Operation Manual
TPS61-F32
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS61-F32
nMmax 594
HT591998
t
t
650
620
Mmax
Bmax
1/s
°C
nBmax 565
00650 kg
8
25
25
Application according to
the Operation Manual
Year 2019
made in Switzerland
ABB Turbocharging
ꢀꢁꢁ
Operation Manual / TPS44-F.. - TPS61-F..
Page 1
Table of contents
Table of contents
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
Page 2
Table of contents
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Purpose of this manual
1.1
Page 3
1 Preliminary remarks
1.1 Purpose of this manual
1.1
This operation manual belongs to the turbocharger with the identical HT
number (01), see the cover sheet of the operation manual and the turbo-
charger rating plate.
Operation Manual
This Operation Manual enables you to familiarize yourself with the turbo-
charger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be op-
erated safely, correctly and efficiently.
This Operation Manual complements and expands existing national regu-
lations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechanics
who are responsible for operating the engine and the turbocharger in-
stalled 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.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Layout and function
1.2
Page 4
1.2 Layout and function
1.2
1 Suction branch / filter silencer
2 Compressor casing
3 Diffuser
8 Gas outlet flange
9 Nozzle ring
10 Turbine casing
4 Bearing casing
11 Turbine-end bearing flange
12 Compressor-end bearing flange
13 Compressor wheel
5 Axial thrust bearing
6 Radial plain bearing (visible only
at turbine end)
7 Turbine
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Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Layout and function
1.2
Page 5
Mode of operation
The turbocharger is a turbomachine consisting of the following main com-
ponents:
€ Turbine
€ Compressor
These are mounted on a common shaft.
Exhaust gases from the diesel or gas engine flow through the turbine cas-
ing (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 the
compressor wheel (13). The compressor draws in fresh air, compresses it
and then forces it into the engine's cylinders.
The exhaust gases escape into the ambient air through the exhaust gas
pipe, which is connected to the gas outlet flange (8).
The air, which is necessary for operation of the diesel or gas engine and
is compressed in the turbocharger, is drawn into the compressor wheel
(13) through the suction branch or filter silencer (1). It then passes
through the diffuser (3) and leaves the turbocharger through the outlet on
the compressor casing (2).
The rotor runs in two radial plain bearings (6), which are located in the
bearing flanges (11/12) between the compressor and the turbine. The axi-
al 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 the
lowest point of the bearing casing (4).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Intended use of the turbocharger
1.3
Page 6
1.3 Intended use of the turbocharger
1.3
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
The engine builder has provided ABB Turbo Systems with information
regarding the intended use of the engine, from which the operating lim-
its specific to the turbocharger shown on the rating plate (such as oper-
ating speeds, temperatures, exchange intervals / replacement intervals)
have been derived.
NOTICE
If it is used in conjunction with a gas engine, the engine must not be in-
stalled in a potentially explosive environment, and precautionary
measures must be taken to ensure that the machine room as a whole is
classified as not potentially explosive.
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-
tems reserves the right to reject all warranty claims.
State of the art
This turbocharger was built according to state-of-the-art technology and is
operationally safe according to recognised safety regulations.
Improper operation and maintenance of the turbocharger can result in
danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine.
τ The machine may be operated only by trained personnel.
WARNING
Use of the turbocharger as intended also includes observance of the in-
stallation / fitting, disassembly / removal, operating, maintenance / servic-
ing and repair conditions specified by the manufacturer. Disposal regula-
tions 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's manual.
It may be used only for the intended purpose and operated in compliance
with the operation manual.
τ Malfunctions which could affect safety must be eliminated immediately.
The manufacturer accepts no liability for any damage resulting from unau-
thorised alterations to the turbocharger.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Storage of new turbochargers and
spare parts
1.4
Page 7
1.4 Storage of new turbochargers and spare
parts
1.4
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)
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:
WARNING
τ Ensure good room ventilation.
τ Do not eat, drink or keep food at the workplace while working with
VCIs.
τ Wear safety gloves.
τ Clean hands and face after working with VCIs.
Wear safety gloves to protect against chemical hazards.
The following mothballing measures are required every 6 months:
τ Open the package.
τ 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
τ Dispose of the old VCI corrosion protection emitter in an environmen-
tally compatible manner, professionally and in accordance with local
regulations.
τ Seal the package. The better the external seal is designed, the more
permanent the protection.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Storage of new turbochargers and
spare parts
1.4
Page 8
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB Tur-
bo Systems for prolonged storage. The package is equipped with a hyg-
rometer (see illustration).
The following measures are required every 6 months:
τ 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 turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
and repacked.
τ Inspect the package for damage. If the package is damaged, the tur-
bocharger or cartridge group must be inspected by an ABB Turbo-
charging 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.
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 pri-
or testing by an ABB Turbocharging Service Station.
NOTICE
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 content
of the package must have the same temperature during unpacking.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Essential information
1.5
Page 9
1.5 Essential information
1.5
Organisational measures
In addition to this manual, the general, statutory regulations applicable in
the respective country for the prevention of accidents and the protection of
the environment must be observed.
This also applies to the provision and wearing of personnel protection
equipment.
The safety and risk consciousness of the personnel working on and
with the turbocharger must be checked regularly with reference to this
manual.
NOTICE
τ The turbocharger must be shut down immediately by stopping the en-
gine in the event of alterations affecting safety or of corresponding op-
erating behaviour. The fault must be reported to the person or depart-
ment responsible.
Additions and alterations to, and conversions of the turbocharger that
could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTICE
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Essential information
1.5
Page 10
Original parts and safety
Original parts and accessories are specially designed for the turbocharger
supplied by ABB Turbo Systems.
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.
WARNING
τ Only use original parts from ABB Turbo Systems.
ABB Turbo Systems 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.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Essential information
1.5
Page 11
Design variants
This document is valid for different design variants of turbochargers.
There may be sections and descriptions of components that are not rele-
vant 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
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 ®.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Symbols and definitions
1.6
Page 12
1.6 Symbols and definitions
1.6
The following symbols are used in the documents:
ϖ Prerequisite
τ Step of a procedure
€ List, first level
- List, second level
[➙ ] Refers to a page number
Definition of notes
Note
A note provides suggestions which facilitate the work on the product.
Definition of mandatory signs
NOTICE
Mandatory signs show the protective equipment to be worn for a task. The
mandatory signs are described in chapter Safety and must be complied
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 Turbo-
charging Service Stations. They are inspected and certified regularly by
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Turbocharger rating plate
1.7
Page 13
1.7 Turbocharger rating plate
1.7
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 inspection
and replacement intervals
of turbocharger compo-
nents
03 Inspection interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h
Further data
06 Customer part number
07 Designation of the special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Turbocharger rating plate
1.7
Page 14
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 informa-
tion is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such cases, we recommend that you
contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during tri-
als on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk 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 the
turbocharger bearing casing.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
1
Preliminary remarks
Contact information
1.8
Page 15
1.8 Contact information
1.8
Contact information
Contact information for the official service stations of ABB Turbo Systems
is available online.
τ Scan the QR code to access our website.
ABB Turbo Systems Ltd
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Introduction
2.1
Page 17
2 Safety
2.1 Introduction
2.1
Turbochargers manufactured by ABB Turbo Systems are state of the art
and comply with the pertinent safety and health-protection requirements
that applied when the turbocharger was manufactured. Consequently, the
turbocharger 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 operator is responsible for access to the turbocharger as well as the
organisational measures which regulate the safe handling of the turbo-
charger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-
ble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled Defini-
tion of safety instructions).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Definition of mandatory signs
2.3
Page 19
2.3 Definition of mandatory signs
2.3
To be worn at all times
Protective clothing
Safety footwear to protect
against mechanical hazard
and risk of falling
To be worn according to the specific work
Safety glasses
Safety goggles
Safety gloves to protect
against
Respiratory mask to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Dusts
- Gases
Safety helmet
Ear protection
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Definition of Safety instructions
2.4
Page 20
2.4 Definition of Safety instructions
2.4
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
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 precisely.
WARNING
τ Warning signs must be observed at all times.
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.
CAUTION
τ Caution signs must be observed at all times.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Warning plates on the turbocharger
2.5
Page 21
2.5 Warning plates on the turbocharger
2.5
Warning plates are attached to the turbocharger at the following places:
If warning plates are not present at the intended places or are not legible,
then proceed as follows:
τ Order new warning plates from ABB Turbocharging Service Stations.
τ Remove unreadable warning plates.
τ Clean and degrease surfaces provided for warning plates.
τ Attach new warning plates.
Uninsulated turbochargers
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.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Safe operation and maintenance
2.6
Page 22
2.6 Safe operation and maintenance
2.6
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
Risk of falling
There is the risk that someone can fall when working on the turbo-
charger.
WARNING
τ Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
τ When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
τ Observe all general regulations for the prevention of accidents.
τ Do not work on the turbocharger if you are under physical or mental
stress.
τ Work only with suitable tools as well as equipment and working mate-
rials that are in perfect condition.
τ Electric tools must be solidly earthed, and connecting cables may not
be damaged.
τ Keep the workplace clean, clear away loose objects and remove ob-
stacles on the floor.
τ Keep the floor, equipment and the turbocharger clean.
τ Have oil binding materials ready at hand and keep oil catch pans
ready or in position
τ Eliminate leaks.
τ Keep fire-protection materials and fire-extinguishing equipment ready.
Welding work in the vicinity of the turbocharger
τ When performing welding work in the vicinity of the turbocharger, al-
ways cover the filter silencer to prevent the filter mat from being dam-
aged.
τ Keep flammable objects and substances out of the range of flying
sparks.
τ Cover all connections on the turbocharger so that no foreign objects
can enter the turbocharger.
τ Wear personal protective equipment (PPE) for welding operations.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Safe operation and maintenance
2.6
Page 23
Safety during start-up / commissioning and operation
The turbine casing insulation of the TPS44-F supplied by ABB Turbo
Systems is also burst protection.
Serious personal injuries or fatal accidents can occur, if the turbine cas-
ing insulation of the TPS44-F supplied by ABB Turbo Systems is re-
moved. The burst protection is integrated into the turbine casing insula-
tion of the TPS44-F supplied by ABB Turbo Systems.
WARNING
Separate burst protection is fitted to TPS44-F turbochargers without in-
sulation that have been ordered from ABB Turbo Systems.
τ Never operate TPS44-F turbochargers that have been supplied by
ABB Turbo Systems with insulation if this insulation from ABB Turbo
Systems is not in place.
