Abb Tps48-f32 User manual

Operation Manual

ABB Turbocharging 

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPS48-F32 HT571289

nMmax 1029 t Mmax 680

nBmax 978 t Bmax 650

1/s °C

SOLD08 00180 12 60 60

Year 2017 made in Switzerland

Application according to

the Operation Manual

HZTL2412 English

TPS48-F32

Original Operation Manual

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-

ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon

between the engine builder and ABB.

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

turbocharger speed. In case the operation conditions differs signiﬁcantly from what is considered to be normal for the cur-

rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,

high temperatures and high speed lower the life of components.

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

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

Table of contents Page 1

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Table of contents

1Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Intended use of the turbocharger

1.4

Storage of new turbochargers and spare parts

1.5

Essential information

1.6

Symbols and definitions

1.7

Turbocharger rating plate

1.8

Contact information

2Safety

2.1

Introduction

2.2

CE conformity

Definition of mandatory signs

2.4

Definition of Safety instructions

2.5

Warning plates on the turbocharger

2.6

Safe operation and maintenance

2.7

Hazards during operation and maintenance

2.8

Deflagration on gas engines

2.9

Periodic checking of the pressure vess

2.10

Lifting loads

3Start-up

3.1

Oil supply

3.2

Inspection work

3.3

Commissioning after taking out of operation

4Operation

4.1

Noise emissions

4.2

Servicing work

4.3

Expected exchange intervals

4.4

Speed measurement

4.5

Stopping the engine

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5Maintenance

5.1

Forewor

d to Maintenance

5.2

Cleaning the compressor during operation

5.3

Turbine cleaning during operation

5.4

Cleaning components mechanically

6Troubleshooting

6.1

Malfunctions when starti

6.2

Surging of the turbocharger

6.3

Malfunctions during operation

6.4

Malfunctions when stopping

Speed measurement system

7Removal and installation

7.1

Transport

7.2

Turbocharger weights

7.3

Remove the turbocharger

7.4

Installing the turbocharger

8Disassembly and assembly

8.1

Introduction

8.2

Module weights

8.3

Disassembling and assembling turbocharger

8.4

Axial clearance A and radial clearance B

8.5

Radial clearances N and R

8.6

Table of tightening torques

9Taking out of operation

9.1

Shutting down the turbocharger

10 Mothballing the turbocharger

10.1

Taking the engine out of operation for up to 12

months

10.2

Taking the engine out of operation for more than 12

months

11 Disposing of turbocharger components

12 Spare parts

12.1

Ordering spare parts

12.2

View of turbocharger showing part numbers

12.3

View of cartridge group showing part numbers

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Preliminary remarks 1

Purpose of this manual 1.1 Page 3

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Preliminary remarks

Purpose of this manual

1.1

This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-

charger rating plate.

Operation Manual

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

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

It provides important information in order that the turbocharger can be op-

erated safely, correctly and efficiently.

This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-

stalled on it.

Availability of operation manual

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

turbocharger is used.

Everyone who operates or works on the turbocharger must have first read

and understood the operation manual.

1.1

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Preliminary remarks 1

Layout and function 1.2 Page 4

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Layout and function

1.2

1Suction branch / filter silencer 8 Gas outlet flange

2Compressor casing 9 Nozzle ring

3Diffuser 10 Turbine casing

4Bearing casing 11 Turbine-end bearing flange

5Axial thrust bearing 12 Compressor-end bearing flange

6Radial plain bearing (visible only

at turbine end)

13 Compressor wheel

7Turbine

1.2

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Preliminary remarks 1

Layout and function 1.2 Page 5

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Mode of operation

The turbocharger is a turbomachine consisting of the following main com-

ponents:

€Turbine

€Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine cas-

ing (10) and the nozzle ring (9) to impinge on the turbine (7).

The turbine (7) uses the energy contained in the exhaust gas to drive the

compressor wheel (13). The compressor draws in fresh air, compresses it

and then forces it into the engine's cylinders.

The exhaust gases escape into the ambient air through the exhaust gas

pipe, which is connected to the gas outlet flange (8).

The air, which is necessary for operation of the diesel or gas engine and

is compressed in the turbocharger, is drawn into the compressor wheel

(13) through the suction branch or filter silencer (1). It then passes

through the diffuser (3) and leaves the turbocharger through the outlet on

the compressor casing (2).

