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ABB HT564962 Operation Manual

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Operation Manual
Type TPL65VA33
n
Mmax
n
Bmax
Year
ABB Turbocharging
TPL65VA33
ABB Turbo Systems Ltd
CH 5401 Baden
503
1/s
486
01210
kg
2016
made in Switzerland
HT564962
t
650
Mmax
t
620
Bmax
35
50
50
Application according to
the Operation Manual
°C

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  • Page 1 Operation Manual TPL65VA33 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65VA33 HT564962 Mmax Mmax °C Bmax Bmax 01210 Application according to Year 2016 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

    Periodic checking of the pressure vessel Lifting loads Commissioning Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement Emergency operation TPL..VA Stopping the engine © Copyright 2015 ABB. All rights reserved.
  • Page 4 Installing cartridge group 8.10 Table of tightening torques Taking out of operation at short notice Possibilities for emergency repair Fitting the cover plate Blocking the inlets and outlets Turbocharger bypass Mothballing the turbocharger © Copyright 2015 ABB. All rights reserved.
  • Page 5 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 with part numbers 12.3 View of cartridge group with part numbers © Copyright 2015 ABB. All rights reserved.

  • Page 7: Preliminary Remarks

    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.

  • Page 8: Layout And Function

    09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Air outlet casing 07 Gas inlet casing © Copyright 2015 ABB. All rights reserved.
  • Page 9 In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing. © Copyright 2015 ABB. All rights reserved.
  • Page 10 Operation Manual / TPL65VA32/33 Preliminary remarks Layout and function Page 8 Additional function TPL..V. These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring. © Copyright 2015 ABB. All rights reserved.

  • Page 11: 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 Systems reserves the right to reject all warranty claims.

  • Page 12: Storage Of New Turbochargers And 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 13 Page 11 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 (02) in the sight-glass.

  • Page 14: Essential Information

    The fault must be reported to the person or department responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems. NOTICE © Copyright 2015 ABB. All rights reserved.
  • Page 15 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 authorised personnel.
  • Page 16 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant 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 17: 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 Turbocharging Service Stations.

  • Page 18: Turbocharger Rating Plate

    Replacement interval for compressor in 1000 h turbocharger components Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction © Copyright 2015 ABB. All rights reserved.
  • Page 19 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 insulation of the gas outlet casing.

  • Page 20: Contact Information

    Operation Manual / TPL65VA32/33 Preliminary remarks Contact information Page 18 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 AG Bruggerstrasse 71a...

  • Page 21: Safety

    Page 19 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...

  • Page 22: Ce Conformity

    Operation Manual / TPL65VA32/33 Safety CE conformity Page 20 CE conformity Information ABB turbochargers fulfil Directive 2006/42/EC on machinery and are considered partly completed machinery in the sense of Article 2 g. © Copyright 2015 ABB. All rights reserved.

  • Page 23: Definition Of Mandatory Signs

    To be worn according to the specific work Safety glasses Safety goggles Safety gloves against Respiratory mask against - mechanical hazards - dust - chemical hazards - gases - heat hazards Safety helmet Ear protection © Copyright 2015 ABB. All rights reserved.

  • Page 24: Definition Of Safety Instructions

    Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2015 ABB. All rights reserved.

  • Page 25: Warning Plates On The Turbocharger

    Warning plates on the turbocharger Page 23 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Systems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.

  • Page 26: Safe Operation And Maintenance

    Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2015 ABB. All rights reserved.
  • Page 27 Protect the floor against unintentional penetration of detergents or  solvents before starting cleaning operations. Wear appropriate protective clothing.  Inspect the electric cables for abrasion and damaged areas before and  after your cleaning work. © Copyright 2015 ABB. All rights reserved.
  • Page 28 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2015 ABB. All rights reserved.

