Abb TPS 52E01 User Manual

Operation Manual

TPS 52E01

ABB Turbo Systems Ltd CH 5401 Baden

Type TPS 52E01 HT843367 n

Mmax

n

Bmax

SOLD08 00250 12 60 60 Year 2017

HZTL2410 English

Original Operation Manual

859 t 816 t

Mmax

1/s °C

Bmax

kg

made in Switzerland

680 650

Application according to

the Operation Manual

ABB Turbocharging



Operating condition and replacement intervals

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

Note: Replacement intervals of components depends on the load proﬁ le, turbine inlet temperature, suction air temperature and

Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

turbocharger speed. In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the current application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Table of contents

1

Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Intended use of the turbocharger

1.4

Storage of new turbochargers and spare parts

1.5

Essential information

1.6

Symbols and definitions

1.7

Turbocharger rating plate

1.8

Contact information

2

Safety

2.1

Introduction

2.2

CE conformity

2.3

Definition of mandatory signs

2.4

Definition of Safety instructions

2.5

Warning plates on the turbocharger

2.6

Safe operation and maintenance

2.7

Hazards during operation and maintenance

2.8

Deflagration on gas engines

2.9

Periodic checking of the pressure vessel

2.10

Lifting loads

3

Commissioning

3.1

Oil supply

3.2

Inspection work

3.3

Commissioning after taking out of operation

4

Operation

4.1

Noise emissions

4.2

Servicing work

4.3

Expected exchange intervals

4.4

Speed measurement

4.5

Stopping the engine

Page 1

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Table of contents

5

Maintenance

5.1

Foreword to Maintenance

5.2

Cleaning the compressor during operation

5.3

Turbine cleaning during operation

5.4

Cleaning components mechanically

6

Troubleshooting

6.1

Malfunctions when starting

6.2

Surging of the turbocharger

6.3

Malfunctions during operation

6.4

Malfunctions when stopping

6.5

Speed measurement system

7

Removal and installation

7.1

Transport

7.2

Turbocharger weights

7.3

Remove the turbocharger

7.4

Installing the turbocharger

8

Disassembly and assembly

8.1

Introduction

8.2

Module weights

8.3

Disassembling and assembling turbocharger

8.4

Axial clearance A and radial clearance B

8.5

Radial clearances N and R

8.6

Table of tightening torques

9

Taking out of operation

9.1

Shutting down the turbocharger

10

Mothballing the turbocharger

10.1

Taking the engine out of operation for up to 12 months

10.2

Taking the engine out of operation for more than 12 months

11

Disposing of turbocharger components

12

Spare parts

12.1

Ordering spare parts

12.2

View of turbocharger showing part numbers

12.3

View of cartridge group showing part numbers

Page 2

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Purpose of this manual

1.1

Preliminary remarks

Purpose of this manual

Operation Manual

Target group

Availability of operation manual

1

1.1

Page 3

1.1

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This operation manual belongs to the turbocharger with the identical HT number (01), see the cover sheet of the operation manual and the turbocharger rating plate.

This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended.

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

This Operation Manual complements and expands existing national regulations concerning work safety and accident prevention.

This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the engine and the turbocharger installed on it.

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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Layout and function

1.2

Layout and function

1.2

Page 4

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1 Suction branch / filter silencer 8 Gas outlet flange

2

Compressor casing 9 Nozzle ring

3

Diffuser 10 Turbine casing

4

Bearing casing 11 Turbine-end bearing flange

5

Axial thrust bearing 12 Compressor-end bearing flange

6

Radial plain bearing (visible

13 Compressor wheel

only at turbine end)

7

Turbine

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Layout and function

1.2

Mode of operation

Page 5

The turbocharger is a turbomachine consisting of the following main components:

 Turbine

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 Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine casing (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 axial thrust bearing (5) is located between the two radial plain bearings.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Intended use of the turbocharger

1.3

Intended use of the turbocharger

NOTICE

This turbocharger supplied by ABB Turbo Systems has been developed

used

with a gas engine

not

explosive environment

not potentially explosive

WARNING

Improper operation and maintenance of the turbocharger can result in

1.3

State of the art

Perfect condition

1.3

Page 6

for use on diesel engines to generate the volume of air and the charging 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 limits specific to the turbocharger shown on the rating plate (such as operating speeds, temperatures, exchange intervals / replacement intervals) have been derived.

If it is stalled in a potentially

in conjunction

, the engine must

, and precautionary

be in-

measures must be taken to ensure that the machine room as a whole is classified as

.

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

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

danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine.

 The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the installation / fitting, disassembly / removal, operating, maintenance / servicing and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condition 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.

 Malfunctions which could affect safety must be eliminated immediately.

The manufacturer accepts no liability for any damage resulting from unauthorised alterations to the turbocharger.

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Storage of new turbochargers and spare parts

1.4

Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

V

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

WARNING

Protection of health when handling VCIs

1.4

Page 7

1.4

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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).

olatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and no condensation can form are suitable for storage.

VCI products are not hazardous in the sense of the Hazardous Substances Ordinance. Nevertheless, the following points are to be observed when handling VCIs:

 Ensure good room ventilation.  Do not eat, drink or keep food at the workplace while working with

VCIs.

 Wear safety gloves.  Clean hands and face after working with VCIs.  For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

 Open the package.

 Remove the VCI corrosion protection emitter from the package and

 Dispose of the old VCI corrosion protection emitter in an environmen-

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

replace it with a new, identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be obtained at www.branopac.com.

tally compatible manner, professionally and in accordance with local regulations.

permanent the protection.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Storage of new turbochargers and spare parts

1.4

Long-term storage of replacement turbochargers or spare parts

NOTICE

Replacement components ready for operation

Unpacking replacement turbochargers or spare parts

Page 8

Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration).

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The following measures are required every 6 months:

 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.

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

bocharger or cartridge group must be inspected by an ABB Turbocharging 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.

If the 70% display field of the hygrometer (02) has not changed colour and the package is undamaged, the replacement turbocharger or replacement cartridge group can be placed into operation without any prior testing by an ABB Turbocharging Service Station.

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.

ts reserved.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Essential information

1.5

Essential information

Organisational measures

NOTICE

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

NOTICE

Any modifications, additions or conversions made to the turbocharger,

1.5

Page 9

In addition to the Operation Manual, the general statutory regulations for

September 2016 HZTL2410_EN Revision E

the prevention of accidents and for environmental protection in the country of use must also be observed.

This also applies to the provision and wearing of personal protective equipment.

regard to safety and risks is to be checked on a regular basis in accordance with the Operation Manual.

 The turbocharger must be shut down immediately in the event of modi-

fications affecting safety or of corresponding operating behaviour by stopping the engine. The fault should be reported to the person or department responsible.

which could impair safety, require the prior approval of ABB Turbo Systems.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Essential information

1.5

Original parts and safety

WARNING

Use original parts

Competence of personnel

Page 10

Original parts and accessories are specially designed for the turbocharger supplied by ABB Turbo Systems.

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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.

 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.

