ABB HT562838 User manual

Operation Manual
Turbocharging
ABB Turbo Systems Ltd 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL65-A33 HT562838
nMmax 503 t Mmax 600
nBmax 486 t Bmax 600
1/s °C
01230 35 50 50
Year 2013 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2498 English
TPL65-A33
Original Operation Manual

We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to
the „European Machinery Directives“.
We reserve all rights in this document and in the information contained herein.
Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.
©Copyright by ABB TURBO SYSTEMS Ltd 2004
Design and specifications are subject to change without notice.
Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.
The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of
recycled cardboard.
These materials may be disposed with the domestic wastes or at a specialised collecting centre.
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland

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 / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Table of contents
Page 1
September 2014HZTL2498_ENRevision A
Table of contents
1
Preliminary remarks
1.1
Purpose of this manual
1.2
Layout and function
1.3
Correct 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 address and after-sales service
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
Periodic checking of the pressure vessel
2.9
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
Replacement intervals for turbocharger components
4.4
Speed measurement
4.5
Stopping the engine
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Ta
ble of contents Page 2
September 2014HZTL2498_ENRevision A
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
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
Turbocharger weights
7.2
Remove the turbocharger
7.3
Installing the turbocharger
8
Disassembly and assembly
8.1
Introduction
8.2
Module weights
8.3
Removing and fitting filter silencer or air suction branch
8.4
Axial clearance
8.5
Removing cartridge group
8.6
Dismantling and installing the turbine diffuser and nozzle ring
8.7
Installing cartridge group
8.8
Turbine-end removal / fitting of the nozzle ring
8.9
Table of tightening torques
9
Taking out of operation at short notice
9.1
Possibilities for emergency repair
9.2
Locking the rotor
9.3
Fit cover plate
9.4
Blocking the inlets and outlets
9.5
Bypass the turbocharger
© Copyright 2014 ABB. All rights reserved.