τ Never operate turbochargers without burst protection. If the insula-
tion from ABB Turbo Systems is not in place, the separate burst pro-
tection (57200) must be fitted before operation. (See View of tur-
τ Before starting work, carry out visual inspection of working area.
τ Remove any obstacles and objects lying around.
τ Before start-up / commissioning, check all pipes from and to turbo-
charger for damage and leaks.
τ Don't work in any way that could impair safety when working on turbo-
charger.
τ After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
τ Immediately report any damage or changes in operational perfor-
mance to person responsible.
τ If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
τ 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 "Hazards
due to operating and auxiliary materials" must be observed.
τ Observe the material safety data sheet for the cleaning agent or solvent.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Safe operation and maintenance
2.6
Page 24
τ Wear personal protective equipment (PPE) according to the material
safety data sheet.
τ Inspect the electric cables for abrasion and damage before and after
your cleaning work.
Safety during disassembly, assembly, maintenance and troubleshooting
τ Always perform the specified adjustments, servicing as well as inspec-
tion work and observe inspection intervals.
τ Inform operating personnel about all service and repair work before
beginning.
τ Before opening a cover or removing a protective device on a turbo-
charger, the engine must be switched off and the turbocharger must
have come to a standstill.
τ Ensure that the supply of oil is interrupted, especially with an external
oil supply.
τ Put the engine into operation only after all parts have been refitted
properly.
Mechanical work on the turbocharger
Possible damage to or destruction of components on the turbocharger.
τ Perform only those tasks that are described in this manual.
τ Perform work only for which training has been carried out.
CAUTION
Safety when taking out of operation or preparing for mothballing
τ Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
τ Clean the turbocharger before mothballing it.
τ Observe the material safety data sheet for the cleaning and mothball-
ing agents.
τ Wear personal protective equipment (PPE) according to the material
safety data sheet.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Hazards during operation and
maintenance
2.7
Page 25
2.7 Hazards during operation and maintenance
2.7
Mechanical hazards during operation
During normal operation, no mechanical hazards emanate from the turbo-
charger if it has been installed properly.
Risk of injury
Contact with rotating parts can lead to serious injuries. The turbo-
charger must never be operated without a filter silencer or an air suction
WARNING
branch. When the engine is at a standstill, the rotor can turn on its own
because of stack draught.
τ Operate the turbocharger in accordance with instructions.
τ 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 instructions,
due to inadequate care or as a consequence of insufficient training.
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by me-
chanical influences as a consequence of hazardous and inadequate
operational procedures.
WARNING
τ Observe the general rules for occupational safety and prevention of
accidents.
τ Ensure workplace safety.
τ Only perform operations that are described in this document.
τ Only perform operations for which you have previously received in-
struction or training.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Hazards during operation and
maintenance
2.7
Page 26
Hazards due to noise
The development of noise during operation is influenced by the installation
and operating conditions. Noise with a sound pressure level exceeding
85 dB(A) is harmful.
Hazards due to noise
Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
τ Always wear ear protection when the engine is running.
WARNING
τ 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 op-
erating materials (lubricating oil) become hot. The surface temperature is
dependent on the effectiveness of the insulation being used. The tem-
perature can become high enough so that it falls into ranges where burns
are possible.
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
τ Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
τ Wear heat-resistant safety gloves and protective clothing.
τ Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Hazards during operation and
maintenance
2.7
Page 27
Hot surfaces on the non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel
(burns).
WARNING
The turbocharger is supplied by ABB Turbo Systems without insulation
depending on the order from the enginebuilder. If supply is without insu-
lation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with
hot surfaces.
τ Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
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. Operat-
ing and auxiliary materials can be combustible and easily ignited.
Handling operating and auxiliary materials
Ingestion or inhalation of vapours of operating and auxiliary materials or
contact with such can cause damage to health.
τ Avoid inhalation and contact with the skin.
WARNING
τ Ensure good ventilation.
τ Observe details in the safety data sheets of the operating and auxil-
iary materials.
τ Observe local laws.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Hazards during operation and
maintenance
2.7
Page 28
Risk of fire, explosion
Flammable and combustible operating materials and supplies can catch
fire or resulting vapours can lead to an explosion.
WARNING
τ Observe the details in the material safety data sheets of the operat-
ing and auxiliary materials.
τ Comply with local legislation.
τ Do not allow any exposed flame or ignition source during cleaning
work.
τ Carry out cleaning in the open or provide sufficient aeration and ven-
tilation.
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.
CAUTION
τ Handle operating and auxiliary materials carefully.
τ Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
τ Wear appropriate protective clothing.
τ Avoid inhalation and contact with the skin.
τ Ensure that the work space is adequately ventilated.
τ Seal containers tightly immediately after use and put them away.
τ Collect used working and auxiliary materials safely, store them sepa-
rately in suitable containers and dispose of them properly and in an
environmentally compatible manner in accordance with statutory regu-
lations.
τ 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.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
2
Safety
Hazards during operation and
maintenance
2.7
Page 29
Hazards when handling insulating materials
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.
WARNING
τ Use only suitable, non-combustible insulating materials.
τ Ensure that the work area is well ventilated.
τ Avoid stirring up dust.
τ Use tools and processes which keep dust to a minimum.
τ Remove packing materials only in the work area.
τ Take particular care when removing old insulating materials.
τ 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.
τ Use only suitable, non-combustible insulating materials.
τ Ensure that the work area is well ventilated.
τ Wear suitable work clothing (safety glasses, respiratory mask).
τ Avoid stirring up dust.
τ Use tools and processes which keep dust to a minimum.
τ Remove packing materials only in the work area.
τ Take particular care when removing old insulating materials.
τ Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
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2
Safety
Hazards during operation and
maintenance
2.7
Page 30
Hazards due to electrical components
Hazards due to electrical components
Electrical components operate with voltages which can present hazards
to humans.
WARNING
τ All work on or with electrical components may only be performed by
trained specialists.
τ Heed any country-specific regulations.
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2
Safety
Deflagration on gas engines
2.8
Page 31
2.8 Deflagration on gas engines
2.8
ABB turbochargers can tolerate a deflagration with a transient pressure
increase of 12 bar.
After a deflagration event ABB Turbo Systems recommends verifying the
following points on the turbocharger:
€ 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 particularly strong
deflagration event has taken place, it is also recommended to check the
bearings of the turbochargers before the next start. This inspection and
evaluation must be carried out by an ABB Turbocharging Service Station.
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2
Safety
Periodic checking of the pressure
vessel
2.9
Page 32
2.9 Periodic checking of the pressure vessel
2.9
The pressure vessels used by ABB Turbo Systems, such as those for wet
or dry cleaning, are so-called "simple pressure vessels".
€ The local, statutory regulations covering periodic checks of pressure
vessels must be observed.
€ The operator is responsible for the safe operation of the pressure ves-
sel.
Hazards from pressure vessels
The operator must keep the pressure vessel in a proper condition and
monitor it. Necessary repair or maintenance work must be carried out
WARNING
without delay and the required safety precautions must be taken.
τ Pressure equipment must not be operated if it has defects.
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2
Safety
Lifting loads
2.10
Page 33
2.10 Lifting loads
2.10
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
τ Loads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
τ Make sure the load is suspended properly on the crane hook.
τ Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
In the case of two or more suspension points, the slinging angle must not
exceed 45°. This avoids excessive loading due to inclined tensile loading.
τ Fasten turbocharger assemblies / components as described in respec-
tive handling steps.
τ Before attaching slings, allow turbocharger components to cool down
(maximum 80°C).
τ Use suitable protection at sharp edges.
τ Completely screw in assembly / fitting devices without fail so that they
cannot work loose during use.
τ Use assembly / fitting devices only for applications described.
τ Make sure removed turbocharger components stand safely and se-
curely.
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Operation Manual / TPS44-F.. - TPS61-F..
3
Start-up
Oil supply
3.1
Page 35
3 Start-up
3.1 Oil supply
3.1
A carefully designed and installed oil supply, which functions in all possi-
ble operational conditions, is an important prerequisite for trouble-free tur-
bocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit.
If a separate lubricating system is used, then emergency lubrication is al-
so to be provided.
τ Heed the instructions of the engine builder when selecting the lubricat-
ing oil and oil-change intervals.
Oil filtration
Depending on the turbine specifications and bearings used, varying
amounts of contaminants have to be filtered out of the lubricating oil to
avoid dangerous wear of the bearing parts.
CAUTION
The standard oil filter specification for the turbocharger is 34 µm. This
means that contaminants larger than 0.034 mm must be filtered out of the
oil with a separation efficiency > 99%.
τ Fit an accessory filter if engine oil filter is not efficient enough.
τ If the engine is started cold and the flow resistance rises to above 0.5
bar due to deposits of dirt in the accessory filter, a bypass must open
which ensures that oil flows to the turbocharger by circumventing the
filter.
τ Check that oil filters are clean before commissioning.
Also follow the enginebuilder's instructions regarding filter mesh and
separation efficiency.
NOTICE
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3
Start-up
Oil supply
3.1
Page 36
Lubricant
All lubricating oils used for engines are admissible.
NOTICE
Oil inlet viscosity and temperature
The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet vis-
cosities and oil-inlet temperatures are shown in the following chart.
1)
2)
A
Kinematic viscosity (mm2/s = cSt)
Oil-inlet temperature (°C)
Permissible range
Falling below the minimum oil inlet temperature
Serious machine or property damage can be caused by excessively
high oil viscosity and the resulting lack of oil in the bearings.
CAUTION
τ Do not allow the oil inlet temperature to fall below the minimum 30 ºC
when starting the engine.
τ The oil inlet temperature must never be less than 10 °C.
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3
Start-up
Oil supply
3.1
Page 37
Oil pressure
The oil pressure in front of the turbocharger must be maintained precisely
to ensure trouble-free operation.
Status for operation
Oil pressure in front of
turbocharger
[bar]
2.0 … 4.5
≤ 8.0
Normal operation
Engine start: cold oil, permissible for maximum
15 minutes
Engine idling
≥ 0.2
Pre- and post-lubrication (engine stopped)
≤ 1.0
Prelubrication
Serious machine or property damage might result if the turbocharger is
not supplied with oil when the engine is starting.
τ Activate prelubrication device before starting engine.
CAUTION
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3
Start-up
Oil supply
3.1
Page 38
Lubricating oil temperature at the inlet
Machine damage
Machine damage may result if the oil temperature at the oil inlet ex-
ceeds the permissible range.
CAUTION
τ Keep the oil temperature at the oil inlet as specified in the following
table.
