operating state precondition for wet cleaning

NOTE

Z After the engine has been started or during operation, the engine

Version 5

output must be adjusted until the scavenging air pressure pscav is within the range of 0.3 – 0.6 bar (gauge pressure). Z Wait 10 to 15 minutes (stabilising time), until the exhaust temperature at the turbine inlet is stable and below 430°C, the auxiliary blower must also be operating. X Cleaning cycle started according to the following description in Procedure for wet cleaning.

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In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met:


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5.4

Page 19

Version 5

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January 2008

Procedure for wet cleaning

L_00394

Operating the wet cleaning system

1

Water supply (fresh water only) at least 6.0 bar

8

Drain pipe

2

Regulating valve

9

Drain cock

3

Manometer

10

Outflow

4

Air supply with 3-way-valve

11

Orifice (integrated in turbocharger)

5

Stainless-steel pipe

21

Air duct from compressor casing

6

Other turbochargers

A

Position 1

7

Injection nozzle

B

Position 2

Z The Operating state preconditions for wet cleaning must be satisfied

before cleaning is begun.

X Check that the water supply (1) is open and ensured, and also con-

nected to the regulating value (2) in front of the turbocharger. X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing to Position 1 and check whether exhaust gas escapes.


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5


5.4

Page 20

X X X X

X X

valve (2) until the manometer (3) shows a pressure of 1 ± 0.2 bar. Inject water for 5 minutes at constant engine output. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Position 2, in order to keep the drain pipe clean with air from the compressor casing (21). The water supply connection (1) to the regulating valve (2) must be disconnected. After cleaning, wait at least 10 minutes with engine running to allow turbocharger to dry.

January 2008

X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating

Points to remember when cleaning



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 150°C). 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 wet cleaning operation must be terminated and the wet cleaning cycle begun again with a lower water pressure or higher engine loading.

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Version 5

NOTE

HZTL2491_EN

If the cleaning operation was not successful, it can be repeated up to 2 times.


January 2008

5.4.2

Maintenance

5


5.4

Page 21

Integrated dry cleaning of turbine and nozzle ring during operation This cleaning method is not suitable for removing thick dirt deposits and must therefore be carried out more often (see chapter Cleaning turbine blades and nozzle ring in operation).

NOTE

Operating mode prerequisites for integrated dry cleaning device

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be met:

HZTL2491_EN

NOTE

Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature upstream of the turbine must be below 590°C.

Version 5

Otherwise, there is considerable danger that the dry cleaning agent will be burnt off. X Start the cleaning cycle with reference to the following description Operating procedure for integrated dry cleaning device.


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5.4

Page 22

HZTL2491_EN

January 2008

Operation of integrated dry cleaning device

1

Container for granulated material

5

ON/OFF valve

2

Trap-cover

6

Safety valve

3

Compressed air supply [4 to 10 bar]

7

Combined air valve/pressure relief valve

4

Pipe made from stainless steel

8

Cleaning instructions

The air system must be protected against overpressure (> 10 bar). CAUTION


ABB

Version 5

L_00094

January 2008


Operation of the dry cleaning device

Maintenance

5


5.4

Z The Operating mode prerequisites for integrated dry cleaning must be X X X X X X X X X X X

HZTL2491_EN

Page 23

X

satisfied before cleaning begins. Ensure that the ON/OFF valve (5) is closed. Check that combined air valve/pressure relief valve (7) is in pressure relief position. Carefully open trap cover (2). Fill container (1) with specified amount of granulate. Close and seal trap cover (2). Open air valve (7). Open safety valve (6). Open ON/OFF valve (5) and leave it open for approx. 1 minute to clean turbine. Close ON/OFF valve (5). Close safety valve (6). Set the combined air valve/pressure relief valve (7) to the pressure relief position. Check whether exhaust gas temperature after turbine has dropped.

In order to obtain the best possible cleaning effect, it is essential that the prescribed quantity of granulate is blown in. NOTE

The drain openings in the gas outlet casing must remain closed while the turbine is being cleaned. Careless handling can cause incompletely combusted soot particles to escape.

Version 5




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5.4

Page 24

Selection of materials

January 2008

Cleaning parameters for integrated dry cleaning device

The following materials are suitable for use when dry cleaning: Hard, granulated materials, such as natural core granulates Softblast media Activated carbon particles

The mean grain size of the cleaning granulate must be between 1.2 and 2.0 mm.

Amount of granulate per turbocharger [litres]

HZTL2491_EN

The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.

TPL 85-B 3.0

The cleaning granulate must be stored in a dry, clean place in order to avoid clogging the pipes during cleaning. The table in chapter Suppliers of dry cleaning agents lists possible suppliers of dry cleaning agents.

