ABB

Operation Manual

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Table of Contents

Page 1

Table of Contents 1

Preliminary remarks

1.1

Purpose of the manual

1.2

Layout and function

1.3

Correct use of the turbocharger

1.4

Essential information

1.5

Abbreviations and symbols

1.6

Turbocharger rating plate

2

Safety

2.1

Basic safety instructions

2.2

General safety instructions

2.3

Special safety instructions

2.4

Safety instructions and hazard protection

2.5

Warnings on the turbocharger

3

Commissioning

3.1

Oil supply

3.2

Inspection work

3.3

Putting into operation after laying up

4

Operation

4.1

Servicing work

4.2

Monitoring

4.3

Surging of turbocharger

4.4

Contact with rotating parts

4.5

Shutting the engine down

5

Maintenance

5.1

Foreword to Maintenance

5.2

Cleaning the filter silencer

5.3

Cleaning the compressor during operation

5.4

Cleaning turbine blades and nozzle ring in operation

ABB Turbo Systems Ltd

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Operation Manual

6.1

Possible remedies for failures

7

Removal and installation

7.1

Turbocharger weights

7.2

Remove the turbocharger

7.3

Installing the turbocharger

8

Disassembly and assembly

8.1

Module weights

8.2

Removing and fitting the filter silencer or air suction branch

8.3

Removing cartridge group

8.4

Axial clearance

8.5

Dismantling and installing the turbine diffuser and nozzle ring

8.6

Installing the cartridge group

8.7

Turbine-end removal / fitting of the nozzle ring

8.8

Table of tightening torques

9

Taking out of operation temporarily

9.1

Possibilities for emergency repair

9.2

Locking the rotor

9.3

Fitting the cover plate

9.4

Blocking the inlets and outlets

9.5

Bypass the turbocharger

10

Mothballing the turbocharger

10.1

Taking out of operation for up to 12 months

10.2

Taking out of operation for more than 12 months

11

Reserve and spare parts

11.1

Ordering spare parts

11.2

Directory of part numbers

11.3

General view of turbocharger

11.4

General view of cartridge group


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Troubleshooting

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Page 2

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Table of Contents

ABB

Operation Manual Preliminary remarks

1

Purpose of the manual

1.1

Page 1

1.1 Purpose of the manual Operation manual

This operation manual will help you to become familiar with your ABB Turbo Systems Ltd turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and economical operation of the turbocharger.

Target group

The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon.

Content of operation manual

This operation manual includes helpful information on the following topics: Information on the operation of the turbocharger and ways to prolong

the turbocharger's service life. Early awareness and avoidance of hazards. Minimising repair costs and failure times.

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

1 Preliminary remarks

This operation manual is a complement to, and an extension of, existing national regulations on accident protection and prevention.

NOTE

An operation manual must be available at all times at the site where the turbocharger is used. It is essential that this operation manual is read before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g. during installation and maintenance) must also have read and fully understood the operating manual before beginning work.

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The instructions included in this operation manual must be followed under all circumstances.

WARNING

This applies especially to the general and special safety instructions preceding and in the respective chapters. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. In the event of doubt, consult the officer for safety and accident protection responsible for your area.


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Layout and function

1.2

Page 2

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

1.2 Layout and function


1

Filter silencer

8

Nozzle ring

2

Radial plain bearing

9

Turbine wheel

3

Thrust bearing

10

Bearing casing

4

Bearing bush

11

Diffuser

5

Radial plain bearing

12

Compressor wheel

6

Gas outlet casing

13

Air outlet casing

7

Gas inlet casing

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Layout and function

1.2

Page 3

Mode of operation May 2006

The turbocharger is a turbo-machine and consists of the following main components: Turbine Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel.

HZTL2481_EN (TPL73-A.. - 80-A..)

The turbine wheel (9) uses the energy contained in the exhaust gas to drive the compressor wheel (12), whereby the compressor draws in fresh air, and the compressed air is forced into the cylinders. The exhaust gases escape through the exhaust pipe which is connected to the gas outlet casing (6). The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch or the filter silencer (1) into the compressor wheel (12). It then passes through the diffuser (11) and leaves the turbocharger through the compressor outlet on the air outlet casing (13). The rotor runs in two radial plain bearings (2/5) which are located in the bearing bush (4) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side.

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The plain bearings are connected to a central lubricating oil feed which is supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (10).


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Correct use of the turbocharger

1.3

Page 4

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

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1.3 Correct use of the turbocharger

The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate.

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

Latest technology

WARNING

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

HZTL2481_EN (TPL73-A.. - 80-A..)

If it is used in conjunction with a gas engine, the engine must not be installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive.

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. The machine may only be operated by trained personnel.

Perfect condition

The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual. X Defects which could affect safety must be eliminated immediately.

The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.


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Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.


1


1.4

Page 5

May 2006

1.4 Essential information Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed. This also applies to the provision and wearing of personnel protection equipment.

NOTE

X The turbocharger must be shut down immediately in the event of al-

terations affecting safety or of corresponding operating behaviour. The fault should be reported to the person or department responsible.

Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems. NOTE

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The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual.


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1.4

Page 6

May 2006

Original parts and safety Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems Ltd. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us. NOTE

WARNING

Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine. ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories. Qualification of personnel

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If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger.

The turbocharger must only be operated and maintained by trained and authorised personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems Ltd.! CAUTION


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It must be ensured that only authorised personnel work on the turbocharger.

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1.4

Page 7

After-sales service May 2006

The Contact Information brochure contains an overview of official ABB Turbo Systems Ltd. service stations worldwide. Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.

HZTL2481_EN (TPL73-A.. - 80-A..)

Our service stations and agencies will gladly answer your questions relating specifically to your model. Accuracy of illustrations The graphics and images shown in this operation manual are of a general nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.

Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems Ltd. can be stored without additional safeguarding measures for a period of 6 months after the delivery date. Ensure that the storage area is dry with humidity of 40-70% and free of condensation. X After 6 months, rust-proofing oil should be sprayed on exposed surVersion 2.0

faces and all accessible areas of the turbocharger. X To do this, the insulating materials must be removed.

Repeat the steps described for rust-proofing your turbocharger every 6 months. NOTE


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Abbreviations and symbols

1.5

Page 8

1.5 Abbreviations and symbols May 2006

The following abbreviations are used in this document: Z Prerequisite X Work step D Result

9 Positive checkpoint (activity that must be carried out without fail) U Negative checkpoint (activity that must not be carried out under any circumstances)

HZTL2481_EN (TPL73-A.. - 80-A..)

Basic Instructions The following symbol is used for notes in this manual: This note provides suggestions and tips to make work on the turbocharger easier. NOTE

The note provides further essential information.

ABB Turbo Systems The term used in this manual ABB Turbo Systems signifies ABB Turbo Systems Ltd.

The term used in this manual Official ABB Turbo Systems service station signifies ABB Turbocharger service stations, that have been tested and certified by ABB Turbo Systems Ltd.


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Official ABB Turbo Systems service station


1


1.6

Page 9

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

1.6 Turbocharger rating plate

L_00012

Operational limits

1

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2

Recommended replacement periods / exchange intervals for turbocharger components


3 4 5

Turbocharger operational limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer. Turbocharger operational limits in service.

Replacement interval for the plain bearings in 1000 h Exchange interval for the compressor in 1000 h (no data for 100,000 h) Exchange interval for the turbine in 1000 h (no data for 100,000 h)

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Operation Manual 1


1.6

6 7 8 9 10 11 12

Page 10

Customer part number Field for special design designation Weight of the turbocharger in kg CE = Conformité Européenne Turbocharger type Series number Year of construction of the turbocharger

May 2006

Additional specifications:

Preliminary remarks

The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific.

CAUTION

Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we recommend you contact the nearest official service station of ABB Turbo Systems Ltd. nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in service for special applications. The operation over nMmax , tMmax is not permitted.

HZTL2481_EN (TPL73-A.. - 80-A..)

Explanations of the rating plate

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Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.


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Operation Manual Safety

2

Basic safety instructions

2.1

Page 1

2 Safety May 2006

2.1 Basic safety instructions The following symbols and terms are used for the safety instructions in this manual: Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents. Warning signs must be strictly observed at all times.

Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed. CAUTION

Caution signs must be strictly observed at all times.

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HZTL2481_EN (TPL73-A.. - 80-A..)

WARNING


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General safety instructions

2.2

Page 2

The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associated operating materials.

May 2006

2.2 General safety instructions

The following safety instructions must be followed when operating and when working on the turbocharger. WARNING

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

stress.

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Helmet Ear protection Protective glasses Protective suit Oil and petrol resistant gloves Protective shoes Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. Do not stand under suspended loads. If welding work is to be carried out above the turbocharger, the air filter must be covered to prevent damage to the filter mat. When working on the turbocharger, be aware of the risk of it falling. For overhead assembly work, use the steps and platforms provided for this purpose.

HZTL2481_EN (TPL73-A.. - 80-A..)

Wear protective clothing at all times.


