ABB HT842101 User manual

Operation Manual
Turbocharging
ABB Turbo Systems Ltd 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS44-F31 HT842101
nMmax 1207 t Mmax 680
nBmax 1147 t Bmax 650
1/s °C
00120 16 50 50
Year 2016 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2412 English
TPS44-F31
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 / TPS44-F.. - TPS61-F..
Table of contents
Page 1
April 2015HZTL2412_ENRevision E
Table of contents
1
Preliminary remarks
1.1
Purpose of this manual
1.2
Layout and function
1.3
Intended 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
Use of ABB turbochargers on gas engines
2.9
Periodic checking of the pressure vessel
2.10
Lifting loads
3
Start-up
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
Expected exchange intervals
4.4
Speed measurement
4.5
Stopping the engine
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Table of contents
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April 2015HZTL2412_ENRevision E
5
Maintenance
5.1
Foreword to Maintenance
5.2
Cleaning the compressor during operation
5.3
Turbine cleaning during operation
5.4
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
Transport
7.2
Turbocharger weights
7.3
Remove the turbocharger
7.4
Installing the turbocharger
8
Disassembly and assembly
8.1
Introduction
8.2
Module weights
8.3
Disassembling and assembling turbocharger
8.4
Axial clearance A and radial clearance B
8.5
Radial clearances N and R
8.6
Table of tightening torques
9
Taking out of operation
9.1
Shutting down the turbocharger
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 turbocharger showing part numbers
12.3
View of cartridge group showing part numbers
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Purpose of this manual
1.1
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April 2015HZTL2412_ENRevision E
Preliminary remarks
Purpose of this manual
1.1
This operation manual belongs to the turbocharger with the identical HT
number (01), 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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Layout and function
1.2
Page 4
April 2015HZTL2412_ENRevision E
Layout and function
1.2
1 Suction branch / filter silencer 8 Gas outlet flange
2 Compressor casing 9 Nozzle ring
3 Diffuser 10 Turbine casing
4 Bearing casing 11 Turbine-end bearing flange
5 Axial thrust bearing 12 Compressor-end bearing flange
6 Radial plain bearing (visible only
at turbine end)
13 Compressor wheel
7 Turbine
1.2
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Layout and function
1.2
Page 5
April 2015HZTL2412_ENRevision E
Mode of operation
The turbocharger is a turbomachine consisting of the following main
components:
Turbine
Compressor
These are mounted on a common shaft.
Exhaust gases from the diesel or gas engine flow through the turbine
casing (10) and the nozzle ring (9) to impinge on the turbine (7).
The turbine (7) uses the energy contained in the exhaust gas to drive the
compressor wheel (13). The compressor draws in fresh air, compresses it
and then forces it into the engine's cylinders.
The exhaust gases escape into the ambient air through the exhaust gas
pipe, which is connected to the gas outlet flange (8).
The air, which is necessary for operation of the diesel or gas engine and
is compressed in the turbocharger, is drawn into the compressor wheel
(13) through the suction branch or filter silencer (1). It then passes
through the diffuser (3) and leaves the turbocharger through the outlet on
the compressor casing (2).
The rotor runs in two radial plain bearings (6), which are located in the
bearing flanges (11/12) between the compressor and the turbine. The
axial thrust bearing (5) is located between the two radial plain bearings.
The bearings are connected to a central lubricating oil duct which is
supplied by the engine's lubricating oil circuit. The oil outlet is always at
the lowest point of the bearing casing (4).
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Intended use of the turbocharger
1.3
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April 2015HZTL2412_ENRevision E
Intended 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
operating speeds, temperatures, exchange intervals / replacement
intervals) have been derived.
If it is
used
in conjunction
with a gas engine
, the engine must
not
be
installed in a potentially
explosive environment
, and precautionary
measures must be taken to ensure that the machine room as a whole is
classified as
not potentially explosive
.
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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 7
April 2015HZTL2412_ENRevision E
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
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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Stor
age of new turbochargers and
spare parts
1.4
Page 8
April 2015HZTL2412_ENRevision E
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 illustration).
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.
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 9
April 2015HZTL2412_ENRevision E
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 package.
To avoid the formation of condensation, the surroundings and the content
of the package must have the same temperature during unpacking.
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
Page 10
April 2015HZTL2412_ENRevision E
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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
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April 2015HZTL2412_ENRevision E
Original parts and safety
Original parts and accessories are designed especially for the
turbocharger supplied by ABB Turbo Systems.
NOTICE
It is herewith explicitly stated that original parts and accessories that
were not supplied by ABB Turbo Systems have also not been tested
and approved by ABB Turbo Systems.
WARNING
The use of components and assemblies are used which have not been
manufactured and tested by ABB Turbo Systems can have a negative
effect on the specified design characteristics of the turbocharger.
Furthermore, the active and/or passive safety of the turbocharger may
be negatively influenced by using non-original parts. It must be noted
that improper use such as this can be hazardous to persons and the
engine.
Always use 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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
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April 2015HZTL2412_ENRevision E
Design variants
This Operation Manual is valid for various turbocharger design variants.
It should be noted that the Operation Manual contains sections and
descriptions that are not relevant for the turbocharger supplied.
The ABB Turbocharging Service Stations are at your disposal for
questions concerning the design version of the supplied turbocharger (see
chapter Contact address and after-sales service [➙ 16]).
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 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Symbols and definitions
1.6
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April 2015HZTL2412_ENRevision E
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. See also chapter Contact address and after-sales
service [➙ 16].
1.6
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 14
April 2015HZTL2412_ENRevision E
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
enginebuilder.
2 Turbocharger operating limits during operation
3 Inspection 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 inspection
and replacement intervals
for turbocharger
components
Further information
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 15
April 2015HZTL2412_ENRevision E
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.
nMmax and tMmax normally apply only when running at overload (110%) during
trials on the engine tes
t 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 (1) is attached to the left and right-hand sides of the
turbocharger bearing casing.
1.7.1
1.7.2
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Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Contact address and after
-
sales service
1.8
Page 16
April 2015HZTL2412_ENRevision E
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
A list of the official ABB Turbo Systems
service stations is available online.
1.8
© Copyright 2015 ABB. All rights reserved.

Operation Manual / TPS44-F.. - TPS61-F..
Safety
2
Introduction
2.1
Page 17
April 2015HZTL2412_ENRevision E
Safety
Introduction
2.1
Turbochargers manufactured by ABB Turbo Systems are state of the art
and comply with the pertinent safety and health-protection requirements
that applied when the turbocharger was manufactured. Consequently, the
turbocharger is safe to operate. Nevertheless, during turbocharger
operation and when working on the turbocharger, residual risks can exist
which:
originate from the turbocharger itself and its accessories
originate from the operating and auxiliary materials used
are the consequence of insufficient observance of the safety
instructions
are the consequence of unsatisfactory and improper execution of
maintenance and inspection work
The operator is responsible for access to the turbocharger as well as the
organisational measures which regulate the safe handling of the
turbocharger by his personnel.
All instructions in this chapter must be observed to ensure safe and
trouble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled
Definition of safety instructions).
2
2.1
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Operation Manual / TPS44-F.. - TPS61-F..
Safety
2
CE conformity
2.2
Page 18
April 2015HZTL2412_ENRevision E
CE conformity
2.2
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are
considered partly completed machinery in the sense of Article 2 g.
2.2
© Copyright 2015 ABB. All rights reserved.