ABB TPL71 C35 User Manual

Operation Manual

TPL71-C35

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPL71-C35

n_Mmax404

HT587584

650

620

Mmax

Bmax

1/s

°C

n_Bmax383

02040 kg 35

Application according to

the Operation Manual

Year 2019

made in Switzerland

ABB Turbocharging

ꢀꢁꢁ

Operation Manual / TPL67-C.. - TPL71-C..

Table of contents

Operation Manual

Preliminary remarks................................................................................................. 3

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Purpose of this manual.................................................................................................. 3

Layout and function........................................................................................................ 4

Intended use..................................................................................................................... 6

Storage of new turbochargers and spare parts ....................................................... 8

Essential information................................................................................................... 10

Symbols and definitions.............................................................................................. 12

Turbocharger rating plate........................................................................................... 13

Contact information..................................................................................................... 14

Safety....................................................................................................................... 15

Introduction ................................................................................................................... 15

CE conformity ................................................................................................................ 15

Definition of mandatory signs ................................................................................... 16

Definition of Safety instructions ............................................................................... 16

Warning plates on the turbocharger......................................................................... 17

Safe operation and maintenance............................................................................... 18

Hazards during operation and maintenance........................................................... 21

Periodic checking of the pressure vessel................................................................. 26

Lifting loads ................................................................................................................... 26

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

Commissioning...................................................................................................... 28

Oil supply ........................................................................................................................ 28

Inspection work............................................................................................................. 31

Commissioning after taking out of operation........................................................ 33

3.1

3.2

3.3

Operation ............................................................................................................... 34

Noise emissions ............................................................................................................ 34

Servicing work ............................................................................................................... 36

Replacement intervals for turbocharger components.......................................... 39

Speed measurement .................................................................................................... 41

Stopping the engine.................................................................................................... 45

4.1

4.2

4.3

4.4

4.5

Maintenance .......................................................................................................... 46

Foreword to Maintenance .......................................................................................... 46

Cleaning the filter silencer........................................................................................... 47

Cleaning the compressor during operation ........................................................... 50

Cleaning turbine blades and nozzle ring in operation........................................... 56

Cleaning components mechanically.......................................................................... 61

5.1

5.2

5.3

5.4

5.5

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Table of contents

Troubleshooting.................................................................................................... 70

6.1

6.2

6.3

6.4

6.5

Malfunctions when starting........................................................................................ 70

Surging of the turbocharger....................................................................................... 71

Malfunctions during operation .................................................................................. 72

Malfunctions when stopping...................................................................................... 75

Speed measurement system ...................................................................................... 76

Removal and installation....................................................................................... 77

Turbocharger weights.................................................................................................. 77

Removing the turbocharger........................................................................................ 78

Installing the turbocharger ........................................................................................ 80

7.1

7.2

7.3

Disassembly and assembly.................................................................................. 81

Introduction ................................................................................................................... 81

Module weights ............................................................................................................. 83

Removing and fitting filter silencer or air suction branch.................................... 85

Axial clearance ............................................................................................................... 87

Removing cartridge group .......................................................................................... 87

Dismantling and installing the turbine diffuser and nozzle ring......................... 92

Installing cartridge group............................................................................................ 95

Dismantling and fitting nozzle ring at turbine end............................................. 100

Table of tightening torques..................................................................................... 104

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

8.9

Taking out of operation at short notice .......................................................... 106

Possibilities for emergency repair.......................................................................... 106

Locking the rotor......................................................................................................... 107

Fitting the cover plate................................................................................................. 111

Blocking the inlets and outlets................................................................................. 115

Bypass the turbocharger........................................................................................... 115

9.1

9.2

9.3

9.4

9.5

10.1

10.2

Mothballing turbocharger................................................................................... 116

Taking out of operation for up to 12 months........................................................ 116

Taking out of operation for more than 12 months............................................... 117

Disposing of turbocharger components........................................................... 118

Spare parts............................................................................................................ 119

Ordering spare parts.................................................................................................. 119

View of turbocharger with part numbers .............................................................. 122

View of turbine cleaning system with part numbers (optional)........................ 124

12.1

12.2

12.3

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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 identical

serial number (01), see the cover sheet of the Operation Manual and the

turbocharger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the tur-

bocharger supplied by ABB Turbo Systems and to use it as intended.

It provides important information in order that the turbocharger can be

operated safely, correctly and efficiently.

This Operation Manual complements and expands existing 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 turbocharger

installed on it.

Availability of operation manual

An operation manual must be available at all times at the place where

the turbocharger is used.

Everyone who operates or works on the turbocharger must have first

read and understood the operation manual.

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1 Preliminary remarks / 1.2 Layout and function

1.2 Layout and function

TPL67/71-C

01Filter silencer

08Nozzle ring

02Radial plain bearing

03Thrust bearing

04Bearing bush

09Turbine wheel

10Bearing casing

11Diffuser

05Radial plain bearing

06Gas outlet casing

07Gas inlet casing

12Compressor wheel

13Compressor casing

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1 Preliminary remarks / 1.2 Layout and function

Mode of operation

The turbocharger is a turbomachine and consists of the following main

components:

Turbine

Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet cas-

ing (07) and nozzle ring (08) to the turbine wheel.