Status for operation
Oil temperature at inlet
Toil,inlet
Permissible
30 … 105 °C
> 105 °C
> 110 °C
< 30 °C
Temporarily permissible (< 1 h) → alarm
Not permissible → stop engine
Not permissible → do not start engine (before
starting: preheat oil)
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 the fol-
lowing table. The specified oil outlet temperature must be regarded as an
alarm value for turbocharger operation and be monitored in accordance
with standard regulations.
Status for operation
Oil temperature at outlet
Toil,outlet
Permissible
≤ 160 °C
> 160 °C
Temporarily permissible → alarm
Not permissible → stop engine
Permissible
> 180 °C
≤ Toil,inlet + 55 K
> Toil,inlet + 55 K
Temporarily permissible → alarm
If the turbocharger has been operated outside the permissible range for a
prolonged period of time, ABB Turbo Systems recommends having the
turbocharger inspected by an ABB Turbocharging Service Station.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
3
Start-up
Inspection work
3.2
Page 39
3.2 Inspection work
3.2
Inspection work includes preventive visual controls plus monitoring and
measuring work before and during commissioning. Inspections help detect
changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring devices
Filter mat
τ Check for correct functioning.
τ Inspect for damage.
Lubricating system
τ Check oil filter for cleanliness before commissioning.
Contaminated oil
Particles of dirt and solid matter in the oil can cause serious damage to
the machine or property.
CAUTION
τ During initial commissioning and after all service work, the complete
lubricating system must be flushed thoroughly with warm oil.
τ When running in the engine and after all service work on the lubricat-
ing system, special running-in filters must be used.
τ Check oil pressure in oil supply lines.
Prelubrication
Serious machine or property damage might result if the turbocharger is
not supplied with oil when the engine is starting.
τ Activate prelubrication device before starting engine.
CAUTION
Warning plates on tur-
bocharger
τ Check whether the warning plates are present and legible.
τ Check whether the protective sheets have been removed.
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3
Start-up
Inspection work
3.2
Page 40
3.2.2 Check after start-up (engine at idling speed)
Lubricating system
τ Check oil pressure in oil supply lines.
τ Check oil inlet temperature.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
τ Check all gas, air and oil lines for leaks after starting the engine.
3.2.3 Check when running up engine
τ Measure speed, oil pressure and charging pressure at various engine
performance levels.
τ Measure exhaust gas temperature in front of and behind turbine.
τ Measure air temperature in front of and behind compressor.
The measured values must be compared with the values in the acceptance
test report, while taking different operating conditions into account.
Lubricants and pastes used during assembly of the turbocharger liquefy
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 leakage of the oil
supply to the turbocharger. If this is leaky, contact an official ABB Tur-
bocharging service station.
NOTICE
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
Start-up
Commissioning after taking out of
operation
3.3
Page 41
3.3 Commissioning after taking out of operation
3.3
If provided
τ Remove cover plates (blind flanges) between compressor casing out-
let and charge air duct, before gas inlet and after gas outlet.
τ Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and re-
move.
τ Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
τ Start up turbocharger oil circulation system at engine end.
τ Prepare turbocharger for operation as instructed in section "Inspection
work before start-up / commissioning" of chapter headed "Start-up /
commissioning".
τ Start up turbocharger.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Noise emissions
4.1
Page 43
4 Operation
4.1 Noise emissions
4.1
Hazards due to noise
Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
τ Always wear ear protection when the engine is running.
WARNING
τ 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 order
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 acoustically
by the engine builder. He is also responsible for insulating the charge
air / scavenging air line and the charge air cooler.
1)
2)
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 en-
sure that equivalent acoustic insulating measures are taken.
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4
Operation
Noise emissions
4.1
Page 44
Suggestion for noise insulation of the bellows
01 Compressor casing
02 Bellows
04 Insulation pads
05 Insulation mat (at least 15 mm)
06 Sheet metal cover
03 Charge air duct / scavenging
air line
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Servicing work
4.2
Page 45
4.2 Servicing work
4.2
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 working
order.
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.
τ Carry out service work at specified time intervals.
CAUTION
CAUTION
Shortened service intervals
Despite observance of the service intervals, unusual loads, such as
several start-stops a day, harsh environmental factors, poor fuel quality
or heavy installation vibration can lead to premature machine damage.
τ A shortened service interval must be arranged with ABB Turbo Sys-
tems.
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.
NOTICE
4.2.1 Service work every 25 … 50 hours
τ Visual inspection for air, exhaust gas, water and oil leaks.
τ Record operating data and enter it in the engine logbook.
τ Clarify the cause of any variances.
Unknown changes during operation
The consequences can range from an impairment to a breakdown.
τ Have unknown causes clarified by an ABB Turbocharging service
CAUTION
station.
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Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Servicing work
4.2
Page 46
4.2.2 Servicing work according to the engine manufacturer's instructions
Oil filter
τ Clean or replace oil filter in supply line to turbocharger when engine is
not running.
4.2.3 Service work in accordance with instructions on rating plate
(In general, after 8000 - 12000 hours of operation)
Rotor and bearing parts must be inspected and assessed by an ABB Turbo-
charging Service Station. The following work can be carried in preparation.
τ Remove cartridge group as described in chapter Disassembly and as-
sembly.
τ Measure clearances.
τ Clean turbine and compressor casings and check them for cracks and
erosion / corrosion.
τ Clean bearing casing and blow air through oil ports / holes.
τ Clean nozzle ring and check for cracks and erosion.
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4
Operation
Servicing work
4.2
Page 47
4.2.4 Entries in engine logbook
By monitoring the engine, conclusions can be drawn about the turbo-
charger performance.
The following operating data and measured values must be entered regu-
larly 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
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Expected exchange intervals
4.3
Page 48
4.3 Expected exchange intervals
4.3
Rotating components
The recommended replacement intervals for compressor wheels and tur-
bine wheels are defined depending on the operating conditions and based
on the safety concept (SiKo) for rotating parts. These intervals can be
found on the turbocharger rating plate.
Non-rotating components
Depending on the system-specific operating conditions, a distinction is
made between:
€ the replacement interval for the bearing parts and
€ the replacement interval for those non-rotating components that are
exposed to hot gases.
Decisive in this respect are various influencing parameters, which can
drastically shorten the replacement intervals of these parts in extreme
cases.
During the specified periodic service work, the individual components are
inspected for wear and, if necessary, replaced.
Expected replacement intervals [h]
GAS / MDO
25000 … 50000
50000
HFO
Turbine casing
Nozzle ring
25000 … 50000
10000 … 25000
35000 … 50000
35000 … 50000
Gas outlet flange
Partition wall
50000
50000
Rotor components
Bearing parts
Other casings
See the data on the rating plate
12000 … 24000
50000
12000 … 24000
50000
GAS = Natural gas
MDO = Marine diesel oil
HFO = Heavy fuel oil
The specified values are a guide only and not guaranteed (see following
section Influencing parameters).
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4
Operation
Expected exchange intervals
4.3
Page 49
Influencing parameters
The specified values are only guide values and not guaranteed. The actu-
al values can deviate considerably from the guide values due, for exam-
ple, to the following influences:
€ Fuel quality and preparation
€ Load profile (thermal load cycles, also starts / stops, emergency shut-
downs)
€ Gas inlet temperature
€ Frequency and execution of turbine and compressor cleaning
€ Turbocharger specification
€ System-specific operating conditions (operating point, combustion
quality, composition of exhaust gas)
For bearing parts
€ Lubricating oil quality (oil filtration, condition of lubricating oil, oil moni-
toring)
€ Load profile (rpm / speed, pressure conditions, temperature)
€ State of rotor unbalance (degree of contamination)
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Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Speed measurement
4.4
Page 50
4.4 Speed measurement
4.4
A speed measuring system permits continuous monitoring of the turbo-
charger speed.
Do not use cables as a climbing aid
If you pull the speed measurement cables too hard, contacts can be
pulled out.
CAUTION
τ Do not tension the speed measurement cables.
86505(A) Speed sensor (cable not integrated)
86505(B) Speed sensor (cable integrated)
86515(A) Cable connector to 86505(A)
86515(B) Cable connector to 86505(B)
86526 F/I converter
86528 Tachometer
01 Screw plug
02 Gasket
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4
Operation
Speed measurement
4.4
Page 51
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 nBmax
.
If this permissible range of difference is exceeded, the following steps
must be carried out:
τ Reduce engine performance immediately until the highest turbo-
charger speed no longer exceeds 70% of nBmax
.
τ If the engine cannot be stopped, continue to run at this reduced engine
performance or turbocharger speed.
τ If the turbocharger surges continuously, engine performance must be
reduced further.
τ 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:
τ Inspect the air and gas lines as well as the turbocharger and eliminate
any problems.
τ In any event, it is recommended that you contact the nearest ABB
Turbocharging Service Station.
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4
Operation
Speed measurement
4.4
Page 52
4.4.2 Replacing the speed sensor
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.
WARNING
τ Wear safety gloves when removing the cable connector and speed
sensor.
Wear safety gloves to protect against thermal hazards.
τ Reduce engine performance to the idling speed, then stop the engine.
τ Switch off the lubricating oil supply to the turbocharger.
τ Disconnect the cable connector from the speed sensor.
τ Screw out defective speed sensor.
τ Screw in a new speed sensor up to the limit block.
τ Adhere to tightening torque.
Part number
86505
TPS44
15 Nm
TPS48
15 Nm
TPS52
15 Nm
TPS57
15 Nm
TPS61
15 Nm
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4
Operation
Speed measurement
4.4
Page 53
Sealing the speed sensor
The speed sensor is designed with a sealing lip and does not require an
additional gasket when fitted.
NOTICE
τ Connect cable connector to speed sensor.
τ 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 described
in the chapter Troubleshooting.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
4
Operation
Stopping the engine
4.5
Page 54
4.5 Stopping the engine
4.5
Stopping the engine of oil-cooled turbocharger version
Heat in the turbocharger must be dissipated by the further circulating
lubricating oil.
τ Post-lubricate for 15 … 20 minutes.
CAUTION
τ Maintain oil pressure of 0.5 … 1.0 bar for post-lubrication.
Stopping the engine of water-cooled turbocharger version
Heat in the turbocharger must be dissipated.
τ Allow turbocharger cooling water to run for 15 … 20 minutes after
CAUTION
stopping engine.
τ Allow oil lubrication to continue running until rotor comes to a stop.
