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Operation Manual

Table of Contents Page 1

Table of Contents
May 2006

1 Preliminary remarks
1.1 Purpose of the manual
1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate

2 Safety
HZTL2481_EN (TPL73-A.. - 80-A..)

2.1 Basic safety instructions


2.2 General safety instructions
2.3 Special safety instructions
2.4 Safety instructions and hazard protection
2.5 Warnings on the turbocharger

3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up

4 Operation
4.1 Servicing work
4.2 Monitoring
4.3 Surging of turbocharger
4.4 Contact with rotating parts
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4.5 Shutting the engine down

5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation

ABB Turbo Systems Ltd ABB


Operation Manual

Table of Contents Page 2

6 Troubleshooting
6.1 Possible remedies for failures

May 2006
7 Removal and installation
7.1 Turbocharger weights
7.2 Remove the turbocharger
7.3 Installing the turbocharger

8 Disassembly and assembly


8.1 Module weights
8.2 Removing and fitting the filter silencer or air suction branch
8.3 Removing cartridge group
8.4 Axial clearance
8.5 Dismantling and installing the turbine diffuser and nozzle ring

HZTL2481_EN (TPL73-A.. - 80-A..)


8.6 Installing the cartridge group
8.7 Turbine-end removal / fitting of the nozzle ring
8.8 Table of tightening torques

9 Taking out of operation temporarily


9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Fitting the cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger

10 Mothballing the turbocharger


10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months

11 Reserve and spare parts


11.1 Ordering spare parts
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11.2 Directory of part numbers


11.3 General view of turbocharger
11.4 General view of cartridge group

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Purpose of the manual 1.1 Page 1

1 Preliminary remarks
1.1 Purpose of the manual
May 2006

Operation manual This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.

Target group The content of this operation manual is intended for persons such as en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.

Content of operation ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
HZTL2481_EN (TPL73-A.. - 80-A..)

Early awareness and avoidance of hazards.


Minimising repair costs and failure times.

This operation manual is a complement to, and an extension of, existing


national regulations on accident protection and prevention.

An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbo-
NOTE charger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully un-
derstood the operating manual before beginning work.

The instructions included in this operation manual must be followed under


all circumstances.

This applies especially to the general and special safety instructions


preceding and in the respective chapters. Ignoring hazards and the sa-
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fety instructions can lead to serious personal injury and damage to e-


WARNING quipment.

In the event of doubt, consult the officer for safety and accident protection
responsible for your area.

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Layout and function 1.2 Page 2

1.2 Layout and function

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
00000_001

1 Filter silencer 8 Nozzle ring


2 Radial plain bearing 9 Turbine wheel
3 Thrust bearing 10 Bearing casing
4 Bearing bush 11 Diffuser
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5 Radial plain bearing 12 Compressor wheel


6 Gas outlet casing 13 Air outlet casing
7 Gas inlet casing

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Layout and function 1.2 Page 3

Mode of operation

The turbocharger is a turbo-machine and consists of the following main


components:
May 2006

Turbine
Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (7) and nozzle ring (8) to the turbine wheel.

The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
HZTL2481_EN (TPL73-A.. - 80-A..)

The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (6).

The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). It then
passes through the diffuser (11) and leaves the turbocharger through the
compressor outlet on the air outlet casing (13).

The rotor runs in two radial plain bearings (2/5) which are located in the
bearing bush (4) between the compressor and the turbine. The axial thrust
bearing (3) is on the compressor side.

The plain bearings are connected to a central lubricating oil feed which is
supplied by the oil lubrication circuit of the engine. The oil outlet is always
at the lowest point of the bearing casing (10).
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ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Correct use of the turbocharger 1.3 Page 4

1.3 Correct use of the turbocharger

May 2006
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
If it is used in conjunction with a gas engine, the engine must not be in-
stalled in a potentially explosive environment, and precautionary meas-
ures must be taken to ensure that the machine room as a whole is clas-
sified as not potentially explosive.
Any other usage shall be regarded as a special application which must
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-

HZTL2481_EN (TPL73-A.. - 80-A..)


tems reserves the right to reject all claims under the warranty.

Latest technology This turbocharger was built according to state-of-the-art technology and is
operationally safe according to prevailing safety regulations.

Improper operation and maintenance of the turbocharger can result in


danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine. The machine may only be ope-
WARNING rated by trained personnel.

Correct use of the turbocharger also includes observation of the assem-


bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be ob-
served when disposing of the turbine.

Perfect condition The turbocharger must only be installed in a technically perfect condition,
Version 2.0

corresponding to its intended purpose and following the instructions in the


Engine Manufacturers' Manual, and must be operated and used in com-
pliance with the Operation Manual.

X Defects which could affect safety must be eliminated immediately.

The manufacturer shall not accept liability for damages resulting from un-
authorised alterations to the turbocharger.

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Essential information 1.4 Page 5

1.4 Essential information


May 2006

Organisational measures

In addition to this manual, the general, statutory regulations applicable in


the respective country for the prevention of accidents and the protection of
the environment must be observed.

This also applies to the provision and wearing of personnel protection e-


quipment.

The safety and risk consciousness of the personnel working on and


with the turbocharger must be checked regularly with reference to this
manual.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

X The turbocharger must be shut down immediately in the event of al-


terations affecting safety or of corresponding operating behaviour. The
fault should 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 Sys-
tems.
NOTE
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ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Essential information 1.4 Page 6

Original parts and safety

May 2006
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems Ltd.

We herewith expressly state that parts and accessories not supplied by


us have also not been tested and approved by us.

NOTE

If components and assemblies not manufactured and tested by ABB


Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
WARNING Moreover, the active and/or passive safety of the turbocharger may be

HZTL2481_EN (TPL73-A.. - 80-A..)


compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.

ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.

Qualification of personnel

The turbocharger must only be operated and maintained by trained and


authorised personnel.

Work on mechanical components, such as bearings or rotors, must only


be performed by qualified fitters from an official service station of ABB
Turbo Systems Ltd.!
CAUTION

It must be ensured that only authorised personnel work on the turbo-


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charger.

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Essential information 1.4 Page 7

After-sales service

The Contact Information brochure contains an overview of official ABB


May 2006

Turbo Systems Ltd. service stations worldwide.

Design variants

This operating manual is valid for various turbocharger design variants.

This means that some sections and component descriptions in this oper-
ating manual do not apply to your turbocharger.

Our service stations and agencies will gladly answer your questions relat-
ing specifically to your model.
HZTL2481_EN (TPL73-A.. - 80-A..)

Accuracy of illustrations

The graphics and images shown in this operation manual are of a general
nature and are intended to assist understanding of the work steps and in-
structions. Differences may exist in certain details.

Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems Ltd. can be stored


without additional safeguarding measures for a period of 6 months after
the delivery date.

Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.

X After 6 months, rust-proofing oil should be sprayed on exposed sur-


faces and all accessible areas of the turbocharger.
X To do this, the insulating materials must be removed.
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Repeat the steps described for rust-proofing your turbocharger every 6


months.

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Abbreviations and symbols 1.5 Page 8

1.5 Abbreviations and symbols


The following abbreviations are used in this document:

May 2006
Z Prerequisite
X Work step

D Result

9 Positive checkpoint (activity that must be carried out without fail)


U Negative checkpoint (activity that must not be carried out under any
circumstances)

Basic Instructions

HZTL2481_EN (TPL73-A.. - 80-A..)


The following symbol is used for notes in this manual:

This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE

ABB Turbo Systems

The term used in this manual ABB Turbo Systems signifies ABB Turbo
Systems Ltd.

Official ABB Turbo Systems service station


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The term used in this manual Official ABB Turbo Systems service station
signifies ABB Turbocharger service stations, that have been tested and
certified by ABB Turbo Systems Ltd.

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Turbocharger rating plate 1.6 Page 9

1.6 Turbocharger rating plate


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00012

Operational limits 1 Turbocharger operational limits at engine overload (110 %).


In test rig operation only, unless otherwise agreed with the
engine manufacturer.
2 Turbocharger operational limits in service.
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Recommended replace- 3 Replacement interval for the plain bearings in 1000 h


ment periods / exchange
4 Exchange interval for the compressor in 1000 h (no data for
intervals for turbocharger
100,000 h)
components
5 Exchange interval for the turbine in 1000 h (no data for
100,000 h)

ABB Turbo Systems Ltd ABB


Operation Manual
Preliminary remarks 1

Turbocharger rating plate 1.6 Page 10

Additional specifications: 6 Customer part number


7 Field for special design designation
8 Weight of the turbocharger in kg

May 2006
9 CE = Conformit Europenne
10 Turbocharger type
11 Series number
12 Year of construction of the turbocharger

Explanations of the rating plate

The recommended exchange intervals and the corresponding operation


limits are defined together with the engine builder. These specifications
are system-specific.

HZTL2481_EN (TPL73-A.. - 80-A..)


Continuous running above the indicated nBmax, tBmax values may consid-
erably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
CAUTION Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) dur-
ing trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-
crease the risk of unpredictable component failure.

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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Basic safety instructions 2.1 Page 1

2 Safety
2.1 Basic safety instructions
May 2006

The following symbols and terms are used for the safety instructions in
this manual:

Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
WARNING Warning signs must be strictly observed at all times.

Serious damage to the machine or to other property may result if the


HZTL2481_EN (TPL73-A.. - 80-A..)

working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION Caution signs must be strictly observed at all times.
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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

General safety instructions 2.2 Page 2

2.2 General safety instructions


The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating

May 2006
materials.

The following safety instructions must be followed when operating and


when working on the turbocharger.

WARNING

Do not work on the turbocharger if you are under physical or mental


stress.
Wear protective clothing at all times.
Helmet
Ear protection

HZTL2481_EN (TPL73-A.. - 80-A..)


Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suit-
able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.

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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Special safety instructions 2.3 Page 3

2.3 Special safety instructions


May 2006

Safety when connecting

Work only on those connections for which you are qualified.

Safety when commissioning and during operation

Before starting work, make a visual inspection of the working area.


Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
HZTL2481_EN (TPL73-A.. - 80-A..)

once a day for visible damage and defects.


Report any damage or changes in operational performance to the per-
son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Special safety instructions 2.3 Page 4

Safety when cleaning

When handling detergents, solvents, acids and alkalis be sure to observe

May 2006
the respective safety directions on the manufacturers' labels.

Follow directions regarding the environmentally compatible collection, sto-


rage and disposal of these liquids.

Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extin-
guish naked flames (including cigarettes!) due to the risk of explosion.

HZTL2481_EN (TPL73-A.. - 80-A..)


Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
You must wear protective clothing (see section General safety instruc-
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.

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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Special safety instructions 2.3 Page 5

Safety during disassembly, assembly, maintenance and troubleshooting

Follow the prescribed maintenance and inspection schedules for all ad-
May 2006

justment, maintenance and inspection work.


Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any opera-
tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and dis-
posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.

Assembly and disassembly work must only be performed by trained


HZTL2481_EN (TPL73-A.. - 80-A..)

personnel. Work on mechanical components, such as bearings or ro-


tors, must only be performed by qualified fitters from an official service
CAUTION station of ABB Turbo Systems.

Safety when taking out of operation or putting into storage

Secure the rotor against turning.


Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Safety instructions and hazard 2.4 Page 6


protection

2.4 Safety instructions and hazard protection


Associated hazards may arise during operation of and work on the turbo-
charger:

May 2006
from the turbocharger and its accessories.
from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.

Mechanical influences

Mechanical influences can cause serious injury or even fatal injury.

HZTL2481_EN (TPL73-A.. - 80-A..)


WARNING

Personal injury Unconsciousness and injury due to:

crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
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Causes sharp edges, pointed parts


crush, shear and winding areas
fragmentation / ejection of parts
fracture or rupture of parts due to overload
Elastic elements (springs), liquids and / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor

ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Safety instructions and hazard 2.4 Page 7


protection

Protective measures 9 Wear leather protective gloves


9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection)
9 Wear face and eye protection
May 2006

9 Wear protective shoes


9 Keep floor, equipment and the turbocharger clean
9 Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
9 Eliminate leaks

Operation and process materials

Operation and process materials refer to chemical and hazardous sub-


stances:

Oils
Grease
HZTL2481_EN (TPL73-A.. - 80-A..)

Coolants
Detergents and solvents
Acids

Note that operation and process materials are harmful to the environ-
ment if they penetrate soil or water.

CAUTION

Personal injury The following injuries can be caused by operation and process materials:

Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation

Causes Inhalation of toxic gases, smoke and vapours


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Skin contact with aggressive fluids


Clothing wet or soaked with hazardous substances
Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials

ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Safety instructions and hazard 2.4 Page 8


protection

Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation under all circumstances
9 Ensure that the workroom is properly ventilated

May 2006
9 Observe the hazard indications on the containers for operation and
process materials
9 Immediately after use, seal the hazardous substance container tight
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-
scribed, and disposed of as special waste in a technically and envi-
ronmentally compatible manner
9 Ensure that containers for new / used operation materials are sealed
tight
9 In the event of leaks or spills immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste

Handling insulating materials

HZTL2481_EN (TPL73-A.. - 80-A..)


9 Ensure that the work area is well ventilated
9 Keep the work area clean
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps
9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials
9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses
9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream

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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Safety instructions and hazard 2.4 Page 9


protection

Noise

The effects of noise above a legally permitted level can cause personal in-
May 2006

jury.

Personal injury Loss of hearing


Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances

Causes Machine noise level above 85 dB (A)

Protective measures 9 Wear ear protection


HZTL2481_EN (TPL73-A.. - 80-A..)

Heat hazard

When the turbocharger is operated, surfaces become very hot.

Personal injury Burns

Causes Missing or incorrectly fitted insulation.

Protective measures 9 Wear leather protective gloves.


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ABB Turbo Systems Ltd ABB


Operation Manual
Safety 2

Warnings on the turbocharger 2.5 Page 10

2.5 Warnings on the turbocharger

May 2006
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Miss-
ing or illegible warnings must be replaced by new warnings.

HZTL2481_EN (TPL73-A.. - 80-A..)


L_00227

Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
NOTE

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ABB Turbo Systems Ltd ABB


Operation Manual
Commissioning 3

Oil supply 3.1 Page 1

3 Commissioning
3.1 Oil supply
May 2006

A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.

Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.

Regarding the oil supply, follow the engine manufacturer's instructions


concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

3.1.1 Oil filtration

A lubrication oil filter system with a mesh size 0.050 mmis adequate for
TPL 73 - TPL 80 turbochargers.

3.1.2 Oil pressure

The oil pressure before the bearings (measuring point in blind connection)
must be exactly maintained to ensure fault-free operation.
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ABB Turbo Systems Ltd ABB


Operation Manual
Commissioning 3

Inspection work 3.2 Page 2

3.2 Inspection work


This inspection work includes preventive visual controls, as well as moni-
toring and measurement to ensure the correct functioning of the turbo-

May 2006
charger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.

The safety instructions must be followed before and during all inspec-
tion work.

3.2.1 Inspection before commissioning

Monitoring equipment X To be checked for correct functioning.

HZTL2481_EN (TPL73-A.. - 80-A..)


Air filter mat X Inspect for damage.

Lubricating system X Check oil filter for cleanliness before commissioning.

It is urgently recommended that the entire lubrication system be flushed


thoroughly with warm oil using a bypass pipe before commissioning and
after every servicing operation on the lubrication system.
CAUTION We strongly recommend the use of a starting filter when running the
engine in and after every servicing operation on the lubrication system.

X Check oil pressure in oil supply lines.

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ABB Turbo Systems Ltd ABB


Operation Manual
Commissioning 3

Inspection work 3.2 Page 3

3.2.2 Inspection after commissioning


May 2006

Lubricating system X Check oil pressure in oil supply lines.

Charger speed X Measuring

Charger pressure X Measuring

Temperatures X Measure upstream/downstream from turbine, compressor and oil feed


for various engine speeds
HZTL2481_EN (TPL73-A.. - 80-A..)

Gas, air, and oil lines X After the engine has been started up, check all gas, air and oil lines for
leaks.

Further must be observed:

Lubricants and pastes are liquefied or vaporised during assembly of the


turbocharger and may escape as an oily liquid in the first few hours af-
ter commissioning. If oily liquid continues to escape after this period,
NOTE the cause must be treated as an oil leak and located. The first step in
this process is to check the oil supply to the turbocharger for leaks. If
this is not in order, contact an official ABB Turbo Systems service sta-
tion.

X Measure the speed, oil pressure, charging pressure and temperatures


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before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, tak-
ing into account the different operating conditions.

3.2.3 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.

ABB Turbo Systems Ltd ABB


Operation Manual
Commissioning 3

Putting into operation after laying up 3.3 Page 4

3.3 Putting into operation after laying up


If provided X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, down-

May 2006
stream of the gas outlet.

X Inspect the exhaust pipe before and after the turbine for any combus-
tion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Start up the turbocharger.

HZTL2481_EN (TPL73-A.. - 80-A..)


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ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Servicing work 4.1 Page 1

4 Operation
4.1 Servicing work
May 2006

Servicing work during operation includes visual checks, monitoring and


measuring as well as inspection and function checks in order to ensure
correct functioning of the turbocharger. It serves as an aid to detecting
anomalies during operation, thus preventing damage to the machine.
The inspection, measurement and servicing operations listed must be car-
ried out at the intervals indicated.

The pertinent safety instructions must be observed during all servicing


work.

WARNING
HZTL2481_EN (TPL73-A.. - 80-A..)

Servicing work must be carried out at the prescribed intervals in order


to avoid damage to and malfunctioning of the turbocharger.

CAUTION

4.1.1 Servicing work every 25 to 50 hours

Operation data X must be recorded


X Enter in the machine logbook
X In the event of significant anomalies, establish the cause

If you are unable to establish the cause of the anomalies, contact an


official ABB Turbo Systems service station.

CAUTION
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Servicing work 4.1 Page 2

4.1.2 Entries in the machine logbook

May 2006
Monitoring of the machine plant provides information about the perform-
ance of the turbocharger.

The following operation data and measurement values must be entered


regularly in the engine manufacturer's machine log book:

Output and speed of the engine


Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature

HZTL2481_EN (TPL73-A.. - 80-A..)


If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
Pressure loss in the air filter

4.1.3 Servicing work according to the engine manufacturer's instructions

Oil filters X With the engine at standstill clean or replace oil filters

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Servicing work 4.1 Page 3

4.1.4 Servicing work every 8,000 - 12,000 hours


May 2006

X Dismantle the turbocharger


X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor and bearing parts

The inspection and assessment of the rotor and bearing parts must be
performed by an official ABB Turbo Systems service station.

NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

4.1.5 Servicing work every 35,000 hours

X Dismantle the turbocharger


X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor
X Replacement of the plain bearings with original parts from ABB Turbo
Systems

The replacement of the bearing parts as well as the inspection and as-
sessment of the rotor must be carried out by an official ABB Turbo Sys-
tems service station.
NOTE
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Monitoring 4.2 Page 4

4.2 Monitoring

May 2006
4.2.1 Speed measurement

HZTL2481_EN (TPL73-A.. - 80-A..)


L_278

1 Bearing casing 6 Connecting cable


2 Axial bearing 7 Line amplifier (option)
3 Guide in the axial bearing 8 Speed transmitter
4 Gasket ring 9 Installation variant of the
speed transmitter
Version 2.0

5 Screw plug

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Monitoring 4.2 Page 5

The speed transmitter system for the measurement of the turbocharger


speed also permits, in conjunction with the corresponding measuring in-
struments and/or monitoring systems (not included in the scope of deliv-
ery), a constant remote monitoring of the turbocharger speed. With con-
May 2006

tinuous monitoring of the machine installation, the turbocharger speed can


be used as a suitable control parameter. The line amplifier can be pur-
chased as an optional addition to the described speed measuring system.

Possible reasons for failure of the speed indicator:

Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.
Turbocharger damage.

Failure of the speed indicator


HZTL2481_EN (TPL73-A.. - 80-A..)

If the speed indication fails, it is recommended that the engine output


be reduced to idling speed and the engine stopped. The cause of the
CAUTION failure should then be determined.

We recommend that subsequent assembly or replacement of the speed


transmitter system should be carried out only by an official ABB Turbo
Systems service station.
NOTE

A reduction in speed of a charger can signify:

Damaged turbine or bearing


Defects in the connected pulse charging cylinders
Severe soiling of the turbine

Increased turbocharger speed


Version 2.0

With 4-stroke applications, heavy fouling of the turbine can also be a


cause of an increase in the turbocharger speed.
NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Surging of turbocharger 4.3 Page 6

4.3 Surging of turbocharger


Surging of the turbocharger can occur with certain engine operating sta-
tes, such as rapid load removal or while manoeuvring. The direction of

May 2006
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbo-
charger.

Prolonged or periodic surging


If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer

HZTL2481_EN (TPL73-A.. - 80-A..)


Action to be taken:

The operating safety of the turbocharger is no longer ensured with con-


tinuous or periodically recurring surging. The operator must take immedi-
ate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Contact with rotating parts 4.4 Page 7

4.4 Contact with rotating parts


Mild, uniform wear around the circumference of rotor components, caused
by slight local grazing against adjacent components, is non-hazardous
May 2006

and permissible. This slightly reduces the length of the blades in the com-
pressor and/or the turbine. Certain tolerances must be observed to avoid
significant loss of efficiency.

X A check on dimensions must be carried out by an official ABB Turbo


Systems service station.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Operation 4

Shutting the engine down 4.5 Page 8

4.5 Shutting the engine down

May 2006
Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Foreword to Maintenance 5.1 Page 1

5 Maintenance
5.1 Foreword to Maintenance
May 2006

Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.

The external condition and the degree of contamination of the cleaning


points specified in this chapter must be established by visual checks at
the intervals indicated.
The safety instructions must be observed during all cleaning work.

The cleaning points described in the following are:


HZTL2481_EN (TPL73-A.. - 80-A..)

Filter silencer
Compressor
Turbine and nozzle ring
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 2

5.2 Cleaning the filter silencer

May 2006
5.2.1 Filter silencer with tension band

HZTL2481_EN (TPL73-A.. - 80-A..)

L_00210
Version 2.0

81265 Filter ring (if provided) 81266 Cover grids


81270 Tension ring 81136 Fleece segment
38271 Trap cover 81137 Cover panel
81268 Connecting strip 81135 Filter silencer body
E Slide-in module = fleece segment + cover panel installed

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 3

Disassembling and cleaning the filter silencer

If provided X Remove filter ring (81265).


May 2006

X Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal stress (water jet).

The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 ser-
vice hours.
NOTE

X Loosen tension bands (81270) on trap covers (81271) and carefully


remove cover grid (81266) from connecting strips (81268).
HZTL2481_EN (TPL73-A.. - 80-A..)

In the case of a slide-in module (E), with a cleaning container attached


to the filter silencer (available as option depending on turbocharger ty-
pe) the water injection line must first be removed (see also following
NOTE section Disassembling the cleaning line).

X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
and then take out the fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Oth-
erwise the segments may be damaged or lose their shape.

Heavily soiled fleece segments and filter ring as well as damaged con-
necting strips should be replaced with original parts from ABB Turbo
Systems.
Version 2.0

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 4

Assembling the filter silencer

X Assemble the slide-in modules (E) by inserting fleece segments

May 2006
(81136) in the cover panels (81137).
X Bend the cover panels back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).

With a cleaning container fitted to the filter silencer (available as option


depending on turbocharger type) the water injection line must now be
re-installed (see also following section Assembling the cleaning line).
NOTE

HZTL2481_EN (TPL73-A.. - 80-A..)


X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).

If provided X Fit filter ring (81265).

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 5

5.2.2 Filter silencer and connecting rod


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00185

81265 Filter ring (if provided) 81136 Fleece segment


81269 Connecting rods 81137 Cover panel
81266 Cover grids 81135 Filter silencer body
Version 2.0

B Screw N Locknut
E Slide-in module = fleece segment + cover panel

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 6

Disassembling and cleaning the filter silencer

X Remove filter ring (81265).

May 2006
If provided
Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal stress (water jet).

The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 ser-
vice hours.
NOTE

X Loosen and remove locknuts (N).


Loosen and remove screws (B) on connecting rods (81269).

HZTL2481_EN (TPL73-A.. - 80-A..)


X
X Remove connecting rods (81269).
X Carefully remove the cover grid (81266).

In the case of a slide-in module (E), with a cleaning container attached


to the filter silencer (available as option depending on turbocharger ty-
pe) the water injection line must first be removed (see also following
NOTE section Disassembling the cleaning line).

X Withdraw the slide-in modules (E), bend open the cover panels
(81137) and then take out the fleece segments (81136).
X Clean fleece segment (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air and a soft brush or damp cloth.
Otherwise the segments may be damaged or lose their shape.

Heavily soiled fleece segments and filter ring as well as damaged con-
necting rods should be replaced with original parts from ABB Turbo
Version 2.0

Systems.
NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 7

Assembling the filter silencer

X Assemble the slide-in modules (E) by inserting fleece segments


May 2006

(81136) in the cover panels (81137).


X Bend cover panels (81137) back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).

With a cleaning container fitted to the filter silencer (available as option


depending on turbocharger type) the water injection line must now be
re-installed (see also following section Assembling the cleaning line).
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

X Place cover grids (81266) evenly in the correct position.


X Push the connecting rods (81269) through the clips on the cover grids
(81266).

If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grid (81266) can twist and
shift. This can allow foreign bodies and dirt to get into the compressor.
CAUTION
Version 2.0

L_00232

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 8

May 2006
L_00234

HZTL2481_EN (TPL73-A.. - 80-A..)


X Connect the connecting rods (81269) with screws (B). While tightening
the screws (B), ensure that the connecting rods (81269) are located
correctly in the recesses in the filter silencer body (81135). Now tighten
screws (B) alternately to the following max. tightening torque:

Screw Tightening torque


B 20 Nm

X Fit locknuts (N) on screw (B) and tighten to the following torque:

Locknut Tightening torque


N 40 Nm

If provided X Fit filter ring (81265).


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 9

5.2.3 Removing / installing the cleaning line


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00192

1 Injection pipe 2 Pipe


3 Guide tube

Removing the cleaning line

X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Withdraw the pipe (2) from the guide tube (3).
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 10

Punch out the guide tube

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00193

X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.

Heavily soiled components of the cleaning line must be replaced with


original parts from ABB Turbo Systems.

NOTE

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the filter silencer 5.2 Page 11

Installing the cleaning line


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00194

X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 12


operation

5.3 Cleaning the compressor during operation

May 2006
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE

The dirt in the compressor stage (compressor wheel and diffuser) de-
pends on the cleanness of the air drawn in and the operating point.

A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:

Oil or saline mist

HZTL2481_EN (TPL73-A.. - 80-A..)


Solid combustion residues
Dust of various kinds

Soiling of the compressor stage has a negative effect on compressor effi-


ciency and charging pressure, particularly for smaller turbochargers.

This results in higher exhaust temperatures and increased fuel consump-


tion by the engine. Contamination of the compressor also increases the
rotor imbalance.

Periodic cleaning of the compressor in operation prevents or retards a se-


vere increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.

Interval between clea- The interval between periodic cleaning depends in large measure on the
nings operating conditions. In general, cleaning should be carried out every 25
to 100 operating hours.

Should the prescribed cleaning intervals prove incompatible with the


Version 2.0

operation of the ship, please contact ABB Turbo Systems.

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 13


operation

Cleaning method

The compressor is cleaned while operating using the cleaning method de-
scribed in the following. This method has been tested and is approved by
May 2006

ABB Turbo Systems:

Wet cleaning

Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.

The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, pro-
vided the soiling is not too advanced.
HZTL2481_EN (TPL73-A.. - 80-A..)

Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION

Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger compressor ning the turbocharger compressors one after the other.

V-engines For V-engines with several turbochargers on each engine, we recommend


parallel cleaning of the compressors. This cleaning process is faster and
avoids the risk of engine surging.

Register supercharging With register supercharging it must be ensured that both turbocharger
Version 2.0

compressors are cleaned regularly, especially following periods of opera-


tion in the lower performance range.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 14


operation

5.3.1 Wet cleaning the compressor with external pressurised water con-
tainer (XC3)

May 2006
The water feed with the externally mounted dosing vessel is only suit-
able for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the com-
NOTE pressor or high-pressure compressor stage in the case of two-stage
charging).

Operating state preconditions for cleaning compressors with XC3

In order to carry out a successful cleaning procedure that has been


tested and is recommended by ABB Turbo Systems, the following pre-

HZTL2481_EN (TPL73-A.. - 80-A..)


conditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 15


operation

Procedure for compressor wet cleaning with XC3


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00198

X Screw plug
Y Valve lever

Operating the pressure X The Operating state preconditions for cleaning compressors with XC3
water vessel must be met before cleaning can begin.
X Remove the screw plug (X).
X Fill the vessel with pure water.
Version 2.0

X Tighten screw plug (X).


X Actuate valve lever (Y) against the spring and hold it for 10 to 15 sec-
onds until all the water has been injected.
X After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 16


operation

If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-


mes.

May 2006
If cleaning is still unsuccessful after three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.

Cleaning parameters for XC3 for each turbocharger compressor

Turbocharger type Turbocharger Contents of the Water injection


speed dosing vessel time
[dm3] t1 [s]
TPL65-A If possible 0.4 415
nBmax

HZTL2481_EN (TPL73-A.. - 80-A..)


TPL69-A
TPL73-A 1.0
TPL77-A 1.0
TPL80-A 2.0

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 17


operation

5.3.2 Wet cleaning compressors with water vessel (XC4)


May 2006

Operating state preconditions for cleaning compressors with XC4

In order to carry out a successful cleaning procedure that has been


tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC4.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 18


operation

Procedure for compressor wet cleaning with XC4

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00197

1 Cleaning container 2 Pipe


3 Injection pipe 4 Cleaning instructions
5 Cover 6 Valve

If the cleaning container on the filter silencer is used, the detailed clean-
ing instructions provided on the plate (4) fitted to the filter silencer
should be followed.
NOTE
Version 2.0

Use of cleaning container X The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin.
X Open filling cap (5) on cleaning container (1).
X Fill with clean water.
X Screw filling cap (5) back into place.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out.
X After cleaning, a waiting time of at least 5 minutes with the engine run-
ning must be allowed so that the turbocharger can dry.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning the compressor during 5.3 Page 19


operation

If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-


mes.
May 2006

If cleaning is still unsuccessful after three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.

Cleaning parameters for XC4 for each turbocharger compressor

Turbocharger type Turbocharger Contents of the Water injection


speed dosing vessel time
[dm3] t1 [s]
TPL65-A If possible 0.4 415
nBmax
HZTL2481_EN (TPL73-A.. - 80-A..)

TPL69-A
TPL73-A 2
TPL77-A
TPL80-A 3
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 20


in operation

5.4 Cleaning turbine blades and nozzle ring in


operation

May 2006
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers. The deposits on the
turbine components are caused by the following products of combustion:

Soot
Molten ash
Cinders
Incompletely burned fuel
Sodium vanadyl vanadate

Therefore, it is advantageous to use fuels with a low content of ash, sul-


phur, sodium and vanadium. The fuel must also be stored, prepared and

HZTL2481_EN (TPL73-A.. - 80-A..)


handled correctly.

We recommend the use of fuels with a mass ratio of vanadium to so-


dium less than 3:1, so that the melting point of the sodium vanadyl va-
nadate is as high as possible.
NOTE

Soiling increases with time, so that regular and properly performed clean-
ing is important to remove the accumulated deposits.

The charging pressure can rise somewhat if the turbine profile is con-
stricted due to fouled turbine components. Contamination causes loss of
performance in the turbine and the engine temperature after the cylinders
can increase. This may mean that the engine output has to be reduced.

A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.

Experience in operation has shown that despite periodic cleaning during


operation, it is impossible to dispense with overhauls during which the tur-
Version 2.0

bine and nozzle ring are mechanically cleaned. However, if cleaning is


performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 21


in operation

Wet cleaning interval The interval between periodic cleaning depends in large measure on the
operating conditions. In general, cleaning should be carried out every 50
to 500 operating hours.
May 2006

Cleaning method

The turbine and nozzle ring are cleaned while operating using the clean-
ing method described in the following. This method has been tested and is
approved by ABB Turbo Systems:

Wet cleaning
HZTL2481_EN (TPL73-A.. - 80-A..)

The dry cleaning method may be used as an alternative to wet clean-


ing. However, this is not the preferred method, and must be approved
by an official ABB Turbo Systems service station.
NOTE
Principle of wet cleaning
During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.

Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION

Should the prescribed cleaning intervals prove incompatible with the


Version 2.0

operation of the ship, please contact ABB Turbo Systems.

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 22


in operation

Stabilising and drying time

Cleaning of the turbine-side components begins after engine start or

May 2006
reduction of engine load. The exhaust temperature must not exceed the
value specified in the corresponding cleaning instructions (see the re-
NOTE spective section Operating state preconditions).

Failure to maintain the prescribed exhaust temperature upstream of the


turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
CAUTION with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.

HZTL2481_EN (TPL73-A.. - 80-A..)


V-engines
For V-engines with several turbochargers on each engine, we recommend
parallel cleaning of both turbochargers. This cleaning process is faster
and avoids the risk of engine surging. We recommend conducting tests to
find the most suitable method.

Register supercharging With register supercharging it must be ensured that both turbocharger tur-
bines and nozzle rings are cleaned regularly, especially following periods
of operation in the lower performance range.

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 23


in operation

5.4.1 Wet cleaning the turbine and nozzle ring during operation
May 2006

The maximum exhaust gas temperature specified by the engine manufac-


turer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the en-
gine cylinder and exhaust valve rises.

Operating state preconditions for wet cleaning the turbine and nozzle ring
during operation
HZTL2481_EN (TPL73-A.. - 80-A..)

In order to carry out a successful cleaning procedure that has been


tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z After the engine is started up or the engine load has been reduced to
the lowest possible level
Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-
perature is stable and less than 430C.
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 24


in operation

Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)

In engines with one turbo-

May 2006
charger (TL 1)

HZTL2481_EN (TPL73-A.. - 80-A..)


L_00203

In V-engines with two


turbochargers (TL 1 and
2)

Version 2.0

L_00204

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 25


in operation

1 Water supply (freshwater only) 6 Other turbochargers


2 Regulating valve 7 Injection pipe
3 Manometer 8 Drainage line
May 2006

4 Air supply with 3-way-valve 9 Drain cock


5 Stainless steel piping 10 Outflow
11 Baffle (optional, can be integrated in the nozzle)

Operating the wet clea- Z The Operating state preconditions must have been fulfilled before
ning system cleaning is begun!
X Check that the water supply (1) is connected, open and reliable.
X Open the drain pipe (8, 9) on the gas outlet casing.
X Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.
X Slowly open the 3-way-valve (4) first, then the regulating valve (2) until
HZTL2481_EN (TPL73-A.. - 80-A..)

the manometer (3) shows a pressure of 2 0.2 bar.


X Inject water for 10 minutes.
X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
X Close the drain pipe (8, 9) on the gas outlet casing.
X The water supply connection (1) must be isolated at the regulating val-
ve (2).
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.

The repeating of cleaning cycles directly one after the other is to be a-


voided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
NOTE If the cleaning process is unsuccessful, the time of this can be ex-
tended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be in-
Version 2.0

stalled and be open during the cleaning. If no drainage system is pre-


sent, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in in-
dividual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 26


in operation

Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).

May 2006
Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these case, washing must be
stopped immediately and the washing cycle repeated from the begin-
ning with lower water pressure or higher engine load.

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 27


in operation

Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)
May 2006

In engines with one turbo-


charger (TL 1)
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00252

In V-engines with two


turbochargers (TL 1 and
2)
Version 2.0

L_00253

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 28


in operation

1 Water supply (freshwater 6 Other turbochargers


only)
2 Regulating valve 7 Injection pipe

May 2006
3 Manometer 8 Drainage line
4 Air supply with 3-way-valve 9 Drain cock
5 Stainless steel piping 10 Outflow
11 Baffle (optional, can be integrated in the nozzle)

Operating the wet clea- Z The Operating state preconditions must have been fulfilled before
ning system cleaning is begun!
X Check that the water supply (1) is connected, open and reliable.
X Open the drain pipe (8, 9) on the gas outlet casing.
X Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.

HZTL2481_EN (TPL73-A.. - 80-A..)


X Slowly open the 3-way-valve (4) first, then the regulating valve (2) until
the manometer (3) shows a pressure of 2 0.2 bar.
X Inject water for 10 minutes.
X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
X Close the drain pipe (8, 9) on the gas outlet casing.
X The water supply connection (1) must be isolated at the regulating val-
ve (2).
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.

The repeating of cleaning cycles directly one after the other is to be a-


voided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
NOTE If the cleaning process is unsuccessful, the time of this can be ex-
tended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
Version 2.0

this purpose, a drainage system for the gas outlet casing must be in-
stalled and be open during the cleaning. If no drainage system is pre-
sent, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in in-
dividual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 29


in operation

Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
May 2006

Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these case, washing must be
stopped immediately and the washing cycle repeated from the begin-
ning with lower water pressure or higher engine load.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 30


in operation

Operating state preconditions for wet cleaning the turbine and nozzle ring
(3 nozzles)

May 2006
In order to carry out a successful cleaning procedure that has been
tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z Reduction of engine loading to the lowest possible level
X The best cleaning effect is achieved at a loading level of 20 to 30%.

Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-


perature is stable and less than 430C.
X Cleaning cycle started according to the following description in Pro-

HZTL2481_EN (TPL73-A.. - 80-A..)


cedure for wet cleaning

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 31


in operation

Procedure for wet cleaning the turbine and nozzle ring (3 nozzles)
May 2006

In engines with one turbo-


charger (TL 1)
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00200

In V-engines with two


turbochargers (TL 1 and
2)
Version 2.0

L_00201

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 32


in operation

1 Water supply (freshwater only) 6 other turbochargers


2 Regulating valve 7 3 injection nozzles
3 Manometer 8 Drainage line

May 2006
4 Air supply with 3-way-valve 9 Drain cock
5 Water pipe made from stainless 10 Outflow
steel

Operating the wet clea- X The operating state preconditions must be met before cleaning can
ning system begin!
X Ensure that the water supply (1) is connected, turned on and constant.
X Open the drainage line (8,9).
X First open the 3-way valve (4), then open the regulating valve (2) slow-
ly until the pressure gauge (3) indicates a pressure of 2.5 bar.
X Inject water for 10 minutes. Check whether the exhaust gas tempera-

HZTL2481_EN (TPL73-A.. - 80-A..)


ture falls after the turbine.
X Close the regulating valve (2).
X This completes the cleaning process. The water supply must be dis-
connected from the gas inlet casing.
X Switching the 3-way-valve (4) for the water supply to blow-out mode
with compressed air.
X Close drain hole (at 8) above drainage line (8,9).
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.

The repeating of cleaning cycles directly one after the other is to be a-


voided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
NOTE If the cleaning process is unsuccessful, the time of this can be ex-
tended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be in-
stalled and be open during the cleaning. If no drainage system is pre-
Version 2.0

sent, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in in-
dividual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.

ABB Turbo Systems Ltd ABB


Operation Manual
Maintenance 5

Cleaning turbine blades and nozzle ring 5.4 Page 33


in operation

Points to remember when The gas outlet casing should be drained via the drainage line (8) during
cleaning cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
May 2006

Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the washing op-
eration must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Troubleshooting 6

Possible remedies for failures 6.1 Page 1

6 Troubleshooting
6.1 Possible remedies for failures
May 2006

Exhaust temperature too high

Engine output and speed unchanged

Engine Z Malfunction in the injection system


X Repair, or contact the manufacturer.

Z Air starvation, e.g. air filter clogged with dirt


HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger
X Clean

Z Compressor / turbine soiled


X Clean

Z Exhaust counterpressure too high


X Clean or repair boiler or exhaust silencer

Z Turbine damaged or worn


X Contact an official ABB Turbo Systems service station.

Charge-air cooler Z Cooler soiled


X Clean

Z Insufficient coolant water quantity


X Replenish

Z Coolant water inlet temperature too hot


Version 2.0

X Clean/inspect cooling system

Z Ventilation inadequate
X Improve ventilation

ABB Turbo Systems Ltd ABB


Operation Manual
Troubleshooting 6

Possible remedies for failures 6.1 Page 2

Charge-air pressure too low

Engine output and speed unchanged

May 2006
Intake condition normal

Engine Z Air receiver leaking


X Repair

Z Gas line between engine and turbine leaking


X Repair

Z Injection misadjusted
X Correct adjustment

HZTL2481_EN (TPL73-A.. - 80-A..)


Z Valve control misadjusted
X Correct adjustment

Turbocharger Z Manometer display faulty


X Replace manometer

Z Leak in line to the manometer


X Repair leak

Z Air filter dirty, causing excessive loss of pressure


X Clean

Z Compressor / turbine soiled


X Clean

Z Compressor / turbine damaged


X Contact an official ABB Turbo Systems service station.
Version 2.0

Z Excessive exhaust counterpressure


X Clean boiler or exhaust silencer

ABB Turbo Systems Ltd ABB


Operation Manual
Troubleshooting 6

Possible remedies for failures 6.1 Page 3

Charge-air pressure too high

Engine output and speed unchanged


May 2006

Intake condition normal

Engine Z Malfunction in the injection system


X Correct adjustment

Z Engine output higher than expected


X Check engine output

Z Injection misadjusted
X Correct adjustment
HZTL2481_EN (TPL73-A.. - 80-A..)

Turbocharger Z Manometer display faulty


X Replace manometer

Vibrations

Turbocharger Z Rotor imbalance due to heavy fouling of compressor/turbine


Z Turbine or compressor damaged
Z Bearing defective
X Contact an official ABB Turbo Systems service station.

Noises during run-out

Turbocharger Z Turbocharger dirty


X Clean
Version 2.0

Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.

ABB Turbo Systems Ltd ABB


Operation Manual
Troubleshooting 6

Possible remedies for failures 6.1 Page 4

Run-out time too short

Z Turbocharger dirty

May 2006
Turbocharger
X Clean

Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.

Sluggish start-up

Turbocharger Z Turbocharger dirty


X Clean

HZTL2481_EN (TPL73-A.. - 80-A..)


Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.

Lubricating oil pressure too low

Engine Z Oil filter heavily soiled


X Clean

Z Oil pump in the lubricating system defective


X Inspect

Z Manometer provides false reading


X Replace manometer

Turbocharger Z Axial clearance of the rotor too big


Version 2.0

X Contact an official ABB Turbo Systems service station.

ABB Turbo Systems Ltd ABB


Operation Manual
Troubleshooting 6

Possible remedies for failures 6.1 Page 5

Constant surging of the turbocharger

Z Exhaust pressure after the turbine elevated because boiler or exhaust


May 2006

Engine
silencer is dirty
Z Trap dirty
X Clean

Turbocharger Z Charge-air cooler or silencer dirty


Z Heavy deposits of contamination in the turbine
X Clean

If it is not possible to determine the reason for the surging, contact an


official ABB Turbo Systems service station.
HZTL2481_EN (TPL73-A.. - 80-A..)

NOTE
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Turbocharger weights 7.1 Page 1

7 Removal and installation


7.1 Turbocharger weights
May 2006

Attach individual parts and larger component modules carefully to suit-


able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
WARNING
Turbocharger parts that are not suspended in accordance with the
regulations during disassembly and assembly may fall and can cause
serious or even fatal injury.

X Select a suitable rope taking into account the weight of the turbo-
charger parts.
X Cross and loop the rope over the crane hook
X Do not stand under suspended loads.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

L_00082

For the safety of loads on the crane hook, the ropes must be sus-
pended crossed over each other. See also previous illustration.

WARNING

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Turbocharger weights 7.1 Page 2

Turbocharger complete unit without silencer/air suction branch

Weights [kg] TPL 73 TPL 77 TPL 80

May 2006
2080 3200 4920

Turbocharger complete unit with silencer

Weights [kg] TPL 73 TPL 77 TPL 80


2324 3604 5496

Turbocharger complete unit with air suction branch

HZTL2481_EN (TPL73-A.. - 80-A..)


Weights [kg] TPL 73 TPL 77 TPL 80
2220 3355 5162

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Remove the turbocharger 7.2 Page 3

7.2 Remove the turbocharger


X Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturers instructions.
May 2006

The two oil supply channels in the bearing casing are fitted with one ori-
fice each. In order to obtain the required oil pressure, the of this ori-
fice has been individually adjusted by the engine builder. Whenever
NOTE these orifices are removed, or if the bearing casing or the complete tur-
bocharger is replaced, it is essential to ensure that the orifice with the
correct is fitted into the oil-conducting oil-inlet channel.

X Remove the insulating shell from the bearing casing.


X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2481_EN (TPL73-A.. - 80-A..)

Observe weight of the turbocharger.

CAUTION
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Remove the turbocharger 7.2 Page 4

Turbocharger without
reinforced suspension lug

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00052

During removal, a turbocharger that is not lifted in compliance with


regulations may fall, and can cause serious or even fatal injury.

Z If the bearing casing is not provided with a reinforced suspension lug


Version 2.0

WARNING
(lugs are flush with external diameter of the flange), the complete
charger must be secured by the air outlet casing and gas inlet cas-
ing. See following illustration.
X Select a suitable rope taking into account the weight of the turbo-
charger.

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Remove the turbocharger 7.2 Page 5

Turbocharger with reinfor-


ced suspension lug
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00051

X Release the fixing screws on the foot.


X Lift the turbocharger from the engine and place it aside.

If the support for the turbocharger is missing or defective, the turbo-


charger may tip over during installation and removal and can cause se-
rious or even fatal injury.
WARNING

X Support turbocharger in a suitable location.


X Cover oil connector.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Removal and installation 7

Installing the turbocharger 7.3 Page 6

7.3 Installing the turbocharger

May 2006
During installation, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.

WARNING Z If the bearing casing is not provided with a reinforced suspension


lug, the complete charger must be secured by the air outlet casing
and gas inlet casing.
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs provided for
this purpose.

X Remove cover from the oil connector.

HZTL2481_EN (TPL73-A.. - 80-A..)


X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.

If provided X Secure the lifting equipment to the suspension lugs on the gas inlet ca-
sing (see illustration under Removing the turbocharger).

Observe weight of the turbocharger.

CAUTION

X Mate turbocharger with the engine.


X Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Mate the insulating shell with the bearing casing and secure.
Version 2.0

X Secure all gas, air, and oil lines in accordance with the engine manu-
facturers instructions.

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Module weights 8.1 Page 1

8 Disassembly and assembly


8.1 Module weights
May 2006

Attach individual parts and larger component modules carefully to suit-


able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
WARNING
Turbocharger parts that are not suspended in accordance with the
regulations during disassembly and assembly may fall and can cause
serious or even fatal injury.

X Select a suitable rope taking into account the weight of the turbo-
charger parts.
X Cross and loop the rope over the crane hook
X Do not stand under suspended loads.
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

L_00082

For the safety of loads on the crane hook, the ropes must be sus-
pended crossed over each other. See also previous illustration.

WARNING

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Module weights 8.1 Page 2

Modules

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00048

Weights [kg] Description TPL 73 TPL 77 TPL 80


1 Air suction branch, radial 140 155 242
2 Air suction branch, axial - - -
3 Filter silencer 244 404 576
4 Compressor casing, internal part 148 260 355
5 Wall insert 134 276 431
Version 2.0

6 Diffuser 57 80 125
7 Compressor casing external part 290 475 680
8 Cartridge group 546 950 1356
9 Turbine diffuser 72 150 250
10 Nozzle ring 25 44 63

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Module weights 8.1 Page 3

Compressor casing, internal part, complete

Weights [kg] TPL 73 TPL 77 TPL 80


339 616 911
May 2006

The total weight of the complete internal part of the compressor casing
includes the internal part of the compressor casing, the diffuser and the
wall insert.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing and fitting the filter silencer or 8.2 Page 4


air suction branch

8.2 Removing and fitting the filter silencer or air


suction branch

May 2006
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).

NOTE

X Remove insulation where necessary.


X Disconnect all air ducts in accordance with the engine manufacturers
instructions.

HZTL2481_EN (TPL73-A.. - 80-A..)


TPL 69 - 73

81000_003

X Fit safety ring bolt (90231) on the filter silencer.


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing and fitting the filter silencer or 8.2 Page 5


air suction branch

TPL 77 - 85
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00011

X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.

TPL 77 85
Version 2.0

L_00226

X Mount shackle (90195) on the fin on the filter silencer.

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing and fitting the filter silencer or 8.2 Page 6


air suction branch

Remove filter silencer X Sling lifting gear through the loops at the rear and secure to the
shackle (90195) or to the safety ring bolt (90231) with a shackle.
X Release nuts (74027) with Verbus washers (74028) and remove the fil-
ter silencer or air suction branch.

May 2006
Install the filter silencer X The filter silencer or air suction branch is installed in the reverse se-
quence.

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 7

8.3 Removing cartridge group


May 2006

Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).

NOTE

X Remove insulation
X Disconnect the oil lines in accordance with the engine manufacturer's
instructions.

If provided:
HZTL2481_EN (TPL73-A.. - 80-A..)

Position of the safety X Take nuts (90458) out of the toolbox and fit them on the threaded pins
segments before disas- of the safety segments (Y) on the internal part of the compressor cas-
sembly ing (76000).

L_00269
Version 2.0

X Tighten nuts (90458) to a maximum torque of 30 Nm.

D The internal part of the compressor casing is now detached from the
external part of the compressor casing (74000) and can be removed.

Note control dimension (u).

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 8

Control dimension u [mm] Dimension TPL73-A TPL77-A TPL80-A


u 18.6 19.0 19.6

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00266

X Release and remove nuts (74027) and discs (74028).


X Remove six studs (74026) in the upper section and and fit four guide
bolts (90320).
X Leave 2 holes free for fitting the lifting device (90190).
X Push back internal part of compressor casing (76000) with extraction
screws (90900) until the lifting device (90190) can be attached with
Version 2.0

shackle (90195) and secured to the crane.


X Raise internal part of compressor casing slightly with wall insert and
diffuser, remove guide bolts (90320) and then withdraw.
X Fit support angle (90025).
X Place internal part of compressor casing with wall insert and diffuser on
support bracket and shim.
X Remove O-ring gasket (76040).

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 9

Compressor casing, inter-


nal part
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00047

X Refit the lifting device on the other side of the flange (F).
X Turn the internal part of the compressor casing with wall insert and dif-
fuser carefully over the support bracket (90025) and set down with the
front side of the flange (F) on the shim.

Ensure that the shim does not slip.


Version 2.0

X Check shim and adjust as necessary.


CAUTION

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 10

Diffuser

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00053

For the turbocharger sizes up to and including TPL 73-A, the diffuser is
Version 2.0

positioned by hand and therefore has no threaded holes in the diffuser


for the safety ring bolt 90230.
NOTE

X Loosen and remove screws (76002).

If provided: X Fit safety ring bolts (90230) on diffuser (79000).

X Remove diffuser (79000).

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 11

Compressor casing exter-


nal part
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

74000_002

X Secure lifting device (90190) with shackle (90195) to external part of


compressor casing (74000) and attach securely to the crane.
X Loosen nuts (61037), press off external part of compressor casing e-
venly with the three press-off nuts (61037) and remove.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 12

Cartridge group

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00054

X Withdraw cable (86515) and unscrew speed measuring transmitter


(86505) with O-ring gasket (86506).

If provided: X Disconnect cable to line amplifier (86525).


Version 2.0

X Remove the three screws (61059) and Verbus washers (61058).


X Check lifting equipment and secure to bearing casing (42001).

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Removing cartridge group 8.3 Page 13

During removal, a cartridge group that is not lifted in compliance with


regulations may fall, and can cause serious or even fatal injury.
May 2006

X Select a suitable rope taking into account the weight of the cartridge
CAUTION
group.

X Press cartridge group down evenly with jack screws (90900) into the
holes provided.

If the turbine blades on the rotor have too little or no clearance, this may
damage the blades and the casing.
X By turning the rotor, check that the turbine blades do not touch the
CAUTION
turbine diffuser.
HZTL2481_EN (TPL73-A.. - 80-A..)

X Extract the cartridge group and fit supports (90450).


X Cover oil connections.

Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Axial clearance 8.4 Page 14

8.4 Axial clearance

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
01000_001

Z Axial clearance A must be measured after the cartridge group is re-


moved and before it is fitted.
X Measure and note the axial clearance A.

Clearance A [mm] TPL 73 TPL 77 TPL 80


0.36 - 0.53 0.39 - 0.57 0.42 - 0.65
Version 2.0

If the axial clearance (A) is out of tolerance, an official service station of


ABB Turbo Systems must be contacted.

CAUTION

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 15


diffuser and nozzle ring

8.5 Dismantling and installing the turbine diffuser


and nozzle ring
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00055

X Place clamp (90921) over stud (61036) until it lies flush with the inner
radius of the gas outlet casing.
X Insert extension (A) of torque spanner (B) through the clamp hole and
release the torque of screws (61056) and Verbus washers (61057) in
succession.
X Do not yet remove the screws (61056) and Verbus washers (61057).
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 16


diffuser and nozzle ring

Removing the turbine


diffuser

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
56001_001

X In the upper section of the turbine diffuser (63000), replace the two
screws (61056) and Verbus washers (61057) with two guide bolts
(90320). Pass the guide bolts through the holes in clamps (90921).
X To secure, fit hexagon nuts (90178).

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 17


diffuser and nozzle ring

Secure diffuser
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

61000_002

X Before dismantling the turbine diffuser, if possible the nozzle ring


should be secured against falling with a clamping set and a wooden
block.
X Loosen the remaining screws (61056) and Verbus washers (61057).
X Push back the turbine diffuser (63000) with extraction screws (90901)
and withdraw the turbine diffuser until clamp (90921) contacts the hex-
headed nut (90178).

If the nozzle ring is not secured when the turbine diffuser is withdrawn,
it may fall. Note that the nozzle ring (56001) hangs loosely from the po-
sitioning pins.
CAUTION

X Fix turbine diffuser (63000) to the lifting gear and remove.


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 18


diffuser and nozzle ring

Remove diffuser

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
56001_002

X Fix the holder (90490) on gas outlet casing.

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 19


diffuser and nozzle ring
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

56001_003

X Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting
gear and remove.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Dismantling and installing the turbine 8.5 Page 20


diffuser and nozzle ring

Fitting the turbine diffuser and nozzle ring

X Fit the nozzle ring and the turbine diffuser by reversing the sequence

May 2006
Fitting
for removal.
X Align the nozzle ring with the holes in the gas inlet casing and assem-
ble with screws, nuts and bushings.

Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.

NOTE

Work that exceeds the scope of the description in this chapter must on-

HZTL2481_EN (TPL73-A.. - 80-A..)


ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 21

8.6 Installing the cartridge group


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00054

X Remove cover from the oil connector.


X Check the lifting equipment and secure it to the bearing casing (42001)
so that the cartridge group is hanging straight.
X Remove supports (90450) and carefully insert cartridge group.
X Tighten screws (61059) and the Verbus washers (61058) evenly.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 22

If the blades on the rotor have too little or no clearance, this may dam-
age the blades and the casing.

May 2006
X By turning the rotor, check that the turbine blades do not touch the
CAUTION
turbine diffuser.

X Remove lifting equipment.

If provided: X Connect cable to line amplifier (86525).

X Screw in the speed measuring transmitter (86505) with O-ring gasket


(86506) and connect cable (86515).

HZTL2481_EN (TPL73-A.. - 80-A..)

74000_002
Version 2.0

X Secure lifting device (90190) and shackle (90195) to external part of


compressor casing (74000) and attach securely to the crane.
X Assemble the external part of the compressor casing (74000) and se-
cure with nuts (61037).

Before fitting the external part of the compressor casing, screw three
press-off nuts (61037) to the end of the thread on the studs provided for
this purpose.
NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 23


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00053

For the turbocharger sizes up to and including TPL 73-A, the diffuser is
Version 2.0

positioned by hand and therefore has no threaded holes in the diffuser


for the safety ring bolt 90230.
NOTE
If provided X Transport diffuser (79000) with the fitted safety ring bolts (90230).

X Mount diffuser (79000) and align. Remove safety ring bolts.


X Fit the diffuser with the screws (76002).

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 24

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00047

X Attach the lifting device (90190) and shackle (90195) securely to the
back side of flange (F).
X Turn the internal part of compressor casing with wall insert and diffuser
carefully over the support bracket (90025) to the vertical position and
set down on the shim and support bracket.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 25


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00266

X Check that the nuts (90348) on the three safety segments are all tight-
ened.
X Attach the lifting device (90190) and shackle (90195) securely to the
front side of flange (F).
X Fit O-ring gasket (76040).
X Remove the support angle. (90025)
X Fit four guide bolts (90320).
X Carefully place the internal part of the compressor casing together with
the wall insert and the diffuser over the guide bolts.
Version 2.0

If provided:

Position of the safety X Loosen nuts (90458) on the threaded pins of the safety segments (Y)
segments after assembly on the internal part of the compressor casing (76000) and push the
threaded pins together with safety segment (Y) as far as they will go
against the external part of the compressor casing (74000).

D The internal part of the compressor casing (76000) is now secured a-


gainst the external part of the compressor casing (74000).

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Installing the cartridge group 8.6 Page 26

May 2006
L_00276

Note control dimension (s). Safety segments (Y) are in an operating


state again.

HZTL2481_EN (TPL73-A.. - 80-A..)


NOTE
Control dimension s [mm] Dimension TPL73-A TPL77-A TPL80-A
s 12.1 12.9 11.9
X Replace the nuts (90458) that were taken from the toolbox.

X Measure and note the axial clearance

Clearance A [mm] TPL 73 TPL 77 TPL 80


0.36 - 0.53 0.39 - 0.60 0.42 - 0.65

If the axial clearance A is out of tolerance, an official service station of


ABB Turbo Systems Ltd. must be contacted.

CAUTION

X Connect the oil lines and all air lines in accordance with the engine
Version 2.0

manufacturers instructions.
X Mount filter silencer or air suction branch and secure with nuts (72027)
and Verbus washers (74028).
X Fit insulation again.

Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Turbine-end removal / fitting of the 8.7 Page 27


nozzle ring

8.7 Turbine-end removal / fitting of the nozzle


ring
May 2006

If only the nozzle ring has to be removed, it is possible to dismantle it at


the turbine end.

NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00290

Disassembly of the nozzle X Remove the insulation on the gas inlet casing (51001).
ring X Secure the gas inlet casing with shackle (90195) and a suspension ro-
pe.
Version 2.0

X Remove the two hexagon head screws (61044) and Verbus washers
(61043) from the lower section and replace them with two studs
(90177).
X To secure, fit hexagon nuts (90178) onto the studs (90177).
X Loosen and remove the remaining screws (61044) and Verbus wash-
ers (61043) on the gas inlet casing flange (61001).
X Withdraw the gas inlet casing with the nozzle ring from the gas outlet
casing until holder (90175) can be fitted from outside with screws
(61044) and Verbus washers (61043).
X Release the hexagon nuts (90178) from the studs.

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Turbine-end removal / fitting of the 8.7 Page 28


nozzle ring

X Withdraw gas inlet casing fully and remove.

When positioning the gas inlet casing, use suitable shims and take care

May 2006
to avoid damaging the brackets for the insulation.

CAUTION
X Release holder (90175) and remove the nozzle ring with gasket
(61050).

Assembly of the nozzle X Fit nozzle ring and place the holder (90175) over the nozzle ring.
ring X Tighten holder (90175) with screw (61044) and Verbus washer
(61043).
X Insert gasket (61050) in the groove in the gas inlet casing (61001).
X Align the gas inlet casing and secure by fitting hexagon nuts (90178)
on the studs (90177).

HZTL2481_EN (TPL73-A.. - 80-A..)


X Remove holder (90175) and screw (61044) and Verbus washers
(61043).
X Fit and tighten the gas inlet casing flange to the gas outlet casing with
screws (61044) and Verbus washers (61043).
X Remove hexagon nuts (90178) from studs (90177).
X Replace the studs (91077) with hexagon head screws (61044) and
Verbus washers (61043).
X Remove shackle (90195) and suspension rope from gas inlet casing
(51001).
X Secure the insulation on the gas inlet casing (51001).

Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Table of tightening torques 8.8 Page 29

8.8 Table of tightening torques


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00044

The following tightening torques must be maintained for the specified


screwed connections:
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Disassembly and assembly 8

Table of tightening torques 8.8 Page 30

Tightening torques [Nm] Part no. TPL 73 TPL 77 TPL 80


42059 M16 M20 M20
105 240 240

May 2006
61036 M18 M20 M22
80 80 80
61037 M18 M20 M22
160 210 280
61044 M18 M20 M22
370 480 480
61056 M18 M20 M22
370 480 480
61059 M18 M20 M22
370 480 480
74026 M18 M20 M22
80 80 80

HZTL2481_EN (TPL73-A.. - 80-A..)


74027 M18 M20 M22
135 175 235
76002 M14 M16 M18
1) 1) 1)
82005 M16 x 1.5 M16 x 1.5 M16 x 1.5
50 50 50
86505 M18 x 1.5 M18 x 1.5 M22 x 1.5
150 150 220
90458 M10 M10 M10
30 30 30

1) Tighten so that the diffuser can still be moved.


Version 2.0

L_00228

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Possibilities for emergency repair 9.1 Page 1

9 Taking out of operation temporarily


9.1 Possibilities for emergency repair
May 2006

Lubricating oil leaks are a fire hazard.

WARNING

The instructions of the engine manufacturer for operation of the engine


with locked / isolated turbocharger must be followed precisely in all ca-
ses!
CAUTION
HZTL2481_EN (TPL73-A.. - 80-A..)

If the diesel engine must be capable of operation again as soon as possi-


ble after damage to the turbocharger (emergency repair), the following
possibilities are available:

Lock the turbocharger rotor


Fitting the cover plate
Blocking the inlets and outlets
Bypass the turbocharger
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 2

9.2 Locking the rotor

May 2006
A locked rotor must be disassembled following turbocharger repair and
given an imbalance check.

CAUTION

The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
NOTE locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.

U Once unscrewed, balancing screws must not be screwed in again.

HZTL2481_EN (TPL73-A.. - 80-A..)


Various intermediate rings are provided with the locking device for dif-
ferent compressor wheels. The compressor wheel type CV (for the
balancing screw holes) must be noted. The space between the locking
NOTE flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depend-
ing on the version of compressor wheel.

During operation of the engine with a locked turbocharger, the lubrica-


tion oil system must also remain connected to this turbocharger and tur-
ned on if the gas inlet cannot be blocked (see section Further measures
CAUTION and information for operation with a locked rotor for 4-stroke engines).
Otherwise components that are still intact can be damaged by over-
heating.
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 3

Locking rotor with screwed connection


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00225

Table of tightening tor- Part no. TPL73-A TPL77-A TPL80-A


ques [Nm]
74027 M18 M20 M22
135 175 235
94006 M8 M8 M10
25 25 45
94007 M8 M8 M10
15 15 35
Version 2.0

These operations must be carried out as described in the chapter Dis-


assembly and assembly.

NOTE
X Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 4

X Remove screw plug (25005).


X Fit studs (74026) as needed for the locking device on the compressor
casing.
X Mount the assembly-disassembly device (90020) and tighten nuts

May 2006
(74027) to the torques indicated in theTable of tightening torques.
X Block the rotor with lock (90480).
X Cut a thread (M12 or 1/2") in the existing hole and secure the lock with
a screw (A).

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 5

Locking rotor with polygon connection


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

L_00046

Table of tightening tor- Part no. TPL73-A TPL77-A TPL80-A


ques [Nm]
74027 M18 M20 M22
135 175 235
94006 M8 M8 M10
Version 2.0

25 25 45
94007 M8 M8 M10
15 15 35

These operations must be carried out as described in the chapter Dis-


assembly and assembly.

NOTE

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 6

X Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.

May 2006
X Fit partition wall clamp (94005) with screws (90442).
X Fit locking flange (94003) with the nuts (74027) and then with the
screws (94007 / 94006) according to the Table of tightening torques.

D For engines with three or four turbochargers, the balancing screws


should be removed from the compressor wheel concerned.

D For engines with one or two turbochargers, eight screws are sufficient
for secure fixing of the locking flange.

Locking rotor with polygon connection

Compressor type CV10

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

94000_002

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 7

Compressor type CV 20
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

94000_003

It must be ensured that all components are clean and free from grease.

CAUTION

X Push the intermediate rings (94001 and/or 94002) and assembly-


disassembly device (90020) onto the locking flange (94003) in the cor-
rect sequence.
X Now push on the other remaining intermediate rings (94001 and/or
94002).
X Tighten intermediate rings, assembly-disassembly device (90020) and
locking flange (94003) with the screws (94006) according to the values
Version 2.0

shown in the preceding Table of tightening torques.


X Now tighten the assembly-/disassembly device (74027) to the com-
pressor casing with the nuts (74027) and the studs to the values shown
in the preceding Tightening torques table.

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Locking the rotor 9.2 Page 8

Further measures and information for operation with a locked rotor for 4-
stroke engines

May 2006
4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as natu-


rally aspirated engine according to the instructions of the manufacturer.

4-stroke engine with several turbochargers

Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated en-
gine according to the instructions of the manufacturer.

HZTL2481_EN (TPL73-A.. - 80-A..)


Common air receiver If the engine is equipped with a common air receiver and separate ex-
haust-gas receivers, the compensator at the compressor outlet of the da-
maged turbocharger must be dismantled and the air line on the engine si-
de must be isolated. Otherwise the undamaged turbocharger can spin
"unloaded" and overspeed.

More or less powerful pulses from the exhaust-gas system are applied to
the locked rotor, depending on the engine turbocharging system. Particu-
larly with pulse supercharging (turbine casing with more than one gas in-
let) the locking device is then subjected to heavy loading. The following
operating limits should therefore not be exceeded:

In systems similar to those with constant pressure (1 gas inlet) the en-
gine can be operated up to a maximum of 25% engine load. The pres-
sure in the charge-air receiver must not exceed 0.9 bar overpressure.
With pulse supercharging (2...4 gas inlets) the engine can be operated
up to a maximum of 20% engine load. The pressure in the charge-air
receiver must not exceed 0.5 bar overpressure.
Version 2.0

Attention must be paid to the speed of the undamaged turbocharger in


all cases. Rotating speed limit nBmax as indicated on the rating plate
must not be exceeded.
CAUTION

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Fitting the cover plate 9.3 Page 9

9.3 Fitting the cover plate


May 2006

The cover plate (material: General structural steel, in accordance with


DIN EN 10025-2) must be produced in-house according to the drawing.

NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)

90000_001

Cover plate dimensions Type B1 B2 B3 B4 B5 B6 B7 B8


[mm]
TPL 73 50 50 9 12 8 94
Version 2.0

TPL 77 9 12 107
TPL 80 11 15 136

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Fitting the cover plate 9.3 Page 10

Type 1 2 3 4 5 6
TPL 73 844 948 905 20 28 20
TPL 77 1003 1124 1075 22 30

May 2006
TPL 80 1164 1300 1248 24 32

Type 1 2 3
TPL 73 - 80 4 x 90 37.5 24 x 15

HZTL2481_EN (TPL73-A.. - 80-A..)

20000_003
Version 2.0

These operations must be carried out as described in the chapter Dis-


assembly and assembly.

NOTE
X Removing cartridge group

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Fitting the cover plate 9.3 Page 11


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)

61000_003

X Block the opening in the gas outlet casing with the cover plate.
X Secure cover plate with spacer sleeves and nuts (61037).

Shut off the supply of lubricating oil to the turbocharger.

CAUTION
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Fitting the cover plate 9.3 Page 12

Further measures and information for operation with a turbocharger with

May 2006
cover plate in 4-stroke engines

4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as natu-


rally aspirated engine according to the instructions of the manufacturer.

4-stroke engine with several turbochargers

Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated en-

HZTL2481_EN (TPL73-A.. - 80-A..)


gine according to the instructions of the manufacturer.

Common receiver The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.

The engine can be operated according to the instructions of the engine


manufacturer. Attention must be paid to the speed of the undamaged
turbocharger in all cases. Rotating speed limit nBmax as indicated on the
CAUTION rating plate must not be exceeded.

Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Blocking the inlets and outlets 9.4 Page 13

9.4 Blocking the inlets and outlets


May 2006

Shut off the supply of lubricating oil to the turbocharger.

CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.

For information about how to do this, see the manufacturer's instruc-


tions.

NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Taking out of operation temporarily 9

Bypass the turbocharger 9.5 Page 14

9.5 Bypass the turbocharger

May 2006
Shut off the supply of lubricating oil to the turbocharger.

CAUTION

Z For engines with one turbocharger only:


Z The connections are ready and pipes for the bypass are to hand.
X Fit the bypass around the turbocharger.

For information about how to do this, see the manufacturer's instruc-


tions.

NOTE

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Mothballing the turbocharger 10

Taking out of operation for up to 12 10.1 Page 1


months

10 Mothballing the turbocharger


10.1 Taking out of operation for up to 12 months
May 2006

If a turbocharger has to be laid up for up to 12 months, the decision


whether the turbocharger needs special protection or not depends mainly
on the condition of the lubricating oil before laying up.

If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special


measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.

If the turbocharger is left mounted on the engine, and the engine oil is re-
placed by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
HZTL2481_EN (TPL73-A.. - 80-A..)

sensitive bearing parts will be largely protected against corrosion.

If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Mothballing the turbocharger 10

Taking out of operation for more than 12 10.2 Page 2


months

10.2 Taking out of operation for more than 12


months

May 2006
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbo-
charger must be done by an official ABB Turbo Systems service station.

Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.

Check mothballed turbochargers yearly for corrosion.


In the event of rust, clean and renew the corrosion protection.
NOTE

HZTL2481_EN (TPL73-A.. - 80-A..)


Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

Ordering spare parts 11.1 Page 1

11 Reserve and spare parts


11.1 Ordering spare parts
May 2006

When making inquiries or ordering spare parts, the following data should
be specified:

Turbocharger type
HT number
Description and part number

Our service stations and agents accept orders for spare parts.

X If special variants/cases are not addressed in these general instruc-


tions, contact an official ABB Turbo Systems Ltd. service station or an
ABB agent.
HZTL2481_EN (TPL73-A.. - 80-A..)

Spare-parts set

Spare-parts set (97070) is required for the work described in this man-
ual. The parts included in the spare-parts set are only available as part
of the complete set.
NOTE

TPL73-A Quantity Description Part number


2 Hexagon head 42059 / 42064
screw
2 Verbus washer 42058 / 42063
15 Hexagon head 61044 / 61056 / 61059
screw
15 Verbus washer 61043 / 61057 / 61058
Version 2.0

3 Hexagon nut 61037


1 Gasket 42041
1 Gasket 42045
2 O-ring gasket 42012 / 76040
2 O-ring gasket 77005 / 77006
1 O-ring gasket 86506
1 O-ring gasket 25011

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

Ordering spare parts 11.1 Page 2

TPL77-A Quantity Description Part number


15 Hexagon head 42059 / 42064 / 61044 / 61056 / 61059
screw

May 2006
15 Verbus washer 42058 / 42063 / 61043 / 61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring gasket 42012 / 76040
2 O-ring gasket 77005 / 77006
1 O-ring gasket 86506
1 O-ring gasket 25011

TPL80-A Quantity Description Part number

HZTL2481_EN (TPL73-A.. - 80-A..)


2 Hexagon head 42059 / 42064
screw
2 Verbus washer 42058 / 42063
15 Hexagon head 61044 / 61056 / 61059
screw
15 Verbus washer 61043 / 61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring gasket 42012 / 76040
2 O-ring gasket 77005 / 77006
1 O-ring gasket 86506
1 O-ring gasket 25011

All spare parts that have been ordered with the turbocharger should be
Version 2.0

kept complete and serviceable.


X Rusty parts should be carefully cleaned and greased.
CAUTION

X Dispose of parts that have been exchanged and are no longer usable
in a technically and environmentally compatible manner.

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

Directory of part numbers 11.2 Page 3

11.2 Directory of part numbers


The following part numbers and descriptions must be used in ALL corre-
spondence or orders:
May 2006

Turbocharger Part number Description


Cartridge group
51001 Gas inlet casing
56001 Nozzle ring
61001 Gas outlet casing
61043 (in spare parts set) Verbus washer
61044 (in spare parts set) Hexagon headed screw
61050 Gasket
61056 (in spare parts set) Hexagon headed screw
61057 (in spare parts set) Verbus washer
HZTL2481_EN (TPL73-A.. - 80-A..)

61058 (in spare parts set) Verbus washer


61059 (in spare parts set) Hexagon headed screw
61037 (in spare parts set) Hex.-headed nut
63000 Turbine diffuser
68000 Foot
74027 Hex.-headed nut
74000 Compressor casing external part
76000 Compressor casing, internal part
76040 (in spare parts set) O-ring gasket
76080 Safety segment
77000 Wall insert
77005 (in spare parts set) O-ring gasket
77006 (in spare parts set) O-ring gasket
79000 Diffuser
81000 Silencer
82000 Air suction branch, radial
Version 2.0

82000 Air suction branch, axial

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

Directory of part numbers 11.2 Page 4

Cartridge group screwed Part number Description


connection
21000 Shaft
25000 Compressor wheel

May 2006
25005 Screw plug
32001 Cam bearing
32101 Radial bearing, compressor side
32102 Radial bearing, turbine side
32104 Auxiliary bearing
32105 Float disc
32106 Axial bearing
32107 Bearing bush
42001 Bearing casing
42002 Cowling
42011 O-ring gasket

HZTL2481_EN (TPL73-A.. - 80-A..)


42012 (in spare parts set) O-ring gasket
42015 Gasket cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
42058 (in spare parts set) Verbus washer
42059 (in spare parts set) Hexagon headed screw
42063 (in spare parts set) Verbus washer
42064 (in spare parts set) Hexagon headed screw
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
86506 (in spare parts set) O-ring gasket
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

Directory of part numbers 11.2 Page 5

Cartridge group - polygon Part number Description


connection
21000 Shaft
25000 Compressor wheel
May 2006

25008 Threaded pin


25009 Ring nut
32001 Cam bearing
32101 Radial bearing, compressor side
32102 Radial bearing, turbine side
32104 Auxiliary bearing
32105 Float disc
32106 Axial bearing
32107 Bearing bush
42001 Bearing casing
42002 Cowling
HZTL2481_EN (TPL73-A.. - 80-A..)

42011 O-ring gasket


42012 (in spare parts set) O-ring gasket
42015 Gasket cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
42058 (in spare parts set) Verbus washer
42059 (in spare parts set) Hexagon headed screw
42063 (in spare parts set) Verbus washer
42064 (in spare parts set) Hexagon headed screw
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
86506 (in spare parts set) O-ring gasket
Version 2.0

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

General view of turbocharger 11.3 Page 6

11.3 General view of turbocharger

May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

L_00291

ABB Turbo Systems Ltd ABB


Operation Manual
Reserve and spare parts 11

General view of cartridge group 11.4 Page 7

11.4 General view of cartridge group


May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
Version 2.0

L_00039

ABB Turbo Systems Ltd ABB

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