Version 5

NOTE


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January 2008

5.4.3

Maintenance

5


5.4

Page 25

Non-integrated dry cleaning device for turbine and nozzle ring during operation As an alternative to the built-in dry cleaning system, a non-integrated dry cleaning device can be installed in front of the gas inlet casing by the engine manufacturer. Operating mode prerequisites for non-integrated dry cleaning device

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be met: NOTE

Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature in front of the turbine must be below 590°C.

Version 5

HZTL2491_EN

Otherwise, there is considerable danger that the dry cleaning agent will be burnt off. X Start the cleaning cycle with reference to the following description Operating procedure for non-integrated dry cleaning device.


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5.4

Page 26

Version 5

HZTL2491_EN

January 2008

Operation of non-integrated dry cleaning device

L_00208


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January 2008


5


5.4

Page 27

1

Trap cover G2“

6

Strap for securing the container

2

Poss. copper gasket

7

Safety valve with ventilation

3

Double nipple G2“

8

Compressed air shut-off valve

4

Copper gasket

9

Compressed air pipe (internal diameter 8mm)

5

Friction cock or slide controller G1''

10

Compressed air max. 6 bar

The air system must be protected against overpressure (> 6 bar). CAUTION

Operation of the dry cleaning device

Z The Operating mode prerequisites for non-integrated dry cleaning de-

HZTL2491_EN

Z X X X

Version 5

X X X X X X X X X X X X X


vice must be satisfied before cleaning begins. Friction cock or slide controller (5) closed and safety valve with ventilation (7) open. Close safety valve with ventilation (7). Tighten trap cover (1). Open compressed air shut-off valve (8) so that deposits and any condensation are blown off. Close compressed air shut-off valve (8) again after about 3 minutes. Close friction cock / slide controller (5). Open safety valve with ventilation (7) to blow out exhaust gases. Carefully open trap cover (1) on granulate container. Fill granulate container with specified quantity of granulate. Close and seal trap cover (1). Close safety valve with ventilation (7). Open compressed air shut-off valve (8). Open friction cock or slide controller (5) for approx. 1 minute. Close friction cock or slide controller (5). Close compressed air shut-off valve (8). Open safety valve with ventilation (7). Check whether exhaust gas temperature has dropped after turbine.

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5.4

Page 28

In order to obtain the best possible cleaning effect, it is essential that the spcified quantity of granulate is blown in. NOTE

The drain openings in the gas outlet casing must remain closed while the turbine is being cleaned. Careless handling can cause incompletely combusted soot particles to escape.

January 2008

Maintenance

If the cleaning operation was not successful, it can be repeated up to 2 times. If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.

HZTL2491_EN

NOTE

Cleaning parameters for the non-integrated dry cleaning device

The choice of material takes place according to chapter Integrated dry cleaning of the turbine and nozzle ring during operation.

Granulate quantity per turbocharger


Turbocharger type

Amount of granulate [dm3]

Container size

TPL 69BA

1.0

II

TPL 73-B

1.0

II

TPL 77-B

1.5

II

TPL 80-B

2.0

II

TPL 85-B

3.0

III

TPL 91-B

3.5

III

Version 5

NOTE

ABB


5

Suppliers of materials for dry cleaning

5.5

Page 29

Manufacturer

Country

Address

Number for contact

ABB Australia Pty. Limited

Australia

Dock 7W Bapaume Road 2170 Moorebank- N.S.W.

Tel.: +61 2 9821 0940 Fax: +61 2 9821 0941 Email: [email protected]

Paul AUER GmbH

Germany

Bad Kreuznacherstr. 18 D-68309 MannheimKaefertal

Tel.: +49 621 72 769 - 0 Fax: +49 621 72 769 - 88 Email: [email protected]

BRIGANTINE Service Ltd.

Hong Kong

48 Wang Lok Street Yuen Long Industrial Estate N.T. Hong Kong

Tel.: +852 2473 7933 Fax: +852 2237 4731 Email: [email protected]

LEERING HENGELO B.V.

Netherlands

Barnsteenstraat 1 NL-7554 TC Hengelo The Netherlands

Tel.: +31 74 255 82 82 Fax: +31 74 242 23 73 Email: [email protected]

GUYSON International Ltd

United Kingdom

Snaygill Industrial Estate Keighley Road, Skipton, North Yorkshire BD23 2QR United Kingdom


DASIC International Ltd.

United Kingdom

Winchester Hill, Romsey, Hampshire SO51 7YD United Kingdom


PAN Abrasives (Pte) Ltd.