The rotor runs in two radial plain bearings (6), which are located in the

bearing flanges (11/12) between the compressor and the turbine. The axi-

al thrust bearing (5) is located between the two radial plain bearings.

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

plied by the engine's lubricating oil circuit. The oil outlet is always at the

lowest point of the bearing casing (4).

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Preliminary remarks 1

Intended use of the turbocharger 1.3 Page 6

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Intended use of the turbocharger

1.3

NOTICE

This turbocharger supplied by ABB Turbo Systems has been developed

for use on diesel engines to generate the volume of air and the charg-

ing pressure required to operate the engine.

The engine builder has provided ABB Turbo Systems with information

regarding the intended use of the engine, from which the operating lim-

its specific to the turbocharger shown on the rating plate (such as oper-

ating speeds, temperatures, exchange intervals / replacement intervals)

have been derived.

If it is used in conjunction with a gas engine, the engine must not be in-

stalled in a potentially explosive environment, and precautionary

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

classified as not potentially explosive.

Any other use will be regarded as a special application which must first

be discussed with ABB Turbo Systems. The manufacturer accepts no

liability for other applications. If it is used otherwise, ABB Turbo Sys-

tems reserves the right to reject all warranty claims.

This turbocharger was built according to state-of-the-art technology and is

operationally safe according to recognised safety regulations.

WARNING

Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper

use may cause damage to the machine.

τThe machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-

ing and repair conditions specified by the manufacturer. Disposal regula-

tions set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's manual.

It may be used only for the intended purpose and operated in compliance

with the operation manual.

τMalfunctions which could affect safety must be eliminated immediately.

The manufacturer accepts no liability for any damage resulting from unau-

thorised alterations to the turbocharger.

1.3

State of the art

Perfect condition

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Preliminary remarks 1

Storage of new turbochargers and

spare parts

1.4 Page 7

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Storage of new turbochargers and spare

parts

1.4

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbo Systems can be stored

in sealed packaging without additional mothballing measures for up to 6

months from the date of delivery (marked by the VCI label on the package).

Volatile Corrosion Inhibitor (VCI)

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

no condensation can form are suitable for storage.

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

WARNING

Protection of health when handling VCIs

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

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

served when handling VCIs:

τEnsure good room ventilation.

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

VCIs.

τWear safety gloves.

τClean hands and face after working with VCIs.

τFor further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

τOpen the package.

τRemove the VCI corrosion protection emitter from the package and

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

VCI corrosion protection emitters can be obtained at

www.branopac.com.

τDispose of the old VCI corrosion protection emitter in an environmen-

tally compatible manner, professionally and in accordance with local

regulations.

τSeal the package. The better the external seal is designed, the more

permanent the protection.

1.4

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Preliminary remarks 1

Storage of new turbochargers and

spare parts

1.4 Page 8

August 2017HZTL2412_ENRevision F

Long-term storage of replacement turbochargers or spare parts

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

bo Systems for prolonged storage. The package is equipped with a hyg-

rometer (see illustration).

The following measures are required every 6 months:

τCheck the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When

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

permissible humidity has been exceeded. In this case the turbocharger

or rotor must be inspected by an ABB Turbocharging Service Station

and repacked.

τInspect the package for damage. If the package is damaged, the tur-

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

charging Service Station and repacked.

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

ABB Turbocharging Service Station:

€Inspect the components

€Exchange the desiccant agent

€Repackage the components.

NOTICE

Replacement components ready for operation

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

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

placement cartridge group can be placed into operation without any pri-

or testing by an ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from

the VCI package.

To avoid the formation of condensation, the surroundings and the content

of the package must have the same temperature during unpacking.

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Preliminary remarks 1

Essential information 1.5 Page 9

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Essential information

1.5

Organisational measures

In addition to this manual, the general, statutory regulations applicable in

the respective country for the prevention of accidents and the protection of

the environment must be observed.

This also applies to the provision and wearing of personnel protection

equipment.

NOTICE

The safety and risk consciousness of the personnel working on and

with the turbocharger must be checked regularly with reference to this

manual.

τThe turbocharger must be shut down immediately by stopping the en-

gine in the event of alterations affecting safety or of corresponding op-

erating behaviour. The fault must be reported to the person or depart-

ment responsible.

NOTICE

Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-

tems.

1.5

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Preliminary remarks 1

Essential information 1.5 Page 10

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Original parts and safety

Original parts and accessories are specially designed for the turbocharger

supplied by ABB Turbo Systems.

