ABB TPS 50B01 Operation Manual
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ABB TPS 50B01 Operation Manual

ABB TPS 50B01 Operation Manual

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Operation Manual
Type TPS 50B01
n
Mmax
n
Bmax
Year
ABB Turbocharging
TPS 50B01
840
1/s
800
00270
kg
2021
HT846529
t
750
Mmax
t
710
Bmax
10
50
50
Application according to
the Operation Manual
°C

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Summary of Contents for ABB TPS 50B01

  • Page 1 Operation Manual TPS 50B01 Type TPS 50B01 HT846529 Mmax Mmax °C Bmax Bmax 00270 Application according to Year 2021 the Operation Manual 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 / TPS50 Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................6 Essential information..................... 7 Symbols and definitions ....................9 Turbocharger rating plate ................... 10 CE conformity ........................
  • Page 4 Operation Manual / TPS50 Table of contents Removing the turbocharger..................44 Installing the turbocharger ..................45 Disassembly and assembly .................. 46 Introduction ........................46 Module weights ......................48 Disassembling and assembling turbochargers ............. 49 Axial clearance A and radial clearance B ..............55 Radial clearances N and R....................

  • Page 5: Operation Manual

    1.1 Purpose of this manual Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.

  • Page 6: Layout And Function

    Operation Manual / TPS50 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 1Compressor casing 7Turbine 2Diffuser 8Nozzle ring 3Axial thrust bearing 9Gas inlet casing 4Radial bearing 10Bearing casing 5Radial bearing 11Compressor wheel 6Gas outlet flange © Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021...
  • Page 7 Operation Manual / TPS50 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine consisting of the following main components: ¡ turbine ¡ compressor These are mounted on a common shaft. The exhaust gas from the diesel or gas engine flows through the gas in- let casing (9) and nozzle ring (8) to the turbine (7).

  • Page 8: Intended Use Of The Turbocharger

    The use of the turbocharger is limited to the specific application re- leased at the time of delivery. ABB accepts no liability and rejects all warranty claims for any non-inten- ded applications. © Copyright 2021 . All rights reserved.

  • Page 9: Essential Information

    Only use original parts from ABB. ABB 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 10 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not rel- evant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).

  • Page 11: Symbols And Definitions

    ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Tur- bocharging. See also chapter Contact address and after-sales service. © Copyright 2021 . All rights reserved.

  • Page 12: Turbocharger Rating Plate

    Operation Manual / TPS50 1 Preliminary remarks / 1.6 Turbocharger rating plate 1.6 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder. 02 Turbocharger operating limits during operation Recommended inspec- 3 Inspection interval for plain bearings in 1000 h tion / replacement inter-...

  • Page 13: Ce Conformity

    Operation above the indicated values n can considerably shorten Bmax Bmax the recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. and t normally apply only when running at overload (110%) during Mmax Mmax trials on the engine test bed.

  • Page 14: Safety

    2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...

  • Page 15: Warning Plates On The Turbocharger

    This is the responsibility of the enginebuilder. Warning plates that have been attached to turbochargers by ABB Tur- bocharging must not be removed. Illegible warning plates must be re- placed with new ones. Further information is available from ABB Tur- bocharging Service Stations.

  • Page 16: Safe Operation And Maintenance

    Operation Manual / TPS50 2 Safety / 2.4 Safe operation and maintenance 2.4 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. Work safety and work area safety WARNING Injuries to persons...
  • Page 17 Operation Manual / TPS50 2 Safety / 2.4 Safe operation and maintenance Keep the workplace clean, clear away loose objects and remove obstacles on the floor. Keep the floor, equipment and the turbocharger clean. Have oil binding materials ready at hand and keep oil catch pans ready or in position Eliminate leaks.
  • Page 18 Operation Manual / TPS50 2 Safety / 2.4 Safe operation and maintenance Wear personal protective equipment (PPE) according to the material safety data sheet. Inspect the electric cables for abrasion and damage before and after your cleaning work. Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals.

  • Page 19: Hazards During Operation And Maintenance

    Operation Manual / TPS50 2 Safety / 2.5 Hazards during operation and maintenance 2.5 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly. WARNING Risk of injury Contact with rotating parts can lead to serious injuries.
  • Page 20 Operation Manual / TPS50 2 Safety / 2.5 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful. WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb-...
  • Page 21 Operation Manual / TPS50 2 Safety / 2.5 Hazards during operation and maintenance Hazards due to hot surfaces and substances During operation, turbocharger surfaces and attached parts as well as operating materials (lubricating oil) become hot. The surface temperat- ure is dependent on the effectiveness of the insulation being used. The temperature can become high enough so that it falls into ranges where burns are possible.
  • Page 22 Operation Manual / TPS50 2 Safety / 2.5 Hazards during operation and maintenance WARNING Handling operating and auxiliary materials Swallowing or inhaling vapours of operating and auxiliary materials or contact with them may be harmful to health. Do not breathe in these substances and avoid contact with the skin. Ensure proper ventilation.
  • Page 23 Operation Manual / TPS50 2 Safety / 2.5 Hazards during operation and maintenance Ensure that the work space is adequately ventilated. Seal containers tightly immediately after use and put them away. Collect used working and auxiliary materials safely, store them separ- ately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory reg- ulations.

  • Page 24: Deflagration On Gas Engines

    If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. This in- spection and evaluation must be carried out by an ABB Turbocharging Service Station. 2.7 Lifting loads...
  • Page 25 Operation Manual / TPS50 2 Safety / 2.7 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading. Fasten turbocharger assemblies / components as described in re- spective handling steps.

  • Page 26: Commissioning

    Operation Manual / TPS50 3 Commissioning / 3.1 Oil supply 3 Commissioning 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation. The turbocharger is normally lubricated with oil from the engine oil cir- cuit.
  • Page 27 Operation Manual / TPS50 3 Commissioning / 3.1 Oil supply Oil inlet viscosity and temperature The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet viscosities and oil-inlet temperatures are shown in the following chart. Kinematic viscosity (mm /s = cSt) Oil-inlet temperature (°C) Permissible range CAUTION...

  • Page 28: Inspection Work

    Operation Manual / TPS50 3 Commissioning / 3.2 Inspection work Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. Status for operation Oil pressure in front of turbocharger [bar] Normal operation 2.0 … 4.5 Engine start: cold oil, permissible for maximum 15 ≤ 8.0...
  • Page 29 The first step is to check for leaks in the oil supply to the turbocharger. If this is not in proper condition, contact an ABB Turbocharger service station. © Copyright 2021 . All rights reserved.

  • Page 30: Commissioning After Taking Out Of Operation

    Operation Manual / TPS50 3 Commissioning / 3.3 Commissioning after taking out of operation 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours. 3.3 Commissioning after taking out of operation If provided Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, before gas inlet and after gas outlet.

  • Page 31: Operation

    Operation Manual / TPS50 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running. When the sound pressure level is above 85 dB(A), always wear ear protection.

  • Page 32: Servicing Work

    Despite observance of the service intervals, unusual loads, such as sev- eral start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbochar- ging. © Copyright 2021 . All rights reserved.
  • Page 33 NOTICE Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.

  • Page 34: Stopping The Engine

    4.2.3 Service work in accordance with instructions on rating plate (In general, after 8000 … 16000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Tur- bocharging Service Station. The following work can be carried in prepar- ation.

  • Page 35: Maintenance

    If the coating of dirt is very thick and hard, the compressor can only be cleaned manually when disassembled. This cleaning must be carried out by an ABB Turbocharging Service Station. Cleaning interval The interval between periodic cleaning is very dependent on the operat- ing conditions.
  • Page 36 Cleaning method Cleaning the compressor while in operation is carried out as wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer or the suction branch.
  • Page 37 Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Run engine at load from 50 … 85 %.
  • Page 38 Operation Manual / TPS50 5 Maintenance / 5.2 Cleaning the compressor during operation Procedure for compressor wet cleaning with XC1 Screw plug Pressurized air Valve activator Water Container Operating the water pres- Remove the screw plug (X). sure vessel Fill the vessel with clean water. Replace the screw plug.
  • Page 39 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that the tur- bocharger be inspected and cleaned by an official ABB Turbocharger service station. Cleaning parameters per...

  • Page 40: Troubleshooting

    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 Turbochar- ging Service Station. 6.2 Surging of the turbocharger Turbocharger surging...

  • Page 41: Malfunctions During Operation

    Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.
  • Page 42 6 Troubleshooting / 6.3 Malfunctions during operation Increase in speed Possible causes Elimination Turbochar- Heavily contaminated nozzle Contact an ABB Turbocharging ring (with 4-stroke application) Service Station Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes...
  • Page 43 Contaminated filter silencer Clean it causing excessive loss of pres- sure Compressor / turbine contam- inated Damaged compressor / tur- Contact an ABB Turbocharging bine Service Station Exhaust counterpressure too Clean or repair the boiler or ex- high haust silencer...

  • Page 44: Malfunctions When Stopping

    6 Troubleshooting / 6.4 Malfunctions when stopping 6.4 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbochar- Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbochar- Turbocharger contaminated...

  • Page 45: Removal And Installation

    Operation Manual / TPS50 7 Removal and installation / 7.1 Turbocharger weights 7 Removal and installation 7.1 Turbocharger weights Turbocharger suspension Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible.

  • Page 46: Removing The Turbocharger

    Operation Manual / TPS50 7 Removal and installation / 7.2 Removing the turbocharger 7.2 Removing the turbocharger Disconnect all gas and air lines in accordance with the engine builder’s instructions. Turbocharger without an exhaust gas pipe Fig. 3 Secure the lifting gear to the bearing casing. Loosen the fixing screws (C) on the bearing casing.

  • Page 47: Installing The Turbocharger

    7.3 Installing the turbocharger Remove covers from oil connections. Visually inspect O-ring gaskets of the oil supply and drain pipe (O-ring gaskets for the engine are not delivered by ABB Turbocharging). Inspect the lifting gear. Turbocharger without a gas outlet bend Fig. 4...

  • Page 48: Disassembly And Assembly

    For safety and product liability reasons, work on the cartridge group that is not described in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station. Unqualified work on the cartridge group can lead to total system failure and void the warranty.
  • Page 49 The specified tightening torques of screw connections for turbocharger components must be observed (see section Table of tightening torques). Tightening torques for assembly devices from ABB Unless otherwise described, the screws and nuts of the assembly devices must be secured so they are tight-fitting.

  • Page 50: Module Weights

    ¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value.

  • Page 51: Disassembling And Assembling Turbochargers

    Operation Manual / TPS50 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bochargers 8.3 Disassembling and assembling turbochargers Removing the compressor casing Disconnect all air lines in accordance with engine builder’s instruc- tions. Loosen the V-clamp (72020) and remove the filter silencer or air suc- tion branch.
  • Page 52 Operation Manual / TPS50 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bochargers Loosen the V-clamp (72030) and horizontally move away the com- pressor casing (72000) with the wall insert (77000). Tap the wall insert (77000) out of the compressor casing using a nylon hammer and remove the O-ring (77005).
  • Page 53 Operation Manual / TPS50 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bochargers Installing compressor casing NOTICE Always replace O-rings (see section Spare and customer spare parts) Fit O-rings (42005 and 79005) The hole in the diffuser (79000) must be aligned with the positioning pin (42010) in the bearing flange (42005).
  • Page 54 Operation Manual / TPS50 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bochargers Removing the cartridge group If provided Disconnect all pipes in accordance with engine manufacturer's in- structions. Remove the turbocharger and then the filter silencer as well as the compressor casing (also see the previous chapter).
  • Page 55 Do not damage or shift the gasket rings in the mounting support when fitting the cartridge group. The gasket rings belong to the engine and are not included in the scope of delivery of ABB Turbocharging. Fit V-clamp (52410) and tighten to the specified tightening torque (use torque spanner!).
  • Page 56 Operation Manual / TPS50 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bochargers NOTICE An optimal setting of the V-clamp is achieved by lightly striking the cover clamp with a plastic tip hammer. Fit bearing casing (42001) using the fixing screws (C). Tighten the fixing screws to the tightening torques specified in the following table.

  • Page 57: Axial Clearance A And Radial Clearance B

    Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2021 . All rights reserved.

  • Page 58: Radial Clearances N And R

    Operation Manual / TPS50 8 Disassembly and assembly / 8.5 Radial clearances N and R 8.5 Radial clearances N and R Fig. 6 N and R These are the theoretical values of the radial clearance between the com- pressor wheel and the wall insert and / or turbine wheel and the gas out- let flange.
  • Page 59 Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2021 . All rights reserved.

  • Page 60: Table Of Tightening Torques

    Operation Manual / TPS50 8 Disassembly and assembly / 8.6 Table of tightening torques 8.6 Table of tightening torques Fig. 7 Item Part number Tightening torques [Nm] 72020 / 72030 52410 / 52420 43003 © Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021...

  • Page 61: Taking Out Of Operation

    Operation Manual / TPS50 9 Taking out of operation / 9.1 Shut down turbocharger 9 Taking out of operation 9.1 Shut down turbocharger If the turbocharger is damaged and the engine can be shut down for only a short time for emergency repairs, proceed as follows: Fit the cover plate.
  • Page 62 Operation Manual / TPS50 9 Taking out of operation / 9.1 Shut down turbocharger Fitting the cover plate Close the opening in the gas outlet casing with the cover plate (91000). Secure the cover plate on the gas inlet casing (51000) with the V- clamp (52410) and bolt it tightly for support.
  • Page 63 9 Taking out of operation / 9.1 Shut down turbocharger Cover plate drawing The cover is not supplied by ABB Turbocharging and must be manufac- tured by the operator according to the following drawing. Material: Common structural steel, in compliance with DIN EN 10025-2...

  • Page 64: Mothballing The Turbocharger

    Remove turbocharger. Rotor and bearing parts must be removed by an official ABB Tur- bocharging service station and refitted afterwards. Clean all parts. Oil machined, bright surfaces of steel and cast parts using anticorros- ive oil.

  • Page 65: Taking Out Of Operation For More Than 12 Months

    Operation Manual / TPS50 10 Mothballing the turbocharger / 10.2 Taking out of operation for more than 12 months 10.2 Taking out of operation for more than 12 months If the engine is taken out of service, the following can be done with the turbocharger: ¡...

  • Page 66: Material And Disposal

    11.1 REACH and RoHS Compliance Declaration For Products We hereby confirm that all genuine products, parts and components supplied by ABB Switzerland Ltd, Turbocharging are fully compliant with the requirements of European Union Regulation (EC) 1907/2006 con- cerning the Registration, Evaluation, Authorization and Restriction of...

  • Page 67: Disposing Of Turbocharger Components

    Operation Manual / TPS50 11 Material and Disposal / 11.2 Disposing of turbocharger components 11.2 Disposing of turbocharger components Environmentally compatible disposal of turbocharger components Disposal must be environmentally compatible, professional and in ac- cordance with local regulations. The turbocharger mainly consists of metal (cast-iron materials, steel, nickel-steel alloys, aluminium, bearing brass).

  • Page 68: Spare Parts

    Serial number (HT……) ¡ Designation and part number. Spare parts can be ordered from an official ABB Turbocharging service station. If different design versions have not been taken into consideration in this document, please contact an ABB Turbocharging service station.
  • Page 69 Operation Manual / TPS50 12 Spare parts / 12.1 Ordering spare parts Spare parts kit NOTICE The spare parts kit (97070) is required for the work described in this manual. The parts included in the spare parts kit are available only as a complete set.

  • Page 70: View Of Turbocharger Showing Part Numbers

    Operation Manual / TPS50 12 Spare parts / 12.2 View of turbocharger showing part numbers 12.2 View of turbocharger showing part numbers © Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021...
  • Page 71 Operation Manual / TPS50 12 Spare parts / 12.2 View of turbocharger showing part numbers Part number Description 51000 Turbine casing 52400 Gas outlet flange 52410 V-clamp 52420 V-clamp 72000 Compressor casing 72020 V-clamp 72030 V-clamp 77000 Wall insert 77005 (in spare parts kit) O-ring 77006 (in spare parts kit) O-ring...

  • Page 72: View Of Cartridge Group Showing Part Numbers

    Operation Manual / TPS50 12 Spare parts / 12.3 View of cartridge group showing part numbers 12.3 View of cartridge group showing part numbers © Copyright 2021 . All rights reserved. HZTL2401_EN Rev.A September 2021...
  • Page 73 Operation Manual / TPS50 12 Spare parts / 12.3 View of cartridge group showing part numbers Part number Description 10900 Cartridge group 21000 Shaft 21002 Piston ring 21003 Lock nut 21004 Cup spring 25000 Compressor wheel 32101 Plain bearing bush 32103 Safety ring 32105...
  • Page 74  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

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