ABB TPR56-F32 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPR56-F32 HT554216
nMmax 724 t Mmax 680
nBmax 686 t Bmax 650
1/s °C
00360 36 50 50
Year 2019 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2490 English
TPR56-F32
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 / TPR56-F + TPR61-F
Table of contents
© Copyright 2018 . All rights reserved. HZTL2490_EN Revision D May 2018
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 .............................................................................. 6
1.4 Storage of new turbochargers and spare parts ....................................................... 7
1.5 Essential information..................................................................................................... 9
1.6 Symbols and definitions .............................................................................................. 11
1.7 Turbocharger rating plate ........................................................................................... 12
1.8 Contact information..................................................................................................... 13
2 Safety...................................................................................................................... 14
2.1 Introduction ................................................................................................................... 14
2.2 CE conformity ................................................................................................................ 14
2.3 Definition of mandatory signs ................................................................................... 15
2.4 Definition of Safety instructions ............................................................................... 15
2.5 Warning plates on the turbocharger......................................................................... 16
2.6 Safe operation and maintenance............................................................................... 17
2.7 Hazards during operation and maintenance........................................................... 20
2.8 Periodic checking of the pressure vessel ................................................................. 25
2.9 Lifting loads ................................................................................................................... 26
3 Start-up / commissioning .................................................................................... 27
3.1 Oil supply ........................................................................................................................ 27
3.2 Inspection work............................................................................................................ 30
3.3 Commissioning after taking out of operation........................................................ 32
4 Operation ................................................................................................................ 33
4.1 Noise emissions ............................................................................................................ 33
4.2 Servicing work ............................................................................................................... 35
4.3 Replacement intervals for turbocharger components.......................................... 37
4.4 Speed measurement .................................................................................................... 39
4.5 Stopping the engine ..................................................................................................... 42
5 Maintenance .......................................................................................................... 43
5.1 Foreword to Maintenance ........................................................................................... 43
5.2 Cleaning the filter silencer.......................................................................................... 44
6 Troubleshooting.................................................................................................... 46
6.1 Malfunctions when starting....................................................................................... 46
6.2 Surging of the turbocharger....................................................................................... 47

Operation Manual / TPR56-F + TPR61-F
Table of contents
© Copyright 2018 . All rights reserved. HZTL2490_EN Revision D May 2018
6.3 Malfunctions during operation ................................................................................. 48
6.4 Malfunctions when stopping ..................................................................................... 50
6.5 Speed measurement system ...................................................................................... 51
7 Removal and installation...................................................................................... 52
7.1 Turbocharger weights.................................................................................................. 52
7.2 Removing the turbocharger........................................................................................ 52
7.3 Installing the turbocharger ........................................................................................ 54
8 Disassembly and assembly .................................................................................. 55
8.1 Introduction ................................................................................................................... 55
8.2 Module weights ............................................................................................................. 57
8.3 Removing and installing the air suction branch / filter silencer ......................... 58
8.4 Axial clearance .............................................................................................................. 60
8.5 Removing cartridge group .......................................................................................... 61
8.6 Dismantling and installing the turbine diffuser and nozzle ring ......................... 65
8.7 Installing cartridge group............................................................................................ 67
8.8 Table of tightening torques........................................................................................ 70
9 Mothballing the turbocharger .............................................................................. 72
9.1 Taking the engine out of operation for up to 12months...................................... 72
9.2 Taking the engine out of operation for more than 12months ............................ 74
10 Disposing of turbocharger components............................................................ 75
11 Spare parts............................................................................................................. 76
11.1 Ordering spare parts .................................................................................................... 76
11.2 View of turbocharger with part numbers ................................................................ 78

Operation Manual / TPR56-F + TPR61-F
1 Preliminary remarks / 1.1 Purpose of this manual
© Copyright 2018 . All rights reserved. HZTL2490_EN Revision D May 2018
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
The Operation Manual explains the turbocharger and contains instruc-
tions for safe operation.
The Operation Manual is a complement to and expansion of existing na-
tional regulations for occupational safety, accident prevention and envir-
onmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics re-
sponsible for the proper operation of the engine and for the turbochar-
ger connected to it.
Availability of the Operation Manual
The Operation Manual must be available where the turbocharger is used.
All persons operating or working on the turbocharger must have read
and fully understood the Operation Manual.
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