The turbine wheel (09) uses the energy contained in the exhaust gas to

drive the compressor wheel (12). The compressor then draws in fresh air,

compresses it and then forces it into the cylinders.

The exhaust gases escape to free air through an exhaust gas pipe which

is connected to the gas outlet casing (06).

The air which is necessary for operation of the diesel engine and is com-

pressed in the turbocharger is drawn through the suction branch or the

filter silencer (01) into the compressor wheel (12). This air then passes

through the diffuser (11) and leaves the turbocharger through the com-

pressor casing (13).

The rotor runs in two radial plain bearings (02/05). One plain bearing is

in the bearing bush (04), and the second one is in the axial thrust bearing

(03) at the compressor end.

The plain bearings are connected to a central lubricating oil duct which is

fed with oil from the engine's lubricating oil circuit. The oil outlet is al-

ways at the lowest point of the bearing casing (10).

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is

provided with a compressor wheel cooling system. Com-

pressor wheel cooling means that, after the charge air

cooler at the engine end, cooled compressor air is de-

livered to the turbocharger to cool the compressor

wheel.

In view of the respective operating conditions, it is ab-

solutely essential that the compressor wheel is cooled in

order to guarantee its reliability and replacement inter-

vals. In the case of the turbocharger version with com-

pressor wheel cooling, the cooling air is supplied

through the side connection (15) in the bearing casing.

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1 Preliminary remarks / 1.3 Intended use

1.3 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging internal combustion

engines.

To ensure compliance with the machinery directive 2006/42/EC when

using on gas engines, the turbocharger must be operated in an engine

room classified as "not at risk of explosion". This is in accordance with

the position paper [2] relating to ATEX issued by EUROMOT [1].

The turbocharger supplies the engine with the air volume or air/gas mix-

ture and the associated charging pressure required for operation.

The turbocharger is solely intended to be operated with a clockwise dir-

ection of rotation as viewed from the turbine end.

The specific operating limits of the turbocharger were determined on

the basis of information from the enginebuilder about the intended use.

These data are given on the rating plate.

ABB Turbo Systems accepts no liability and rejects all warranty claims

for any non-intended uses.

[1]Euromot = The European Association of Internal Combustion Engine

Manufacturers

[2]Directive 94/9/EC concerning equipment and protective systems in-

tended for use in potentially explosive atmospheres (ATEX) The Eur-

omot Position as of November 2003, ATEX Euromot Position 191103

WARNING

Unapproved operation

Any operation of the turbocharger outside of its operating limits can be

hazardous to personnel.

u The turbocharger must only be operated within the operating limits.

u Only trained personnel must operate the turbocharger.

The intended use of the turbocharger includes compliance with all regu-

lations and conditions. In particular, the following must be observed:

Operation Manual

Instructions of the enginebuilder

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1 Preliminary remarks / 1.3 Intended use

State of the art

The turbocharger is designed and built according to the state of the art

and is safe to operate.

Flawless condition

The turbocharger must only be used when it is in a technically flawless

condition and operated in compliance with its intended use.

ABB Turbo Systems excludes any liability for damage resulting from un-

authorized modifications to the turbocharger or improper operation.

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1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

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 Turbo Systems can be

stored in sealed packaging without additional mothballing measures for

up to 6 months from the date of delivery (marked by the VCI label on the

package).

Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and

no condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6

months (VCI)

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-

stances Ordinance. Nevertheless, the following points are to be ob-

served when handling VCIs:

u Ensure good room ventilation.

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

VCIs.

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 and

replace it with a new, identical VCI corrosion protection emitter. New

VCI 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 with

local regulations.

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

permanent the protection.

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1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB

Turbo Systems for prolonged storage. The package is equipped with a

hygrometer (see illustration).

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. When

the display field has changed colour at the 70% level, the maximum

permissible humidity has been exceeded. In this case the turbochar-

ger or rotor must be inspected by an ABB Turbocharging Service Sta-

tion and repacked.

u Inspect the package for damage. If the package is damaged, the tur-

bocharger or cartridge group must be inspected by an ABB Tur-

bocharging Service Station and repacked.

After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:

Inspect the components

Exchange the desiccant agent

Repackage the components.

NOTICE

Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour

and the package is undamaged, the replacement turbocharger or re-

placement cartridge group can be placed into operation without any

prior testing by an ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from

the VCI package.

To avoid the formation of condensation, the surroundings and the con-

tent of the package must have the same temperature during unpacking.

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1 Preliminary remarks / 1.5 Essential information

1.5 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulations

for the prevention of accidents and for environmental protection in the

country of use must also be observed.

This also applies to the provision and wearing of personal protective

equipment.