  • Page 29: Hazards During Operation And Maintenance

    Heed the general rules for work safety and accident prevention.  Ensure the safety of the work area.  Perform only those tasks that are described in this manual.  Perform work only for which training has been carried out.  © Copyright 2015 ABB. All rights reserved.
  • Page 30 Do not touch hot surfaces and heed the warning plate on the  turbocharger. Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.  Wear safety gloves against thermal risks. © Copyright 2015 ABB. All rights reserved.
  • Page 31 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.
  • Page 32 In the event of leaks or after spilling, immediately spread a suitable  binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations. © Copyright 2015 ABB. All rights reserved.
  • Page 33 Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  Dispose of insulating materials properly and in an environmentally  compatible way in accordance with applicable local regulations. © Copyright 2015 ABB. All rights reserved.
  • Page 34 Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by  trained specialists. Heed any country-specific regulations.  © Copyright 2015 ABB. All rights reserved.

  • Page 35: Periodic Checking Of The Pressure Vessel

    Page 33 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.

  • Page 36: Lifting Loads

    Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and  securely. © Copyright 2015 ABB. All rights reserved.

  • Page 37: Commissioning

    NOTICE Oil filtration A lubricating oil filter system with a filter mesh size of ≤ 0.034 mm is adequate for this turbocharger. © Copyright 2015 ABB. All rights reserved.
  • Page 38 To make sure these oil pressures are obtained, a regulating orifice is fitted in the turbocharger oil inlet. The orifice is fitted by the engine NOTICE builder and secured by a safety ring. © Copyright 2015 ABB. All rights reserved.
  • Page 39 > 160 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2015 ABB. All rights reserved.

  • Page 40: Inspection Work

    Failure of compressor wheel cooling system The service life of the compressor wheel will be impaired if the breakdown of the compressor wheel cooling system lasts long. CAUTION Ensure supply of cooling air.  © Copyright 2015 ABB. All rights reserved.
  • Page 41 The first step is NOTICE to check the seal for the oil supply to the turbocharger. If this is not in proper condition, 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.

  • Page 42: Commissioning After Taking Out Of Operation

    / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  TPL65: Version with compressor wheel cooling system Remove screw plug on cooling air connection and fit cooling air line.  © Copyright 2015 ABB. All rights reserved.

  • Page 43: Operation

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must ensure that equivalent acoustic insulating measures are taken. © Copyright 2015 ABB. All rights reserved.
  • Page 44 Operation Noise emissions Page 42 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 © Copyright 2015 ABB. All rights reserved.

  • Page 45: Servicing Work

     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.
  • Page 46  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2015 ABB. All rights reserved.
  • Page 47 (Customer Part Exchange) programme. 4.2.5 Service work every 30000 hours The replacement of bearing parts as well as the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.

  • Page 48: Replacement Intervals For Turbocharger Components

    Parameters influencing non-rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Load profile (thermal load changes, number of starts/stops)  Temperature level of exhaust gas  Turbine cleaning frequency  Procedure for turbine cleaning © Copyright 2015 ABB. All rights reserved.
  • Page 49 50000 … 100000 Variable turbine geometry module 15000 (The variable turbine geometry module can be replaced with a CPEX variable turbine geometry module by an ABB Turbocharging service station.) Turbine diffuser / cover ring 35000 … 50000 Other casings 100000 Axial bearing components 24000 …...

  • Page 50: Speed Measurement

    If you pull the speed measurement cables too hard, contacts can be pulled out. CAUTION Do not tension the speed measurement cables.  Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer © Copyright 2015 ABB. All rights reserved.
  • Page 51 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. © Copyright 2015 ABB. All rights reserved.
  • Page 52 Screw in speed sensor (86505) as far as it will go and tighten to torque  specified in table. (See chapter Table of tightening torques.) Connect speed sensor using cable connector (86515).  © Copyright 2015 ABB. All rights reserved.
  • Page 53 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.4 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2015 ABB. All rights reserved.

  • Page 54: Emergency Operation Tpl

    (B) using at least 3 washers (C) spaced around the circumference. When fixing, the position of the variable turbine geometry module and / or the blades must be specified by the enginebuilder. © Copyright 2015 ABB. All rights reserved.

