neues Deckblatt mit Textbaustein · 1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :...

Operation Manual

ABB Turbocharging ��

Type TPS44-F31 HT596383

nMmax 1207 t Mmax 680

nBmax 1147 t Bmax 6501/s °C

SSTI01 00120 16 60 60

Year 2020Application according tothe Operation Manual

kg

HZ

TL2

412

Eng

lish

TPS44-F31

Orig

inal

Ope

ratio

n M

anua

l

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-ents 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 profi le, turbine inlet temperature, suction air temperature and turbocharger speed. In case the operation conditions differs signifi cantly from what is considered to be normal for the cur-rent 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.

Operation Manual / TPS44-F.. - TPS61-F..Table of contents

© Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G March 2020

Operation Manual1 Preliminary remarks................................................................................................. 31.1 Purpose of this manual .................................................................................................. 31.2 Layout and function........................................................................................................ 41.3 Intended use of the turbocharger .............................................................................. 61.4 Storage of new turbochargers and spare parts ....................................................... 71.5 Essential information..................................................................................................... 91.6 Symbols and definitions .............................................................................................. 111.7 Turbocharger rating plate........................................................................................... 121.8 Contact information..................................................................................................... 13

2 Safety...................................................................................................................... 142.1 Introduction ................................................................................................................... 142.2 CE conformity ................................................................................................................ 142.3 Definition of mandatory signs ................................................................................... 152.4 Definition of Safety instructions ............................................................................... 152.5 Warning plates on the turbocharger......................................................................... 162.6 Safe operation and maintenance............................................................................... 162.7 Hazards during operation and maintenance........................................................... 202.8 Deflagration on gas engines....................................................................................... 252.9 Periodic checking of the pressure vessel ................................................................. 262.10 Lifting loads ................................................................................................................... 26

3 Start-up ................................................................................................................. 283.1 Oil supply ........................................................................................................................ 283.2 Inspection work............................................................................................................. 323.3 Commissioning after taking out of operation........................................................ 34

4 Operation ............................................................................................................... 354.1 Noise emissions ............................................................................................................ 354.2 Servicing work ............................................................................................................... 364.3 Expected exchange intervals ...................................................................................... 394.4 Speed measurement .................................................................................................... 414.5 Stopping the engine .................................................................................................... 44

5 Maintenance .......................................................................................................... 455.1 Foreword to Maintenance .......................................................................................... 455.2 Cleaning the compressor during operation ........................................................... 465.3 Turbine cleaning during operation........................................................................... 505.4 Cleaning components mechanically.......................................................................... 56

Operation Manual / TPS44-F.. - TPS61-F..Table of contents


6 Troubleshooting.................................................................................................... 676.1 Malfunctions when starting........................................................................................ 676.2 Surging of the turbocharger...................................................................................... 686.3 Malfunctions during operation ................................................................................. 696.4 Malfunctions when stopping...................................................................................... 726.5 Speed measurement system ...................................................................................... 73

7 Removal and installation...................................................................................... 747.1 Transport ........................................................................................................................ 747.2 Turbocharger weights.................................................................................................. 757.3 Removing the turbocharger........................................................................................ 757.4 Installing the turbocharger ......................................................................................... 76

8 Disassembly and assembly .................................................................................. 788.1 Introduction ................................................................................................................... 788.2 Module weights ............................................................................................................. 818.3 Disassembling and assembling turbocharger ........................................................ 828.4 Axial clearance A and radial clearance B .................................................................. 968.5 Radial clearances N and R........................................................................................... 988.6 Table of tightening torques..................................................................................... 100

9 Taking out of operation .................................................................................... 1019.1 Shutting down the turbocharger ............................................................................ 101

10 Mothballing the turbocharger ........................................................................... 10510.1 Taking the engine out of operation for up to 12 months.................................... 10510.2 Taking the engine out of operation for more than 12 months ......................... 106

11 Disposing of turbocharger components.......................................................... 108

12 Spare parts........................................................................................................... 10912.1 Ordering spare parts .................................................................................................. 10912.2 View of turbocharger showing part numbers....................................................... 11012.3 View of cartridge group showing part numbers .................................................. 112

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.1 Purpose of this manual


1 Preliminary remarks

1.1 Purpose of this manual

This Operation Manual belongs to the turbocharger with the identicalserial number (01), see the cover sheet of the Operation Manual and theturbocharger rating plate.

Operation Manual

This Operation Manual helps familiarise the user with the turbochargerfrom ABB Turbocharging and how to use it as intended.

It provides important information in order that the turbocharger can beoperated safely, correctly and efficiently.

This Operation Manual complements and expands existing national reg-ulations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechan-ics who are responsible for operating the engine and the turbochargerinstalled on it.

Availability of operation manual

An operation manual must be available at all times at the place wherethe turbocharger is used.

Everyone who operates or works on the turbocharger must have firstread and understood the operation manual.

Pag

e 3

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.2 Layout and function


1.2 Layout and function

1Suction branch / filter silencer 8Gas outlet flange2Compressor casing 9Nozzle ring3Diffuser 10Turbine casing4Bearing casing 11Turbine-end bearing flange5Axial thrust bearing 12Compressor-end bearing

flange6Radial plain bearing (visible only

at turbine end)13Compressor wheel

7Turbine

Pag

e 4

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.2 Layout and function


Mode of operation

The turbocharger is a turbomachine consisting of the following maincomponents:

¡ Turbine

¡ Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbinecasing (10) and the nozzle ring (9) to impinge on the turbine (7).

The turbine (7) uses the energy contained in the exhaust gas to drive thecompressor wheel (13). The compressor draws in fresh air, compresses itand then forces it into the engine's cylinders.

The exhaust gases escape into the ambient air through the exhaust gaspipe, which is connected to the gas outlet flange (8).

The air, which is necessary for operation of the diesel or gas engine andis compressed in the turbocharger, is drawn into the compressor wheel(13) through the suction branch or filter silencer (1). It then passesthrough the diffuser (3) and leaves the turbocharger through the outleton the compressor casing (2).

The rotor runs in two radial plain bearings (6), which are located in thebearing flanges (11/12) between the compressor and the turbine. Theaxial thrust bearing (5) is located between the two radial plain bearings.

The bearings are connected to a central lubricating oil duct which is sup-plied by the engine's lubricating oil circuit. The oil outlet is always at thelowest point of the bearing casing (4).

Pag

e 5

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.3 Intended use of the turbocharger


1.3 Intended use of the turbocharger

NOTICEThis turbocharger supplied by ABB Turbocharging has been developedfor use on diesel engines to generate the volume of air and the char-ging pressure required to operate the engine.

The enginebuilder has provided ABB Turbocharging with informationregarding the intended use of the engine, from which the operatinglimits specific to the turbocharger shown on the rating plate, such asoperating speeds, temperatures, exchange intervals / replacement in-tervals, have been derived.

Use in connection with a gas engine requires that the engine is not in-stalled in a potentially explosive environment and that precautions aretaken to ensure that the engine room as a whole is classified as non-ex-plosive.

Any other use is considered to be a special application, which must firstbe clarified with ABB Turbocharging. The manufacturer accepts no liab-ility for any other type of use. If the equipment is used for any otherpurpose, ABB Turbocharging reserves the right to reject all warrantyclaims.

State of the art This turbocharger was built according to state-of-the-art technologyand is operationally safe according to recognised safety regulations.

WARNINGImproper operation and maintenance of the turbocharger can result indanger to life and limb of the user or third parties. In addition, im-proper use may cause damage to the machine.

u The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-stallation / fitting, disassembly / removal, operating, maintenance / ser-vicing and repair conditions specified by the manufacturer. Disposal reg-ulations set down by local authorities must be observed.

Perfect condition The turbocharger may be installed only when in technically perfect condi-tion while observing the instructions given in the engine builder'smanual. It may be used only for the intended purpose and operated incompliance with the operation manual.

u Malfunctions which could affect safety must be eliminated immedi-ately.

The manufacturer accepts no liability for any damage resulting from un-authorised alterations to the turbocharger.

Pag

e 6

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.4 Storage of new turbochargers and spareparts


1.4 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbocharging can bestored in sealed packaging without additional mothballing measures forup to 6 months from the date of delivery (marked by the VCI label on thepackage).

Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % andno condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6months (VCI)

WARNINGProtection of health when handling VCIsVCI products are not hazardous in the sense of the Hazardous Sub-stances Ordinance. Nevertheless, the following points are to be ob-served when handling VCIs:

u Ensure good room ventilation.

u Do not eat, drink or keep food at the workplace while working withVCIs.

u Wear safety gloves.

u Clean hands and face after working with VCIs.

u For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

u Open the package.

u Remove the VCI corrosion protection emitter from the package andreplace it with a new, identical VCI corrosion protection emitter. NewVCI corrosion protection emitters can be obtained at www.brano-pac.com.

u Dispose of the old VCI corrosion protection emitter in an environ-mentally compatible manner, professionally and in accordance withlocal regulations.

Pag

e 7

/ 11

3

http://www.branopac.com



Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.4 Storage of new turbochargers and spareparts


u Seal the package. The better the external seal is designed, the morepermanent the protection.

Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Tur-bocharging on request. The package is equipped with a hygrometer (seeillustration).

The following measures are required every 6 months:

u Check the hygrometer (02) in the sight-glass. There is an opening (01)in the wooden crate which allows this check to be carried out. Whenthe display field has changed colour at the 70% level, the maximumpermissible humidity has been exceeded. In this case, the turbochar-ger must be inspected by an ABB Turbocharging Service Station andrepacked.

u Inspect the package for damage. If the package is damaged, the tur-bocharger must be inspected by an ABB Turbocharging Service Sta-tion and repacked.

After every 3 years the following work steps must be performed by anABB Turbocharging Service Station:

¡ Inspect the component

¡ Replace the desiccant agent

¡ Repackage the component.

NOTICETurbocharger ready for operationIf the 70% field of the hygrometer (02) has not changed colour and thepackage is undamaged, the turbocharger can be put into operationwithout any prior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

The corrosion protection effect ends after the material is unpacked fromthe VCI package.

To avoid the formation of condensation, the surroundings and the con-tent of the package must have the same temperature during unpacking.

Pag

e 8

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.5 Essential information


1.5 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulationsfor the prevention of accidents and protection of the environment arealso to be observed.

This also applies for the provision and wearing of personal protectiveequipment.

NOTICEThe manner in which personnel work on and with the turbocharger withregard to safety and risks is to be checked on a regular basis in accord-ance with the Operation Manual.

u If the turbocharger shows modifications affecting safety or any cor-responding operating behaviour, it must be shut down immediatelyby stopping the engine. The malfunction must be reported to the per-son or department responsible.

NOTICEAny modifications, additions or conversions made to the turbochargerthat could impair safety require the prior approval of ABB Turbochar-ging. Pa

ge

9 /

113

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.5 Essential information


Original parts and safety

Original parts and accessories are specially designed for the turbochar-ger supplied by ABB.

WARNINGUse original partsOperation of the turbocharger with non-original parts can impair thesafety of the turbocharger and can cause serious damage to propertyand injury to personnel.

u Only use original parts from ABB.

ABB accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories.

Competence of personnel

The turbocharger must only be operated and serviced by trained and au-thorised personnel. Basic mechanical training is a prerequisite.

Design variants

This document is valid for different design variants of turbochargers.There may be sections and descriptions of components that are not rel-evant for a specific turbocharger variant.

ABB Turbocharging Service Stations will be happy to provide informationon questions regarding a design variant (see Contact information atwww.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended forease of understanding. Differences in detail are therefore possible.

Registered Trademarks

Registered trademarks of external companies are used in this document.The trademarks are marked with ®.

Pag

e 10

/ 1

13

http://www.abb.com/turbocharging

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.6 Symbols and definitions


1.6 Symbols and definitionsThe following symbols are used in the documents:

w Prerequisite

u Work step

¡ Enumeration, first level

- Enumeration, second level

→ Refers to a page number

Definition of notes

NOTICENoteA note provides suggestions which facilitate the work on the product.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task.The mandatory signs are described in chapter Safety and must be com-plied with.

Definition of caution / warning

The caution and warning signs are described in the chapter Safety.

ABB Turbocharging

ABB Switzerland Ltd, Turbocharging is identified as ABB Turbochargingin this document.