NOTICE

The manner in which personnel work on and with the turbocharger with

regard to safety and risks is to be checked on a regular basis in accord-

ance with the Operation Manual.

u The turbocharger must be shut down immediately in the event of

modifications affecting safety or of corresponding operating beha-

viour by stopping the engine. The fault should be reported to the per-

son or department responsible.

NOTICE

Any modifications, additions or conversions made to the turbocharger,

which could impair safety, require the prior approval of ABB Turbo Sys-

tems.

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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.

WARNING

Use original parts

Operation of the turbocharger with non-original parts can impair the

safety of the turbocharger and can cause serious damage to property

and 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 information

on questions regarding a design variant (see Contact information at

www.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for

ease 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 ®.

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1 Preliminary remarks / 1.6 Symbols and definitions

1.6 Symbols and definitions

The 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

NOTICE

Note

A 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 Turbo Systems

In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo

Systems.

Official ABB Turbo Systems Service Stations

In this document, official service stations are referred to as ABB Tur-

bocharging Service Stations. They are inspected and certified regularly

by ABB Turbo Systems. See also chapter Contact information →14.

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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 the

enginebuilder.

02 Turbocharger operating limits during operation

Recommended replace-

ment intervals for tur-

bocharger components

03 Replacement interval for plain bearings in 1000 h

04 Replacement interval for compressor in 1000 h

05 Replacement interval for turbine in 1000 h

Further information

06 Part number for customer

07 Designation of special design

08 Turbocharger weight in kg

09 Turbocharger type

10 Serial number

11 Year of turbocharger construction

12 Manufacturing plant

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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 n_Bmax, t_Bmaxcan considerably shorten

the recommended replacement intervals. In such cases, we recommend that

you contact the nearest official ABB Turbocharging service station.

n_Mmaxand t_Mmaxnormally apply only when running at overload (110%) during

trials on the engine test bed. These limits can also be permitted during op-

eration for special applications. Operation above n_Mmaxand t_Mmaxis not per-

mitted.

Non-observance of the recommended replacement intervals can increase

the risk of unpredictable component failures.

1.7.2 Positions of the rating plates

A rating plate is attached to the turbocharger foot, one on the left and

one on the right. On turbochargers with insulation from ABB, at least one

additional rating plate is attached to the insulation of the gas outlet cas-

ing.

1.8 Contact information

Contact information for the official service stations of ABB Turbo Sys-

tems is available online.

u Scan the QR code to access our website.

ABB Turbo Systems Ltd

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

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2 Safety / 2.1 Introduction

2 Safety

2.1 Introduction

Turbochargers manufactured by ABB are state of the art and comply

with 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 exist

which:

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 of

maintenance and inspection work.

The operating company is responsible for access to the turbocharger as

well as the organisational measures that regulate the safe handling of

the turbocharger by its personnel.

All instructions contained in this chapter must be observed for safe and

trouble-free operation of the turbocharger and during all work on the

turbocharger.

All further safety instructions contained and specifically identified in

every chapter of this manual (see section Definition of Safety Instruc-

tions) must also be observed.

2.2 CE conformity

Information

ABB turbochargers fulfil Directive 2006/42/EC on machinery and are

considered partly completed machinery in the sense of Article 2 g.

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2 Safety / 2.3 Definition of mandatory signs

2.3 Definition of mandatory signs

To be worn at all times

Protective clothing

Safety footwear to pro-

tect against mechanical

hazard and risk of fall-

ing

To be worn according to the specific work

Safety glasses

Safety goggles

Safety gloves against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Respiratory mask

against

- Dusts

- Gases

Safety helmet

Ear protection

2.4 Definition of Safety instructions

The following symbols and terms used in this manual concern safety or

refer to possible hazards:

WARNING

Definition of warning

Serious personal injuries and even accidents with fatal consequences

may occur if work and operating instructions marked with this symbol

and the word WARNING are either not followed or not followed pre-

cisely.

u Warning signs must be observed at all times.

CAUTION

Definition of caution

Serious machine or property damage may occur if work and operating

instructions marked with this symbol and the word CAUTION are either

not followed or not followed precisely.

u Caution signs must be observed at all times.

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2 Safety / 2.5 Warning plates on the turbocharger

2.5 Warning plates on the turbocharger

Warning plates that must be observed are attached to the turbocharger.

The warning plates must always be present in the intended locations

and must be legible.

Part number

Size [mm]

Product

81080

105 x 74

TPL / TPR

When uninsulated turbochargers are delivered to the engine builder, the

warning plates must be subsequently attached to the insulation. This is

the responsibility of the engine builder.

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2 Safety / 2.6 Safe operation and maintenance

2.6 Safe operation and maintenance

The instructions specified in this section are for the safety of personnel.

Together with the instructions in the Hazards during operation and

maintenance section, they allow the user to safely use the turbocharger.

