February 26, 2017 | Author: Prashanth | Category: N/A
Turbocharging
Operation Manual TPL85-B15 ABB Turbo Systems Ltd CH 5401 Baden Type
TPL85-B15
HT489493
n Mmax 200
t
Mmax
550
Bmax
520
1/s n Bmax 190
10620kg Year
°C t
36
100
100
Application according to the Operation Manual
2008
HZTL2491 English
made in Switzerland
ABB Turbo Systems Ltd
Operating condition and replacement intervals The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the components 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 current 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.
We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to the „European Machinery Directives“. We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.
© Copyright by ABB TURBO SYSTEMS Ltd 2004 Design and specifications are subject to change without notice.
Printed on naturally white paper, bleached free from chlorine and environmentally acceptable. The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of recycled cardboard. These materials may be disposed with the domestic wastes or at a specialised collecting centre.
ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland
Operation Manual / TPL85-B14/-B15/-B16
Version 5
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January 2008
List of contents
Page 1
List of contents 1
Preliminary remarks
1.1
Purpose of manual
1.2
Layout and function
1.3
Correct use of the turbocharger
1.4
Essential information
1.5
Abbreviations and symbols
1.6
Turbocharger rating plate
2
Safety
2.1
Basic safety instructions
2.2
General safety instructions
2.3
Special safety instructions
2.4
Safety instructions and hazard protection
2.5
Warnings on the turbocharger
3
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Putting into operation after laying up
4
Operation
4.1
Servicing work
4.2
Expected exchange intervals
4.3
Monitoring
4.4
Surging of turbocharger
4.5
Contact with rotating parts
4.6
Shutting the engine down
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
Suppliers of materials for dry cleaning
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16
6.1
Possible remedies for failures
7
Removal and installation
7.1
Turbocharger weights
7.2
Remove the turbocharger
7.3
Installing the turbocharger
8
Disassembly and assembly
8.1
Module weights
8.2
Removing and fitting filter silencer or air suction branch
8.3
Axial clearance
8.4
Dismantling the internal part of the compressor casing
8.5
Dismantling gas inlet casing
8.6
Fitting gas inlet casing
8.7
Fitting the internal part of the compressor casing
8.8
Table of tightening torques
9
Taking out of operation temporarily
9.1
Possibilities for emergency repair
9.2
Locking the rotor
9.3
Blocking the inlets and outlets
9.4
Bypass the turbocharger
10
Mothballing the turbocharger
10.1
Taking out of operation for up to 12 months
10.2
Taking out of operation for more than 12 months
11
Disposal
11.1
Environmentally compatible disposal of turbocharger components
12
Reserve and spare parts
12.1
Ordering spare parts
12.2
Directory of part numbers
12.3
General view of turbocharger
12.4
General view of cartridge group
ABB Turbo Systems Ltd
January 2008
Troubleshooting
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6
Page 2
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List of contents
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Purpose of manual
1.1
Page 1
January 2008
1 Preliminary remarks 1.1 Purpose of manual Operating manual
This operation manual will help you to become familiar with your ABB Turbo Systems turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and economical operation of the turbocharger.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon.
Content of operating manual
This operation manual includes helpful information on the following topics: Information on the operation of the turbocharger and ways to prolong
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the turbocharger's service life. Early identification and avoidance of hazards. Minimizing repair costs and downtime.
This operating manual complements and extends existing national regulations on protection against accidents and accident prevention.
NOTE
An operation manual must be available at all times at the site where the turbocharger is used. It is essential that this operation manual is read before beginning work by all persons working with or on the turbocharger. Anyone who works only occasionally on the machine, e.g. during installation and maintenance, must also read and fully understand the operating manual before beginning work.
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The instructions included in this operating manual must be followed without fail.
WARNING
This applies especially to the general and special safety instructions preceding the respective chapters and in them. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. If in doubt, consult the safety officer responsible and the person accountable for protection against accidents in your domain.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Layout and function
1.2
Page 2
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January 2008
1.2 Layout and function
1.2.
Filter silencer
7
Nozzle ring
2
Radial plain bearing
8
Turbine wheel
3
Thrust bearing
9
Bearing casing
4
Radial plain bearing
10
Diffuser
5
Gas outlet casing
11
Compressor wheel
6
Gas inlet casing
12
Compressor casing Version 5
1
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Layout and function
1.2
Page 3
January 2008
Working principle The turbocharger is a turbo-machine and consists of the following main components: Turbine Compressor
These are both mounted on a common shaft.
Exhaust gases from the diesel engine flow through the gas inlet casing (6) and the nozzle ring (7) to impinge on the turbine wheel (8). The turbine wheel (8) uses the energy contained in the exhaust gas to drive the compressor wheel (11). The compressor draws in fresh air, compresses it and then forces it into the engine cylinders. HZTL2491_EN
The exhaust gas escapes to free air through the exhaust manifold which is connected to the gas outlet casing (5). The air, which is necessary for the operation of the diesel engine and compressed in the turbocharger, is drawn through the suction branch or the filter silencer (1) into the compressor wheel (11). This air then passes through the diffuser (10) and leaves the turbocharger through the compressor casing (12). The rotor runs in two radial plain bearings (2/4), which are located in the bearing casing (9) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side. The plain bearings are connected to a central lubricating oil feed which is normally supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (9).
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The turbocharger is equipped with an emergency lubrication oil tank, which is integrated in the bearing casing. During an emergency stop caused by a failure of the lubrication oil system, this emergency lubrication unit supplies oil to the bearings until the rotor comes to a standstill.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Correct use of the turbocharger
1.3
Page 4
This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine. NOTE
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1.3 Correct use of the turbocharger
The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate.
Latest technology
WARNING
This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations. 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 only be operated by trained personnel.
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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 Systems reserves the right to reject all claims under the warranty.
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed. The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual. X Malfunctions / defects which could affect safety must be eliminated
immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
ABB Turbo Systems Ltd
ABB
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Perfect condition
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Essential information
1.4
Page 5
January 2008
1.4 Essential information 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. The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual. NOTE
X The turbocharger must be shut down immediately by stopping the enHZTL2491_EN
gine in the event of alterations affecting safety or of corresponding operating behaviour. The fault must be reported to the person or department responsible.
Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems.
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NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Essential information
1.4
Page 6
January 2008
Original parts and safety Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us. NOTE
If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger. Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine. ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories.
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WARNING
Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel. Work on mechanical components, such as bearings or rotors, may only be performed by qualified fitters from an official service station of ABB Turbo Systems. CAUTION
ABB Turbo Systems Ltd
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It must be ensured that only authorised personnel work on the turbocharger.
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Essential information
1.4
Page 7
January 2008
After-sales service The Contact Information brochure contains an overview of official ABB Turbo Systems. service stations worldwide. Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger. Our service stations and agencies will gladly answer your questions relating specifically to your model.
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Accuracy of illustrations The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details. 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. X After expiry of the 6 months, all surfaces and accessible areas of the
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turbocharger should be sprayed with anticorrosive agent. X To do this, the insulating materials must be removed.
Repeat the described measures every 6 months to keep your turbocharger free from rust. NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Abbreviations and symbols
1.5
Page 8
January 2008
1.5 Abbreviations and symbols The following abbreviations are used in this document: Z Prerequisite X Work step D Result
9 Positive checkpoint (activity that must be carried out without fail) U Negative checkpoint (activity that must not be carried out under any circumstances)
Basic Instructions HZTL2491_EN
The following symbol is used for notes in this manual: This note provides suggestions and tips to make work on the turbocharger easier. NOTE
The note provides further essential information.
Reference to safety instructions The warnings and cautions are described in the chapter Safety . CAUTION
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Systems. Official ABB Turbo Systems service station The term Official ABB Turbo Systems service station used in this manual signifies ABB turbocharger service stations, that have been tested and certified by ABB Turbo Systems.
ABB Turbo Systems Ltd
ABB
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ABB Turbo Systems
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks
1
Turbocharger rating plate
1.6
Page 9
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January 2008
1.6 Turbocharger rating plate
L_00012
Operational limits
1
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2
Recommended replacement periods / exchange intervals for turbocharger components
ABB Turbo Systems Ltd
3 4 5
Turbocharger operational limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer. Turbocharger operational limits in service.
Replacement interval for the plain bearings in 1000 h Exchange interval for the compressor in 1000 h (no data for 100,000 h) Exchange interval for the turbine in 1000 h (no data for 100,000 h)
ABB
Operation Manual / TPL85-B14/-B15/-B16 1
Turbocharger rating plate
1.6
6 7 8 9 10 11 12
Page 10
Customer part number Field for special design designation Weight of the turbocharger in kg CE = Conformité Européenne Turbocharger type Series number Year of construction of the turbocharger
January 2008
Additional specifications:
Preliminary remarks
Explanations of the rating plate
CAUTION
Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we recommend you contact the nearest official service station of ABB Turbo Systems. nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in service for special applications. The operation over nMmax , tMmax is not permitted.
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The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific.
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Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Basic safety instructions
2.1
Page 1
2 Safety January 2008
2.1 Basic safety instructions The following symbols and terms are used for the safety instructions in this manual: Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents. WARNING
Warning signs must be strictly observed at all times.
CAUTION
Caution signs must be strictly observed at all times.
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Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
General safety instructions
2.2
Page 2
The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associated operating materials.