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2.3

Page 3

May 2006

2.3 Special safety instructions Safety when connecting Work only on those connections for which you are qualified.

Safety when commissioning and during operation Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working with the turbocharger. Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. Report any damage or changes in operational performance to the person/department responsible immediately. In the event of damage, shut down the turbocharger immediately and secure it against inadvertent or unauthorized use.

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2.3

Page 4

When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Follow directions regarding the environmentally compatible collection, storage and disposal of these liquids.

May 2006

Safety when cleaning

Explosion hazard WARNING

Before cleaning, protect the floor against unintended leaks of oil and

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operation materials. You must wear protective clothing (see section General safety instructions). Handle operation materials and detergents with utmost caution. When handling solvents, wear protective clothing and observe the following rules: Avoid skin contact with solvents. Avoid inhaling vapours under all circumstances. Do not allow solvents to soak protective clothing. After cleaning, check electric cables for signs of wear or damage.

HZTL2481_EN (TPL73-A.. - 80-A..)

Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.


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2.3

Page 5

Safety during disassembly, assembly, maintenance and troubleshooting May 2006

Follow the prescribed maintenance and inspection schedules for all ad-

justment, maintenance and inspection work.

Inform operating personnel about special work and repairs before start-

Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.

CAUTION

Safety when taking out of operation or putting into storage

Secure the rotor against turning. Clean the turbocharger before mothballing. Wear protective clothing when mothballing the turbocharger. Keep the work area clean and free of oil and operating materials. Remove any obstacles lying around on the floor.

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HZTL2481_EN (TPL73-A.. - 80-A..)

ing. Ensure that absorbent materials are available to clean up any operation materials that escape accidentally. Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials. Before opening a cover or removing a protective component on the turbocharger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled.


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2.4

Page 6

Associated hazards may arise during operation of and work on the turbocharger:

from the turbocharger and its accessories. from the operating materials used. due to failure to comply with the safety instructions. from inadequate performance of maintenance and inspection work.

May 2006

2.4 Safety instructions and hazard protection

Mechanical influences

Personal injury

Unconsciousness and injury due to:

Causes


crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling

sharp edges, pointed parts crush, shear and winding areas fragmentation / ejection of parts fracture or rupture of parts due to overload Elastic elements (springs), liquids and / or gases under pressure/in a vacuum slippery, oily work area, obstacles on the floor

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WARNING

HZTL2481_EN (TPL73-A.. - 80-A..)

Mechanical influences can cause serious injury or even fatal injury.

Operation Manual

May 2006

Protective measures

Safety

2


2.4

Page 7

Wear leather protective gloves Wear close-fitting protective clothing Tie up long hair and beards (wear hair protection) Wear face and eye protection Wear protective shoes Keep floor, equipment and the turbocharger clean Ensure the availability of oil absorbing materials and have oil collector basins ready or in position 9 Eliminate leaks

9 9 9 9 9 9 9

Operation and process materials Operation and process materials refer to chemical and hazardous substances:

HZTL2481_EN (TPL73-A.. - 80-A..)

Oils Grease Coolants Detergents and solvents Acids Note that operation and process materials are harmful to the environment if they penetrate soil or water.

CAUTION

Personal injury

The following injuries can be caused by operation and process materials:

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Causes


Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation

Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids Clothing wet or soaked with hazardous substances Spilling and tipping over of vessels containing substances used during operation Escape due to leakage Tanks and collectors which are not gas-tight and which do not comply with the regulations on hazardous substances Burning cigarettes or open flame in the proximity of operation materials

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Operation Manual


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9 9 9 9 9 9 9

9 9

Page 8

Utmost caution when handling process and operation materials Protective clothing must be worn Avoid skin contact and inhalation under all circumstances Ensure that the workroom is properly ventilated Observe the hazard indications on the containers for operation and process materials Immediately after use, seal the hazardous substance container tight Used operation materials must be collected safely in accordance with the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in a technically and environmentally compatible manner Ensure that containers for new / used operation materials are sealed tight In the event of leaks or spills immediately apply a suitable absorbent material and dispose of this in a technically and environmentally compatible manner as special waste

Handling insulating materials 9 9 9 9 9 9 9

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9 9 9 9

Ensure that the work area is well ventilated Keep the work area clean Avoid disturbing dust Dust-suppressing tools and processing steps Remove from packaging only in the work area Exercise particular care when removing old insulating materials Dispose of insulating materials in a technically and environmentally compatible manner If large quantities of dust are created, wear protective glasses Use half or quarter masks Wear suitable work clothing and gloves For sensitive skin, apply moisturising, protective barrier cream

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2

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Protective measures

Safety


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2.4

Page 9

Noise

Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances

Personal injury

Causes

Machine noise level above 85 dB (A)

Protective measures

9 Wear ear protection Heat hazard When the turbocharger is operated, surfaces become very hot.

Personal injury

Burns

Causes

Missing or incorrectly fitted insulation.

Protective measures

9 Wear leather protective gloves.

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The effects of noise above a legally permitted level can cause personal injury.


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Warnings on the turbocharger

2.5

Page 10

L_00227

Apply warnings so that they are clearly visible in the positions intended for that purpose. Please contact an official ABB Turbo Systems service station for further information.

HZTL2481_EN (TPL73-A.. - 80-A..)

Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.

May 2006

2.5 Warnings on the turbocharger

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NOTE


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Operation Manual Commissioning

3

Oil supply

3.1

Page 1

3 Commissioning May 2006

3.1 Oil supply A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger. Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit. Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature.

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NOTE

3.1.1 Oil filtration A lubrication oil filter system with a mesh size ≤ 0.050 mmis adequate for TPL 73 - TPL 80 turbochargers.

3.1.2 Oil pressure

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The oil pressure before the bearings (measuring point in blind connection) must be exactly maintained to ensure fault-free operation.


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Inspection work

3.2

Page 2

This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during commissioning, thus preventing possible damage to the machine.

May 2006

3.2 Inspection work

The safety instructions must be followed before and during all inspec-

tion work.

Monitoring equipment

X To be checked for correct functioning.

Air filter mat

X Inspect for damage.

Lubricating system

X Check oil filter for cleanliness before commissioning.

It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system. CAUTION

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3.2.1 Inspection before commissioning

We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.

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X Check oil pressure in oil supply lines.


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Inspection work

3.2

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3.2.2 Inspection after commissioning Lubricating system

X Check oil pressure in oil supply lines.

Charger speed

X Measuring

Charger pressure

X Measuring

Temperatures

X Measure upstream/downstream from turbine, compressor and oil feed

Gas, air, and oil lines

X After the engine has been started up, check all gas, air and oil lines for

for various engine speeds

leaks.

Further must be observed:

Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape after this period, the cause must be treated as an oil leak and located. The first step in this process is to check the oil supply to the turbocharger for leaks. If this is not in order, contact an official ABB Turbo Systems service station.

NOTE

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X Measure the speed, oil pressure, charging pressure and temperatures

before and after the turbine and the compressor at various engine speeds. X Compare the measured values with those of the inspection report, taking into account the different operating conditions.

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


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Putting into operation after laying up

3.3

Page 4

If provided

X Remove the cover plates (blind flanges) between the compressor cas-

ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.

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3.3 Putting into operation after laying up

X X X

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X

tion residue, clean / remove foreign bodies or residual water. Inspect air supply line or filter silencer for any foreign bodies, clean / remove. Start up the turbocharger's engine end oil circulation system. Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning. Start up the turbocharger.

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X Inspect the exhaust pipe before and after the turbine for any combus-


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4

Servicing work

4.1

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4 Operation May 2006

4.1 Servicing work Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be carried out at the intervals indicated. The pertinent safety instructions must be observed during all servicing work.

HZTL2481_EN (TPL73-A.. - 80-A..)

WARNING

Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger. CAUTION

4.1.1 Servicing work every 25 to 50 hours Operation data

X must be recorded X Enter in the machine logbook X In the event of significant anomalies, establish the cause

If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.

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CAUTION


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Operation Manual 4

Servicing work

4.1

Page 2

4.1.2 Entries in the machine logbook Monitoring of the machine plant provides information about the performance of the turbocharger.

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Operation

Output and speed of the engine Air intake temperature Exhaust temperature before and after the turbine Pressure of the charge-air Pressure drop in the charge-air cooler Lubricating oil pressure, lubricating oil temperature

Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter

If provided

4.1.3 Servicing work according to the engine manufacturer's instructions X With the engine at standstill clean or replace oil filters

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Oil filters

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The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book:


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Servicing work

4.1

Page 3

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4.1.4 Servicing work every 8,000 - 12,000 hours X Dismantle the turbocharger X Clearance measurement X Clean turbine- and compressor casings and check for any cracks and

erosion / corrosion. X Clean bearing casing, blow through oil ports X Clean nozzle ring and check for cracks and erosion X Inspection and assessment of the rotor and bearing parts

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The inspection and assessment of the rotor and bearing parts must be performed by an official ABB Turbo Systems service station. NOTE

4.1.5 Servicing work every 35,000 hours X Dismantle the turbocharger X Clearance measurement X Clean turbine- and compressor casings and check for any cracks and X X X X

erosion / corrosion. Clean bearing casing, blow through oil ports Clean nozzle ring and check for cracks and erosion Inspection and assessment of the rotor Replacement of the plain bearings with original parts from ABB Turbo Systems

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The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station. NOTE


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Monitoring

4.2

Page 4

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4.2 Monitoring

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4.2.1 Speed measurement


1

Bearing casing

6

Connecting cable

2

Axial bearing

7

Line amplifier (option)

3

Guide in the axial bearing

8

Speed transmitter

4

Gasket ring

9

Installation variant of the speed transmitter

5

Screw plug

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4

Monitoring

4.2

Page 5

May 2006

The speed transmitter system for the measurement of the turbocharger speed also permits, in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery), a constant remote monitoring of the turbocharger speed. With continuous monitoring of the machine installation, the turbocharger speed can be used as a suitable control parameter. The line amplifier can be purchased as an optional addition to the described speed measuring system. Possible reasons for failure of the speed indicator: Defects in the speed transmitter, the connecting cable and plug to the

measuring unit, in the measuring unit itself or the power supply.