Work safety and work area safety

WARNING

Risk of falling

There 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 use

these as climbing aids.

u When working at levels above the head, use climbing aids and work

platforms 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 mental

stress.

u Work only with suitable tools as well as equipment and working ma-

terials that are in perfect condition.

u Electric tools must be solidly earthed, and connecting cables may not

be damaged.

u Keep the workplace clean, clear away loose objects and remove

obstacles on the floor.

u Keep the floor, equipment and the turbocharger clean.

u Have oil binding materials ready at hand and keep oil catch pans

ready or in position

u Eliminate leaks.

u Keep fire-protection materials and fire-extinguishing equipment

ready.

Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, al-

ways cover the filter silencer to prevent the filter mat from being

damaged.

u Keep flammable objects and substances out of the range of flying

sparks.

u Cover all connections on the turbocharger so that no foreign objects

can enter the turbocharger.

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

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2 Safety / 2.6 Safe operation and maintenance

Safety during start-up / commissioning and operation

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

u Remove any obstacles and objects lying around.

u Before start-up / commissioning, check all pipes from and to tur-

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, inspect

turbocharger 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 from

supplying these power sources.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding

material 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 or

solvent.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Inspect the electric cables for abrasion and damage before and after

your cleaning work.

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2 Safety / 2.6 Safe operation and maintenance

Safety during disassembly, assembly, maintenance and

troubleshooting

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 before

beginning.

u Before opening a cover or removing a protective device on a tur-

bocharger, the engine must be switched off and the turbocharger

must have come to a standstill.

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

oil supply.

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

properly.

CAUTION

Mechanical work on the turbocharger

Possible 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 from

the 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.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

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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.

WARNING

Risk of injury

Contact with rotating parts can lead to serious injuries. The turbochar-

ger must never be operated without a filter silencer or an air suction

branch. When the engine is at a standstill, the rotor can turn on its own

because 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 improper

handling of components, through the non-observance of work instruc-

tions, due to inadequate care or as a consequence of insufficient train-

ing.

WARNING

Mechanical hazard

Severe 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 of

accidents.

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.

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2 Safety / 2.7 Hazards during operation and maintenance

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.

WARNING

Hazards due to noise

Noise 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 ear

protection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well as

operating materials (lubricating oil) become hot. The surface temperat-

ure is dependent on the effectiveness of the insulation being used. The

temperature can become high enough so that it falls into ranges where

burns are possible.

WARNING

Risk of burning

Touching hot surfaces or contact with hot operating materials can lead

to 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.

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2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).

The turbocharger is supplied with or without insulation in accordance

with the purchase order received from the enginebuilder. If supply is

without insulation, the enginebuilder is responsible for providing the

turbocharger with proper insulation and for providing protection

against 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 or

the execution of maintenance work. Oils, greases, coolants, cleaning

agents and solvents, acids, etc. can be regarded as hazardous materials.

Operating and auxiliary materials can be combustible and easily ignited.

WARNING

Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials

or 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 safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Risk of fire, explosion

Flammable and combustible operating materials and supplies can

catch fire or resulting vapours can lead to an explosion.

u Observe the details in the 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 cleaning

work.

u Carry out cleaning in the open or provide sufficient aeration and

ventilation.

CAUTION

Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or

contamination of the ground and water due to improper disposal can

lead to environmental damage.

u Handle operating and auxiliary materials carefully.

u Heed the instructions for use, safety data sheets and hazard notices

on 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 an

environmentally compatible manner in accordance with statutory reg-

ulations.

u In the event of leaks or after spilling, immediately spread a suitable

binding agent and dispose of it properly and in an environmentally

compatible manner in accordance with statutory regulations.

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2 Safety / 2.7 Hazards during operation and maintenance

Hazards when handling insulating materials

WARNING

Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health

or irritations. Unsuitable, combustible insulating materials signify a fire

hazard.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Avoid stirring up dust.

u Use tools and processes which keep 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 environmentally

compatible way in accordance with applicable local regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

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 environmentally

compatible way in accordance with applicable local regulations.

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2 Safety / 2.8 Periodic checking of the pressure vessel

Hazards due to electrical components

WARNING

Hazards due to electrical components

Electrical components operate with voltages which can present hazards

to humans.

u All work on or with electrical components may only be performed by

trained specialists.

u Heed any country-specific regulations.

2.8 Periodic checking of the pressure vessel

The 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 of

the pressure vessels must be observed.

The operating company is responsible for the safe operation of the

pressure vessel.

WARNING

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in

proper working condition and monitor them. Necessary repair or main-

tenance work must be carried out without delay and the required safety

precautions must be taken.

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

2.9 Lifting loads

WARNING

Suspended loads

Loads 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 gear

with 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.

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2 Safety / 2.9 Lifting loads

In the case of two or more suspension points, the slinging angle must

not exceed 45°. This avoids excessive loading due to inclined tensile

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 that

they 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.

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3 Commissioning / 3.1 Oil supply

3 Commissioning

3.1 Oil supply

A 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.

