ABB HT842293 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL76-C33 HT842293
nMmax 348 t Mmax 650
nBmax 342 t Bmax 620
1/s °C
04070 35 50 50
Year 2016 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2485 English
TPL76-C33
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 / TPL76-C
Table of contents
Page 1
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
Table of contents
1
Preliminary remarks
1.1
Purpose of this manual
1.2
Layout and function
1.3
Intended use
1.4
Deflagration on gas engines
1.5
Storage of new turbochargers and spare parts
1.6
Essential information
1.7
Symbols and definitions
1.8
Turbocharger rating plate
1.9
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

Operation Manual / TPL76-C
Table of contents
Page 2
© Copyright 2016 ABB. All rights r
eserved.
February 2016HZTL2485_ENRevision C
5
Maintenance
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 weight
7.2
Remove 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 the turbocharger

Operation Manual / TPL76-C
Table of contents
Page 3
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
10.1
Taking out of operation for up to 12 months
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

Operation Manual / TPL76-C
Preliminary remarks
1
Purpose of this manual
1.1
Page 5
© Copyright 2016 ABB. All rights res
erved.
February 2016HZTL2485_ENRevision C
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

Operation Manual / TPL76-C
Preliminary remarks
1
Layout and function
1.2
Page 6
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
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

Operation Manual / TPL76-C
Preliminary remarks
1
Layout and function
1.2
Page 7
© Copyright 2016 ABB. All rights res
erved.
February 2016HZTL2485_ENRevision C
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
casing (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
compressed in the turbocharger is drawn through the suction branch or
the filter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the
compressor 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
provided 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 turbocharger to cool the compressor
wheel.
Depending on the respective operating conditions, it is
absolutely essential that the compressor wheel is cooled in
order to guarantee its reliability and the 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.

Operation Manual / TPL76-C
Preliminary remarks
1
Intended use
1.3
Page 8
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
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
using 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
position paper [2] relating to ATEX issued by EUROMOT [1].
The turbocharger supplies the engine with the air volume or air/gas
mixture and the associated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise
direction 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
Manufacturers
[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.
Only operate the turbocharger within its operating limits.
Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all
regulations and conditions.
In particular, the following must be observed:
Operation Manual
Instructions of the enginebuilder
1.3

Operation Manual / TPL76-C
Preliminary remarks
1
Deflagration on gas engines
1.4
Page 9
© Copyright 2016 ABB. All rights res
erved.
February 2016HZTL2485_ENRevision C
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
unauthorized modifications to the turbocharger or improper operation.
Deflagration on gas engines
1.4
ABB turbochargers can tolerate a deflagration with a transient pressure
increase of 12 bar.
ABB Turbo Systems recommends subjecting the turbocharger to a visual
inspection after a deflagration event. As part of the inspection, the position
of the turbine casing and the position of the compressor casing to the
bearing casing must be checked, and the bearing casing must be
examined to see if it has shifted in relation to the bracket. A crack
inspection of the casings and the bellows is also recommended. The
nearest ABB Turbocharging Service Station should be instructed to carry
out this inspection and assessment.
1.4

Operation Manual / TPL76-C
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.5
Page 10
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
Storage of new turbochargers and spare parts
1.5
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.
1.5

Operation Manual / TPL76-C
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.5
Page 11
© Copyright 2016 ABB. All rights res
erved.
February 2016HZTL2485_ENRevision C
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 (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
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.
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
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.

Operation Manual / TPL76-C
Preliminary remarks
1
Essential information
1.6
Page 12
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
Essential information
1.6
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.
1.6

Operation Manual / TPL76-C
Preliminary remarks
1
Essential information
1
.6 Page 13
© Copyright 2016 ABB. All rights res
erved.
February 2016HZTL2485_ENRevision C
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
authorised personnel. Basic mechanical training is a prerequisite.

Operation Manual / TPL76-C
Preliminary remarks
1
Essential information
1.6
Page 14
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
Design variants
This document is valid for different design variants of turbochargers.
There may be sections and descriptions of components that are not
relevant 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.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without
additional safeguarding measures for a period of 6 months after the
delivery date.
Suitable storage locations are dry rooms where the relative humidity is
between 40-70% and no condensation can form.
After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
To do this, the insulating materials must be removed.
NOTICE
Repeat the described measures every 6 months to keep your
turbocharger free from rust.

Operation Manual / TPL76-C
Preliminary remarks
1
Symbols and definitions
1.7
Page 15
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erved.
February 2016HZTL2485_ENRevision C
Symbols and definitions
1.7
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
Turbocharging Service Stations. They are inspected and certified regularly
by ABB Turbo Systems. See also chapter Contact information [➙ 18].
1.7

Operation Manual / TPL76-C
Preliminary remarks
1
Turbocharger rating plate
1.8
Page 16
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February 2016HZTL2485_ENRevision C
Turbocharger rating plate
1.8
01 Turbocharger operating limits at engine overload (110%).
Only when operating in the test rig unless otherwise agreed with the
enginebuilder.
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 Part number for customer
07
Designation of special design
08
Turbocharger weight in kg
09
Turbocharger type
10
Serial number
11
Year of turbocharger construction
1.8
Operating limits
Recommended
replacement intervals for
turbocharger components
Further information

Operation Manual / TPL76-C
Preliminary remarks
1
Turbocharger rating plate
1.8
Page 17
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erved.
February 2016HZTL2485_ENRevision C
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.
nMmaxand tMmax normally apply only when running at overload (110%) during
trials 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
insulation of the gas outlet casing.
1.8.1
1.8.2

Operation Manual / TPL76-C
Preliminary remarks
1
Contact information
1.9
Page 18
© Copyright 2016 ABB. All rights reserved.
February 2016HZTL2485_ENRevision C
Contact information
1.9
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
1.9