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

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Essential information

1.5

Design variants

Accuracy of illustrations

Registered Trademarks

Page 11

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

September 2016 HZTL2410_EN Revision E

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

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

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Symbols and definitions

1.6

Symbols and definitions

Definition of notes

NOTICE

Note

Definition of mandatory signs

Definition of caution / warning

ABB Turbo Systems

Official ABB Turbo Systems Service Stations

1.6

Page 12

The following symbols are used in the documents:

 Prerequisite

 Step of a procedure

 List, first level

- List, second level

[➙ ] Refers to a page number

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

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.

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

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

In this document, official service stations are referred to as ABB Turbocharging Service Stations. They are inspected and certified regularly by ABB Turbo Systems. See also chapter Contact information [➙ 15].

ts reserved.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Turbocharger rating plate

1.7

Turbocharger rating plate

06 Customer part number

07 Designation of the special design

08 Weight of turbocharger in kg

09 Turbocharger type

11 Year of construction of turbocharger

1.7

Operating limits

Recommended inspection and replacement intervals of turbocharger components

Further data

1.7

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Page 13

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

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

10 Serial number

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Turbocharger rating plate

1.7

Explanation of the rating plate

Positions of the rating plates

1.7.1

1.7.2

Page 14

The recommended replacement intervals and the corresponding operational limits are jointly defined with the engine manufacturer. This information is specific to the system.

Operation above the indicated values n

Bmax

, t

can considerably shorten the

Bmax

recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station.

n

Mmax

and t

normally apply only when running at overload (110%) during tri-

Mmax

als on the engine test bed. These limits can also be permitted during operation for special applications. Operation above n

Mmax

and t

is not permitted.

Mmax

Non-observance of the recommended replacement intervals can increase the risk of unpredictable component failures.

September 2016 HZTL2410_EN Revision E

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

ts reserved.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

1

Contact information

1.8

Contact information

1.8

Page 15

Contact information for the official service stations of ABB Turbo Systems

September 2016 HZTL2410_EN Revision E

is available online.

 Scan the QR code to access our website.

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

www.abb.com/turbocharging

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Introduction

2.1

Safety

Introduction

2

2.1

Page 17

2.1

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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 operation 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 turbocharger by his personnel.

All instructions in this chapter must be observed to ensure safe and trouble-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 Definition of safety instructions).

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

CE conformity

2.2

CE conformity

Information

2.2

Page 18

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

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Definition of mandatory signs

2.3

Definition of mandatory signs

To be worn at all times

Protective clothing

Safety footwear

To be worn according to the specific work

Safety glasses

Safety goggles

Safety gloves to protect

Respiratory mask to protect

Safety helmet

Ear protection

2.3

Page 19

to protect against mechanical hazard and risk of falling

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against

- Mechanical hazard

- Chemical hazard

against

- Dusts

- Gases

- Thermal hazard

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Definition of Safety instructions

2.4

Definition of Safety instructions

WARNING

Definition of warning

WARNING

Warning signs must be observed at all times.

CAUTION

Definition of caution

CAUTION

Caution signs must be observed at all times

2.4

Page 20

The following symbols and terms used in this manual concern safety or refer to possible hazards:

Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word



are either not followed or not followed precisely.

Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word

are either

not followed or not followed precisely.



.

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Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Warning plates on the turbocharger

2.5

Warning plates on the turbocharger

Uninsulated turbochargers

2.5

Page 21

Warning plates are attached to the turbocharger at the following places:

September 2016 HZTL2410_EN Revision E

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

 Order new warning plates from ABB Turbocharging Service Stations.

 Remove unreadable warning plates.

 Clean and degrease surfaces provided for warning plates.

 Attach new warning plates.

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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Safe operation and maintenance

2.6

Safe operation and maintenance

Work safety and work area safety

WARNING

Risk of falling

Welding work in the vicinity of the turbocharger

2.6

Page 22

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.

September 2016 HZTL2410_EN Revision E

There is the risk that someone can fall when working on the turbocharger.

 Do not climb on the turbocharger or on parts attached to it or use

these as climbing aids.

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

platforms suitable for this purpose.

 Observe all general regulations for the prevention of accidents.

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

stress.

 Work only with suitable tools as well as equipment and working mate-

rials that are in perfect condition.

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

be damaged.

 Keep the workplace clean, clear away loose objects and remove ob-

stacles on the floor.

 Keep the floor, equipment and the turbocharger clean.

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

ready or in position

 Eliminate leaks.

 Keep fire-protection materials and fire-extinguishing equipment ready.

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

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

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

sparks.

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

can enter the turbocharger.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Safe operation and maintenance

2.6

Safety during start-up / commissioning and operation

Safety during cleaning

Page 23

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

 Remove any obstacles and objects lying around.

 Before start-up / commissioning, check all pipes from and to turbo-

September 2016 HZTL2410_EN Revision E

charger for damage and leaks.

 Don't work in any way that could impair safety when working on turbo-

charger.

 After about every 12 hours of operation or at least once a day, inspect

turbocharger for visible damage and defects.

 Immediately report any damage or changes in operational perfor-

mance to person responsible.

 If damage is discovered, immediately shut down turbocharger and se-

cure it against inadvertent or unauthorized use.

 When switching on auxiliary power sources (hydraulics, pneumatics,

electricity, water), keep an eye open for any hazards resulting from supplying these power sources.

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.

 Observe the material safety data sheet for the cleaning agent or sol-

vent.

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

safety data sheet.

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

your cleaning work.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Safe operation and maintenance

2.6

Safety during disassembly, assembly, maintenance and troubleshooting

CAUTION

Mechanical work on the turbocharger

Safety when taking out of operation or preparing for mothballing

Page 24

 Always perform the specified adjustments, servicing as well as inspec-

tion work and observe inspection intervals.

 Inform operating personnel about all service and repair work before

beginning.

September 2016 HZTL2410_EN Revision E

 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.

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

oil supply.

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

properly.

Possible damage to or destruction of components on the turbocharger.

 Perform only those tasks that are described in this manual.  Perform work only for which training has been carried out.

 Secure the rotor so it cannot turn. The rotor can turn on its own from

the force of the stack draught.

 Clean the turbocharger before mothballing it.

 Observe the material safety data sheet for the cleaning and mothball-

ing agents.

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

safety data sheet.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operation and maintenance

2.7

Hazards during operation and maintenance

Mechanical hazards during operation

WARNING

Risk of injury

Mechanical hazards when working on the turbocharger

WARNING

Mechanical hazards

2.7

Page 25

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charger if it has been installed properly.

During normal operation, no mechanical hazards emanate from the turbo-

Contact with rotating parts can lead to serious injuries. The turbocharger must never be operated without a filter silencer or an air suction branch. When the engine is at a standstill, the rotor can turn on its own because of stack draught.

 Operate the turbocharger in accordance with instructions.  During maintenance work, secure the rotor against unintentional ro-

tation.

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.

Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedures.

 Observe the general rules for occupational safety and prevention of

accidents.