NOTICE

With regard to the oil supply, please observe the engine builder's spe-

cifications for lubricating oil selection, oil change intervals, oil filtration,

oil pressure and oil temperature.

Oil filtration

Filtration of the lubricating oil using a filter mesh size ≤ 0.034 mm is ad-

equate for TPL67-C turbochargers and a mesh size ≤0.050 mm for

TPL71-C turbochargers.

NOTICE

This filtration can also be carried out using an additional self-cleaning

fine filter.

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3 Commissioning / 3.1 Oil supply

Oil pressure

The oil pressure in front of the turbocharger must be maintained pre-

cisely to ensure trouble-free operation.

The permissible oil pressure ranges at measuring point M (blind connec-

tion) on the turbocharger are listed below.

Status for operation

Oil pressure at measuring

point M

p_oil,in[bar]

Permissible, for normal operation

Permissible, during engine warm-up

Temporarily admissible ( < 1 h ) -> alarm

Not permissible -> emergency stop

1.3 … 2.5

1.3 … 5.0

1.1 … 1.3

0.0 … 1.1

0.2 … 2.5

Permissible, during pre- and post-lubrication

(engine stopped)

Oil orifice

A metering orifice is installed in the oil inlet of the turbocharger to en-

sure these oil pressures. The orifice is installed by the enginebuilder and

it is fixed in place with a locking ring.

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3 Commissioning / 3.1 Oil supply

Lubricating oil temperature at the inlet

CAUTION

Machine damage

If the oil temperature at the oil inlet exceeds the admissible range, this

may lead to engine damage.

u Observe oil temperature at the oil inlet according to the following

table.

Oil temperature at the

inlet

T_oil,inlet[°C]

30 … 90

> 90

Status for operation

Permissible

Temporarily permissible (< 1h) -> alarm

Not permissible -> stop the engine

> 95

Not permissible -> Do not start the engine

< 30

(before starting: preheat the oil)

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:

Lubricating oil temperature and pressure at the oil inlet

Engine load and turbocharger speed

Exhaust gas temperature

The maximum admissible oil temperature at the outlet is listed in the fol-

lowing table. The specified oil outlet temperature is to be considered as

alarm value for the turbocharger operation and must be monitored ac-

cording to the current regulations.

Oil temperature at the outlet

Status for operation

T_oil,outlet[°C]

Permissible

≤ 140

Temporarily permissible -> alarm

Not permissible -> stop the engine

> 140

> 160

If the turbocharger was operated for a longer period of time outside of

the admissible range, ABB Turbo Systems recommends to have the tur-

bocharger inspected by an ABB Turbocharging Service Station.

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3 Commissioning / 3.2 Inspection work

3.2 Inspection work

Inspection work includes preventive visual controls plus monitoring and

measuring work before and during commissioning. Inspections help de-

tect changes to the turbocharger. 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.

CAUTION

Contaminated oil

Particles of dirt and solid matter in the oil can cause serious damage to

the machine or property.

u During initial commissioning and after all service work, the complete

lubricating system 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.

CAUTION

Prelubrication

Serious machine or property damage might result if the turbocharger is

not 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.

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3 Commissioning / 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 engine

performance 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.

NOTICE

Lubricants and pastes used during assembly of the turbocharger li-

quefy or vaporise and might escape as an oily liquid in the first few

hours after commissioning. If oily liquid continues to escape after this

period, 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.

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3 Commissioning / 3.3 Commissioning after taking out of operation

3.3 Commissioning after taking out of operation

If 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 any

combustion deposits, foreign matter or residual water. Clean and re-

move.

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

and 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.

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4 Operation / 4.1 Noise emissions

4 Operation

4.1 Noise emissions

WARNING

Hazards due to noise

Noise 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 ear

protection.

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 of

105 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 the

charge air / scavenging air line and the charge air cooler.

Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :

A-weighted emission sound pressure level

In the event of divergent insulation designs, the engine builder must

ensure that equivalent acoustic insulating measures are taken.

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4 Operation / 4.1 Noise emissions

Suggestion for noise insulation of the bellows

01 Compressor casing

02 Bellows

04 Insulation pads

05 Insulation mat (at least 15 mm)

03 Charge air duct / scavenging 06 Sheet metal cover

air line

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4 Operation / 4.2 Servicing work

4.2 Servicing work

Service work to be carried out during operation involves visual checks,

monitoring, measuring, inspection work and functional checks. It is then

possible 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.

CAUTION

Service intervals

Service work on the turbocharger that is neglected or carried out too

late can lead to excessive contamination and wear as well as operating

failures.

u Carry out service work at specified time intervals.

CAUTION

Shortened service intervals

Despite observance of the service intervals, unusual loads, such as sev-

eral start-stops a day, harsh environmental factors, poor fuel quality or

heavy installation vibration can lead to premature machine damage.

u A shortened service interval must be arranged with ABB Turbo Sys-

tems.

NOTICE

Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection

by an ABB Turbocharging Service Station is recommended at the latest

5 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.