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Table of contents
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September 2014HZTL2498_ENRevision A
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 the turbocharger with part numbers
12.3
View of cartridge group with part numbers TPL65-A32 / -A33 / -
A36
12.4
View of cartridge group with part numbers TPL69-A32 / -A33
12.5
View of turbine cleaning system with part numbers (optional)
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Purpose of this manual
1.1
Page 5
September 2014HZTL2498_ENRevision A
Preliminary remarks
Purpose of this manual
1.1
This operation manual belongs to the turbocharger with the identical HT
number (1), see the cover sheet of the operation manual and the
turbocharger rating plate.
Operation Manual
This Operation Manual enables you to familiarize yourself with the
turbocharger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be
operated safely, correctly and efficiently.
This Operation Manual complements and expands existing national
regulations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechanics
who are responsible for operating the engine and the turbocharger
installed on it.
Availability of operation manual
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
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Layout and function
1.2
Page 6
September 2014HZTL2498_ENRevision A
Layout and function
1.2
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 Compressor casing
7 Gas inlet casing
1.2
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Layout and function
1.2
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September 2014HZTL2498_ENRevision A
Working principle
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.
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 to free air through the exhaust manifold 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 diffusor (11) and leaves the turbocharger through the
compressor casing (13).
The rotor runs in two radial plain bearings (2/5). One plain bearing is
situated in the bearing bush (4) and one plain bearing is situated in the
axial thrust bearing (3) at the compressor side.
The plain bearings are connected to a central lubricating oil channel which
is fed with oil from the engine lubrication circuit. The oil outlet is always at
the lowest point of the bearing casing (10).
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Layout and function
1.2
Page 8
September 2014HZTL2498_ENRevision A
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is
provided with a compressor wheel cooling system.
C
ompressor wheel cooling means that, after the charge air
cooler at the engine end, cooled compressor air is
delivered to the turbocharger to cool the compressor
wheel.
In view of the respective operating conditions, it is
absolutely essential that the comp
ressor wheel is cooled in
order to guarantee its reliability and replacement intervals.
In the case of the turbocharger version with compressor
wheel cooling, the cooling air is supplied through the side
connection (15) in the bearing casing.
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Correct use of the turbocharger
1.3
Page 9
September 2014HZTL2498_ENRevision A
Correct 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
charging pressure required to operate the engine.
The engine builder has provided ABB Turbo Systems with information
regarding the intended use of the engine, from which the operating
limits specific to the turbocharger shown on the rating plate, such as
speeds, temperatures, replacement intervals, have been derived.
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo
Systems reserves the right to reject all warranty claims.
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.
The machine may be operated only by trained personnel.
Use of the turbocharger as intended also includes observance of the
installation / fitting, disassembly / removal, operating, maintenance /
servicing and repair conditions specified by the manufacturer. Disposal
regulations set down by local authorities must be observed.
The turbocharger may be installed only when in technically perfect
condition while observing the instructions given in the engine builder's
manual. It may be used only for the intended purpose and operated in
compliance with the operation manual.
Malfunctions which could affect safety must be eliminated
immediately.
The manufacturer accepts no liability for any damage resulting from
unauthorised alterations to the turbocharger.
1.3
State of the art
Perfect condition
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 10
September 2014HZTL2498_ENRevision A
Storage of new turbochargers and spare
parts
1.4
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and cartridge groups 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
packaging).
Only dry rooms in which the relative humidity is between 40 to 70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months (VCI)
WARNING
Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous
Substances Ordinance. Nevertheless, the following points are to be
observed when handling VCIs:
Ensure good room ventilation.
Do not eat, drink or keep food at the workplace while working with
VCIs.
Wear safety gloves.
Clean hands and face after working with VCIs.
For further information refer to www.branopac.com.
Wear safety gloves against chemical risks.
The following mothballing measures are required every 6 months:
Open the package.
Remove the VCI corrosion protection emitter from the package and
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at
www.branopac.com.
Dispose of the old VCI corrosion protection emitter in an
environmentally compatible manner, professionally and in accordance
with local regulations.
Seal the package. The better the external seal is designed, the more
permanent the protection.
1.4
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 11
September 2014HZTL2498_ENRevision A
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB
Turbo Systems for prolonged storage. The package is equipped with a
hygrometer (see the figure).
The following measures are required every 6 months:
Check the hygrometer (2) in the sight-glass. There is an opening (1) in
the wooden crate which allows this check to be carried out. When the
display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
and repacked.
Inspect the package for damage. If the package is damaged, the
turbocharger or cartridge group must be inspected by an ABB
Turbocharging Service Station and repacked.
After every 3 years the following work steps must be performed by an
ABB Turbocharging Service Station:
Inspect the components.
Exchange the desiccant agent.
Repackage the components.
NOTICE
Replacement components ready for operation
If the 70% display field of the hygrometer (2) has not changed colour
and the package is undamaged, the replacement turbocharger or
replacement cartridge group can be placed into operation without any
prior testing by an ABB Turbocharging Service Station.
Unpacking replacement turbochargers or spare parts
The corrosion protection effect ends after the material is unpacked from
the VCI packaging.
To avoid the formation of condensation, the surroundings and the content
of the package must have the same temperature during unpacking.
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Essential information
1.5
Page 12
September 2014HZTL2498_ENRevision A
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.
The turbocharger must be shut down immediately by stopping the
engine in the event of alterations affecting safety or of corresponding
operating behaviour. The fault must be reported to the person or
department responsible.
NOTICE
Additions and alterations to, and conversions of the turbocharger that
could compromise safety require the prior approval of ABB Turbo
Systems.
1.5
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Essential information
1.5
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September 2014HZTL2498_ENRevision A
Original parts and safety
Original parts and accessories are specially designed for turbochargers
supplied by ABB Turbo Systems.
NOTICE
We herewith expressly state that parts and accessories not supplied by
us have also not been tested and approved by us.
WARNING
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.
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.
Use only original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability whatsoever for any damage
caused by the use of non-original parts and accessories.
Qualification of personnel
The turbocharger may be operated and maintained only by trained and
authorized personnel.
CAUTION
Work on mechanical components, such as bearings or rotors, may be
carried out only by trained fitters from an official ABB Turbocharging
service station.
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Essential information
1.5
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September 2014HZTL2498_ENRevision A
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.
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 manual are of a general nature
and are intended to assist understanding of the work steps and
instructions. Differences may exist in certain details.
Registered Trademarks
Registered trademarks of external companies are used in this document.
The trademarks are marked with ®.
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Symbols and definitions
1.6
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September 2014HZTL2498_ENRevision A
Symbols and definitions
1.6
The following symbols are used in the documents:
Prerequisite
Work step
Enumeration, first level
- Enumeration, second level
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
Turbocharging Service Stations. They are inspected and certified regularly
by ABB Turbo Systems.
1.6
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 16
September 2014HZTL2498_ENRevision A
Turbocharger rating plate
1.7
1
Turbocharger operating limits at engine overload (110%).
Only when operating in the test rig unless otherwise agreed with the
engine builder.
2
Turbocharger operating limits during operation
3
Replacement interval for plain bearings in 1000 h
4
Replacement interval for compressor in 1000 h
5
Replacement interval for turbine in 1000 h
6
Part number for customer
7 Designation of special design
8
Turbocharger weight in kg
9 Turbocharger type
10
Serial number
11 Year of turbocharger construction
1.7
Operating limits
Recommended
replacement intervals for
turbocharger components
Further information
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 17
September 2014HZTL2498_ENRevision A
Explanation of the rating plate
The recommended replacement intervals and the corresponding
operational limits are jointly defined with the engine manufacturer. This
information is specific to the system.
Operation above the indicated values 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
trials on the engine test b
ed. 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
A rating plate is attached to the turbocharger foot, one on the left and one
on the right. In the case of turbochargers with insulation supplied by ABB
Turbo Systems, at least one additional rating plate is attached to the
insulation of the gas outlet casing.
1.7.1
1.7.2
© Copyright 2014 ABB. All rights reserved.

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33
Preliminary remarks
1
Contact address and after
-
sales service
1.8
Page 18
September 2014HZTL2498_ENRevision A
Contact address and after-sales service
1.8
Contact address
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
After-sales service
Official ABB Turbo Systems Service
Stations
A list of the service stations is available
in the brochure "Contact Information"
or online.
1.8
© Copyright 2014 ABB. All rights reserved.