January 2008
2.2 General safety instructions
The following safety instructions must be followed when operating and when working on the turbocharger. WARNING
Do not work on the turbocharger if you are under physical or mental
stress.
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Helmet Ear protection Protective glasses Protective suit Oil and petrol resistant gloves Protective shoes Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. Do not stand under suspended loads. If welding work is to be carried out above the turbocharger, the air filter must be covered to prevent damage to the filter mat. When working on the turbocharger, be aware of the risk of it falling. For overhead assembly work, use the steps and platforms provided for this purpose.
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Wear protective clothing at all times.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Special safety instructions
2.3
Page 3
January 2008
2.3 Special safety instructions Safety when connecting Work only on those connections for which you are qualified.
Safety when commissioning and during operation Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working with the turbocharger. Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. Report any damage or changes in operational performance to the person/department responsible immediately. In the event of damage, shut down the turbocharger immediately and secure it against inadvertent or unauthorized use.
HZTL2491_EN
Safety when cleaning When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Follow directions regarding the environmentally compatible collection, storage and disposal of these liquids. Explosion hazard
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WARNING
ABB Turbo Systems Ltd
Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Special safety instructions
2.3
Page 4
operation materials. You must wear protective clothing (see section General safety instructions). Handle operation materials and detergents with utmost caution. When handling solvents, wear protective clothing and observe the following rules: Avoid skin contact with solvents. Avoid inhaling vapours under all circumstances. Do not allow solvents to soak protective clothing. After cleaning, check electric cables for signs of wear or damage.
January 2008
Before cleaning, protect the floor against unintended leaks of oil and
Safety during disassembly, assembly, maintenance and troubleshooting
Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.
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CAUTION
justment, maintenance and inspection work. Inform operating personnel about special work and repairs before starting. Ensure that absorbent materials are available to clean up any operation materials that escape accidentally. Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials. Before opening a cover or removing a protective component on the turbocharger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled.
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Follow the prescribed maintenance and inspection schedules for all ad-
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Special safety instructions
2.3
Page 5
January 2008
Safety when taking out of operation or putting into storage Secure the rotor against turning. Clean the turbocharger before mothballing. Wear protective clothing when mothballing the turbocharger. Keep the work area clean and free of oil and operating materials. Remove any obstacles lying around on the floor.
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ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Safety instructions and hazard protection
2.4
Page 6
Associated hazards may arise during operation of and work on the turbocharger:
from the turbocharger and its accessories. from the operating materials used. due to failure to comply with the safety instructions. from inadequate performance of maintenance and inspection work.
January 2008
2.4 Safety instructions and hazard protection
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
Unconsciousness and injury due to:
ABB Turbo Systems Ltd
crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling
ABB
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Personal injury
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WARNING
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Safety instructions and hazard protection
2.4
Page 7
sharp edges, pointed parts crush, shear and winding areas fragmentation / ejection of parts fracture or rupture of parts due to overload Elastic elements (springs), liquids and / or gases under pressure/in a vacuum slippery, oily work area, obstacles on the floor
Protective measures
9 9 9 9 9 9 9
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Causes
Wear leather protective gloves Wear close-fitting protective clothing Tie up long hair and beards (wear hair protection) Wear face and eye protection Wear protective shoes Keep floor, equipment and the turbocharger clean Ensure the availability of oil absorbing materials and have oil collector basins ready or in position 9 Eliminate leaks
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Operation and process materials Operation and process materials refer to chemical and hazardous substances:
Oils Grease Coolants Detergents and solvents Acids Note that operation and process materials are harmful to the environment if they penetrate soil or water.
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CAUTION
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 2
Safety instructions and hazard protection
2.4
Page 8
The following injuries can be caused by operation and process materials: Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation
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Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids Clothing wet or soaked with hazardous substances Spilling and tipping over of vessels containing substances used during operation Escape due to leakage Tanks and collectors which are not gas-tight and which do not comply with the regulations on hazardous substances Burning cigarettes or open flame in the proximity of operation materials
Causes
Protective measures
9 9 9 9 9 9 9
9
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9
Utmost caution when handling process and operation materials Protective clothing must be worn Avoid skin contact and inhalation Ensure that the workroom is properly ventilated Observe the hazard indications on the containers for operation and process materials Seal the hazardous substance container tight immediately after use Used operation materials must be collected safely in accordance with the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in an environmentally compatible manner Ensure that containers with new / used operation materials are sealed tight In the event of leaks or spills, immediately apply a suitable absorbent material and dispose of this in a technically and environmentally compatible manner as special waste
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Personal injury
Safety
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
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Safety instructions and hazard protection
2.4
Page 9
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Handling insulating materials 9 9 9 9 9 9 9 9 9 9 9
Ensure that the work area is well ventilated Keep the work area clean Avoid disturbing dust Dust-suppressing tools and processing steps Remove from packaging only in the work area Exercise particular care when removing old insulating materials Dispose of insulating materials in a technically and environmentally compatible manner If large quantities of dust are created, wear protective glasses Use half or quarter masks Wear suitable work clothing and gloves For sensitive skin, apply moisturising, protective barrier cream
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Noise The effects of noise above a legally permitted level can cause personal injury. Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances
Personal injury
Causes
Machine noise level above 85 dB (A)
Protective measures
9 Wear ear protection Heat hazard
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When the turbocharger is operated, surfaces become very hot. Personal injury
Burns
Causes
Missing or incorrectly fitted insulation.
Protective measures
9 Wear leather protective gloves.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Safety
2
Warnings on the turbocharger
2.5
Page 10
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Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.
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2.5 Warnings on the turbocharger
L_00227
Apply warnings so that they are clearly visible in the positions intended for that purpose. Please contact an official ABB Turbo Systems service station for further information.
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NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Commissioning
3
Oil supply
3.1
Page 1
3 Commissioning January 2008
3.1 Oil supply A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger. Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit. Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature. NOTE
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Oil filtration A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for TPL ..-B turbochargers. Oil pressure The oil pressure in front of the bearings must be maintained precisely to ensure trouble-free operation.
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The permissible oil pressures are specified in the following tables dependent on the lubrication (engine lubrication or separate lubricating system).
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16
Separate lubricating system
NOTE
3
Oil supply
3.1
Page 2
Oil pressure [bar]
Inadmissible oil pressure range -> Emergency shutdown (without time lag)
0.0 - 0.6
Oil pressure range permissible in short term ( Alarm
0.6 - 0.8
Permissible oil pressure range for normal operation
0.8 - 2.5
Permissible oil pressure range during engine warmup phase
0.8 - 4.0
Kinetic viscosity 12 - 170 cST
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Kinetic viscosity 45 - 170 cST
Oil pressure [bar]
Inadmissible oil pressure range -> Emergency shutdown (without time lag)
0.0 - 0.9
Oil pressure range permissible in short term ( Alarm
0.9 - 1.1
Permissible oil pressure range for normal operation
1.1 - 2.5
Permissible oil pressure range during engine warmup phase
1.1 - 4.0
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Engine lubrication
Commissioning
If a separate lubricating system has been designed for operation in the viscosity range of the engine lubrication system, i.e. 45 – 170 cSt, the oil pressure limits according to the engine lubrication information may be used for this system.
Engine lubrication
ABB Turbo Systems Ltd
Oil entry temperature [ °C ]
Engine load [%]
Oil entry pressure [bar]
Oil exit temperature [ °C ]
45
100
1.5 - 2
70 - 90
70
100
1.5 - 2
90 - 110
ABB
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Oil temperature during normal operation
Operation Manual / TPL85-B14/-B15/-B16 Commissioning
3
Inspection work
3.2
Page 3
3.2 Inspection work January 2008
This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during commissioning, thus preventing possible damage to the machine. The safety instructions must be followed before and during all inspec-
tion work.
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3.2.1
Inspection before commissioning
Monitoring equipment
X Check for correct functioning.
Air filter mat
X Inspect for damage.
Lubrication system
X Check that the oil filter is clean before commissioning.
It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system. CAUTION
We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.
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X Check oil pressure in oil supply lines.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 3
Inspection work
3.2
Page 4
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Inspection after commissioning
Lubrication system
X Check oil pressure in oil supply lines.
Charger speed
X Measure
Charger pressure
X Measuring
Measure temperatures
X upstream/downstream from turbine, compressor and oil feed for vari-
Gas, air, and oil lines
X Check all gas, air, and oil lines for leaks after the engine has been star-
ous engine speeds
ted up.
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3.2.2
Commissioning
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours after commissioning. If further oily liquid continues to appear after this period, an oil leak must be suspected. Then, the first step is to check for leakage of the oil supply to the turbocharger. If something wrong is detected, contact an official ABB Turbo Systems service station.
NOTE
before and after the turbine and the compressor at various engine speeds. X Compare the measured values with those of the inspection report, taking into account the different operating conditions.
3.2.3
Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
ABB Turbo Systems Ltd
ABB
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X Measure the speed, oil pressure, charging pressure and temperatures
Operation Manual / TPL85-B14/-B15/-B16 Commissioning
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Putting into operation after laying up
3.3
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January 2008
3.3 Putting into operation after laying up If they are present
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and the charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any comX X X
Version 5
HZTL2491_EN
X
bustion residue, clean / remove foreign bodies or residual water. Inspect air supply line or filter silencer for any foreign bodies, clean / remove. Start up the turbocharger's engine end oil circulation system. Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning. Commission the turbocharger.
