Abb TPS52-F33 User Manual

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Operation Manual

TPS52-F33

ABB Turbo Systems Ltd CH 5401 Baden

Type TPS52-F33 HT845348 n

Mmax

Bmax

SOLD06 00250 20 60 60 Year 2020

HZTL2412 English

Original Operation Manual

843 t 801 t

Mmax

1/s °C

Bmax

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 / TPS44-F.. - TPS61-F..

Table of contents

Operation Manual

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

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

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

1.3 Intended use of the turbocharger .............................................................................. 6

1.4 Storage of new turbochargers and spare parts ....................................................... 7

1.5 Essential information ..................................................................................................... 9

1.6 Symbols and definitions .............................................................................................. 11

1.7 Turbocharger rating plate ........................................................................................... 12

1.8 Contact information..................................................................................................... 13

2 Safety...................................................................................................................... 14

2.1 Introduction ................................................................................................................... 14

2.2 CE conformity ................................................................................................................ 14

2.3 Definition of mandatory signs ................................................................................... 15

2.4 Definition of Safety instructions ............................................................................... 15

2.5 Warning plates on the turbocharger......................................................................... 16

2.6 Safe operation and maintenance............................................................................... 16

2.7 Hazards during operation and maintenance........................................................... 20

2.8 Deflagration on gas engines....................................................................................... 25

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

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

3 Start-up ................................................................................................................. 28

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

3.2 Inspection work ............................................................................................................. 32

3.3 Commissioning after taking out of operation ........................................................ 34

4 Operation ............................................................................................................... 35

4.1 Noise emissions ............................................................................................................ 35

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

4.3 Expected exchange intervals ...................................................................................... 39

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

4.5 Stopping the engine .................................................................................................... 44

5 Maintenance .......................................................................................................... 45

5.1 Foreword to Maintenance .......................................................................................... 45

5.2 Cleaning the compressor during operation ........................................................... 46

5.3 Turbine cleaning during operation........................................................................... 50

5.4 Cleaning components mechanically.......................................................................... 56

Operation Manual / TPS44-F.. - TPS61-F..

Table of contents

6 Troubleshooting.................................................................................................... 67

6.1 Malfunctions when starting........................................................................................ 67

6.2 Surging of the turbocharger...................................................................................... 68

6.3 Malfunctions during operation ................................................................................. 69

6.4 Malfunctions when stopping ...................................................................................... 72

6.5 Speed measurement system ...................................................................................... 73

7 Removal and installation...................................................................................... 74

7.1 Transport ........................................................................................................................ 74

7.2 Turbocharger weights.................................................................................................. 75

7.3 Removing the turbocharger........................................................................................ 75

7.4 Installing the turbocharger ......................................................................................... 76

8 Disassembly and assembly .................................................................................. 78

8.1 Introduction ................................................................................................................... 78

8.2 Module weights ............................................................................................................. 81

8.3 Disassembling and assembling turbocharger ........................................................ 82

8.4 Axial clearance A and radial clearance B .................................................................. 96

8.5 Radial clearances N and R........................................................................................... 98

8.6 Table of tightening torques..................................................................................... 100

9 Taking out of operation .................................................................................... 101

9.1 Shutting down the turbocharger ............................................................................ 101

10 Mothballing the turbocharger ........................................................................... 105

10.1 Taking the engine out of operation for up to 12months.................................... 105

10.2 Taking the engine out of operation for more than 12months ......................... 106

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

12 Spare parts........................................................................................................... 109

12.1 Ordering spare parts .................................................................................................. 109

12.2 View of turbocharger showing part numbers ....................................................... 110

12.3 View of cartridge group showing part numbers .................................................. 112

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.1 Purpose of this manual

1 Preliminary remarks

1.1 Purpose of this manual

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

Operation Manual

This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how 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.

Target group

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

Availability of operation manual

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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 / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.2 Layout and function

1.2 Layout and function

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1Suction branch / filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing

4Bearing casing 11Turbine-end bearing flange 5Axial thrust bearing 12Compressor-end bearing

flange

6Radial plain bearing (visible only

at turbine end)

7Turbine

13Compressor wheel

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.2 Layout and function

Mode of operation

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

¡ Turbine

¡ 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).

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Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.3 Intended use of the turbocharger

1.3 Intended use of the turbocharger

NOTICE

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

The enginebuilder has provided ABB Turbocharging 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.

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

Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liability for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.

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State of the art

Perfect condition

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

WARNING

Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine.

u 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.

u Malfunctions which could affect safety must be eliminated immedi-

ately.

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

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts

1.4 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbocharging can be stored in sealed packaging without additional mothballing measures for up to 6months from the date of delivery (marked by the VCI label on the package).

Volatile Corrosion Inhibitor (VCI)

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

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

WARNING

Protection of health when handling VCIs

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

u Ensure good room ventilation.

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

VCIs.

u Wear safety gloves.

u Clean hands and face after working with VCIs.

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

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6months:

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u Open the package.

u Remove the VCI corrosion protection emitter from the package and

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

u Dispose of the old VCI corrosion protection emitter in an environ-

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

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts

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

permanent the protection.

Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Turbocharging on request. The package is equipped with a hygrometer (see illustration).

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The following measures are required every 6months:

u Check the hygrometer(02) in the sight-glass. There is an opening(01)

in the wooden crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maximum permissible humidity has been exceeded. In this case, the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

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

bocharger 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 component

¡ Replace the desiccant agent

¡ Repackage the component.

NOTICE

Turbocharger ready for operation

If the 70% field of the hygrometer(02) has not changed colour and the package is undamaged, the turbocharger can be put into operation without any prior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

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.

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.5 Essential information

1.5 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulations for the prevention of accidents and protection of the environment are also to be observed.

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

NOTICE

The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accordance with the Operation Manual.

u If the turbocharger shows modifications affecting safety or any cor-

responding operating behaviour, it must be shut down immediately by stopping the engine. The malfunction must be reported to the person or department responsible.

NOTICE

Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbocharging.

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Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.5 Essential information

Original parts and safety

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

WARNING

Use original parts

Operation of the turbocharger with non-original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel.

u Only use original parts from ABB.

