ABB HT843602 Manuel utilisateur

Operation Manual

ABB Turbocharging 

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPS 57E01 HT843602

nMmax 716 t Mmax 650

nBmax 680 t Bmax 620

1/s °C

SSDF02 00410 12 50 50

Year 2017 made in Switzerland

Application according to

the Operation Manual

HZTL2410 English

TPS 57E01

Original Operation Manual

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-

ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon

between the engine builder and ABB.

Note: Replacement intervals of components depends on the load proﬁle, turbine inlet temperature, suction air temperature and

turbocharger speed. In case the operation conditions differs signiﬁcantly from what is considered to be normal for the cur-

rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,

high temperatures and high speed lower the life of components.

Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Table of contents

Page 1

September 2016HZTL2410_ENRevision E

Table of contents

Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Intended use of the turbocharger

1.4

Storage of new turbochargers and spare parts

1.5

Essential information

1.6

Symbols and definitions

1.7

Turbocharger rating plate

1.8

Contact information

Safety

2.1

Introduction

2.2

CE conformity

2.3

Definition of mandatory signs

2.4

Definition of Safety instructions

2.5

Warning plates on the turbocharger

2.6

Safe operation and maintenance

2.7

Hazards during operation and maintenance

2.8

Deflagration on gas engines

2.9

Periodic checking of the pressure vessel

2.10

Lifting loads

Commissioning

3.1

Oil supply

3.2

Inspection work

3.3

Commissioning after taking out of operation

Operation

4.1

Noise emissions

4.2

Servicing work

4.3

Expected exchange intervals

4.4

Speed measurement

4.5

Stopping the engine

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Table of contents

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September 2016HZTL2410_ENRevision E

Maintenance

5.1

Foreword to Maintenance

5.2

Cleaning the compressor during operation

5.3

Turbine cleaning during operation

5.4

Cleaning components mechanically

Troubleshooting

6.1

Malfunctions when starting

6.2

Surging of the turbocharger

6.3

Malfunctions during operation

6.4

Malfunctions when stopping

6.5

Speed measurement system

Removal and installation

7.1

Transport

7.2

Turbocharger weights

7.3

Remove the turbocharger

7.4

Installing the turbocharger

Disassembly and assembly

8.1

Introduction

8.2

Module weights

8.3

Disassembling and assembling turbocharger

8.4

Axial clearance A and radial clearance B

8.5

Radial clearances N and R

8.6

Table of tightening torques

Taking out of operation

9.1

Shutting down the turbocharger

Mothballing the turbocharger

10.1

Taking the engine out of operation for up to 12 months

10.2

Taking the engine out of operation for more than 12 months

Disposing of turbocharger components

Spare parts

12.1

Ordering spare parts

12.2

View of turbocharger showing part numbers

12.3

View of cartridge group showing part numbers

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Purpose of this manual

1.1

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September 2016HZTL2410_ENRevision E

Preliminary remarks

Purpose of this manual

1.1

This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-

charger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the turbo-

charger supplied by ABB Turbo Systems and to use it as intended.

It provides important information in order that the turbocharger can be op-

erated safely, correctly and efficiently.

This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-

stalled on it.

Availability of operation manual

An operation manual must be available at all times at the place where the

turbocharger is used.

Everyone who operates or works on the turbocharger must have first read

and understood the operation manual.

1.1

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Layout and function

1.2

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September 2016HZTL2410_ENRevision E

Layout and function

1.2

Suction branch / filter silencer 8

Gas outlet flange

Compressor casing 9

Nozzle ring

Diffuser 10

Turbine casing

Bearing casing 11

Turbine-end bearing flange

Axial thrust bearing 12

Compressor-end bearing flange

Radial plain bearing (visible

only at turbine end)

Compressor wheel

Turbine

1.2

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Layout and function

1.2

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September 2016HZTL2410_ENRevision E

Mode of operation

The turbocharger is a turbomachine consisting of the following main com-

ponents:

Turbine

Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine cas-

ing (10) and the nozzle ring (9) to impinge on the turbine (7).

The turbine (7) uses the energy contained in the exhaust gas to drive the

compressor wheel (13). The compressor draws in fresh air, compresses it

and then forces it into the engine's cylinders.

The exhaust gases escape into the ambient air through the exhaust gas

pipe, which is connected to the gas outlet flange (8).