 Ensure workplace safety.  Only perform operations that are described in this document.  Only perform operations for which you have previously received in-

struction or training.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operation and maintenance

2.7

Hazards due to noise

WARNING

Hazards due to noise

Hazards due to hot surfaces and substances

WARNING

Risk of burning

Page 26

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.

Noise can cause impaired hearing, damage to health, mental disturb-

September 2016 HZTL2410_EN Revision E

ances, diminished attention and irritation.

 Always wear ear protection when the engine is running.  When the sound pressure level is above 85 dB(A), always wear ear

protection.

Wear ear protection.

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

Touching hot surfaces or contact with hot operating materials can lead to serious burns.

 Do not touch hot surfaces and heed the warning plate on the turbo-

charger.

 Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operation and mainten

2.7

WARNING

Hot surfaces on the non-insulated turbocharger

Hazards due to operating and auxiliary materials

WARNING

Handling operating and auxiliary materials

Page 27

ance

Non-insulated turbochargers can cause serious injuries to personnel (burns).

The turbocharger is supplied by ABB Turbo Systems without insulation depending on the order from the enginebuilder. If supply is without insu-

September 2016 HZTL2410_EN Revision E

lation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.

 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.

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

Ingestion or inhalation of vapours of operating and auxiliary materials or contact with such can cause damage to health.

 Avoid inhalation and contact with the skin.  Ensure good ventilation.  Observe details in the safety data sheets of the operating and auxil-

iary materials.

 Observe local laws.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operation and maintenance

2.7

WARNING

Risk of fire, explosion

CAUTION

Risk of environmental damage

Page 28

Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion.

 Observe the details in the material safety data sheets of the operat-

ing and auxiliary materials.

 Comply with local legislation.  Do not allow any exposed flame or ignition source during cleaning

September 2016 HZTL2410_EN Revision E

work.

 Carry out cleaning in the open or provide sufficient aeration and ven-

tilation.

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.

 Handle operating and auxiliary materials carefully.

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

on the containers of the operating and auxiliary materials.

 Wear appropriate protective clothing.

 Avoid inhalation and contact with the skin.

 Ensure that the work space is adequately ventilated.

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

 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 regulations.

 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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operation and maintenance

2.7

Hazards when handling insulating materials

WARNING

Hazards due to insulating materials

Page 29

September 2016 HZTL2410_EN Revision E

Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.

 Use only suitable, non-combustible insulating materials.  Ensure that the work area is well ventilated.  Avoid stirring up dust.  Use tools and processes which keep dust to a minimum.  Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  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.

 Use only suitable, non-combustible insulating materials.

 Ensure that the work area is well ventilated.

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

 Avoid stirring up dust.

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

 Remove packing materials only in the work area.

 Take particular care when removing old insulating materials.

 Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Hazards during operati maintenance

2.7

Hazards due to electrical components

WARNING

Hazards due to electrical components

on and

Page 30

Electrical components operate with voltages which can present hazards to humans.

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

trained specialists.

 Heed any country-specific regulations.

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Deflagration on gas engines

2.8

Deflagration on gas engines

2.8

Page 31

ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar.

After a deflagration event ABB Turbo Systems recommends verifying the

September 2016 HZTL2410_EN Revision E

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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Periodic checking of the pressure vessel

2.9

Periodic checking of the pressure vessel

WARNING

Hazards from pressure vessels

2.9

Page 32

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.

September 2016 HZTL2410_EN Revision E

 The operator is responsible for the safe operation of the pressure vessel.

The operator must keep the pressure vessel in a proper condition and monitor it. Necessary repair or maintenance work must be carried out without delay and the required safety precautions must be taken.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Safety

2

Lifting loads

2.10

Lifting loads

WARNING

Suspended loads

2.10

Page 33

September 2016 HZTL2410_EN Revision E

Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences.

 Loads must always be fastened to technically perfect lifting gear with

sufficient loading capacity.

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

 Fasten turbocharger assemblies / components as described in respec-

tive handling steps.

 Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).

 Use suitable protection at sharp edges.

 Completely screw in assembly / fitting devices without fail so that they

cannot work loose during use.

 Use assembly / fitting devices only for applications described.

 Make sure removed turbocharger components stand safely and se-

curely.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Oil supply

3.1

Commissioning

Oil supply

Oil filtration

CAUTION

Depending on the turbine specifications and bearings used, varying

NOTICE

Also follow the enginebuilder's instructions regarding filter mesh and

3

3.1

Page 35

3.1

September 2016 HZTL2410_EN Revision E

A carefully designed and installed oil supply, which functions in all possible operational conditions, is an important prerequisite for trouble-free turbocharger operation.

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

 Heed the instructions of the engine builder when selecting the lubricat-

ing oil and oil-change intervals.

amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts.

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%.

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

 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.

 Check that oil filters are clean before commissioning.

separation efficiency.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Oil supply

3.1

Lubricant

NOTICE

All lubricating oils used for engines are admissible.

Oil inlet viscosity and temperature

CAUTION

Falling below the minimum oil inlet temperature

Page 36

September 2016 HZTL2410_EN Revision E

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

1) Kinematic viscosity (mm2/s = cSt)

2) Oil-inlet temperature (°C)

A Permissible range

Serious machine or property damage can be caused by excessively high oil viscosity and the resulting lack of oil in the bearings.

 Do not allow the oil inlet temperature to fall below the minimum 30 ºC

when starting the engine.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Oil supply

3.1

Oil pressure

Status for operation

Oil pressure in front of

turbocharger

[bar]

CAUTION

Prelubrication

Page 37

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

September 2016 HZTL2410_EN Revision E

Normal operation 2.0 … 4.5

Engine start: cold oil, permissible for maximum

≤ 8.0

15 minutes

Engine idling ≥ 0.2

Pre- and post-lubrication (engine stopped) ≤ 1.0

Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting.

 Activate prelubrication device before starting engine.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Oil supply

3.1

Lubricating oil temperature at the inlet

CAUTION

Machine damage

Status for operation

Oil temperature at inlet

T

oil,inlet

Permissible

30 … 105 °C

Not permissible → stop engine

> 110 °C

Lubricating oil temperature at the outlet

Status for operation

Oil temperature at outlet

T

oil,outlet

Page 38

Machine damage may result if the oil temperature at the oil inlet exceeds the permissible range.

 Keep the oil temperature at the oil inlet as specified in the following

table.

Temporarily permissible (< 1 h) → alarm > 105 °C

Not permissible → do not start engine (before

starting: preheat oil)

< 30 °C

September 2016 HZTL2410_EN Revision E

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 following table. The specified oil outlet temperature must be regarded as an alarm value for turbocharger operation and be monitored in accordance with standard regulations.

Permissible ≤ 160 °C

Temporarily permissible → alarm > 160 °C

Not permissible → stop engine > 180 °C

Permissible ≤ T

Temporarily permissible → alarm > T

oil,inlet

+ 55 K

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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Inspection work

3.2

Inspection work

Inspection before commissioning

CAUTION

Contaminated oil

CAUTION

Prelubrication

3.2

3.2.1

Monitoring devices

Filter mat

Lubricating system

Warning plates on turbocharger

3.2

Page 39

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.