Official service stations of ABB Turbocharging

Official service stations are regularly audited and certified by ABB Tur-bocharging. See also chapter Contact information →13.

Pag

e 11

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.7 Turbocharger rating plate


1.7 Turbocharger rating plate

Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with theenginebuilder.

02 Turbocharger operating limits during operation

Recommended inspectionand replacement intervalsfor turbocharger compon-ents

03 Inspection interval for plain bearings in 1000 h04 Replacement interval for compressor in 1000 h05 Replacement interval for turbine in 1000 h

Further information 06 Part number for customer07 Designation of special design08 Turbocharger weight in kg09 Turbocharger type10 Serial number11 Year of turbocharger construction12 Manufacturing plant

Pag

e 12

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..1 Preliminary remarks / 1.8 Contact information


1.7.1 Explanation of the rating plate

The recommended replacement intervals and the corresponding opera-tional limits are jointly defined with the engine manufacturer. This in-formation is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shortenthe recommended replacement intervals. In such cases, we recommend thatyou contact the nearest official ABB Turbocharging service station.nMmaxand tMmax normally apply only when running at overload (110%) duringtrials on the engine test bed. Operation above nMmax and tMmax is not permit-ted.Non-observance of the recommended replacement intervals increases therisk of unpredictable component failures.

1.7.2 Positions of the rating plates

One rating plate (01) each is attached on the left and the right side of theturbocharger bearing casing.

1.8 Contact informationContact information for the official service stations of ABB Turbochar-ging is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, TurbochargingBruggerstrasse 71aCH-5401 BadenSwitzerland

www.abb.com/turbocharging

Pag

e 13

/ 1

13

http://www.abb.com/turbocharging

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.1 Introduction


2 Safety

2.1 IntroductionTurbochargers manufactured by ABB are state of the art and complywith the pertinent safety and health-protection requirements that ap-plied when the turbocharger was manufactured. Consequently, the tur-bocharger is safe to operate. Nevertheless, during turbocharger opera-tion and when working on the turbocharger, residual risks can existwhich:

¡ originate from the turbocharger itself and its accessories

¡ originate from the operating and auxiliary materials used

¡ are the consequence of insufficient observance of the safety instruc-tions

¡ are the consequence of unsatisfactory and improper execution ofmaintenance and inspection work.

The operating company is responsible for access to the turbocharger aswell as the organisational measures that regulate the safe handling ofthe turbocharger by its personnel.

All instructions contained in this chapter must be observed for safe andtrouble-free operation of the turbocharger and during all work on theturbocharger.

All further safety instructions contained and specifically identified inevery chapter of this manual (see section Definition of Safety Instruc-tions) must also be observed.

2.2 CE conformityInformation

ABB turbochargers fulfil Directive 2006/42/EC on machinery and areconsidered partly completed machinery in the sense of Article 2 g.

Pag

e 14

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.3 Definition of mandatory signs


2.3 Definition of mandatory signs

To be worn at all timesProtective clothing Safety footwear to pro-

tect against mechanicalhazard and risk of fall-ing

To be worn according to the specific workSafety glasses Safety goggles

Safety gloves against- Mechanical hazard- Chemical hazard- Thermal hazard

Respiratory maskagainst- Dusts- Gases

Safety helmet Ear protection

2.4 Definition of Safety instructionsThe following symbols and terms used in this manual concern safety orrefer to possible hazards:

WARNINGDefinition of warningSerious personal injuries and even accidents with fatal consequencesmay occur if work and operating instructions marked with this symboland the word WARNING are either not followed or not followed pre-cisely.

u Warning signs must be observed at all times.

CAUTIONDefinition of cautionSerious machine or property damage may occur if work and operatinginstructions marked with this symbol and the word CAUTION are eithernot followed or not followed precisely.

u Caution signs must be observed at all times.

Pag

e 15

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.5 Warning plates on the turbocharger


2.5 Warning plates on the turbochargerWarning plates are attached to the turbocharger at the following places:

If warning plates are not present at the intended places or are notlegible, then proceed as follows:

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove unreadable warning plates.

u Clean and degrease surfaces provided for warning plates.

u Attach new warning plates.

Uninsulated turbochargers

When uninsulated turbochargers are delivered to the engine builder, thewarning plates must be subsequently attached to the insulation. This isthe responsibility of the engine builder.

2.6 Safe operation and maintenanceThe instructions specified in this section are for the safety of personnel.Together with the instructions in the Hazards during operation andmaintenance section, they allow the user to safely use the turbocharger.

Pag

e 16

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.6 Safe operation and maintenance


Work safety and work area safety

WARNINGRisk of fallingThere is the risk that someone can fall when working on the turbochar-ger.

u Do not climb on the turbocharger or on parts attached to it or usethese as climbing aids.

u When working at levels above the head, use climbing aids and workplatforms suitable for this purpose.

u Observe all general regulations for the prevention of accidents.

u Do not work on the turbocharger if you are under physical or mentalstress.

u Work only with suitable tools as well as equipment and working ma-terials that are in perfect condition.

u Electric tools must be solidly earthed, and connecting cables may notbe damaged.

u Keep the workplace clean, clear away loose objects and removeobstacles on the floor.

u Keep the floor, equipment and the turbocharger clean.

u Have oil binding materials ready at hand and keep oil catch pansready or in position

u Eliminate leaks.

u Keep fire-protection materials and fire-extinguishing equipmentready.

Welding work close to the turbocharger

u If welding work is being carried out in the vicinity of the turbocharger,cover the filter silencer so that the filter mat is not damaged.

u Remove combustible objects and substances out of the range of fly-ing sparks.

u Cover all connections on the turbocharger so that no foreign objectscan get into the turbocharger.

u Wear personal protective equipment (PPE) for welding operations.

Pag

e 17

/ 1

13



Safety during start-up / commissioning and operation

WARNINGThe turbine casing insulation of the TPS44-F supplied by ABB is alsoburst protectionSerious personal injuries or fatal accidents can occur, if the turbine cas-ing insulation of the TPS44-F supplied by ABB is removed. The burstprotection is integrated into the turbine casing insulation of the TPS44-F supplied by ABB.

Separate burst protection is fitted to TPS44-F turbochargers that havebeen ordered from ABB without insulation.

u Never operate TPS44-F turbochargers that have been supplied byABB with insulation if this insulation from ABB is not in place.

u Never operate turbochargers without burst protection. If the insula-tion from ABB is not in place, the separate burst protection (57200)must be fitted before operation (see View of turbocharger showingpart numbers →110).

u Before starting work, carry out visual inspection of working area.

u Remove any obstacles and objects lying around.

u Before start-up / commissioning, check all pipes from and to tur-bocharger for damage and leaks.

u Don't work in any way that could impair safety when working on tur-bocharger.

u After about every 12 hours of operation or at least once a day, inspectturbocharger for visible damage and defects.

u Immediately report any damage or changes in operational perform-ance to person responsible.

u If damage is discovered, immediately shut down turbocharger and se-cure it against inadvertent or unauthorized use.

u When switching on auxiliary power sources (hydraulics, pneumatics,electricity, water), keep an eye open for any hazards resulting fromsupplying these power sources.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the correspondingmaterial safety data sheet and the safety instructions in section "Haz-ards due to operating and auxiliary materials" must be observed.

u Observe the material safety data sheet for the cleaning agent orsolvent.

u Wear personal protective equipment (PPE) according to the materialsafety data sheet.

Pag

e 18

/ 1

13



u Inspect the electric cables for abrasion and damage before and afteryour cleaning work.

Safety during disassembly, assembly, maintenance andtroubleshooting

u Always perform the specified adjustments, servicing as well as in-spection work and observe inspection intervals.

u Inform operating personnel about all service and repair work beforebeginning.

u Before opening a cover or removing a protective device on a tur-bocharger, the engine must be switched off and the turbochargermust have come to a standstill.

u Ensure that the supply of oil is interrupted, especially with an externaloil supply.

u Put the engine into operation only after all parts have been refittedproperly.

CAUTIONMechanical work on the turbochargerPossible damage to or destruction of components on the turbocharger.

u Perform only those tasks that are described in this manual.

u Perform work only for which training has been carried out.

Safety when taking out of operation or preparing for mothballing

u Secure the rotor so it cannot turn. The rotor can turn on its own fromthe force of the stack draught.

u Clean the turbocharger before mothballing it.

u Observe the material safety data sheet for the cleaning and moth-balling agents.


Pag

e 19

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.7 Hazards during operation and maintenance


2.7 Hazards during operation and maintenance

Mechanical hazards during operation

During normal operation, no mechanical hazards emanate from the tur-bocharger if it has been installed properly.

WARNINGRisk of injuryContact with rotating parts can lead to serious injuries. The turbochar-ger must never be operated without a filter silencer or an air suctionbranch. When the engine is at a standstill, the rotor can turn on its ownbecause of stack draught.

u Operate the turbocharger in accordance with instructions.

u During maintenance work, secure the rotor against unintentional ro-tation.

Mechanical hazards when working on the turbocharger

During maintenance work, various risks can occur through the improperhandling of components, through the non-observance of work instruc-tions, due to inadequate care or as a consequence of insufficient train-ing.

WARNINGMechanical hazardSevere injuries to personnel or fatal accidents can be caused by mech-anical influences as a consequence of hazardous and inadequate opera-tional procedures.

u Observe the general rules for occupational safety and prevention ofaccidents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have previously received in-struction or training.

Pag

e 20

/ 1

13



Hazards due to noise

The development of noise during operation is influenced by the installa-tion and operating conditions. Noise with a sound pressure level exceed-ing 85 dB(A) is harmful.

WARNINGHazards due to noiseNoise can cause impaired hearing, damage to health, mental disturb-ances, diminished attention and irritation.

u Always wear ear protection when the engine is running.

u When the sound pressure level is above 85 dB(A), always wear earprotection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well asoperating materials (lubricating oil) become hot. The surface temperat-ure is dependent on the effectiveness of the insulation being used. Thetemperature can become high enough so that it falls into ranges whereburns are possible.

WARNINGRisk of burningTouching hot surfaces or contact with hot operating materials can leadto serious burns.

u Do not touch hot surfaces and heed the warning plate on the tur-bocharger.

u Wear heat-resistant safety gloves and protective clothing.

u Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.Pa

ge

21 /

113



WARNINGHot surfaces on uninsulated turbochargersUninsulated turbochargers can cause serious personal injuries (burns).

The turbocharger is supplied with or without insulation in accordancewith the purchase order received from the enginebuilder. If supply iswithout insulation, the enginebuilder is responsible for providing theturbocharger with proper insulation and for providing protectionagainst contact with hot surfaces.

u Compliance with the instructions and specifications given by the en-ginebuilder to protect against hot turbocharger surfaces is compuls-ory.

Wear safety gloves to protect against thermal hazards.

Hazards due to operating and auxiliary materials

Operating and auxiliary materials are substances used for operation orthe execution of maintenance work. Oils, greases, coolants, cleaningagents and solvents, acids, etc. can be regarded as hazardous materials.Operating and auxiliary materials can be combustible and easily ignited.

WARNINGHandling operating and auxiliary materialsIngestion or inhalation of vapours of operating and auxiliary materialsor contact with such can cause damage to health.

u Avoid inhalation and contact with the skin.

u Ensure good ventilation.

u Observe details in the safety data sheets of the operating and auxili-ary materials.

u Observe local laws.

Wear safety goggles.


Wear a respiratory mask to protect against gases.

Pag

e 22

/ 1

13



WARNINGRisk of fire, explosionFlammable and combustible operating materials and supplies cancatch fire or resulting vapours can lead to an explosion.

u Observe the details in the material safety data sheets of the operat-ing and auxiliary materials.

u Comply with local legislation.

u Do not allow any exposed flame or ignition source during cleaningwork.

u Carry out cleaning in the open or provide sufficient aeration andventilation.