Singapore

24 Pioneer Sector 2 Jurong 628381 Singapore


CARLANDER & Co.

Sweden

Valtersang 9 S-442 49 Kungalv Sweden


BOSUNG Engineering Co., Ltd.

Korea

1189-1, Choryang-3 Dong, Dong-Ku, Busan, 601-013

Tel.: +82 51 466 0881-5 Fax: +82 51 466 0886-9 Email: [email protected]

POLITEK Ltd.

Turkey

Barajyolu Cad. No: 22/6 Y. Camlica Mahallesi Yukari Dudullu 34779 Umraniye Istanbul / Turkey

Tel.: +90 216 455 77 66 Fax: +90 216 455 77 25 Email: [email protected]

UNISERVICE S.A.

Italy

Via Al Santuario di N.S. della Guardia 58 / A 16162 Genova


Version 5

HZTL2491_EN

January 2008

5.5 Suppliers of materials for dry cleaning


ABB

Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting

6


6.1

Page 1

6 Troubleshooting January 2008

6.1 Possible remedies for failures Exhaust temperature too high Engine output and speed unchanged

Z Malfunction in the injection system X Repair, or contact the manufacturer.

Turbocharger

Z Air starvation, e.g. air filter clogged with dirt X Clean

HZTL2491_EN

Engine

Z Compressor / turbine soiled X Clean Z Exhaust counterpressure too high X Clean or repair boiler or exhaust silencer Z Turbine damaged or worn X Contact an official ABB Turbo Systems service station.

Charge-air cooler

Z Cooler soiled X Clean Z Insufficient coolant water quantity X Replenish

Version 5

Z Coolant water inlet temperature too hot X Clean/inspect cooling system Z Ventilation inadequate X Improve ventilation


ABB


6


6.1

Page 2

January 2008

Charge-air pressure too low Engine output and speed unchanged Intake condition normal

Engine

Z Air receiver leaking X Repair Z Gas line between engine and turbine leaking X Repair Z Injection misadjusted X Correct adjustment

Turbocharger

HZTL2491_EN

Z Valve control misadjusted X Correct adjustment

Z Manometer display faulty X Replace manometer Z Leak in line to the manometer X Repair leak Z Air filter dirty, causing excessive loss of pressure X Clean Z Compressor / turbine soiled X Clean Z Compressor / turbine damaged X Contact an official ABB Turbo Systems service station.


Version 5

Z Excessive exhaust counterpressure X Clean boiler or exhaust silencer

ABB


6


6.1

Page 3

January 2008

Charge-air pressure too high Engine output and speed unchanged Intake condition normal

Engine

Z Malfunction in the injection system X Correct adjustment Z Engine output higher than expected X Check engine output

HZTL2491_EN

Z Injection misadjusted X Correct adjustment

Turbocharger

Z Manometer display faulty X Replace manometer

Vibrations Turbocharger

Z Z Z X

Rotor imbalance due to heavy fouling of compressor/turbine Turbine or compressor damaged Bearing defective Contact an official ABB Turbo Systems service station.

Noises during run-out Turbocharger

Z Turbocharger dirty X Clean

Version 5

Z Z Z X


Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.

ABB


6


6.1

Page 4

Turbocharger

January 2008

Run-out time too short Z Turbocharger dirty X Clean Z Z Z X


Sluggish start-up Z Turbocharger dirty X Clean Z Z Z X


HZTL2491_EN

Turbocharger

Lubricating oil pressure too low Engine

Z Oil filter heavily soiled X Clean Z Oil pump in the lubricating system defective X Inspect Z Manometer provides false reading X Replace manometer


Z Axial clearance of the rotor too big X Contact an official ABB Turbo Systems service station.

Version 5

Turbocharger

ABB


6


6.1

Page 5

January 2008

Constant surging of the turbocharger Z Exhaust pressure to the turbine elevated because boiler or exhaust si-

Engine

lencer is dirty

Z Trap dirty X Clean

Turbocharger

Z Charge-air filter or silencer dirty Z Heavy deposits of contamination in the turbine X Clean

If it is not possible to determine the reason for the surging, contact an official ABB Turbo Systems service station.

Version 5

HZTL2491_EN

NOTE


ABB

Operation Manual / TPL85-B14/-B15/-B16 Removal and installation

7


7.1

Page 1

January 2008

7 Removal and installation 7.1 Turbocharger weights 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. WARNING

Loads that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.