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Servicing work
4.1
Page 1
4 Operation January 2008
4.1 Servicing work Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be carried out at the intervals indicated. The pertinent safety instructions must be observed during all servicing work.
HZTL2491_EN
WARNING
Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger. CAUTION
4.1.1 Operation data
Servicing work every 25 to 50 hours X Record X Record in the machine logbook X In the event of significant deviations, establish the cause.
If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.
Version 5
CAUTION
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 4
Servicing work
4.1
Page 2
Entries in the machine logbook Monitoring of the machine plant provides information about the performance of the turbocharger.
January 2008
4.1.2
Operation
The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book: Output and speed of the engine Air intake temperature Exhaust temperature before and after the turbine Pressure of the charge-air Pressure drop in the charge-air cooler Lubricating oil pressure, lubricating oil temperature
Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter
If provided
4.1.3
X With the engine at standstill clean or replace oil filters
Version 5
Oil filters
Servicing work according to the engine manufacturer's instructions
HZTL2491_EN
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 4
Servicing work
4.1
Page 3
Inspection work every 18,000 hours Remove filter silencer or air suction branch Clean filter silencer as far as accessible, and inspect for damage Remove internal part of compressor casing Check clearance A (axial bearing play). Clean accessible parts (compressor wheel, diffusor, wall insert), and inspect for damage X Without removing turbine parts and using an endoscope, carry out a visual check for possible soiling and damage (nozzle ring, turbine diffusor/cover ring, turbine blades). As an option, this inspection can be carried out after removal of gas inlet casing. X Refit internal part of compressor casing X Re-install filter silencer or air suction branch. X X X X X
This inspection work and checks must be carried out by an official service station of ABB Turbo Systems. NOTE
Version 5
HZTL2491_EN
January 2008
4.1.4
Operation
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16
Servicing work
4.1
Page 4
Servicing work every 36,000 hours Remove filter silencer or air suction branch Clean filter silencer as far as accessible, and inspect for damage Remove internal part of compressor casing Check clearance A (axial bearing play). Clean accessible parts (diffusor, wall insert), and inspect for damage. Take apart gas inlet casing and remove nozzle ring. Clean nozzle ring and check for damage or wear. Clean turbine diffusor / cover ring and check for damage or wear. Replace radial bearing and thrust bearing with original parts from ABB Turbo Systems. X Inspect and assess rotor.
X X X X X X X X X
Replacement of the bearing parts as well as inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
Version 5
NOTE
January 2008
4
HZTL2491_EN
4.1.5
Operation
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Expected exchange intervals
4.2
Page 5
January 2008
4.2 Expected exchange intervals Expected replacement intervals [h]
Turbocharger part
HFO
Gas inlet casing
50'000 … 100’000
Gas outlet casing
50'000 … 100’000
Nozzle ring
35'000 … 50’000
Turbine diffusor / cover ring
25'000 … 50’000
Other housings
100’000
Rotor components
See rating plate for information
Bearings
See rating plate for information
HZTL2491_EN
HFO
The values indicated are for guidance only and are not guaranteed values. These values may vary significantly for example due to inadequate servicing, frequent emergency stoppages as well as through the use of fuel or lubricating oil of inferior quality.
Version 5
NOTE
= Heavy Fuel Oil
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Monitoring
4.3
Page 6
4.3.1
January 2008
4.3 Monitoring Measuring speed 1 9
2 11
3 10
HZTL2491_EN
6 7
8 L_01246
1
Bearing casing
7
Line amplifier (optional)
2
Thrust bearing
8
Speed transmitter
3
Guide in axial bearing
9
Auxiliary bearing
-
-
10
Alternative for fitting speed transmitter
5
Screw plug
11
Tachometer (option)
6
Connecting cable (with voltage limiting module)
-
-
The speed transmitter system for measuring the turbocharger speed also permits continuous remote monitoring of the turbocharger speed when it is used in conjunction with the corresponding measuring instruments and / or monitoring systems (not included in the scope of delivery). If the machine installation is monitored continuously, the turbocharger speed can be used as a suitable control parameter. The line amplifier (7) can be purchased as an option to the described speed measuring system.
ABB Turbo Systems Ltd
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Version 5
5
Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Monitoring
4.3
Page 7
Possible reasons for failure of speed transmitter system: Defects of the speed transmitter (8), connecting cable (6) and connect-
January 2008
ing plug for the measuring unit or on the measuring unit or power supply. Turbocharger breakdown. Failure of speed indicator CAUTION
If the speed indicator fails, it is recommended that the engine output be reduced to idling and the engine then stopped. X Investigate cause of failure and eliminate problem.
Fitting speed transmitter system
HZTL2491_EN
NOTE
It is recommended that fitting or replacing a speed transmitter system on an in-place turbocharger be carried out only by an official ABB Turbo Systems service station.
A reduction in turbocharger speed can signify:
Version 5
Damaged turbine or bearing Severe soiling of the turbine
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 4
Monitoring
4.3
Page 8
Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for measuring the negative pressure at the filter silencer.
January 2008
4.3.2
Operation
This measuring can be used for the following purposes: Measuring the correction factor for calculating the turbocharger effi-
ciency during engine acceptance The use of a filter mat on the filter silencer can cause a loss of pressure. More significant pressure loss is an indication of increased soiling of the filter material.
ABB Turbo Systems Ltd
Version 5
HZTL2491_EN
U-tube manometer
L_00003
L_00004
1
Felt discs
A [mm H2O]
Pressure differential / pressure loss
ABB
Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Monitoring
4.3
Page 9
January 2008
All parts required for assembly are supplied in a separate package. Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1). The U-tube manometer must be exposed to minimum possible mechanical shock or vibration. NOTE
X Fit U-tube manometer to filter silencer as shown in preceding illustra-
tion.
X Fill U-tube manometer with slightly coloured water to obtain best legibil-
ity.
HZTL2491_EN
Under as-new conditions (new or clean filter silencer and filter mat), the maximum pressure loss (A) is 120 mm H2O under full loading. X Clean filter at latest as soon as loss of pressure (A) reaches a value of
200 mm H2O.
For better legibility of the pressure differential (A) on the U-tube manometer, the measuring rod can be withdrawn to the level of the bottom water level.
Version 5
NOTE
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Operation Manual / TPL85-B14/-B15/-B16 Operation
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Surging of turbocharger
4.4
Page 10
Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of flow in the compressor is then briefly reversed. However, sporadic surging of this kind does not generally affect the safe operation of the turbocharger.
January 2008
4.4 Surging of turbocharger
Prolonged or periodic surging
Action to be taken:
Version 5
NOTE
The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB Turbo Systems service station. The components listed above must be inspected for damage by an official ABB Turbo Systems service station, and replaced in cases of doubt.
HZTL2491_EN
CAUTION
If surging is prolonged or occurs periodically, the following components may be damaged: - Compressor wheel (vibration fractures, ...) - Turbine blades (cracks) - Bearing (overheating) - Filter silencer
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Contact with rotating parts
4.5
Page 11
4.5 Contact with rotating parts January 2008
Slight, uniform wear around the periphery of rotor components, caused by their just touching adjacent components locally, is not hazardous and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid a significant loss of efficiency. X A check on dimensions must be carried out by an official ABB Turbo
Version 5
HZTL2491_EN
Systems service station.
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Operation Manual / TPL85-B14/-B15/-B16 Operation
4
Shutting the engine down
4.6
Page 12
Before shutting down the engine, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can take away heat from the turbocharger bearings.
January 2008
4.6 Shutting the engine down
Version 5
HZTL2491_EN
CAUTION
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Foreword to Maintenance
5.1
Page 1
January 2008
5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and cleaning to ensure that the turbocharger and its attached units function troublefree.
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.
HZTL2491_EN
The cleaning points described in the following are:
Version 5
Filter silencer Compressor Turbine and nozzle ring
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the filter silencer
5.2
Page 2
5.2.1
January 2008
5.2 Cleaning the filter silencer Filter silencer with tension band 81137
81136
81266 81268 81271 L
HZTL2491_EN
81270
81135
81266
81268
81270
Version 5
81265
L_01158
ABB Turbo Systems Ltd
81265
Filter ring (if provided)
81266
Cover grids
81270
Tension ring
81136
Fleece segment
38271
Trap cover
81137
Cover panel
81268
Connecting strip
81135
Filter silencer body
E
Slide-in module = fleece segment + cover plate installed
ABB
January 2008
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the filter silencer
5.2
Page 3
Disassembling and cleaning filter silencer X Remove filter ring (81265). X Rinse filter ring (81265) with water using detergent or, if very dirty, soak
If provided
it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air is. Wash or replace the filter ring as necessary or every 500 service hours. NOTE
X Loosen clamping straps (81270) at tightening point (81271) and re-
HZTL2491_EN
move together with mesh covers (81266) and connecting bars (81268).
NOTE
In the case of a slide-in module (E) when a cleaning container is attached to the filter silencer (available as option depending on turbocharger type), the water injection line must first be removed (see also following section Disassembling cleaning line).
X Withdraw slide-in modules (E), bend open cover plates (81137) and
then take out fleece segments (81136).
X Clean fleece segments (81136).
Version 5
When cleaning, ensure that fleece segments (81136) are cleaned only with a weak jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well as damaged connecting bars should be replaced with original parts from ABB Turbo Systems. NOTE
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
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Cleaning the filter silencer
5.2
Page 4
X Assemble slide-in modules (E) by inserting fleece segments (81136) in
cover plates (81137).