Turbocharger damage.

HZTL2481_EN (TPL73-A.. - 80-A..)

Failure of the speed indicator CAUTION

If the speed indication fails, it is recommended that the engine output be reduced to idling speed and the engine stopped. The cause of the failure should then be determined.

We recommend that subsequent assembly or replacement of the speed transmitter system should be carried out only by an official ABB Turbo Systems service station. NOTE

A reduction in speed of a charger can signify:

Version 2.0

Damaged turbine or bearing Defects in the connected pulse charging cylinders Severe soiling of the turbine

Increased turbocharger speed NOTE


With 4-stroke applications, heavy fouling of the turbine can also be a cause of an increase in the turbocharger speed.

ABB


4

Surging of turbocharger

4.3

Page 6

Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of flow in the compressor is then briefly reversed. However, sporadic surging of this kind does not generally affect the safe operation of the turbocharger.

May 2006

4.3 Surging of turbocharger

Prolonged or periodic surging

Action to be taken:

Version 2.0

The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB Turbo Systems service station. The components listed above must be inspected for damage by an official ABB Turbo Systems service station, and replaced in cases of doubt.

HZTL2481_EN (TPL73-A.. - 80-A..)

CAUTION

If surging is prolonged or occurs periodically, the following components may be damaged: - Compressor wheel (vibration fractures, ...) - Turbine blades (cracks) - Bearing (overheating) - Filter silencer


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4

Contact with rotating parts

4.4

Page 7

4.4 Contact with rotating parts May 2006

Mild, uniform wear around the circumference of rotor components, caused by slight local grazing against adjacent components, is non-hazardous and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid significant loss of efficiency. X A check on dimensions must be carried out by an official ABB Turbo

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

Systems service station.


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4

Shutting the engine down

4.5

Page 8

Before shutting the engine down, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can dissipate the heat in the turbocharger bearings.

May 2006

4.5 Shutting the engine down

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

CAUTION


ABB

Operation Manual Maintenance

5

Foreword to Maintenance

5.1

Page 1

May 2006

5 Maintenance 5.1 Foreword to Maintenance Cleaning work includes regular visual checks and washing to ensure the correct functioning of the turbocharger and its auxiliary appliances.

The external condition and the degree of contamination of the cleaning

points specified in this chapter must be established by visual checks at the intervals indicated. The safety instructions must be observed during all cleaning work.

HZTL2481_EN (TPL73-A.. - 80-A..)

The cleaning points described in the following are:

Version 2.0

Filter silencer Compressor Turbine and nozzle ring


ABB


5


5.2

Page 2

May 2006

5.2 Cleaning the filter silencer

HZTL2481_EN (TPL73-A.. - 80-A..)

5.2.1 Filter silencer with tension band


81265

Filter ring (if provided)

81266

Cover grids

81270

Tension ring

81136

Fleece segment

38271

Trap cover

81137

Cover panel

81268

Connecting strip

81135

Filter silencer body

E

Slide-in module = fleece segment + cover panel installed

Version 2.0

L_00210

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5


5.2

Page 3

May 2006

Disassembling and cleaning the filter silencer X Remove filter ring (81265). X Rinse filter ring (81265) with water using detergent or, if very dirty, so-

If provided

ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).

The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 service hours. NOTE

HZTL2481_EN (TPL73-A.. - 80-A..)

X Loosen tension bands (81270) on trap covers (81271) and carefully

remove cover grid (81266) from connecting strips (81268).

NOTE

In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following section Disassembling the cleaning line).

X Pull the slide-in modules (E) out, bend the cover panels (81137) open,

and then take out the fleece segments (81136).

X Clean fleece segments (81136).

Version 2.0

When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.

Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo Systems. NOTE


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5


5.2

Page 4

X Assemble the slide-in modules (E) by inserting fleece segments

(81136) in the cover panels (81137).

X Bend the cover panels back to their original shape. X Insert slide-in modules (E) in the grooves in the filter silencer body

May 2006

Assembling the filter silencer

(81135).

With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).

X When fitting, insert the cover grid (81266) into the connecting strips

(81268). X Fit the tension bands (81270) and tighten on the trap covers (81271).

X Fit filter ring (81265).

Version 2.0

If provided

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


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5


5.2

Page 5

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

5.2.2 Filter silencer and connecting rod

Version 2.0

L_00185


81265

Filter ring (if provided)

81136

Fleece segment

81269

Connecting rods

81137

Cover panel

81266

Cover grids

81135

Filter silencer body

B

Screw

N

Locknut

E

Slide-in module = fleece segment + cover panel

ABB


5


5.2

Page 6

X Remove filter ring (81265).

If provided

Rinse filter ring (81265) with water using detergent or, if very dirty, soak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).

May 2006

Disassembling and cleaning the filter silencer

The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 service hours.

X X X X

NOTE

Loosen and remove locknuts (N). Loosen and remove screws (B) on connecting rods (81269). Remove connecting rods (81269). Carefully remove the cover grid (81266).

In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following section Disassembling the cleaning line).

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

X Withdraw the slide-in modules (E), bend open the cover panels

Heavily soiled fleece segments and filter ring as well as damaged connecting rods should be replaced with original parts from ABB Turbo Systems. NOTE


ABB

Version 2.0

(81137) and then take out the fleece segments (81136). X Clean fleece segment (81136). When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air and a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.


5


5.2

Page 7

Assembling the filter silencer May 2006

X Assemble the slide-in modules (E) by inserting fleece segments

(81136) in the cover panels (81137).

X Bend cover panels (81137) back to their original shape. X Insert slide-in modules (E) in the grooves in the filter silencer body

(81135).

With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).

X Place cover grids (81266) evenly in the correct position. X Push the connecting rods (81269) through the clips on the cover grids

(81266).

If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover grid (81266) can twist and shift. This can allow foreign bodies and dirt to get into the compressor. CAUTION

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

L_00232


ABB

Operation Manual 5


5.2

Page 8

May 2006

Maintenance

X Connect the connecting rods (81269) with screws (B). While tightening

the screws (B), ensure that the connecting rods (81269) are located correctly in the recesses in the filter silencer body (81135). Now tighten screws (B) alternately to the following max. tightening torque:

Screw

Tightening torque

B

20 Nm

HZTL2481_EN (TPL73-A.. - 80-A..)

L_00234

X Fit locknuts (N) on screw (B) and tighten to the following torque: Tightening torque

N

40 Nm

X Fit filter ring (81265). Version 2.0

If provided

Locknut


ABB


5


5.2

Page 9

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

5.2.3 Removing / installing the cleaning line

L_00192

1

Injection pipe

3

Guide tube

2

Pipe

Removing the cleaning line X Disconnect the line (2) at the injection pipe (1) and remove the screw Version 2.0

coupling from the pipe. X Withdraw the pipe (2) from the guide tube (3).


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5


5.2

Page 10

L_00193

X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16

mm) and withdraw it.

Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems.

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Punch out the guide tube

Version 2.0

NOTE


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5


5.2

Page 11

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Installing the cleaning line

L_00194

X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-

Version 2.0

caulk it. X Fit the pipe (2) and screw to the injection pipe (1).


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5


5.3

Page 12

These guidelines for wet cleaning apply exclusively for cleaning with clean water and are subject to permission for the procedure being obtained from the engine manufacturer.

May 2006

5.3 Cleaning the compressor during operation

NOTE

The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point.

Oil or saline mist Solid combustion residues Dust of various kinds

Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the rotor imbalance. Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is completely dismantled.

The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems.

NOTE


ABB

Version 2.0

Interval between cleanings

HZTL2481_EN (TPL73-A.. - 80-A..)

A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air:


5


5.3

Page 13

Cleaning method May 2006

The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by ABB Turbo Systems: Wet cleaning

Principle of wet cleaning

Water is injected before the compressor wheel via an injection pipe fitted in the filter silencer or the suction branch in order to clean the compressor stage in operation.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.

Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts. CAUTION

Cleaning more than one turbocharger compressor

If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.

V-engines

For V-engines with several turbochargers on each engine, we recommend parallel cleaning of the compressors. This cleaning process is faster and avoids the risk of engine surging.

Register supercharging

With register supercharging it must be ensured that both turbocharger compressors are cleaned regularly, especially following periods of operation in the lower performance range.