September 2016 HZTL2410_EN Revision E

 Check for correct functioning.

 Inspect for damage.

 Check oil filter for cleanliness before commissioning.

Particles of dirt and solid matter in the oil can cause serious damage to the machine or property.

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

lubricating system must be flushed thoroughly with warm oil.

 When running in the engine and after all service work on the lubricat-

ing system, special running-in filters must be used.

 Check oil pressure in oil supply lines.

Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting.

 Activate prelubrication device before starting engine.

 Check whether the warning plates are present and legible.

 Check whether the protective sheets have been removed.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Inspection work

3.2

Check after start-up (engine at idling speed)

Lubricating system

Gas, air and oil lines

Check when running up engine

NOTICE

Lubricants and pastes used during assembly of the turbocharger liquefy

Inspection after 100 service hours

3.2.2

3.2.3

3.2.4

Page 40

 Check oil pressure in oil supply lines.

 Check oil inlet temperature.

September 2016 HZTL2410_EN Revision E

The permissible values are listed in the section Oil supply.

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

 Measure speed, oil pressure and charging pressure at various engine

performance levels.

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

 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.

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 Turbocharging service station.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Commissioning

3

Commissioni operation

3.3

Commissioning after taking out of operation

3.3

If provided

ng after taking out of

Page 41

3.3

 Remove cover plates (blind flanges) between compressor casing out-

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

September 2016 HZTL2410_EN Revision E

 Inspect exhaust gas duct / line in front of and after turbine for any

combustion deposits, foreign matter or residual water. Clean and remove.

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

and remove.

 Start up turbocharger oil circulation system at engine end.

 Prepare turbocharger for operation as instructed in section "Inspection

work before start-up / commissioning" of chapter headed "Start-up / commissioning".

 Start up turbocharger.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Noise emissions

4.1

Operation

Noise emissions

WARNING

Hazards due to noise

1)

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

2)

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

4

4.1

Page 43

4.1

September 2016 HZTL2410_EN Revision E

Noise can cause impaired hearing, damage to health, mental disturbances, diminished attention and irritation.

 Always wear ear protection when the engine is running.  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 distance of 1 metre from the turbocharger.

1)

The highest sound pressure level of emissions

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 taken

2)

.

 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.

A-weighted emission sound pressure level

sure that equivalent acoustic insulating measures are taken.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Noise emissions

4.1

Suggestion for noise insulation of the bellows

02

Bellows

05

Insulation mat (at least 15 mm)

Page 44

September 2016 HZTL2410_EN Revision E

01 Compressor casing 04 Insulation pads

03 Charge air duct / scavenging

air line

06 Sheet metal cover

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Servicing work

4.2

Servicing work

CAUTION

Service intervals

CAUTION

Shortened service intervals

NOTICE

Service inspection after 5 years

4.2

Page 45

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

September 2016 HZTL2410_EN Revision E

order.

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.

 Carry out service work at specified time 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.

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

tems.

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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Servicing work

4.2

Service work every 25 … 50 hours

CAUTION

Unknown changes during operation

Servicing work according to the engine manufacturer's instructions

Service work in accordance with instructions on rating plate

4.2.1

4.2.2

Oil filter

4.2.3

Page 46

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

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

 Clarify the cause of any variances.

September 2016 HZTL2410_EN Revision E

The consequences can range from an impairment to a breakdown.

 Have unknown causes clarified by an ABB Turbocharging service

station.

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

not running.

(In general, after 8000 - 12000 hours of operation)

Rotor and bearing parts must be inspected and assessed by an ABB Turbocharging Service Station. The following work can be carried in preparation.

 Remove cartridge group as described in chapter Disassembly and as-

sembly.

 Measure clearances.

 Clean turbine and compressor casings and check them for cracks and

erosion / corrosion.

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

 Clean nozzle ring and check for cracks and erosion.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Servicing work

4.2

Entries in engine logbook

4.2.4

If provided

Page 47

By monitoring the engine, conclusions can be drawn about the turbocharger performance.

September 2016 HZTL2410_EN Revision E

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

 Engine performance and speed

 Air intake temperature

 Exhaust gas temperature in front of and behind the turbine

 Pressure of charge air

 Pressure drop in charge air cooler

 Lubricating oil pressure and lubricating oil temperature

 Air temperature behind compressor and charge air cooler

 Turbocharger speed

 Pressure loss in air filter

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Expected exchange intervals

4.3

Expected exchange intervals

Rotating components

Non-rotating components

Expected replacement intervals [h]

GAS / MDO

HFO

Nozzle ring

50000

10000 … 25000

Partition wall

50000

35000 … 50000

Bearing parts

12000 … 24000

4.3

Page 48

The recommended replacement intervals for compressor wheels and turbine 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.

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.

September 2016 HZTL2410_EN Revision E

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.

Turbine casing 25000 … 50000 25000 … 50000

Gas outlet flange 50000 35000 … 50000

Rotor components See the data on the rating plate

Other casings 50000 50000

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

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Expected exchange intervals

4.3

Influencing parameters

Page 49

The specified values are only guide values and not guaranteed. The actual values can deviate considerably from the guide values due, for example, to the following influences:

September 2016 HZTL2410_EN Revision E

 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)

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Speed measurement

4.4

Speed measurement

CAUTION

Do not use cables as a climbing aid

4.4

Page 50

A speed measuring system permits continuous monitoring of the turbocharger speed.

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

 Do not tension the speed measurement cables.

September 2016 HZTL2410_EN Revision E

86505(A) Speed sensor (cable not integrated) 86526 F/I converter

86505(B)

86515(A)

86515(B)

Speed sensor (cable integrated) 86528 Tachometer

Cable connector to 86505(A) 01 Screw plug

Cable connector to 86505(B) 02 Gasket

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Speed measurement

4.4

Speed differences with multiple turbochargers per engine

4.4.1

Page 51

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

September 2016 HZTL2410_EN Revision E

The difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the speed limit n

Bmax

.

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

 Reduce engine performance immediately until the highest turbo-

charger speed no longer exceeds 70% of n

Bmax

.

 If the engine cannot be stopped, continue to run at this reduced engine

performance or turbocharger speed.

 If the turbocharger surges continuously, engine performance must be

reduced further.

 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:

 Inspect the air and gas lines as well as the turbocharger and eliminate

any problems.

 In any event, it is recommended that you contact the nearest ABB

Turbocharging Service Station.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Speed measurement

4.4

Replacing the speed sensor

WARNING

Hot cable connector and hot speed sensor

Part number

TPS48

TPS52

TPS57

TPS61

4.4.2

Page 52

Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C.

 Wear safety gloves when removing the cable connector and speed

sensor.

Wear safety gloves to protect against thermal hazards.

September 2016 HZTL2410_EN Revision E

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



 Switch off the lubricating oil supply to the turbocharger.

 Disconnect the cable connector from the speed sensor.

 Screw out defective speed sensor.

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

 Adhere to tightening torque.

86505 15 Nm 15 Nm 15 Nm 15 Nm

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Speed measurement

4.4

NOTICE

Sealing the speed sensor

Failure of speed measuring system

4.4.3

Page 53

September 2016 HZTL2410_EN Revision E

The speed sensor is designed with a sealing lip and does not require an additional gasket when fitted.