Further post-lubrication is not required and not recommended.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Foreword to Maintenance
5.1
Page 55
5 Maintenance
5.1 Foreword to Maintenance
5.1
General maintenance work involves regular visual checks and cleaning
tasks which are intended to ensure the trouble-free functioning of the tur-
bocharger.
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
Risk of damage during mechanical cleaning
If mechanical cleaning is carried out too often, this can lead to damage
and corrosion on the components.
CAUTION
τ If cleaning during operation is not sufficient to achieve acceptable
values regarding thermal load and engine performance, mechanical
cleaning of certain spots can be carried out.
τ Perform mechanical cleaning, especially of the cartridge group, only
once within the service interval.
Cleaning method
To allow you to observe the standard service intervals and to maintain a
high turbocharger efficiency, ABB Turbo Systems recommends that the
cleaning procedure be carried out during operation. This allows the
thermal load of the engine to be kept low while ensuring maximum fuel
efficiency.
NOTICE
τ Dispose of dirty water and cleaning agents in an environmentally com-
patible manner, professionally and in accordance with valid local regu-
lations.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning the compressor during
operation
5.2
Page 56
5.2 Cleaning the compressor during operation
5.2
General
The contamination of the compressor stage (compressor wheel, wall in-
sert and diffuser) depends on the degree of purity of the taken-in air.
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. But it never replaces the regular
service work where the turbocharger is completely dismantled and the
compressor is mechanically cleaned.
If the coating of dirt is very thick and hard, the compressor can only be
cleaned manually when disassembled. This cleaning must be carried
out by an ABB Turbocharging Service Station.
NOTICE
Cleaning interval
The interval between periodic cleaning is very dependent on the operating
conditions. In general, cleaning should be carried out every 25 ... 100 op-
erating hours.
Should the specified cleaning intervals prove incompatible with engine
operation, please contact ABB Turbo Systems.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning the compressor during
operation
5.2
Page 57
Cleaning method
Cleaning the compressor while in operation is carried out as 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 through an injection pipe fitted in the filter silenc-
er or the suction branch.
The water does not act as a solvent, but the dirt deposit is removed by the
mechanical impact of the droplets. This is a very suitable process, provid-
ed that the degree of contamination is not too high.
Corrosion and deposits when cleaning
Damage and impairment of turbocharger parts due to salt water and
cooling water additives
τ Don't use salt water for cleaning, but only clean fresh water.
CAUTION
The injection pipe must on no account be connected directly via a cock
to a water pipe or a dosing vessel larger than the one supplied. This
prevents uncontrolled volumes of water entering the turbocharger and
engine, which can lead to serious damage.
CAUTION
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.
Sequential charging
In the case of sequential charging, care must be taken to ensure that tur-
bocharger compressors are cleaned regularly, especially after periods of
operation in the lower performance range.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning the compressor during
operation
5.2
Page 58
5.2.1 Wet cleaning compressor using external water pressure vessel (XC1)
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 ap-
proves the process.
Supplying water from the externally mounted water vessel is suitable
only for those applications where a negative pressure exists in front of
the compressor wheel (not used for: blowers connected in front of the
compressor or high-pressure compressor stages with two-stage charg-
ing).
NOTICE
Operating state prerequisites for cleaning compressor with XC1
To be able to carry out a satisfactory cleaning process that has been
tested and is recommended by ABB Turbo Systems, the following pre-
requisites must be fulfilled:
τ Run engine at load from 50 … 85 %.
NOTICE
τ Start cleaning cycle according to following description Wet cleaning
operation with XC1.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning the compressor during
operation
5.2
Page 59
Procedure for wet cleaning the compressor with XC1
X Sealing plug
Y Valve activator
Z Vessel
D Compressed air
W Water
Operating the water pres-
sure vessel
τ Remove sealing plug (X).
τ Fill the vessel (Z) with clean water.
τ Screw in the sealing plug.
τ Push the valve activator (Y) against the spring and hold for 10 to
15 seconds until the entire volume of water has been injected.
τ Do not repeat the cleaning cycle until a stabilisation period of at least
10 minutes has elapsed.
Whether or not cleaning has been successful can be seen from the
charging or flushing pressure and also from the exhaust gas tempera-
tures. If the cleaning process is unsatisfactory, it can be repeated up to
2 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 Turbocharging
Service Station.
NOTICE
Cleaning parameters per
turbocharger compressor
Product
TPS
Engine load
50 … 85 %
Contents
Water
of cleaning medium vessel
injection time
[dm3]
0.4
t1 [s]
10
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Turbine cleaning during operation
5.3
Page 60
5.3 Turbine cleaning during operation
5.3
The combustion of fuels such as heavy fuel oil (HFO) in diesel engines
produces contamination of the turbocharger's turbine components. In
combination with a high exhaust gas temperature, poor quality fuel can
lead to particularly hard deposits on the nozzle ring and especially on the
gas outlet flange.
ABB Turbo Systems recommends using fuels with a low ash, sulphur, so-
dium and vanadium content.
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 contamination
deposits.
Experience with turbocharger operation shows that the intervals between
overhauls can be extended if cleaning while in operation is carried out pe-
riodically. Wet cleaning the turbine, as described below, should be used
for 4-stroke applications when there are heavy deposits from, 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 turbocharger is
completely dismantled and cleaned mechanically.
Turbines which are very heavily contaminated cannot be cleaned this way
any longer. In this case, the contaminated components must be mechani-
cally cleaned by an ABB Turbocharging Service Station.
Regular cleaning
Regular turbine cleaning during operation prevents or delays excessive
build-up of contamination.
NOTICE
Cleaning intervals
The interval between periodic cleaning is very dependent on the operating
conditions. In general, cleaning should be carried out every 50 to 200 op-
erating hours.
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5
Maintenance
Turbine cleaning during operation
5.3
Page 61
Cleaning intervals
Should the specified cleaning intervals prove incompatible with engine
operation, please contact ABB Turbo Systems.
NOTICE
Cleaning method
Turbine components are cleaned during operation using the wet cleaning
processes described in the following. These have been tested and are
approved by ABB Turbo Systems.
The turbine casing design and the type of turbine casing sealing are deci-
sive for the choice of cleaning method.
Approval by engine manufacturer
The prerequisite for wet cleaning is that the engine manufacturer ap-
proves the method and his instructions are followed.
NOTICE
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 turbo-
charger designs without additional sealing by means of C-rings.
The process is based on the principle of thermal shock in combination
with 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 turbo-
charger designs with additional sealing by means of C-rings.
Based on a 10-minute injection phase, this cleaning process utilises the
water solubility of the dirty deposits.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Turbine cleaning during operation
5.3
Page 62
Choice of cleaning method
If you need information about the choice of cleaning method (short /
long), you can contact the engine builder or an official ABB Turbo-
charger service station.
NOTICE
5.3.2 Prerequisites
Risk of corrosion and deposits
Impairment and damage of turbocharger by salt water and cooling wa-
ter additives in flow ducts
CAUTION
τ Don't use salt water for cleaning, but only clean fresh water.
τ Avoid corrosion on casing inner surfaces.
τ Let engine run for 10 minutes after wet cleaning.
Maximum temperature in front of turbine during cleaning
When cleaning, the temperature in front of the turbine will rise and can
heavily stress the material of turbine components. The temperature at
the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This should be taken into consideration
when setting the operating point before cleaning.
CAUTION
τ Don't exceed maximum temperature in front of turbine when clean-
ing.
Impermissible thermal stressing and flooding of the turbine
Smaller volumes of water can result in poor cleaning. Larger volumes of
water lead to impermissible thermal stressing of the turbine compo-
nents and can cause flooding of the turbine.
CAUTION
τ Be absolutely sure to observe turbine cleaning parameters.
V-engines
In the case of V-engines with several turbochargers on each engine, we
recommend parallel cleaning of both turbochargers. This cleaning pro-
cess is faster and the risk of turbocharger surging is reduced.
NOTICE
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Turbine cleaning during operation
5.3
Page 63
Recommended operating state for turbine wet cleaning
The following operating state has been tested and is approved by ABB
Turbo Systems:
Characteristic / component
Conditions
short
long
water injection time
water injection time
Engine load (guide value)
20 … 40 %
Turbine inlet temperature
TTE before water injection
350 - 400 °C
350 - 430 °C
1.5 bar
Water supply
ensured
Water pressure (overpres-
sure over atmosphere) pWT
2.0 bar
If necessary, engine performance must be reduced to maintain these
conditions.
The cleaning cycle can now be started based on the following description.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Turbine cleaning during operation
5.3
Page 64
5.3.3 Procedure for method with short water injection time
ϖ Prerequisites have been fulfilled.
τ Wait 10 minutes during a stabilising phase after reducing the engine
load.
τ Open the shut-off valve.
τ Set the required water flow rate as specified in the table of cleaning
parameters using the flowmeter and inject for 30 seconds.
τ Observe a pause of 3 or 5 minutes as specified in the table.
τ Repeat the 30-second water injection two times.
τ Close the shut-off valve.
τ Wait 10 minutes during a stabilising phase before increasing engine
load again.
This completes the turbine cleaning process.
Cleaning parameters during the process
Temperature in
front of the turbine
during cleaning
Water
volume flow 1)
[dm3/min]
Injection time Pause between
injections
[min]
[min]
TPS
[°C]
44
48
52
57
61
≤ 450
4.5
6
0.5
(3 x)
3
8
11
17
5
1) corresponds to a water pressure pWT of 2.0 bar (overpressure over at-
mosphere)
Maximum temperature in front of turbine during cleaning
When cleaning, the temperature in front of the turbine will rise and can
heavily stress the material of turbine components. The temperature at
the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This should be taken into consideration
when setting the operating point before cleaning.
CAUTION
τ Don't exceed maximum temperature in front of turbine when cleaning.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Turbine cleaning during operation
5.3
Page 65
5.3.4 Procedure for method with long water injection time
ϖ Prerequisites have been fulfilled.
τ Wait 10 minutes as a stabilising phase after reducing the engine load.
τ Open the shut-off valve.
τ Set the required water flow rate as specified in the table of cleaning
parameters using a flowmeter and inject for 10 minutes.
τ Close the shut-off valve.
τ Wait 10 minutes as a stabilising phase before increasing the engine
load again.
This completes the turbine cleaning process.
Cleaning parameters during the process
Temperature in
front of the turbine
during cleaning
Water
Injection time Stabilising phase
volume flow 1)
[dm3/min]
[min]
before / after water
injection
TPS
[°C]
[min]
10
44
48
52
57
61
≤ 530
2.5
4
10
5.5
8.5
12
1) corresponds to a water pressure pWT of 1.5 bar (overpressure over at-
mosphere)
Maximum temperature in front of turbine during cleaning
When cleaning, the temperature in front of the turbine will rise and can
heavily stress the material of turbine components. The temperature at
the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This should be taken into consideration
when setting the operating point before cleaning.