CAUTION

Unknown changes during operation

The consequences can range from an impairment to a breakdown.

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

tion.

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4 Operation / 4.2 Servicing work

4.2.2 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

Air temperature behind compressor and charge air cooler

Turbocharger speed

If provided

Pressure loss in air filter

4.2.3 Servicing work according to the engine

manufacturer's instructions

Oil filter

u Clean or replace oil filter in supply line to turbocharger when engine is

not running.

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4 Operation / 4.2 Servicing work

4.2.4 Service work every 8000 … 12000 hours

The inspection and assessment of the rotor and the bearing parts must

be carried out by an official ABB Turbocharging service station.

u Disassemble turbocharger.

u Measure clearances.

u Clean the turbine and compressor wheels and inspect for damage.

u Clean the turbine and compressor casings and inspect for any cracks

and erosion or corrosion.

u Clean bearing casing and blow air through oil ports.

u Clean nozzle ring and check for cracks and erosion.

u Inspect and assess bearing parts and rotor.

4.2.5 Service work every 24000 … 36000 hours

The replacement of bearing parts and the inspection and assessment of

the rotor must be carried out by an ABB Turbocharging Service Station.

u Disassemble turbocharger.

u Clearance measurement.

u Clean the turbine and compressor wheels and inspect for damage.

u Clean turbine casing as well as compressor casing and check for any

cracks and erosion or corrosion.

u Clean bearing casing and blow air through oil ports.

u Clean nozzle ring and check for cracks and erosion.

u Dismantle, inspect and balance the rotor.

u Replace plain bearings with original parts from ABB Turbo Systems.

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4 Operation / 4.3 Replacement intervals for turbocharger components

4.3 Replacement intervals for turbocharger

components

Rotating components

The recommended replacement intervals for the compressor and turbine

wheels due to stress caused by centrifugal forces and load cycles are cal-

culated under consideration of the operating conditions while applying

the safety concept for rotating components. They can be found on the

turbocharger rating plate. Incalculable influencing parameters can

shorten the recommended replacement intervals for the rotor, see Influ-

encing parameters.

Non-rotating components

The expected replacement intervals for non-rotating components and

bearing parts are extremely dependent upon system-specific operating

conditions, see Influencing parameters.

When the specified, periodic inspections are carried out, the individual

components are inspected for wear and tear and replaced if necessary.

In this way, trouble-free operation is ensured.

Influencing parameters

The following parameters influence the replacement intervals for tur-

bocharger components:

Parameters influencing bearing parts

Poor quality of the lubricating oil (lubrication oil filter system, condi-

tion of lubricating oil)

Unusual loads (vibration, start/stop frequency)

Non-permissible state of rotor unbalance

Parameters influencing non-rotating components exposed to

exhaust gas

Fuel quality (gas, MDO, HFO)

Load profile (thermal load changes, number of starts/stops)

Temperature level of exhaust gas

Turbine cleaning frequency

Procedure for turbine cleaning

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4 Operation / 4.3 Replacement intervals for turbocharger components

Parameters influencing rotating components exposed to exhaust

gas

Fuel quality (gas, MDO, HFO)

Turbine cleaning frequency

Procedure for turbine cleaning

Load profile

Expected replacement in-

tervals [h]

Component

Gas inlet casing

Gas outlet casing

Nozzle ring

Turbine diffuser / cover ring

Other casings

GAS / MDO

50000 … 100000

35000 … 50000

100000

HFO

25000 … 50000

35000 … 100000

25000 … 50000

100000

Axial bearing components

Radial bearing components

24000 … 36000

- -

24000 … 36000

≥ 12000

Turbine blades

(due to wear)

Recommended replace-

ment intervals [h]

Rotor components

See rating plate information

GAS

MDO

HFO

= Gas Engine

= Marine Diesel Oil

= Heavy Fuel Oil

NOTICE

The specified values are guides and not guaranteed. (See Influencing

parameters.)

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4 Operation / 4.4 Speed measurement

4.4 Speed measurement

A speed measuring system permits continuous monitoring of the tur-

bocharger speed.

CAUTION

Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be

pulled out.

u Do not tension the speed measurement cables.

Part number

42047

Description

Screw plug

86505

86515

86526

Speed sensor

Cable connector for 86505

F/I converter

86528

Tachometer

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4 Operation / 4.4 Speed measurement

4.4.1 Speed differences with multiple turbochargers per

engine

The speeds of all turbochargers on one engine differ only slightly from

each other in normal operation.

The difference between the highest and the lowest turbocharger speed

must not be more than 3 % relative to the speed limit n_Bmax

If this permissible range of difference is exceeded, the following steps

must be carried out:

u Reduce engine performance immediately until the highest turbochar-

ger speed no longer exceeds 70% of n_Bmax

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 be

reduced 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 eliminate

any problems.

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

bocharging Service Station.