X Bend cover plates back to their original shape. X Insert slide-in modules (E) in grooves in filter silencer body (81135).
January 2008
Mounting filter silencer
When the cleaning container is fitted to the filter silencer (available as option depending on turbocharger type), the water injection line must be re-installed (see also following section Assembling cleaning line). NOTE
lencer body (81135). X Pass clamping straps (81270) through eyelets in connecting bars (see detail L in illustration L_01158). X Tension all clamping straps at tightening points (81271).
X Fit filter ring (81265).
Version 5
If provided
HZTL2491_EN
X Fit mesh covers (81266) and connecting bars (81268) onto filter si-
ABB Turbo Systems Ltd
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5.2.2
Maintenance
5
Cleaning the filter silencer
5.2
Page 5
Removing / installing the cleaning line
HZTL2491_EN
January 2008
Operation Manual / TPL85-B14/-B15/-B16
L_00192
Injection pipe
3
Guide tube
2
Pipe
Version 5
1
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the filter silencer
5.2
Page 6
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Pull line (2) out of the guide tube(3).
January 2008
Disassembling the cleaning line
HZTL2491_EN
Punching out the guide tube
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and pull it out.
Version 5
Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems. NOTE
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
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Cleaning the filter silencer
5.2
Page 7
HZTL2491_EN
January 2008
Installing the cleaning line
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
Version 5
caulk it. X Fit line (2) and screw it to the injection pipe (1).
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the compressor during operation
5.3
Page 8
These guidelines for wet cleaning apply exclusively for cleaning with clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
January 2008
5.3 Cleaning the compressor during operation
NOTE
The contamination of the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in. A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air:
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the rotor imbalance.
HZTL2491_EN
Oil or saline mist Solid combustion residues Dust of various kinds
Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is completely dismantled.
The interval between periodic cleaning depends considerably on the operating conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Should the prescribed cleaning intervals prove incompatible with the operation of the engine, please contact ABB Turbo Systems.
NOTE
ABB Turbo Systems Ltd
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Version 5
Interval between cleanings
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the compressor during operation
5.3
Page 9
January 2008
Cleaning method The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by ABB Turbo Systems: Wet cleaning
Principle of wet cleaning
Water is injected before the compressor wheel via an injection pipe fitted in the filter silencer or the suction branch in order to clean the compressor stage in operation.
HZTL2491_EN
The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts. CAUTION
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
Version 5
Cleaning more than one turbocharger compressor
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16
NOTE
5
Cleaning the compressor during operation
5.3
Page 10
Wet cleaning the compressor with external pressurised water container (XC3) The supply of water with the externally fitted dosing vessel is only suitable for applications with underpressure before the compressor wheel (not applicable for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).
January 2008
5.3.1
Maintenance
Operating state preconditions for cleaning compressors with XC3
NOTE
Z Engine loading as full as possible Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-
Version 5
cedure for wet cleaning with XC3.
HZTL2491_EN
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning the compressor during operation
5.3
Page 11
HZTL2491_EN
January 2008
Procedure for compressor wet cleaning with XC3
L_00198
Operating the pressurised water container
Version 5
Screw plug
Y
Valve activator
X The Operating state preconditions for cleaning the compressor with X X X X X
ABB Turbo Systems Ltd
X
XC3 must be met before cleaning can begin. Remove screw plug (X). Fill container with clean water. Screw screw plug (X) back in. Actuate valve lever (Y) against the spring and hold for 10 to 15 seconds, until all the water has been injected. After cleaning, the turbocharger must be allowed to dry for at least 5 minutes before any further activity.
ABB
Operation Manual / TPL85-B14/-B15/-B16 5
Cleaning the compressor during operation
5.3
Page 12
If the cleaning operation was not successful, it can be repeated up to 2 times. NOTE
If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
January 2008
Maintenance
Cleaning parameters for each turbocharger compressor Turbocharger type
Turbocharger speed
Contents of the dosing vessel [dm3]
Water injection time t1 [s]
TPL 69BA
Possible nBmax
0.4
4 ... 15
TPL 73-B
1
TPL 77-B 2
HZTL2491_EN
TPL 80-B TPL 85-B
Version 5
TPL 91-B
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16
January 2008
5.3.2
Maintenance
5
Cleaning the compressor during operation
5.3
Page 13
Wet cleaning compressors using water vessel (XC4) Operating state preconditions for cleaning compressors with XC4
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met: NOTE
Z Engine loading as full as possible Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC4.
Version 5
HZTL2491_EN
Procedure for compressor wet cleaning with XC34
L_00197
ABB Turbo Systems Ltd
1
Cleaning container
2 Pipe
3
Injection pipe
4 Cleaning instructions
5
Cover
6 Valve
ABB
Operation Manual / TPL85-B14/-B15/-B16 5
Cleaning the compressor during operation
5.3
Page 14
If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer should be followed. NOTE
X The Operating state preconditions for cleaning compressors with XC4 X X X X X X
must be met before cleaning can begin. Open lid (5) of the cleaning container (1). Fill with clean water. Screw lid (5) closed. Open valve (6) for about 3 minutes. Close valve (6) and check that all the water has been sucked out. After cleaning, the turbocharger must be allowed to dry for at least 5 minutes with the engine running before any further activity.
If the cleaning operation was not successful, it can be repeated up to 2 times. NOTE
If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
HZTL2491_EN
Operation of the cleaning container
January 2008
Maintenance
Cleaning parameters for each turbocharger compressor Turbocharger type
Turbocharger speed
Contents of the dosing vessel [dm3]
Water injection time t1 [s]
TPL 69BA
Possible nBmax
2
4 ... 15
TPL 73-B TPL 80-B
Version 5
TPL 77-B 3
TPL 85-B TPL 91-B
ABB Turbo Systems Ltd
ABB
January 2008
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 15
5.4 Cleaning turbine blades and nozzle ring in operation Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits. The exhaust gas temperature downstream of the cylinders can rise and the charging pressure at the air receiver can fall if turbine components become soiled.
Experience in operation has shown that despite periodic cleaning during operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended. Wet cleaning interval
The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours.
Interval for dry cleaning
The interval between periodic cleaning depends considerably on the operating conditions. In general, cleaning should be carried out every 20 to 50 operating hours.
Version 5
HZTL2491_EN
A soiled turbine also results in rotor unbalance. Severe soiling can lead to impermissibly high rotor imbalance.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 16
Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the following have been tested and are recommended by ABB Turbo Systems:
January 2008
Cleaning methods
Wet cleaning Dry cleaning
During wet cleaning using droplets of water, the water does not act as a solvent. Instead, the deposit is removed by the mechanical impact of the drops.
Due to the risk of corrosion, only clean water may be used and on no account salt water. Furthermore, the water should contain no cooling additives, which could form deposits in the flow ducts. CAUTION Principle of dry cleaning
During dry cleaning using dry solid particles in granulate form, the deposit is removed by the mechanical impact of the grains hitting the surface.
HZTL2491_EN
Principle of wet cleaning
Wet and dry cleaning are equally effective. However, it may be useful to apply both methods together.
Version 5
NOTE
ABB Turbo Systems Ltd
ABB
January 2008
Operation Manual / TPL85-B14/-B15/-B16
NOTE
Cleaning more than one turbocharger turbine
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 17
Components at the turbine end are not cleaned until the engine has been started or the engine load reduced. The exhaust temperature must not exceed the value specified in the pertaining cleaning instructions (see respective section Operating state prerequisites).
Failure to maintain the specified exhaust temperature in front of the turbine, the minimum stabilising time before as well as between cleaning operations and the drying time after cleaning in accordance with the pertaining cleaning instructions will drastically shorten the expected service life of the components.
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger turbines with nozzle rings one after the other.
Version 5
HZTL2491_EN
CAUTION
Maintenance
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 18
Wet cleaning turbine and nozzle ring during operation The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature shown on the turbocharger rating plate must not be exceeded under any circumstances. During wet cleaning the turbine delivers less power to the shaft and the turbocharger speed sinks. As a result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
January 2008
5.4.1
Maintenance
Operating state precondition for wet cleaning
NOTE
Z After the engine has been started or during operation, the engine
Version 5
output must be adjusted until the scavenging air pressure pscav is within the range of 0.3 – 0.6 bar (gauge pressure). Z Wait 10 to 15 minutes (stabilising time), until the exhaust temperature at the turbine inlet is stable and below 430°C, the auxiliary blower must also be operating. X Cleaning cycle started according to the following description in Procedure for wet cleaning.
HZTL2491_EN
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 19
Version 5
HZTL2491_EN
January 2008
Procedure for wet cleaning
L_00394
Operating the wet cleaning system
1
Water supply (fresh water only) at least 6.0 bar
8
Drain pipe
2
Regulating valve
9
Drain cock
3
Manometer
10
Outflow
4
Air supply with 3-way-valve
11
Orifice (integrated in turbocharger)
5
Stainless-steel pipe
21
Air duct from compressor casing
6
Other turbochargers
A
Position 1
7
Injection nozzle
B
Position 2
Z The Operating state preconditions for wet cleaning must be satisfied
before cleaning is begun.
X Check that the water supply (1) is open and ensured, and also con-
nected to the regulating value (2) in front of the turbocharger. X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing to Position 1 and check whether exhaust gas escapes.
