ABB HT576102 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL67-C34 HT576102
nMmax 478 t Mmax 650
nBmax 478 t Bmax 620
1/s °C
01330 36 50 50
Year 2017 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2488 English
TPL67-C34
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 / TPL67-C.. - TPL71-C..
Table of contents
Page 1
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
Table of contents
1
Preliminary remarks
1.1
Purpose of this manual
1.2
Layout and function
1.3
Intended use
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
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
5
Maintenance

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© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
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
5.5
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
Turbocharger weights
7.2
Removing 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
Dismantling and fitting nozzle ring at turbine end
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
10
Mothballing turbocharger
10.1
Taking out of operation for up to 12 months

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10.2
Taking 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 with part numbers
12.3
View of turbine cleaning system with part numbers (optional)

Operation Manual / TPL67-C.. - TPL71-C..
Preliminary remarks
1
Purpose of this manual
1.1
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© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
Preliminary remarks
Purpose of this manual
1.1
This Operation Manual belongs to the turbocharger with the identical seri-
al number (01), see the cover sheet of the Operation Manual and the tur-
bocharger 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

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Preliminary remarks
1
Layout and function
1.2
Page 6
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
Layout and function
1.2
01
Filter silencer 08 Nozzle ring
02
Radial plain bearing 09 Turbine wheel
03
Thrust bearing 10 Bearing casing
04
Bearing bush 11 Diffuser
05
Radial plain bearing 12 Compressor wheel
06
Gas outlet casing 13 Compressor casing
07
Gas inlet casing
1.2
TPL67/71-C

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Preliminary remarks
1
Layout and function
1.2
Page 7
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
Mode of operation
The turbocharger is a turbomachine 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 cas-
ing (07) and nozzle ring (08) to the turbine wheel.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air,
compresses it and then forces it into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
The air which is necessary for operation of the diesel engine and is com-
pressed in the turbocharger is drawn through the suction branch or the fil-
ter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the com-
pressor casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is in
the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is always
at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is provid-
ed with a compressor wheel cooling system. Compressor
wheel cooling means that, after the charge air cooler at the
engine end, cooled compressor air is delivered to the tur-
bocharger to cool the compressor wheel.
In view of the respective operating conditions, it is abso-
lutely essential that the compressor wheel is cooled in or-
der 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.

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Preliminary remarks
1
Intended use
1.3
Page 8
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
Intended use
1.3
Use on internal combustion engines in general
ABB turbochargers are intended for turbocharging internal combustion
engines.
To ensure compliance with the machinery directive 2006/42/EC when us-
ing on gas engines, the turbocharger must be operated in an engine room
classified as "not at risk of explosion". This is in accordance with the posi-
tion paper [2] relating to ATEX issued by EUROMOT [1].
The turbocharger supplies the engine with the air volume or air/gas mix-
ture and the associated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direc-
tion of rotation as viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the
basis of information from the enginebuilder about the intended use. These
data are given on the rating plate.
ABB Turbo Systems accepts no liability and rejects all warranty claims for
any non-intended uses.
[1] Euromot = The European Association of Internal Combustion Engine Man-
ufacturers
[2] Directive 94/9/EC concerning equipment and protective systems intended
for use in potentially explosive atmospheres (ATEX) The Euromot Position
as of November 2003, ATEX Euromot Position 191103
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be
hazardous to personnel.
The turbocharger must only be operated within the operating limits.
Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regula-
tions and conditions. In particular, the following must be observed:
Operation Manual
Instructions of the enginebuilder
1.3

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Preliminary remarks
1
Intended use
1.3
Page 9
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
State of the art
The turbocharger is designed and built according to the state of the art
and is safe to operate.
Flawless condition
The turbocharger must only be used when it is in a technically flawless
condition and operated in compliance with its intended use.
ABB Turbo Systems excludes any liability for damage resulting from un-
authorized modifications to the turbocharger or improper operation.

Operation Manual / TPL67-C.. - TPL71-C..
Preliminary remarks
1
Storage of new t
urbochargers and
spare parts
1.4
Page 10
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
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).
V
olatile
C
orrosion
I
nhibitor (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:
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 to protect against chemical hazards.
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 environmen-
tally 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

Operation Manual / TPL67-C.. - TPL71-C..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 11
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
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
hygrometer (see illustration).
The following measures are required every 6 months:
Check the hygrometer (02) in the sight-glass. There is an opening (01)
in the wooden crate which allows this check to be carried out. When
the display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
and repacked.
Inspect 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
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February 2017HZTL2488_ENRevision D
Essential information
1.5
Organisational measures
In addition to the Operation Manual, the general statutory regulations for
the prevention of accidents and for environmental protection in the country
of use must also be observed.
This also applies to the provision and wearing of personal protective
equipment.
NOTICE
The manner in which personnel work on and with the turbocharger with
regard to safety and risks is to be checked on a regular basis in ac-
cordance with the Operation Manual.
The turbocharger must be shut down immediately in the event of modi-
fications affecting safety or of corresponding operating behaviour by
stopping the engine. The fault should be reported to the person or de-
partment responsible.
NOTICE
Any modifications, additions or conversions made to the turbocharger,
which could impair safety, require the prior approval of ABB Turbo Sys-
tems.
1.5

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1
Essential information
1.5
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February 2017HZTL2488_ENRevision D
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.
Only 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.
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
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Symbols and definitions
1.6
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February 2017HZTL2488_ENRevision D
Symbols and definitions
1.6
The following symbols are used in the documents:
Prerequisite
Step 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 [➙ 17].
1.6

Operation Manual / TPL67-C.. - TPL71-C..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 15
© Copyright 2017 ABB. All rights reserved.
February 2017HZTL2488_ENRevision D
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 en-
ginebuilder.
02 Turbocharger operating limits during operation
03 Replacement interval for plain bearings in 1000 h
04 Replacement interval for compressor in 1000 h
05 Replacement interval for turbine in 1000 h
06 Customer part number
07 Designation of the special design
08 Turbocharger weight in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
1.7
Operating limits
Recommended replace-
ment intervals for turbo-
charger components
Further information

Operation Manual / TPL67-C.. - TPL71-C..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 16
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February 2017HZTL2488_ENRevision D
Explanation of the rating plate
The recommended replacement intervals and the corresponding opera-
tional 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 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
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 insu-
lation of the gas outlet casing.
1.7.1
1.7.2

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Preliminary remarks
1
Contact information
1.8
Page 17
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February 2017HZTL2488_ENRevision D
Contact information
1.8
Contact information
Contact information for the official service stations of ABB Turbo Systems
is available online.
Scan the QR code to access our website.
ABB Turbo Systems Ltd
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
1.8