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4 Operation / 4.4 Speed measurement

4.4.2 Assembly

If the speed sensor is not fitted on the turbocharger, the following pro-

cedure must be adopted to fit it:

w Engine and turbocharger are not running.

w The turbocharger lubricating system is switched off.

u Remove screw plug (42047) from bearing casing.

NOTICE

Part position

The position of the screw plug for measuring the speed is marked "n"

on the bearing casing.

u Screw in speed sensor (86505) as far as it will go and tighten to

torque specified in table. (See chapter Table of tightening torques.)

u Connect speed sensor using cable connector (86515).

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4 Operation / 4.4 Speed measurement

4.4.3 Replacing the speed sensor

WARNING

Hot cable connector and hot speed sensor

Risk of burning. During operation, the cable connector and the speed

sensor can reach temperatures exceeding 100 °C.

u Wear safety gloves when removing the cable connector and speed

sensor.

Wear safety gloves to protect against thermal hazards.

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 to the stop.

u Observe the tightening torque (see the table of tightening torques in

the chapter entitled Disassembly and assembly).

NOTICE

Sealing of the speed sensor

The speed sensor is designed with a sealing lip and does not require

any additional gasket for assembly.

u Connect cable connector to speed sensor.

u Switch on lubricating oil supply to turbocharger.

4.4.4 Failure of speed measuring system

Possible reasons for failure of the speed measuring system are de-

scribed in the chapter Troubleshooting.

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4 Operation / 4.5 Stopping the engine

4.5 Stopping the engine

CAUTION

Stopping the engine

Heat in the turbocharger must be dissipated by the further circulating

lubricating oil.

u Allow the engine to continue running at idling speed for a further 10

minutes before stopping.

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5 Maintenance / 5.1 Foreword to Maintenance

5 Maintenance

5.1 Foreword to Maintenance

Maintenance and servicing work involves regular visual checks and clean-

ing to ensure that the turbocharger and its attached units function

trouble-free.

The external condition and how dirty the cleaning points specified in

this chapter are, must be established by visual checks at the spe-

cified intervals.

The safety precautions must be observed during all maintenance and

servicing work.

The cleaning points described in the following are:

Filter silencer

Compressor

Turbine and nozzle ring

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5 Maintenance / 5.2 Cleaning the filter silencer

5.2 Cleaning the filter silencer

5.2.1 Filter silencer and connecting rod

81265

81269

81266

81272

Filter ring (if provided)

Connecting rods

Cover grid

81136 Absorption segment

81137 Sheet-metal covering

81135 Filter silencer body

81273 Lock nut

Screwdriver

Insert unit = absorption segment + sheetmetal covering

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5 Maintenance / 5.2 Cleaning the filter silencer

Removing and cleaning filter silencer

If provided

u Remove filter strip (81265).

u Rinse filter strip (81265) using water with detergent additive or, if very

dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid

rough treatment (not a jet of water).

NOTICE

How dirty the filter strip (81265) is, depends on how clean the drawn-in

air is. Clean filter strip every 500 hours of service or more frequently if

necessary.

u Unscrew and remove lock nuts (81273).

u Unscrew and remove screws (81272) for connecting rods (81269).

u Remove connecting rods (81269).

u Carefully remove cover grids (81266).

u Pull out insert units (E), bend open sheet-metal coverings (81137) and

then remove absorption segments (81136).

u Clean the absorption segments (81136).

During cleaning, ensure that the absorption segments (81136) are

only cleaned with a mild jet of compressed air, soft brush or a damp

cloth. Otherwise there is a risk of damage or deformation.

NOTICE

Replace heavily contaminated or damaged parts with original parts

from ABB Turbo Systems.

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5 Maintenance / 5.2 Cleaning the filter silencer

Fitting the filter silencer

u Assemble the insert units (E) by inserting the absorption segments

(81136) into the sheet metal coverings (81137).

u Bend sheet metal coverings (81137) back to original shape.

u Insert the insert units (E) into slot guides in filter silencer unit (81135).

u Install cover grids (81266) uniformly and in the correct position.

u Push connecting rods (81269) through the lugs of cover grids (81266).

CAUTION

If connecting rods (81269) are not correctly positioned in their recesses

on filter silencer body (81135), cover grid (81266) can twist and shift.

There is then a risk of foreign matter and contamination getting into

the compressor.

u Join connecting rods (81269) using screws (81272). When tightening

the screws (81272), ensure that connecting rods (81269) are located

correctly in recesses in filter silencer body (81135). Now tighten

screws (81272) alternately until the following maximum torque is

reached:

Screw

Tightening torque [Nm]

81272

u Screw lock nuts (81273) onto screw (81272) and tighten to following

torque:

Lock nut

Tightening torque [Nm]

81273

If provided

u Fit filter strip (81265).

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5 Maintenance / 5.3 Cleaning the compressor during operation

5.3 Cleaning the compressor during operation

Approval by enginebuilder

These instructions for wet cleaning only apply when cleaning is carried

out with clean water and under the precondition that the enginebuilder

approves the process.

General

The contamination of the compressor stage (compressor wheel, wall in-

sert and diffuser) depends on the degree of purity of the air that is

drawn in.

Deposits can form in the flow channels if salt, oil mist, exhaust gas or

dust are sucked in with the air.

Consequences of contamination:

Impaired compressor efficiency

Higher exhaust gas temperatures

Increased fuel consumption

Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays

any major increase in contamination. It does not, however, replace the

regular service work, during which the turbocharger is completely dis-

mantled and the compressor is cleaned mechanically.

Cleaning interval

The interval between periodic cleaning is very dependent on the operat-

ing conditions. In general, cleaning should be carried out every 25 ... 100

operating hours.

Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbo Systems.

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5 Maintenance / 5.3 Cleaning the compressor during operation

Cleaning method

Cleaning of the compressor during operation is carried out using the

cleaning method described in the following:

Wet cleaning

This cleaning method has been tested and approved by ABB Turbo Sys-

tems.

Principle of wet cleaning

To clean the compressor stage during operation, water is injected in

front of the compressor wheel.

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 suitable

process, provided that the degree of contamination is not too high.

CAUTION

Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and

cooling water additives

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

CAUTION

Uncontrolled volumes of water

Uncontrolled volumes of water can damage the turbocharger and the

engine.

u Never connect the water line without the orifice specified for the tur-

bocharger.

CAUTION

Formation of ice at low temperatures

Damage to turbocharger due to the formation of ice during wet clean-

ing if the intake air temperatures are too low.

u Never carry out wet cleaning if intake air temperatures are under

5 °C.

V-engines

In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of the compressors. This cleaning process

is faster and the risk of turbocharger surging is reduced.

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5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)

Operating state prerequisites for wet cleaning XC2

WARNING

Increased stress on material

During cleaning of the compressor at an engine load of 85 to 100 %, the

stress on the material of the compressor-end turbocharger parts can

be increased.

u No personnel is allowed to be present in the vicinity of the tur-

bocharger during compressor cleaning.

u Compressor cleaning must be activated from the engine control

panel.

Wet cleaning procedure for compressor with XC2

u Trigger water injection according to the specifications of the en-

ginebuilder.

u The specified water pressure upstream of the connection to the tur-

bocharger must be maintained.

u Operate engine for at least five additional minutes after cleaning.

Not more than three cleaning cycles should be conducted consecutively.

Cleaning parameters per turbocharger compressor

Product

Engine

load

Water

pressure

[bar]

Water injec- Water tem- Ø orifice

tion time

[sec]

perature

[°C]

[mm]

TPL67-C

TPL71-C

50 …

100%

5 … 50

2.1

2.5

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Surging of the compressor stage

Should repeated surging of the compressor stage occur during com-

pressor cleaning, first the cleaning parameters as well as the engine-side

system must be checked with regard to deviations (e.g. an increased

pressure loss in the charge air cooler) and corrected if necessary.

If, despite correct settings, surging of the compressor stage occurs

while cleaning the compressor, as a remedial measure the engine load

can be reduced further while cleaning the compressor. The reduction of

the engine load can lead to a reduction in the effectiveness of the com-

pressor cleaning.

u To avoid a decreased engine availability, the compressor stage can be

cleaned at reduced engine load during the drying time after wet

cleaning of the turbine has been completed. (see section Wet cleaning

turbine and nozzle ring during operation). In this case, the water injec-

tion time for cleaning the compressor can be increased from ten to

forty seconds.

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5.3.2 Wet cleaning using external water-pressure vessel

(XC3)

Operating state prerequisites for wet cleaning XC3

NOTICE

To be able to carry out a satisfactory cleaning process which has been

tested and is recommended by ABB Turbo Systems, the following pre-

requisites must be fulfilled:

Engine load 50 ... 85%

u Start of cleaning cycle in accordance with following description for

wet cleaning operation with XC3.

Operating procedure for compressor wet cleaning with XC3

Operating the water pres-

sure vessel

u The operating state prerequisites for compressor cleaning with XC3

must be fulfilled.

u Remove sealing plug (X).

u Fill vessel with required volume of clean water (see table Cleaning

parameters).

u Screw in sealing plug (X).

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u Push the valve activator (Y) against the spring and hold it for 10 ... 15

seconds until the entire volume of water has been injected.

u After cleaning, wait at least 5 minutes to allow turbocharger to dry.

NOTICE

If the cleaning operation is not satisfactory, it may be repeated up to

two times.

If the cleaning result is still not satisfactory after three attempts and

the engine values are also unsatisfactory, we recommend that you have

the turbocharger inspected and cleaned by an official ABB Turbochar-

ging Service Station.

Cleaning parameters per turbocharger compressor

Product

Engine load

Water temperat- Contents of wa-

ure

ter vessel

[°C]

[dm³]

TPL67-C + 71-C

50 … 85%

5 … 50

0.4 or 1