WARNING

Use original parts

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

safety of the turbocharger and can cause serious damage to property

and injury to personnel.

τOnly use original parts from ABB Turbo Systems.

ABB Turbo Systems accepts no liability for any damage resulting from the

use of non-original parts and corresponding accessories.

Competence of personnel

The turbocharger must only be operated and serviced by trained and au-

thorised personnel. Basic mechanical training is a prerequisite.

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Preliminary remarks 1

Essential information 1.5 Page 11

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Design variants

This document is valid for different design variants of turbochargers.

There may be sections and descriptions of components that are not rele-

vant for a specific turbocharger variant.

ABB Turbocharging Service Stations will be happy to provide information

on questions regarding a design variant (see Contact information at

www.abb.com/turbocharging).

Accuracy of illustrations

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

ease of understanding. Differences in detail are therefore possible.

Registered Trademarks

Registered trademarks of external companies are used in this document.

The trademarks are marked with ®.

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Preliminary remarks 1

Symbols and definitions 1.6 Page 12

August 2017HZTL2412_ENRevision F

Symbols and definitions

1.6

The following symbols are used in the documents:

ϖPrerequisite

τStep of a procedure

€List, first level

- List, second level

[➙ ] Refers to a page number

Definition of notes

NOTICE

Note

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

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The

mandatory signs are described in chapter Safety and must be complied

with.

Definition of caution / warning

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

ABB Turbo Systems

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

Systems.

Official ABB Turbo Systems Service Stations

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

charging Service Stations. They are inspected and certified regularly by

ABB Turbo Systems. See also chapter Contact information [➙15].

1.6

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Preliminary remarks 1

Turbocharger rating plate 1.7 Page 13

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Turbocharger rating plate

1.7

01 Turbocharger operating limits at engine overload (110%).

Only when operating in the test rig unless otherwise agreed with the

enginebuilder.

02 Turbocharger operating limits during operation

03 Inspection interval of plain bearings in 1000 h

04 Replacement interval of compressor in 1000 h

05 Replacement interval of turbine in 1000 h

06 Customer part number

07 Designation of the special design

08 Weight of turbocharger in kg

09 Turbocharger type

10 Serial number

11 Year of construction of turbocharger

1.7

Operating limits

Recommended in

spection

and replacement intervals

of turbocharger compo-

nents

Further data

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Preliminary remarks 1

Turbocharger rating plate 1.7 Page 14

August 2017HZTL2412_ENRevision F

Explanation of the rating plate

The recommended replacement intervals and the corresponding opera-

tional limits are jointly defined with the engine manufacturer. This informa-

tion is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shorten the

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

contact the nearest official ABB Turbocharging service station.

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

als on the engine test bed. These limits can also be permitted during operation

for special applications. Operation above nMmax and tMmax is not permitted.

Non-observance of the recommended replacement intervals can increase the

risk of unpredictable component failures.

Positions of the rating plates

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

turbocharger bearing casing.

1.7.1

1.7.2

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Preliminary remarks 1

Contact information 1.8 Page 15

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Contact information

1.8

Contact information

Contact information for the official service stations of ABB Turbo Systems

is available online.

τScan the QR code to access our website.

ABB Turbo Systems Ltd

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

1.8

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Safety 2

Introduction 2.1 Page 17

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Safety

Introduction

2.1

Turbochargers manufactured by ABB Turbo Systems are state of the art

and comply with the pertinent safety and health-protection requirements

that applied when the turbocharger was manufactured. Consequently, the

turbocharger is safe to operate. Nevertheless, during turbocharger opera-

tion and when working on the turbocharger, residual risks can exist which:

€originate from the turbocharger itself and its accessories

€originate from the operating and auxiliary materials used

€are the consequence of insufficient observance of the safety instruc-

tions

€are the consequence of unsatisfactory and improper execution of

maintenance and inspection work

The operator is responsible for access to the turbocharger as well as the

organisational measures which regulate the safe handling of the turbo-

charger by his personnel.

All instructions in this chapter must be observed to ensure safe and trou-

ble-free turbocharger operation and during work on the turbocharger.

In the same vein, all other specially marked safety instructions in every

chapter of this manual must be observed (see the section entitled Defini-

tion of safety instructions).

2.1

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Safety 2

CE conformity 2.2 Page 18

August 2017HZTL2412_ENRevision F

CE conformity

2.2

Information

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

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

2.2

Table of contents

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