 Connect cable connector to speed sensor.

 Switch on lubricating oil supply to turbocharger.

Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Operation

4

Stopping the engine

4.5

Stopping the engine

CAUTION

Stopping the engine of oil-cooled turbocharger version

CAUTION

Stopping the engine of water-cooled turbocharger version

4.5

Page 54

Heat in the turbocharger must be dissipated by the further circulating lubricating oil.

 Post-lubricate for 15 … 20 minutes.  Maintain oil pressure of 0.5 … 1.0 bar for post-lubrication.

Heat in the turbocharger must be dissipated.

 Allow turbocharger cooling water to run for 15 … 20 minutes after

stopping engine.

 Allow oil lubrication to continue running until rotor comes to a stop.

Further post-lubrication is not required and not recommended.

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Foreword to Maintenance

5.1

Maintenance

Foreword to Maintenance

CAUTION

Risk of damage during mechanical cleaning

NOTICE

Cleaning method

5

5.1

Page 55

5.1

September 2016 HZTL2410_EN Revision E

General maintenance work involves regular visual checks and cleaning tasks which are intended to ensure the trouble-free functioning of the turbocharger.

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

If mechanical cleaning is carried out too often, this can lead to damage and corrosion on the components.

 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.

 Perform mechanical cleaning, especially of the cartridge group, only

once within the service interval.

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.

 Dispose of dirty water and cleaning agents in an environmentally com-

patible manner, professionally and in accordance with valid local regulations.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning the compressor during operation

5.2

Cleaning the compressor during operation

NOTICE

If the coating of dirt is very thick and hard, the compressor can only be

5.2

General

Cleaning interval

5.2

Page 56

The contamination of the compressor stage (compressor wheel, wall insert 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.

September 2016 HZTL2410_EN Revision E

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.

cleaned manually when disassembled. This cleaning must be carried out by an ABB Turbocharging Service Station.

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

Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning the compressor during operation

5.2

Cleaning method

CAUTION

Corrosion and deposits when cleaning

CAUTION

The injection pipe must on no account be connected directly via a cock

Principle of wet cleaning

V-engines

Sequential charging

Page 57

Cleaning the compressor while in operation is carried out as wet cleaning. This cleaning method has been tested and approved by ABB Turbo Systems.

September 2016 HZTL2410_EN Revision E

To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the filter silencer 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, provided that the degree of contamination is not too high.

Damage and impairment of turbocharger parts due to salt water and cooling water additives

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

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.

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.

In the case of sequential charging, care must be taken to ensure that turbocharger compressors are cleaned regularly, especially after periods of operation in the lower performance range.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning the compressor during operation

5.2

Wet cleaning compressor using external water pressure vessel (XC1)

NOTICE

Supplying water from the externally mounted water vessel is suitable

Operating state prerequisites for cleaning compressor with XC1

NOTICE

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

5.2.1

Approval by enginebuilder

Page 58

These instructions for wet cleaning only apply when cleaning is carried out with clean water and under the precondition that the enginebuilder approves the process.

September 2016 HZTL2410_EN Revision E

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 charging).

tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled:

 Run engine at load from 50 … 85 %.  Start cleaning cycle according to following description Wet cleaning

operation with XC1.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning the compressor during operation

5.2

Procedure for wet cleaning the compressor with XC1

NOTICE

Whether or not cleaning has been successful can be seen from the

Product

Engine load

Contents

of cleaning medium vessel

[dm3]

Water

injection time

t1 [s]

TPS

50 … 85 %

0.4

10

Operating the water pressure vessel

Cleaning parameters per turbocharger compressor

Page 59

September 2016 HZTL2410_EN Revision E

X Sealing plug D Compressed air

Y

Valve activator W Water

Z

Vessel

 Remove sealing plug (X).

 Fill the vessel (Z) with clean water.

 Screw in the sealing plug.

 Push the valve activator (Y) against the spring and hold for 10 to

15 seconds until the entire volume of water has been injected.

 Do not repeat the cleaning cycle until a stabilisation period of at least

10 minutes has elapsed.

charging or flushing pressure and also from the exhaust gas temperatures. 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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Turbine cleaning during operation

NOTICE

Regular cleaning

5.3

Page 60

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, sodium 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.

September 2016 HZTL2410_EN Revision E

Experience with turbocharger operation shows that the intervals between overhauls can be extended if cleaning while in operation is carried out periodically. 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 operation 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 mechanically cleaned by an ABB Turbocharging Service Station.

Regular turbine cleaning during operation prevents or delays excessive build-up of contamination.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Cleaning intervals

NOTICE

Cleaning intervals

Cleaning method

NOTICE

Approval by engine manufacturer

Page 61

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

September 2016 HZTL2410_EN Revision E

Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems.

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 decisive for the choice of cleaning method.

The prerequisite for wet cleaning is that the engine manufacturer approves the method and his instructions are followed.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Wet cleaning methods

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

Process with long water injection time (10 minutes cleaning)

NOTICE

Choice of cleaning method

5.3.1

Page 62

The cleaning process with short water injection time is used for turbocharger 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.

The cleaning process with a long water injection time is used for turbocharger 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.

September 2016 HZTL2410_EN Revision E

If you need information about the choice of cleaning method (short / long), you can contact the engine builder or an official ABB Turbocharger service station.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Prerequisites

CAUTION

Risk of corrosion and deposits

CAUTION

Maximum temperature in front of turbine during cleaning

CAUTION

Impermissible thermal stressing and flooding of the turbine

NOTICE

V-engines

5.3.2

Page 63

September 2016 HZTL2410_EN Revision E

Impairment and damage of turbocharger by salt water and cooling water additives in flow ducts

 Don't use salt water for cleaning, but only clean fresh water.  Avoid corrosion on casing inner surfaces.  Let engine run for 10 minutes after wet 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 temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning.

 Don't exceed maximum temperature in front of turbine when cleaning.

Smaller volumes of water can result in poor cleaning. Larger volumes of water lead to impermissible thermal stressing of the turbine components and can cause flooding of the turbine.

 Be absolutely sure to observe turbine cleaning parameters.

In the case of V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers. This cleaning process is faster and the risk of turbocharger surging is reduced.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Recommended operating state for turbine wet cleaning

Characteristic / component

Conditions

short

water injection time

long

water injection time

Page 64

The following operating state has been tested and is approved by ABB Turbo Systems:

September 2016 HZTL2410_EN Revision E

Engine load (guide value) 20 … 40 %

Turbine inlet temperature

before water injection

T

TE

350 - 400 °C 350 - 430 °C

Water supply ensured

Water pressure (overpressure over atmosphere) p

WT

2.0 bar 1.5 bar

If necessary, engine performance must be reduced to maintain these conditions.