  • Page 55: 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  minutes before stopping. © Copyright 2015 ABB. All rights reserved.

  • Page 57: Maintenance

     The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and Guide Blades © Copyright 2015 ABB. All rights reserved.

  • Page 58: Cleaning The Filter Silencer

    Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut Insert unit = absorption segment + sheet­metal covering © Copyright 2015 ABB. All rights reserved.
  • Page 59 Otherwise there is a risk of damage or deformation. Replace heavily contaminated or damaged parts with original parts from ABB Turbo Systems. NOTICE © Copyright 2015 ABB. All rights reserved.
  • Page 60 If the connecting rods (81269) are not correctly positioned in their recesses on the filter silencer unit (81135), the cover grid (81266) can twist and shift. There is then a risk of foreign matter and contamination getting into the compressor. CAUTION © Copyright 2015 ABB. All rights reserved.
  • Page 61 (81272) alternately until the following maximum torque is reached: Screw Tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut Tightening torque [Nm] 81273 Fit filter strip (81265). If provided  © Copyright 2015 ABB. All rights reserved.

  • Page 62: Cleaning The Compressor During Operation

    Cleaning interval conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Cleaning intervals Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. NOTICE © Copyright 2015 ABB. All rights reserved.
  • Page 63 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 Systems. To clean the compressor stage during operation, water is injected in front...
  • Page 64 Operating state prerequisites for cleaning compressor with XC2 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 ... 85% ...
  • Page 65 Operating state prerequisites for compressor cleaning with XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 ... 85% ...
  • Page 66 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 Turbocharging Service Station. Cleaning parameters per turbocharger compressor...

  • Page 67: Cleaning Turbines And Guide Vanes During Operation

    Cleaning turbines and guide vanes during operation HFO applications The TPL65VA.. has not been released for HFO applications. Wet cleaning of the turbine blades and guide vanes during operation is thus NOTICE neither required nor planned. © Copyright 2015 ABB. All rights reserved.

  • Page 69: 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 70: Surging Of The Turbocharger

    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 ...

  • Page 71: Malfunctions During Operation

    Defects such as leaks in the Make repairs exhaust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging charger ring (with 4-stroke application) Service Station © Copyright 2015 ABB. All rights reserved.
  • Page 72 Charge air Cooler contaminated Clean it cooler Cooling water volume too Top up the water Entry temperature of cooling Inspect / clean the cooling water too high system Inadequate ventilation Improve the ventilation © Copyright 2015 ABB. All rights reserved.
  • Page 73 Elimination Engine Malfunctioning injection system Repair it or contact the manufacturer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbo- Manometer display wrong Replace the manometer charger © Copyright 2015 ABB. All rights reserved.

  • Page 74: Malfunctions When Stopping

    Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2015 ABB. All rights reserved.

  • Page 75: Speed Measurement System

    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 speeds too attract metal particles.

  • Page 76: Variable Turbine Geometry

    Variable Turbine Geometry (VTG) not adjustable Possible causes Elimination Turbocharger Heavy turbine Contact an ABB Turbocharging contamination Service Station VTG bearing damaged Drive unit No drive energy Contact an ABB Turbocharging Service Station (electrical components) © Copyright 2015 ABB. All rights reserved.

  • Page 77: Removal And Installation

    Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification. Weight [kg] TPL65VA32/33 1210 © Copyright 2015 ABB. All rights reserved.

  • Page 78: Removing The Turbocharger

    Remove air supply line. (See also chapter entitled Preliminary  remarks / Layout and functionality) Inspect the lifting gear.  Fasten separate lifting gear to each of the two ribs on the bearing  casing provided for this purpose. © Copyright 2015 ABB. All rights reserved.
  • Page 79 WARNING serious or even fatal injury. Support the turbocharger at a suitable point.  If possible secure it using lifting gear.  Wear safety helmet. Cover the oil connection.  © Copyright 2015 ABB. All rights reserved.