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5


5.3

Page 14

NOTE

The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).

May 2006

5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met: NOTE

Z Engine warm from running (engine under full loading as far as possi-

Version 2.0

ble) Z High turbocharger speed X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.

HZTL2481_EN (TPL73-A.. - 80-A..)

Operating state preconditions for cleaning compressors with XC3


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5


5.3

Page 15

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Procedure for compressor wet cleaning with XC3

L_00198

Operating the pressure water vessel

Version 2.0

Screw plug

Y

Valve lever

X The Operating state preconditions for cleaning compressors with XC3 X X X X X


X

must be met before cleaning can begin. Remove the screw plug (X). Fill the vessel with pure water. Tighten screw plug (X). Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds until all the water has been injected. After cleaning, a waiting time of at least 5 minutes is necessary to allow the turbocharger to dry.

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5


5.3

Page 16

NOTE

If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.

May 2006

If the cleaning operation is unsuccessful, it can be repeated up to 2 times.

Cleaning parameters for XC3 for each turbocharger compressor Turbocharger speed

Contents of the dosing vessel [dm3]

Water injection time t1 [s]

TPL65-A

If possible nBmax

0.4

4…15

TPL69-A

1.0

TPL77-A

1.0

TPL80-A

2.0

Version 2.0

TPL73-A

HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger type


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5


5.3

Page 17

May 2006

5.3.2 Wet cleaning compressors with water vessel (XC4) Operating state preconditions for cleaning compressors with XC4


Z Engine warm from running (engine under full loading as far as possi-

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

ble) Z High turbocharger speed X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.


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5


5.3

Page 18

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Procedure for compressor wet cleaning with XC4

L_00197

1

Cleaning container

2 Pipe

3

Injection pipe

4 Cleaning instructions

5

Cover

6 Valve

If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer should be followed.

Use of cleaning container

X The Operating state preconditions for cleaning compressors with XC4 X X X X X X


must be met before cleaning can begin. Open filling cap (5) on cleaning container (1). Fill with clean water. Screw filling cap (5) back into place. Open valve (6) for about 3 minutes. Close valve (6) and check that all the water has been sucked out. After cleaning, a waiting time of at least 5 minutes with the engine running must be allowed so that the turbocharger can dry.

ABB

Version 2.0

NOTE


5


5.3

Page 19

May 2006

If the cleaning operation is unsuccessful, it can be repeated up to 2 times. NOTE

If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.

HZTL2481_EN (TPL73-A.. - 80-A..)

Cleaning parameters for XC4 for each turbocharger compressor Turbocharger type

Turbocharger speed

Contents of the dosing vessel [dm3]

Water injection time t1 [s]

TPL65-A

If possible nBmax

0.4

4…15

TPL69-A TPL73-A

2

TPL77-A 3

Version 2.0

TPL80-A


ABB


5


5.4

Page 20

Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. The deposits on the turbine components are caused by the following products of combustion: Soot Molten ash Cinders Incompletely burned fuel Sodium vanadyl vanadate

Therefore, it is advantageous to use fuels with a low content of ash, sulphur, sodium and vanadium. The fuel must also be stored, prepared and handled correctly. We recommend the use of fuels with a mass ratio of vanadium to sodium less than 3:1, so that the melting point of the sodium vanadyl vanadate is as high as possible. NOTE

Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits.

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

5.4 Cleaning turbine blades and nozzle ring in operation

The charging pressure can rise somewhat if the turbine profile is constricted due to fouled turbine components. Contamination causes loss of performance in the turbine and the engine temperature after the cylinders can increase. This may mean that the engine output has to be reduced.

Experience in operation has shown that despite periodic cleaning during operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended.


ABB

Version 2.0

A soiled turbine also results in rotor unbalance. Severe soiling can lead to impermissibly high rotor imbalance.

Operation Manual 5


5.4

Page 21

The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours.

May 2006

Wet cleaning interval

Maintenance

Cleaning method The turbine and nozzle ring are cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by ABB Turbo Systems:

HZTL2481_EN (TPL73-A.. - 80-A..)

Wet cleaning

The dry cleaning method may be used as an alternative to wet cleaning. However, this is not the preferred method, and must be approved by an official ABB Turbo Systems service station. NOTE Principle of wet cleaning

During wet cleaning using droplets of water, the water does not act as a solvent. Instead, the deposit is removed by the mechanical impact of the drops.

Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.

Version 2.0

CAUTION

Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems. NOTE


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5


5.4

Page 22

CAUTION

V-engines

For V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers. This cleaning process is faster and avoids the risk of engine surging. We recommend conducting tests to find the most suitable method. With register supercharging it must be ensured that both turbocharger turbines and nozzle rings are cleaned regularly, especially following periods of operation in the lower performance range.

Version 2.0

Register supercharging

Failure to maintain the prescribed exhaust temperature upstream of the turbine, and to allow the minimum stabilising time before and between cleaning procedures and the drying time after cleaning in accordance with the pertinent cleaning instructions will shorten the expected service life of the components significantly. HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

Cleaning of the turbine-side components begins after engine start or reduction of engine load. The exhaust temperature must not exceed the value specified in the corresponding cleaning instructions (see the respective section Operating state preconditions).

May 2006

Stabilising and drying time


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5


5.4

Page 23

May 2006

5.4.1 Wet cleaning the turbine and nozzle ring during operation The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate must not be exceeded under any circumstances. During wet cleaning, the turbine is braked and the turbocharger operates at reduced speed. As a result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.

Operating state preconditions for wet cleaning the turbine and nozzle ring


Z After the engine is started up or the engine load has been reduced to

the lowest possible level

Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-

perature is stable and less than 430°C. X Cleaning cycle started according to the following description in Procedure for wet cleaning

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

during operation


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5


5.4

Page 24

Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

In engines with one turbocharger (TL 1)

L_00203

Version 2.0

In V-engines with two turbochargers (TL 1 and 2)

L_00204


ABB

May 2006

Operation Manual

Operating the wet cleaning system

Maintenance

5


5.4

1

Water supply (freshwater only) 6

Other turbochargers

2

Regulating valve

7

Injection pipe

3

Manometer

8

Drainage line

4

Air supply with 3-way-valve

9

Drain cock

5

Stainless steel piping

10

Outflow

11

Baffle (optional, can be integrated in the nozzle)

Z The Operating state preconditions must have been fulfilled before X X X X

HZTL2481_EN (TPL73-A.. - 80-A..)

Page 25

X X X X X X

cleaning is begun! Check that the water supply (1) is connected, open and reliable. Open the drain pipe (8, 9) on the gas outlet casing. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. Slowly open the 3-way-valve (4) first, then the regulating valve (2) until the manometer (3) shows a pressure of 2 ∓ 0.2 bar. Inject water for 10 minutes. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Close the drain pipe (8, 9) on the gas outlet casing. The water supply connection (1) must be isolated at the regulating valve (2). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.

The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently to a reduction in the service life of the components.

Version 2.0

NOTE


If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that no unacceptable quantity of water collects in the gas outlet casing. For this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems service station. The influence of the cleaning water on the peripheral aggregates (such as e.g. Boiler) must be clarified by the operator.

ABB

Operation Manual 5


5.4

Page 26

when cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.

May 2006

The gas outlet casing must be drained of water via the drain pipe (8)

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

Points to remember when cleaning

Maintenance


ABB


5


5.4

Page 27


L_00252 In V-engines with two turbochargers (TL 1 and 2)

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)

L_00253


ABB

Operation Manual


5.4

1

Water supply (freshwater only)

6

Other turbochargers

2

Regulating valve

7

Injection pipe

3

Manometer

8

Drainage line

4


9

Drain cock

5

Stainless steel piping

10

Outflow

11

Baffle (optional, can be integrated in the nozzle)

Page 28

May 2006

5

Z The Operating state preconditions must have been fulfilled before X X X X X X X X X X

cleaning is begun! Check that the water supply (1) is connected, open and reliable. Open the drain pipe (8, 9) on the gas outlet casing. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. Slowly open the 3-way-valve (4) first, then the regulating valve (2) until the manometer (3) shows a pressure of 2 ∓ 0.2 bar. Inject water for 10 minutes. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Close the drain pipe (8, 9) on the gas outlet casing. The water supply connection (1) must be isolated at the regulating valve (2). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.

HZTL2481_EN (TPL73-A.. - 80-A..)


Maintenance

NOTE



ABB

Version 2.0


Operation Manual 5


5.4

Page 29

The gas outlet casing must be drained of water via the drain pipe (8)

when cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


Maintenance


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5.4

Page 30

Operating state preconditions for wet cleaning the turbine and nozzle ring May 2006

(3 nozzles)


Z Reduction of engine loading to the lowest possible level X The best cleaning effect is achieved at a loading level of 20 to 30%.

Version 2.0

perature is stable and less than 430°C. X Cleaning cycle started according to the following description in Procedure for wet cleaning

HZTL2481_EN (TPL73-A.. - 80-A..)

Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-


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5.4

Page 31


HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Procedure for wet cleaning the turbine and nozzle ring (3 nozzles)

L_00200

Version 2.0

In V-engines with two turbochargers (TL 1 and 2)

L_00201


ABB

Operation Manual


5.4

1

Water supply (freshwater only)

6

other turbochargers

2

Regulating valve

7

3 injection nozzles

3

Manometer

8

Drainage line

4


9

Drain cock

5

Water pipe made from stainless 10 steel

Page 32

May 2006

5

Outflow

X The operating state preconditions must be met before cleaning can X X X X X X X X X

begin! Ensure that the water supply (1) is connected, turned on and constant. Open the drainage line (8,9). First open the 3-way valve (4), then open the regulating valve (2) slowly until the pressure gauge (3) indicates a pressure of 2.5 bar. Inject water for 10 minutes. Check whether the exhaust gas temperature falls after the turbine. Close the regulating valve (2). This completes the cleaning process. The water supply must be disconnected from the gas inlet casing. Switching the 3-way-valve (4) for the water supply to blow-out mode with compressed air. Close drain hole (at 8) above drainage line (8,9). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.

HZTL2481_EN (TPL73-A.. - 80-A..)


Maintenance

NOTE



ABB

Version 2.0


Operation Manual 5


5.4

Page 33

The gas outlet casing should be drained via the drainage line (8) during

cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these cases, the washing operation must be terminated and the washing cycle begun again with a lower water pressure or higher engine loading.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


Maintenance


ABB

Operation Manual Troubleshooting

6


6.1

Page 1

6 Troubleshooting May 2006

6.1 Possible remedies for failures Exhaust temperature too high

HZTL2481_EN (TPL73-A.. - 80-A..)

Engine output and speed unchanged

Engine

Z Malfunction in the injection system X Repair, or contact the manufacturer.

Turbocharger

Z Air starvation, e.g. air filter clogged with dirt X Clean Z Compressor / turbine soiled X Clean Z Exhaust counterpressure too high X Clean or repair boiler or exhaust silencer Z Turbine damaged or worn X Contact an official ABB Turbo Systems service station.

Charge-air cooler

Z Cooler soiled X Clean Z Insufficient coolant water quantity X Replenish

Version 2.0

Z Coolant water inlet temperature too hot X Clean/inspect cooling system Z Ventilation inadequate X Improve ventilation


ABB


6


6.1

Page 2

Charge-air pressure too low May 2006

Engine output and speed unchanged Intake condition normal

Engine

Z Air receiver leaking X Repair Z Gas line between engine and turbine leaking X Repair

HZTL2481_EN (TPL73-A.. - 80-A..)

Z Injection misadjusted X Correct adjustment Z Valve control misadjusted X Correct adjustment

Turbocharger

Z Manometer display faulty X Replace manometer Z Leak in line to the manometer X Repair leak Z Air filter dirty, causing excessive loss of pressure X Clean Z Compressor / turbine soiled X Clean

Version 2.0

Z Compressor / turbine damaged X Contact an official ABB Turbo Systems service station. Z Excessive exhaust counterpressure X Clean boiler or exhaust silencer


ABB


6


6.1

Page 3

Charge-air pressure too high May 2006

Engine output and speed unchanged Intake condition normal

Engine

Z Malfunction in the injection system X Correct adjustment Z Engine output higher than expected X Check engine output

HZTL2481_EN (TPL73-A.. - 80-A..)

Z Injection misadjusted X Correct adjustment

Turbocharger

Z Manometer display faulty X Replace manometer

Vibrations Turbocharger

Z Z Z X

Rotor imbalance due to heavy fouling of compressor/turbine Turbine or compressor damaged Bearing defective Contact an official ABB Turbo Systems service station.

Noises during run-out

Version 2.0

Turbocharger

Z Turbocharger dirty X Clean Z Z Z X


Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.

ABB


6


6.1

Page 4

Run-out time too short Z Turbocharger dirty X Clean Z Z Z X

May 2006

Turbocharger


Sluggish start-up Z Turbocharger dirty X Clean Z Z Z X

HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger


Lubricating oil pressure too low Engine

Z Oil filter heavily soiled X Clean Z Oil pump in the lubricating system defective X Inspect Z Manometer provides false reading X Replace manometer


Z Axial clearance of the rotor too big X Contact an official ABB Turbo Systems service station.

Version 2.0

Turbocharger

ABB


6


6.1

Page 5

May 2006

Constant surging of the turbocharger Z Exhaust pressure after the turbine elevated because boiler or exhaust

Engine

silencer is dirty

Z Trap dirty X Clean

Z Charge-air cooler or silencer dirty Z Heavy deposits of contamination in the turbine X Clean

If it is not possible to determine the reason for the surging, contact an official ABB Turbo Systems service station. NOTE

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger


ABB

Operation Manual Removal and installation

7


7.1

Page 1

7 Removal and installation May 2006

7.1 Turbocharger weights Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. WARNING

Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury. X Select a suitable rope taking into account the weight of the turbo-

charger parts.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

X Cross and loop the rope over the crane hook X Do not stand under suspended loads.

L_00082

For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration. WARNING


ABB


7


7.1

Page 2

Weights [kg]

TPL 73

TPL 77

TPL 80

2080

3200

4920

May 2006

Turbocharger complete unit without silencer/air suction branch

Turbocharger complete unit with silencer Weights [kg]

TPL 73

TPL 77

TPL 80

2324

3604

5496

TPL 73

TPL 77

TPL 80

2220

3355

5162

Version 2.0

Weights [kg]

HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger complete unit with air suction branch


ABB


7


7.2

Page 3

7.2 Remove the turbocharger X Disconnect all gas, air, and oil lines in accordance with the engine ma-

May 2006

nufacturer’s instructions.

X Remove the insulating shell from the bearing casing. X Check the lifting equipment. X Secure lifting equipment to the suspension lugs on the bearing casing.

Observe weight of the turbocharger. CAUTION

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the ∅ of this orifice has been individually adjusted by the engine builder. Whenever these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the correct ∅ is fitted into the oil-conducting oil-inlet channel.


ABB


7


7.2

Page 4

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Turbocharger without reinforced suspension lug

L_00052

WARNING


Z If the bearing casing is not provided with a reinforced suspension lug

(lugs are flush with external diameter of the flange), the complete charger must be secured by the air outlet casing and gas inlet casing. See following illustration. X Select a suitable rope taking into account the weight of the turbocharger.

ABB

Version 2.0

During removal, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury.


7


7.2

Page 5

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Turbocharger with reinforced suspension lug

L_00051

X Release the fixing screws on the foot. X Lift the turbocharger from the engine and place it aside.

If the support for the turbocharger is missing or defective, the turbocharger may tip over during installation and removal and can cause serious or even fatal injury. WARNING

Version 2.0

X Support turbocharger in a suitable location. X Cover oil connector.


ABB


7

Installing the turbocharger

7.3

Page 6

During installation, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. Z If the bearing casing is not provided with a reinforced suspension

lug, the complete charger must be secured by the air outlet casing and gas inlet casing. X Select a suitable rope taking into account the weight of the turbocharger. X Suspend the complete turbocharger using the two ribs provided for this purpose.

X Remove cover from the oil connector. X Check the lifting equipment. X Secure lifting equipment to the suspension lugs on the bearing casing.

If provided

X Secure the lifting equipment to the suspension lugs on the gas inlet ca-

sing (see illustration under Removing the turbocharger).

HZTL2481_EN (TPL73-A.. - 80-A..)

WARNING

May 2006

7.3 Installing the turbocharger

Observe weight of the turbocharger. CAUTION

manufacturer's instructions. X Mate the insulating shell with the bearing casing and secure. X Secure all gas, air, and oil lines in accordance with the engine manufacturer’s instructions.


ABB

Version 2.0

X Mate turbocharger with the engine. X Tighten the fixing screws on the foot, in accordance with the engine

Operation Manual Disassembly and assembly

8

Module weights

8.1

Page 1

8 Disassembly and assembly May 2006

8.1 Module weights Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. WARNING

Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury. X Select a suitable rope taking into account the weight of the turbo-

charger parts.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

X Cross and loop the rope over the crane hook X Do not stand under suspended loads.

L_00082

For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration. WARNING


ABB


8

Module weights

8.1

Page 2

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Modules

Weights [kg]


Description

TPL 73

TPL 77

TPL 80

1

Air suction branch, radial

140

155

242

2

Air suction branch, axial

-

-

-

3

Filter silencer

244

404

576

4

Compressor casing, internal part

148

260

355

5

Wall insert

134

276

431

6

Diffuser

57

80

125

7

Compressor casing external part

290

475

680

8

Cartridge group

546

950

1356

9

Turbine diffuser

72

150

250

10

Nozzle ring

25

44

63

ABB

Version 2.0

L_00048


8

Module weights

8.1

Page 3

Compressor casing, internal part, complete

May 2006

Weights [kg]

TPL 73

TPL 77

TPL 80

339

616

911

The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing, the diffuser and the wall insert.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


ABB


8

Removing and fitting the filter silencer or 8.2 air suction branch

Page 4

Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox).