The cleaning cycle can now be started based on the following description.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during

5.3

Procedure for method with short water injection time

Cleaning parameters during the process

TPS

Temperature in

front of the turbine

during cleaning

[°C]

Water

volume flow 1)

[dm3/min]

Injection time

[min]

Pause between

injections

[min]

48

≤ 450

6

0.5

3

CAUTION

Maximum temperature in front of turbine during cleaning

5.3.3

operation

Page 65

 Prerequisites have been fulfilled.

 Wait 10 minutes during a stabilising phase after reducing the engine

September 2016 HZTL2410_EN Revision E

load.

 Open the shut-off valve.

 Set the required water flow rate as specified in the table of cleaning

parameters using the flowmeter and inject for 30 seconds.

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

 Repeat the 30-second water injection two times.

 Close the shut-off valve.

 Wait 10 minutes during a stabilising phase before increasing engine

load again.

This completes the turbine cleaning process.

52 8

57 11

61 17 5

1)

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

(3x)

mosphere)

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 temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning.

 Don't exceed maximum temperature in front of turbine when cleaning.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Turbine cleaning during operation

5.3

Procedure for method with long water injection time

Cleaning parameters during the process

TPS

Temperature in

front of the turbine

during cleaning

[°C]

Water

volume flow 1)

[dm3/min]

Injection time

[min]

Stabilising phase

before / after water

injection

[min]

57

8.5

CAUTION

Maximum temperature in front of turbine during cleaning

5.3.4

Page 66

 Prerequisites have been fulfilled.

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

 Open the shut-off valve.

 Set the required water flow rate as specified in the table of cleaning

parameters using a flowmeter and inject for 10 minutes.

 Close the shut-off valve.

 Wait 10 minutes as a stabilising phase before increasing the engine

load again.

This completes the turbine cleaning process.

September 2016 HZTL2410_EN Revision E

48 ≤ 530 4 10 10

52 5.5

61 12

1)

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

mosphere)

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 temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning.

 Don't exceed maximum temperature in front of turbine when cleaning.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Cleaning components mechanically

Introduction

CAUTION

Choosing cleaning tools

NOTICE

Disassembly and assembly

5.4

5.4.1

5.4

Page 67

September 2016 HZTL2410_EN Revision E

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.

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

 Dispose of dirty water and cleaning agents in an environmentally com-

patible manner, professionally and in accordance with valid local regulations.

The disassembly and assembly of the components is described in chapter Disassembly and assembly.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Cleaning the filter silencer

NOTICE

Disassembly and assembly

Cleaning the filter ring (if provided)

5.4.2

Page 68

September 2016 HZTL2410_EN Revision E

81135 Filter silencer body 81266 Cover grid

81136

81137

81265

Absorption segment 81270 Tension band

Sheet-metal covering 81271 Lock

Filter ring

The procedure for disassembly and assembly of the filter silencer is described in the chapter entitled Disassembly and Assembly.

 Remove filter ring (81265).

 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 cleanliness of the air that is drawn in.

 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).

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

 Dispose of dirty water and gentle detergents in accordance with valid

local regulations.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Cleaning the absorption segments

Fitting the filter silencer

Page 69

 Loosen the tension bands (81270).

 Remove the cover grid (81266).

 Pull out the sheet-metal coverings (81137), bend them up and remove

September 2016 HZTL2410_EN Revision E

the absorption segments (81136).

 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.

 Have absorption segments which are heavily contaminated replaced

by an official ABB Turbocharging Service Station.

 Insert the absorption segments (81136) into the sheet-metal coverings

(81137).

 Bend the sheet-metal coverings (81137) back into their original shape

and insert them into the slot guides in the silencer body (81135).

 Fit the cover grid (81266).

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

 Damaged tension bands must be replaced with new ones.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Compressor-end, non-rotating parts

WARNING

Handling operating materials and supplies

5.4.3

Page 70

Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.

 Do not breathe in these substances and avoid contact with the skin.  Ensure proper ventilation.  Observe the information in the material safety data sheet for the op-

erating materials and supplies.

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

safety data sheet.

 Comply with local legislation.

Wear safety goggles.

September 2016 HZTL2410_EN Revision E

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

 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.

 Dry components completely.

 Spray cleaned surfaces with penetrating oil. Do not spray the outer

surfaces of the turbocharger.

 Dispose of dirty water and cleaning agent in accordance with the spec-

ifications in the safety data sheet.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Turbine-end, non-rotating parts

WARNING

Handling operating materials and supplies

5.4.4

Page 71

September 2016 HZTL2410_EN Revision E

Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.

 Do not breathe in these substances and avoid contact with the skin.  Ensure proper ventilation.  Observe the information in the material safety data sheet for the op-

erating materials and supplies.

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

safety data sheet.

 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 Turbine casing 56001 Nozzle ring

52400 Gas outlet flange

 Place contaminated parts in hot water or in a liquid such as carbon

remover to soften the contamination.

 Brush away the contamination or remove with a steam cleaner.

 Repeat the soaking and brushing if necessary.

 Use clean water to completely clean parts of any solvents.

 Dry components completely.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning compo

5.4

Cartridge group

Introduction

CAUTION

Corrosion

5.4.5

nents mechanically

 Spray cleaned surfaces with penetrating oil. Do not spray the outer

Page 72

surfaces of the turbocharger.

 Dispose of contaminated water and cleaning agents in accordance

with the information in the material safety data sheet.

September 2016 HZTL2410_EN Revision E

If the cartridge group is not put into operation again immediately after cleaning, parts may corrode.

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

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).

 Remove turbocharger from the engine (see chapter Removal and in-

stallation [➙ 87]).

 Remove cartridge group (see chapter Disassembly and assembly

[➙ 93]).

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Cleaning the compressor end

CAUTION

Selection of the cleaning agent

CAUTION

Water and contamination in the cartridge group

Page 73

September 2016 HZTL2410_EN Revision E

Cleaning agents which contain chlorine attack metals.

 Use only pH-neutral cleaning agents which do not attack metals.  Observe safety data sheet.

If water or contamination penetrates the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge group.

 Make sure that no water or contamination can enter into the cartridge

group.

 Clean compressor wheel with a cloth or soft brush soaked in water

with household detergent. Do not use any wire brushes!

 Dry the compressor wheel and the gap between the compressor and

the bearing casing with a weak jet of compressed air.

 Lightly spray the compressor wheel and the gap between the com-

pressor and the bearing casing with penetrating oil.

 Dispose of dirty water and cleaning agent in accordance with the safe-

ty data sheet.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

Cleaning the turbine end

Product

A [mm]

B [mm]

C [mm]

TPS52

128

20

245

TPS61

187

30

357

CAUTION

Selection of the cleaning agent

Soaking the dirt

Page 74

Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the turbine 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.

September 2016 HZTL2410_EN Revision E

TPS48 108 17 205

TPS57 157 25 300

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

 Place the tank (02) in a larger container (03), so that the excess liquid

can be collected.

Cleaning agents which contain chlorine attack metals.

 Use only pH-neutral cleaning agents which do not attack metals.  Observe safety data sheet.

 Fill the tank (02) with soaking liquid.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

NOTICE

Heat the liquid

WARNING

Heating up of cleaning agents and operating fluids

CAUTION

Water and dirt in the cartridge group

To shorten the soaking time the liquid can be heated to maximum

Page 75

60 ºC.

