ABB HT597524 User manual

Operation Manual
ABB Turbocharging 
Type TPL71-C35 HT597524
nMmax 410 t Mmax 650
nBmax 397 t Bmax 620
1/s °C
02040 35 50 50
Year 2020 Application according to the Operation Manual
kg
HZTL2488 English
TPL71-C35
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
© Copyright 2020 . All rights reserved. HZTL2488_EN Rev.G March 2020
Operation Manual
1 Preliminary remarks................................................................................................. 3
1.1 Purpose of this manual .................................................................................................. 3
1.2 Layout and function........................................................................................................ 4
1.3 Intended use..................................................................................................................... 6
1.4 Storage of new turbochargers and spare parts ....................................................... 8
1.5 Essential information................................................................................................... 10
1.6 Symbols and definitions .............................................................................................. 12
1.7 Turbocharger rating plate ........................................................................................... 13
1.8 Contact information..................................................................................................... 14
2 Safety....................................................................................................................... 15
2.1 Introduction ................................................................................................................... 15
2.2 CE conformity ................................................................................................................ 15
2.3 Definition of mandatory signs ................................................................................... 16
2.4 Definition of Safety instructions ............................................................................... 16
2.5 Warning plates on the turbocharger......................................................................... 17
2.6 Safe operation and maintenance............................................................................... 18
2.7 Hazards during operation and maintenance........................................................... 21
2.8 Periodic checking of the pressure vessel ................................................................. 26
2.9 Lifting loads ................................................................................................................... 26
3 Commissioning...................................................................................................... 28
3.1 Oil supply ........................................................................................................................ 28
3.2 Inspection work............................................................................................................. 31
3.3 Commissioning after taking out of operation........................................................ 33
4 Operation ............................................................................................................... 34
4.1 Noise emissions ............................................................................................................ 34
4.2 Servicing work ............................................................................................................... 36
4.3 Replacement intervals for turbocharger components.......................................... 39
4.4 Speed measurement .................................................................................................... 41
4.5 Stopping the engine .................................................................................................... 45
5 Maintenance .......................................................................................................... 46
5.1 Foreword to Maintenance .......................................................................................... 46
5.2 Cleaning the filter silencer........................................................................................... 47
5.3 Cleaning the compressor during operation ........................................................... 50
5.4 Cleaning turbine blades and nozzle ring in operation........................................... 56
5.5 Cleaning components mechanically.......................................................................... 61

Operation Manual / TPL67-C.. - TPL71-C..
Table of contents
© Copyright 2020 . All rights reserved. HZTL2488_EN Rev.G March 2020
6 Troubleshooting.................................................................................................... 70
6.1 Malfunctions when starting........................................................................................ 70
6.2 Surging of the turbocharger....................................................................................... 71
6.3 Malfunctions during operation .................................................................................. 72
6.4 Malfunctions when stopping ...................................................................................... 75
6.5 Speed measurement system ...................................................................................... 76
7 Removal and installation....................................................................................... 77
7.1 Turbocharger weights.................................................................................................. 77
7.2 Removing the turbocharger........................................................................................ 78
7.3 Installing the turbocharger ........................................................................................ 80
8 Disassembly and assembly .................................................................................. 81
8.1 Introduction ................................................................................................................... 81
8.2 Module weights ............................................................................................................. 83
8.3 Removing and fitting filter silencer or air suction branch.................................... 85
8.4 Axial clearance ............................................................................................................... 87
8.5 Removing cartridge group .......................................................................................... 87
8.6 Dismantling and installing the turbine diffuser and nozzle ring ......................... 92
8.7 Installing cartridge group............................................................................................ 95
8.8 Dismantling and fitting nozzle ring at turbine end ............................................. 100
8.9 Table of tightening torques..................................................................................... 104
9 Taking out of operation at short notice .......................................................... 106
9.1 Possibilities for emergency repair.......................................................................... 106
9.2 Locking the rotor......................................................................................................... 107
9.3 Fitting the cover plate................................................................................................. 111
9.4 Blocking the inlets and outlets................................................................................. 115
9.5 Bypass the turbocharger ........................................................................................... 115
10 Mothballing turbocharger................................................................................... 116
10.1 Taking out of operation for up to 12 months........................................................ 116
10.2 Taking out of operation for more than 12 months............................................... 117
11 Disposing of turbocharger components........................................................... 118
12 Spare parts............................................................................................................ 119
12.1 Ordering spare parts .................................................................................................. 119
12.2 View of turbocharger with part numbers .............................................................. 122
12.3 View of turbine cleaning system with part numbers (optional)........................ 124

Operation Manual / TPL67-C.. - TPL71-C..
1 Preliminary remarks / 1.1 Purpose of this manual
© Copyright 2020 . All rights reserved. HZTL2488_EN Rev.G March 2020
1 Preliminary remarks
1.1 Purpose of this manual
This Operation Manual belongs to the turbocharger with the identical
serial number (01), see the cover sheet of the Operation Manual and the
turbocharger rating plate.
Operation Manual
This Operation Manual helps familiarise the user with the turbocharger
from ABB Turbocharging and how 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 reg-
ulations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechan-
ics 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.
Page 3 / 125