ABB HT843602 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS 57E01 HT843602
nMmax 716 t Mmax 650
nBmax 680 t Bmax 620
1/s °C
SSDF02 00410 12 50 50
Year 2017 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2410 English
TPS 57E01
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 / TPS48-D/E.. - TPS61-D/E..
Table of contents
Page 1
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2410_ENRevision E
Table of contents
1
Preliminary remarks
1.1
Purpose of this manual
1.2
Layout and function
1.3
Intended use of the turbocharger
1.4
Storage of new turbochargers and spare parts
1.5
Essential information
1.6
Symbols and definitions
1.7
Turbocharger rating plate
1.8
Contact information
2
Safety
2.1
Introduction
2.2
CE conformity
2.3
Definition of mandatory signs
2.4
Definition of Safety instructions
2.5
Warning plates on the turbocharger
2.6
Safe operation and maintenance
2.7
Hazards during operation and maintenance
2.8
Deflagration on gas engines
2.9
Periodic checking of the pressure vessel
2.10
Lifting loads
3
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Commissioning after taking out of operation
4
Operation
4.1
Noise emissions
4.2
Servicing work
4.3
Expected exchange intervals
4.4
Speed measurement
4.5
Stopping the engine

Operation Manual / TPS48-D/E.. - TPS61-D/E..
Table of contents
Page 2
© Copyright 2016 A
BB. All rights reserved.
September 2016HZTL2410_ENRevision E
5
Maintenance
5.1
Foreword to Maintenance
5.2
Cleaning the compressor during operation
5.3
Turbine cleaning during operation
5.4
Cleaning components mechanically
6
Troubleshooting
6.1
Malfunctions when starting
6.2
Surging of the turbocharger
6.3
Malfunctions during operation
6.4
Malfunctions when stopping
6.5
Speed measurement system
7
Removal and installation
7.1
Transport
7.2
Turbocharger weights
7.3
Remove the turbocharger
7.4
Installing the turbocharger
8
Disassembly and assembly
8.1
Introduction
8.2
Module weights
8.3
Disassembling and assembling turbocharger
8.4
Axial clearance A and radial clearance B
8.5
Radial clearances N and R
8.6
Table of tightening torques
9
Taking out of operation
9.1
Shutting down the turbocharger
10
Mothballing the turbocharger
10.1
Taking the engine out of operation for up to 12 months
10.2
Taking the engine out of operation for more than 12 months
11
Disposing of turbocharger components
12
Spare parts
12.1
Ordering spare parts
12.2
View of turbocharger showing part numbers
12.3
View of cartridge group showing part numbers

Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Purpose of this manual
1.1
Page 3
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2410_ENRevision E
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
1.1