September 2016 HZTL2410_EN Revision E

When cleaning agents or operating fluids are heated up, explosive vapours can be produced which are hazardous to health.

 Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

If water or dirt gets into the cartridge group, the turbocharger function may be impaired and parts in the cartridge group may be damaged.

 Place the cartridge group on suitable wooden or metal supports (01).  Maintain dimension (B) for the supports (01), so that the cartridge

group does not submerge too deep.

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

WARNING

Health hazard due to soot particles

Removing the dirt

Page 76

If soot particles enter the eyes or respiratory tract, this can be harmful to health.

 Avoid the formation of dust.  Vacuum up dust with a suitable vacuum cleaner.  Wear a respiratory mask to protect against particles (P1 or P2 mask).  Wear safety goggles.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

 Raise the cartridge group and align horizontally.

September 2016 HZTL2410_EN Revision E

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

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Maintenance

5

Cleaning components mechanically

5.4

CAUTION

Water and dirt in the cartridge group

CAUTION

Non-permissible rotor unbalance after cleaning

Page 77

September 2016 HZTL2410_EN Revision E

If water or dirt gets into the cartridge group, the turbocharger function may be impaired and parts in the cartridge group may be damaged.

 Make sure that water or dirt does not get into the gap between the

partition wall and turbine.

Unevenly distributed residual contamination deposits lead to rotor unbalance. This can result in bearing or turbocharger damage.

 Remove all traces of contamination from the turbine.

 After brushing off the contamination, fill the tank (02) with clean water,

not salt water.

 Submerge the turbine of the cartridge group in clean water, so that

loose particles of dirt detach completely.

 Raise the cartridge group and align horizontally.

 Clamp the partition wall with the bearing casing.

 Dry the turbine and the gap between the turbine and partition wall with

a weak jet of compressed air.

 Lightly spray the turbine and the gap between the turbine and partition

wall with penetrating oil.

 Dispose of dirty water and cleaning agent in accordance with the spec-

ifications in the safety data sheet.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfunctions w

6.1

Troubleshooting

Malfunctions when starting

Sluggish start-up

Possible causes

Elimination

Vibrations

Possible causes

Elimination

Damaged turbine or compres-

Rubbing of rotating parts

Normal behaviour, no malfunction

6

6.1

hen starting

Page 79

6.1

September 2016 HZTL2410_EN Revision E

Turbocharger Turbocharger contaminated Clean it

Damaged bearing Contact an ABB Turbocharging

Rubbing rotor

Foreign object in turbocharger

Service Station

Turbocharger Rotor unbalance Contact an ABB Turbocharging

Service Station

sor

Damaged bearing

Turbocharger Minor uniform wear around the periphery of rotor components,

caused by slight local rubbing of adjacent components, is permissible. 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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Surging of the turbocharger

6.2

Surging of the turbocharger

Turbocharger surging

Possible causes

Elimination

Turbocharger

Filter silencer or diffuser contaminated

Clean it Charge air

Cooler contaminated

Clean it

CAUTION

Prolonged or periodic surging

Sporadic surge blows

6.2

Page 80

September 2016 HZTL2410_EN Revision E

Engine Guard in front of the turbocharger is

contaminated or damaged

Heavy deposits of dirt in the turbine or nozzle ring

cooler

Charge air duct blocked

Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer

 Have the cause clarified immediately by an ABB Turbocharging ser-

vice station and rectified.

 Have components inspected for damage and, if necessary, replaced

by an ABB Turbocharging service station.

Clean / replace it

Surging of the turbocharger can occur during certain operating conditions such as when reducing the engine performance quickly when manoeuvring. At the same time, the flow direction in the compressor is momentarily 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.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfunctions during operation

6.3

Malfunctions during operation

Lubricating oil pressure too low

Possible causes

Elimination

Defective oil pump in lubricat-

Check / replace it

Turbocharger

Rotor axial clearance too large

Contact an ABB Turbocharging

Reduction in speed

Possible causes

Elimination

Engine

Defects of connected cylin-

Contact the enginebuilder

Damaged rotor components or

Contact an ABB Turbocharging

Increase in speed

Possible causes

Elimination

6.3

Page 81

September 2016 HZTL2410_EN Revision E

Engine Oil filter heavily contaminated Clean it

ing system

Manometer display wrong Replace the manometer

Service Station

ders when pulse charging

Turbocharger Heavy contamination of the

Clean it

turbine

bearing

Pipes Defects such as leaks in the

Service Station

Make repairs exhaust gas pipes or charge air ducts

Turbocharger Heavily contaminated nozzle

ring (with 4-stroke application)

Contact an ABB Turbocharging

Service Station

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfunctions during operation

6.3

Exhaust gas temperature too high

Possible causes

Elimination

Page 82

Engine performance and engine speed unchanged

Engine Malfunctioning injection system Repair it or contact the

manufacturer

Turbocharger Air starvation, for example filter

Clean it

silencer clogged with dirt

Compressor / turbine contaminated

Exhaust counterpressure too high Clean or repair the boiler

or exhaust silencer

Damaged or eroded turbine Contact an ABB Turbo-

charging 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

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfu

6.3

Charge air pressure too low

Possible causes

Elimination

nctions during operation

Page 83

Engine performance and engine speed unchanged, air intake condition normal

September 2016 HZTL2410_EN Revision E

Engine 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 Replace the manometer

Line to manometer leaking Repair the leak

Contaminated filter silencer caus-

Clean it

ing excessive loss of pressure

Compressor / turbine contaminated

Damaged compressor / turbine Contact an ABB Turbocharg-

ing Service Station

Exhaust counterpressure too high Clean or repair the boiler or

exhaust silencer

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfunctions during operation

6.3

Charge air pressure too high

Possible causes

Elimination

Fouling of the compressor due to the feeding in of ventilation gases

Possible causes

Remedy

Possible causes

Remedy

Turbocharger

Material of compressor

Check the fuel and its corrosive

Page 84

Engine performance and engine speed unchanged, air intake condition normal

Engine Malfunctioning injection sys-

tem

Poorly adjusted injection

Repair it or contact the manufacturer

Correct it

September 2016 HZTL2410_EN Revision E

system

Engine performance higher

Check engine performance

than expected

Turbocharger Manometer display wrong Replace the manometer

Reduced compressor performance/efficiency, hence engine performance losses

Turbocharger Heavy fouling of the com-

pressor components

Increased vibrations, compressor blade damage

Clean compressor

Optimize oil separation

Correct the feed of ventilation gases according to instructions of enginebuilder.

