Turbocharging Operation Manual TPS48-F32 ABB Turbo Systems Ltd CH 5401 Baden Type TPS48-F32 HT562738 1029 Mmax Mmax °C Bmax Bmax SOLD08 00180 Application according to Year 2013 the Operation Manual made in Switzerland ABB Turbo Systems Ltd...
Definition of mandatory signs Definition of Safety instructions Warning plates on the turbocharger Safe operation and maintenance Hazards during operation and maintenance Use of ABB turbochargers on gas engines Periodic checking of the pressure vessel 2.10 Lifting loads Start-up Oil supply...
Operation Manual This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all warranty claims.
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 8 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (2) in the sight-glass.
NOTICE replacement cartridge group can be placed into operation without any prior 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.
Original parts and accessories are designed especially for the turbocharger supplied by ABB Turbo Systems. It is herewith explicitly stated that original parts and accessories that were not supplied by ABB Turbo Systems have also not been tested and approved by ABB Turbo Systems. NOTICE...
It should be noted that the Operation Manual contains sections and descriptions that are not relevant for the turbocharger supplied. The ABB Turbocharging Service Stations are at your disposal for questions concerning the design version of the supplied turbocharger (see chapter Contact address and after-sales service [➙...
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 Turbocharging Service Stations.
Operation above the indicated values n can considerably shorten the Bmax Bmax 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 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...
Warning plates are attached to the turbocharger at the following places: If warning plates are not present at the intended places or are not legible, then proceed as follows: Order new warning plates from ABB Turbocharging Service Stations. Remove unreadable warning plates.
Safe operation and maintenance Page 23 Safety during start-up / commissioning and operation The turbine casing insulation of the TPS44-F supplied by ABB Turbo Systems is also burst protection. Serious personal injuries or fatal accidents can occur, if the turbine...
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.
Use of ABB turbochargers on gas engines ABB turbochargers can withstand a deflagration with a transient pressure increase of 12 bar. A maximum of 11 bar has been measured during deflagration trials on engines with flame traps. The practical operating experience of well-known manufacturers of gas engines reinforces this value.
Page 32 vessel 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 Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Systems. 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 NOTICE 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.
Service work in accordance with instructions on rating plate (In general, after 8000 … 12000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Turbocharging Service Station. The following work can be carried in preparation.
Cleaning method To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the NOTICE cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
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. NOTICE The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions.
Cleaning method Cleaning the compressor while in operation is carried out as wet cleaning. This cleaning method has been tested and approved by ABB Turbo Systems. To clean the compressor stage during operation, water is injected in front Principle of wet cleaning of the compressor wheel through an injection pipe fitted in the filter silencer or the suction branch.
Operating state prerequisites for cleaning compressor with XC1 To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Run engine at load from 50 … 85 %.
NOTICE If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per Product...
Maintenance Turbine cleaning during operation Page 62 Choice of cleaning method If you need information about the choice of cleaning method (short / long), you can contact the engine builder or an official ABB NOTICE Turbocharger service station. 5.3.2 Prerequisites...
Operation Manual / TPS44-F.. - TPS61-F.. Maintenance Turbine cleaning during operation Page 63 Recommended operating state for turbine wet cleaning The following operating state has been tested and is approved by ABB Turbo Systems: Characteristic / component Conditions short long...
Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings ...
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.
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging service station and rectified. Have components inspected for damage and, if necessary, replaced ...
As a result, the voltage amplitude of the speed signal decreases, which can cause problems for the evaluation electronics. This problem is eliminated by removing the gasket. Defective sensor Contact an ABB Turbocharging Service Station Measured Contaminated The sensor tip is magnetic and can thus...
Visually inspect O-ring seals of oil supply and drain pipe (O-ring seals for engine are not delivered by ABB Turbo Systems). Fasten lifting gear to bearing casing. If a gas outlet manifold is provided, sling lifting gear around it ...
only by trained personnel from an ABB Turbocharging Service Station. 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.
The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.) Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.
Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely (not supplied by ABB). Swivel lifting eye Product Thread...
Nozzle ring press fit for single inlet turbine casing If the calculated value (PD) is less than 0.1 mm, an official ABB Turbocharging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ...
Nozzle ring press fit for multiple inlet turbine casing If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbocharging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ...
If provided, fit the C-ring (52408). Fit the gas outlet flange (52400). In the case of gas outlet bends (51100) from ABB Turbo Systems: always replace the gasket (52406) (see the chapter entitled Spare parts). Apply high-temperature grease to contacting surfaces and threads.
Shutting down the turbocharger Page 115 Cover plate drawing The cover is not supplied by ABB Turbo Systems and must be manufactured by the operator according to the following drawing. Material: Common structural steel, according to DIN EN 10025-2 Product ±0.5...
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: 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. ...
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 individual parts.