ABB TPL71-C34 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL71-C34 HT842511
nMmax 408 t Mmax 650
nBmax 389 t Bmax 620
1/s °C
SFUS06 02040 35 50 50
Year 2016 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2488 English
TPL71-C34
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..
Tabl
e of contents Page 1
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
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 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 / TPL67-C.. - TPL71-C..
Table of contents
Page 2
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_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
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 weights
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

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Tabl
e of contents Page 3
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
10
Mothballing turbocharger
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
12.3
View of turbine cleaning system with part numbers (optional)

Operation Manual / TPL67-C.. - TPL71-C..
Maintenance
5
Foreword to Maintenance
5.1
Page 51
© Copyri
ght 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Maintenance
Foreword to Maintenance
5.1
Maintenance and servicing work involves regular visual checks and clean-
ing to ensure that the turbocharger and its attached units function trouble-
free.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:
Filter silencer
Compressor
Turbine and nozzle ring
5
5.1

Operation Manual / TPL67-C.. - TPL71-C..
Maintenance
5
Cleaning the filter silencer
5.2
Page 52
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Cleaning the filter silencer
5.2
Filter silencer and connecting rod
81265 Filter ring (if provided) 81136 Absorption segment
81269
Connecting rods
81137
Sheet-metal covering
81266 Cover grid 81135 Filter silencer body
81272 Screwdriver 81273 Lock nut
E
Insert unit = absorption segment + sheetmetal covering
5.2
5.2.1

Operation Manual / TPL67-C.. - TPL71-C..
Maintenance
5
Cleaning the filter silencer
5.2
Page 53
© Copyri
ght 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Removing and cleaning filter silencer
Remove filter strip (81265).
Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid
rough treatment (not a jet of water).
NOTICE
How dirty the filter strip (81265) is, depends on how clean the drawn-in
air is. Clean filter strip every 500 hours of service or more frequently if
necessary.
Unscrew and remove lock nuts (81273).
Unscrew and remove screws (81272) for connecting rods (81269).
Remove connecting rods (81269).
Carefully remove cover grids (81266).
Pull out insert units (E), bend open sheet-metal coverings (81137) and
then remove absorption segments (81136).
Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
Otherwise there is a risk of damage or deformation.
NOTICE
Replace heavily contaminated or damaged parts with original parts from
ABB Turbo Systems.
If provided

Operation Manual / TPL67-C.. - TPL71-C..
Maintenance
5
Cleaning the filter silencer
5.2
Page 54
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Fitting the filter silencer
Assemble the insert units (E) by inserting the absorption segments
(81136) into the sheet metal coverings (81137).
Bend sheet metal coverings (81137) back to original shape.
Insert the insert units (E) into slot guides in filter silencer unit (81135).
Uniformly place cover grids (81266) in correct position.
Push connecting rods (81269) through lugs of cover grids (81266).
CAUTION
If the connecting rods (81269) are not correctly positioned in their re-
cesses on the filter silencer unit (81135), the cover grid (81266) can
twist and shift. There is then a risk of foreign matter and contamination
getting into the compressor.
Join connecting rods (81269) using screws (81272). When tightening
the screws (81272), ensure that connecting rods (81269) are located
correctly in recesses in filter silencer body (81135). Now tighten
screws (81272) alternately until the following maximum torque is
reached:
Screw
Tightening torque [Nm]
81272 20
Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:

Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice
9
Fit cover plate
9.3
Page 109
© Copyright 2016
ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Fit cover plate
9.3
NOTICE
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
Product
B1
B2
B3
B4
B5
B6
B7
B8
TPL67-C
13
325
30
30
8
10
6
70
TPL71-C 13 385 30 30 8 10 6 84
Product
Ø 1
Ø 2
Ø 3
Ø 4
Ø 5 min.
Ø 6 min.
TPL67-C 616 694 660 16 22 15
TPL71-C 726 818 779 18 25 15
Product
⍺ 1
⍺ 2
⍺ 3
TPL67-C 4 x 90° 37.5° 24 x 15°
TPL71-C
4 x 90°
37.5°
24 x 15°
9.3
Cover plate dimensions
[mm]

Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice
9
Fit cover plate
9.3
Page 110
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
NOTICE
Carry out the work as described in the chapter Disassembly and As-
sembly
.
Removing the cartridge group

Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice
9
Fit cover plate
9.3
Page 111
© Copyright 2016
ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Close opening in gas outlet casing using cover plate.
Fasten cover plate using spacer sleeves and nuts (61037).
CAUTION
Shut off the supply of lubricating oil to the turbocharger.

Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice
9
Fit cover plate
9.3
Page 112
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Further measures and information for operation with a turbocharger with
cover plate on 4-stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a
naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
The air line must be closed off at the engine end because the undamaged
turbochargers build up a receiver pressure.
CAUTION
The engine can be operated according to the engine builder's instruc-
tions. Attention must always be paid to the speed of the undamaged
turbocharger. The speed limit nBmax given on the rating plate must not
be exceeded.
Separate receivers
Common receiver

Operation Manual / TPL67-C.. - TPL71-C..
Spare parts
12
View of turbocharger wit
h part numbers
12.2
Page 122
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
View of turbocharger with part numbers
12.2
12.2

Operation Manual / TPL67-C.. - TPL71-C..
Spare parts
12
View of turbocharger with part numbers
12.2
Page 123
© Copyright 2016 ABB. All rights reserved.
April 2016HZTL2488_ENRevision C
Part number
Description
42012 (in customer spare part set) O-ring
51001
Gas inlet casing
51012 Segment
56001
Nozzle ring
61001 Gas outlet casing
61037 (in customer spare part set)
Hexagon nut
61044 Hexagon-head screw
61050 (if provided)
Gasket
61056 (in customer spare part set) Hexagon-head screw
61057 (in customer spare part set)
Verbus Ripp® Washer
61058 (in customer spare part set) Verbus Ripp® Washer
61059 (in customer spare part set)
Hexagon-head screw
63000 Turbine diffuser
68001
Foot at compressor end
68002 Foot at turbine end
68003
Slide plate
68006 Cup spring
68007
Bush
72000 Compressor casing
77000
Wall insert
77005 (in customer spare part set) O-ring
79000
Diffuser
81000 Filter silencer
82000
Radial air suction branch