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 20
X X X X
X X
valve (2) until the manometer (3) shows a pressure of 1 ± 0.2 bar. Inject water for 5 minutes at constant engine output. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Position 2, in order to keep the drain pipe clean with air from the compressor casing (21). The water supply connection (1) to the regulating valve (2) must be disconnected. After cleaning, wait at least 10 minutes with engine running to allow turbocharger to dry.
January 2008
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
Points to remember when cleaning
ABB Turbo Systems Ltd
If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these cases, the wet cleaning operation must be terminated and the wet cleaning cycle begun again with a lower water pressure or higher engine loading.
ABB
Version 5
NOTE
HZTL2491_EN
If the cleaning operation was not successful, it can be repeated up to 2 times.
Operation Manual / TPL85-B14/-B15/-B16
January 2008
5.4.2
Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 21
Integrated dry cleaning of turbine and nozzle ring during operation This cleaning method is not suitable for removing thick dirt deposits and must therefore be carried out more often (see chapter Cleaning turbine blades and nozzle ring in operation).
NOTE
Operating mode prerequisites for integrated dry cleaning device
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be met:
HZTL2491_EN
NOTE
Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature upstream of the turbine must be below 590°C.
Version 5
Otherwise, there is considerable danger that the dry cleaning agent will be burnt off. X Start the cleaning cycle with reference to the following description Operating procedure for integrated dry cleaning device.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 22
HZTL2491_EN
January 2008
Operation of integrated dry cleaning device
1
Container for granulated material
5
ON/OFF valve
2
Trap-cover
6
Safety valve
3
Compressed air supply [4 to 10 bar]
7
Combined air valve/pressure relief valve
4
Pipe made from stainless steel
8
Cleaning instructions
The air system must be protected against overpressure (> 10 bar). CAUTION
ABB Turbo Systems Ltd
ABB
Version 5
L_00094
January 2008
Operation Manual / TPL85-B14/-B15/-B16
Operation of the dry cleaning device
Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Z The Operating mode prerequisites for integrated dry cleaning must be X X X X X X X X X X X
HZTL2491_EN
Page 23
X
satisfied before cleaning begins. Ensure that the ON/OFF valve (5) is closed. Check that combined air valve/pressure relief valve (7) is in pressure relief position. Carefully open trap cover (2). Fill container (1) with specified amount of granulate. Close and seal trap cover (2). Open air valve (7). Open safety valve (6). Open ON/OFF valve (5) and leave it open for approx. 1 minute to clean turbine. Close ON/OFF valve (5). Close safety valve (6). Set the combined air valve/pressure relief valve (7) to the pressure relief position. Check whether exhaust gas temperature after turbine has dropped.
In order to obtain the best possible cleaning effect, it is essential that the prescribed quantity of granulate is blown in. NOTE
The drain openings in the gas outlet casing must remain closed while the turbine is being cleaned. Careless handling can cause incompletely combusted soot particles to escape.
Version 5
If the cleaning operation was not successful, it can be repeated up to 2 times. NOTE
ABB Turbo Systems Ltd
If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 24
Selection of materials
January 2008
Cleaning parameters for integrated dry cleaning device
The following materials are suitable for use when dry cleaning: Hard, granulated materials, such as natural core granulates Softblast media Activated carbon particles
The mean grain size of the cleaning granulate must be between 1.2 and 2.0 mm.
Amount of granulate per turbocharger [litres]
HZTL2491_EN
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
TPL 85-B 3.0
The cleaning granulate must be stored in a dry, clean place in order to avoid clogging the pipes during cleaning. The table in chapter Suppliers of dry cleaning agents lists possible suppliers of dry cleaning agents.
Version 5
NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16
January 2008
5.4.3
Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 25
Non-integrated dry cleaning device for turbine and nozzle ring during operation As an alternative to the built-in dry cleaning system, a non-integrated dry cleaning device can be installed in front of the gas inlet casing by the engine manufacturer. Operating mode prerequisites for non-integrated dry cleaning device
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be met: NOTE
Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature in front of the turbine must be below 590°C.
Version 5
HZTL2491_EN
Otherwise, there is considerable danger that the dry cleaning agent will be burnt off. X Start the cleaning cycle with reference to the following description Operating procedure for non-integrated dry cleaning device.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 26
Version 5
HZTL2491_EN
January 2008
Operation of non-integrated dry cleaning device
L_00208
ABB Turbo Systems Ltd
ABB
January 2008
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 27
1
Trap cover G2“
6
Strap for securing the container
2
Poss. copper gasket
7
Safety valve with ventilation
3
Double nipple G2“
8
Compressed air shut-off valve
4
Copper gasket
9
Compressed air pipe (internal diameter 8mm)
5
Friction cock or slide controller G1''
10
Compressed air max. 6 bar
The air system must be protected against overpressure (> 6 bar). CAUTION
Operation of the dry cleaning device
Z The Operating mode prerequisites for non-integrated dry cleaning de-
HZTL2491_EN
Z X X X
Version 5
X X X X X X X X X X X X X
ABB Turbo Systems Ltd
vice must be satisfied before cleaning begins. Friction cock or slide controller (5) closed and safety valve with ventilation (7) open. Close safety valve with ventilation (7). Tighten trap cover (1). Open compressed air shut-off valve (8) so that deposits and any condensation are blown off. Close compressed air shut-off valve (8) again after about 3 minutes. Close friction cock / slide controller (5). Open safety valve with ventilation (7) to blow out exhaust gases. Carefully open trap cover (1) on granulate container. Fill granulate container with specified quantity of granulate. Close and seal trap cover (1). Close safety valve with ventilation (7). Open compressed air shut-off valve (8). Open friction cock or slide controller (5) for approx. 1 minute. Close friction cock or slide controller (5). Close compressed air shut-off valve (8). Open safety valve with ventilation (7). Check whether exhaust gas temperature has dropped after turbine.
ABB
Operation Manual / TPL85-B14/-B15/-B16 5
Cleaning turbine blades and nozzle ring in operation
5.4
Page 28
In order to obtain the best possible cleaning effect, it is essential that the spcified quantity of granulate is blown in. NOTE
The drain openings in the gas outlet casing must remain closed while the turbine is being cleaned. Careless handling can cause incompletely combusted soot particles to escape.
January 2008
Maintenance
If the cleaning operation was not successful, it can be repeated up to 2 times. If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
HZTL2491_EN
NOTE
Cleaning parameters for the non-integrated dry cleaning device
The choice of material takes place according to chapter Integrated dry cleaning of the turbine and nozzle ring during operation.
Granulate quantity per turbocharger
ABB Turbo Systems Ltd
Turbocharger type
Amount of granulate [dm3]
Container size
TPL 69BA
1.0
II
TPL 73-B
1.0
II
TPL 77-B
1.5
II
TPL 80-B
2.0
II
TPL 85-B
3.0
III
TPL 91-B
3.5
III
Version 5
NOTE
ABB
Operation Manual / TPL85-B14/-B15/-B16 Maintenance
5
Suppliers of materials for dry cleaning
5.5
Page 29
Manufacturer
Country
Address
Number for contact
ABB Australia Pty. Limited
Australia
Dock 7W Bapaume Road 2170 Moorebank- N.S.W.
Tel.: +61 2 9821 0940 Fax: +61 2 9821 0941 Email:
[email protected]
Paul AUER GmbH
Germany
Bad Kreuznacherstr. 18 D-68309 MannheimKaefertal
Tel.: +49 621 72 769 - 0 Fax: +49 621 72 769 - 88 Email:
[email protected]
BRIGANTINE Service Ltd.
Hong Kong
48 Wang Lok Street Yuen Long Industrial Estate N.T. Hong Kong
Tel.: +852 2473 7933 Fax: +852 2237 4731 Email:
[email protected]
LEERING HENGELO B.V.
Netherlands
Barnsteenstraat 1 NL-7554 TC Hengelo The Netherlands
Tel.: +31 74 255 82 82 Fax: +31 74 242 23 73 Email:
[email protected]
GUYSON International Ltd
United Kingdom
Snaygill Industrial Estate Keighley Road, Skipton, North Yorkshire BD23 2QR United Kingdom
Tel.: +44 1756 799911 Fax: +44 1756 790213 Email:
[email protected]
DASIC International Ltd.
United Kingdom
Winchester Hill, Romsey, Hampshire SO51 7YD United Kingdom
Tel.: +44 1794 512 419 Fax: +44 1794 522 346 Email:
[email protected]
PAN Abrasives (Pte) Ltd.
Singapore
24 Pioneer Sector 2 Jurong 628381 Singapore
Tel.: +65 6861 6988 Fax: +65 6861 0919 Email:
[email protected]
CARLANDER & Co.
Sweden
Valtersang 9 S-442 49 Kungalv Sweden
Tel.: +46 303 630 75 Fax: +46 303 630 77 Email:
[email protected]
BOSUNG Engineering Co., Ltd.
Korea
1189-1, Choryang-3 Dong, Dong-Ku, Busan, 601-013
Tel.: +82 51 466 0881-5 Fax: +82 51 466 0886-9 Email:
[email protected]
POLITEK Ltd.
Turkey
Barajyolu Cad. No: 22/6 Y. Camlica Mahallesi Yukari Dudullu 34779 Umraniye Istanbul / Turkey
Tel.: +90 216 455 77 66 Fax: +90 216 455 77 25 Email:
[email protected]
UNISERVICE S.A.