CAUTIONRisk of environmental damageThe escape of operating and auxiliary materials into the atmosphere orcontamination of the ground and water due to improper disposal canlead to environmental damage.

u Handle operating and auxiliary materials carefully.

u Heed the instructions for use, safety data sheets and hazard noticeson the containers of the operating and auxiliary materials.

u Wear appropriate protective clothing.

u Avoid inhalation and contact with the skin.

u Ensure that the work space is adequately ventilated.

u Seal containers tightly immediately after use and put them away.

u Collect used working and auxiliary materials safely, store them separ-ately in suitable containers and dispose of them properly and in anenvironmentally compatible manner in accordance with statutory reg-ulations.

u In the event of leaks or after spilling, immediately spread a suitablebinding agent and dispose of it properly and in an environmentallycompatible manner in accordance with statutory regulations.

Pag

e 23

/ 1

13



Hazards when handling insulating materials

WARNINGHazards due to insulating materialsDust and fibres from insulating materials can cause damage to healthor irritations. Unsuitable, combustible insulating materials signify a firehazard.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentallycompatible way in accordance with applicable local regulations.


Wear a respiratory mask to protect against dusts.


u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Wear suitable work clothing (safety glasses, respiratory mask).

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentallycompatible way in accordance with applicable local regulations.

Pag

e 24

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.8 Deflagration on gas engines


Hazards due to electrical components

WARNINGHazards due to electrical componentsElectrical components operate with voltages which can present hazardsto humans.

u All work on or with electrical components may only be performed bytrained specialists.

u Heed any country-specific regulations.

2.8 Deflagration on gas enginesABB turbochargers can withstand a deflagration with a transient pres-sure increase of 12 bar.

ABB Turbocharging recommends that, following a deflagration event,the turbocharger undergoes an inspection of the following points:

¡ Position of the turbine and compressor casings to the bearing casing

¡ Shifting of the bearing casing in relation to the bracket

¡ Cracks in casings

If during external inspection anomalies are found or if a particularlystrong deflagration event has taken place, it is also recommended tocheck the bearings of the turbochargers before the next start. This in-spection and evaluation must be carried out by an ABB TurbochargingService Station.

Pag

e 25

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.9 Periodic checking of the pressure vessel


2.9 Periodic checking of the pressure vesselThe pressure vessels used by ABB, such as those for wet or dry cleaning,are so-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks ofthe pressure vessels must be observed.

¡ The operating company is responsible for the safe operation of thepressure vessel.

WARNINGDanger due to pressure vesselsThe operating company must make sure the pressure vessels are inproper working condition and monitor them. Necessary repair or main-tenance work must be carried out without delay and the required safetyprecautions must be taken.

u Pressure equipment must not be operated if it has defects.

2.10 Lifting loads

WARNINGSuspended loadsLoads not suspended in compliance with regulations may lead to per-sonal injury or accidents with fatal consequences.

u Loads must always be fastened to technically perfect lifting gearwith sufficient loading capacity.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Pag

e 26

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..2 Safety / 2.10 Lifting loads


In the case of two or more suspension points, the slinging angle mustnot exceed 45°. This avoids excessive loading due to inclined tensileloading.

u Fasten turbocharger assemblies / components as described in re-spective handling steps.

u Before attaching slings, allow turbocharger components to cool down(maximum 80°C).

u Use suitable protection at sharp edges.

u Completely screw in assembly / fitting devices without fail so thatthey cannot work loose during use.

u Use assembly / fitting devices only for applications described.

u Make sure removed turbocharger components stand safely and se-curely.

Pag

e 27

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..3 Start-up / 3.1 Oil supply


3 Start-up

3.1 Oil supplyA carefully designed and installed oil supply, which functions in all pos-sible operational conditions, is an important prerequisite for trouble-free turbocharger operation.

The turbocharger is normally lubricated with oil from the engine oil cir-cuit. If a separate lubricating system is used, then emergency lubricationis also to be provided.

u Heed the instructions of the engine builder when selecting the lubric-ating oil and oil-change intervals.

Oil filtration

CAUTIONDepending on the turbine specifications and bearings used, varyingamounts of contaminants have to be filtered out of the lubricating oilto avoid dangerous wear of the bearing parts.

The standard oil filter specification for the turbocharger is 34 µm. Thismeans that contaminants larger than 0.034 mm must be filtered out ofthe oil with a separation efficiency > 99%.

u Fit an accessory filter if engine oil filter is not efficient enough.

u If the engine is started cold and the flow resistance rises to above 0.5bar due to deposits of dirt in the accessory filter, a bypass must openwhich ensures that oil flows to the turbocharger by circumventing thefilter.

u Check that oil filters are clean before commissioning.

NOTICEAlso follow the enginebuilder's instructions regarding filter mesh andseparation efficiency.

Pag

e 28

/ 1

13



Lubricant

NOTICEAll lubricating oils used for engines are admissible.

Oil inlet viscosity and temperature

The oil-inlet temperature must not exceed 105°C. Permissible oil-inletviscosities and oil-inlet temperatures are shown in the following chart.

1) Kinematic viscosity (mm2/s = cSt)2) Oil-inlet temperature (°C)A Permissible range

CAUTIONFalling below the minimum oil inlet temperatureSerious machine or property damage can be caused by excessively highoil viscosity and the resulting lack of oil in the bearings.

u Do not allow the oil inlet temperature to fall below the minimum 30ºC when starting the engine.

u The oil inlet temperature must never be less than 10 °C.

Pag

e 29

/ 1

13



Oil pressure

The oil pressure in front of the turbocharger must be maintained pre-cisely to ensure trouble-free operation.

Status for operation Oil pressure in frontof turbocharger

[bar]Normal operation 2.0 … 4.5Engine start: cold oil, permissible for maximum 15minutes

≤ 8.0

Engine idling ≥ 0.2Pre- and post-lubrication (engine stopped) ≤ 1.0

CAUTIONPrelubricationSerious machine or property damage might result if the turbocharger isnot supplied with oil when the engine is starting.

u Activate prelubrication device before starting engine.

Pag

e 30

/ 1

13



Lubricating oil temperature at the inlet

CAUTIONMachine damageMachine damage may result if the oil temperature at the oil inlet ex-ceeds the permissible range.

u Keep the oil temperature at the oil inlet as specified in the followingtable.

Status for operation Oil temperature at the in-let

Toil,inlet

Admissible 30 … 105 °CTemporarily admissible (< 1 h) → alarm > 105 °CNot admissible → stop engine > 110 °CNot admissible → do not start engine (beforestarting: preheat oil)

< 30 °C

Lubricating oil temperature at the outlet

The oil temperature at the outlet depends mainly on:

¡ lubricating oil temperature and pressure at the oil inlet

¡ engine load and turbocharger speed

¡ exhaust gas temperature

The maximum permissible oil temperature at the outlet is listed in thefollowing table. The specified oil outlet temperature must be regardedas an alarm value for turbocharger operation and be monitored in ac-cordance with standard regulations.

Status for operation Oil temperature at outletToil,outlet

Admissible ≤ 160 °CTemporarily admissible → alarm > 160 °CNot admissible → stop engine > 180 °CAdmissible ≤ Toil,inlet + 55 KTemporarily admissible → alarm > Toil,inlet + 55 K

If the turbocharger has been operated outside the permissible range fora prolonged period of time, ABB Turbocharging recommends having theturbocharger inspected by an ABB Turbocharging Service Station.

Pag

e 31

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..3 Start-up / 3.2 Inspection work


3.2 Inspection workInspection work includes preventive visual controls plus monitoring andmeasuring work before and during commissioning. Inspections help de-tect changes to the turbocharger. Machine damage can be avoided.

3.2.1 Inspection before commissioning

Monitoring devices u Check for correct functioning.

Filter mat u Inspect for damage.

Lubricating system u Check oil filter for cleanliness before commissioning.

CAUTIONContaminated oilParticles of dirt and solid matter in the oil can cause serious damage tothe machine or property.

u During initial commissioning and after all service work, the completelubricating system must be flushed thoroughly with warm oil.

u When running in the engine and after all service work on the lubricat-ing system, special running-in filters must be used.

u Check oil pressure in oil supply lines.

CAUTIONPrelubricationSerious machine or property damage might result if the turbocharger isnot supplied with oil when the engine is starting.

u Activate prelubrication device before starting engine.

Warning plates on tur-bocharger

u Check whether the warning plates are present and legible.

u Check whether the protective sheets have been removed.

Pag

e 32

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..3 Start-up / 3.2 Inspection work


3.2.2 Check after start-up (engine at idling speed)

Lubricating system

u Check oil pressure in oil supply lines.

u Check oil inlet temperature.

The permissible values are listed in the section Oil supply.

Gas, air and oil lines

u Check all gas, air and oil lines for leaks after starting the engine.

3.2.3 Check when running up engine

u Measure speed, oil pressure and charging pressure at various engineperformance levels.

u Measure exhaust gas temperature in front of and behind turbine.

u Measure air temperature in front of and behind compressor.

The measured values must be compared with the values in the accept-ance test report, while taking different operating conditions into ac-count.

NOTICELubricants and pastes used during assembly of the turbocharger li-quefy or vaporise and might escape as an oily liquid in the first fewhours after commissioning. If oily liquid continues to escape after thisperiod, an oil leak must be suspected. The first step is to check for leak-age of the oil supply to the turbocharger. If this is leaky, contact an offi-cial ABB Turbocharging service station.

3.2.4 Inspection after 100 service hours

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

ge

33 /

113

Operation Manual / TPS44-F.. - TPS61-F..3 Start-up / 3.3 Commissioning after taking out of operation


3.3 Commissioning after taking out of operationIf provided u Remove cover plates (blind flanges) between compressor casing out-

let and charge air duct, before gas inlet and after gas outlet.

u Inspect exhaust gas duct / line in front of and after turbine for anycombustion deposits, foreign matter or residual water. Clean and re-move.

u Inspect air supply line or filter silencer for any foreign matter. Cleanand remove.

u Start up turbocharger oil circulation system at engine end.

u Prepare turbocharger for operation as instructed in section "Inspec-tion work before start-up / commissioning" of chapter headed "Start-up / commissioning".

u Start up turbocharger.

Pag

e 34

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.1 Noise emissions


4 Operation

4.1 Noise emissions

WARNINGHazards due to noiseNoise can cause impaired hearing, damage to health, mental disturb-ances, diminished attention and irritation.

u Always wear ear protection when the engine is running.

u When the sound pressure level is above 85 dB(A), always wear earprotection.

Wear ear protection.

The sound pressure level (A-weighted) of emissions is measured at a dis-tance of 1 metre from the turbocharger.

The highest sound pressure level of emissions1) reaches a maximum of105 dB(A) near the filter silencer and over the entire speed range.

The following prerequisites must be fulfilled on the turbocharger in or-der to observe this limit value:

¡ Fitted air-inlet system

¡ All standard, noise-reducing measures have been taken2).

¡ The bellows at the air outlet have been perfectly insulated acoustic-ally by the engine builder. He is also responsible for insulating thecharge air / scavenging air line and the charge air cooler.

1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level

2) In the event of divergent insulation designs, the engine builder mustensure that equivalent acoustic insulating measures are taken.

Pag

e 35

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.2 Servicing work


Suggestion for noise insulation of the bellows

01 Compressor casing 04 Insulation pads02 Bellows 05 Insulation mat (at least 15 mm)03 Charge air duct / scavenging

air line06 Sheet metal cover

4.2 Servicing workService work to be carried out during operation involves visual checks,monitoring, measuring, inspection work and functional checks. It is thenpossible for changes to the turbocharger to be identified and rectified.In this way, it can be ensured that the turbocharger remains in full work-ing order.

CAUTIONService intervalsService work on the turbocharger that is neglected or carried out toolate can lead to excessive contamination and wear as well as operatingfailures.

u Carry out service work at specified time intervals.

CAUTIONShortened service intervalsDespite observance of the service intervals, unusual loads, such as sev-eral start-stops a day, harsh environmental factors, poor fuel quality orheavy installation vibration can lead to premature machine damage.

u A shortened service interval must be arranged with ABB Turbochar-ging.

Pag

e 36

/ 1

13



NOTICEService inspection after 5 yearsTo prevent age- and stoppage-related machine damage, an inspectionby an ABB Turbocharging Service Station is recommended at the latest5 years after the last service.

4.2.1 Service work every 25 … 50 hours

u Visual inspection for air, exhaust gas, water and oil leaks.

u Record operating data and enter it in the engine logbook.

u Clarify the cause of any variances.

