ABB HT598026 User manual

Operation Manual
ABB Turbocharging 
Type TPL65VA33 HT598026
nMmax 499 t Mmax 680
nBmax 499 t Bmax 650
1/s °C
01210 35 50 50
Year 2020 Application according to the Operation Manual
kg
HZTL2464 English
TPL65VA33
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 / TPL65VA32 / VA33
Table of contents
© Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E 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 of the turbocharger .............................................................................. 7
1.4 Storage of new turbochargers and spare parts ....................................................... 8
1.5 Essential information................................................................................................... 10
1.6 Symbols and definitions .............................................................................................. 13
1.7 Turbocharger rating plate ........................................................................................... 14
1.8 Contact information..................................................................................................... 15
2 Safety...................................................................................................................... 16
2.1 Introduction ................................................................................................................... 16
2.2 CE conformity ................................................................................................................ 16
2.3 Definition of mandatory signs ................................................................................... 17
2.4 Definition of Safety instructions ............................................................................... 17
2.5 Warning plates on the turbocharger......................................................................... 18
2.6 Safe operation and maintenance............................................................................... 18
2.7 Hazards during operation and maintenance........................................................... 21
2.8 Periodic checking of the pressure vessel ................................................................. 27
2.9 Lifting loads ................................................................................................................... 27
3 Commissioning...................................................................................................... 29
3.1 Oil supply ........................................................................................................................ 29
3.2 Inspection work............................................................................................................. 32
3.3 Commissioning after taking out of operation........................................................ 33
4 Operation ............................................................................................................... 35
4.1 Noise emissions ............................................................................................................ 35
4.2 Servicing work ............................................................................................................... 36
4.3 Replacement intervals for turbocharger components.......................................... 38
4.4 Speed measurement ................................................................................................... 40
4.5 Emergency operation TPL..VA ................................................................................... 44
4.6 Stopping the engine .................................................................................................... 45
5 Maintenance .......................................................................................................... 47
5.1 Foreword to Maintenance ........................................................................................... 47
5.2 Cleaning the filter silencer.......................................................................................... 48
5.3 Cleaning the compressor during operation ............................................................ 51
5.4 Cleaning turbines and guide vanes during operation ........................................... 55
5.5 Cleaning components mechanically.......................................................................... 55

Operation Manual / TPL65VA32 / VA33
Table of contents
© Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020
6 Troubleshooting.................................................................................................... 64
6.1 Malfunctions when starting....................................................................................... 64
6.2 Surging of the turbocharger...................................................................................... 64
6.3 Malfunctions during operation ................................................................................. 66
6.4 Malfunctions when stopping ..................................................................................... 68
6.5 Speed measurement system ..................................................................................... 69
6.6 Variable Turbine Geometry ........................................................................................ 69
7 Removal and installation....................................................................................... 71
7.1 Turbocharger weights.................................................................................................. 71
7.2 Removing the turbocharger........................................................................................ 71
7.3 Installing the turbocharger ......................................................................................... 73
8 Disassembly and assembly .................................................................................. 74
8.1 Introduction ................................................................................................................... 74
8.2 Module weights ............................................................................................................. 75
8.3 Removing and fitting filter silencer or air suction branch.................................... 77
8.4 Axial clearance ............................................................................................................... 79
8.5 Removing cartridge group .......................................................................................... 79
8.6 Removing and fitting turbine diffuser..................................................................... 84
8.7 Removing variable turbine geometry module with gas inlet casing .................. 85
8.8 Fitting the variable turbine geometry module and the gas inlet casing .......... 86
8.9 Installing cartridge group............................................................................................ 87
8.10 Table of tightening torques........................................................................................ 93
9 Taking out of operation at short notice ............................................................ 95
9.1 Possibilities for emergency repair............................................................................. 95
9.2 Fit cover plate ............................................................................................................... 96
9.3 Blocking the inlets and outlets.................................................................................. 99
9.4 Bypass the turbocharger ............................................................................................ 99
10 Mothballing the turbocharger ........................................................................... 101
10.1 Taking the engine out of operation for up to 12months.................................... 101
10.2 Taking the engine out of operation for more than 12months .......................... 102
11 Disposing of turbocharger components.......................................................... 104
12 Spare parts........................................................................................................... 105
12.1 Ordering spare parts .................................................................................................. 105
12.2 View of turbocharger with part numbers .............................................................. 107

Operation Manual / TPL65VA32 / VA33
1 Preliminary remarks / 1.1 Purpose of this manual
© Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E 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.
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