Table of Contents
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Table of Contents
Related Manuals for ABB TPS48 -F Series
Summarization of Contents
Preliminary Remarks
Purpose of Operation Manual
Explains the manual's aim to familiarize users with the turbocharger and ensure safe, correct operation.
Turbocharger Layout and Function
Describes the main components of the turbocharger and their basic layout.
Intended Use of Turbocharger
Specifies the intended application of the turbocharger and conditions for warranty.
Storage of New Turbochargers and Spare Parts
Provides guidelines for storing new turbochargers and spare parts to maintain their condition.
Essential Information
Covers organizational measures, safety consciousness, and required approvals for alterations.
Symbols and Definitions
Explains symbols used in the documents and defines key terms like ABB Turbo Systems.
Turbocharger Rating Plate
Details the information found on the turbocharger's rating plate, including operating limits.
Contact Information
Provides contact details for ABB Turbo Systems and their service stations.
Safety
Safety Introduction
Discusses residual risks during turbocharger operation and working, and operator responsibilities.
CE Conformity
States that ABB turbochargers comply with Directive 2006/42/EC on machinery.
Mandatory Safety Signs
Illustrates and explains mandatory signs for personal protective equipment required for specific tasks.
Safety Instructions Definitions
Explains the meaning of warning and caution symbols and their importance for preventing injury or damage.
Warning Plates on Turbocharger
Identifies the locations of warning plates on the turbocharger and procedures if they are missing or illegible.
Safe Operation and Maintenance
Provides instructions for safe personnel and work area practices during operation and maintenance.
Safety During Start-up, Commissioning, and Operation
Highlights safety precautions related to burst protection and general operational safety.
Safety During Cleaning
Emphasizes safety when using cleaning agents or solvents, referring to material safety data sheets.
Safety During Service Work
Covers safety precautions for disassembly, assembly, maintenance, and troubleshooting activities.
Mechanical Work Safety
Warns about potential damage from mechanical work and restricts tasks to manual procedures.
Safety When Taking Out of Operation
Provides safety guidelines for securing the rotor and cleaning the turbocharger before mothballing.
Mechanical Hazards During Operation
Warns about contact with rotating parts and the need to operate the turbocharger correctly.
Mechanical Hazards When Working On Turbocharger
Highlights risks from improper handling, non-observance of instructions, and inadequate care during maintenance.
Hazards Due to Noise
Explains the risks of noise exposure, including hearing impairment, and the need for ear protection.
Hazards From Hot Surfaces and Substances
Warns about burns from touching hot surfaces or materials and the need for protective clothing.
Hot Surfaces on Non-Insulated Turbochargers
Warns about the risk of burns from non-insulated turbochargers and the engine builder's responsibility for insulation.
Hazards from Operating and Auxiliary Materials
Discusses health risks from ingesting or inhaling operating materials and the need for ventilation and PPE.
Risk of Fire and Explosion
Warns about flammable materials, ignition sources, and the need for ventilation during cleaning.
Risk of Environmental Damage
Addresses hazards from spills and improper disposal of operating materials, emphasizing environmental compatibility.
Hazards When Handling Insulating Materials
Warns about dust and fiber hazards from insulating materials and the need for proper ventilation and PPE.
Hazards From Electrical Components
Warns about hazards from electrical components operating with voltages and requires trained specialists for work.
Deflagration on Gas Engines
Addresses turbocharger tolerance for deflagration and recommended checks after such an event.
Periodic Pressure Vessel Checks
Outlines the requirement for periodic checks of 'simple pressure vessels' and operator responsibility.
Lifting Loads Safety
Provides safety guidelines and precautions for lifting turbocharger assemblies and components.
Start-up
Oil Supply
Details the importance of proper oil supply, filtration, and selection of lubricating oil.
Minimum Oil Inlet Temperature Warning
Warns of machine damage from excessively high oil viscosity and low oil levels in bearings.
Prelubrication Safety
Highlights the risk of damage if the turbocharger is not oiled before starting and the need for prelubrication.
Machine Damage From Oil Temperature
Warns about machine damage if oil inlet temperature exceeds the permissible range.
Inspection Work
Details visual, monitoring, and measuring tasks performed before and during commissioning.
Pre-Commissioning Inspection
Lists checks for monitoring devices, filter, lubricating system, and warning plates before commissioning.
Contaminated Oil Warning
Warns about damage from contaminated oil and the need for system flushing and special filters.
Prelubrication Safety Check
Highlights the risk of damage if the turbocharger is not oiled before starting and the need for prelubrication.
Post Start-up Checks (Idling Speed)
Specifies checks for lubricating system and gas/air/oil lines after engine start-up at idling speed.
Checks During Engine Run-up
Details measurements for speed, pressures, and temperatures during engine run-up.
Inspection After 100 Service Hours
Instructs to clean or replace lubricating oil filters after the first 100 service hours.
Operation
Noise Emissions
Discusses noise levels, hazards, and measurement of sound pressure from the turbocharger.
Hazards Due to Noise
Explains the risks of noise exposure, including hearing impairment, and the need for ear protection.
Noise Emissions
Discusses noise levels, hazards, and measurement of sound pressure from the turbocharger.
Noise Emissions
Discusses noise levels, hazards, and measurement of sound pressure from the turbocharger.
Hazards Due to Noise
Explains the risks of noise exposure, including hearing impairment, and the need for ear protection.
Servicing Work
Details visual checks, monitoring, measuring, and functional checks for turbocharger service.
Service Work (25-50 Hours)
Outlines tasks for service work performed every 25-50 hours, including visual inspection and data recording.
Unknown Operational Changes Warning
Warns about consequences of unknown operational changes and recommends consulting a service station.
Servicing Work
Details visual checks, monitoring, measuring, and functional checks for turbocharger service.
Servicing Per Engine Manufacturer Instructions
Instructs to clean or replace the oil filter in the supply line when the engine is not running.
Service Work Per Rating Plate Instructions
Specifies service work after 8000-12000 hours, including inspection and assessment by a service station.
Servicing Work
Details visual checks, monitoring, measuring, and functional checks for turbocharger service.
Engine Logbook Entries
Lists operating data and measured values that must be regularly entered into the engine logbook.
Expected Exchange Intervals
Provides recommended replacement intervals for rotating and non-rotating turbocharger components.
Expected Exchange Intervals
Provides recommended replacement intervals for rotating and non-rotating turbocharger components.
Speed Measurement
Describes the turbocharger speed measuring system and its components.
Speed Sensor Cable Safety
Warns against using speed measurement cables as climbing aids to prevent damage to contacts.
Speed Measurement
Describes the turbocharger speed measuring system and its components.
Speed Differences (Multiple Turbochargers)
Addresses acceptable speed differences between multiple turbochargers and actions if exceeded.
Speed Measurement
Describes the turbocharger speed measuring system and its components.
Replacing the Speed Sensor
Provides instructions for safely replacing the turbocharger speed sensor.
Hot Sensor Connector Warning
Warns of burn risk from hot cable connectors and speed sensors, requiring safety gloves.
Speed Measurement
Describes the turbocharger speed measuring system and its components.
Speed Measuring System Failures
Discusses possible reasons for speed measuring system failure and refers to the troubleshooting chapter.
Stopping the Engine
Provides procedures for stopping the engine with oil-cooled and water-cooled turbochargers.
Stopping Oil-Cooled Turbocharger Engine
Details post-lubrication requirements for oil-cooled turbochargers after stopping the engine.
Stopping Water-Cooled Turbocharger Engine
Details cooling water circulation and oil lubrication requirements after stopping water-cooled turbochargers.
Maintenance
Foreword to Maintenance
Introduces general maintenance work, visual checks, and cleaning tasks for trouble-free operation.
Mechanical Cleaning Damage Risk
Warns that frequent mechanical cleaning can cause damage and corrosion to components.
Compressor Cleaning During Operation
Explains how to clean the turbocharger's compressor stage while it is running.
Compressor Cleaning During Operation
Explains how to clean the turbocharger's compressor stage while it is running.
Cleaning Corrosion and Deposit Warning
Warns against using salt water for cleaning and advises on preventing corrosion.
Compressor Cleaning During Operation
Explains how to clean the turbocharger's compressor stage while it is running.
Wet Cleaning Compressor (XC1 Method)
Details the XC1 method for wet cleaning the compressor using an external water vessel.
Compressor Cleaning During Operation
Explains how to clean the turbocharger's compressor stage while it is running.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Wet Cleaning Methods
Describes two wet cleaning methods: short and long water injection times.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Turbine Cleaning Prerequisites
Lists prerequisites for turbine wet cleaning, including risk of corrosion and temperature limits.
Corrosion and Deposit Risk During Cleaning
Warns about damage from salt water and cooling water additives, advising fresh water use.
Max Temperature Risk During Turbine Cleaning
Warns about high temperatures stressing turbine components and advises against exceeding limits.
Thermal Stress and Flooding Risk
Warns about risks from incorrect water volumes causing poor cleaning, stress, or flooding.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Recommended Operating State for Turbine Wet Cleaning
Specifies tested and approved operating states for turbine wet cleaning procedures.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Short Water Injection Cleaning Procedure
Step-by-step guide for performing turbine wet cleaning using short water injection.
Max Temperature Risk During Turbine Cleaning
Warns about high temperatures stressing turbine components and advises against exceeding limits.
Turbine Cleaning During Operation
Details procedures for cleaning the turbocharger turbine components during operation.
Long Water Injection Cleaning Procedure
Step-by-step guide for performing turbine wet cleaning using long water injection.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Cleaning Introduction
Provides general advice and warnings about choosing cleaning tools for turbocharger components.
Choosing Cleaning Tools
Advises using only soft tools to avoid damaging turbocharger components and their protective coatings.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Cleaning the Filter Silencer
Provides instructions for disassembling, cleaning, and reassembling the filter silencer and its components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Compressor-End Non-Rotating Parts Cleaning
Details cleaning procedures for compressor casing, wall insert, and diffuser.
Handling Operating Materials Safety
Warns about health risks from operating materials and requires PPE and ventilation.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Turbine-End Non-Rotating Parts Cleaning
Details cleaning procedures for turbine casing, nozzle ring, and gas outlet flange.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Mechanical Component Cleaning
Describes methods for mechanically cleaning individual turbocharger components.
Troubleshooting
Malfunctions During Start-up
Lists potential causes and solutions for problems encountered when starting the turbocharger.
Turbocharger Surging
Explains the phenomenon of turbocharger surging, its causes, and potential consequences.
Malfunctions During Operation
Addresses issues that may arise during the turbocharger's normal operation.
Malfunctions During Operation
Addresses issues that may arise during the turbocharger's normal operation.
Malfunctions During Operation
Addresses issues that may arise during the turbocharger's normal operation.
Malfunctions During Operation
Addresses issues that may arise during the turbocharger's normal operation.
Malfunctions When Stopping
Details problems that can occur when shutting down the turbocharger.
Speed Measurement System Issues
Discusses potential problems with the turbocharger's speed measurement system and their solutions.
Removal and Installation
Turbocharger Transport
Guidelines for transporting the turbocharger safely.
Turbocharger Weights
Lists the weights of different turbocharger models for handling and lifting.
Removing the Turbocharger
Step-by-step instructions for safely removing the turbocharger from the engine.
Installing the Turbocharger
Step-by-step instructions for correctly installing the turbocharger onto the engine.
Disassembly and Assembly
Disassembly and Assembly Introduction
General information and precautions before starting disassembly and assembly work.
Module Weights
Provides weights for individual turbocharger components and assemblies.
Disassembling and Assembling Turbocharger
Detailed, step-by-step instructions for the complete disassembly and assembly of the turbocharger.
Axial and Radial Clearances
Explains how to measure and the permissible values for axial and radial clearances.
Radial Clearances N and R
Details the measurement and permissible values for radial clearances N and R.
Table of Tightening Torques
Lists the specified tightening torques for various screw connections on the turbocharger.
Taking Out of Operation
Shutting Down the Turbocharger
Instructions on how to properly shut down the turbocharger and the engine.
Shutting Down the Turbocharger
Instructions on how to properly shut down the turbocharger and the engine.
Shutting Down the Turbocharger
Instructions on how to properly shut down the turbocharger and the engine.
Shutting Down the Turbocharger
Instructions on how to properly shut down the turbocharger and the engine.
Mothballing the Turbocharger
Engine Out of Operation (Up to 12 Months)
Procedures for mothballing the turbocharger when the engine is out of operation for up to 12 months.
Engine Out of Operation (Over 12 Months)
Procedures for mothballing the turbocharger when the engine is out of operation for more than 12 months.
Spare Parts
Ordering Spare Parts
Details the information required when ordering spare parts from ABB Turbo Systems.
Turbocharger Part Identification
Diagrams showing the turbocharger with part numbers for identification.
Cartridge Group Part Identification
Diagrams showing the cartridge group with part numbers for identification.
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