Reduced fatigue strength of the compressor wheel, compressor blade failure.

wheel corroded

components, and change fuel if necessary.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Malfunctions when stopping

6.4

Malfunctions when stopping

Noises during run-down

Possible causes

Elimination

Damaged bearing

Contact an ABB Turbocharg-

Foreign object in turbocharger

Run-down time too short

Possible causes

Elimination

Turbocharger

Turbocharger contaminated

Clean it

Rubbing rotor

6.4

Page 85

September 2016 HZTL2410_EN Revision E

Turbocharger Turbocharger contaminated Clean it

Rubbing rotor

ing Service Station

Damaged bearing Contact an ABB Turbocharg-

ing Service Station

Foreign object in turbocharger

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Troubleshooting

6

Speed measurement system

6.5

Speed measurement system

Possible causes

Elimination

Defective sensor

Contact an ABB Turbocharging Service Sta-

6.5

Page 86

No signal or amplitude is poor

Measured speeds too high

Measured speed too low

Other sources of errors

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.

tion

Contaminated sensor tip

The sensor tip is magnetic and can thus attract metal particles. As a result, the distance 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.

- - Contact an ABB Turbocharging Service Station

- - 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.

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Removal and installation

7

Transport

7.1

Removal and installation

Transport

Suspension of uninsulated turbocharger

Turbocharger with oil-cooled bearing

Complete turbocharger with gas outlet

Suspension of insulated turbocharger

7

7.1

Page 87

7.1

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casing

Turbocharger with oil-cooled bearing casing

Complete turbocharger with gas outlet casing

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Removal and installation

7

Turbocharger weights

7.2

Turbocharger weights

TPS48

[kg]

TPS52

[kg]

TPS57

[kg]

TPS61

[kg]

7.2

Page 88

Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification.

180 250 410 650

September 2016 HZTL2410_EN Revision E

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Removal and installation

7

Remove the turbocharger

7.3

Remove the turbocharger

7.3

 Disconnect all exhaust gas and air lines according to the instructions

Page 89

of the enginebuilder.

Version with water-cooled bearing casing:

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 Disconnect the water pipes according to the instructions of the en-

ginebuilder.

If present, remove hard insulation as follows:

 Remove screws and sheet metal (B) from the bearing casing insula-

tion.

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

 Pull the bearing casing insulation up and off. The bearing casing insu-

lation can be compressed to facilitate the removal process.

 Unplug the cable connector from the speed sensor.

 Attach lifting gear to bearing casing.

 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).

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

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

 Cover oil connections.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Removal and installation

7

Installing the turbocharger

7.4

Installing the turbocharger

Product

Through hole in

bearing casing

[mm]

Thread size

[mm]

Tightening

torque

[Nm]

Strength class

in acc. with

DIN/ISO 898

7.4

Page 90

 Remove covers from the oil connections.

 Visually inspect the O-ring gaskets of the oil intake and drain pipe (the

O-ring gaskets on the engine side are not supplied by ABB Turbo Systems).

September 2016 HZTL2410_EN Revision E

**) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque)

TPS48 17 M16 230 10.9/12.9

TPS52 21 M20 455 10.9/12.9

TPS57 21 M20 455 10.9/12.9

TPS61 25 M24 780 10.9/12.9

 Attach lifting gear to bearing casing.

 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) (see also section Transport / Weights).

 Lift turbocharger, place on bracket and align.

 Tighten fixing screws (D) to the bearing casing in accordance with the

table above.

 Attach all gas, water and air lines in accordance with the enginebuild-

er's instructions.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Removal and installation

7

Installing the turbocharger

7.4

Page 91

If present:

 Fit speed sensor and plug in cable connector.

 Adapt and fit bearing casing insulation (A).

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

Version with water-cooled bearing casing:

 Remove the screw plugs on the water connections and fit the water

pipes according to the enginebuilder's specifications.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Introduction

8.1

Disassembly and assembly

Introduction

CAUTION

Further work

NOTICE

Marking casing positions for assembly

Identifying assembly devices

WARNING

Maintaining assembly devices

8

8.1

Page 93

8.1

September 2016 HZTL2410_EN Revision E

Precondition for the work described below is a turbocharger removed from the engine (refer to the chapter entitled Removal and Installation).

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.

 ABB Turbo Systems recommends having further work carried out on-

ly by trained personnel from an ABB Turbocharging Service Station.

ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger.

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.

Assembly devices must be checked for damage before and after use.

 Visually check for corrosion, cracks, deformation and wear.  Don't use damaged assembly devices, but replace them.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Introduction

8.1

Customer spare parts set

Oil orifice

Tightening torques for turbocharger components

Tightening torques for assembly devices of ABB Turbo Systems

Page 94

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

 See chapter Spare parts.

September 2016 HZTL2410_EN Revision E

 When disassembling the turbocharger, a fitted oil orifice must not be

removed.

The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.)

If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Introduction

8.1

WARNING

Suspended loads

Definition of terms

Suspension point

Assembly device

Lifting gear

Page 95

September 2016 HZTL2410_EN Revision E

Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences.

 Attach turbochargers, assemblies or individual components only to

lifting gear which is in technically perfect condition and has sufficient load capacity.

 Make sure the load is suspended properly on the crane hook.  Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.



Defined load carrying point on a component or an assembly (blind hole thread, eye, lug).



Devices mounted on the turbocharger to create a suspension point. Assembly devices are calculated and designed especially for the defined application. They are not commercially available products. Use assembly / fitting devices only for the applications described.



Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Introduction

8.1

Swivel lifting eye to be used

Swivel lifting eye

Product

Thread

M

Length

L

Minimum load limit

(loading ca-

pacity)

Page 96

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

September 2016 HZTL2410_EN Revision E

TPS48 M10 17 mm 250 kg

TPS52 M10 17 mm 250 kg

TPS57 M12 21 mm 350 kg

TPS61 M12 21 mm 500 kg

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Module weights

8.2

Module weights

Description

TPS48

[kg]

TPS52

[kg]

TPS57

[kg]

TPS61

[kg]

8.2

Page 97

The specified weights of individual parts or assemblies are guides rounded off to the next highest value.

September 2016 HZTL2410_EN Revision E

1 Filter silencer 19 30 40 65

2 Radial air suction branch 6 8 11 21

3 Axial air suction branch 4 4 6 9

4 Compressor casing 24 35 55 90

5 Wall insert 7 10 13 30

6 Diffuser 2 3 6 10

7 Cartridge group 35 50 85 140

8 Nozzle ring 1 2 3 6

9 Burst ring 2 3 5 12

10 Turbine casing

with external burst protection

11 Gas outlet flange 4 8 16 30

12 Gas outlet bend 18 25 40 60

1 inlet 35 50 80 130

2 inlets 35 50 86 150

3 inlets - 53 95 170

4 inlets - - 95 170

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Disassembly and assembly

8

Disas turbocharger

8.3

Disassembling and assembling turbocharger

Removing the compressor casing

WARNING

Risk of burning

8.3

If provided

8.3

sembling and assembling

Page 98

Touching hot surfaces or contact with hot operating materials can lead to serious burns.

 Do not touch hot surfaces and heed the warning plate on the turbo-

charger.

 Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

September 2016 HZTL2410_EN Revision E

 Disconnect all air lines in accordance with the enginebuilder’s instruc-

tions.

 Remove the screws for the compressor casing insulation and disman-

tle the insulation.

 Undo the V-clamp (72020) and remove the filter silencer (81000) or air

suction branch (82000).

Abb TPS 52E01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual