Page 1 Operation Manual TPL69-A10 ABB Turbo Systems Ltd CH 5401 Baden Type TPL69-A10 HT842690 Mmax Mmax °C Bmax Bmax 01780 Application according to Year 2017 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly 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.
Page 3: Table Of Contents
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Table of contents Page 1 Table of contents Preliminary remarks Purpose of this manual Layout and function Intended use of the turbocharger Storage of new turbochargers and spare parts Essential information...
Page 4 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Table of contents Page 2 Maintenance Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbine blades and nozzle ring in operation Cleaning components mechanically Troubleshooting...
Page 5 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Table of contents Page 3 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...
Page 7: Preliminary Remarks
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.
Page 8: Layout And Function
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Layout and function Page 6 Layout and function 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush...
Page 9 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Layout and function Page 7 Mode of operation The turbocharger is a turbomachine and consists of the following main components:  Turbine  Compressor These are both mounted on a common shaft.
Page 10: Intended Use Of The Turbocharger
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.
Page 11: Storage Of New Turbochargers And Spare Parts
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Storage of new turbochargers and Page 9 spare parts Storage of new turbochargers and spare parts 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).
Page 12 Page 10 spare parts 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.
Page 13: Essential Information
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Essential information Page 11 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.
Page 14 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 15: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Turbo- charging Service Stations.
Page 16: Turbocharger Rating Plate
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Turbocharger rating plate Page 14 Turbocharger rating plate Operating limits Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the en- ginebuilder.
Page 17 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.
Page 18: Contact Information
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Contact information Page 16 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.
Page 19: Safety
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Introduction Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate.
Page 20: Definition Of Mandatory Signs
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Definition of mandatory signs Page 18 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear against mechanical hazards To be worn according to the specific work...
Page 21: Warning Plates On The Turbocharger
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Warning plates on the turbocharger Page 19 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones.
Page 22: Safe Operation And Maintenance
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Safe operation and maintenance Page 20 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
Page 23 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Safe operation and maintenance Page 21 Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area.  Remove any obstacles and objects lying around.
Page 24 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Safe operation and maintenance Page 22 Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as inspec-  tion work and observe inspection intervals.
Page 25: Hazards During Operation And Maintenance
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Hazards during operation and Page 23 maintenance Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the turbo- charger if it has been installed properly.
Page 26 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Hazards during operation and Page 24 maintenance Hazards due to noise The development of noise during operation is influenced by the installation and operating conditions. Noise with a sound pressure level exceeding 85 dB(A) is harmful.
Page 27 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Hazards during operation and Page 25 maintenance Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work. Oils, greases, coolants, cleaning agents and solvents, acids, etc.
Page 28 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Hazards during operation and Page 26 maintenance Heed the instructions for use, safety data sheets and hazard notices  on the containers of the operating and auxiliary materials. Wear appropriate protective clothing.
Page 29: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 30: Lifting Loads
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Safety Lifting loads Page 28 Lifting loads Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. WARNING Loads must always be fastened to technically perfect lifting gear with ...
Page 31: Start-Up
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Start-up Oil supply Page 29 Start-up Oil supply A carefully designed and installed oil supply, which functions in all possi- ble operational conditions, is an important prerequisite for trouble-free tur- bocharger operation.
Page 32 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Start-up Oil supply Page 30 Oil pressure The oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
Page 33 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Start-up Oil supply Page 31 Oil temperature Lubricating oil temperature at the inlet Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.
Page 34: Inspection Work
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Start-up Inspection work Page 32 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.
Page 35 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 36: Commissioning After Taking Out Of Operation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Start-up Commissioning after taking out of Page 34 operation Commissioning after taking out of operation Remove cover plates (blind flanges) between compressor casing out- If provided  let and charge air duct, before gas inlet and after gas outlet.
Page 37: Operation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Noise emissions Page 35 Operation Noise emissions Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. WARNING Always wear ear protection when the engine is running.
Page 38 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Noise emissions Page 36 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line ©...
Page 39: Servicing Work
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Servicing work Page 37 Servicing work Service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and functional checks. It is then possible for changes to the turbocharger to be identified and rectified. In this way, it can be ensured that the turbocharger remains in full working order.
Page 40 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Servicing work Page 38 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the turbo- charger performance. The following operating data and measured values must be entered regu- larly in the engine manufacturer's engine logbook: ...
Page 41  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.
Page 42: Replacement Intervals For Turbocharger Components
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Replacement intervals for turbocharger Page 40 components Replacement intervals for turbocharger com- ponents The recommended replacement intervals for the compressor and turbine Rotating components wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components.
Page 43 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Replacement intervals for turbocharger Page 41 components Parameters influencing rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Turbine cleaning frequency  Procedure for turbine cleaning ...
Page 44: Speed Measurement
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Speed measurement Page 42 Speed measurement A speed measuring system permits continuous monitoring of the turbo- charger speed. Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 45 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. 4.4.2...
Page 46 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Speed measurement Page 44 4.4.3 Replacing the speed sensor Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C.
Page 47: Underpressure Measurement On Filter Silencer
Page 45 silencer Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for meas- uring the negative pressure at the filter silencer. The measurement can be used for the following purposes:  To measure the correction factor for calculating the turbocharger effi- ciency during the engine acceptance test.
Page 48: Stopping The Engine
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Operation Stopping the engine Page 46 Stopping the engine Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further 10 ...
Page 49: Maintenance
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Foreword to Maintenance Page 47 Maintenance Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble- free.
Page 50: Cleaning The Filter Silencer
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 48 Cleaning the filter silencer 5.2.1 Filter silencer with tension band 81265 Filter ring (if provided) 81266 Cover grid 81270 Tension band 81136 Absorption segment...
Page 51 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 49 Removing and cleaning the filter silencer Remove filter ring (81265). If provided  Rinse the filter ring (81265) using water with detergent additive or, if it ...
Page 52 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 50 5.2.2 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid...
Page 53 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 51 Removing and cleaning filter silencer Remove filter strip (81265). If provided  Rinse filter strip (81265) using water with detergent additive or, if very ...
Page 54 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 52 Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments  (81136) into the sheet metal coverings (81137). Bend sheet metal coverings (81137) back to original shape.
Page 55 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the filter silencer Page 53 Join connecting rods (81269) using screws (81272). When tightening  the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten...
Page 56: Cleaning The Compressor During Operation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the compressor during Page 54 operation Cleaning the compressor during operation These instructions for wet cleaning only apply when cleaning is carried out Approval by enginebuilder with clean water and under the precondition that the enginebuilder ap- proves the process.
Page 57 Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. To clean the compressor stage during operation, water is injected in front...
Page 58 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the compressor during Page 56 operation 5.3.1 Wet cleaning with orifice plate on filter silencer (XC2) Compressor wet cleaning operation with XC2 Trigger water injection according to the specifications of the en- ...
Page 59 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the compressor during Page 57 operation 5.3.2 Wet cleaning using external water-pressure vessel (XC3) Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been...
Page 60 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning the compressor during Page 58 operation Screw in sealing plug (X).  Push the valve activator (Y) against the spring and hold it for 10 ... 15 ...
Page 61: Cleaning Turbine Blades And Nozzle Ring In Operation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning turbine blades and nozzle ring Page 59 in operation Cleaning turbine blades and nozzle ring in operation The combustion of heavy fuel oil in diesel engines contaminates the tur- bine blades and nozzle rings of turbochargers.
Page 62 When cleaning the turbine components during operation, use wet clean- Cleaning method ing. This cleaning method has been tested and approved by ABB Turbo Systems. Prerequisites for wet cleaning are that the engine builder approves the process and his instructions are followed.
Page 63 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning turbine blades and nozzle ring Page 61 in operation 5.4.1 Wet cleaning turbine and nozzle ring during operation Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap-...
Page 64 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning turbine blades and nozzle ring Page 62 in operation Layout of cleaning pipes Wet cleaning procedure for turbine during operation Meet prerequisites and operating state requirements without fail before ...
Page 65 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning turbine blades and nozzle ring Page 63 in operation To obtain the correct water flow rate, a certain pressure in the water pipe Recommendation for is necessary (see table Cleaning parametersTPL-C: 3 nozzles - Cleaning water pressure parameters for wet cleaning of turbine and nozzle ring).
Page 66 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning turbine blades and nozzle ring Page 64 in operation Wet cleaning parameters for turbine and nozzle ring Table of cleaning Product Maximum temper- Injection time Water flow rate per turbo-...
Page 67: Cleaning Components Mechanically
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 65 Cleaning components mechanically 5.5.1 Introduction Compressor wheels can be heavily contaminated by badly filtered intake air, as can turbines by heavy fuel oil operation or coked oil. Such contam-...
Page 68 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 66 Turbine-end, non-rotating parts 5.5.2 Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.
Page 69 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 67 Spray cleaned surfaces with penetrating oil. Do not spray the outer  surfaces of the turbocharger. Dispose of contaminated water and cleaning agent in accordance with ...
Page 70 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 68 Clean compressor wheel with a scouring cloth or soft brush soaked in  water with household cleaning agent. Do not use any wire brushes! Dry the compressor wheel and the gap between the compressor and ...
Page 71 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 69 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure two lifting loops with swivel lifting eyes in the lower push-off threads and suspend from a second crane.
Page 72 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 70 Cartridge group with two side suspension points Or use two swivel lifting eyes at top. Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation.
Page 73 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 71 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane. 5. Tighten chain block until entire cartridge group is suspended from first crane.
Page 74 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 72 Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. NOTICE Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
Page 75 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Maintenance Cleaning components mechanically Page 73 Remove contamination manually with a soft brush or wire brush.  Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbocharger...
Page 77: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 78: Surging Of The Turbocharger
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Surging of the turbocharger Page 76 Surging of the turbocharger Turbocharger surging Possible causes Elimination Engine Guard in front of the turbo- Clean / replace it charger is contaminated or...
Page 79: Malfunctions During Operation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Malfunctions during operation Page 77 Malfunctions during operation Lubricating oil pressure too low Possible causes Elimination Engine Oil filter heavily contaminated Clean it Defective oil pump in lubricating Check / replace it...
Page 80 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Malfunctions during operation Page 78 Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Elimination Engine Malfunctioning injection sys- Repair it or contact the manufac-...
Page 81 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Malfunctions during operation Page 79 Charge air pressure too low Engine performance and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Air receiver leaking Make repairs...
Page 82: Malfunctions When Stopping
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Malfunctions when stopping Page 80 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor...
Page 83: Speed Measurement System
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Troubleshooting Speed measurement system Page 81 Speed measurement system Possible causes Elimination Signal amplitu- Fitting error The screw plug for the sensor is fitted with a de non existent gasket.
Page 85: Removal And Installation
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Removal and installation Turbocharger weights Page 83 Removal and installation Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and in- stalling the turbocharger. The following weight specification is the heaviest variant possible.
Page 86: Removing The Turbocharger
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Removal and installation Removing the turbocharger Page 84 Removing the turbocharger Disconnect all gas, air and oil pipes in accordance with the en-  ginebuilder’s instructions. Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing.
Page 87 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Removal and installation Removing the turbocharger Page 85 Ribs (01) not in the middle at the top:  Completely remove the bearing casing insulation (02) and place a  sling around the bearing casing.
Page 88: Installing The Turbocharger
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Removal and installation Installing the turbocharger Page 86 Installing the turbocharger Remove cover from oil connection.  Inspect lifting gear.  Fasten separate lifting gear to each of two ribs on bearing casing pro- ...
Page 89: Disassembly And Assembly
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Introduction Page 87 Disassembly and assembly Introduction Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station.
Page 90 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Introduction Page 88 Tightening torques for turbocharger components The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.)