May 2006

8.2 Removing and fitting the filter silencer or air suction branch

NOTE

X Remove insulation where necessary. X Disconnect all air ducts in accordance with the engine manufacturer’s

HZTL2481_EN (TPL73-A.. - 80-A..)

instructions.

TPL 69 - 73

81000_003

Version 2.0

X Fit safety ring bolt (90231) on the filter silencer.


ABB


8


Page 5

L_00011

X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.

TPL 77 – 85

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

TPL 77 - 85

L_00226

X Mount shackle (90195) on the fin on the filter silencer.


ABB

Operation Manual 8


Page 6

Remove filter silencer

X Sling lifting gear through the loops at the rear and secure to the

Install the filter silencer

X The filter silencer or air suction branch is installed in the reverse se-

shackle (90195) or to the safety ring bolt (90231) with a shackle. X Release nuts (74027) with Verbus washers (74028) and remove the filter silencer or air suction branch.

May 2006


Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

quence.


ABB


8


8.3

Page 7

May 2006

8.3 Removing cartridge group Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox). NOTE

X Remove insulation X Disconnect the oil lines in accordance with the engine manufacturer's

instructions.

HZTL2481_EN (TPL73-A.. - 80-A..)

If provided: Position of the safety segments before disassembly

X Take nuts (90458) out of the toolbox and fit them on the threaded pins

of the safety segments (Y) on the internal part of the compressor casing (76000).

Version 2.0

L_00269

X Tighten nuts (90458) to a maximum torque of 30 Nm. D The internal part of the compressor casing is now detached from the

external part of the compressor casing (74000) and can be removed.

Note control dimension (u). NOTE


ABB

Operation Manual 8


8.3

Page 8

Dimension

TPL73-A

TPL77-A

TPL80-A

u

18.6

19.0

19.6

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Control dimension u [mm]


L_00266

X Release and remove nuts (74027) and discs (74028). X Remove six studs (74026) in the upper section and and fit four guide

bolts (90320).

X X X X


screws (90900) until the lifting device (90190) can be attached with shackle (90195) and secured to the crane. Raise internal part of compressor casing slightly with wall insert and diffuser, remove guide bolts (90320) and then withdraw. Fit support angle (90025). Place internal part of compressor casing with wall insert and diffuser on support bracket and shim. Remove O-ring gasket (76040).

ABB

Version 2.0

X Leave 2 holes free for fitting the lifting device (90190). X Push back internal part of compressor casing (76000) with extraction


8


8.3

Page 9

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


L_00047

X Refit the lifting device on the other side of the flange (F). X Turn the internal part of the compressor casing with wall insert and dif-

Version 2.0

fuser carefully over the support bracket (90025) and set down with the front side of the flange (F) on the shim.

Ensure that the shim does not slip. X Check shim and adjust as necessary. CAUTION


ABB


8


8.3

Page 10

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Diffuser

For the turbocharger sizes up to and including TPL 73-A, the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230. NOTE

X Loosen and remove screws (76002). If provided:

X Fit safety ring bolts (90230) on diffuser (79000).

X Remove diffuser (79000).


ABB

Version 2.0

L_00053


8


8.3

Page 11


HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Operation Manual

74000_002

X Secure lifting device (90190) with shackle (90195) to external part of

Version 2.0

compressor casing (74000) and attach securely to the crane. X Loosen nuts (61037), press off external part of compressor casing evenly with the three press-off nuts (61037) and remove.


ABB


8


8.3

Page 12

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Cartridge group

L_00054

X Withdraw cable (86515) and unscrew speed measuring transmitter

(86505) with O-ring gasket (86506).

X Disconnect cable to line amplifier (86525).

Version 2.0

If provided:

X Remove the three screws (61059) and Verbus washers (61058). X Check lifting equipment and secure to bearing casing (42001).


ABB


8


8.3

Page 13

May 2006

During removal, a cartridge group that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. CAUTION

X Select a suitable rope taking into account the weight of the cartridge

group.

X Press cartridge group down evenly with jack screws (90900) into the

holes provided.

If the turbine blades on the rotor have too little or no clearance, this may damage the blades and the casing.

HZTL2481_EN (TPL73-A.. - 80-A..)

CAUTION

X By turning the rotor, check that the turbine blades do not touch the

turbine diffuser.

X Extract the cartridge group and fit supports (90450). X Cover oil connections.

Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems service station.

Version 2.0

CAUTION


ABB


8

Axial clearance

8.4

Page 14

01000_001

Z Axial clearance A must be measured after the cartridge group is re-

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

8.4 Axial clearance

Clearance A [mm]

TPL 73

TPL 77

TPL 80

0.36 - 0.53

0.39 - 0.57

0.42 - 0.65

If the axial clearance (A) is out of tolerance, an official service station of ABB Turbo Systems must be contacted. CAUTION


ABB

Version 2.0

moved and before it is fitted. X Measure and note the axial clearance A.


8


8.5

Page 15

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

8.5 Dismantling and installing the turbine diffuser and nozzle ring

L_00055

X Place clamp (90921) over stud (61036) until it lies flush with the inner

Version 2.0

radius of the gas outlet casing. X Insert extension (A) of torque spanner (B) through the clamp hole and release the torque of screws (61056) and Verbus washers (61057) in succession. X Do not yet remove the screws (61056) and Verbus washers (61057).


ABB


8


8.5

Page 16

56001_001

X In the upper section of the turbine diffuser (63000), replace the two

Version 2.0

screws (61056) and Verbus washers (61057) with two guide bolts (90320). Pass the guide bolts through the holes in clamps (90921). X To secure, fit hexagon nuts (90178).

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Removing the turbine diffuser


ABB


8


8.5

Page 17

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Secure diffuser

61000_002

X Before dismantling the turbine diffuser, if possible the nozzle ring

should be secured against falling with a clamping set and a wooden block. X Loosen the remaining screws (61056) and Verbus washers (61057). X Push back the turbine diffuser (63000) with extraction screws (90901) and withdraw the turbine diffuser until clamp (90921) contacts the hexheaded nut (90178). If the nozzle ring is not secured when the turbine diffuser is withdrawn, it may fall. Note that the nozzle ring (56001) hangs loosely from the positioning pins. CAUTION

Version 2.0

X Fix turbine diffuser (63000) to the lifting gear and remove.


ABB


8


8.5

Page 18

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Remove diffuser

56001_002

Version 2.0

X Fix the holder (90490) on gas outlet casing.


ABB

Operation Manual 8


8.5

Page 19

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


56001_003

X Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting

Version 2.0

gear and remove.


ABB


8


8.5

Page 20

X Fit the nozzle ring and the turbine diffuser by reversing the sequence

Fitting

for removal.

X Align the nozzle ring with the holes in the gas inlet casing and assem-

May 2006

Fitting the turbine diffuser and nozzle ring

ble with screws, nuts and bushings.

Smear all screws in and on the gas casings with Anti Scuff Paste 868 from SPANJAARD.


Version 2.0

CAUTION

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


ABB


8


8.6

Page 21

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

8.6 Installing the cartridge group

L_00054

X Remove cover from the oil connector. X Check the lifting equipment and secure it to the bearing casing (42001)

Version 2.0

so that the cartridge group is hanging straight. X Remove supports (90450) and carefully insert cartridge group. X Tighten screws (61059) and the Verbus washers (61058) evenly.


ABB


8


8.6

Page 22

CAUTION

X By turning the rotor, check that the turbine blades do not touch the

turbine diffuser.

May 2006

If the blades on the rotor have too little or no clearance, this may damage the blades and the casing.

X Remove lifting equipment. X Connect cable to line amplifier (86525).

If provided:

X Screw in the speed measuring transmitter (86505) with O-ring gasket

HZTL2481_EN (TPL73-A.. - 80-A..)

(86506) and connect cable (86515).

X Secure lifting device (90190) and shackle (90195) to external part of

compressor casing (74000) and attach securely to the crane. X Assemble the external part of the compressor casing (74000) and secure with nuts (61037). Before fitting the external part of the compressor casing, screw three press-off nuts (61037) to the end of the thread on the studs provided for this purpose. NOTE


ABB

Version 2.0

74000_002

Operation Manual 8


8.6

Page 23

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


L_00053

Version 2.0

For the turbocharger sizes up to and including TPL 73-A, the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230. NOTE If provided

X Transport diffuser (79000) with the fitted safety ring bolts (90230). X Mount diffuser (79000) and align. Remove safety ring bolts. X Fit the diffuser with the screws (76002).


ABB

Operation Manual 8


8.6

Page 24

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


L_00047

X Attach the lifting device (90190) and shackle (90195) securely to the

Version 2.0

back side of flange (F). X Turn the internal part of compressor casing with wall insert and diffuser carefully over the support bracket (90025) to the vertical position and set down on the shim and support bracket.


ABB

Operation Manual 8


8.6

Page 25

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006


L_00266

X Check that the nuts (90348) on the three safety segments are all tight-

ened.

X Attach the lifting device (90190) and shackle (90195) securely to the

Version 2.0

X X X X

front side of flange (F). Fit O-ring gasket (76040). Remove the support angle. (90025) Fit four guide bolts (90320). Carefully place the internal part of the compressor casing together with the wall insert and the diffuser over the guide bolts.

