Operation Manual TPL69-A32 ABB Turbo Systems Ltd CH 5401 Baden Type TPL69-A32 HT842870 Mmax Mmax °C Bmax Bmax 01780 Application according to Year 2017 the Operation Manual made in Switzerland ABB Turbocharging...
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.
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.
Any other use is considered to be a special application, which must first be clarified with ABB Turbo Systems. The manufacturer accepts no lia- bility for any other type of use. If the equipment is used for any other purpose, ABB Turbo Systems reserves the right to reject all warranty claims.
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 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 hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
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.
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.
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.
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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. ABB Turbo Systems Ltd Bruggerstrasse 71a...
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. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
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. Further information is available from ABB Turbocharging service stations.
Wear safety gloves against thermal risks. Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
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.
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.
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys- tems. Service inspection after 5 years...
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.
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...
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...
If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor Product...
Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Engine load 50 ... 85% ...
If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharg- ing Service Station. Cleaning parameters per turbocharger compressor...
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.
Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap- proved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced ...
The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clari- fied by the operator.
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.
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
CAUTION Only carry out those tasks that are described in this chapter. Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s ...
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.
Turbocharger type Serial number (HT……) Description 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.