Version 5

HZTL2491_EN

X Select a suitable rope taking into account the weight of the load X Hang rope crossed over on the crane hook X Do not stand under suspended loads

L_00082


ABB


7


7.1

Page 2

Weight [kg]

January 2008

Turbocharger complete unit without filter silencer/air suction branch TPL 85-B 9745

Turbocharger complete unit with filter silencer Weight [kg]

TPL 85-B 10700

Turbocharger complete unit with air suction branch Weight [kg]

TPL 85-B

Version 5

HZTL2491_EN

10035


ABB


7


7.2

Page 3

7.2 Remove the turbocharger January 2008

X Disconnect all gas, air, and oil lines in accordance with the engine ma-

nufacturer’s instructions.

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 supplying oil-inlet channel.

Version 5

HZTL2491_EN

X Check the lifting equipment. X Secure lifting equipment to the suspension lugs on the bearing casing.

7.2


ABB



7.2

Page 4

During removal, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING

X Select a suitable rope taking into account the weight of the turbo-

charger. X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose. X The turbocharger must be transported as horizontally as possible.

January 2008

Removal and installation

X Release the fixing screws on the foot. X Lift the turbocharger from the engine and place it aside.

If the support for the turbocharger is missing or defective when setting aside, the turbocharger may tip over and can cause serious or even fatal injury. HZTL2491_EN

WARNING

Version 5

X Support turbocharger in a suitable location. X Cover oil connector.


ABB


7

Installing the turbocharger

7.3

Page 5

January 2008

7.3 Installing the turbocharger During installation, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING

X Select a suitable rope taking into account the weight of the turbo-

charger. X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose. X The turbocharger must be transported as horizontally as possible. Remove cover from oil connector. Check the lifting equipment. Secure lifting equipment to the suspension lugs on the bearing casing. Mate turbocharger to engine. Tighten the fixing screws on the foot, in accordance with the engine manufacturer's instructions. X Secure all gas, air, and oil lines in accordance with the engine manufacturer’s instructions.

Version 5

HZTL2491_EN

X X X X X


ABB

Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly

8

Module weights

8.1

Page 1

January 2008

8 Disassembly and assembly 8.1 Module weights 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. WARNING

Loads that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.

Version 5

HZTL2491_EN

X Select a suitable rope taking into account the weight of the load X Hang rope crossed over on the crane hook X Do not stand under suspended loads

L_00082


ABB


8

Module weights

8.1

Page 2

HZTL2491_EN

January 2008

Modules

Version 5

8.1


ABB


8

Module weights

8.1

January 2008

Weights [kg]

Page 3

Description

TPL 85-B

1

Air suction branch, radial

290

2

Filter silencer

955

3

Compressor casing, internal part

550

4

Wall insert

850

5

Diffuser

225

6

Compressor casing external part

1200

7

Cartridge group

3000

8

Cover ring

145

9

Nozzle ring

95

10

Gas inlet casing radial

495

HZTL2491_EN

Compressor casing, internal part, complete Weight [kg]

TPL 85-B 1625

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 5

NOTE


ABB



8.2

Page 4

8.2 Removing and fitting filter silencer or air suction branch Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox).

January 2008


NOTE

X Remove insulation where necessary. X Disconnect all air ducts in accordance with the engine manufacturer’s

HZTL2491_EN

instructions.

74027 74018

90195

Version 5

L_01214

X Secure shackle (90195) to rib / fin on filter silencer.


ABB


8


8.2

Page 5

During removal and assembly, turbocharger components that have not been suspended in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING

X Do not stand under suspended loads.

Remove filter silencer

X Pass lifting gear through lugs on rear side and secure to shackle

Mounting the filter silencer

X Mount filter silencer or air suction branch in reverse order.

(90195). X Unscrew nuts (74027) with washers (74018) and remove filter silencer or air suction branch.

Version 5

HZTL2491_EN

January 2008



ABB


8

Axial clearance

8.3

Page 6

January 2008

8.3 Axial clearance 74018 74027

L_01250

Z Before removing as well as after fitting the internal part of the compres-

HZTL2491_EN

A

sor casing and the gas inlet casing (if removed), the axial clearance (A) must be measured. X Screw on at least four nuts (74027) with washers (74018) equally spaced around circumference and tighten to secure partition wall axially. X Measure and note axial clearance A. If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.

Clearance A [mm]

Version 5

CAUTION

TPL 85-B 0.54 – 0.79


ABB


8


8.4

Page 7

January 2008

8.4 Dismantling the internal part of the compressor casing Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox). NOTE

Blocked safety segments (Y) during disassembly CAUTION

Observe the maximal tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (Y). X Screw on and tighten four nuts (74027) with washers (74018/74028)

HZTL2491_EN

equally spaced around circumference.