If provided: Position of the safety segments after assembly

X Loosen nuts (90458) on the threaded pins of the safety segments (Y)

on the internal part of the compressor casing (76000) and push the threaded pins together with safety segment (Y) as far as they will go against the external part of the compressor casing (74000).

D The internal part of the compressor casing (76000) is now secured a-

gainst the external part of the compressor casing (74000).


ABB

Operation Manual 8


8.6

Page 26

May 2006


L_00276

NOTE Control dimension s [mm]

Dimension

TPL73-A

TPL77-A

TPL80-A

s

12.1

12.9

11.9

HZTL2481_EN (TPL73-A.. - 80-A..)

Note control dimension (s). Safety segments (Y) are in an operating state again.

X Replace the nuts (90458) that were taken from the toolbox.

X Measure and note the axial clearance Clearance A [mm]

TPL 73

TPL 77

TPL 80

0.36 - 0.53

0.39 - 0.60

0.42 - 0.65

If the axial clearance A is out of tolerance, an official service station of ABB Turbo Systems Ltd. must be contacted.

X Connect the oil lines and all air lines in accordance with the engine

manufacturer’s instructions.

X Mount filter silencer or air suction branch and secure with nuts (72027)

and Verbus washers (74028). X Fit insulation again.

Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems service station. CAUTION


ABB

Version 2.0

CAUTION


8


8.7

Page 27

May 2006

8.7 Turbine-end removal / fitting of the nozzle ring If only the nozzle ring has to be removed, it is possible to dismantle it at the turbine end.

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

L_00290

Version 2.0

Disassembly of the nozzle ring

X Remove the insulation on the gas inlet casing (51001). X Secure the gas inlet casing with shackle (90195) and a suspension roX

X X X

X


pe. Remove the two hexagon head screws (61044) and Verbus washers (61043) from the lower section and replace them with two studs (90177). To secure, fit hexagon nuts (90178) onto the studs (90177). Loosen and remove the remaining screws (61044) and Verbus washers (61043) on the gas inlet casing flange (61001). Withdraw the gas inlet casing with the nozzle ring from the gas outlet casing until holder (90175) can be fitted from outside with screws (61044) and Verbus washers (61043). Release the hexagon nuts (90178) from the studs.

ABB


8


8.7

Page 28

When positioning the gas inlet casing, use suitable shims and take care to avoid damaging the brackets for the insulation. CAUTION

May 2006

X Withdraw gas inlet casing fully and remove.

X Release holder (90175) and remove the nozzle ring with gasket

(61050).

X Fit nozzle ring and place the holder (90175) over the nozzle ring. X Tighten holder (90175) with screw (61044) and Verbus washer X X X X X X X X

(61043). Insert gasket (61050) in the groove in the gas inlet casing (61001). Align the gas inlet casing and secure by fitting hexagon nuts (90178) on the studs (90177). Remove holder (90175) and screw (61044) and Verbus washers (61043). Fit and tighten the gas inlet casing flange to the gas outlet casing with screws (61044) and Verbus washers (61043). Remove hexagon nuts (90178) from studs (90177). Replace the studs (91077) with hexagon head screws (61044) and Verbus washers (61043). Remove shackle (90195) and suspension rope from gas inlet casing (51001). Secure the insulation on the gas inlet casing (51001).

HZTL2481_EN (TPL73-A.. - 80-A..)

Assembly of the nozzle ring


Version 2.0

CAUTION


ABB


8


8.8

Page 29

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

8.8 Table of tightening torques

L_00044

Version 2.0

The following tightening torques must be maintained for the specified screwed connections:


ABB

Operation Manual


8.8

Tightening torques [Nm]

Page 30

Part no.

TPL 73

TPL 77

TPL 80

42059

M16 105

M20 240

M20 240

61036

M18 80

M20 80

M22 80

61037

M18 160

M20 210

M22 280

61044

M18 370

M20 480

M22 480

61056

M18 370

M20 480

M22 480

61059

M18 370

M20 480

M22 480

74026

M18 80

M20 80

M22 80

74027

M18 135

M20 175

M22 235

76002

M14 – 1)

M16 – 1)

M18 – 1)

82005

M16 x 1.5 50

M16 x 1.5 50

M16 x 1.5 50

86505

M18 x 1.5 150

M18 x 1.5 150

M22 x 1.5 220

90458

M10 30

M10 30

M10 30

Tighten so that the diffuser can still be moved.

Version 2.0

1)

May 2006

8

HZTL2481_EN (TPL73-A.. - 80-A..)


L_00228


ABB

Operation Manual Taking out of operation temporarily

9

Possibilities for emergency repair

9.1

Page 1

9 Taking out of operation temporarily May 2006

9.1 Possibilities for emergency repair Lubricating oil leaks are a fire hazard. WARNING

The instructions of the engine manufacturer for operation of the engine with locked / isolated turbocharger must be followed precisely in all cases! HZTL2481_EN (TPL73-A.. - 80-A..)

CAUTION

If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available: Lock the turbocharger rotor Fitting the cover plate Blocking the inlets and outlets Bypass the turbocharger

Version 2.0


ABB


9

Locking the rotor

9.2

Page 2

A locked rotor must be disassembled following turbocharger repair and given an imbalance check.

May 2006

9.2 Locking the rotor

CAUTION

NOTE

The only exceptions are test rig runs up to a maximum of 25% engine load on new engines with one or a number of turbochargers, which are requested by some customers. Since in these cases operation with a locked rotor is brief and the loads are small, subsequent disassembly of the rotor is unnecessary.

NOTE

CAUTION

Various intermediate rings are provided with the locking device for different compressor wheels. The compressor wheel type ”CV” (for the balancing screw holes) must be noted. The space between the locking flange (94003) and the assembly-disassembly device (90020) must be compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.

HZTL2481_EN (TPL73-A.. - 80-A..)

U Once unscrewed, balancing screws must not be screwed in again.

During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures and information for operation with a locked rotor for 4-stroke engines). Otherwise components that are still intact can be damaged by overheating.

Version 2.0

The supply of lubricating oil to the turbocharger must be shut off in the event of a lubricating oil leak on the turbocharger.


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9

Locking the rotor

9.2

Page 3

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Locking rotor with screwed connection

L_00225

Version 2.0

Table of tightening torques [Nm]

Part no.

TPL73-A

TPL77-A

TPL80-A

74027

M18 135

M20 175

M22 235

94006

M8 25

M8 25

M10 45

94007

M8 15

M8 15

M10 35

These operations must be carried out as described in the chapter Disassembly and assembly. NOTE

X Remove the silencer or air suction branch and the compressor casing

internal part together with the wall insert and the diffuser.


ABB


9

Locking the rotor

9.2

Page 4

X Remove screw plug (25005). X Fit studs (74026) as needed for the locking device on the compressor

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

(74027) to the torques indicated in theTable of tightening torques. X Block the rotor with lock (90480). X Cut a thread (M12 or 1/2") in the existing hole and secure the lock with a screw (A).

May 2006

casing.

X Mount the assembly-disassembly device (90020) and tighten nuts


ABB


9

Locking the rotor

9.2

Page 5

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Locking rotor with polygon connection

L_00046

Version 2.0

Table of tightening torques [Nm]

Part no.

TPL73-A

TPL77-A

TPL80-A

74027

M18 135

M20 175

M22 235

94006

M8 25

M8 25

M10 45

94007

M8 15

M8 15

M10 35



ABB


9

Locking the rotor

9.2

Page 6

internal part together with the wall insert and the diffuser. X Fit partition wall clamp (94005) with screws (90442). X Fit locking flange (94003) with the nuts (74027) and then with the screws (94007 / 94006) according to the Table of tightening torques.

May 2006

X Remove the silencer or air suction branch and the compressor casing

D For engines with three or four turbochargers, the balancing screws

should be removed from the compressor wheel concerned.

D For engines with one or two turbochargers, eight screws are sufficient

for secure fixing of the locking flange.

Locking rotor with polygon connection

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

Compressor type CV10

94000_002


ABB


9

Locking the rotor

9.2

Page 7

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Compressor type CV 20

94000_003

It must be ensured that all components are clean and free from grease. CAUTION

X Push the intermediate rings (94001 and/or 94002) and assembly-

Version 2.0

disassembly device (90020) onto the locking flange (94003) in the correct sequence. X Now push on the other remaining intermediate rings (94001 and/or 94002). X Tighten intermediate rings, assembly-disassembly device (90020) and locking flange (94003) with the screws (94006) according to the values shown in the preceding Table of tightening torques. X Now tighten the assembly-/disassembly device (74027) to the compressor casing with the nuts (74027) and the studs to the values shown in the preceding Tightening torques table.


ABB


9

Locking the rotor

9.2

Page 8

Further measures and information for operation with a locked rotor for 4May 2006

stroke engines

4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.

Separate receivers

No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.