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

Competence of personnel

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

Design variants

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

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

Accuracy of illustrations

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

Registered Trademarks

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

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.6 Symbols and definitions

1.6 Symbols and definitions

The following symbols are used in the documents:

w Prerequisite

u Work step

¡ Enumeration, first level

- Enumeration, second level

→ Refers to a page number

Definition of notes

NOTICE

Note

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

Definition of mandatory signs

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

Definition of caution / warning

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

ABB Turbocharging

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

Official service stations of ABB Turbocharging

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

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Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.7 Turbocharger rating plate

1.7 Turbocharger rating plate

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Operating limits

Recommended inspection and replacement intervals for turbocharger components

Further information

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 for plain bearings in 1000h 04 Replacement interval for compressor in 1000h 05 Replacement interval for turbine in 1000h

06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type

10 Serial number

11 Year of turbocharger construction

12 Manufacturing plant

Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.8 Contact information

1.7.1 Explanation of the rating plate

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

Operation above the indicated values n

Bmax

the 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

Mmax

trials on the engine test bed. Operation above n ted. Non-observance of the recommended replacement intervals increases the risk of unpredictable component failures.

1.7.2 Positions of the rating plates

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

, t

can considerably shorten

Bmax

Mmax

and t

is not permit-

Mmax

Page 13 / 113

1.8 Contact information

Contact information for the official service stations of ABB Turbocharging is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland

www.abb.com/turbocharging

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.1 Introduction

2 Safety

2.1 Introduction

Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that 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.

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

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

All further safety instructions contained and specifically identified in every chapter of this manual (see section Definition of Safety Instructions) must also be observed.

2.2 CE conformity

Information

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

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.3 Definition of mandatory signs

2.3 Definition of mandatory signs

To be worn at all times

Protective clothing Safety footwear to pro-

To be worn according to the specific work

Safety glasses Safety goggles

tect against mechanical hazard and risk of falling

Safety gloves against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Safety helmet Ear protection

2.4 Definition of Safety instructions

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

WARNING

Definition of warning

Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed precisely.

u Warning signs must be observed at all times.

Respiratory mask

against

- Dusts

- Gases

Page 15 / 113

CAUTION

Definition of caution

Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either not followed or not followed precisely.

u Caution signs must be observed at all times.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.5 Warning plates on the turbocharger

2.5 Warning plates on the turbocharger

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

Page 16 / 113

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

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove unreadable warning plates.

u Clean and degrease surfaces provided for warning plates.

u Attach new warning plates.

Uninsulated turbochargers

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

2.6 Safe operation and maintenance

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

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.6 Safe operation and maintenance

Work safety and work area safety

WARNING

Risk of falling

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

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

these as climbing aids.

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

platforms suitable for this purpose.

u Observe all general regulations for the prevention of accidents.

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

stress.

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

terials that are in perfect condition.

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

be damaged.

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

obstacles on the floor.

u Keep the floor, equipment and the turbocharger clean.

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

ready or in position

u Eliminate leaks.

u Keep fire-protection materials and fire-extinguishing equipment

ready.

Welding work close to the turbocharger

u If welding work is being carried out in the vicinity of the turbocharger,

cover the filter silencer so that the filter mat is not damaged.

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

ing sparks.

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

can get into the turbocharger.

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

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.6 Safe operation and maintenance

Safety during start-up / commissioning and operation

WARNING

The turbine casing insulation of the TPS44-F supplied by ABB is also burst protection

Serious personal injuries or fatal accidents can occur, if the turbine casing insulation of the TPS44-F supplied by ABB is removed. The burst protection is integrated into the turbine casing insulation of the TPS44F supplied by ABB.

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

u Never operate TPS44-F turbochargers that have been supplied by

ABB with insulation if this insulation from ABB is not in place.

u Never operate turbochargers without burst protection. If the insula-

tion from ABB is not in place, the separate burst protection (57200) must be fitted before operation (see View of turbocharger showing

part numbers →110).

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

u Remove any obstacles and objects lying around.

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

bocharger for damage and leaks.

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

bocharger.

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

turbocharger for visible damage and defects.

u Immediately report any damage or changes in operational perform-

ance to person responsible.

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

cure it against inadvertent or unauthorized use.

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

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

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section "Hazards due to operating and auxiliary materials" must be observed.

u Observe the material safety data sheet for the cleaning agent or

solvent.

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

safety data sheet.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.6 Safe operation and maintenance

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

your cleaning work.

Safety during disassembly, assembly, maintenance and troubleshooting

u Always perform the specified adjustments, servicing as well as in-

spection work and observe inspection intervals.

u Inform operating personnel about all service and repair work before

beginning.

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

bocharger, the engine must be switched off and the turbocharger must have come to a standstill.

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

oil supply.

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

properly.

CAUTION

Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.

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

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

Safety when taking out of operation or preparing for mothballing

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

the force of the stack draught.

u Clean the turbocharger before mothballing it.

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

balling agents.

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

safety data sheet.

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Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.7 Hazards during operation and maintenance

2.7 Hazards during operation and maintenance

Mechanical hazards during operation

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

WARNING

Risk of injury

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.

u Operate the turbocharger in accordance with instructions.

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

tation.

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Mechanical hazards when working on the turbocharger

During maintenance work, various risks can occur through the improper handling of components, through the non-observance of work instructions, due to inadequate care or as a consequence of insufficient training.

WARNING

Mechanical hazard

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

u Observe the general rules for occupational safety and prevention of

accidents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have previously received in-

struction or training.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.7 Hazards during operation and maintenance

Hazards due to noise

The development of noise during operation is influenced by the installation and operating conditions. Noise with a sound pressure level exceeding 85dB(A) is harmful.

WARNING

Hazards due to noise

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

u Always wear ear protection when the engine is running.

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

protection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well as operating materials (lubricating oil) become hot. The surface 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.

WARNING

Risk of burning

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

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

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

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

Wear safety gloves to protect against thermal hazards.

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Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).

The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.

u Compliance with the instructions and specifications given by the en-

ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Page 22 / 113

Hazards due to operating and auxiliary materials

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

WARNING

Handling operating and auxiliary materials

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

u Avoid inhalation and contact with the skin.

u Ensure good ventilation.

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

ary materials.

u Observe local laws.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Risk of fire, explosion

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

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

ing and auxiliary materials.

u Comply with local legislation.

u Do not allow any exposed flame or ignition source during cleaning

work.

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

ventilation.

CAUTION

Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can lead to environmental damage.

u Handle operating and auxiliary materials carefully.

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

on the containers of the operating and auxiliary materials.

u Wear appropriate protective clothing.

u Avoid inhalation and contact with the skin.

u Ensure that the work space is adequately ventilated.

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

u Collect used working and auxiliary materials safely, store them separ-

ately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regulations.

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

binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations.

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Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.7 Hazards during operation and maintenance

Hazards when handling insulating materials

WARNING

Hazards due to insulating materials

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

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Avoid stirring up dust.

