ABB HT604623 User manual

Turbocharging
Operation Manual / TPS52-H33
HT604623
Document identification
Document number HZTL4037
Revision G
Language English
Original Operation Manual
Product identification
Serial number HT604623
Customer part number 12453772
Delivery date (yyyy-mm-dd) 2021-08-09
Weight 250 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 847 1/s
Speed limit during operation nBmax 805 1/s
Gas inlet temperature limit in test rig operation only tMmax 680 °C
Gas inlet temperature limit during operation tBmax 650 °C

Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Registered trademarks................................................................................................. 5
1.5 Layout and function of the turbocharger ................................................................ 6
1.6 Symbols, definitions...................................................................................................... 7
1.7 Storage of new turbochargers and spare parts .................................................... 10
2 Safety .................................................................................................................... 12
2.1 Introduction .................................................................................................................. 12
2.2 CE conformity............................................................................................................... 12
2.3 Definition of mandatory signs .................................................................................. 13
2.4 Definition of safety instructions .............................................................................. 13
2.5 Intended use ................................................................................................................. 14
2.6 Deflagration on gas engines ..................................................................................... 15
2.7 Warning plates on the turbocharger........................................................................ 16
2.8 Turbocharger rating plate.......................................................................................... 17
2.9 Lifting of loads ............................................................................................................. 19
2.10 Prerequisites for operation and maintenance...................................................... 20
2.11 Hazards during operation and maintenance ......................................................... 21
2.12 Safe operation.............................................................................................................. 23
2.13 Safe maintenance ....................................................................................................... 24
3 Removing and Installing...................................................................................... 28
3.1 Turbocharger weight and transportation ............................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger........................................................................................ 31
4 Commissioning .................................................................................................... 34
4.1 Oil supply ...................................................................................................................... 34
4.2 Inspection procedures............................................................................................... 35
4.3 Commissioning after taking out of operation....................................................... 37
5 Monitoring operation .......................................................................................... 38
5.1 Oil pressure, oil temperature.................................................................................... 38
5.2 Exhaust gas temperature before turbine ............................................................... 41
5.3 Turbocharger speed.................................................................................................... 41
6 Operation and service ......................................................................................... 45
6.1 Noise emission ............................................................................................................ 45
6.2 Service work................................................................................................................. 47

Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
6.3 Expected replacement intervals .............................................................................. 50
7 Stopping the engine ............................................................................................ 52
8 Periodic maintenance work ................................................................................ 53
8.1 Foreword to maintenance......................................................................................... 53
8.2 Cleaning components mechanically ....................................................................... 53
9 Eliminating malfunctions.................................................................................... 63
9.1 Malfunctions when starting...................................................................................... 63
9.2 Malfunctions during operation ................................................................................ 64
9.3 Turbocharger is surging............................................................................................ 67
9.4 Malfunctions when stopping.................................................................................... 68
9.5 Speed measurement system.................................................................................... 69
10 Dismantling and fitting....................................................................................... 70
10.1 Introduction ................................................................................................................. 70
10.2 Material required.......................................................................................................... 71
10.3 Weights of individual parts........................................................................................ 73
10.4 Removing the gas outlet casing .............................................................................. 74
10.5 Removing air inlets ...................................................................................................... 75
10.6 Removing the compressor casing........................................................................... 76
10.7 Removing the cartridge group.................................................................................. 77
10.8 Removing nozzle ring ................................................................................................. 80
10.9 Measuring clearance A and B..................................................................................... 81
10.10 Nozzle ring compression PD..................................................................................... 82
10.11 Fitting the diffuser ..................................................................................................... 83
10.12 Installing the cartridge group .................................................................................. 84
10.13 Installing the nozzle ring ........................................................................................... 86
10.14 Fitting the turbine casing ......................................................................................... 87
10.15 Turning the turbocharger.......................................................................................... 88
10.16 Measuring radial clearances N and R ...................................................................... 89
10.17 Installing the gas outlet casing................................................................................ 90
10.18 Installing air inlets ....................................................................................................... 91
10.19 Table of tightening torques...................................................................................... 92
11 Taking out of operation at short notice ........................................................... 93
11.1 Possible emergency repairs...................................................................................... 93
12 Mothballing the turbocharger............................................................................ 94
12.1 Taking the engine out of operation for up to 12months ................................... 94
12.2 Taking the engine out of operation for more than 12months.......................... 95
13 Material and Disposal.......................................................................................... 96
13.1 REACH and RoHS Compliance Declaration For Products ................................... 96
13.2 Disposing of turbocharger components ............................................................... 97

Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
14 Spare parts ........................................................................................................... 98
14.1 Ordering spare parts.................................................................................................. 98
14.2 Required customer spare part set (97070)............................................................ 98
14.3 Spare part - Illustrations............................................................................................ 99
15 Tools .................................................................................................................... 107
Figures................................................................................................................. 108
Tables .................................................................................................................. 109