Common air receiver

If the engine is equipped with a common air receiver and separate exhaust-gas receivers, the compensator at the compressor outlet of the damaged turbocharger must be dismantled and the air line on the engine side must be isolated. Otherwise the undamaged turbocharger can spin "unloaded" and overspeed. More or less powerful pulses from the exhaust-gas system are applied to the locked rotor, depending on the engine turbocharging system. Particularly with pulse supercharging (turbine casing with more than one gas inlet) the locking device is then subjected to heavy loading. The following operating limits should therefore not be exceeded:

HZTL2481_EN (TPL73-A.. - 80-A..)

4-stroke engine with several turbochargers

In systems similar to those with constant pressure (1 gas inlet) the en-

Attention must be paid to the speed of the undamaged turbocharger in all cases. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded. CAUTION


ABB

Version 2.0

gine can be operated up to a maximum of 25% engine load. The pressure in the charge-air receiver must not exceed 0.9 bar overpressure. With pulse supercharging (2...4 gas inlets) the engine can be operated up to a maximum of 20% engine load. The pressure in the charge-air receiver must not exceed 0.5 bar overpressure.


9


9.3

Page 9

May 2006

9.3 Fitting the cover plate The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be produced in-house according to the drawing.

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE

90000_001

Version 2.0

Cover plate dimensions [mm]


Type

B3

B4

B5

B6

B7

B8

50

50

9

12

8

94

TPL 77

9

12

107

TPL 80

11

15

136

TPL 73

B1

B2

ABB


9


9.3

Page 10

Ø1

Ø2

Ø3

Ø4

Ø5

Ø6

TPL 73

844

948

905

20

28

20

TPL 77

1003

1124

1075

22

30

TPL 80

1164

1300

1248

24

32

May 2006

Type

α1

α2

α3

TPL 73 - 80

4 x 90°

37.5°

24 x 15°

HZTL2481_EN (TPL73-A.. - 80-A..)

Type



X Removing cartridge group

ABB

Version 2.0

20000_003

Operation Manual 9


9.3

Page 11

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Taking out of operation temporarily

61000_003

X Block the opening in the gas outlet casing with the cover plate. X Secure cover plate with spacer sleeves and nuts (61037).

Shut off the supply of lubricating oil to the turbocharger.

Version 2.0

CAUTION


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9


9.3

Page 12

May 2006

Further measures and information for operation with a turbocharger with cover plate in 4-stroke engines

4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.

Separate receivers

No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.

Common receiver

The air line must be blocked on the engine side, since the undamaged turbochargers develop a receiver pressure.

Version 2.0

CAUTION

The engine can be operated according to the instructions of the engine manufacturer. Attention must be paid to the speed of the undamaged turbocharger in all cases. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded.

HZTL2481_EN (TPL73-A.. - 80-A..)

4-stroke engine with several turbochargers


ABB


9

Blocking the inlets and outlets

9.4

Page 13

May 2006

9.4 Blocking the inlets and outlets Shut off the supply of lubricating oil to the turbocharger. CAUTION

X Block the compressor casing outlet, gas inlet and gas outlet by fitting

cover plates.

For information about how to do this, see the manufacturer's instructions.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


ABB


9

Bypass the turbocharger

9.5

Page 14

May 2006

9.5 Bypass the turbocharger Shut off the supply of lubricating oil to the turbocharger. CAUTION

Z For engines with one turbocharger only: Z The connections are ready and pipes for the bypass are to hand. X Fit the bypass around the turbocharger.

For information about how to do this, see the manufacturer's instructions.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


ABB

Operation Manual Mothballing the turbocharger

10

Taking out of operation for up to 12 months

10.1

Page 1

May 2006

10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger needs special protection or not depends mainly on the condition of the lubricating oil before laying up. If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be taken. However, if the neutralisation factor is higher the turbocharger must be dismantled after laying up, cleaned and protective oil must be applied to the naked parts.

HZTL2481_EN (TPL73-A.. - 80-A..)

If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the sensitive bearing parts will be largely protected against corrosion.

Version 2.0

If the rotor turns due to a draught from the flue, fit a blind flange between the compressor casing and the charge-air duct.


ABB

Operation Manual Mothballing the turbocharger

10

Taking out of operation for more than 12 10.2 months

Page 2

If the turbocharger has to be removed from the engine and stored for a prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station.

May 2006

10.2 Taking out of operation for more than 12 months

Ensure that the storage area is dry with humidity of 40-70% and free of condensation. Check mothballed turbochargers yearly for corrosion. In the event of rust, clean and renew the corrosion protection.

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE


ABB

Operation Manual Reserve and spare parts

11


11.1

Page 1

11 Reserve and spare parts May 2006

11.1 Ordering spare parts When making inquiries or ordering spare parts, the following data should be specified: Turbocharger type HT number Description and part number

Our service stations and agents accept orders for spare parts. X If special variants/cases are not addressed in these general instruc-

HZTL2481_EN (TPL73-A.. - 80-A..)

tions, contact an official ABB Turbo Systems Ltd. service station or an ABB agent.

Spare-parts set Spare-parts set (97070) is required for the work described in this manual. The parts included in the spare-parts set are only available as part of the complete set. NOTE

Version 2.0

TPL73-A


Quantity

Description

Part number

2

Hexagon head screw

42059 / 42064

2

Verbus washer

42058 / 42063

15

Hexagon head screw

61044 / 61056 / 61059

15

Verbus washer

61043 / 61057 / 61058

3

Hexagon nut

61037

1

Gasket

42041

1

Gasket

42045

2

O-ring gasket

42012 / 76040

2

O-ring gasket

77005 / 77006

1

O-ring gasket

86506

1

O-ring gasket

25011

ABB

Operation Manual

11.1

Page 2

Quantity

Description

Part number

15

Hexagon head screw

42059 / 42064 / 61044 / 61056 / 61059

15

Verbus washer

42058 / 42063 / 61043 / 61057 / 61058

3

Hexagon nut

61037

1

Gasket

42041

1

Gasket

42045

2

O-ring gasket

42012 / 76040

2

O-ring gasket

77005 / 77006

1

O-ring gasket

86506

1

O-ring gasket

25011

Quantity

Description

Part number

2

Hexagon head screw

42059 / 42064

2

Verbus washer

42058 / 42063

15

Hexagon head screw

61044 / 61056 / 61059

15

Verbus washer

61043 / 61057 / 61058

3

Hexagon nut

61037

1

Gasket

42041

1

Gasket

42045

2

O-ring gasket

42012 / 76040

2

O-ring gasket

77005 / 77006

1

O-ring gasket

86506

1

O-ring gasket

25011

All spare parts that have been ordered with the turbocharger should be kept complete and serviceable. CAUTION

X Rusty parts should be carefully cleaned and greased. X Dispose of parts that have been exchanged and are no longer usable

in a technically and environmentally compatible manner.


May 2006


HZTL2481_EN (TPL73-A.. - 80-A..)

TPL80-A

11

ABB

Version 2.0

TPL77-A



11


11.2

Page 3

The following part numbers and descriptions must be used in ALL correspondence or orders: Turbocharger

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

11.2 Directory of part numbers


Part number

Description

–

Cartridge group

51001

Gas inlet casing

56001

Nozzle ring

61001

Gas outlet casing

61043 (in spare parts set)

Verbus washer


Hexagon headed screw

61050

Gasket




Verbus washer


Verbus washer




Hex.-headed nut

63000

Turbine diffuser

68000

Foot

74027

Hex.-headed nut

74000


76000



O-ring gasket

76080

Safety segment

77000

Wall insert


O-ring gasket


O-ring gasket

79000

Diffuser

81000

Silencer

82000

Air suction branch, radial

82000

Air suction branch, axial

ABB

Operation Manual

11.2

Part number

Description

21000

Shaft

25000

Compressor wheel

25005

Screw plug

32001

Cam bearing

32101

Radial bearing, compressor side

32102

Radial bearing, turbine side

32104

Auxiliary bearing

32105

Float disc

32106

Axial bearing

32107

Bearing bush

42001

Bearing casing

42002

Cowling

42011

O-ring gasket


O-ring gasket

42015

Gasket cover


Gasket


Gasket


Verbus washer




Verbus washer



43001

Partition wall

43005

O-ring gasket

86505

Speed sensor


O-ring gasket

Page 4

May 2006


HZTL2481_EN (TPL73-A.. - 80-A..)

11

Version 2.0

Cartridge group – screwed connection



ABB

Operation Manual 11


11.2

Part number

Description

21000

Shaft

25000

Compressor wheel

25008

Threaded pin

25009

Ring nut

32001

Cam bearing

32101

Radial bearing, compressor side

32102

Radial bearing, turbine side

32104

Auxiliary bearing

32105

Float disc

32106

Axial bearing

32107

Bearing bush

42001

Bearing casing

42002

Cowling

42011

O-ring gasket


O-ring gasket

42015

Gasket cover


Gasket


Gasket


Verbus washer




Verbus washer



43001

Partition wall

43005

O-ring gasket

86505

Speed sensor


O-ring gasket

Page 5

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Cartridge group - polygon connection



ABB


11

General view of turbocharger

11.3

Page 6

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

11.3 General view of turbocharger

L_00291


ABB


11

General view of cartridge group

11.4

Page 7

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

11.4 General view of cartridge group

L_00039


ABB

ABB

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