ABB TPS44-F33 User manual

Operation Manual
ABB Turbocharging 
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS44-F33 HT842296
nMmax 1203 t Mmax 750
nBmax 1142 t Bmax 710
1/s °C
00120 10 25 25
Year 2016 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2412 English
TPS44-F33
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 / TPS44-F.. - TPS61-F..
Table of contents
Page 1
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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
Deflagration 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

Operation Manual / TPS44-F.. - TPS61-F..
Table of contents
Page 2
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Purpose of this manual
1.1
Page 3
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 turbo-
charger rating plate.
Operation Manual
This Operation Manual enables you to familiarize yourself with the turbo-
charger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be op-
erated safely, correctly and efficiently.
This Operation Manual complements and expands existing national regu-
lations 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 in-
stalled 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 / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Layout and function
1.2
Page 4
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Layout and function
1.2
Page 5
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Mode of operation
The turbocharger is a turbomachine consisting of the following main com-
ponents:
Turbine
Compressor
These are mounted on a common shaft.
Exhaust gases from the diesel or gas engine flow through the turbine cas-
ing (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 axi-
al thrust bearing (5) is located between the two radial plain bearings.
The bearings are connected to a central lubricating oil duct which is sup-
plied by the engine's lubricating oil circuit. The oil outlet is always at the
lowest point of the bearing casing (4).

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Intended use of the turbocharger
1.3
Page 6
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 charg-
ing 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 lim-
its specific to the turbocharger shown on the rating plate (such as oper-
ating speeds, temperatures, exchange intervals / replacement intervals)
have been derived.
If it is
used
in conjunction
with a gas engine
, the engine must
not
be in-
stalled 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 Sys-
tems 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 in-
stallation / fitting, disassembly / removal, operating, maintenance / servic-
ing and repair conditions specified by the manufacturer. Disposal regula-
tions set down by local authorities must be observed.
The turbocharger may be installed only when in technically perfect condi-
tion 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 unau-
thorised alterations to the turbocharger.
1.3
State of the art
Perfect condition

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
Page 7
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 Sub-
stances Ordinance. Nevertheless, the following points are to be ob-
served 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 to protect against chemical hazards.
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 environmen-
tally 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

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Stora
ge of new turbochargers and
spare parts
1.4
Page 8
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB Tur-
bo Systems for prolonged storage. The package is equipped with a hyg-
rometer (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 tur-
bocharger or cartridge group must be inspected by an ABB Turbo-
charging 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 re-
placement cartridge group can be placed into operation without any pri-
or 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 / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
Page 9
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 en-
gine in the event of alterations affecting safety or of corresponding op-
erating behaviour. The fault must be reported to the person or depart-
ment responsible.
NOTICE
Additions and alterations to, and conversions of the turbocharger that
could compromise safety require the prior approval of ABB Turbo Sys-
tems.
1.5

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
Page 10
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 au-
thorised personnel. Basic mechanical training is a prerequisite.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Essential information
1.5
Page 11
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Design variants
This document is valid for different design variants of turbochargers.
There may be sections and descriptions of components that are not rele-
vant 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.
Registered Trademarks
Registered trademarks of external companies are used in this document.
The trademarks are marked with ®.

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Symbols and definitions
1.6
Page 12
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Symbols and definitions
1.6
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 Turbo-
charging Service Stations. They are inspected and certified regularly by
ABB Turbo Systems. See also chapter Contact information [➙ 15].
1.6

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 13
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Turbocharger rating plate
1.7
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 Inspection interval of plain bearings in 1000 h
04
Replacement interval of compressor in 1000 h
05
Replacement interval of turbine in 1000 h
06 Customer part number
07
Designation of the special design
08
Weight of turbocharger in kg
09
Turbocharger type
10
Serial number
11
Year of construction of turbocharger
1.7
Operating limits
Recommended inspection
and replacement intervals
of turbocharger compo-
nents
Further data

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Turbocharger rating plate
1.7
Page 14
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Explanation of the rating plate
The recommended replacement intervals and the corresponding opera-
tional limits are jointly defined with the engine manufacturer. This informa-
tion 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 tri-
als 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
One rating plate (01) each is attached on the left and the right side of the
turbocharger bearing casing.
1.7.1
1.7.2

Operation Manual / TPS44-F.. - TPS61-F..
Preliminary remarks
1
Contact information
1.8
Page 15
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
Contact information
1.8
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
1.8

Operation Manual / TPS44-F.. - TPS61-F..
Safety
2
Introduction
2.1
Page 17
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
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 opera-
tion 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 instruc-
tions
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 turbo-
charger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-
ble-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 Defini-
tion of safety instructions).
2
2.1

Operation Manual / TPS44-F.. - TPS61-F..
Safety
2
CE conformity
2.2
Page 18
© Copyright 2016 ABB. All rights reserved.
September 2016HZTL2412_ENRevision F
CE conformity
2.2
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con-
sidered partly completed machinery in the sense of Article 2 g.
2.2