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

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

Page 24 / 113

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

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

u Avoid stirring up dust.

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

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.8 Deflagration on gas engines

Hazards due to electrical components

WARNING

Hazards due to electrical components

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

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

trained specialists.

u Heed any country-specific regulations.

2.8 Deflagration on gas engines

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

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

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

¡ Shifting of the bearing casing in relation to the bracket

¡ Cracks in casings

If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. This inspection and evaluation must be carried out by an ABB Turbocharging Service Station.

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2 Safety / 2.9 Periodic checking of the pressure vessel

2.9 Periodic checking of the pressure vessel

The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of

the pressure vessels must be observed.

¡ The operating company is responsible for the safe operation of the

pressure vessel.

WARNING

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in proper working condition and monitor them. Necessary repair or maintenance work must be carried out without delay and the required safety precautions must be taken.

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

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2.10 Lifting loads

WARNING

Suspended loads

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

u Loads must always be fastened to technically perfect lifting gear

with sufficient loading capacity.

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

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Operation Manual / TPS44-F.. - TPS61-F..

2 Safety / 2.10 Lifting loads

In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading.

u Fasten turbocharger assemblies / components as described in re-

spective handling steps.

u Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).

u Use suitable protection at sharp edges.

u Completely screw in assembly / fitting devices without fail so that

they cannot work loose during use.

u Use assembly / fitting devices only for applications described.

u Make sure removed turbocharger components stand safely and se-

curely.

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3 Start-up / 3.1 Oil supply

3 Start-up

3.1 Oil supply

A carefully designed and installed oil supply, which functions in all possible operational conditions, is an important prerequisite for troublefree 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.

u Heed the instructions of the engine builder when selecting the lubric-

ating oil and oil-change intervals.

Oil filtration

Page 28 / 113

CAUTION

Depending on the turbine specifications and bearings used, varying amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts.

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%.

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

u If the engine is started cold and the flow resistance rises to above 0.5

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.

u Check that oil filters are clean before commissioning.

NOTICE

Also follow the enginebuilder's instructions regarding filter mesh and separation efficiency.

Operation Manual / TPS44-F.. - TPS61-F..

3 Start-up / 3.1 Oil supply

Lubricant

NOTICE

All lubricating oils used for engines are admissible.

Oil inlet viscosity and temperature

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

CAUTION

Falling below the minimum oil inlet temperature

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

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

ºC when starting the engine.

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

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3 Start-up / 3.1 Oil supply

Oil pressure

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

Status for operation Oil pressure in front

Normal operation 2.0…4.5 Engine start: cold oil, permissible for maximum 15

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

CAUTION

Prelubrication

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

u Activate prelubrication device before starting engine.

of turbocharger

[bar]

≤8.0

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Operation Manual / TPS44-F.. - TPS61-F..

3 Start-up / 3.1 Oil supply

Lubricating oil temperature at the inlet

CAUTION

Machine damage

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

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

table.

Status for operation Oil temperature at the in-

Admissible 30…105°C Temporarily admissible (<1h) → alarm >105°C Not admissible → stop engine >110°C Not admissible → do not start engine (before

starting: preheat oil)

let

oil,inlet

<30°C

Lubricating oil temperature at the outlet

The oil temperature at the outlet depends mainly on:

¡ lubricating oil temperature and pressure at the oil inlet

¡ engine load and turbocharger speed

¡ exhaust gas temperature

The maximum permissible oil temperature at the outlet is listed in 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.

Status for operation Oil temperature at outlet

oil,outlet

Admissible ≤160°C Temporarily admissible → alarm >160°C Not admissible → stop engine >180°C Admissible ≤ T Temporarily admissible → alarm > T

oil,inlet

+ 55K + 55K

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

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Operation Manual / TPS44-F.. - TPS61-F..

3 Start-up / 3.2 Inspection work

3.2 Inspection work

Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.

3.2.1 Inspection before commissioning

Page 32 / 113

Monitoring devices

Filter mat

Lubricating system

u Check for correct functioning.

u Inspect for damage.

u Check oil filter for cleanliness before commissioning.

CAUTION

Contaminated oil

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

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

lubricating system must be flushed thoroughly with warm oil.

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

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

u Check oil pressure in oil supply lines.

CAUTION

Prelubrication

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

u Activate prelubrication device before starting engine.

Warning plates on turbocharger

u Check whether the warning plates are present and legible.

u Check whether the protective sheets have been removed.

Operation Manual / TPS44-F.. - TPS61-F..

3 Start-up / 3.2 Inspection work

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

Lubricating system

u Check oil pressure in oil supply lines.

u Check oil inlet temperature.

The permissible values are listed in the section Oil supply.

Gas, air and oil lines

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

3.2.3 Check when running up engine

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

performance levels.

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

u Measure air temperature in front of and behind compressor.

The measured values must be compared with the values in the acceptance test report, while taking different operating conditions into account.

NOTICE

Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil supply to the turbocharger. If this is leaky, contact an official ABB Turbocharging service station.

3.2.4 Inspection after 100 service hours

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

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3 Start-up / 3.3 Commissioning after taking out of operation

3.3 Commissioning after taking out of operation

If provided

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

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

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

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

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

and remove.

u Start up turbocharger oil circulation system at engine end.

u Prepare turbocharger for operation as instructed in section "Inspec-

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

u Start up turbocharger.

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Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.1 Noise emissions

4 Operation

4.1 Noise emissions

WARNING

Hazards due to noise

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

u Always wear ear protection when the engine is running.

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

protection.

Wear ear protection.

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

The highest sound pressure level of emissions1) reaches a maximum of 105 dB(A) near the filter silencer and over the entire speed range.

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

¡ Fitted air-inlet system

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

¡ The bellows at the air outlet have been perfectly insulated acoustic-

ally by the engine builder. He is also responsible for insulating the

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

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

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

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4 Operation / 4.2 Servicing work

Suggestion for noise insulation of the bellows

Page 36 / 113

01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat (at least 15 mm) 03 Charge air duct / scavenging

air line

4.2 Servicing work

Service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and functional checks. It is then possible for changes to the turbocharger to be identified and rectified. In this way, it can be ensured that the turbocharger remains in full working order.

CAUTION

Service intervals

Service work on the turbocharger that is neglected or carried out too late can lead to excessive contamination and wear as well as operating failures.

u Carry out service work at specified time intervals.

06 Sheet metal cover

CAUTION

Shortened service intervals

Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage.

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

ging.

Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.2 Servicing work

NOTICE

Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service.

4.2.1 Service work every 25 … 50 hours

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

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

u Clarify the cause of any variances.

CAUTION

Unknown changes during operation

The consequences can range from an impairment to a breakdown.

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

tion.

Oil filter

4.2.2 Servicing work according to the engine manufacturer's instructions

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

not running.

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Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.2 Servicing work

4.2.3 Service work in accordance with instructions on rating plate

(In general, after 8000 … 16000 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.

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

sembly.

u Measure clearances.

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

erosion / corrosion.

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

u Clean nozzle ring and check for cracks and erosion.

Page 38 / 113

If provided

4.2.4 Entries in engine logbook

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

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 / TPS44-F.. - TPS61-F..

4 Operation / 4.3 Expected exchange intervals

4.3 Expected exchange intervals

Rotating components

The recommended replacement intervals for compressor wheels and 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.

Non-rotating components

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

¡ the replacement interval for the bearing parts and

¡ the replacement interval for those non-rotating components that are

exposed to hot gases.

Decisive in this respect are various influencing parameters, which can drastically shorten the replacement intervals of these parts in extreme cases.

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

Expected replacement intervals [h]

GAS / MDO HFO

Turbine casing 25000…50000 25000…50000 Nozzle ring 50000 10000…25000 Gas outlet flange 50000 35000…50000 Partition wall 50000 35000…50000 Rotor components See rating plate information Bearing parts 12000…32000 12000…24000 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).

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Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.3 Expected exchange intervals

Influencing parameters

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

¡ Fuel quality and preparation

¡ Load profile (thermal load cycles, also starts / stops, emergency

shut-downs)

¡ Gas inlet temperature

¡ Frequency and execution of turbine and compressor cleaning

¡ Turbocharger specification

¡ System-specific operating conditions (operating point, combustion

quality, composition of exhaust gas)

For bearing parts

Page 40 / 113

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

monitoring)

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

¡ State of rotor unbalance (degree of contamination)

Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.4 Speed measurement

4.4 Speed measurement

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

CAUTION

Do not use cables as a climbing aid

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

u Do not tension the speed measurement cables.

86505(A)Speed sensor (cable not integ-

rated)

86505(B)Speed sensor (cable integrated) 86528Tachometer

86515(A)Cable connector to 86505(A) 01 Screw plug 86515(B)Cable connector to 86505(B) 02 Gasket

86526F/I converter

Page 41 / 113

Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.4 Speed measurement

4.4.1 Speed differences with multiple turbochargers per engine

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

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

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

u Reduce engine performance immediately until the highest turbochar-

ger speed no longer exceeds 70% of n

u If the engine cannot be stopped, continue to run at this reduced en-

gine performance or turbocharger speed.

u If the turbocharger surges continuously, engine performance must be

reduced further.

Bmax

Page 42 / 113

u Measure the temperatures in the air and gas lines to and from the tur-

bochargers and compare them with standard values.

If the engine can be stopped for a short time:

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

any problems.

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

bocharging Service Station.

Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.4 Speed measurement

4.4.2 Replacing the speed sensor

WARNING

Hot cable connector and hot speed sensor

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

u Wear safety gloves when removing the cable connector and speed

sensor.

Wear safety gloves to protect against thermal hazards.

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

u Switch off the lubricating oil supply to the turbocharger.

u Disconnect the cable connector from the speed sensor.

u Screw out defective speed sensor.

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

u Adhere to tightening torque.

Part num-

TPS44 TPS48 TPS52 TPS57 TPS61

ber

86505 15Nm 15Nm 15Nm 15Nm 15Nm

Page 43 / 113

Operation Manual / TPS44-F.. - TPS61-F..

4 Operation / 4.5 Stopping the engine

NOTICE

Sealing of the speed sensor

The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly.

u Connect cable connector to speed sensor.

u Switch on lubricating oil supply to turbocharger.

4.4.3 Failure of speed measuring system

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

4.5 Stopping the engine

Page 44 / 113

CAUTION

Stopping the engine of oil-cooled turbocharger version

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

u Post-lubricate for 15…20minutes.

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

CAUTION

Stopping the engine of water-cooled turbocharger version

Heat in the turbocharger must be dissipated.

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

stopping engine.

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

Further post-lubrication is not required and not recommended.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.1 Foreword to Maintenance

5 Maintenance

5.1 Foreword to Maintenance

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

CAUTION

Risk of damage during mechanical cleaning

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

u 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.

u 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 Turbocharging 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.

u Dispose of dirty water and cleaning agents in an environmentally

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

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Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.2 Cleaning the compressor during operation

5.2 Cleaning the compressor during operation

General

The contamination of the compressor stage (compressor wheel, wall insert and diffuser) depends on the degree of purity of the air that is drawn in.

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

Consequences of contamination:

¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures

¡ Increased fuel consumption

¡ Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination. It does not, however, replace the regular service work, during which the turbocharger is completely dismantled and the compressor is cleaned mechanically.

NOTICE

If the coating of dirt is very thick and hard, the compressor can only be cleaned manually when disassembled. This cleaning must be carried out by an ABB Turbocharging Service Station.

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Cleaning interval

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 Turbocharging.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.2 Cleaning the compressor during operation

Cleaning method

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

Principle of wet cleaning

V-engines

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 contamination 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.

CAUTION

Corrosion and deposits when cleaning

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

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

CAUTION

The injection pipe must on no account be connected directly via a cock to a water pipe or a dosing vessel larger than the one supplied. This prevents uncontrolled volumes of water entering the turbocharger and engine, which can lead to serious damage.

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.

Page 47 / 113

Sequential charging

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 / TPS44-F.. - TPS61-F..

5 Maintenance / 5.2 Cleaning the compressor during operation

5.2.1 Wet cleaning compressor using external water pressure vessel (XC1)

Page 48 / 113

Approval by enginebuilder

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

NOTICE

Supplying water from the externally mounted water vessel is suitable only for those applications where a negative pressure exists in front of the compressor wheel (not used for: blowers connected in front of the compressor or high-pressure compressor stages with two-stage charging).

Operating state prerequisites for cleaning compressor with XC1

NOTICE

To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following prerequisites must be fulfilled:

u Run engine at load from 50…85%.

u Start cleaning cycle according to following description Wet cleaning

operation with XC1.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.2 Cleaning the compressor during operation

Procedure for wet cleaning the compressor with XC1

Operating the water pressure vessel

XSealing plug DCompressed air YValve activator WWater ZVessel

u Remove sealing plug (X).

u Fill the vessel (Z) with clean water.

u Screw in the sealing plug.