X Take nuts (90458) out of toolbox and screw onto threaded studs of

three safety segments (Y) in internal part of compressor casing (76000).

Position of safety segments during disassembly

76000

74000

Version 5

u

Y

90458

90458

L_00269

X Tighten nuts (90458) to a maximal torque of 30 Nm. D The internal part of the compressor casing (76000) is now separated

from the external part of the compressor casing (74000) and can be removed.


ABB


8


8.4

Page 8

January 2008

Note check dimension (u). NOTE

Check dimension (u) [mm]

Dimension

TPL 85-B

u

27.6

X Remove nuts (74027) with washers (74018). X Remove 4 studs (74026/74029) from upper area. X Hoist up lifting device (90190) using shackle (90195) and lifting gear.

90320

HZTL2491_EN

Removing internal part of compressor casing

74026 / 74029

90195 90190 90900

74018 74027

76040 76000 F

74000

Version 5

90195 90025 90458

L_01215

X Press off internal part of compressor casing (76000) using press-off

screws (90900), until lifting device (90190/90195) can be fitted.


ABB


8


8.4

Page 9

X Fit lifting device to internal part of compressor casing (76000). X Withdraw internal part of compressor casing (76000) complete with January 2008

wall insert and diffuser.

X Fit support angle (90025). X Set down internal part of compressor casing (76000) in a horizontal

position.

If necessary

X Attach two shackles (90195) to support angle (90025) and fasten a se-

cond set of lifting gear to both shackles (90195). X Slightly raise internal part of compressor casing (76000) complete with wall insert and diffuser using lifting device (90190). X Use second set of lifting gear to carefully move internal part of compressor casing (76000) into vertical position. X Set down casing on flange (F) on an underlay.

WARNING

X Rest internal part of compressor casing only on flange (F). X Check underlay and adjust if necessary.

Version 5

HZTL2491_EN

Ensure that the underlay does not slip.


ABB


8


8.4

Page 10

Remove diffuser

January 2008

76002 90235 79000 90230 90900 77000

77005 HZTL2491_EN

77006

76000

F

90025

X Remove screws (76002). X Remove diffuser (79000) using ring bolts (90235). X Ease off wall insert (77000) using press-off screws (90900) and re-

move using ring bolts (90230). X Remove O-rings (77005, 77006).

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 5

L_01251


8

Dismantling gas inlet casing

8.5

Page 11

8.5 Dismantling gas inlet casing January 2008

X Remove the insulation on the gas inlet casing (51001). X Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).

Do not stand under or near the suspended gas inlet casing.

HZTL2491_EN

WARNING

L_00022

X Loosen the screws (61044) and remove gas inlet casing (51001) with

Version 5

X X X X

nozzle ring (56001). Remove screws (56014), bushings (56013) and nozzle ring (56001). Loosen and remove screws (57005). Fit two guide studs (90320). Press off the cover ring (51085) with press-off screws (90320) and remove over the guide bolts (90907).

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


8

Fitting gas inlet casing

8.6

Page 12

8.6 Fitting gas inlet casing January 2008

X Fit cover ring (51085) using two guide bolts (90320) as a help.

If removed:

Positioning cover ring CAUTION

The marking "TOP" on the cover ring (51085) must be as far up as possible. X Pay attention to installing cover ring in correct position. X Screw in and tighten screws (57005). X Remove guide bolts (90320).

X Mount nozzle ring (56001) on gas inlet casing (51001) using screws

Smear all screws in and on the gas casings with Anti Scuff Paste 868 from SPANJAARD.

HZTL2491_EN

(56014) and sleeves (56013).

NOTE

X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing

(61044) with screws (61009). X Remove lifting gear with shackle (90195).

Version 5

X Fit the insulation on the gas inlet casing (51001).


ABB

January 2008


8


8.7

Page 13

8.7 Fitting the internal part of the compressor casing Fitting the diffuser

76002 90235 79000 90230 90900

HZTL2491_EN

77000

77005 77006

76000

Version 5

F

90025

L_01251

X Put O-rings (77005, 77006) on wall insert (77000). X Fit wall insert (77000) and diffuser (79000) in internal part of compres-

sor casing (76000). X Tighten screws (76002), then loosen again by a ¼ turn. X Secure lifting gear to lifting device (90190) and shackles (90195) in support bracket (90025). X Lift internal part of compressor casing (76000) complete with wall insert and diffuser using two sets of lifting gear. ABB Turbo Systems Ltd

ABB


8


8.7

Page 14

as a result, bring internal part of compressor casing (76000) into a horizontal position. X Remove support bracket (90025) complete with shackle (90195).

Fitting internal part of compressor casing

90320

January 2008

X Carefully slacken lifting gear attached to support bracket (90025) and,

74026 / 74029

90195 90190

74018 74027

76040 76000 F

HZTL2491_EN

90900

74000

90195 90025 90458

L_01215

X X X X

with wall insert and diffuser over guide bolts (90320) into external part of compressor casing (74000). Remove lifting device (90190/90195). Insert internal part of compressor casing as far as it will go. Remove guide bolts (90320) and screw in studs (74026/74029). Use studs [10x 74029, 2x 74026 (each screwed in at top and bottom)].

74026

74029

L_01124


ABB

Version 5

X Put O-ring (76040) onto internal part of compressor casing (76000). X Fit guide bolts (90320). X Carefully insert internal part of compressor casing (76000)complete


8


8.7

Page 15

X Screw on at least four nuts (74027) with washers (74018) equally January 2008

spaced around circumference and tighten to secure partition wall axially.

Blocked safety segments (Y) during assembly CAUTION

The safety segments (Y) are not in the operating position. There is no guarantee of additional axial securing of the two compressor casings (74000/76000). X Screw on and tighten four nuts (74027) with washers (74018/74028)

equally spaced around circumference.

X Unscrew nuts (90458) on threaded studs of three safety segments (Y)

on internal part of compressor casing (76000).

relative to the external part of the compressor casing (74000).

Position of safety segments after assembly

76000

74000 Y

s

HZTL2491_EN

D The internal part of the compressor casing (76000) is now secured

90458

90458

Version 5

L_00276


ABB



8.7

Page 16

Note check dimension (s). The safety segments (Y) are back in the operating position. NOTE

Check dimension (s) [mm]

Dimension

January 2008


TPL 85-B

s

18.5

X Put nuts (90458) back into toolbox.

If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted. CAUTION

Clearance A [mm]

HZTL2491_EN

X Measure and note axial clearance A.

TPL 85-B 0.54 – 0.79

X Remove nuts (74027) with washers (74018).


X Mount filter silencer or air suction branch and secure with nuts (74027)

and washers (74018) (see section Removing and mounting filter silencer or air suction branch). X Connect all air lines / ducts in accordance with engine manufacturer’s instructions. X Fit all insulation that was removed.

ABB

Version 5

Mounting the filter silencer



8.7

Page 17

Version 5

HZTL2491_EN

January 2008



ABB


8


8.8

Page 18

74026 74029

90458

74027

76002 42059 42064

57005

61044

HZTL2491_EN

82002

January 2008

8.8 Table of tightening torques

56014

L_01216

L_00228

The following tightening torques must be kept to for the specified threaded connections:


ABB

Version 5

86505


8


8.8

HZTL2491_EN

January 2008

Tightening torques [Nm]

Part number

TPL 85-B

42059, 42064

M12 110

56014

M16 160

57005

M16 160

61044

M24 480

74026 / 74029

M24 80

74027 (with larger washer)

M24 400

76002

M20 - 1)

82005

M16 x 1.5 50

86505

M22 x 1.5 220

90458

M12 30

Tighten only so much that the diffuser can still be moved.

Version 5

1)

Page 19


ABB

Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily

9

Possibilities for emergency repair

9.1

Page 1

9 Taking out of operation temporarily January 2008

9.1 Possibilities for emergency repair Lubricating oil leakage is a fire hazard. WARNING

The instructions of the engine manufacturer for operation of the engine with locked / isolated turbocharger must be followed precisely in all cases! CAUTION

HZTL2491_EN

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 Blocking the inlets and outlets Bypass the turbocharger

Emergency repairs that can be carried out quickest have been described first.

Version 5

NOTE


ABB


9

Locking the rotor

9.2

Page 2

January 2008

9.2 Locking the rotor A blocked/ jammed rotor must be disassembled following the turbocharger repair and given an imbalance check. CAUTION

NOTE

The only exception is a test rig run up to maximum 25% of the engine load with new engines with one or a number of turbochargers, which are requested by some customers. Since in these cases operation with a blocked rotor is brief and the loads are low, subsequent disassembly of the rotor is unnecessary.

NOTE

CAUTION

Various intermediate rings are provided with the blocking device for different compressor wheels. The compressor wheel type ”CV” (for the balancing screw holes) must be noted. The space between the blocking 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.

HZTL2491_EN

U Once unscrewed, balancing screws must not be screwed in again.

During operation of the engine with a blocked 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 blocked rotor for 2-stroke engines). Otherwise components that are still intact can be damaged by overheating.

Version 5

The supply of lubricating oil to the turbocharger must be shut off in the event of a lubricating oil leak on the turbocharger.


ABB


9

Locking the rotor

9.2

Page 3

HZTL2491_EN

January 2008

Locking rotor with polygon connection

Version 5

L_00261


ABB


Locking the rotor

9.2

Page 4

These operations must be carried out as described in the chapter Disassembly and assembly. NOTE

X Remove the filter silencer or air suction branch and the compressor ca-

January 2008

Taking out of operation temporarily

sing internal part together with the wall insert and the diffuser.

X Fix partition wall with press-off tools (90920).

Fit locking flange (94003) to the compressor wheel with at least 9 screws (94007 or 94008) (refer to Table of tightening torques).

Table of tightening torques [Nm]

Part number

TPL85-B

94006

M12 75

94007 / 94008

M12 60

HZTL2491_EN

CAUTION

X Fit the locking flange (94003) with screws (94007 or 94008, using the

Version 5

longest possible screws) as well as the adjustment ring (94004) and intermediate ring (94031).


ABB


9

Locking the rotor

9.2

Page 5

HZTL2491_EN

January 2008

Compressor type CV11

94000_15

Version 5

It must be ensured that all components are clean and free from grease. CAUTION

X Push correct intermediate rings (94001 and/or 94002) on to the locking

flange (94003). X Fit assembly-disassembly device (90020) in each case with 2 washers (94032). X Insert the remaining intermediate rings (94001 and/or 94002) and mount the locking flange (94003) with screws (94006).


ABB


9

Locking the rotor

9.2

Page 6

HZTL2491_EN

January 2008

Compressor type CV12, CV13

94000_012

It must be ensured that all components are clean and free from grease. CAUTION

flange (94003).

X Fit assembly-disassembly device (90020) in each case with 2 washers

(94032). X Insert the remaining intermediate rings (94001 and/or 94002) and mount the locking flange (94003) with screws (94006).


ABB

Version 5

X Push correct intermediate rings (94001 and/or 94002) on to the locking


9

Locking the rotor

9.2

Page 7

January 2008

Further measures and information for operation with blocked rotor for 2stroke engines 2-stroke engine with one turbocharger:

No further measures are necessary. The engine can be operated with the auxiliary blower according to the manufacturer's instructions. 9 The lubrication oil system must remain connected and turned on.

HZTL2491_EN

2-stroke engine with several turbochargers:

X The compensator at the compressor outlet must be dismantled and the

air duct blocked at the engine end, as undamaged turbochargers develop a receiver pressure. X The operating limit of the engine can be raised by additionally blocking the gas inlet, as the exhaust gas is then used to drive the undamaged turbocharger. In addition, the loading and temperature of the blocked rotor is reduced.

If the gas inlet cannot be blocked, the following operating limits must be observed: The pressure in the charge-air receiver must not exceed 1 bar over-

pressure. Max. permissible engine load: 50%.

Attention must be paid to the speed of the undamaged turbochargers in all cases. The speed limit nBmax according to the turbocharger rating plate must not be exceeded.

Version 5

CAUTION


ABB


9

Blocking the inlets and outlets

9.3

Page 8

January 2008

9.3 Blocking the inlets and outlets Shut off the supply of lubricating oil to the turbocharger. CAUTION

X Block the compressor casing outlet, gas inlet and gas outlet by fitting

cover plates.

For information about how to do this, see the manufacturer's instructions.

Version 5

HZTL2491_EN

NOTE


ABB


9

Bypass the turbocharger

9.4

Page 9

January 2008

9.4 Bypass the turbocharger Shut off the supply of lubricating oil to the turbocharger. CAUTION

Z Only applies for engines with one turbocharger. Z The connections are ready and pipes for the bypass are to hand. X Fit the bypass around the turbocharger.

For information about how to do this, see the manufacturer's instructions.

Version 5

HZTL2491_EN

NOTE


ABB

Operation Manual / TPL85-B14/-B15/-B16 Mothballing the turbocharger

10

Taking out of operation for up to 12 months

10.1

Page 1

January 2008

10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger needs special protection or not depends mainly on the condition of the lubricating oil before laying up. If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be taken. However, if the neutralisation factor is higher the turbocharger must be dismantled after laying up, cleaned and protective oil must be applied to the naked parts. 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.

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HZTL2491_EN

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


Taking out of operation for more than 12 10.2 months

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10.2 Taking out of operation for more than 12 months 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.

January 2008

Mothballing the turbocharger

Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form. Check mothballed turbochargers yearly for corrosion.

