ABB TPS 50B01 User manual

Operation Manual
ABB Turbocharging 
Type TPS 50B01 HT846529
nMmax 840 t Mmax 750
nBmax 800 t Bmax 710
1/s °C
00270 10 50 50
Year 2021 Application according to the Operation Manual
kg
HZTL2401 English
TPS 50B01
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 / TPS50
Table of contents
© Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021
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 Essential information..................................................................................................... 7
1.5 Symbols and definitions ................................................................................................ 9
1.6 Turbocharger rating plate........................................................................................... 10
1.7 CE conformity ................................................................................................................ 11
2 Safety....................................................................................................................... 12
2.1 Introduction ................................................................................................................... 12
2.2 Definition of Safety instructions ............................................................................... 12
2.3 Warning plates on the turbocharger......................................................................... 13
2.4 Safe operation and maintenance............................................................................... 14
2.5 Hazards during operation and maintenance........................................................... 17
2.6 Deflagration on gas engines....................................................................................... 22
2.7 Lifting loads ................................................................................................................... 22
3 Commissioning...................................................................................................... 24
3.1 Oil supply ........................................................................................................................ 24
3.2 Inspection work............................................................................................................. 26
3.3 Commissioning after taking out of operation........................................................ 28
4 Operation ............................................................................................................... 29
4.1 Noise emissions ............................................................................................................ 29
4.2 Servicing work .............................................................................................................. 30
4.3 Stopping the engine..................................................................................................... 32
5 Maintenance ........................................................................................................... 33
5.1 Foreword to Maintenance ........................................................................................... 33
5.2 Cleaning the compressor during operation ............................................................ 33
6 Troubleshooting.................................................................................................... 38
6.1 Malfunctions when starting........................................................................................ 38
6.2 Surging of the turbocharger....................................................................................... 38
6.3 Malfunctions during operation .................................................................................. 39
6.4 Malfunctions when stopping...................................................................................... 42
7 Removal and installation...................................................................................... 43
7.1 Turbocharger weights.................................................................................................. 43

Operation Manual / TPS50
Table of contents
© Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021
7.2 Removing the turbocharger....................................................................................... 44
7.3 Installing the turbocharger ........................................................................................ 45
8 Disassembly and assembly .................................................................................. 46
8.1 Introduction .................................................................................................................. 46
8.2 Module weights ............................................................................................................ 48
8.3 Disassembling and assembling turbochargers ..................................................... 49
8.4 Axial clearance A and radial clearance B ................................................................... 55
8.5 Radial clearances N and R............................................................................................ 56
8.6 Table of tightening torques........................................................................................ 58
9 Taking out of operation ....................................................................................... 59
9.1 Shut down turbocharger ............................................................................................. 59
10 Mothballing the turbocharger ............................................................................. 62
10.1 Taking out of operation for up to 12 months.......................................................... 62
10.2 Taking out of operation for more than 12 months................................................. 63
11 Material and Disposal ........................................................................................... 64
11.1 REACH and RoHS Compliance Declaration For Products .................................... 64
11.2 Disposing of turbocharger components.................................................................. 65
12 Spare parts............................................................................................................. 66
12.1 Ordering spare parts................................................................................................... 66
12.2 View of turbocharger showing part numbers ........................................................ 68
12.3 View of cartridge group showing part numbers .................................................... 70

Operation Manual / TPS50
1 Preliminary remarks / 1.1 Purpose of this manual
© Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021
1 Preliminary remarks
1.1 Purpose of this manual
Operation Manual
This Operation Manual helps familiarise the user with the turbocharger
from ABB Turbocharging and how 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 reg-
ulations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechan-
ics 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.
Contact address
ABB Switzerland Ltd, Turbocharging
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
After-sales service
The Contact Information brochure contains an overview of official ABB
Turbocharging Service Stations worldwide.
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