CAUTION
τ Don't exceed maximum temperature in front of turbine when cleaning.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 66
5.4 Cleaning components mechanically
5.4
5.4.1 Introduction
Choosing cleaning tools
Turbocharger components are sensitive to mechanical damage. The
use of needle guns or other impact tools, for example, damages the
components. Depending on the specification, nozzle rings and turbine
casings have protective coatings, which can also be damaged.
CAUTION
τ Only use soft tools such as cloths, brushes or wire brushes.
τ In the event of heavy contamination, the cleaning methods that have
been described such as soaking can be repeated until a satisfactory
result has been achieved.
τ Dispose of dirty water and cleaning agents in an environmentally com-
patible manner, professionally and in accordance with valid local regu-
lations.
Disassembly and assembly
The disassembly and assembly of the components is described in
chapter Disassembly and assembly.
NOTICE
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 67
5.4.2 Cleaning the filter silencer
81135 Filter silencer body
81136 Absorption segment
81137 Sheet-metal covering
81265 Filter ring
81266 Cover grid
81270 Tension band
81271 Lock
Disassembly and assembly
The procedure for disassembly and assembly of the filter silencer is de-
scribed in the chapter entitled Disassembly and Assembly.
NOTICE
Cleaning the filter ring (if provided)
τ Remove filter ring (81265).
τ Clean filter ring (81265) as required or every 500 operating hours, and
replace 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.
τ Wash filter ring (81265) using water containing light-duty detergent or,
if very heavily contaminated, soak it while squeezing carefully. Rinse
in cold water. Avoid rough handling (do not use a water jet).
τ Allow the filter ring to dry out completely before assembly.
τ Dispose of dirty water and gentle detergents in accordance with valid
local regulations.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
Cleaning the absorption segments
5.4
Page 68
τ Loosen the tension bands (81270).
τ Remove the cover grid (81266).
τ Pull out the sheet-metal coverings (81137), bend them up and remove
the absorption segments (81136).
τ 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.
τ Have absorption segments which are heavily contaminated replaced
by an official ABB Turbocharging Service Station.
Fitting the filter silencer
τ Insert the absorption segments (81136) into the sheet-metal coverings
(81137).
τ Bend the sheet-metal coverings (81137) back into their original shape
and insert them into the slot guides in the silencer body (81135).
τ Fit the cover grid (81266).
τ Fit the tension bands (81270) and apply tension at the locks (81271).
τ Damaged tension bands must be replaced with new ones.
τ If provided, fit the filter ring (81265).
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 69
5.4.3 Compressor-end, non-rotating parts
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
τ Do not breathe in these substances and avoid contact with the skin.
WARNING
τ Ensure proper ventilation.
τ Observe the information in the material safety data sheet for the op-
erating materials and supplies.
τ Wear personal protective equipment (PPE) according to the material
safety data sheet.
τ Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
The following performance-relevant parts can be cleaned according to the
following description.
72000 Compressor casing
77000 Wall insert
79000 Diffuser
τ Clean the components specified above with steam or allow to soak in
diesel oil or water with household detergent. After soaking, remove the
dirt with a brush.
τ Dry components completely.
τ Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
τ Dispose of dirty water and cleaning agent in accordance with the spec-
ifications in the safety data sheet.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 70
5.4.4 Turbine-end, non-rotating parts
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
τ Do not breathe in these substances and avoid contact with the skin.
WARNING
τ Ensure proper ventilation.
τ Observe the information in the material safety data sheet for the op-
erating materials and supplies.
τ Wear personal protective equipment (PPE) according to the material
safety data sheet.
τ Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
Baked layers of contamination, for example, from heavy fuel oil or coked
oil occur at the turbine end. The following parts, which are relevant in
terms of performance, can be cleaned in accordance with the description
below.
51000
52400
Turbine casing
56001
Nozzle ring
Gas outlet flange
τ Place contaminated parts in hot water or in a liquid such as carbon
remover to soften the contamination.
τ Brush away the contamination or remove with a steam cleaner.
τ Repeat the soaking and brushing if necessary.
τ Use clean water to completely clean parts of any solvents.
τ Dry components completely.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 71
τ Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
τ Dispose of contaminated water and cleaning agents in accordance
with the information in the material safety data sheet.
5.4.5 Cartridge group
Introduction
Corrosion
If the cartridge group is not put into operation again immediately after
cleaning, parts may corrode.
τ Re-install and use the cartridge group immediately after cleaning.
CAUTION
Compressor wheels or turbines may be heavily contaminated due to
heavy fuel oil operation or coked oil. Such contamination may possibly no
longer be removed through cleaning during operation and must be
cleaned mechanically during the standard service intervals (see chapter
entitled Service work).
stallation [➙ 85]).
First clean the compressor end and then the turbine end in accordance
with the following description.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 72
Cleaning the compressor end
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
τ Use only pH-neutral cleaning agents which do not attack metals.
τ Observe safety data sheet.
CAUTION
CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
τ Make sure that no water or contamination can enter into the cartridge
group.
τ Clean compressor wheel with a cloth or soft brush soaked in water
with household detergent. Do not use any wire brushes!
τ Dry the compressor wheel and the gap between the compressor and
the bearing casing with a weak jet of compressed air.
τ Lightly spray the compressor wheel and the gap between the com-
pressor and the bearing casing with penetrating oil.
τ Dispose of dirty water and cleaning agent in accordance with the safe-
ty data sheet.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 73
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 are
described below.
Product
TPS44
TPS48
TPS52
TPS57
TPS61
A [mm]
91
B [mm]
15
C [mm]
173
108
128
157
187
17
205
20
245
25
300
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.
τ Place the tank (02) in a larger container (03), so that the excess liquid
can be collected.
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
τ Use only pH-neutral cleaning agents which do not attack metals.
τ Observe safety data sheet.
CAUTION
τ Fill the tank (02) with soaking liquid.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 74
Heat the liquid
To shorten the soaking time the liquid can be heated to maximum 60 ºC.
Heating up of cleaning agents and operating fluids
NOTICE
When cleaning agents or operating fluids are heated up, explosive va-
pours can be produced which are hazardous to health.
τ Observe the information in the material safety data sheet.
WARNING
Wear a respiratory mask according to material safety data sheet.
Water and dirt in the cartridge group
If water or dirt gets into the cartridge group, the turbocharger function
may be impaired and parts in the cartridge group may be damaged.
τ Place the cartridge group on suitable wooden or metal supports (01).
CAUTION
τ Maintain dimension (B) for the supports (01), so that the cartridge
group does not submerge too deep.
τ Allow the layers of dirt on the turbine to soak for four hours.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 75
Removing the dirt
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful
to health.
τ Avoid the formation of dust.
WARNING
τ Vacuum up dust with a suitable vacuum cleaner.
τ Wear a respiratory mask to protect against particles (P1 or P2 mask).
τ Wear safety goggles.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
τ Raise the cartridge group and align horizontally.
τ Remove dirt manually with a soft brush or wire brush.
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Operation Manual / TPS44-F.. - TPS61-F..
5
Maintenance
Cleaning components mechanically
5.4
Page 76
Water and dirt in the cartridge group
If water or dirt gets into the cartridge group, the turbocharger function
may be impaired and parts in the cartridge group may be damaged.
CAUTION
CAUTION
τ Make sure that water or dirt does not get into the gap between the
partition wall and turbine.
Non-permissible rotor unbalance after cleaning
Unevenly distributed residual contamination deposits lead to rotor un-
balance. This can result in bearing or turbocharger damage.
τ Remove all traces of contamination from the turbine.
τ After brushing off the contamination, fill the tank (02) with clean water,
not salt water.
τ Submerge the turbine of the cartridge group in clean water, so that
loose particles of dirt detach completely.
τ Raise the cartridge group and align horizontally.
τ Clamp the partition wall with the bearing casing.
τ Dry the turbine and the gap between the turbine and partition wall with
a weak jet of compressed air.
τ Lightly spray the turbine and the gap between the turbine and partition
wall with penetrating oil.
τ Dispose of dirty water and cleaning agent in accordance with the spec-
ifications in the safety data sheet.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions when starting
6.1
Page 77
6 Troubleshooting
6.1 Malfunctions when starting
6.1
Sluggish start-up
Possible causes
Elimination
Clean it
Turbocharger Turbocharger contaminated
Damaged bearing
Contact an ABB Turbocharg-
ing Service Station
Rubbing rotor
Foreign object in turbocharger
Vibrations
Possible causes
Elimination
Turbocharger Rotor unbalance
Damaged turbine or compressor
Damaged bearing
Contact an ABB Turbocharg-
ing Service Station
Rubbing of rotating parts
Normal behaviour, no malfunction
Turbocharger 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 then
shortened somewhat. Certain tolerances must be observed to
avoid a significant loss of efficiency.
€ If there is any doubt about the extent of rubbing, then an ABB
Turbocharging Service Station must be contacted.
€ Have a dimension check carried out by an ABB Turbocharg-
ing Service Station.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Surging of the turbocharger
6.2
Page 78
6.2 Surging of the turbocharger
6.2
Turbocharger surging
Possible causes
Engine
Elimination
Clean / replace it
Guard in front of the turbo-
charger is contaminated or
damaged
Turbocharger Filter silencer or diffuser con- Clean it
taminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air
cooler
Cooler contaminated
Clean it
Charge air duct blocked
Prolonged or periodic surging
Possible damage to components, such as the compressor wheel, tur-
bine blades, bearings and filter silencer
CAUTION
τ Have the cause clarified immediately by an ABB Turbocharging ser-
vice station and rectified.
τ Have components inspected for damage and, if necessary, replaced
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions
such as when reducing the engine performance quickly when manoeu-
vring. At the same time, the flow direction in the compressor is momentari-
ly reversed. Such sporadic surge blows do not impair the safe operation of
the turbocharger.
€ A surge blow is accompanied by a loud bang and escape of hot air
from the filter silencer.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions during operation
6.3
Page 79
6.3 Malfunctions during operation
6.3
Lubricating oil pressure too low
Possible causes
Engine
Elimination
Oil filter heavily contaminated Clean it
Defective oil pump in lubricat- Check / replace it
ing system
Manometer display wrong
Replace the manometer
Turbocharger Rotor axial clearance too large Contact an ABB Turbocharging
Service Station
Reduction in speed
Possible causes
Engine
Elimination
Defects of connected cylin-
ders when pulse charging
Contact the enginebuilder
Turbocharger Heavy contamination of the
turbine
Clean it
Damaged rotor components or Contact an ABB Turbocharging
bearing
Service Station
Pipes
Defects such as leaks in the
exhaust gas pipes or charge
air ducts
Make repairs
Increase in speed
Possible causes
Elimination
Turbocharger Heavily contaminated nozzle Contact an ABB Turbocharging
ring (with 4-stroke application) Service Station
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Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions during operation
6.3
Page 80
Exhaust gas temperature too high
Engine performance and engine speed unchanged
Possible causes
Engine
Elimination
Malfunctioning injection system Repair it or contact the manu-
facturer
Turbocharger Air starvation, for example filter Clean it
silencer clogged with dirt
Compressor / turbine contami-
nated
Exhaust counterpressure too
high
Clean or repair the boiler or
exhaust silencer
Damaged or eroded turbine
Contact an ABB Turbocharg-
ing Service Station
Charge air
cooler
Cooler contaminated
Clean it
Cooling water volume too low
Top up the water
Entry temperature of cooling
water too high
Inspect / clean the cooling
system
Inadequate ventilation
Improve the ventilation
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions during operation
6.3
Page 81
Charge air pressure too low
Engine performance and engine speed unchanged, air intake condition
normal
Possible causes
Engine
Elimination
Air receiver leaking
Make repairs
Gas piping between the engine
and the turbine leaking
Poorly adjusted injection system Correct it
Poorly adjusted valve control
Turbocharger Manometer display wrong
Line to manometer leaking
Replace the manometer
Repair the leak
Contaminated filter silencer caus- Clean it
ing excessive loss of pressure
Compressor / turbine contamina-
ted
Damaged compressor / turbine
Contact an ABB Turbocharg-
ing Service Station
Exhaust counterpressure too high Clean or repair the boiler or
exhaust silencer
Charge air pressure too high
Engine performance and engine speed unchanged, air intake condition
normal
Possible causes
Engine
Elimination
Malfunctioning injection system
Repair it or contact the man-
ufacturer
Poorly adjusted injection system Correct it
Engine performance higher than Check engine performance
expected
Turbocharger Manometer display wrong
Replace the manometer
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions during operation
6.3
Page 82
Fouling of the compressor due to the feeding in of ventilation gases
Reduced compressor performance/efficiency, hence engine performance
losses
Possible causes
Remedy
Turbocharger Heavy fouling of the com-
pressor components
Clean compressor
Optimize oil separation
Increased vibrations, com-
pressor blade damage
Correct the feed of ventilation
gases according to instructions
of enginebuilder.
Reduced fatigue strength of the compressor wheel, compressor blade
failure.
Possible causes
Remedy
Turbocharger Material of compressor
wheel corroded
Check the fuel and its corrosive
components, and change fuel if
necessary.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Malfunctions when stopping
6.4
Page 83
6.4 Malfunctions when stopping
6.4
Noises during run-down
Possible causes
Elimination
Clean it
Turbocharger Turbocharger contaminated
Damaged bearing
Contact an ABB Turbocharg-
ing Service Station
Rubbing rotor
Foreign object in turbocharger
Run-down time too short
Possible causes
Elimination
Clean it
Turbocharger Turbocharger contaminated
Damaged bearing
Contact an ABB Turbocharg-
ing Service Station
Rubbing rotor
Foreign object in turbocharger
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
6
Troubleshooting
Speed measurement system
6.5
Page 84
6.5 Speed measurement system
6.5
Possible causes
Elimination
No signal or
amplitude is
poor
Fitting error
The screw plug for the sensor is fitted with
an additional gasket (copper ring).
When fitting the speed sensor, this gasket
must be removed. If the gasket is fitted by
mistake, the distance from the sensor tip to
the signal-generating sealing disc increases.
As a result, the voltage amplitude of the
speed signal decreases, which can cause
problems for the evaluation electronics.
This problem is eliminated by removing the
gasket.
Defective sensor Contact an ABB Turbocharging Service Sta-
tion
Measured
speeds too
high
Contaminated
sensor tip
The sensor tip is magnetic and can thus at-
tract metal particles. As a result, the dis-
tance to the signal-generating sealing disc is
reduced, which can lead to amplification of
the noise component and consequently to
faulty triggering.
Dismantle the sensor, clean its tip and refit
the sensor using the specified tightening
torque.
Measured
speed too low
- -
Contact an ABB Turbocharging Service Sta-
tion
Other sources - -
of errors
If none of the above measures eliminates
the malfunction, we recommend that you
have the speed measuring system inspected
by an ABB Turbocharging Service Station.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
7
Removal and installation
Transport
7.1
Page 85
7 Removal and installation
7.1 Transport
7.1
Suspension of uninsulated turbocharger
Turbocharger with oil-cooled bearing
casing
Complete turbocharger with gas outlet
casing
Suspension of insulated turbocharger
Turbocharger with oil-cooled bearing
casing
Complete turbocharger with gas outlet
casing
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Operation Manual / TPS44-F.. - TPS61-F..
7
Removal and installation
Turbocharger weights
7.2
Page 86
7.2 Turbocharger weights
7.2
Lifting gear with a sufficient load limit must be used for removing and in-
stalling the turbocharger. The following weight specification is the heaviest
possibility. This guide value can differ from data on the rating plate, de-
pending on the specification.
TPS44
[kg]
TPS48
[kg]
TPS52
[kg]
TPS57
[kg]
TPS61
[kg]
120
180
250
410
650
Turbocharger weights
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Operation Manual / TPS44-F.. - TPS61-F..
7
Removal and installation
Remove the turbocharger
7.3
Page 87
7.3 Remove the turbocharger
7.3
τ Disconnect all exhaust gas and air lines according to the instructions
of the enginebuilder.
Version with water-cooled bearing casing:
τ Disconnect the water pipes according to the instructions of the en-
ginebuilder.
If present, remove hard insulation as follows:
τ Remove screws and sheet metal (B) from the bearing casing insula-
tion.
τ Remove the remaining screws from the bearing casing insulation (A).
τ Pull the bearing casing insulation up and off. The bearing casing insu-
lation can be compressed to facilitate the removal process.
τ Unplug the cable connector from the speed sensor.
τ Attach lifting gear to bearing casing.
τ If a gas outlet bend is present, sling lifting gear around it or secure it to
the lifting gear with a swivel lifting eye (C).
τ Loosen the fixing screws (D) on the bearing casing.
τ Lift the turbocharger from the engine and put it down.
τ Cover oil connections.
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Operation Manual / TPS44-F.. - TPS61-F..
7
Removal and installation
Installing the turbocharger
7.4
Page 88
7.4 Installing the turbocharger
7.4
τ Remove covers from oil connections.
τ Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring
gaskets for engine are not delivered by ABB Turbo Systems).
**) When the turbocharger is mounted on the engine support, the bolt
threads and screw heads must be lightly oiled (assumed friction coeffi-
cient µ = 0.12 for tightening torque)
Product
Through hole in
bearing casing
[mm]
Thread size
[mm]
Tightening
torque
Strength class
in acc. with
DIN/ISO 898
[Nm]
TPS44
TPS48
TPS52
TPS57
TPS61
17
17
21
21
25
M16
M16
M20
M20
M24
230
230
455
455
780
10.9/12.9
10.9/12.9
10.9/12.9
10.9/12.9
10.9/12.9
τ Attach lifting gear to bearing casing.
τ If a gas outlet manifold is provided, sling lifting gear around it addition-
ally or fasten it to lifting gear using a swivel lifting eye (C) (see also
section Transport / Weights).
τ Lift turbocharger, place on bracket and align.
τ Tighten fixing screws (D) to the bearing casing in accordance with the
table above.
τ Fasten all gas, water and air lines in accordance with the enginebuild-
er's instructions.
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Operation Manual / TPS44-F.. - TPS61-F..
7
Removal and installation
Installing the turbocharger
7.4
Page 89
If present:
τ Fit speed sensor and plug in cable connector.
τ Adapt and fit bearing casing insulation (A).
τ Adapt and fit sheet metal (B) of bearing casing insulation.
Version with water-cooled bearing casing:
τ Remove the screw plugs from the water connections and fit the water
pipes in accordance with the enginebuilder's instructions.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Introduction
8.1
Page 91
8 Disassembly and assembly
8.1 Introduction
8.1
Precondition for the work described below is a turbocharger removed from
the engine (refer to the chapter entitled Removal and Installation).
Further work
Only the work described in this Operation Manual may be carried out.
Incorrectly performed disassembly and assembly of the cartridge group
can lead to serious machine damage.
CAUTION
τ ABB Turbo Systems recommends having further work carried out on-
ly by trained personnel from an ABB Turbocharging Service Station.
Marking casing positions for assembly
ABB Turbo Systems recommends that the casing positions are marked
before disassembling the turbocharger.
NOTICE
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices
Assembly devices must be checked for damage before and after use.
τ Visually check for corrosion, cracks, deformation and wear.
τ Don't use damaged assembly devices, but replace them.
WARNING
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Introduction
8.1
Page 92
Customer spare parts set
Before beginning work, ensure that the required customer spare parts
sets are available.
τ See chapter Spare parts.
Oil orifice
τ When disassembling the turbocharger, a fitted oil orifice must not be
removed.
Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger
components must be observed. (See section Table of tightening torques.)
Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
τ Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has sufficient
load capacity.
τ Make sure the load is suspended properly on the crane hook.
τ Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Definition of terms
€ Suspension point
Defined load carrying point on a component or an assembly (blind hole
thread, eye, lug).
€ Assembly device
Devices mounted on the turbocharger to create a suspension point.
Assembly devices are calculated and designed especially for the de-
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Introduction
8.1
Page 93
fined application. They are not commercially available products. Use
assembly / fitting devices only for the applications described.
€ Lifting gear
Equipment for lifting and transporting loads (ropes, chain hoists,
cranes). Lifting gear is not supplied by ABB Turbo Systems.
Swivel lifting eye to be used
A swivel lifting eye is required to lift loads safely (not supplied by ABB).
Swivel lifting eye
Product Thread Length
Minimum
load limit
(loading
capacity)
M
L
TPS44
TPS48
TPS52
TPS57
TPS61
M8
13 mm
17 mm
17 mm
21 mm
21 mm
150 kg
250 kg
250 kg
350 kg
500 kg
M10
M10
M12
M12
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Module weights
8.2
Page 94
8.2 Module weights
8.2
The specified weights of individual parts or assemblies are guides round-
ed off to the next highest value.