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

seconds until the entire volume of water has been injected.

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

10 minutes has elapsed.

NOTICE

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

Page 49 / 113

Cleaning parameters per turbocharger compressor

Product Engine load Contents

of cleaning me-

dium vessel

Water

injection time

t1 [s]

[dm3]

TPS 50…85% 0.4 10

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

5.3 Turbine cleaning during operation

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

Consequences of contamination:

¡ Poor turbine efficiency

¡ elevated exhaust gas temperatures

¡ higher charging and ignition pressures as turbocharger speed rises

¡ lower engine performance.

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

tion deposits.

Page 50 / 113

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.

NOTICE

Regular cleaning

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

Cleaning intervals

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

NOTICE

Cleaning intervals

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

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

Cleaning method

Turbine components are cleaned during operation by using the wet cleaning method described below. This cleaning method is tested and approved by ABB Turbocharging.

The turbine casing design and the type of turbine casing seal are decisive for the choice of cleaning method.

NOTICE

Approval by engine manufacturer

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

5.3.1 Wet cleaning methods

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

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

Process with long water injection time (10 minutes cleaning)

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.

NOTICE

Choice of cleaning method

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

Page 51 / 113

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

5.3.2 Prerequisites

CAUTION

Risk of corrosion and deposits

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

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

u Avoid corrosion on casing inner surfaces.

u Let engine run for 10 minutes after wet cleaning.

CAUTION

Maximum temperature in front of turbine during cleaning

When cleaning, the temperature in front of the turbine will rise and can heavily stress the material of turbine components. The temperature at the turbine inlet can be up to 100°C higher than the exhaust gas temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning.

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

ing.

Page 52 / 113

CAUTION

Impermissible thermal stressing and flooding of the turbine

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

u Be absolutely sure to observe turbine cleaning parameters.

NOTICE

V-engines

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.

Recommended operating state for turbine wet cleaning

The following operating state is tested and approved by ABB Turbocharging:

Characteristic / com-

ponent

Water injection time

Engine load (guide value) 20…40% Turbine inlet temperature

TTE before water injection

short

350…400°C 350…430°C

Conditions

long

Water injection time

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

Characteristic / com-

ponent

short

Water injection time

Water supply ensured Water pressure (overpres-

sure over atmosphere) p

2.0bar 1.5bar

Conditions

long

Water injection time

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

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

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Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

5.3.3 Procedure for method with short water injection time

w Prerequisites have been fulfilled.

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

load.

u Open the shut-off valve.

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

parameters using the flowmeter and inject for 30seconds.

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

u Repeat the 30-second water injection two times.

u Close the shut-off valve.

u Wait 10 minutes during a stabilising phase before increasing engine

load again.

This completes the turbine cleaning process.

Page 54 / 113

Cleaning parameters during the process

Temperature in

front of the tur-

bine during clean-

TPS

ing

Water

volume flow

[dm3/min]

Injection time

[min]

Pause

between injec-

tions [min]

[°C]

44 ≤450 4.5 0.5 48 6 52 8 57 11

61 17 5

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

(3 x)

mosphere)

CAUTION

Maximum temperature in front of turbine during cleaning

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

ing.

5.3.4 Procedure for method with long water injection time

w Prerequisites have been fulfilled.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.3 Turbine cleaning during operation

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

u Open the shut-off valve.

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

parameters using a flowmeter and inject for 10minutes.

u Close the shut-off valve.

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

load again.

This completes the turbine cleaning process.

Cleaning parameters during the process

TPS

Temperature in

front of the tur-

bine during

cleaning

Water

volume flow

[dm3/min]

Injection

time

[min]

Stabilising phase

before / after wa-

ter injection

[min]

[°C]

44 ≤530 2.5 10 10 48 4 52 5.5 57 8.5 61 12

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

mosphere)

CAUTION

Maximum temperature in front of turbine during cleaning

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

ing.

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Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

5.4 Cleaning components mechanically

5.4.1 Introduction

CAUTION

Choosing cleaning tools

Turbocharger components are sensitive to mechanical damage. The use of needle guns or other impact tools, for example, damages the components. Depending on the specification, nozzle rings and turbine casings have protective coatings, which can also be damaged.

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

u 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.

u Dispose of dirty water and cleaning agents in an environmentally

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

Page 56 / 113

NOTICE

Disassembly and assembly

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

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

5.4.2 Cleaning the filter silencer

81135Filter silencer body 81266Cover grid 81136Absorption segment 81270Tension band 81137Sheet-metal covering 81271Lock

81265Filter ring

NOTICE

Disassembly and assembly

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

Cleaning the filter ring (if provided)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 operating hours, 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.

u 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).

Page 57 / 113

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

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

local regulations.

Cleaning the absorption segments

u Loosen the tension bands (81270).

u Remove the cover grid (81266).

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

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

the absorption segments (81136).

u Clean the absorption segments (81136).

During cleaning, ensure that the absorption segments (81136) are only cleaned with a mild jet of compressed air, soft brush or a damp cloth.

u Have absorption segments which are heavily contaminated replaced

by an official ABB Turbocharging Service Station.

Fitting the filter silencer

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

ings (81137).

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

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

u Fit the cover grid (81266).

Page 58 / 113

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

u Damaged tension bands must be replaced with new ones.

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

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

5.4.3 Compressor-end, non-rotating parts

WARNING

Handling operating materials and supplies

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

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

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the op-

erating materials and supplies.

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

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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

72000 Compressor casing 77000 Wall insert 79000 Diffuser

u 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.

Page 59 / 113

u Dry components completely.

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

surfaces of the turbocharger.

u Dispose of dirty water and cleaning agent in accordance with the spe-

cifications in the safety data sheet.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

5.4.4 Turbine-end, non-rotating parts

WARNING

Handling operating materials and supplies

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

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

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the op-

erating materials and supplies.

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

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Page 60 / 113

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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

51000 Turbine casing 56001 Nozzle ring 52400 Gas outlet flange

u Place contaminated parts in hot water or in a liquid such as brake

cleaner, so that the contamination softens.

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

u Repeat the soaking and brushing if necessary.

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

u Dry components completely.

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

surfaces of the turbocharger.

u Dispose of contaminated water and cleaning agent in accordance

with the specifications in the safety data sheet.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

5.4.5 Cartridge group

Introduction

CAUTION

Corrosion

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

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

Compressor wheels or turbines may be heavily contaminated due to exhaust gas deposits 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).