CAUTIONUnknown changes during operationThe consequences can range from an impairment to a breakdown.

u Have unknown causes clarified by an ABB Turbocharging service sta-tion.

4.2.2 Servicing work according to the enginemanufacturer's instructions

Oil filter u Clean or replace oil filter in supply line to turbocharger when engine isnot running.

Pag

e 37

/ 1

13



4.2.3 Service work in accordance with instructions onrating plate

(In general, after 8000 … 16000 hours of operation)

Rotor and bearing parts must be inspected and assessed by an ABB Tur-bocharging Service Station. The following work can be carried in prepar-ation.

u Remove cartridge group as described in chapter Disassembly and as-sembly.

u Measure clearances.

u Clean turbine and compressor casings and check them for cracks anderosion / corrosion.

u Clean bearing casing and blow air through oil ports / holes.

u Clean nozzle ring and check for cracks and erosion.

4.2.4 Entries in engine logbook

By monitoring the engine, conclusions can be drawn about the tur-bocharger performance.

The following operating data and measured values must be entered reg-ularly in the engine manufacturer's engine logbook:

¡ Engine performance and speed

¡ Air intake temperature

¡ Exhaust gas temperature in front of and behind the turbine

¡ Pressure of charge air

¡ Pressure drop in charge air cooler

¡ Lubricating oil pressure and lubricating oil temperature

If provided ¡ Air temperature behind compressor and charge air cooler

¡ Turbocharger speed

¡ Pressure loss in air filter

Pag

e 38

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.3 Expected exchange intervals


4.3 Expected exchange intervals

Rotating components

The recommended replacement intervals for compressor wheels and tur-bine wheels are defined depending on the operating conditions andbased on the safety concept (SiKo) for rotating parts. These intervalscan be found on the turbocharger rating plate.

Non-rotating components

Depending on the system-specific operating conditions, a distinction ismade between:

¡ the replacement interval for the bearing parts and

¡ the replacement interval for those non-rotating components that areexposed to hot gases.

Decisive in this respect are various influencing parameters, which candrastically shorten the replacement intervals of these parts in extremecases.

During the specified periodic service work, the individual componentsare inspected for wear and, if necessary, replaced.

Expected replacement intervals [h]

GAS / MDO HFOTurbine casing 25000 … 50000 25000 … 50000Nozzle ring 50000 10000 … 25000Gas outlet flange 50000 35000 … 50000Partition wall 50000 35000 … 50000Rotor components See rating plate informationBearing parts 12000 … 32000 12000 … 24000Other casings 50000 50000

GAS = Natural gas MDO = Marine diesel oil HFO = Heavy fuel oil

The specified values are a guide only and not guaranteed (see followingsection Influencing parameters).

Pag

e 39

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.3 Expected exchange intervals


Influencing parameters

The specified values are only guide values and not guaranteed. The ac-tual values can deviate considerably from the guide values due, for ex-ample, to the following influences:

¡ Fuel quality and preparation

¡ Load profile (thermal load cycles, also starts / stops, emergencyshut-downs)

¡ Gas inlet temperature

¡ Frequency and execution of turbine and compressor cleaning

¡ Turbocharger specification

¡ System-specific operating conditions (operating point, combustionquality, composition of exhaust gas)

For bearing parts

¡ Lubricating oil quality (oil filtration, condition of lubricating oil, oilmonitoring)

¡ Load profile (rpm / speed, pressure conditions, temperature)

¡ State of rotor unbalance (degree of contamination)

Pag

e 40

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.4 Speed measurement


4.4 Speed measurementA speed measuring system permits continuous monitoring of the tur-bocharger speed.

CAUTIONDo not use cables as a climbing aidIf you pull the speed measurement cables too hard, contacts can bepulled out.

u Do not tension the speed measurement cables.

86505(A)Speed sensor (cable not integ-rated)

86526F/I converter

86505(B)Speed sensor (cable integrated) 86528Tachometer86515(A)Cable connector to 86505(A) 01Screw plug86515(B)Cable connector to 86505(B) 02Gasket

Pag

e 41

/ 1

13



4.4.1 Speed differences with multiple turbochargers perengine

The speeds of all turbochargers on one engine differ only slightly fromeach other in normal operation.

The difference between the highest and the lowest turbocharger speedmust not be more than 3 % relative to the speed limit nBmax.

If this permissible range of difference is exceeded, the following stepsmust be carried out:

u Reduce engine performance immediately until the highest turbochar-ger speed no longer exceeds 70% of nBmax.

u If the engine cannot be stopped, continue to run at this reduced en-gine performance or turbocharger speed.

u If the turbocharger surges continuously, engine performance must bereduced further.

u Measure the temperatures in the air and gas lines to and from the tur-bochargers and compare them with standard values.

If the engine can be stopped for a short time:

u Inspect the air and gas lines as well as the turbocharger and eliminateany problems.

u In any event, it is recommended that you contact the nearest ABB Tur-bocharging Service Station.

Pag

e 42

/ 1

13



4.4.2 Replacing the speed sensor

WARNINGHot cable connector and hot speed sensorRisk of burning. During operation, the cable connector and the speedsensor can reach temperatures exceeding 100 °C.

u Wear safety gloves when removing the cable connector and speedsensor.


u Reduce engine performance to the idling speed, then stop the engine.

u Switch off the lubricating oil supply to the turbocharger.

u Disconnect the cable connector from the speed sensor.

u Screw out defective speed sensor.

u Screw in a new speed sensor up to the limit block.

u Adhere to tightening torque.

Part num-ber

TPS44 TPS48 TPS52 TPS57 TPS61

86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm

Pag

e 43

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..4 Operation / 4.5 Stopping the engine


NOTICESealing of the speed sensorThe speed sensor is designed with a sealing lip and does not requireany additional gasket for assembly.

u Connect cable connector to speed sensor.

u Switch on lubricating oil supply to turbocharger.

4.4.3 Failure of speed measuring system

Possible reasons for failure of the speed measuring system are de-scribed in the chapter Troubleshooting.

4.5 Stopping the engine

CAUTIONStopping the engine of oil-cooled turbocharger versionHeat in the turbocharger must be dissipated by the further circulatinglubricating oil.

u Post-lubricate for 15 … 20 minutes.

u Maintain oil pressure of 0.5 … 1.0 bar for post-lubrication.

CAUTIONStopping the engine of water-cooled turbocharger versionHeat in the turbocharger must be dissipated.

u Allow turbocharger cooling water to run for 15 … 20 minutes afterstopping engine.

u Allow oil lubrication to continue running until rotor comes to a stop.Further post-lubrication is not required and not recommended.

Pag

e 44

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..5 Maintenance / 5.1 Foreword to Maintenance


5 Maintenance

5.1 Foreword to MaintenanceGeneral maintenance work involves regular visual checks and cleaningtasks which are intended to ensure the trouble-free functioning of theturbocharger.

The maintenance points described here are differentiated as follows:

¡ Cleaning during operation:– Compressor– Turbine and nozzle ring.

¡ Mechanical cleaning of individual components:– Filter silencer– Casings, diffuser, nozzle ring– Cartridge group: Compressor, turbine

CAUTIONRisk of damage during mechanical cleaningIf mechanical cleaning is carried out too often, this can lead to damageand corrosion on the components.

u If cleaning during operation is not sufficient to achieve acceptablevalues regarding thermal load and engine performance, mechanicalcleaning of certain spots can be carried out.

u Perform mechanical cleaning, especially of the cartridge group, onlyonce within the service interval.

To allow you to observe the standard service intervals and to maintain ahigh turbocharger efficiency, ABB Turbocharging recommends that thecleaning procedure be carried out during operation. This allows thethermal load of the engine to be kept low while ensuring maximum fuelefficiency.

u Dispose of dirty water and cleaning agents in an environmentallycompatible manner, professionally and in accordance with valid localregulations.

Pag

e 45

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..5 Maintenance / 5.2 Cleaning the compressor during operation


5.2 Cleaning the compressor during operationGeneral The contamination of the compressor stage (compressor wheel, wall in-

sert and diffuser) depends on the degree of purity of the air that isdrawn in.

Deposits can form in the flow channels if salt, oil mist, exhaust gas ordust are sucked in with the air.

Consequences of contamination:

¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures

¡ Increased fuel consumption

¡ Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delaysany major increase in contamination. It does not, however, replace theregular service work, during which the turbocharger is completely dis-mantled and the compressor is cleaned mechanically.

NOTICEIf the coating of dirt is very thick and hard, the compressor can only becleaned manually when disassembled. This cleaning must be carried outby an ABB Turbocharging Service Station.

Cleaning interval The interval between periodic cleaning is very dependent on the operat-ing conditions. In general, cleaning should be carried out every 25 ... 100operating hours.

Should the specified cleaning intervals prove incompatible with engineoperation, please contact ABB Turbocharging.

Pag

e 46

/ 1

13



Cleaning method

Cleaning the compressor while in operation is carried out as wet clean-ing. This cleaning method is tested and approved by ABB Turbocharging.

Principle of wet cleaning To clean the compressor stage during operation, water is injected infront of the compressor wheel through an injection pipe fitted in the fil-ter silencer or the suction branch.

The water does not act as a solvent, but the contamination deposit is re-moved by the mechanical impact of the droplets. This is a very suitableprocess, provided that the degree of contamination is not too high.

CAUTIONCorrosion and deposits when cleaningDamage and impairment of turbocharger parts due to salt water andcooling water additives

u Don't use salt water for cleaning, but only clean fresh water.

CAUTIONThe injection pipe must on no account be connected directly via a cockto a water pipe or a dosing vessel larger than the one supplied. Thisprevents uncontrolled volumes of water entering the turbocharger andengine, which can lead to serious damage.

V-engines In the case of V-engines with several turbochargers on each engine, werecommend parallel cleaning of the compressors. This cleaning processis faster and the risk of turbocharger surging is reduced.

Sequential charging In the case of sequential charging, care must be taken to ensure that tur-bocharger compressors are cleaned regularly, especially after periods ofoperation in the lower performance range.

Pag

e 47

/ 1

13



5.2.1 Wet cleaning compressor using external waterpressure vessel (XC1)

Approval by enginebuilder These instructions for wet cleaning only apply when cleaning is carriedout with clean water and under the precondition that the enginebuilderapproves the process.

NOTICESupplying water from the externally mounted water vessel is suitableonly for those applications where a negative pressure exists in front ofthe compressor wheel (not used for: blowers connected in front of thecompressor or high-pressure compressor stages with two-stage char-ging).

Operating state prerequisites for cleaning compressor with XC1

NOTICETo be able to carry out a satisfactory cleaning process which has beentested and is recommended by ABB Turbocharging, the following pre-requisites must be fulfilled:

u Run engine at load from 50 … 85 %.

u Start cleaning cycle according to following description Wet cleaningoperation with XC1.

Pag

e 48

/ 1

13



Procedure for wet cleaning the compressor with XC1

XSealing plug DCompressed airYValve activator WWaterZVessel

Operating the water pres-sure vessel

u Remove sealing plug (X).

u Fill the vessel (Z) with clean water.

u Screw in the sealing plug.

u Push the valve activator (Y) against the spring and hold for 10 to 15seconds until the entire volume of water has been injected.

u Do not repeat the cleaning cycle until a stabilisation period of at least10 minutes has elapsed.

NOTICEWhether or not cleaning has been successful can be seen from the char-ging or flushing pressure and also from the exhaust gas temperatures.If the cleaning process is unsatisfactory, it can be repeated up to 2times.

If the cleaning result is still not satisfactory after three attempts andthe engine values are also unsatisfactory, we recommend that you havethe turbocharger inspected and cleaned by an official ABB Turbochar-ging Service Station.

Cleaning parameters perturbocharger compressor

Product Engine load Contentsof cleaning me-

dium vessel[dm3]

Waterinjection time

t1 [s]

TPS 50 … 85 % 0.4 10

Pag

e 49

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..5 Maintenance / 5.3 Turbine cleaning during operation


5.3 Turbine cleaning during operationThe combustion of fuels such as heavy fuel oil (HFO) in diesel enginesproduces contamination of the turbocharger's turbine components. Incombination with a high exhaust gas temperature, poor quality fuel canlead to particularly hard deposits on the nozzle ring and especially on thegas outlet flange.

ABB Turbocharging recommends the use of fuels with low ash, sulphur,sodium and vanadium contents.

Consequences of contamination:

¡ Poor turbine efficiency

¡ elevated exhaust gas temperatures

¡ higher charging and ignition pressures as turbocharger speed rises

¡ lower engine performance.

¡ After stopping the engine, the rotor can become stuck in contamina-tion deposits.

Experience with turbocharger operation shows that the intervalsbetween overhauls can be extended if cleaning while in operation is car-ried out periodically. Wet cleaning the turbine, as described below,should be used for 4-stroke applications when there are heavy depositsfrom, for example, HFO.

Under no circumstances is periodic cleaning of the turbine during opera-tion a substitute for the service work carried out when the turbochargeris completely dismantled and cleaned mechanically.

Turbines which are very heavily contaminated cannot be cleaned thisway any longer. In this case, the contaminated components must bemechanically cleaned by an ABB Turbocharging Service Station.

NOTICERegular cleaningRegular turbine cleaning during operation prevents or delays excessivebuild-up of contamination.

Cleaning intervals

The interval between periodic cleaning is very dependent on the operat-ing conditions. In general, cleaning should be carried out every 50 to 200operating hours.

NOTICECleaning intervalsShould the specified cleaning intervals prove incompatible with engineoperation, please contact ABB Turbocharging.

Pag

e 50

/ 1

13



Cleaning method

Turbine components are cleaned during operation by using the wetcleaning method described below. This cleaning method is tested andapproved by ABB Turbocharging.

The turbine casing design and the type of turbine casing seal are decis-ive for the choice of cleaning method.

NOTICEApproval by engine manufacturerThe prerequisite for wet cleaning is that the engine manufacturer ap-proves the method and his instructions are followed.

5.3.1 Wet cleaning methods

Process with short water injection time (3 x 30 seconds cleaning)

The cleaning process with short water injection time is used for tur-bocharger designs without additional sealing by means of C-rings.

The process is based on the principle of thermal shock in combinationwith a subsequent flushing phase.

Process with long water injection time (10 minutes cleaning)

The cleaning process with a long water injection time is used for tur-bocharger designs with additional sealing by means of C-rings.

Based on a 10-minute injection phase, this cleaning process utilises thewater solubility of the dirty deposits.

NOTICEChoice of cleaning methodIf you need information about the choice of cleaning method (short /long), you can contact the engine builder or an official ABB Turbochar-ger service station.

Pag

e 51

/ 1

13



5.3.2 Prerequisites

CAUTIONRisk of corrosion and depositsImpairment and damage of turbocharger by salt water and cooling wa-ter additives in flow ducts

u Don't use salt water for cleaning, but only clean fresh water.

u Avoid corrosion on casing inner surfaces.

u Let engine run for 10 minutes after wet cleaning.

CAUTIONMaximum temperature in front of turbine during cleaningWhen cleaning, the temperature in front of the turbine will rise and canheavily stress the material of turbine components. The temperature atthe turbine inlet can be up to 100 °C higher than the exhaust gas tem-perature after the cylinder. This should be taken into considerationwhen setting the operating point before cleaning.

u Don't exceed maximum temperature in front of turbine when clean-ing.

CAUTIONImpermissible thermal stressing and flooding of the turbineSmaller volumes of water can result in poor cleaning. Larger volumes ofwater lead to impermissible thermal stressing of the turbine compon-ents and can cause flooding of the turbine.

u Be absolutely sure to observe turbine cleaning parameters.

NOTICEV-enginesIn the case of V-engines with several turbochargers on each engine, werecommend parallel cleaning of both turbochargers. This cleaning pro-cess is faster and the risk of turbocharger surging is reduced.

Recommended operating state for turbine wet cleaning

The following operating state is tested and approved by ABB Turbochar-ging:

Characteristic / com-ponent

Conditionsshort

Water injection timelong

Water injection timeEngine load (guide value) 20 … 40 %Turbine inlet temperatureTTE before water injection

350 … 400 °C 350 … 430 °C

Pag

e 52

/ 1

13



Characteristic / com-ponent

Conditionsshort

Water injection timelong

Water injection timeWater supply ensuredWater pressure (overpres-sure over atmosphere) pWT

2.0 bar 1.5 bar

If necessary, engine performance must be reduced to maintain theseconditions.

The cleaning cycle can now be started based on the following descrip-tion.

Pag

e 53

/ 1

13



5.3.3 Procedure for method with short water injectiontime

w Prerequisites have been fulfilled.

u Wait 10 minutes during a stabilising phase after reducing the engineload.

u Open the shut-off valve.

u Set the required water flow rate as specified in the table of cleaningparameters using the flowmeter and inject for 30 seconds.

u Observe a pause of 3 or 5 minutes as specified in the table.

u Repeat the 30-second water injection two times.

u Close the shut-off valve.

u Wait 10 minutes during a stabilising phase before increasing engineload again.

This completes the turbine cleaning process.

Cleaning parameters during the process

TPS

Temperature infront of the tur-

bine during clean-ing[°C]

Watervolume flow 1)

[dm3/min]

Injection time[min]

Pausebetween injec-

tions[min]

44 ≤ 450 4.5 0.5(3 x)

348 652 857 1161 17 5

1) corresponds to a water pressure pWT of 2.0 bar (overpressure over at-mosphere)



5.3.4 Procedure for method with long water injection time

w Prerequisites have been fulfilled.

Pag

e 54

/ 1

13



u Wait 10 minutes as a stabilising phase after reducing the engine load.

u Open the shut-off valve.

u Set the required water flow rate as specified in the table of cleaningparameters using a flowmeter and inject for 10 minutes.

u Close the shut-off valve.

u Wait 10 minutes as a stabilising phase before increasing the engineload again.

This completes the turbine cleaning process.

Cleaning parameters during the process

TPS

Temperature infront of the tur-

bine duringcleaning

[°C]

Watervolume flow 1)

[dm3/min]

Injectiontime[min]

Stabilising phasebefore / after wa-

ter injection[min]

44 ≤ 530 2.5 10 1048 452 5.557 8.561 12

1) corresponds to a water pressure pWT of 1.5 bar (overpressure over at-mosphere)



Pag

e 55

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..5 Maintenance / 5.4 Cleaning components mechanically


5.4 Cleaning components mechanically

5.4.1 Introduction

CAUTIONChoosing cleaning toolsTurbocharger components are sensitive to mechanical damage. Theuse of needle guns or other impact tools, for example, damages thecomponents. Depending on the specification, nozzle rings and turbinecasings have protective coatings, which can also be damaged.

u Only use soft tools such as cloths, brushes or wire brushes.

u In the event of heavy contamination, the cleaning methods that havebeen described such as soaking can be repeated until a satisfactoryresult has been achieved.

u Dispose of dirty water and cleaning agents in an environmentallycompatible manner, professionally and in accordance with valid localregulations.

NOTICEDisassembly and assemblyThe disassembly and assembly of the components is described inchapter Disassembly and assembly.

Pag

e 56

/ 1

13



5.4.2 Cleaning the filter silencer

81135Filter silencer body 81266Cover grid81136Absorption segment 81270Tension band81137Sheet-metal covering 81271Lock81265Filter ring

NOTICEDisassembly and assemblyThe procedure for disassembly and assembly of the filter silencer is de-scribed in the chapter entitled Disassembly and Assembly.

Cleaning the filter ring (if provided)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 operating hours, andreplace after the fifth cleaning operation at the latest.The degree of contamination of the filter ring depends on the cleanli-ness of the air that is drawn in.

u Wash filter ring (81265) using water containing light-duty detergentor, if very heavily contaminated, soak it while squeezing carefully.Rinse in cold water. Avoid rough handling (do not use a water jet).

u Allow the filter ring to dry out completely before assembly.

u Dispose of dirty water and gentle detergents in accordance with validlocal regulations.

Cleaning the absorption segments

u Loosen the tension bands (81270).

u Remove the cover grid (81266).

Pag

e 57

/ 1

13



u Pull out the sheet-metal coverings (81137), bend them up and removethe absorption segments (81136).

u Clean the absorption segments (81136).During cleaning, ensure that the absorption segments (81136) areonly cleaned with a mild jet of compressed air, soft brush or a dampcloth.

u Have absorption segments which are heavily contaminated replacedby an official ABB Turbocharging Service Station.

Fitting the filter silencer

u Insert the absorption segments (81136) into the sheet-metal cover-ings (81137).

u Bend the sheet-metal coverings (81137) back into their original shapeand insert them into the slot guides in the silencer body (81135).

u Fit the cover grid (81266).

u Fit the tension bands (81270) and apply tension at the locks (81271).

u Damaged tension bands must be replaced with new ones.

u If provided, fit the filter ring (81265).

Pag

e 58

/ 1

13



5.4.3 Compressor-end, non-rotating parts

WARNINGHandling operating materials and suppliesSwallowing or inhaling vapours of operating materials and supplies orcontact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin.

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the op-erating materials and supplies.






The following performance-relevant parts can be cleaned according tothe following description.

72000 Compressor casing77000 Wall insert79000 Diffuser

u Clean the components specified above with steam or allow to soak indiesel oil or water with household detergent. After soaking, removethe dirt with a brush.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outersurfaces of the turbocharger.

u Dispose of dirty water and cleaning agent in accordance with the spe-cifications in the safety data sheet.

Pag

e 59

/ 1

13



5.4.4 Turbine-end, non-rotating parts










Baked-on layers of contamination, for example from heavy fuel oil orcoked oil, occur at the turbine end. The following performance-relevantparts can be cleaned according to the following description.

51000 Turbine casing 56001 Nozzle ring52400 Gas outlet flange

u Place contaminated parts in hot water or in a liquid such as brakecleaner, so that the contamination softens.

u Brush off the contamination or remove it with a steam cleaner.

u Repeat the soaking and brushing if necessary.

u Completely remove any solvents from the parts in clean water.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outersurfaces of the turbocharger.

u Dispose of contaminated water and cleaning agent in accordancewith the specifications in the safety data sheet.

Pag

e 60

/ 1

13



5.4.5 Cartridge group

Introduction

CAUTIONCorrosionIf the cartridge group is not put into operation again immediately aftercleaning, parts may corrode.

u Re-install and use the cartridge group immediately after cleaning.

Compressor wheels or turbines may be heavily contaminated due to ex-haust gas deposits or coked oil. Such contamination may possibly nolonger be removed through cleaning during operation and must becleaned mechanically during the standard service intervals (see chapterentitled Service work).

u Remove turbocharger from the engine (see chapter Removal and in-stallation →74).

u Remove cartridge group (see chapter Disassembly and assembly→78).

First clean the compressor end and then the turbine end in accordancewith the following description.

Pag

e 61

/ 1

13



Cleaning the compressor end

CAUTIONSelection of the cleaning agentCleaning agents that contain chlorine corrode metals.

u Only use pH-neutral cleaning agents that do not corrode metals.

u Observe the material safety data sheet.

u Observe country-specific regulations regarding banned and restric-ted substances.

CAUTIONWater and contamination in the cartridge groupIf water or contamination penetrates the cartridge group, this can im-pair the function of the turbocharger and damage parts inside the cart-ridge group.

u Make sure that no water or contamination can enter into the cart-ridge group.

u Clean compressor wheel with a cloth or soft brush soaked in waterwith household detergent. Do not use any wire brushes!

u Dry the compressor wheel and the gap between the compressor andthe bearing casing with a weak jet of compressed air.

u Lightly spray the compressor wheel and the gap between the com-pressor and the bearing casing with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with thesafety data sheet.

Pag

e 62

/ 1

13



Cleaning the turbine end

Soaking the dirt Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the tur-bine end. The contamination can be removed by soaking and brushing.The soaking of the layers of dirt as well as the cleaning of the turbine aredescribed below.

Product A [mm] B [mm] C [mm]TPS44 91 15 173TPS48 108 17 205TPS52 128 20 245TPS57 157 25 300TPS61 187 30 357

To soak the layers of dirt on the turbine, the cartridge group can be sub-merged vertically in a tank (02) with liquid.

u Place the tank (02) in a larger container (03), so that the excess liquidcan be collected.

CAUTIONSelection of the cleaning agentCleaning agents which contain chlorine attack metals.

u Use only pH-neutral cleaning agents which do not attack metals.

u Observe safety data sheet.

u Fill the tank (02) with soaking liquid.

NOTICEHeat the liquidTo shorten the soaking time the liquid can be heated to maximum60 ºC.

Pag

e 63

/ 1

13



WARNINGHeating up of cleaning agents and operating fluidsWhen cleaning agents or operating fluids are heated up, explosive va-pours can be produced which are hazardous to health.

u Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

CAUTIONWater and dirt in the cartridge groupIf water or dirt gets into the cartridge group, the turbocharger functionmay be impaired and parts in the cartridge group may be damaged.

u Place the cartridge group on suitable wooden or metal supports (01).

u Maintain dimension (B) for the supports (01), so that the cartridgegroup does not submerge too deep.

u Allow the layers of dirt on the turbine to soak for four hours.

Pag

e 64

/ 1

13



Removing the dirt

WARNINGHealth hazard due to soot particlesIf soot particles enter the eyes or respiratory tract, this can be harmfulto health.

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

u Wear a respiratory mask to protect against particles (P1 or P2 mask).

u Wear safety goggles.




u Raise the cartridge group and align horizontally.

u Remove dirt manually with a soft brush or wire brush.

Pag

e 65

/ 1

13



CAUTIONWater and dirt in the cartridge groupIf water or dirt gets into the cartridge group, the turbocharger functionmay be impaired and parts in the cartridge group may be damaged.

u Make sure that water or dirt does not get into the gap between thepartition wall and turbine.

CAUTIONNon-permissible rotor unbalance after cleaningUnevenly distributed residual contamination deposits lead to rotor un-balance. This can result in bearing or turbocharger damage.

u Remove all traces of contamination from the turbine.

u After brushing off the contamination, fill the tank (02) with clean wa-ter, not salt water.

u Submerge the turbine of the cartridge group in clean water, so thatloose particles of dirt detach completely.

u Raise the cartridge group and align horizontally.

u Clamp the partition wall with the bearing casing.

u Dry the turbine and the gap between the turbine and partition wallwith a weak jet of compressed air.

u Lightly spray the turbine and the gap between the turbine and parti-tion wall with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with the spe-cifications in the safety data sheet.

Pag

e 66

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..6 Troubleshooting / 6.1 Malfunctions when starting


6 Troubleshooting

6.1 Malfunctions when starting

Sluggish start-up

Possible causes EliminationTurbochar-ger

Turbocharger contaminated Clean itDamaged bearing Contact an ABB Turbocharging

Service StationRubbing rotorForeign object in turbocharger

Vibrations


Rotor unbalance Contact an ABB TurbochargingService StationDamaged turbine or com-

pressorDamaged bearing

Rubbing of rotating parts

Normal behaviour, no malfunctionTurbochar-ger

Minor uniform wear around the periphery of rotor components,caused by slight local rubbing of adjacent components, is per-missible. The compressor blades and turbine blades are thenshortened somewhat. Certain tolerances must be observed toavoid a significant loss of efficiency.

¡ If there is any doubt about the extent of rubbing, then anABB Turbocharging Service Station must be contacted.

¡ Have a dimension check carried out by an ABB Turbochar-ging Service Station.

Pag

e 67

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..6 Troubleshooting / 6.2 Surging of the turbocharger


6.2 Surging of the turbocharger

Turbocharger surging

Possible causes EliminationEngine Guard in front of the tur-

bocharger is contaminatedor damaged

Clean / replace it

Turbocharger Filter silencer or diffusercontaminated

Clean it

Heavy deposits of dirt in theturbine or nozzle ring

Charge aircooler

Cooler contaminated Clean itCharge air duct blocked

CAUTIONProlonged or periodic surgingPossible damage to components, such as the compressor wheel, tur-bine blades, bearings and filter silencer

u Have the cause clarified immediately by an ABB Turbocharging ser-vice station and rectified.

u Have components inspected for damage and, if necessary, replacedby an ABB Turbocharging service station.

Sporadic surge blows

Surging of the turbocharger can occur during certain operating condi-tions such as when reducing the engine performance quickly when man-oeuvring. At the same time, the flow direction in the compressor is mo-mentarily reversed. Such sporadic surge blows do not impair the safeoperation of the turbocharger.

¡ A surge blow is accompanied by a loud bang and escape of hot airfrom the filter silencer.

Pag

e 68

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..6 Troubleshooting / 6.3 Malfunctions during operation


6.3 Malfunctions during operation

Lubricating oil pressure too low

Possible causes EliminationEngine Oil filter heavily contaminated Clean it

Defective oil pump in lubricat-ing system

Check / replace it

Manometer display wrong Replace the manometerTurbochar-ger

Rotor axial clearance too large Contact an ABB TurbochargingService Station

Reduction in speed

Possible causes EliminationEngine Defects of connected cylinders

when pulse chargingContact the enginebuilder

Turbochar-ger

Heavy contamination of theturbine

Clean it

Damaged rotor components orbearing

Contact an ABB TurbochargingService Station

Pipes Defects such as leaks in the ex-haust gas pipes or charge airducts

Make repairs

Increase in speed


Heavily contaminated nozzlering (with 4-stroke application)


Pag

e 69

/ 1

13



Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes EliminationEngine Malfunctioning injection

systemRepair it or contact the manu-facturer

Turbocharger Air starvation, for examplefilter silencer clogged withdirt

Clean it

Compressor / turbine con-taminatedExhaust counterpressuretoo high

Clean or repair the boiler or ex-haust silencer

Enlarged flow cross-sectionof the nozzle ring due to de-formed blade trailing edges


Damaged or eroded turbineCharge aircooler

Cooler contaminated Clean itCooling water volume toolow

Top up the water

Entry temperature of cool-ing water too high

Inspect / clean the cooling sys-tem

Inadequate ventilation Improve the ventilation

Pag

e 70

/ 1

13



Charge air pressure too low

Engine performance and engine speed unchanged, air intake conditionnormal

Possible causes EliminationEngine Air receiver leaking Make repairs

Gas piping between the engineand the turbine leakingPoorly adjusted injection sys-tem

Correct it

Poorly adjusted valve controlTurbochar-ger

Manometer display wrong Replace the manometerLine to manometer leaking Repair the leakContaminated filter silencercausing excessive loss of pres-sure

Clean it

Compressor / turbine contam-inatedDamaged compressor / tur-bine


Exhaust counterpressure toohigh

Clean or repair the boiler or ex-haust silencer

Charge air pressure too high

Engine performance and engine speed unchanged, air intake conditionnormal

Possible causes EliminationEngine Malfunctioning injection sys-

temRepair it or contact the manu-facturer

Poorly adjusted injection sys-tem

Correct it

Engine performance higherthan expected

Check engine performance

Turbochar-ger

Manometer display wrong Replace the manometer

Pag

e 71

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..6 Troubleshooting / 6.4 Malfunctions when stopping


Contamination of the compressor due to the feeding in ofventilation gases

Reduced compressor performance / efficiency and therefore engine per-formance losses


Heavily contaminated com-pressor components

Clean the compressorOptimise oil separation

Increased vibration, compressorblade damage

Correct the feed of ventilationgases according to instructionsof enginebuilder.

Reduced fatigue strength of the compressor wheel, compressor bladebreakage.


Corroded compressor wheelmaterial

Check fuel and its corrosive con-stituents and, if necessary,change fuel.

6.4 Malfunctions when stopping

Noises during run-down




Run-down time too short




Pag

e 72

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..6 Troubleshooting / 6.5 Speed measurement system


6.5 Speed measurement system

Possible causes EliminationNo signal oramplitude ispoor

Fitting error The screw plug for the sensor is fitted withan additional gasket (copper ring).When fitting the speed sensor, this gasketmust be removed. If the gasket is fitted bymistake, the distance from the sensor tipto the signal-generating sealing disc in-creases. As a result, the voltage amplitudeof the speed signal decreases, which cancause problems for the evaluation elec-tronics.This problem is eliminated by removingthe gasket.

Defective sensor Contact an ABB Turbocharging Service Sta-tion

Measuredspeeds toohigh

Contaminatedsensor tip

The sensor tip is magnetic and can thus at-tract metal particles. As a result, the dis-tance to the signal-generating sealing discis reduced, which can lead to amplificationof the noise component and consequentlyto faulty triggering.Dismantle the sensor, clean its tip and refitthe sensor using the specified tighteningtorque.

Measuredspeed too low

- - Contact an ABB Turbocharging Service Sta-tion

Other sourcesof errors

- - If none of the above measures eliminatesthe malfunction, we recommend that youhave the speed measuring system inspec-ted by an ABB Turbocharging Service Sta-tion.

Pag

e 73

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..7 Removal and installation / 7.1 Transport


7 Removal and installation

7.1 Transport

Suspension of uninsulated turbocharger

Turbocharger with oil-cooled bearingcasing

Complete turbocharger with gas out-let casing

Suspension of insulated turbocharger

Turbocharger with oil-cooled bearingcasing

Complete turbocharger with gas out-let casing

Pag

e 74

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..7 Removal and installation / 7.2 Turbocharger weights


7.2 Turbocharger weightsLifting gear with a sufficient load limit must be used for removing andinstalling the turbocharger. The following weight specification is theheaviest variant possible. This standard value may deviate from the dataon the rating plate depending on the specification.

TPS44[kg]

TPS48[kg]

TPS52[kg]

TPS57[kg]

TPS61[kg]

120 180 250 410 650

7.3 Removing the turbochargeru Disconnect all exhaust gas and air lines according to the instructions

of the enginebuilder.

Version with water-cooled bearing casing:

u Disconnect the water pipes according to the instructions of the en-ginebuilder.

If present, remove hard insulation as follows:

u Remove screws and sheet metal (B) from the bearing casing insula-tion.

u Remove the remaining screws from the bearing casing insulation (A).

u Pull the bearing casing insulation up and off. The bearing casing insu-lation can be compressed to facilitate the removal process.

u Unplug the cable connector from the speed sensor.

u Attach lifting gear to bearing casing.

u If a gas outlet bend is present, sling lifting gear around it or secure itto the lifting gear with a swivel lifting eye (C).

Pag

e 75

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..7 Removal and installation / 7.4 Installing the turbocharger


u Loosen the fixing screws (D) on the bearing casing.

u Lift the turbocharger from the engine and put it down.

u Cover oil connections.

7.4 Installing the turbochargeru Remove covers from oil connections.

u Visually inspect O-ring gaskets of oil supply and drain pipe (O-ringgaskets for engine are not included in the scope of delivery of ABB).

**) When the turbocharger is mounted on the engine support, the boltthreads and screw heads must be lightly oiled (assumed friction coeffi-cient µ = 0.12 for tightening torque)

Strength class in accordance with DIN/ISO 898: 10.9/12.9

Product Through hole inbearing casing

Thread size Tightening torque

TPS44 17 mm M16 230 NmTPS48 17 mm M16 230 NmTPS52 21 mm M20 455 NmTPS57 21 mm M20 455 NmTPS61 25 mm M24 780 Nm

u Attach lifting gear to bearing casing.

u If a gas outlet manifold is provided, sling lifting gear around it addi-tionally or fasten it to lifting gear using a swivel lifting eye (C) (seealso section Transport / Weights).

u Lift turbocharger, place on bracket and align.

u Tighten fixing screws (D) to the bearing casing in accordance with thetable above.

Pag

e 76

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..7 Removal and installation / 7.4 Installing the turbocharger


u Fasten all gas, water and air lines in accordance with the engineb-uilder's instructions.

If present:

u Fit speed sensor and plug in cable connector.

u Adapt and fit bearing casing insulation (A).

u Adapt and fit sheet metal (B) of bearing casing insulation.

Version with water-cooled bearing casing:

u Remove the screw plugs from the water connections and fit the waterpipes in accordance with the enginebuilder's instructions.

Pag

e 77

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.1 Introduction


8 Disassembly and assembly

8.1 IntroductionPrecondition for the work described below is a turbocharger removedfrom the engine (refer to the chapter entitled Removal and Installation).

CAUTIONFurther workOnly the work described in this Operation Manual may be carried out.Incorrectly performed disassembly and assembly of the cartridgegroup can lead to serious machine damage.

u ABB Turbocharging recommends having further work carried outonly by trained personnel from an ABB Turbocharging Service Sta-tion.

u Mark the casing position for assembly.

Identifying assembly devices

Not all assembly devices are marked with a part number. They can beidentified using the tool list. This list is enclosed in the toolbox.

WARNINGMaintaining assembly devicesAssembly devices must be checked for damage before and after use.

u Check visually for corrosion, cracks, deformation and wear.

u Don't use damaged assembly devices, but replace them.

Customer spare part set

Before beginning work, ensure that the required customer spare partsets are available.

u See chapter Spare parts.

Oil orifice

u When disassembling the turbocharger, a fitted oil orifice must not beremoved.

Tightening torques for turbocharger components

The specified tightening torques of screw connections for turbochargercomponents must be observed (see section Table of tighteningtorques).

Pag

e 78

/ 1

13



Tightening torques for assembly devices from ABB

Unless otherwise described, the screws and nuts of the assemblydevices must be secured so they are tight-fitting.

WARNINGSuspended loadsLoads not suspended in compliance with regulations may lead to per-sonal injury or accidents with fatal consequences.

u Attach turbochargers, assemblies or individual components only tolifting gear which is in technically perfect condition and has a suffi-cient load limit.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.


Wear safety helmet.

Definition of terms

¡ Suspension pointDefined load attachment point on a component or an assembly (blindhole thread, eye, lug).

¡ Assembly deviceDevices that are fitted on the turbocharger in order to obtain a sus-pension point. Assembly devices are specially constructed and de-signed for the defined use; they are not commercially availableproducts. Use assembly devices only for the described applications.

¡ Lifting gearEquipment for lifting and transporting loads (lifting slings, chainblock, crane). Lifting gear is not supplied by ABB.

Pag

e 79

/ 1

13



Swivel lifting eye to be used

A swivel lifting eye is required to lift loads safely (not supplied by ABB).

Swivel lifting eye Product ThreadM

LengthL

Minimumload limit

(loading ca-pacity)

TPS44 M8 13 mm 150 kgTPS48 M10 17 mm 250 kgTPS52 M10 17 mm 250 kgTPS57 M12 21 mm 350 kgTPS61 M12 21 mm 500 kg

Pag

e 80

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.2 Module weights


8.2 Module weightsThe specified weights of individual parts or assemblies are guides roun-ded off to the next highest value.

DescriptionTPS44

[kg]TPS48

[kg]TPS52

[kg]TPS57

[kg]TPS61

[kg]1Filter silencer 15 19 30 40 652Radial air suction branch 5 6 8 11 213Axial air suction branch 3 4 4 6 94Compressor casing 17 24 35 55 905Wall insert 4 7 10 13 306Diffuser 2 2 3 6 107Cartridge group 25 35 50 85 1408Nozzle ring 1 1 2 3 69Burst ring 1 2 3 5 12

10Turbine casingwith externalburst protec-tion

1 inlet 30 35 50 80 1302 inlets 30 35 50 90 1503 inlets - - 55 95 1704 inlets - - - 95 170

11Gas outlet flange 4 4 8 16 3012Exhaust manifold 16 18 25 40 60

Pag

e 81

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.3 Disassembling and assembling tur-bocharger


8.3 Disassembling and assembling turbocharger

Removing the compressor casing






u Disconnect all air lines in accordance with the enginebuilder’s instruc-tions.

If provided u Remove the screws for the compressor casing insulation and dis-mantle the insulation.

u Undo the V-clamp (72020) and remove the filter silencer (81000) or airsuction branch (82000).

Pag

e 82

/ 1

13



Removing the insulationIf provided u Loosen and remove the screws for the insulation plates (1, 2).

u If provided: Remove the insulation plates (1, 2).

u Remove the remaining screws for the insulation (3).

u Remove the insulation (3).

Pag

e 83

/ 1

13



u Slightly loosen the screws (72011) and turn the compressor casing(72000) until the swivel lifting eye can be fastened to the lifting gear.

(77006* only provided with the wall insert with acceleration aid.)

NOTICEIf the compressor casing cannot be removed easily, it can be pressedoff using the press-off tool (90042) against the turbine casing. To dothis, the two cover plates (1, 2) must be removed from the hard insula-tion on the turbine casing.

CAUTIONAxial forceThe press-off tool can generate a high axial force and, if it is not usedproperly (too much pressure on one side), it can damage the rotor.

u It should thus be used alternately on both sides while avoiding ex-cessive pressure on either side.

u Loosen the screws (72011) and remove them together with the fasten-ing strips (72012).

u Move the compressor casing (72000) with the wall insert (77000)carefully away, doing so horizontally.

u Tap the wall insert (77000) out of the compressor casing using anylon hammer and remove the O-ring seal (77005).

Pag

e 84

/ 1

13



TPS61 wall insert removal

u Fasten lifting beam (90258) to wall insert.

u Fasten swivel lifting eye (a) to lifting beam.

u Remove wall insert (77000) using lifting gear.

Disassembly of diffuser TPS..-F31/32 / FV31/32

u Loosen screws (72041) and remove them together with lockwashers(72040) and diffuser (79000) from compressor casing (72000).

Installing compressor casing

u Refit wall insert (77000) and O-ring (77005) in the reverse order.

Pag

e 85

/ 1

13



NOTICEO-ringsUsed O-rings must always be replaced with new ones. O-rings are onlyavailable as a set (see chapter Spare parts).

Fitting the diffuser TPS..-F31/32 / FV31/32

u Refit diffuser in reverse order.

u Fit compressor housing in reverse order.

u Thoroughly clean fastening strips (72012) before fitting them.

Pag

e 86

/ 1

13



Removing the cartridge group

u Check the lifting gear and fasten it to bearing casing (42001).

If provided u Disconnect all lines in accordance with the engine builder's instruc-tions, remove the insulation, remove the turbocharger and com-pressor casing together with the filter silencer (also see the previouschapter).






w The bearing casing is difficult to loosen.

u Use the press-off tool (90042) against the turbine casing to press offthe bearing casing (see the following illustration).

CAUTIONAxial forceThe press-off tool can generate a high axial force and, if it is not usedproperly (too much pressure on one side), it can damage the rotor.

u It should thus be used alternately on both sides while avoiding ex-cessive pressure on either side.

Pag

e 87

/ 1

13



u Withdraw nozzle ring (56001) using two extraction devices (90070)and withdraw bottom part of service support (90012).

If provided u Remove C-ring (51105).

Disassembly of diffuser TPS..-F33

u Mount the cartridge group on the service support (90012) and bolt itdown firmly.

u Loosen screw (42008) and remove diffuser (79000) complete with O-ring (42012).

u Measure the axial and radial clearances (see the section Axial and ra-dial clearances).

Pag

e 88

/ 1

13



Installing the cartridge group

NOTICEO-ringsUsed O-rings must always be replaced with new ones. O-rings are onlyavailable as a set (see chapter Spare parts).

NOTICEProtruding insulationThe insulation on the turbine casing may protrude at the gas outletside. This can be pushed back in with a screw driver.

u Fit the lamellar sealing ring (56005, if present) in the correct slot (seedetail A). When doing this, pay attention to correct winding of thelamellar sealing ring (see detail B).

u Secure the lamellar sealing ring with adhesive tape.

u Insert the nozzle ring (56001) (with the cam facing forwards) into theturbine casing as far as it will go. Align the cam on the nozzle ring withthe recesses of the turbine casing and insert it into the turbine casing(51000) as far as it will go. Do not remove the adhesive tape (01).

If present u Insert the C-ring (51105) into the turbine casing and secure with high-vacuum grease.

Pag

e 89

/ 1

13



NOTICETo ensure the nozzle ring is held in place during operation, it must beclamped between the partition wall and the turbine casing.

Nozzle ring press fit forsingle inlet turbine casing

u Calculate the press fit (PD) as shown.

NOTICEIf the calculated value (PD) is less than 0.1 mm, an official ABB Tur-bocharging Service Station must be contacted.


Pag

e 90

/ 1

13



Nozzle ring press fit formultiple inlet turbine cas-ing

u Calculate the press fit (PD) as shown.

NOTICEIf the calculated value (PD) is outside ±0.2 mm, an official ABB Tur-bocharging Service Station must be contacted.


Pag

e 91

/ 1

13



Assembly of diffuser TPS..-F33

u Fasten diffuser (79000) and O-ring (42012) using screw (42008).

u Check lifting gear and fasten to bearing casing (42001).

u Unscrew the cartridge group and lift it out of the service support(90012).

u Apply high-temperature grease to the centering points and screwthreads.

u Remove temporary covers from oil connections.

CAUTIONDon't damage or shift gasket rings (A) in the mounting support whenfitting the cartridge group. The gasket rings (A) are supplied by the en-gine builder.

NOTICEIf two turbochargers are mounted on an engine, one with a left-handand one with a right-hand oil inlet, a pin can be fitted in the bracket as aprecaution against incorrect positioning. This pin (B) locates in a cor-respponing groove in the foot of the bearing casing.

Pag

e 92

/ 1

13



u Fasten the cartridge group using fastening strips (51002), VerbusRipp® washers (51003) and nuts (51007) (also see the chapter entitledTable of tightening torques).

u Fasten the bearing casing (42001) using the fixing screws (C).

u Tighten the fixing screws (C) to the torques listed in the followingtable.

**) For the assembly of the turbocharger on the engine support, thethreads of the screws and screw heads must be lightly oiled (assumedcoefficient of friction µ = 0.12 for the tightening torque).

Product Hole in the bearingcasing[mm]

Fixing screws C [mm] Tighteningtorques [Nm] **)

TPS44 Ø 17 M16 230TPS48 Ø 17 M16 230TPS52 Ø 21 M20 455TPS57 Ø 21 M20 455TPS61 Ø 25 M24 780

Pag

e 93

/ 1

13



If provided

u Plug in the cable connector (86515) for the speed sensor (86505) and(if provided) fit the insulation plates (1, 2).

Removing gas outlet manifold and gas outlet flangeIf provided u Disconnect all lines in accordance with enginebuilder's instructions

and remove insulation (see also preceding chapter).

u Loop lifting gear around gas outlet manifold (51100).

u Remove gas outlet manifold (51100) and gasket (52406). Only gasoutlet manifolds from ABB have the gasket (52406).

u Remove gas outlet flange (52400) and, if fitted, C-ring (52408).

Pag

e 94

/ 1

13



Fitting the gas outlet flange and gas outlet manifold

u If provided, fit the C-ring (52408).

u Fit the gas outlet flange (52400).

u For gas outlet manifolds (51100) from ABB: always replace the gasket (52406) (see the chapter entitled Spareparts).

u Apply high-temperature grease to contacting surfaces and threads.

u Fit the turbine casing using the nuts (52433) while observing tighten-ing torques specified in the table of tightening torques.

If provided u Fasten the insulation.

u Attach pipes in accordance with the enginebuilder's instructions.

Pag

e 95

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.4 Axial clearance A and radial clear-ance B


8.4 Axial clearance A and radial clearance B

u Following removal and before installation of the cartridge group, theaxial clearance A and radial clearance B must be measured and noted.

NOTICEIn order to correctly measure the axial clearance A, the turbine must beraised slightly.

WARNINGRisk of injury due to sharp edges on the compressor wheelThe compressor wheel has sharp edges which can cause injuries.



Axial clearance A and ra-dial clearance B [mm]

TPS44 TPS48 TPS52 TPS57 TPS61A minimum 0.08 0.08 0.10 0.12 0.15A maximum 0.16 0.16 0.18 0.21 0.25B minimum*

0.51 0.50 0.61 0.72 0.81

B maximum*

1.00 1.00 1.15 1.31 1.55

* Permissible B clearances for standard radial bearings. If the clearancesmeasured on TPS57 or TPS61 are outside the permissible range, this canindicate radial bearings with a special bearing geometry. Different per-missible values are valid for radial bearings with a special bearing geo-metry (see the table below).

Pag

e 96

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.4 Axial clearance A and radial clear-ance B


Identifying radial bearingswith a special bearinggeometry

The type of bearing can be determined by measuring the rotor run-outtime. To do so, the rotor must be pushed by hand, once to the left (L)and once to the right (R), with a force as close to the same in both direc-tions. The resulting run-out times until the rotor comes to a stop aremeasured for the anticlockwise and clockwise rotations and then com-pared. With standard radial bearings, the run-out time for anticlockwiseand clockwise rotating rotors is the same.

If one run-out time is at least 1.5 times longer than the other, then radialbearings with a special bearing geometry are installed. The following Bclearances are valid for these special bearings.

TPS57 TPS61B minimum 0.46 0.52B maximum 0.73 0.82

CAUTIONClearances out of toleranceClearances out of tolerance and excessively worn components can bethe cause of serious damage to machinery and property.

u Have components assessed and, if necessary, replaced by an ABBTurbocharging Service Station.

Pag

e 97

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.5 Radial clearances N and R


8.5 Radial clearances N and R

N and R

These are the theoretical values of the radial clearance between the com-pressor wheel and the wall insert and / or turbine wheel and the gas out-let flange.

The minimum and maximum values result from the manufacturing toler-ances of the compressor wheel and turbine wheel or the wall insert andgas outlet flange.

Feeler gauge N1 and N2 as well as R1 and R2 are eachmeasured at the same time using twofeeler gauges.To measure N1 and N2, the feelergauges must be pushed between thewall insert and the compressor wheelfree of play, in each case above and be-low.To measure R1 and R2, the feeler gaugesmust be pushed between the gas outletflange and the turbine free of play, ineach case above and below.

Pag

e 98

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.5 Radial clearances N and R


Measuring N and R

The mean values measured must be within the permissible values of theradial clearance N and R.

Radial clearances N and R Product N [mm] R [mm]TPS44 0.15 … 0.49 0.36 … 0.67TPS48 0.22 … 0.58 0.47 … 0.77TPS52 0.30 … 0.67 0.59 … 0.92TPS57 0.40 … 0.86 0.75 … 1.11TPS61 0.50 … 0.94 0.90 … 1.32

CAUTIONClearances out of toleranceClearances out of tolerance and excessively worn components can bethe cause of serious damage to machinery and property.

u Have components assessed and, if necessary, replaced by an ABBTurbocharging Service Station.

Pag

e 99

/ 1

13

Operation Manual / TPS44-F.. - TPS61-F..8 Disassembly and assembly / 8.6 Table of tightening torques


8.6 Table of tightening torques

The following tightening torques must be observed for the specifiedbolted connections:

Tightening torques [Nm] Position Part num-ber

TPS44 TPS48 TPS52 TPS57 TPS61

1 72020 60 Nm 60 Nm 60 Nm 60 Nm 60 Nm2 42008 6 Nm 10 Nm 10 Nm 20 Nm 40 Nm5 52433 20 Nm 20 Nm 40 Nm 65 Nm 65 Nm6 51007 25 Nm 25 Nm 45 Nm 75 Nm 75 Nm9 72011 35 Nm 35 Nm 70 Nm 105 Nm 170 Nm

10 86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm

Pag

e 10

0 /

113

Operation Manual / TPS44-F.. - TPS61-F..9 Taking out of operation / 9.1 Shutting down the turbocharger


9 Taking out of operation

9.1 Shutting down the turbocharger If the turbocharger is damaged and the engine can be shut down for onlya short time for emergency repairs, proceed as follows:

u Fit the cover plate.

CAUTIONAlways heed precisely the engine builder's instructions in case of en-gine operation with a blocked / throttled turbocharger!

Dismantling the turbocharger

u Dismantle the turbocharger (see the section Dismantling and fittingthe turbocharger).

u Do not dismantle the nozzle ring.Pa

ge

101

/ 11

3



Fitting the cover plate

u Close the opening in the turbine casing using the cover plate (A).

u Fasten the cover plate on the turbine casing (51000) using the fasten-ing strips (51002), Verbus Ripp® Verbusripp washers (51003) and nuts(51007) and screw it down securely on the support.

NOTICEThoroughly clean the fastening strips (51002) before fitting them. Applyhigh-temperature grease to the stud threads (51006).

Pag

e 10

2 /

113



Cover plate drawing

The cover is not included in the scope of delivery of ABB and must bemanufactured by the operator according to the following drawing.

Material: Common structural steel, in compliance with DIN EN 10025-2

Product B1±0.5

B2 B3 B4±0.2

B5 B6

TPS44 62.6 54 110 11.0 1 144TPS48 65.7 60 130 11.7 1.5 150TPS52 79.6 78 155 14.2 1.5 180TPS57 98.2 100 190 17.2 2 220TPS61 116.8 120 226 20.5 2.4 260

Product B7 ØD1±0.2

ØD1*±0.2

ØD2 R1 M

TPS44 191.3 191.3 17 ≤88 M8TPS48 35.7 222.7 227.7 17 ≤105 M8TPS52 39.6 265.7 271.7 21 ≤125 M8TPS57 48.2 325.7 332.5 21 ≤153 M10TPS61 56.8 387.7 395.9 25 ≤182 M10

Dimensions in [mm]

Pag

e 10

3 /

113



*) Diameter for turbine casing designs for optional C-ring sealing

NOTICEInformation about the turbine casing design (with / without C-ringsealing) can be requested from an ABB Turbocharging Service Station.

Pag

e 10

4 /

113

Operation Manual / TPS44-F.. - TPS61-F..10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-tion for up to 12 months


10 Mothballing the turbocharger

10.1 Taking the engine out of operation for up to12 months

Condition of engine lubricating oil

The turbocharger normally remains mounted on the engine. Mothballinga turbocharger depends on the condition of the lubricating oil:

¡ If the total acid number (TAN) is lower than 2 mg KOH/g, no meas-ures have to be taken.

¡ If the engine lubricating oil is replaced by preserving oil before takingthe engine out of operation and this is circulated by the pre-lubrica-tion pump, no measures have to be taken. Any remaining old engineoil will therefore be flushed away and the bearing sections largelyprotected against corrosion.

Mothballing measures










Pag

e 10

5 /

113

Operation Manual / TPS44-F.. - TPS61-F..10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-ation for more than 12 months


If the total acid number (TAN) is greater than 2 mg KOH/g, the followingmothballing measures are necessary after taking an engine out of opera-tion:

u Dismantle the turbocharger.

u The rotor and the bearing parts must be removed by an official ABBTurbocharging service station and refitted afterwards.

u Clean all parts.

u Machined, bright surfaces of steel and cast parts must be oiled withanticorrosive oil.

u Reassemble complete turbocharger.

Rotor turning in stack draught

If the rotor turns as a result of the stack draught:

u Install blind flange between compressor casing outlet flange andcharge air duct.

10.2 Taking the engine out of operation for morethan 12 monthsIf the engine is taken out of operation, the following variants are pos-sible with regard to the turbocharger:

¡ The turbocharger remains mounted on the engine.

¡ The turbocharger casing remains mounted on the engine, but the ro-tor and the bearing parts are removed and stored separately by anABB Turbocharging Service Station.

¡ The turbocharger is removed completely, either as a whole or in indi-vidual parts.

See the section Taking out of operation for up to 12 months, underMothballing measures, for the measures always necessary when moth-balling turbocharger parts.

If the turbocharger remains mounted on the engine, refer to the sectionTaking out of operation for up to 12 months, under Rotor turning instack draught.

If the entire turbocharger is removed, or if the turbocharger is re-as-sembled from the individual components thereof:

u Close all turbocharger openings using wooden covers and paraffinpaper.

Only dry rooms with 40 ... 70 % atmospheric humidity, in which no watercondensation can form, are suitable as storage locations.

Pag

e 10

6 /

113

Operation Manual / TPS44-F.. - TPS61-F..10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-ation for more than 12 months


Condition of the mothballed turbocharger

u Check the mothballed turbocharger parts for corrosion once per an-num.

u If there are signs of rust: Clean parts thoroughly and renew protectionagainst corrosion.

Pag

e 10

7 /

113

Operation Manual / TPS44-F.. - TPS61-F..11 Disposing of turbocharger components /


11 Disposing of turbochargercomponents

WARNINGHandling damaged thermal insulationDamaged thermal insulation can lead to dust exposure. The glass fibrescan cause mechanical irritation of the eyes, skin, and respiratory tracts.

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

u Wear a respiratory mask to protect against dusts (P1 or P2 mask).





Disposal must be environmentally compatible, professional, and in com-pliance with locally applicable regulations.

The turbocharger consists largely of metal (cast iron materials, steel,nickel-steel alloys, aluminium and bearing brass).

Further components are: Non-metallic materials (filter components offelt and polyethylene), lubricants (engine oil), electronic parts (speedsensor and associated components), and thermal insulation.

u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

u Dispose of thermal insulation as hazardous waste.

Pag

e 10

8 /

113

Operation Manual / TPS44-F.. - TPS61-F..12 Spare parts / 12.1 Ordering spare parts


12 Spare parts

12.1 Ordering spare partsWhen making inquiries or ordering spare parts, the following data mustbe specified:

¡ Turbocharger type

¡ Serial number (HT……)

¡ Designation and part number.

Spare parts can be ordered from an official ABB Turbocharging servicestation.

u If different design versions have not been taken into consideration inthis document, please contact an ABB Turbocharging service station.

CAUTIONStorage of spare partsAll spare parts ordered with the turbocharger must be kept completeand ready for use.

u Parts showing signs of rust should be carefully cleaned and greased.

u Dispose of replaced and unusable parts in a professional and environ-mentally compatible way.

Customer spare part set (97070)

The customer spare part set (97070) is required for the work describedin this Operation Manual.

Quantity Description Part number1 Socket screw 420081 O-ring 420121 Gasket 52406 *1 O-ring 770052 Counter-sunk screw 720411 O-ring 81010/ 82010

* This gasket can only be installed when a gas outlet casing from ABB isused.

Pag

e 10

9 /

113

Operation Manual / TPS44-F.. - TPS61-F..12 Spare parts / 12.2 View of turbocharger showing part numbers


12.2 View of turbocharger showing part numbers

(……) only available in customer spare part set (97070).

Pag

e 11

0 /

113

Operation Manual / TPS44-F.. - TPS61-F..12 Spare parts / 12.2 View of turbocharger showing part numbers


Part number Description10900 Cartridge group42008 (in customer spare part set) Socket screw42012 (in customer spare part set) O-ring51000 Turbine casing51002 Fastening strips51100 Exhaust bend51105* Metal C-ring52400 Gas outlet flange52406 (in customer spare part set) Gasket52408* Metal C-ring56001 Nozzle ring57200 Burst protection57210 Burst ring72000 Compressor casing72011 Socket screw72012 Fastening strips72020 V-clamp72041 (in customer spare part set) Counter-sunk screw with cross slot-

ted head77000 Wall insert77005 (in customer spare part set) O-ring79000 Diffuser81000 Filter silencer81010 (in customer spare part set) O-ring82000 Axial air suction branch82010 (in customer spare part set) O-ring86505(A)* Speed sensor (cable not integrated)86505(B)* Speed sensor (cable integrated)86515(A)* Cable connector for 86505(A)86515(B)* Cable connector for 86505(B)86526* F/I converter86528* Tachometer

* depends on the turbocharger specification.Pa

ge

111

/ 11

3

Operation Manual / TPS44-F.. - TPS61-F..12 Spare parts / 12.3 View of cartridge group showing part numbers


12.3 View of cartridge group showing part numbers

Pag

e 11

2 /

113

Operation Manual / TPS44-F.. - TPS61-F..12 Spare parts / 12.3 View of cartridge group showing part numbers


Part number Description21000 Shaft21002 Piston ring25000 Compressor wheel32101 Plain bearing bush32103 Locking ring32105 Thrust ring32106 Thrust bearing32108 Piston ring32109 Sealing disc32110 Bearing flange32111 Auxiliary bearing32112 Bearing flange32113 Socket screw32114 Socket screw32221 Bearing cover32222 O-ring42001 Bearing casing42002 Socket screw42008 (in customer spare part set) Socket screw43001 Partition wall43012* Metal C-ring

* depends on the turbocharger specification.

Pag

e 11

3 /

113

ABB Switzerland LtdTurbochargingBruggerstrasse 71aCH-5401 BadenSwitzerland

Date post:	12-Jul-2020
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times

neues Deckblatt mit Textbaustein · 1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :...

Documents