TPS44 TPS48 TPS52 TPS57 TPS61
Description
[kg]
15
5
[kg]
19
6
[kg]
30
8
[kg]
40
11
6
[kg]
1 Filter silencer
65
2 Radial air suction branch
3 Axial air suction branch
4 Compressor casing
5 Wall insert
21
3
4
4
9
17
4
24
7
35
10
3
55
13
6
90
30
6 Diffuser
2
2
10
7 Cartridge group
8 Nozzle ring
25
1
35
1
50
2
85
3
140
6
9 Burst ring
1
2
3
5
12
10 Turbine casing 1 inlet
30
30
-
35
35
-
50
50
55
-
80
90
95
95
16
40
130
150
170
170
30
with external
2 inlets
burst protection
3 inlets
4 inlets
11 Gas outlet flange
-
-
4
4
8
12 Exhaust manifold
16
18
25
60
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 95
8.3 Disassembling and assembling turbocharger
8.3
Removing the compressor casing
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
τ Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
τ Wear heat-resistant safety gloves and protective clothing.
τ Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
τ Disconnect all air lines in accordance with the enginebuilder’s instruc-
tions.
If provided
τ Remove the screws for the compressor casing insulation and disman-
tle the insulation.
τ Undo the V-clamp (72020) and remove the filter silencer (81000) or air
suction branch (82000).
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 96
Removing the insulation
If provided
τ Loosen and remove the screws for the insulation plates (1, 2).
τ If provided: Remove the insulation plates (1, 2).
τ Remove the remaining screws for the insulation (3).
τ Remove the insulation (3).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 97
τ 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.)
If the compressor casing cannot be removed easily, it can be pressed
off using the press-off tool (90042) against the turbine casing. To do
this, the two cover plates (1, 2) must be removed from the hard insula-
tion on the turbine casing.
NOTICE
Axial force
The press-off tool can generate a high axial force and, if it is not used
properly (too much pressure on one side), it can damage the rotor.
CAUTION
τ It should thus be used alternately on both sides while avoiding ex-
cessive pressure on either side.
τ Loosen the screws (72011) and remove them together with the fas-
tening strips (72012).
τ Move the compressor casing (72000) with the wall insert (77000) care-
fully away, doing so horizontally.
τ Tap the wall insert (77000) out of the compressor casing using a nylon
hammer and remove the O-ring seal (77005).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 98
TPS61 wall insert removal
τ Fasten lifting beam (90258) to wall insert.
τ Fasten swivel lifting eye (a) to lifting beam.
τ Remove wall insert (77000) using lifting gear.
Disassembly of diffuser
TPS..-F31/32 / FV31/32
τ Loosen screws (72041) and remove them together with lockwashers
(72040) and diffuser (79000) from compressor casing (72000).
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 99
Installing compressor casing
τ Refit wall insert (77000) and O-ring (77005) in the reverse order.
O-rings
Used O-rings must always be replaced with new ones. O-rings are only
available as a set (see chapter Spare parts).
NOTICE
Fitting the diffuser
TPS..-F31/32 / FV31/32
τ Refit diffuser in reverse order.
τ Fit compressor housing in reverse order.
τ Thoroughly clean fastening strips (72012) before fitting them.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 100
Removing the cartridge group
τ Check the lifting gear and fasten it to bearing casing (42001).
If provided
τ Disconnect all lines in accordance with the engine builder's instruc-
tions, remove the insulation, remove the turbocharger and compressor
casing together with the filter silencer (also see the previous chapter).
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
τ Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
τ Wear heat-resistant safety gloves and protective clothing.
τ Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
ϖ The bearing casing is difficult to loosen.
τ Use the press-off tool (90042) against the turbine casing to press off
the bearing casing (see the following illustration).
Axial force
The press-off tool can generate a high axial force and, if it is not used
properly (too much pressure on one side), it can damage the rotor.
CAUTION
τ It should thus be used alternately on both sides while avoiding ex-
cessive pressure on either side.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 101
τ Withdraw nozzle ring (56001) using two extraction devices (90070)
and withdraw bottom part of service support (90012).
If provided
τ Remove C-ring (51105).
Disassembly of diffuser
TPS..-F33
τ Mount the cartridge group on the service support (90012) and bolt
it down firmly.
τ Loosen screw (42008) and remove diffuser (79000) complete with
O-ring (42012).
τ Measure the axial and radial clearances (see the section Axial and
radial clearances).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 102
Installing the cartridge group
O-rings
Used O-rings must always be replaced with new ones. O-rings are only
available as a set (see chapter Spare parts).
NOTICE
NOTICE
Protruding insulation
The insulation on the turbine casing may protrude at the gas outlet side.
This can be pushed back in with a screw driver.
τ Fit the lamellar sealing ring (56005, if present) in the correct slot (see
detail A). When doing this, pay attention to correct winding of the la-
mellar sealing ring (see detail B).
τ Secure the lamellar sealing ring with adhesive tape.
τ Insert the nozzle ring (56001) (with the cam facing forwards) into the
turbine casing as far as it will go. Align the cam on the nozzle ring with
the 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
τ Insert the C-ring (51105) into the turbine casing and secure with high-
vacuum grease.
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 103
To ensure the nozzle ring is held in place during operation, it must be
clamped between the partition wall and the turbine casing.
NOTICE
Nozzle ring press fit for
single inlet turbine casing
τ Calculate the press fit (PD) as shown.
If the calculated value (PD) is less than 0.1 mm, an official ABB Turbo-
charging Service Station must be contacted.
NOTICE
τ Measure the axial and radial clearances (see the section Axial and ra-
dial clearances).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 104
Nozzle ring press fit for
multiple inlet turbine cas-
ing
τ Calculate the press fit (PD) as shown.
If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbo-
charging Service Station must be contacted.
NOTICE
τ Measure the axial and radial clearances (see the section Axial and ra-
dial clearances).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 105
Assembly of diffuser
TPS..-F33
τ Fasten diffuser (79000) and O-ring (42012) using screw (42008).
τ Check lifting gear and fasten to bearing casing (42001).
τ Unscrew the cartridge group and lift it out of the service support
(90012).
τ Apply high-temperature grease to the centering points and screw
threads.
τ Remove temporary covers from oil connections.
Don't damage or shift gasket rings (A) in the mounting support when
fitting the cartridge group. The gasket rings (A) are supplied by the en-
gine builder.
CAUTION
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 106
If two turbochargers are mounted on an engine, one with a left-hand
and one with a right-hand oil inlet, a pin can be fitted in the bracket as a
precaution against incorrect positioning. This pin (B) locates in a corre-
spponing groove in the foot of the bearing casing.
NOTICE
τ Fasten the cartridge group using fastening strips (51002), Verbus
Ripp® washers (51003) and nuts (51007) (also see the chapter enti-
tled Table of tightening torques).
τ Fasten the bearing casing (42001) using the fixing screws (C).
τ Tighten the fixing screws (C) to the torques listed in the following table.
**) For the assembly of the turbocharger on the engine support, the
threads of the screws and screw heads must be lightly oiled (assumed
coefficient of friction µ = 0.12 for the tightening torque).
Product
Hole in the bearing casing
[mm]
Fixing screws
C [mm]
Tightening torques
[Nm] **)
TPS44
TPS48
TPS52
TPS57
TPS61
Ø 17
Ø 17
Ø 21
Ø 21
Ø 25
M16
M16
M20
M20
M24
230
230
455
455
780
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 107
If provided
τ Plug in the cable connector (86515) for the speed sensor (86505) and
(if provided) fit the insulation plates (1, 2).
Removing gas outlet bend and gas outlet flange
If provided
τ Disconnect all lines in accordance with engine builder's instructions
and remove insulation. (See also preceding chapter.)
τ Loop lifting gear around gas outlet bend (51100).
τ Remove gas outlet bend (51100) and gasket (52406). Only gas outlet
bends from ABB Turbo Systems have the gasket (52406).
τ Remove gas outlet flange (52400) and, if fitted, C-ring (52408).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Disassembling and assembling
turbocharger
8.3
Page 108
Fitting the gas outlet flange and gas outlet bend
τ If provided, fit the C-ring (52408).
τ Fit the gas outlet flange (52400).
τ In the case of gas outlet bends (51100) from ABB Turbo Systems:
always replace the gasket (52406) (see the chapter entitled Spare
parts).
τ Apply high-temperature grease to contacting surfaces and threads.
τ Fit the turbine casing using the nuts (52433) while observing tightening
torques specified in the table of tightening torques.
If provided
τ Fasten the insulation.
τ Attach pipes in accordance with the enginebuilder's instructions.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Axial clearance A and radial clearance
B
8.4
Page 109
8.4 Axial clearance A and radial clearance B
8.4
τ Following removal and before installation of the cartridge group, the axi-
al clearance A and radial clearance B must be measured and noted.
In order to correctly measure the axial clearance A, the turbine must be
raised slightly.
NOTICE
Risk of injury due to sharp edges on the compressor wheel
The compressor wheel has sharp edges which can cause injuries.
τ Wear safety gloves.
WARNING
Wear safety gloves to protect against mechanical hazards.
Axial clearance A and
radial clearance B [mm]
TPS44
0.08
TPS48
0.08
TPS52
0.10
TPS57
0.12
TPS61
0.15
A minimum
A maximum
B minimum *
B maximum *
0.16
0.16
0.18
0.21
0.25
0.51
0.50
0.61
0.72
0.81
1.00
1.00
1.15
1.31
1.55
* Permissible B clearances for standard radial bearings. If the clearances
measured on TPS57 or TPS61 are outside the permissible range, this can
indicate radial bearings with a special bearing geometry. Different permis-
sible values are valid for radial bearings with a special bearing geometry
(see the table below).
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Axial clearance A and radial clearance
B
8.4
Page 110
Identifying radial bearings
with a special bearing
geometry
The type of bearing can be determined by measuring the rotor run-out
time. 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 directions.
The resulting run-out times until the rotor comes to a stop are measured
for the anticlockwise and clockwise rotations and then compared. With
standard radial bearings, the run-out time for anticlockwise and clockwise
rotating rotors is the same.
If one run-out time is at least 1.5 times longer than the other, then radial
bearings with a special bearing geometry are installed. The following B
clearances are valid for these special bearings.