Page 91: Module Weights
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Module weights Page 89 Module weights The specified weights of individual parts or assemblies are guides round- ed off to the next highest value. Assemblies Weights [kg]...
Page 92 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Module weights Page 90 Complete compressor casing internal part Weights [kg] TPL69-A TPL73-A TPL77-A 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.
Page 93: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing and fitting filter silencer or air Page 91 suction branch Removing and fitting filter silencer or air suc- tion branch Disconnect all air lines / ducts in accordance with engine builder’s in- ...
Page 94 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing and fitting filter silencer or air Page 92 suction branch Remove insulation where necessary. Removing filter silencer  Fit swivel lifting eye (90231) to filter silencer.
Page 95: Axial Clearance
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Axial clearance Page 93 Axial clearance Physical hazards due to sharp edges on compressor wheel The compressor wheel has sharp edges which can result in injury. Wear safety gloves.
Page 96: Removing Cartridge Group
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 94 Removing cartridge group Locked safety segments (76080) during disassembly Observe the maximum tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (76080).
Page 97 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 95 Unscrew and remove nuts (74027) together with washers (74018).  Remove six studs (74026/74029) in the upper section and fit four ...
Page 98 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 96 Loop the lifting device around the rear of the flange (F).  Carefully rotate the compressor casing internal part with wall insert ...
Page 99 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 97 Remove screws (76002).  Loop lifting gear around diffuser (79000) and remove diffuser.  Carefully press off the wall insert (77000) using the press-off screws ...
Page 100 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 98 Fasten the lifting device (90190) with shackle (90195) to the compres-  sor casing external part (74000) and secure it to the crane.
Page 101 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 99 Unplug cable connector (86515) and unscrew speed sensor (86505)  with O-ring (86506). Disconnect oil pipes in accordance with enginebuilder's instructions. ...
Page 102 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Removing cartridge group Page 100 Remove the O-ring (42012).  Remove the three screws (61059) together with their Verbus Ripp®  washers (61058). Attach one lifting gear each to the two fins of the bearing casing pro- ...
Page 103: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and installing the turbine Page 101 diffuser and nozzle ring Dismantling and installing the turbine diffuser and nozzle ring Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins.
Page 104 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and installing the turbine Page 102 diffuser and nozzle ring Position clamp (90921) over stud (61036) until it lies flat against inner  radius of gas outlet casing.
Page 105 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and installing the turbine Page 103 diffuser and nozzle ring Replace two screws (61056) in the gas outlet casing with two guide  studs (90320) in the upper section of the turbine diffuser (63000).
Page 106 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and installing the turbine Page 104 diffuser and nozzle ring Fasten the holder (90490) to the gas outlet casing.  Pull the nozzle ring (56001) in the forward direction, fasten it to the lift- ...
Page 107: Installing Cartridge Group
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 105 Installing cartridge group Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing. When the cartridge group, the...
Page 108 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 106 If the rotor blades have insufficient or no clearance, the blades and cas- ing could be damaged. Check that the blades do not rub on the turbine diffuser by rotating ...
Page 109 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 107 Fasten set-down compressor casing external part (74000) to crane us-  ing lifting device (90190) and shackle (90195). Screw three press-off nuts (61090) onto bearing casing studs, equally ...
Page 110 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 108 Fit O-rings (77005 and 77006) to wall insert (77000).  Fit lifting gear and swivel lifting eyes (90230).  Align wall insert (77000) with threaded holes in compressor casing in- ...
Page 111 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 109 Secure the lifting device (90190) and the shackle (90195) to the rear of  the flange (F). Carefully turn compressor casing internal part complete with wall insert ...
Page 112 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Installing cartridge group Page 110 Check that nuts (90458) on three safety segments have been tight-  ened. Fasten lifting device (90190) complete with shackle (90195) to front ...
Page 113 Put the nuts (90458) back in the toolbox.  Measure and note axial clearance (see section Axial clearance).  If the axial clearance (A) is out of tolerance, an ABB Turbocharger ser- vice station must be contacted. CAUTION Remove four nuts (74027) and washers (74018) again.
Page 114: Dismantling And Fitting Nozzle Ring At Turbine End
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 112 turbine end Dismantling and fitting nozzle ring at turbine If only the nozzle ring must be dismantled, this can be done at the tur- bine end.
Page 115 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 113 turbine end Flange connection disassembly Remove two hexagon-head screws (61044) together with Verbus  Ripp® washers (61043) from the bottom section and replace them with two studs (90177).
Page 116 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 114 turbine end Remove holder (90175) and then nozzle ring (56001). TPL73 – TPL77  Segment connection disassembly Figure 1 Remove screws (61044) and segments (51012).
Page 117 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 115 turbine end Flange connection assembly Carefully clean grooves and contact surfaces on the casing and keep  them free of metal chips.
Page 118 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 116 turbine end Segment connection assembly Carefully clean slots and contact surfaces of the casings and keep  them free of metal chips.
Page 119 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 117 turbine end Check Collars (C) of segments (51012) must be in slot (S).  © Copyright 2016 ABB. All rights reserved.
Page 120 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 118 turbine end Tightening procedure and order: Segment connection Flange connection Tighten screws crosswise Begin with two middle screws of ...
Page 122: Table Of Tightening Torques
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Table of tightening torques Page 120 Table of tightening torques © Copyright 2016 ABB. All rights reserved.
Page 123 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Table of tightening torques Page 121 Tightening torques [Nm] Item Part number TPL69-A TPL73-A TPL77-A 82005 M16x1.5 M16x1.5 M16x1.5 76002 74027 With washer 61036 74026/74029 61044 61056...
Page 125: Taking Out Of Operation At Short Notice
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Possibilities for emergency repair Page 123 Taking out of operation at short notice Possibilities for emergency repair Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 126: Locking The Rotor
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Locking the rotor Page 124 Locking the rotor A locked rotor must be removed after the turbocharger repair and checked for unbalance. CAUTION...
Page 127 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Locking the rotor Page 125 Table of tightening tor- Part number TPL69-A TPL73-A TPL77-A ques [Nm] 74027 94006 94007 Carried out work as described in the chapter Disassembly and assem- bly.
Page 128 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Locking the rotor Page 126 Fit locking flange (94003) using nuts (74027) and then screws (94007 /  94006) and tighten according to Table of tightening torques.
Page 129 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Locking the rotor Page 127 Compressor type CV 20 Make sure all components are clean and free from grease. CAUTION Push intermediate rings (94001 and/or 94002) and assembly- ...
Page 130 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Locking the rotor Page 128 Further measures and information for operation with blocked rotor for 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as a naturally-aspirated engine according to the engine builder's instructions.
Page 131: Fit Cover Plate
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Fit cover plate Page 129 Fit cover plate The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 132 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Fit cover plate Page 130 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2016 ABB. All rights reserved.
Page 133 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Fit cover plate Page 131 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).
Page 134 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Fit cover plate Page 132 Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary.
Page 135: Blocking The Inlets And Outlets
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Blocking the inlets and outlets Page 133 Blocking the inlets and outlets Shut off the lubricating oil supply to the turbocharger. CAUTION Shut off compressor casing outlet, gas inlet and gas outlet by fitting ...
Page 137: Mothballing The Turbocharger
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 135 up to 12 months Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months 10.1...
Page 138 Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
Page 139: Taking The Engine Out Of Operation For More Than 12 Months
 The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station.  The turbocharger is removed completely, either as a whole or in indi- vidual parts.
Page 141: Disposing Of Turbocharger Components
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disposing of turbocharger components Taking the engine out of operation for 10.2 Page 139 more than 12 months Disposing of turbocharger components Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Page 143: Spare Parts
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts Ordering spare parts 12.1 Page 141 Spare parts 12.1 Ordering spare parts 12.1 When making inquiries or ordering spare parts, the following data must be specified:  Turbocharger type ...
Page 144 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts Ordering spare parts 12.1 Page 142 TPL73-A Quantity Description Part number Hexagon-head screw 42059 / 42064 Verbus Ripp® washer 42058 / 42063 Hexagon-head screw 61044 / 61056 / 61059 Verbus Ripp®...
Page 145 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts Ordering spare parts 12.1 Page 143 Spare parts set (97078) for turbine cleaning system (if provided) Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system.
Page 146: View Of Turbocharger With Part Numbers
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts View of turbocharger with part numbers 12.2 Page 144 12.2 View of turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 147 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts View of turbocharger with part numbers 12.2 Page 145 Part number Description 10900 Cartridge group 42012 (in customer spare part set) O-ring 42124 (in customer spare part set)
Page 148: View Of Turbine Cleaning System With Part Numbers (Optional)
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts View of turbine cleaning system with 12.3 Page 146 part numbers (optional) 12.3 View of turbine cleaning system with part numbers (optional) 12.3 Part number Description 51229 Cleaning pipe...
Page 149 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

ABB TPL69-A10 Operation Manual

1 Preliminary Remarks

2 Safety

3 Start-Up

4 Operation

5 Maintenance

6 Troubleshooting

7 Removal and Installation

8 Disassembly and Assembly

9 Taking out of Operation at Short Notice

10 Mothballing the Turbocharger

11 Disposing of Turbocharger Components

12 Spare Parts

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