The air, which is necessary for operation of the diesel or gas engine and

is compressed in the turbocharger, is drawn into the compressor wheel

(13) through the suction branch or filter silencer (1). It then passes

through the diffuser (3) and leaves the turbocharger through the outlet on

the compressor casing (2).

The rotor runs in two radial plain bearings (6), which are located in the

bearing flanges (11/12) between the compressor and the turbine. The axi-

al thrust bearing (5) is located between the two radial plain bearings.

The bearings are connected to a central lubricating oil duct which is sup-

plied by the engine's lubricating oil circuit. The oil outlet is always at the

lowest point of the bearing casing (4).

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Intended use of the turbocharger

1.3

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September 2016HZTL2410_ENRevision E

Intended use of the turbocharger

1.3

NOTICE

This turbocharger supplied by ABB Turbo Systems has been developed

for use on diesel engines to generate the volume of air and the charg-

ing pressure required to operate the engine.

The engine builder has provided ABB Turbo Systems with information

regarding the intended use of the engine, from which the operating lim-

its specific to the turbocharger shown on the rating plate (such as oper-

ating speeds, temperatures, exchange intervals / replacement intervals)

have been derived.

If it is

used

in conjunction

with a gas engine

, the engine must

not

be in-

stalled in a potentially

explosive environment

, and precautionary

measures must be taken to ensure that the machine room as a whole is

classified as

not potentially explosive

Any other use will be regarded as a special application which must first

be discussed with ABB Turbo Systems. The manufacturer accepts no

liability for other applications. If it is used otherwise, ABB Turbo Sys-

tems reserves the right to reject all warranty claims.

This turbocharger was built according to state-of-the-art technology and is

operationally safe according to recognised safety regulations.

WARNING

Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper

use may cause damage to the machine.

The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-

ing and repair conditions specified by the manufacturer. Disposal regula-

tions set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's manual.

It may be used only for the intended purpose and operated in compliance

with the operation manual.

Malfunctions which could affect safety must be eliminated immediately.

The manufacturer accepts no liability for any damage resulting from unau-

thorised alterations to the turbocharger.

1.3

State of the art

Perfect condition

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Storage of new turbochargers and

spare parts

1.4

Page 7

September 2016HZTL2410_ENRevision E

Storage of new turbochargers and spare

parts

1.4

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbo Systems can be stored

in sealed packaging without additional mothballing measures for up to 6

months from the date of delivery (marked by the VCI label on the package).

olatile

orrosion

nhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and

no condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6 months (VCI)

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-

stances Ordinance. Nevertheless, the following points are to be ob-

served when handling VCIs:

Ensure good room ventilation.

Do not eat, drink or keep food at the workplace while working with

VCIs.

Wear safety gloves.

Clean hands and face after working with VCIs.

For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

Open the package.

Remove the VCI corrosion protection emitter from the package and

replace it with a new, identical VCI corrosion protection emitter. New

VCI corrosion protection emitters can be obtained at

www.branopac.com.

Dispose of the old VCI corrosion protection emitter in an environmen-

tally compatible manner, professionally and in accordance with local

regulations.

Seal the package. The better the external seal is designed, the more

permanent the protection.

1.4

Operation Manual / TPS48-D/E.. - TPS61-D/E..

Preliminary remarks

Storage of new turbochargers and

spare parts

1.4

Page 8

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September 2016HZTL2410_ENRevision E

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Tur-

bo Systems for prolonged storage. The package is equipped with a hyg-

rometer (see illustration).

The following measures are required every 6 months:

Check the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When

the display field has changed colour at the 70% level, the maximum

permissible humidity has been exceeded. In this case the turbocharger

or rotor must be inspected by an ABB Turbocharging Service Station

and repacked.

Inspect the package for damage. If the package is damaged, the tur-

bocharger or cartridge group must be inspected by an ABB Turbo-

charging Service Station and repacked.

After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:

Inspect the components

Exchange the desiccant agent

Repackage the components.

NOTICE

Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour

and the package is undamaged, the replacement turbocharger or re-

placement cartridge group can be placed into operation without any pri-

or testing by an ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from

the VCI package.

To avoid the formation of condensation, the surroundings and the content

of the package must have the same temperature during unpacking.

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