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HZTL2491_EN

NOTE

If there are signs of rust, clean parts and renew means for protection against corrosion.


ABB

Operation Manual / TPL85-B14/-B15/-B16 Disposal

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11.1

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January 2008

11 Disposal 11.1 Environmentally compatible disposal of turbocharger components


HZTL2491_EN

NOTE

Component disposal must be environmentally compatible, professionaland in accordance with locally regulations. The turbocharger mainly consists of metal (cast-iron materials, steel, nickel-steel alloys, aluminium, bearing brass). Other components are: non-metallic materials (filter components made of felt and polyethylene), lubricants (engine oil), electronic components (speed sensor and associated components), thermal insulation.

X X X X

Dispose of metals by melting down and recycling. Dispose of non-metallic materials as waste. Dispose of lubricant left-overs and residues as used oil. Dispose of electronic components as electrical / electronic scrap.

Handling damaged thermal insulation WARNING

Damaged thermal insulation can burden the air with dust. The glass fibres can cause mechanical irritation of the eyes, skin and respiratory tracts.

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X Prevent dust from being produced. X Remove dust with a suitable vacuum cleaner. X Wear respiratory mask as protection against particles (P1 or P2

mask). X Wear leather protective gloves. X Wear close-fitting safety goggles.

X Dispose of thermal insulation as special waste.


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Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts

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12.1

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January 2008

12 Reserve and spare parts 12.1 Ordering spare parts When making inquiries or ordering spare parts, the following data should be specified: Turbocharger type HT number Description and part number.

Our service stations and agents will take orders for spare parts. X If special variants/cases are not addressed in these general instruc-

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HZTL2491_EN

tions, then contact an official ABB Turbo Systems service station or an ABB agent.


ABB


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12.1

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To carry out the work described in this manual, you need a set of spare parts (97070). These spare parts in this set are available only as a complete set.

Spare parts set (97070)

Quantity

Description

Part number

2

O-ring gasket

42012, 76040

2

Gasket

42041, 42069

12

Hexagon head screw

42059, 42064

1

Gasket

42045

6

Hexagon head screw

56014, 57005

4

Hexagon nut

61037

1

Gasket

61041

2

O-ring gasket

77005, 77006

1

O-ring gasket

86506

HZTL2491_EN

NOTE

January 2008

Spare-parts set

All spare parts that were ordered with the turbocharger should be kept as a complete set and ready for use. CAUTION

X Parts showing signs of rust should be carefully cleaned and grea-

sed.

X Dispose of parts, which have been replaced and are no longer usable,

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in a proper and environmentally compatible manner.


ABB


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12.2

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The following part numbers and descriptions must be used in ALL correspondence or orders: Turbocharger

Part number

Description

-

Cartridge group

51001

Gas inlet casing

51085

Cover ring

56001

Nozzle ring

61001

Gas outlet casing

61035

Hexagon head screw

61037 (in spare parts set)

Hexagon nut

68000

Foot

74000

Compressor casing external part

76000

Compressor casing, internal part


O-ring gasket

76080

Safety segment

77000

Wall insert


O-ring gasket


O-ring gasket

79000

Diffuser

81000

Filter silencer

82000

Air suction branch, radial

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HZTL2491_EN

January 2008

12.2 Directory of part numbers


ABB


12.2

Part number

Description

21000

Shaft

25000

Compressor wheel

25008

Threaded pin

25009

Ring nut

32001

Thrust bearing

32101

Radial bearing, compressor end

32102

Radial bearing, turbine end

32104

Auxiliary bearing

32105

Floating disc

32106

Axial bearing

42001

Bearing casing

42002

Hood

42011

O-ring gasket


O-ring gasket

42015

Sealing cover


Gasket


Gasket


Hexagon head screw


Hexagon head screw

42295

Non-return valve

43001

Partition wall

43005

O-ring gasket

86505

Speed sensor


O-ring gasket

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January 2008


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12

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Cartridge group - polygon connection

Reserve and spare parts


ABB


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General view of turbocharger

12.3

Page 5

61001

68000 61035

61037

76000

77005 77006

76040 76080

82000

81000

Version 5

77000

79000

74000

56001 51085

51001

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January 2008

12.3 General view of turbocharger

L_01217


ABB


12

General view of cartridge group

12.4

Page 6

86505

Version 5

25009

32104

32101

32106

25000

32105

43005

32001

43001

42045

42012

42041

HZTL2491_EN

42059

42001

86506

42064

42295

42002

25008

32102

42011

21000

42015

January 2008

12.4 General view of cartridge group

L_00906


ABB

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ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland

ABB Turbocharger

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