Italy
Via Al Santuario di N.S. della Guardia 58 / A 16162 Genova
Tel.: +39 010 711 395 Fax: +39 010 713 120 Email:
[email protected]
Version 5
HZTL2491_EN
January 2008
5.5 Suppliers of materials for dry cleaning
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting
6
Possible remedies for failures
6.1
Page 1
6 Troubleshooting January 2008
6.1 Possible remedies for failures Exhaust temperature too high Engine output and speed unchanged
Z Malfunction in the injection system X Repair, or contact the manufacturer.
Turbocharger
Z Air starvation, e.g. air filter clogged with dirt X Clean
HZTL2491_EN
Engine
Z Compressor / turbine soiled X Clean Z Exhaust counterpressure too high X Clean or repair boiler or exhaust silencer Z Turbine damaged or worn X Contact an official ABB Turbo Systems service station.
Charge-air cooler
Z Cooler soiled X Clean Z Insufficient coolant water quantity X Replenish
Version 5
Z Coolant water inlet temperature too hot X Clean/inspect cooling system Z Ventilation inadequate X Improve ventilation
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting
6
Possible remedies for failures
6.1
Page 2
January 2008
Charge-air pressure too low Engine output and speed unchanged Intake condition normal
Engine
Z Air receiver leaking X Repair Z Gas line between engine and turbine leaking X Repair Z Injection misadjusted X Correct adjustment
Turbocharger
HZTL2491_EN
Z Valve control misadjusted X Correct adjustment
Z Manometer display faulty X Replace manometer Z Leak in line to the manometer X Repair leak Z Air filter dirty, causing excessive loss of pressure X Clean Z Compressor / turbine soiled X Clean Z Compressor / turbine damaged X Contact an official ABB Turbo Systems service station.
ABB Turbo Systems Ltd
Version 5
Z Excessive exhaust counterpressure X Clean boiler or exhaust silencer
ABB
Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting
6
Possible remedies for failures
6.1
Page 3
January 2008
Charge-air pressure too high Engine output and speed unchanged Intake condition normal
Engine
Z Malfunction in the injection system X Correct adjustment Z Engine output higher than expected X Check engine output
HZTL2491_EN
Z Injection misadjusted X Correct adjustment
Turbocharger
Z Manometer display faulty X Replace manometer
Vibrations Turbocharger
Z Z Z X
Rotor imbalance due to heavy fouling of compressor/turbine Turbine or compressor damaged Bearing defective Contact an official ABB Turbo Systems service station.
Noises during run-out Turbocharger
Z Turbocharger dirty X Clean
Version 5
Z Z Z X
ABB Turbo Systems Ltd
Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.
ABB
Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting
6
Possible remedies for failures
6.1
Page 4
Turbocharger
January 2008
Run-out time too short Z Turbocharger dirty X Clean Z Z Z X
Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.
Sluggish start-up Z Turbocharger dirty X Clean Z Z Z X
Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.
HZTL2491_EN
Turbocharger
Lubricating oil pressure too low Engine
Z Oil filter heavily soiled X Clean Z Oil pump in the lubricating system defective X Inspect Z Manometer provides false reading X Replace manometer
ABB Turbo Systems Ltd
Z Axial clearance of the rotor too big X Contact an official ABB Turbo Systems service station.
Version 5
Turbocharger
ABB
Operation Manual / TPL85-B14/-B15/-B16 Troubleshooting
6
Possible remedies for failures
6.1
Page 5
January 2008
Constant surging of the turbocharger Z Exhaust pressure to the turbine elevated because boiler or exhaust si-
Engine
lencer is dirty
Z Trap dirty X Clean
Turbocharger
Z Charge-air filter or silencer dirty Z Heavy deposits of contamination in the turbine X Clean
If it is not possible to determine the reason for the surging, contact an official ABB Turbo Systems service station.
Version 5
HZTL2491_EN
NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Removal and installation
7
Turbocharger weights
7.1
Page 1
January 2008
7 Removal and installation 7.1 Turbocharger weights Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. WARNING
Loads that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.
Version 5
HZTL2491_EN
X Select a suitable rope taking into account the weight of the load X Hang rope crossed over on the crane hook X Do not stand under suspended loads
L_00082
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Removal and installation
7
Turbocharger weights
7.1
Page 2
Weight [kg]
January 2008
Turbocharger complete unit without filter silencer/air suction branch TPL 85-B 9745
Turbocharger complete unit with filter silencer Weight [kg]
TPL 85-B 10700
Turbocharger complete unit with air suction branch Weight [kg]
TPL 85-B
Version 5
HZTL2491_EN
10035
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Removal and installation
7
Remove the turbocharger
7.2
Page 3
7.2 Remove the turbocharger January 2008
X Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturer’s instructions.
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the ∅ of this orifice has been individually adjusted by the engine builder. Whenever these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the correct ∅ is fitted into the oil supplying oil-inlet channel.
Version 5
HZTL2491_EN
X Check the lifting equipment. X Secure lifting equipment to the suspension lugs on the bearing casing.
7.2
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 7
Remove the turbocharger
7.2
Page 4
During removal, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING
X Select a suitable rope taking into account the weight of the turbo-
charger. X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose. X The turbocharger must be transported as horizontally as possible.
January 2008
Removal and installation
X Release the fixing screws on the foot. X Lift the turbocharger from the engine and place it aside.
If the support for the turbocharger is missing or defective when setting aside, the turbocharger may tip over and can cause serious or even fatal injury. HZTL2491_EN
WARNING
Version 5
X Support turbocharger in a suitable location. X Cover oil connector.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Removal and installation
7
Installing the turbocharger
7.3
Page 5
January 2008
7.3 Installing the turbocharger During installation, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING
X Select a suitable rope taking into account the weight of the turbo-
charger. X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose. X The turbocharger must be transported as horizontally as possible. Remove cover from oil connector. Check the lifting equipment. Secure lifting equipment to the suspension lugs on the bearing casing. Mate turbocharger to engine. Tighten the fixing screws on the foot, in accordance with the engine manufacturer's instructions. X Secure all gas, air, and oil lines in accordance with the engine manufacturer’s instructions.
Version 5
HZTL2491_EN
X X X X X
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Module weights
8.1
Page 1
January 2008
8 Disassembly and assembly 8.1 Module weights Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. WARNING
Loads that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.
Version 5
HZTL2491_EN
X Select a suitable rope taking into account the weight of the load X Hang rope crossed over on the crane hook X Do not stand under suspended loads
L_00082
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Module weights
8.1
Page 2
HZTL2491_EN
January 2008
Modules
Version 5
8.1
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Module weights
8.1
January 2008
Weights [kg]
Page 3
Description
TPL 85-B
1
Air suction branch, radial
290
2
Filter silencer
955
3
Compressor casing, internal part
550
4
Wall insert
850
5
Diffuser
225
6
Compressor casing external part
1200
7
Cartridge group
3000
8
Cover ring
145
9
Nozzle ring
95
10
Gas inlet casing radial
495
HZTL2491_EN
Compressor casing, internal part, complete Weight [kg]
TPL 85-B 1625
The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing, the diffuser and the wall insert.
Version 5
NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 8
Removing and fitting filter silencer or air suction branch
8.2
Page 4
8.2 Removing and fitting filter silencer or air suction branch Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox).
January 2008
Disassembly and assembly
NOTE
X Remove insulation where necessary. X Disconnect all air ducts in accordance with the engine manufacturer’s
HZTL2491_EN
instructions.
74027 74018
90195
Version 5
L_01214
X Secure shackle (90195) to rib / fin on filter silencer.
ABB Turbo Systems Ltd
ABB
Disassembly and assembly
8
Removing and fitting filter silencer or air suction branch
8.2
Page 5
During removal and assembly, turbocharger components that have not been suspended in compliance with regulations may fall, and can cause serious or even fatal injury. WARNING
X Do not stand under suspended loads.
Remove filter silencer
X Pass lifting gear through lugs on rear side and secure to shackle
Mounting the filter silencer
X Mount filter silencer or air suction branch in reverse order.
(90195). X Unscrew nuts (74027) with washers (74018) and remove filter silencer or air suction branch.
Version 5
HZTL2491_EN
January 2008
Operation Manual / TPL85-B14/-B15/-B16
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Axial clearance
8.3
Page 6
January 2008
8.3 Axial clearance 74018 74027
L_01250
Z Before removing as well as after fitting the internal part of the compres-
HZTL2491_EN
A
sor casing and the gas inlet casing (if removed), the axial clearance (A) must be measured. X Screw on at least four nuts (74027) with washers (74018) equally spaced around circumference and tighten to secure partition wall axially. X Measure and note axial clearance A. If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
Clearance A [mm]
Version 5
CAUTION
TPL 85-B 0.54 – 0.79
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Dismantling the internal part of the compressor casing
8.4
Page 7
January 2008
8.4 Dismantling the internal part of the compressor casing Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox). NOTE
Blocked safety segments (Y) during disassembly CAUTION
Observe the maximal tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (Y). X Screw on and tighten four nuts (74027) with washers (74018/74028)
HZTL2491_EN
equally spaced around circumference.
X Take nuts (90458) out of toolbox and screw onto threaded studs of
three safety segments (Y) in internal part of compressor casing (76000).