  • Page 80: Installing The Turbocharger

    TPL65: Version with compressor wheel cooling system Fit air supply line. (See also chapter Preliminary remarks / Layout and  functioning.) Refit removed parts of insulation.  Plug in cable connector on speed sensor.  © Copyright 2015 ABB. All rights reserved.

  • Page 81: Disassembly And Assembly

    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.
  • Page 82 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2015 ABB. All rights reserved.

  • Page 83: Module Weights

    Assemblies Weights [kg] Description TPL65VA32/33 Radial air suction branch Axial air suction branch Filter silencer Compressor casing Wall insert Diffuser Cartridge group Turbine diffuser Variable turbine geometry module Radial gas inlet casing © Copyright 2015 ABB. All rights reserved.
  • Page 84 Page 82 Complete compressor casing Weight [kg] TPL65VA32/33 The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2015 ABB. All rights reserved.

  • Page 85: Removing And Fitting Filter Silencer Or Air Suction Branch

    Unscrew nuts (72027) and remove them together with washers  (72018). Remove filter silencer and set it down to one side.  Install filter silencer in reverse order. Installing the filter silencer  © Copyright 2015 ABB. All rights reserved.
  • Page 86 Unscrew the nuts (72027) and remove them together with the washers  (72018). Remove the air suction branch and set it down to one side.  Fit the air suction branch in reverse order. Installing the air suction  branch © Copyright 2015 ABB. All rights reserved.

  • Page 87: Axial Clearance

    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. © Copyright 2015 ABB. All rights reserved.

  • Page 88: Removing Cartridge Group

    Unscrew nuts (61037).  Uniformly press apart compressor casing (72000) using three press-off  nuts (61090). Slightly lift compressor casing (72000) and withdraw it.  © Copyright 2015 ABB. All rights reserved.
  • Page 89 Check the underlay and adjust it if necessary.  Remove the screws (72002).  Remove the diffuser (79000).  Remove the wall insert (77000) using swivel lifting eyes (90235).  Remove the O-ring (77005) from the wall insert.  © Copyright 2015 ABB. All rights reserved.
  • Page 90 If the rotor blades have insufficient or no clearance, the blades and casing could be damaged. Turn the rotor to check that the blades do not rub against the turbine  diffuser. CAUTION © Copyright 2015 ABB. All rights reserved.
  • Page 91 Operation Manual / TPL65VA32/33 Disassembly and assembly Removing cartridge group Page 89 Withdraw the cartridge group and fit the supports (90450).  Cover the oil connections.  © Copyright 2015 ABB. All rights reserved.

  • Page 92: Removing And Fitting Turbine Diffuser

    (63000) using the press-off screws (90901), then withdraw and remove it. Fitting the turbine diffuser Fit the turbine diffuser in reverse order of removal.  Brush high-temperature grease on all screws at and in the gas outlet casing. NOTICE © Copyright 2015 ABB. All rights reserved.

  • Page 93: Removing Variable Turbine Geometry Module With Gas Inlet Casing

    Carefully separate gas inlet casing (51001) from variable turbine  geometry module (56100) and remove it. Have the variable turbine geometry module overhauled by ABB Turbo Systems. ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX (Customer Part Exchange) programme.

  • Page 94: Fitting The Variable Turbine Geometry Module And The Gas Inlet Casing

    Slide clamping ring (56112) onto studs  Tighten nuts (61042) to specified torque  Fit retaining clips (56121) using screws (56122)  Fit semi-circular section of sealing air line (A) to variable turbine  geometry module © Copyright 2015 ABB. All rights reserved.
  • Page 95 Operation Manual / TPL65VA32/33 Disassembly and assembly Fitting the variable turbine geometry Page 93 module and the gas inlet casing Fit sealing air line (56501) to semi-circular section of line (A).  © Copyright 2015 ABB. All rights reserved.

  • Page 96: Installing Cartridge Group

    Fasten separate lifting gear to each of the two ribs on the bearing  casing provided for this purpose. Remove the supports (90450) and carefully insert the cartridge group.  Uniformly tighten the screws (61059) together with the Verbus Ripp®  washers (61058). © Copyright 2015 ABB. All rights reserved.
  • Page 97 Align and fit the wall insert (77000) using the centring screw (90187).  Place the diffuser (79000) in position using the swivel lifting eye  (90235). Remove the swivel lifting eye (90235).  Fit the screws (72002).  © Copyright 2015 ABB. All rights reserved.
  • Page 98 (72000) by tightening them to specified torque. (See chapter Table of tightening torques.) Remove lifting device (90190).  Fit sealing air line (56501) between compressor casing (72000) and  variable turbine geometry module (56100). © Copyright 2015 ABB. All rights reserved.
  • Page 99 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 pipes and all air lines in accordance with engine builder’s ...

  • Page 100: Table Of Tightening Torques

    Operation Manual / TPL65VA32/33 Disassembly and assembly Table of tightening torques 8.10 Page 98 8.10 Table of tightening torques 8.10 © Copyright 2015 ABB. All rights reserved.
  • Page 101 Part number TPL65VA32/33 82005 M16x1.5 72027 With washer 72002 61037 61090 61036 61041 72029 61059 42059 42064 61056 51075 56110 56114 61042 56122 86505 M18x1.5 Tightening angle [°] Part number TPL65VA32/33 56501 M26x1.5 30° © Copyright 2015 ABB. All rights reserved.

  • Page 103: Taking Out Of Operation At Short Notice

    If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available:  Fitting cover plate  Shutting off inlets and outlets  Bypass around turbocharger © Copyright 2015 ABB. All rights reserved.

  • Page 104: Fitting The Cover Plate

    Cover plate dimensions Product [mm] TPL65 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 Product α 1 α 2 α 3 TPL65 4 x 90° 37.5° 24 x 15° © Copyright 2015 ABB. All rights reserved.
  • Page 105 Operation Manual / TPL65VA32/33 Taking out of operation at short notice Fitting the cover plate Page 103 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2015 ABB. All rights reserved.
  • Page 106 Page 104 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger. CAUTION © Copyright 2015 ABB. All rights reserved.
  • Page 107 The engine can be operated according to the engine builder's instructions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating Bmax plate must not be exceeded. CAUTION © Copyright 2015 ABB. All rights reserved.

  • Page 108: 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  cover plates. In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2015 ABB. All rights reserved.

  • Page 109: Turbocharger Bypass

    This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2015 ABB. All rights reserved.

  • Page 111: Mothballing The Turbocharger

    Observe the information in the material safety data sheet for the  operating materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2015 ABB. All rights reserved.
  • Page 112 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. ...
  • Page 113  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.
  • Page 115  Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2015 ABB. All rights reserved.
  • Page 117  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.
  • Page 118 Operation Manual / TPL65VA32/33 Spare parts View of turbocharger with part numbers 12.2 Page 116 12.2 View of turbocharger with part numbers 12.2 © Copyright 2015 ABB. All rights reserved.
  • Page 119 Compressor casing 72018 Washer 72029 Stud 72027 Hexagon nut 77000 Wall insert 77005 (in customer spare parts set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch 82000 Axial air suction branch © Copyright 2015 ABB. All rights reserved.
  • Page 120 Operation Manual / TPL65VA32/33 Spare parts View of cartridge group with part 12.3 Page 118 numbers 12.3 View of cartridge group with part numbers 12.3 © Copyright 2015 ABB. All rights reserved.
  • Page 121 Verbus Ripp® Washer 42064 Hexagon-head screw 43002 (option with compressor wheel Plate cooling system) 43001 Partition wall 43005 O-ring 43006 O-ring 43007 O-ring 86505 Speed sensor 86506 (in customer spare part set) O-ring © Copyright 2015 ABB. All rights reserved.
  • Page 122 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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