TPS57
0.46
TPS61
0.52
B minimum
B maximum
0.73
0.82
Clearances out of tolerance
Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
τ Have components assessed and, if necessary, replaced by an ABB
Turbocharging Service Station.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Radial clearances N and R
8.5
Page 111
8.5 Radial clearances N and R
8.5
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 outlet
flange.
The minimum and maximum values result from the manufacturing toler-
ances of the compressor wheel and turbine wheel or the wall insert and
gas outlet flange.
Feeler gauge
N1 and N2 as well as R1 and R2 are
each measured at the same time using
two feeler gauges.
To measure N1 and N2, the feeler gaug-
es must be pushed between the wall in-
sert and the compressor wheel free of
play, in each case above and below.
To measure R1 and R2, the feeler gaug-
es must be pushed between the gas out-
let flange and the turbine free of play, in
each case above and below.
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Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Radial clearances N and R
8.5
Page 112
Measuring N and R
The mean values measured must be within the permissible values of the
radial clearance N and R.
Radial clearances N and
R
Product
TPS44
TPS48
TPS52
TPS57
TPS61
N [mm]
R [mm]
0.15 … 0.49
0.22 … 0.58
0.30 … 0.67
0.40 … 0.86
0.50 … 0.94
0.36 … 0.67
0.47 … 0.77
0.59 … 0.92
0.75 … 1.11
0.90 … 1.32
Clearances out of tolerance
Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
τ Have components assessed and, if necessary, replaced by an ABB
Turbocharging Service Station.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
8
Disassembly and assembly
Table of tightening torques
8.6
Page 113
8.6 Table of tightening torques
8.6
The following tightening torques must be observed for the specified screw
connections:
Tightening torques [Nm]
Position Part number TPS44
TPS48
60
TPS52
60
TPS57
60
TPS61
60
1
2
72020
42008
52433
51007
72011
86505
60
6
10
10
20
20
5
20
25
35
15
20
40
65
65
6
25
45
75
75
9
35
70
105
15
170
15
10
15
15
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
9
Taking out of operation
Shutting down the turbocharger
9.1
Page 115
9 Taking out of operation
9.1 Shutting down the turbocharger
9.1
If the turbocharger is damaged and the engine can be shut down for only
a short time for emergency repairs, proceed as follows:
τ Fit the cover plate.
Always heed precisely the engine builder's instructions in case of en-
gine operation with a blocked / throttled turbocharger!
CAUTION
Dismantling the turbocharger
τ Dismantle the turbocharger (see the section Dismantling and fitting the
turbocharger).
τ Do not dismantle the nozzle ring.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
9
Taking out of operation
Shutting down the turbocharger
9.1
Page 116
Fitting the cover plate
τ Close the opening in the turbine casing using the cover plate (A).
τ Fasten the cover plate on the turbine casing (51000) using the fas-
tening strips (51002), Verbus Ripp® Verbusripp washers (51003) and
nuts (51007) and screw it down securely on the support.
Thoroughly clean the fastening strips (51002) before fitting them. Apply
high-temperature grease to the stud threads (51006).
NOTICE
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
9
Taking out of operation
Shutting down the turbocharger
9.1
Page 117
Cover plate drawing
The cover is not supplied by ABB Turbo Systems and must be manufac-
tured by the operator according to the following drawing.
Material: Common structural steel, according to DIN EN 10025-2
Product
B1
±0.5
B2
B3
B4
±0.2
B5
B6
TPS44
TPS48
TPS52
TPS57
TPS61
62.6
65.7
79.6
98.2
116.8
54
60
110
130
155
190
226
11.0
11.7
14.2
17.2
20.5
1
144
150
180
220
260
1.5
1.5
2
78
100
120
2.4
Product
B7
ØD1
±0.2
ØD1*
±0.2
ØD2
R1
M
TPS44
TPS48
TPS52
TPS57
TPS61
191.3
222.7
265.7
325.7
387.7
191.3
227.7
271.7
332.5
395.9
17
17
21
21
25
≤88
M8
M8
35.7
39.6
48.2
56.8
≤105
≤125
≤153
≤182
M8
M10
M10
Dimensions in [mm]
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
9
Taking out of operation
Shutting down the turbocharger
9.1
Page 118
*) Diameter for turbine casing designs for optional C-ring sealing
Information about the turbine casing design (with / without C-ring seal-
ing) can be requested from an ABB Turbocharging Service Station.
NOTICE
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
10
Mothballing the turbocharger
Taking the engine out of operation for
up to 12 months
10.1
Page 119
10 Mothballing the turbocharger
10.1 Taking the engine out of operation for up to
12 months
10.1
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing a
turbocharger depends on the condition of the lubricating oil:
€ If the total acid number (TAN) is lower than 2 mg KOH/g, no measures
have to be taken.
€ If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the pre-lubrication
pump, no measures have to be taken. Any remaining old engine oil will
therefore be flushed away and the bearing sections largely protected
against corrosion.
Mothballing measures
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
τ Do not breathe in these substances and avoid contact with the skin.
WARNING
τ Ensure proper ventilation.
τ Observe the information in the material safety data sheet for the op-
erating materials and supplies.
τ Wear personal protective equipment (PPE) according to the material
safety data sheet.
τ Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
10
Mothballing the turbocharger
Taking the engine out of operation for
up to 12 months
10.1
Page 120
If the total acid number (TAN) is greater than 2 mg KOH/g, the following
mothballing measures are necessary after taking an engine out of operation:
τ Dismantle the turbocharger.
τ The rotor and the bearing parts must be removed by an official ABB
Turbocharging service station and refitted afterwards.
τ Clean all parts.
τ Machined, bright surfaces of steel and cast parts must be oiled with
anticorrosive oil.
τ Reassemble complete turbocharger.
Rotor turning in stack draught
If the rotor turns as a result of the stack draught:
τ Install blind flange between compressor casing outlet flange and
charge air duct.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
10
Mothballing the turbocharger
Taking the engine out of operation for
more than 12 months
10.2
Page 121
10.2 Taking the engine out of operation for more
than 12 months
10.2
If the engine is taken out of service, the following alternatives are possible
with the turbocharger:
€ The turbocharger remains mounted on the engine.
€ The turbocharger casing remains mounted on the engine, but the rotor
and the bearing parts are removed and stored separately by an ABB
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, under Moth-
balling measures, for the measures always necessary when mothballing
turbocharger parts.
If the turbocharger remains mounted on the engine, refer to the section
Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed, or if the turbocharger is re-
assembled from the individual components thereof:
τ Close all turbocharger openings using wooden covers and paraffin paper.
Suitable storage locations are only dry rooms where the relative humidity
is between 40 … 70 % and no condensation can form.
Condition of the mothballed turbocharger
τ Check the mothballed turbocharger parts for corrosion once per an-
num.
τ If there are signs of rust: Clean parts thoroughly and renew protection
against corrosion.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
Disposing of turbocharger components
11
Taking the engine out of operation for
more than 12 months
10.2
Page 123
11 Disposing of turbocharger components
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
τ Avoid the formation of dust.
WARNING
τ Vacuum up dust with a suitable vacuum cleaner.
τ Wear a respiratory mask to protect against particles (P1 or P2 mask).
τ Wear work gloves made of leather.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
Disposal must be environmentally compatible, professional, and in com-
pliance with locally applicable regulations.
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 of felt
and polyethylene), lubricants (engine oil), electronic parts (speed sensor
and associated components), and thermal insulation.
τ Dispose of metals as scrap metal for recycling.
τ Dispose of non-metallic materials as waste.
τ Dispose of residues of lubricants as waste oil.
τ Dispose of electronic components as electronic waste.
τ Dispose of thermal insulation as hazardous waste.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
12
Spare parts
Ordering spare parts
12.1
Page 125
12 Spare parts
12.1 Ordering spare parts
12.1
When making inquiries or ordering spare parts, the following data must be
specified:
€ Turbocharger type
€ Serial number (HT……)
€ Description and part number
Spare parts can be ordered from an official ABB Turbocharging Service
Station.
τ If different design versions have not been taken into consideration in
this document, please contact an ABB Turbocharging Service Station.
Storage of spare parts
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
τ Parts showing signs of rust should be carefully cleaned and greased.
CAUTION
τ Dispose of replaced and unusable parts in a professional and envi-
ronmentally compatible way.
Customer spare part set (97070)
The customer spare part set (97070) is required for the work described in
this manual.
Quantity
Description
Socket screw
O-ring
Part number
42008
1
1
1
1
2
1
42012
Gasket
52406 *
77005
O-ring
Counter-sunk screw
O-ring
72041
81010 / 82010
* This gasket can be used only when using a gas outlet casing from ABB
Turbo Systems.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
12
Spare parts
View of turbocharger showing part
numbers
12.2
Page 127
Part number
Description
10900
Cartridge group
Socket screw
O-ring
42008 (in customer spare part set)
42012 (in customer spare part set)
51000
Turbine casing
Fastening strips
Exhaust bend
Metal C-ring
Gas outlet flange
Gasket
51002
51100
51105*
52400
52406 (in customer spare part set)
52408*
Metal C-ring
Nozzle ring
56001
57200
Burst protection
Burst ring
57210
72000
Compressor casing
Socket screw
Fastening strips
V-clamp
72011
72012
72020
72041 (in customer spare part set)
Counter-sunk screw with cross slotted
head
77000
Wall insert
77005 (in customer spare part set)
O-ring
79000
Diffuser
81000
Filter silencer
81010 (in customer spare part set)
O-ring
82000
Axial air suction branch
O-ring
82010 (in customer spare part set)
86505(A)*
86505(B)*
86515(A)*
86515(B)*
86526*
Speed sensor (cable not integrated)
Speed sensor (cable integrated)
Cable connector for 86505(A)
Cable connector for 86505(B)
F/I converter
86528*
Tachometer
* depends on the turbocharger specification.
© Copyright 2016 ABB. All rights reserved.
Operation Manual / TPS44-F.. - TPS61-F..
12
Spare parts
View of cartridge group showing part
numbers
12.3
Page 129
Part number
Description
21000
Shaft
21002
Piston ring
25000
Compressor wheel
Plain bearing bush
Locking ring
Thrust ring
32101
32103
32105
32106
Thrust bearing
Piston ring
32108
32109
Sealing disc
Bearing flange
Auxiliary bearing
Bearing flange
Socket screw
Socket screw
Bearing cover
O-ring
32110
32111
32112
32113
32114
32221
32222
42001
Bearing casing
Socket screw
Socket screw
Partition wall
Metal C-ring
42002
42008 (in customer spare part set)
43001
43012*
© Copyright 2016 ABB. All rights reserved.
ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland
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