Position of safety segments during disassembly
76000
74000
Version 5
u
Y
90458
90458
L_00269
X Tighten nuts (90458) to a maximal torque of 30 Nm. D The internal part of the compressor casing (76000) is now separated
from the external part of the compressor casing (74000) and can be removed.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Dismantling the internal part of the compressor casing
8.4
Page 8
January 2008
Note check dimension (u). NOTE
Check dimension (u) [mm]
Dimension
TPL 85-B
u
27.6
X Remove nuts (74027) with washers (74018). X Remove 4 studs (74026/74029) from upper area. X Hoist up lifting device (90190) using shackle (90195) and lifting gear.
90320
HZTL2491_EN
Removing internal part of compressor casing
74026 / 74029
90195 90190 90900
74018 74027
76040 76000 F
74000
Version 5
90195 90025 90458
L_01215
X Press off internal part of compressor casing (76000) using press-off
screws (90900), until lifting device (90190/90195) can be fitted.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Dismantling the internal part of the compressor casing
8.4
Page 9
X Fit lifting device to internal part of compressor casing (76000). X Withdraw internal part of compressor casing (76000) complete with January 2008
wall insert and diffuser.
X Fit support angle (90025). X Set down internal part of compressor casing (76000) in a horizontal
position.
If necessary
X Attach two shackles (90195) to support angle (90025) and fasten a se-
cond set of lifting gear to both shackles (90195). X Slightly raise internal part of compressor casing (76000) complete with wall insert and diffuser using lifting device (90190). X Use second set of lifting gear to carefully move internal part of compressor casing (76000) into vertical position. X Set down casing on flange (F) on an underlay.
WARNING
X Rest internal part of compressor casing only on flange (F). X Check underlay and adjust if necessary.
Version 5
HZTL2491_EN
Ensure that the underlay does not slip.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Dismantling the internal part of the compressor casing
8.4
Page 10
Remove diffuser
January 2008
76002 90235 79000 90230 90900 77000
77005 HZTL2491_EN
77006
76000
F
90025
X Remove screws (76002). X Remove diffuser (79000) using ring bolts (90235). X Ease off wall insert (77000) using press-off screws (90900) and re-
move using ring bolts (90230). X Remove O-rings (77005, 77006).
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems service station. CAUTION
ABB Turbo Systems Ltd
ABB
Version 5
L_01251
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Dismantling gas inlet casing
8.5
Page 11
8.5 Dismantling gas inlet casing January 2008
X Remove the insulation on the gas inlet casing (51001). X Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).
Do not stand under or near the suspended gas inlet casing.
HZTL2491_EN
WARNING
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
Version 5
X X X X
nozzle ring (56001). Remove screws (56014), bushings (56013) and nozzle ring (56001). Loosen and remove screws (57005). Fit two guide studs (90320). Press off the cover ring (51085) with press-off screws (90320) and remove over the guide bolts (90907).
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems service station. CAUTION
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Fitting gas inlet casing
8.6
Page 12
8.6 Fitting gas inlet casing January 2008
X Fit cover ring (51085) using two guide bolts (90320) as a help.
If removed:
Positioning cover ring CAUTION
The marking "TOP" on the cover ring (51085) must be as far up as possible. X Pay attention to installing cover ring in correct position. X Screw in and tighten screws (57005). X Remove guide bolts (90320).
X Mount nozzle ring (56001) on gas inlet casing (51001) using screws
Smear all screws in and on the gas casings with Anti Scuff Paste 868 from SPANJAARD.
HZTL2491_EN
(56014) and sleeves (56013).
NOTE
X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing
(61044) with screws (61009). X Remove lifting gear with shackle (90195).
Version 5
X Fit the insulation on the gas inlet casing (51001).
ABB Turbo Systems Ltd
ABB
January 2008
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Fitting the internal part of the compressor casing
8.7
Page 13
8.7 Fitting the internal part of the compressor casing Fitting the diffuser
76002 90235 79000 90230 90900
HZTL2491_EN
77000
77005 77006
76000
Version 5
F
90025
L_01251
X Put O-rings (77005, 77006) on wall insert (77000). X Fit wall insert (77000) and diffuser (79000) in internal part of compres-
sor casing (76000). X Tighten screws (76002), then loosen again by a ¼ turn. X Secure lifting gear to lifting device (90190) and shackles (90195) in support bracket (90025). X Lift internal part of compressor casing (76000) complete with wall insert and diffuser using two sets of lifting gear. ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Fitting the internal part of the compressor casing
8.7
Page 14
as a result, bring internal part of compressor casing (76000) into a horizontal position. X Remove support bracket (90025) complete with shackle (90195).
Fitting internal part of compressor casing
90320
January 2008
X Carefully slacken lifting gear attached to support bracket (90025) and,
74026 / 74029
90195 90190
74018 74027
76040 76000 F
HZTL2491_EN
90900
74000
90195 90025 90458
L_01215
X X X X
with wall insert and diffuser over guide bolts (90320) into external part of compressor casing (74000). Remove lifting device (90190/90195). Insert internal part of compressor casing as far as it will go. Remove guide bolts (90320) and screw in studs (74026/74029). Use studs [10x 74029, 2x 74026 (each screwed in at top and bottom)].
74026
74029
L_01124
ABB Turbo Systems Ltd
ABB
Version 5
X Put O-ring (76040) onto internal part of compressor casing (76000). X Fit guide bolts (90320). X Carefully insert internal part of compressor casing (76000)complete
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Fitting the internal part of the compressor casing
8.7
Page 15
X Screw on at least four nuts (74027) with washers (74018) equally January 2008
spaced around circumference and tighten to secure partition wall axially.
Blocked safety segments (Y) during assembly CAUTION
The safety segments (Y) are not in the operating position. There is no guarantee of additional axial securing of the two compressor casings (74000/76000). X Screw on and tighten four nuts (74027) with washers (74018/74028)
equally spaced around circumference.
X Unscrew nuts (90458) on threaded studs of three safety segments (Y)
on internal part of compressor casing (76000).
relative to the external part of the compressor casing (74000).
Position of safety segments after assembly
76000
74000 Y
s
HZTL2491_EN
D The internal part of the compressor casing (76000) is now secured
90458
90458
Version 5
L_00276
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 8
Fitting the internal part of the compressor casing
8.7
Page 16
Note check dimension (s). The safety segments (Y) are back in the operating position. NOTE
Check dimension (s) [mm]
Dimension
January 2008
Disassembly and assembly
TPL 85-B
s
18.5
X Put nuts (90458) back into toolbox.
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted. CAUTION
Clearance A [mm]
HZTL2491_EN
X Measure and note axial clearance A.
TPL 85-B 0.54 – 0.79
X Remove nuts (74027) with washers (74018).
ABB Turbo Systems Ltd
X Mount filter silencer or air suction branch and secure with nuts (74027)
and washers (74018) (see section Removing and mounting filter silencer or air suction branch). X Connect all air lines / ducts in accordance with engine manufacturer’s instructions. X Fit all insulation that was removed.
ABB
Version 5
Mounting the filter silencer
Operation Manual / TPL85-B14/-B15/-B16 8
Fitting the internal part of the compressor casing
8.7
Page 17
Version 5
HZTL2491_EN
January 2008
Disassembly and assembly
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Table of tightening torques
8.8
Page 18
74026 74029
90458
74027
76002 42059 42064
57005
61044
HZTL2491_EN
82002
January 2008
8.8 Table of tightening torques
56014
L_01216
L_00228
The following tightening torques must be kept to for the specified threaded connections:
ABB Turbo Systems Ltd
ABB
Version 5
86505
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly
8
Table of tightening torques
8.8
HZTL2491_EN
January 2008
Tightening torques [Nm]
Part number
TPL 85-B
42059, 42064
M12 110
56014
M16 160
57005
M16 160
61044
M24 480
74026 / 74029
M24 80
74027 (with larger washer)
M24 400
76002
M20 - 1)
82005
M16 x 1.5 50
86505
M22 x 1.5 220
90458
M12 30
Tighten only so much that the diffuser can still be moved.
Version 5
1)
Page 19
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Possibilities for emergency repair
9.1
Page 1
9 Taking out of operation temporarily January 2008
9.1 Possibilities for emergency repair Lubricating oil leakage is a fire hazard. WARNING
The instructions of the engine manufacturer for operation of the engine with locked / isolated turbocharger must be followed precisely in all cases! CAUTION
HZTL2491_EN
If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available: Lock the turbocharger rotor Blocking the inlets and outlets Bypass the turbocharger
Emergency repairs that can be carried out quickest have been described first.
Version 5
NOTE
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Locking the rotor
9.2
Page 2
January 2008
9.2 Locking the rotor A blocked/ jammed rotor must be disassembled following the turbocharger repair and given an imbalance check. CAUTION
NOTE
The only exception is a test rig run up to maximum 25% of the engine load with new engines with one or a number of turbochargers, which are requested by some customers. Since in these cases operation with a blocked rotor is brief and the loads are low, subsequent disassembly of the rotor is unnecessary.
NOTE
CAUTION
Various intermediate rings are provided with the blocking device for different compressor wheels. The compressor wheel type ”CV” (for the balancing screw holes) must be noted. The space between the blocking flange (94003) and the assembly-disassembly device (90020) must be compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.
HZTL2491_EN
U Once unscrewed, balancing screws must not be screwed in again.
During operation of the engine with a blocked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures and information for operation with a blocked rotor for 2-stroke engines). Otherwise components that are still intact can be damaged by overheating.
Version 5
The supply of lubricating oil to the turbocharger must be shut off in the event of a lubricating oil leak on the turbocharger.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Locking the rotor
9.2
Page 3
HZTL2491_EN
January 2008
Locking rotor with polygon connection
Version 5
L_00261
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 9
Locking the rotor
9.2
Page 4
These operations must be carried out as described in the chapter Disassembly and assembly. NOTE
X Remove the filter silencer or air suction branch and the compressor ca-
January 2008
Taking out of operation temporarily
sing internal part together with the wall insert and the diffuser.
X Fix partition wall with press-off tools (90920).
Fit locking flange (94003) to the compressor wheel with at least 9 screws (94007 or 94008) (refer to Table of tightening torques).
Table of tightening torques [Nm]
Part number
TPL85-B
94006
M12 75
94007 / 94008
M12 60
HZTL2491_EN
CAUTION
X Fit the locking flange (94003) with screws (94007 or 94008, using the
Version 5
longest possible screws) as well as the adjustment ring (94004) and intermediate ring (94031).
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Locking the rotor
9.2
Page 5
HZTL2491_EN
January 2008
Compressor type CV11
94000_15
Version 5
It must be ensured that all components are clean and free from grease. CAUTION
X Push correct intermediate rings (94001 and/or 94002) on to the locking
flange (94003). X Fit assembly-disassembly device (90020) in each case with 2 washers (94032). X Insert the remaining intermediate rings (94001 and/or 94002) and mount the locking flange (94003) with screws (94006).
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Locking the rotor
9.2
Page 6
HZTL2491_EN
January 2008
Compressor type CV12, CV13
94000_012
It must be ensured that all components are clean and free from grease. CAUTION
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032). X Insert the remaining intermediate rings (94001 and/or 94002) and mount the locking flange (94003) with screws (94006).
ABB Turbo Systems Ltd
ABB
Version 5
X Push correct intermediate rings (94001 and/or 94002) on to the locking
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Locking the rotor
9.2
Page 7
January 2008
Further measures and information for operation with blocked rotor for 2stroke engines 2-stroke engine with one turbocharger:
No further measures are necessary. The engine can be operated with the auxiliary blower according to the manufacturer's instructions. 9 The lubrication oil system must remain connected and turned on.
HZTL2491_EN
2-stroke engine with several turbochargers:
X The compensator at the compressor outlet must be dismantled and the
air duct blocked at the engine end, as undamaged turbochargers develop a receiver pressure. X The operating limit of the engine can be raised by additionally blocking the gas inlet, as the exhaust gas is then used to drive the undamaged turbocharger. In addition, the loading and temperature of the blocked rotor is reduced.
If the gas inlet cannot be blocked, the following operating limits must be observed: The pressure in the charge-air receiver must not exceed 1 bar over-
pressure. Max. permissible engine load: 50%.
Attention must be paid to the speed of the undamaged turbochargers in all cases. The speed limit nBmax according to the turbocharger rating plate must not be exceeded.
Version 5
CAUTION
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Blocking the inlets and outlets
9.3
Page 8
January 2008
9.3 Blocking the inlets and outlets Shut off the supply of lubricating oil to the turbocharger. CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructions.
Version 5
HZTL2491_EN
NOTE
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Taking out of operation temporarily
9
Bypass the turbocharger
9.4
Page 9
January 2008
9.4 Bypass the turbocharger Shut off the supply of lubricating oil to the turbocharger. CAUTION
Z Only applies for engines with one turbocharger. Z The connections are ready and pipes for the bypass are to hand. X Fit the bypass around the turbocharger.
For information about how to do this, see the manufacturer's instructions.
Version 5
HZTL2491_EN
NOTE
ABB Turbo Systems Ltd
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Operation Manual / TPL85-B14/-B15/-B16 Mothballing the turbocharger
10
Taking out of operation for up to 12 months
10.1
Page 1
January 2008
10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger needs special protection or not depends mainly on the condition of the lubricating oil before laying up. If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be taken. However, if the neutralisation factor is higher the turbocharger must be dismantled after laying up, cleaned and protective oil must be applied to the naked parts. If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the sensitive bearing parts will be largely protected against corrosion.
Version 5
HZTL2491_EN
If the rotor turns due to a draught from the flue, fit a blind flange between the compressor casing and the charge-air duct.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 10
Taking out of operation for more than 12 10.2 months
Page 2
10.2 Taking out of operation for more than 12 months If the turbocharger has to be removed from the engine and stored for a prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station.
January 2008
Mothballing the turbocharger
Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form. Check mothballed turbochargers yearly for corrosion.
Version 5
HZTL2491_EN
NOTE
If there are signs of rust, clean parts and renew means for protection against corrosion.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Disposal
11
Environmentally compatible disposal of turbocharger components
11.1
Page 1
January 2008
11 Disposal 11.1 Environmentally compatible disposal of turbocharger components
Environmentally compatible disposal of turbocharger components
HZTL2491_EN
NOTE
Component disposal must be environmentally compatible, professionaland in accordance with locally regulations. The turbocharger mainly consists of metal (cast-iron materials, steel, nickel-steel alloys, aluminium, bearing brass). Other components are: non-metallic materials (filter components made of felt and polyethylene), lubricants (engine oil), electronic components (speed sensor and associated components), thermal insulation.
X X X X
Dispose of metals by melting down and recycling. Dispose of non-metallic materials as waste. Dispose of lubricant left-overs and residues as used oil. Dispose of electronic components as electrical / electronic scrap.
Handling damaged thermal insulation WARNING
Damaged thermal insulation can burden the air with dust. The glass fibres can cause mechanical irritation of the eyes, skin and respiratory tracts.
Version 5
X Prevent dust from being produced. X Remove dust with a suitable vacuum cleaner. X Wear respiratory mask as protection against particles (P1 or P2
mask). X Wear leather protective gloves. X Wear close-fitting safety goggles.
X Dispose of thermal insulation as special waste.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts
12
Ordering spare parts
12.1
Page 1
January 2008
12 Reserve and spare parts 12.1 Ordering spare parts When making inquiries or ordering spare parts, the following data should be specified: Turbocharger type HT number Description and part number.
Our service stations and agents will take orders for spare parts. X If special variants/cases are not addressed in these general instruc-
Version 5
HZTL2491_EN
tions, then contact an official ABB Turbo Systems service station or an ABB agent.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts
12
Ordering spare parts
12.1
Page 2
To carry out the work described in this manual, you need a set of spare parts (97070). These spare parts in this set are available only as a complete set.
Spare parts set (97070)
Quantity
Description
Part number
2
O-ring gasket
42012, 76040
2
Gasket
42041, 42069
12
Hexagon head screw
42059, 42064
1
Gasket
42045
6
Hexagon head screw
56014, 57005
4
Hexagon nut
61037
1
Gasket
61041
2
O-ring gasket
77005, 77006
1
O-ring gasket
86506
HZTL2491_EN
NOTE
January 2008
Spare-parts set
All spare parts that were ordered with the turbocharger should be kept as a complete set and ready for use. CAUTION
X Parts showing signs of rust should be carefully cleaned and grea-
sed.
X Dispose of parts, which have been replaced and are no longer usable,
Version 5
in a proper and environmentally compatible manner.
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts
12
Directory of part numbers
12.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders: Turbocharger
Part number
Description
-
Cartridge group
51001
Gas inlet casing
51085
Cover ring
56001
Nozzle ring
61001
Gas outlet casing
61035
Hexagon head screw
61037 (in spare parts set)
Hexagon nut
68000
Foot
74000
Compressor casing external part
76000
Compressor casing, internal part
76040 (in spare parts set)
O-ring gasket
76080
Safety segment
77000
Wall insert
77005 (in spare parts set)
O-ring gasket
77006 (in spare parts set)
O-ring gasket
79000
Diffuser
81000
Filter silencer
82000
Air suction branch, radial
Version 5
HZTL2491_EN
January 2008
12.2 Directory of part numbers
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16
12.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25008
Threaded pin
25009
Ring nut
32001
Thrust bearing
32101
Radial bearing, compressor end
32102
Radial bearing, turbine end
32104
Auxiliary bearing
32105
Floating disc
32106
Axial bearing
42001
Bearing casing
42002
Hood
42011
O-ring gasket
42012 (in spare parts set)
O-ring gasket
42015
Sealing cover
42041 (in spare parts set)
Gasket
42045 (in spare parts set)
Gasket
42059 (in spare parts set)
Hexagon head screw
42064 (in spare parts set)
Hexagon head screw
42295
Non-return valve
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
86506 (in spare parts set)
O-ring gasket
Page 4
January 2008
Directory of part numbers
HZTL2491_EN
12
Version 5
Cartridge group - polygon connection
Reserve and spare parts
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts
12
General view of turbocharger
12.3
Page 5
61001
68000 61035
61037
76000
77005 77006
76040 76080
82000
81000
Version 5
77000
79000
74000
56001 51085
51001
HZTL2491_EN
January 2008
12.3 General view of turbocharger
L_01217
ABB Turbo Systems Ltd
ABB
Operation Manual / TPL85-B14/-B15/-B16 Reserve and spare parts
12
General view of cartridge group
12.4
Page 6
86505
Version 5
25009
32104
32101
32106
25000
32105
43005
32001
43001
42045
42012
42041
HZTL2491_EN
42059
42001
86506
42064
42295
42002
25008
32102
42011
21000
42015
January 2008
12.4 General view of cartridge group
L_00906
ABB Turbo Systems Ltd
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ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland