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

stallation →74).

u Remove cartridge group (see chapter Disassembly and assembly

→78).

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

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Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

Cleaning the compressor end

CAUTION

Selection of the cleaning agent

Cleaning agents that contain chlorine corrode metals.

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

u Observe the material safety data sheet.

u Observe country-specific regulations regarding banned and restric-

ted substances.

CAUTION

Water and contamination in the cartridge group

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

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

ridge group.

Page 62 / 113

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

with household detergent. Do not use any wire brushes!

u Dry the compressor wheel and the gap between the compressor and

the bearing casing with a weak jet of compressed air.

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

pressor and the bearing casing with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with the

safety data sheet.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

Cleaning the turbine end

Soaking the dirt

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.

Product A[mm] B[mm] C[mm]

TPS44 91 15 173 TPS48 108 17 205 TPS52 128 20 245 TPS57 157 25 300 TPS61 187 30 357

Page 63 / 113

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

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

can be collected.

CAUTION

Selection of the cleaning agent

Cleaning agents which contain chlorine attack metals.

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

u Observe safety data sheet.

u Fill the tank (02) with soaking liquid.

NOTICE

Heat the liquid

To shorten the soaking time the liquid can be heated to maximum 60ºC.

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

WARNING

Heating up of cleaning agents and operating fluids

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

u Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

CAUTION

Water and dirt in the cartridge group

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

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

u Maintain dimension (B) for the supports (01), so that the cartridge

group does not submerge too deep.

Page 64 / 113

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

Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

Removing the dirt

WARNING

Health hazard due to soot particles

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

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

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

u Wear safety goggles.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

u Raise the cartridge group and align horizontally.

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

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Operation Manual / TPS44-F.. - TPS61-F..

5 Maintenance / 5.4 Cleaning components mechanically

CAUTION

Water and dirt in the cartridge group

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

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

partition wall and turbine.

CAUTION

Non-permissible rotor unbalance after cleaning

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

u Remove all traces of contamination from the turbine.

u After brushing off the contamination, fill the tank (02) with clean wa-

ter, not salt water.

Page 66 / 113

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

loose particles of dirt detach completely.

u Raise the cartridge group and align horizontally.

u Clamp the partition wall with the bearing casing.

u Dry the turbine and the gap between the turbine and partition wall

with a weak jet of compressed air.

u Lightly spray the turbine and the gap between the turbine and parti-

tion wall with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with the spe-

cifications in the safety data sheet.

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.1 Malfunctions when starting

6 Troubleshooting

6.1 Malfunctions when starting

Sluggish start-up

Possible causes Elimination

Turbocharger

Vibrations

Possible causes Elimination

Turbocharger

Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Rubbing rotor Foreign object in turbocharger

Rotor unbalance Contact an ABB Turbocharging Damaged turbine or com-

pressor Damaged bearing

Service Station

Rubbing of rotating parts

Normal behaviour, no malfunction

Turbocharger

Minor uniform wear around the periphery of rotor components, caused by slight local rubbing of adjacent components, is 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 Turbochar-

ging Service Station.

Page 67 / 113

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.2 Surging of the turbocharger

6.2 Surging of the turbocharger

Turbocharger surging

Possible causes Elimination

Engine Guard in front of the tur-

bocharger is contaminated or damaged

Turbocharger Filter silencer or diffuser

contaminated Heavy deposits of dirt in the

turbine or nozzle ring

Charge air cooler

CAUTION

Prolonged or periodic surging

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

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

vice station and rectified.

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

by an ABB Turbocharging service station.

Cooler contaminated Clean it Charge air duct blocked

Clean / replace it

Clean it

Page 68 / 113

Sporadic surge blows

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 / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.3 Malfunctions during operation

6.3 Malfunctions during operation

Lubricating oil pressure too low

Possible causes Elimination

Engine Oil filter heavily contaminated Clean it

Defective oil pump in lubricating system

Manometer display wrong Replace the manometer

Turbocharger

Reduction in speed

Possible causes Elimination

Engine Defects of connected cylinders

Turbocharger

Pipes Defects such as leaks in the ex-

Rotor axial clearance too large Contact an ABB Turbocharging

when pulse charging Heavy contamination of the

turbine Damaged rotor components or

bearing

haust gas pipes or charge air ducts

Check / replace it

Service Station

Contact the enginebuilder

Clean it

Contact an ABB Turbocharging Service Station

Make repairs

Increase in speed

Possible causes Elimination

Turbocharger

Heavily contaminated nozzle ring (with 4-stroke application)

Contact an ABB Turbocharging Service Station

Page 69 / 113

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.3 Malfunctions during operation

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes Elimination

Engine Malfunctioning injection

system

Turbocharger Air starvation, for example

filter silencer clogged with dirt

Compressor / turbine contaminated

Exhaust counterpressure too high

Enlarged flow cross-section of the nozzle ring due to deformed blade trailing edges

Damaged or eroded turbine

Charge air cooler

Cooler contaminated Clean it Cooling water volume too

low Entry temperature of cool-

ing water too high Inadequate ventilation Improve the ventilation

Repair it or contact the manufacturer

Clean it

Clean or repair the boiler or exhaust silencer

Contact an ABB Turbocharging Service Station

Top up the water

Inspect / clean the cooling system

Page 70 / 113

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.3 Malfunctions during operation

Charge air pressure too low

Engine performance and engine speed unchanged, air intake condition normal

Possible causes Elimination

Engine Air receiver leaking Make repairs

Gas piping between the engine and the turbine leaking

Poorly adjusted injection system

Poorly adjusted valve control

Turbocharger

Manometer display wrong Replace the manometer Line to manometer leaking Repair the leak Contaminated filter silencer

causing excessive loss of pressure

Compressor / turbine contaminated

Damaged compressor / turbine

Exhaust counterpressure too high

Correct it

Clean it

Contact an ABB Turbocharging Service Station

Clean or repair the boiler or exhaust silencer

Charge air pressure too high

Engine performance and engine speed unchanged, air intake condition normal

Possible causes Elimination

Engine Malfunctioning injection sys-

tem Poorly adjusted injection sys-

tem Engine performance higher

than expected

Turbocharger

Manometer display wrong Replace the manometer

Repair it or contact the manufacturer

Correct it

Check engine performance

Page 71 / 113

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.4 Malfunctions when stopping

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

Reduced compressor performance / efficiency and therefore engine performance losses

Possible causes Elimination

Turbocharger

Heavily contaminated compressor components

Increased vibration, compressor blade damage

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

Possible causes Elimination

Turbocharger

Corroded compressor wheel material

Clean the compressor Optimise oil separation Correct the feed of ventilation

gases according to instructions of enginebuilder.

Check fuel and its corrosive constituents and, if necessary, change fuel.

Page 72 / 113

6.4 Malfunctions when stopping

Noises during run-down

Possible causes Elimination

Turbocharger

Run-down time too short

Possible causes Elimination

Turbocharger

Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Rubbing rotor Foreign object in turbocharger

Service Station

Operation Manual / TPS44-F.. - TPS61-F..

6 Troubleshooting / 6.5 Speed measurement system

6.5 Speed measurement system

Possible causes Elimination

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

Defective sensor Contact an ABB Turbocharging Service Sta-

Contaminated sensor tip

- - Contact an ABB Turbocharging Service Sta-

- - If none of the above measures eliminates

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 The sensor tip is magnetic and can thus at-

tract 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.

tion

the malfunction, we recommend that you have the speed measuring system inspected by an ABB Turbocharging Service Station.

Page 73 / 113

Operation Manual / TPS44-F.. - TPS61-F..

7 Removal and installation / 7.1 Transport

7 Removal and installation

7.1 Transport

Suspension of uninsulated turbocharger

Page 74 / 113

Turbocharger with oil-cooled bearing casing

Suspension of insulated turbocharger

Turbocharger with oil-cooled bearing casing

Complete turbocharger with gas outlet casing

Operation Manual / TPS44-F.. - TPS61-F..

7 Removal and installation / 7.2 Turbocharger weights

7.2 Turbocharger weights

Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible. This standard value may deviate from the data on the rating plate depending on the specification.

TPS44

[kg]

120 180 250 410 650

TPS48

[kg]

TPS52

[kg]

7.3 Removing the turbocharger

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

of the enginebuilder.

Version with water-cooled bearing casing:

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

ginebuilder.

TPS57

[kg]

TPS61

[kg]

Page 75 / 113

If present, remove hard insulation as follows:

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

tion.

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

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

lation can be compressed to facilitate the removal process.

u Unplug the cable connector from the speed sensor.

u Attach lifting gear to bearing casing.

u If a gas outlet bend is present, sling lifting gear around it or secure it

to the lifting gear with a swivel lifting eye (C).

Operation Manual / TPS44-F.. - TPS61-F..

7 Removal and installation / 7.4 Installing the turbocharger

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

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

u Cover oil connections.

7.4 Installing the turbocharger

u Remove covers from oil connections.

u Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring

gaskets for engine are not included in the scope of delivery of ABB).

Page 76 / 113

**) 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)

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

Product Through hole in

Thread size Tightening torque

bearing casing

TPS44 17mm M16 230Nm TPS48 17mm M16 230Nm TPS52 21mm M20 455Nm TPS57 21mm M20 455Nm TPS61 25mm M24 780Nm

u Attach lifting gear to bearing casing.

u If a gas outlet manifold is provided, sling lifting gear around it addi-

tionally or fasten it to lifting gear using a swivel lifting eye(C) (see also section Transport / Weights).

u Lift turbocharger, place on bracket and align.

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

table above.

Operation Manual / TPS44-F.. - TPS61-F..

7 Removal and installation / 7.4 Installing the turbocharger

u Fasten all gas, water and air lines in accordance with the engineb-

uilder's instructions.

If present:

u Fit speed sensor and plug in cable connector.

u Adapt and fit bearing casing insulation(A).

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

Version with water-cooled bearing casing:

u Remove the screw plugs from the water connections and fit the water

pipes in accordance with the enginebuilder's instructions.

Page 77 / 113

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.1 Introduction

8 Disassembly and assembly

8.1 Introduction

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

CAUTION

Further work

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

u ABB Turbocharging recommends having further work carried out

only by trained personnel from an ABB Turbocharging Service Station.

Page 78 / 113

u Mark the casing position for assembly.

Identifying assembly devices

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

WARNING

Maintaining assembly devices

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

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

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

Customer spare part set

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

u See chapter Spare parts.

Oil orifice

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

removed.

Tightening torques for turbocharger components

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

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.1 Introduction

Tightening torques for assembly devices from ABB

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

WARNING

Suspended loads

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

u Attach turbochargers, assemblies or individual components only to

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

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

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Definition of terms

¡ Suspension point

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

¡ Assembly device

Devices that are fitted on the turbocharger in order to obtain a suspension point. Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. Use assembly devices only for the described applications.

¡ Lifting gear

Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB.

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.1 Introduction

Swivel lifting eye to be used

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

Swivel lifting eye Product ThreadMLengthLMinimum

load limit

(loading ca-

pacity)

TPS44 M8 13 mm 150 kg TPS48 M10 17 mm 250 kg TPS52 M10 17 mm 250 kg TPS57 M12 21 mm 350 kg TPS61 M12 21 mm 500 kg

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.2 Module weights

8.2 Module weights

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

TPS44

Description

1Filter silencer 15 19 30 40 65

2Radial air suction branch 5 6 8 11 21 3Axial air suction branch 3 4 4 6 9 4Compressor casing 17 24 35 55 90 5Wall insert 4 7 10 13 30 6Diffuser 2 2 3 6 10

7Cartridge group 25 35 50 85 140 8Nozzle ring 1 1 2 3 6 9Burst ring 1 2 3 5 12

10Turbine casing

with external burst protection

11Gas outlet flange 4 4 8 16 30 12Exhaust manifold 16 18 25 40 60

1 inlet 30 35 50 80 130 2 inlets 30 35 50 90 150 3 inlets - - 55 95 170 4 inlets - - - 95 170

[kg]

TPS48

[kg]

TPS52

[kg]

TPS57

[kg]

TPS61

[kg]

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

8.3 Disassembling and assembling turbocharger

Removing the compressor casing

WARNING

Risk of burning

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

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

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

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

Wear safety gloves to protect against thermal hazards.

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If provided

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

tions.

u Remove the screws for the compressor casing insulation and dis-

mantle the insulation.

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

suction branch (82000).

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Removing the insulation

If provided

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

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

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

u Remove the insulation (3).

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

u Slightly loosen the screws (72011) and turn the compressor casing

(72000) until the swivel lifting eye can be fastened to the lifting gear.

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

NOTICE

If the compressor casing cannot be removed easily, it can be pressed off using the press-off tool (90042) against the turbine casing. To do this, the two cover plates (1, 2) must be removed from the hard insulation on the turbine casing.

CAUTION

Axial force

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

u It should thus be used alternately on both sides while avoiding ex-

cessive pressure on either side.

u Loosen the screws (72011) and remove them together with the fasten-

ing strips (72012).

u Move the compressor casing (72000) with the wall insert (77000)

carefully away, doing so horizontally.

u Tap the wall insert (77000) out of the compressor casing using a

nylon hammer and remove the O-ring seal (77005).

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

TPS61 wall insert removal

u Fasten lifting beam (90258) to wall insert.

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

u Remove wall insert (77000) using lifting gear.

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

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u Loosen screws (72041) and remove them together with lockwashers

(72040) and diffuser (79000) from compressor casing (72000).

Installing compressor casing

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

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

NOTICE

O-rings

Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts).

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

u Refit diffuser in reverse order.

u Fit compressor housing in reverse order.

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

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Removing the cartridge group

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

If provided

u Disconnect all lines in accordance with the engine builder's instruc-

tions, remove the insulation, remove the turbocharger and compressor casing together with the filter silencer (also see the previous chapter).

WARNING

Risk of burning

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

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

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

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

Wear safety gloves to protect against thermal hazards.

w The bearing casing is difficult to loosen.

u Use the press-off tool (90042) against the turbine casing to press off

the bearing casing (see the following illustration).

CAUTION

Axial force

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

u It should thus be used alternately on both sides while avoiding ex-

cessive pressure on either side.

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Page 88 / 113

If provided

Disassembly of diffuser TPS..-F33

u Withdraw nozzle ring (56001) using two extraction devices (90070)

and withdraw bottom part of service support (90012).

u Remove C-ring (51105).

u Mount the cartridge group on the service support (90012) and bolt it

down firmly.

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

ring (42012).

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

dial clearances).

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Installing the cartridge group

NOTICE

O-rings

Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts).

NOTICE

Protruding insulation

The insulation on the turbine casing may protrude at the gas outlet side. This can be pushed back in with a screw driver.

If present

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u Fit the lamellar sealing ring(56005, if present) in the correct slot (see

detail A). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).

u Secure the lamellar sealing ring with adhesive tape.

u Insert the nozzle ring (56001) (with the cam facing forwards) into the

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

u Insert the C-ring (51105) into the turbine casing and secure with high-

vacuum grease.

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

NOTICE

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

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Nozzle ring press fit for single inlet turbine casing

u Calculate the press fit (PD) as shown.

NOTICE

If the calculated value (PD) is less than 0.1 mm, an official ABB Turbocharging Service Station must be contacted.

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

dial clearances).

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Nozzle ring press fit for multiple inlet turbine casing

u Calculate the press fit (PD) as shown.

NOTICE

If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbocharging Service Station must be contacted.

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

dial clearances).

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Assembly of diffuser TPS..-F33

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

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

u Unscrew the cartridge group and lift it out of the service support

(90012).

u Apply high-temperature grease to the centering points and screw

threads.

u Remove temporary covers from oil connections.

CAUTION

Don't damage or shift gasket rings (A) in the mounting support when fitting the cartridge group. The gasket rings (A) are supplied by the engine builder.

NOTICE

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

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

u Fasten the cartridge group using fastening strips (51002), Verbus

Ripp® washers (51003) and nuts (51007) (also see the chapter entitled Table of tightening torques).

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

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

table.

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

Product Hole in the bearing

casing

Fixing screws C [mm] Tightening

torques [Nm] **)

[mm]

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

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

If provided

Page 94 / 113

If provided

u Plug in the cable connector (86515) for the speed sensor (86505) and

(if provided) fit the insulation plates (1, 2).

Removing gas outlet manifold and gas outlet flange

u Disconnect all lines in accordance with enginebuilder's instructions

and remove insulation (see also preceding chapter).

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

u Remove gas outlet manifold(51100) and gasket(52406). Only gas

outlet manifolds from ABB have the gasket(52406).

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

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.3 Disassembling and assembling turbocharger

Fitting the gas outlet flange and gas outlet manifold

If provided

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

u Fit the gas outlet flange(52400).

u For gas outlet manifolds(51100) from ABB:

always replace the gasket(52406)(see the chapter entitled Spare parts).

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

u Fit the turbine casing using the nuts(52433) while observing tighten-

ing torques specified in the table of tightening torques.

u Fasten the insulation.

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

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.4 Axial clearance A and radial clearance B

8.4 Axial clearance A and radial clearance B

u Following removal and before installation of the cartridge group, the

axial clearance A and radial clearance B must be measured and noted.

NOTICE

In order to correctly measure the axial clearance A, the turbine must be raised slightly.

Page 96 / 113

Axial clearance A and radial clearance B [mm]

WARNING

Risk of injury due to sharp edges on the compressor wheel

The compressor wheel has sharp edges which can cause injuries.

u Wear safety gloves.

Wear safety gloves to protect against mechanical hazards.

TPS44 TPS48 TPS52 TPS57 TPS61

A minimum 0.08 0.08 0.10 0.12 0.15 A maximum 0.16 0.16 0.18 0.21 0.25 B minimum

* B maximum

* Permissible B clearances for standard radial bearings. If the clearances measured on TPS57 or TPS61 are outside the permissible range, this can indicate radial bearings with a special bearing geometry. Different permissible values are valid for radial bearings with a special bearing geometry (see the table below).

0.51 0.50 0.61 0.72 0.81

1.00 1.00 1.15 1.31 1.55

Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.4 Axial clearance A and radial clearance B

Identifying radial bearings with a special bearing geometry

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

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

TPS57 TPS61

B minimum 0.46 0.52 B maximum 0.73 0.82

CAUTION

Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property.

u Have components assessed and, if necessary, replaced by an ABB

Turbocharging Service Station.

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Operation Manual / TPS44-F.. - TPS61-F..

8 Disassembly and assembly / 8.5 Radial clearances N and R

8.5 Radial clearances N and R

N and R

These are the theoretical values of the radial clearance between the compressor wheel and the wall insert and / or turbine wheel and the gas outlet flange.

Page 98 / 113

Feeler gauge

The minimum and maximum values result from the manufacturing tolerances of the compressor wheel and turbine wheel or the wall insert and gas outlet flange.

N1 and N2 as well as R1 and R2 are each measured at the same time using two feeler gauges. To measure N1 and N2, the feeler gauges must be pushed between the wall insert and the compressor wheel free of play, in each case above and below. To measure R1 and R2, the feeler gauges must be pushed between the gas outlet flange and the turbine free of play, in each case above and below.

Abb TPS52-F33 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual