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ABB HT842305 Operation Manual

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Operation Manual
Type TPL85-B14
n
Mmax
n
Bmax
Year
ABB Turbocharging
TPL85-B14
203
1/s
193
12000
kg
2020
HT842305
t
550
Mmax
t
520
Bmax
36
100
100
Application according to
the Operation Manual
°C

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Summary of Contents for ABB HT842305

  • Page 1 Operation Manual TPL85-B14 Type TPL85-B14 HT842305 Mmax Mmax °C Bmax Bmax 12000 Application according to Year 2020 the Operation Manual ABB Turbocharging...
  • Page 2 In case the operation conditions differs signifi cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.

  • Page 3: Table Of Contents

    Operation Manual / TPL85-B14/-B15/-B16 Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................5 Storage of new turbochargers and spare parts ............6 Essential information..................... 9 Symbols and definitions ....................
  • Page 4 Operation Manual / TPL85-B14/-B15/-B16 Table of contents Cleaning the compressor during operation ............53 Cleaning turbine blades and nozzle ring in operation ........... 58 Troubleshooting..................... 72 Malfunctions when starting..................72 Surging of the turbocharger..................73 Malfunctions during operation .................. 74 Malfunctions when stopping ..................

  • Page 5: Operation Manual

    Operation Manual This Operation Manual enables you to familiarize yourself with the tur- bocharger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.

  • Page 6: Layout And Function

    Operation Manual / TPL85-B14/-B15/-B16 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 1Filter silencer 7Nozzle ring 2Radial plain bearing 8Turbine wheel 3Thrust bearing 9Bearing casing 4Radial plain bearing 10Diffuser 5Gas outlet casing 11Compressor wheel 6Gas inlet casing 12Compressor casing ©...

  • Page 7: Intended Use Of The Turbocharger

    1.3 Intended use of the turbocharger This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.

  • Page 8: Storage Of New Turbochargers And Spare Parts

    ABB Turbo Systems. The manufacturer accepts no liabil- ity for any other type of use. If the equipment is used for any other pur- pose, ABB Turbo Systems reserves the right to reject all warranty claims. State of the art This turbocharger was built according to state-of-the-art technology and is operationally safe according to recognised safety regulations.
  • Page 9 Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration).
  • Page 10 1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts permissible humidity has been exceeded. In this case the turbochar- ger or rotor must be inspected by an ABB Turbocharging Service Sta- tion and repacked. Inspect the package for damage. If the package is damaged, the tur- bocharger or cartridge group must be inspected by an ABB Tur- bocharging Service Station and repacked.

  • Page 11: Essential Information

    The fault should be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger, which could impair safety, require the prior approval of ABB Turbo Sys- tems. © Copyright 2018 . All rights reserved. HZTL2491_EN...
  • Page 12 Only use original parts from ABB. ABB accepts no liability for any damage resulting from the use of non- original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.

  • Page 13: Symbols And Definitions

    Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Tur- bocharging Service Stations.

  • Page 14: Turbocharger Rating Plate

    Operation Manual / TPL85-B14/-B15/-B16 1 Preliminary remarks / 1.7 Turbocharger rating plate 1.7 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder. 02 Turbocharger operating limits during operation Recommended replace- 03 Replacement interval for plain bearings in 1000 h ment intervals for tur-...

  • Page 15: Contact Information

    A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet cas- ing.

  • Page 16: Safety

    2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...

  • Page 17: Definition Of Mandatory Signs

    Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.3 Definition of mandatory signs 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to pro- tect against mechanical hazard and risk of fall- To be worn according to the specific work Safety glasses Safety goggles Safety gloves against...

  • Page 18: Warning Plates On The Turbocharger

    Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.5 Warning plates on the turbocharger 2.5 Warning plates on the turbocharger Warning plates that must be observed are attached to the turbocharger. The warning plates must always be present in the intended locations and must be legible.
  • Page 19 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.6 Safe operation and maintenance Do not work on the turbocharger if you are under physical or mental stress. Work only with suitable tools as well as equipment and working ma- terials that are in perfect condition. Electric tools must be solidly earthed, and connecting cables may not be damaged.
  • Page 20 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.6 Safe operation and maintenance Safety during cleaning If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section "Haz- ards due to operating and auxiliary materials" must be observed. Observe the material safety data sheet for the cleaning agent or solvent.

  • Page 21: Hazards During Operation And Maintenance

    Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.7 Hazards during operation and maintenance 2.7 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly. WARNING Risk of injury Contact with rotating parts can lead to serious injuries.
  • Page 22 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.7 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful. WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb-...
  • Page 23 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.7 Hazards during operation and maintenance WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
  • Page 24 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the details in the material safety data sheets of the operat- ing and auxiliary materials.
  • Page 25 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.7 Hazards during operation and maintenance Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.

  • Page 26: Periodic Checking Of The Pressure Vessel

    Heed any country-specific regulations. 2.8 Periodic checking of the pressure vessel The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
  • Page 27 Operation Manual / TPL85-B14/-B15/-B16 2 Safety / 2.9 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading. Fasten turbocharger assemblies / components as described in re- spective handling steps.

  • Page 28: Start-Up

    Operation Manual / TPL85-B14/-B15/-B16 3 Start-up / 3.1 Oil supply 3 Start-up 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation. The turbocharger is normally lubricated with oil from the engine oil cir- cuit.
  • Page 29 Operation Manual / TPL85-B14/-B15/-B16 3 Start-up / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. The permissible oil pressures are specified in the following tables and depend on the type of lubrication (engine lubrication or separate lubric- ating system).
  • Page 30 If the turbocharger has been operated for a longer period of time out- side the admissible range, ABB Turbo Systems recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2018 . All rights reserved.

  • Page 31: Inspection Work

    Operation Manual / TPL85-B14/-B15/-B16 3 Start-up / 3.2 Inspection work 3.2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help de- tect changes to the turbocharger. Machine damage can be avoided. 3.2.1 Inspection before commissioning Monitoring devices Check for correct functioning.
  • Page 32 The first step is to check for leak- age of the oil supply to the turbocharger. If this is leaky, contact an offi- cial ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.

  • Page 33: Commissioning After Taking Out Of Operation

    Operation Manual / TPL85-B14/-B15/-B16 3 Start-up / 3.3 Commissioning after taking out of operation 3.3 Commissioning after taking out of operation If provided Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, before gas inlet and after gas outlet. Inspect exhaust gas duct / line in front of and after turbine for any combustion deposits, foreign matter or residual water.

  • Page 34: Operation

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running. When the sound pressure level is above 85 dB(A), always wear ear protection.

  • Page 35: Admissible Air Inlet Temperature

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.2 Admissible air inlet temperature Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line 4.2 Admissible air inlet temperature The permitted air inlet temperature must be between -40C°…...
  • Page 36 Despite observance of the service intervals, unusual loads, such as sev- eral start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys- tems. NOTICE...
  • Page 37 Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.3 Servicing work 4.3.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the tur- bocharger performance. The following operating data and measured values must be entered reg- ularly in the engine manufacturer's engine logbook: ¡...
  • Page 38 4.3.5 Service work every 36,000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Remove the filter silencer Clean the filter silencer and inspect for damage...

  • Page 39: Expected Exchange Intervals

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.4 Expected exchange intervals 4.4 Expected exchange intervals Rotating components The recommended replacement intervals for compressor wheels and tur- bine wheels are defined depending on the operating conditions and based on the safety concept (SiKo) for rotating parts. These intervals can be found on the turbocharger rating plate.

  • Page 40: Speed Measurement

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.5 Speed measurement Expected replacement in- Turbocharger part Operation with HFO tervals [h] Gas inlet casing 50000 … 100000 Gas outlet casing 50000 … 100000 Nozzle ring 35000 … 50000 Turbine diffuser / cover ring 25000 …...
  • Page 41 Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.5 Speed measurement Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...
  • Page 42 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate any problems. In any event, it is recommended that you contact the nearest ABB Tur- bocharging Service Station. © Copyright 2018 . All rights reserved.
  • Page 43 Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.5 Speed measurement 4.5.2 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C. Wear safety gloves when removing the cable connector and speed sensor.

  • Page 44: Underpressure Measurement On Filter Silencer

    4 Operation / 4.6 Underpressure measurement on filter silencer 4.6 Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for meas- uring the negative pressure at the filter silencer. The measurement can be used for the following purposes: ¡...

  • Page 45: Flexible Cut-Out

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.7 Flexible cut-out With a clean filter silencer (and clean filter mat, if provided), the max- imum pressure loss (A) is 120 mm H O at full load. When the pressure loss (A) has reached 200 mm H Clean filter silencer.

  • Page 46: Stopping The Engine

    Operation Manual / TPL85-B14/-B15/-B16 4 Operation / 4.8 Stopping the engine CAUTION Manual switching of the flaps If the gas inlet flap is opened during cut-out operation or the air-outlet flap is closed during normal operation, this causes very high turbochar- ger speeds.

  • Page 47: Maintenance

    Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.1 Foreword to Maintenance 5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble-free. ¡ The external condition and how dirty the cleaning points specified in this chapter are, must be established by visual checks at the spe- cified intervals.

  • Page 48: Cleaning The Filter Silencer

    Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.2 Cleaning the filter silencer 5.2 Cleaning the filter silencer 5.2.1 Filter silencer with tension band 81265 Filter ring (if provided) 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Sheet-metal covering 81268 Connecting strip...
  • Page 49 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated absorption segments, filter ring and damaged connecting strips with original parts from ABB Turbo Sys- tems. © Copyright 2018 . All rights reserved. HZTL2491_EN...
  • Page 50 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.2 Cleaning the filter silencer Fitting the filter silencer Assemble the insert units (E) by inserting the absorption seg- ments (81136) into the sheet-metal coverings (81137). Bend the sheet-metal coverings back into the original shape. Insert the insert units (E) into the slot guides in the filter silencer body (81135).
  • Page 51 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.2 Cleaning the filter silencer 5.2.2 Removing / installing the cleaning line Disassembling the cleaning pipe Disconnect feed pipe (02) from injection pipe (01) and remove pipe connector from feed pipe. Withdraw feed pipe (02) from guide tube (03). ©...
  • Page 52 Hammer guide tube (03) free from peen fixing using a bolt (diameter = 16 mm) and withdraw it. Replace damaged parts of the complete cleaning pipe with original parts from ABB Turbo Systems. Fitting complete cleaning pipe Refit guide tube (03) and peen fix it after putting insert units (E) in place.

  • Page 53: Changing The Filter Strip On The Filter Silencer Casing

    Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.3 Changing the filter strip on the filter silencer cas- 5.3 Changing the filter strip on the filter silencer casing This chapter is only applicable to turbochargers with a filter silencer cas- ing. The filter strip (81265) is replaced when a filter silencer is fitted. Dismantle the circumferential part (9).
  • Page 54 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.3 Changing the filter strip on the filter silencer cas- Secure a new filter strip (81265) so that it overlaps the filter strip be- ing replaced. Pull the old filter strip until the new filter strip is wound completely around filter silencer.

  • Page 55: Cleaning The Compressor During Operation

    The interval between periodic cleaning is very dependent on the operat- ing conditions. In general, cleaning should be carried out every 25 ... 100 operating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C...
  • Page 56 Cleaning of the compressor during operation is carried out using the cleaning method described in the following: ¡ Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer.
  • Page 57 5.4.1 Wet cleaning using external water-pressure vessel (XC3) In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 ... 85% If the engine compartment temperature is less than 0°C during wet...
  • Page 58 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. Cleaning parameters per turbocharger compressor...
  • Page 59 5.4.2 Wet cleaning using vacuum cleaning device on filter silencer (XC4) In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 ... 85% If the engine compartment temperature is less than 0°C during wet...

  • Page 60: Cleaning Turbine Blades And Nozzle Ring In Operation

    If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
  • Page 61 Cleaning methods Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the following have been tested and are recommended by ABB Turbo Systems: ¡ Wet cleaning ¡ Dry cleaning Principle of wet cleaning Wet cleaning makes use of various effects.
  • Page 62 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Components at the turbine end are not cleaned until the engine has been started or the engine load reduced. The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions (see section PrerequisitesTPL-A/-C: Operating state prerequisites for wet cleaning turbine and nozzle ring).
  • Page 63 Operating state prerequisites for wet cleaning In order to be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be met: After an engine start-up or during operation, the engine performance...
  • Page 64 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Wet cleaning 1Water supply (fresh water only) 8Drain pipe 2Regulating valve 9Drain cock 3Manometer 10Drain 5Stainless-steel piping 11Orifice (integrated into tur- bocharger) 6Other turbochargers 21Air line from the compressor casing 7Injection nozzle item 7a or 7b...
  • Page 65 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. NOTICE While the water is being injected, grinding noises might be heard at the turbine end.
  • Page 66 Operating state prerequisites for integrated dry cleaning device In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 ... 85% Start the cleaning cycle according to the following description Oper- ating the integrated dry cleaning device.
  • Page 67 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion 02 Cover cap (51503) 08 Clamp (51515) 03 Compressed air supply [4 to 10 09 Pipe elbow (51521) bar] 04 Hose (51512) 10 Heat protection hose (51516) 05 On-Off valve (51505) Screw insert (51514) 06 Ball valve (51513)
  • Page 68 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. © Copyright 2018 . All rights reserved.
  • Page 69 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Cleaning parameters for the integrated dry-cleaning device Possible suppliers of material for dry cleaning can be found on the Inter- net. Choice of materials The following materials are suitable for dry cleaning: ¡...
  • Page 70 Operating state prerequisites for non-integrated dry cleaning device In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 ... 85% Start the cleaning cycle according to the following description Oper- ating the non-integrated dry cleaning device.
  • Page 71 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Operating non-integrated dry cleaning device 01Cover cap G2" 06Strap to secure container 02Possible copper gasket 07Safety valve with vent 03Double nipple G2" 08Compressed air shut-off valve 04Copper gasket 09Compressed air line (inner diameter 8 mm)
  • Page 72 Operation Manual / TPL85-B14/-B15/-B16 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion CAUTION The air system must be protected against overpressure (> 6 bar). Operating the dry clean- Before cleaning, the prerequisite operating state for the non-integ- ing device rated dry cleaning device must be met.
  • Page 73 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. Cleaning parameters for non-integrated dry cleaning device...

  • Page 74: Troubleshooting

    If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted. ¡ Have a dimension check carried out by an ABB Turbochar- ging Service Station. © Copyright 2018 . All rights reserved.

  • Page 75: Surging Of The Turbocharger

    Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.

  • Page 76: Malfunctions During Operation

    Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Turbochar- Heavy contamination in the tur-...
  • Page 77 Exhaust counterpressure Clean or repair the boiler or ex- too high haust silencer Enlarged flow cross-section Contact an ABB Turbocharging of the nozzle ring due to de- Service Station formed blade trailing edges Damaged or eroded turbine Charge air...
  • Page 78 Contaminated filter silencer Clean it causing excessive loss of pres- sure Compressor / turbine contam- inated Damaged compressor / tur- Contact an ABB Turbocharging bine Service Station Exhaust counterpressure too Clean or repair the boiler or ex- high haust silencer...

  • Page 79: Malfunctions When Stopping

    6 Troubleshooting / 6.4 Malfunctions when stopping 6.4 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbochar- Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbochar- Turbocharger contaminated...

  • Page 80: Speed Measurement System

    This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service sta- tion. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.

  • Page 81: Removal And Installation

    Operation Manual / TPL85-B14/-B15/-B16 7 Removal and installation / 7.1 Turbocharger weights 7 Removal and installation 7.1 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible.
  • Page 82 Operation Manual / TPL85-B14/-B15/-B16 7 Removal and installation / 7.2 Removing the turbocharger Unscrew fixing screws in foot. Lift turbocharger off engine and put it down to one side. WARNING If support for the turbocharger is missing or defective when setting it aside, the turbocharger could tip over and cause serious or even fatal injuries.

  • Page 83: Installing The Turbocharger

    Operation Manual / TPL85-B14/-B15/-B16 7 Removal and installation / 7.3 Installing the turbocharger 7.3 Installing the turbocharger Remove cover from oil connection. Fasten each of two sets of lifting gear to each of two bearing casing ribs provided for this purpose. CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two...

  • Page 84: Disassembly And Assembly

    Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station. Only carry out those tasks that are described in this chapter. Mark the casing position for assembly.
  • Page 85 The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.) Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.

  • Page 86: Module Weights

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.2 Module weights 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value. Weights [kg] Item Description TPL85-B Filter silencer Compressor casing internal part Wall insert...
  • Page 87 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.2 Module weights Weight [kg] TPL85-B 1630 NOTICE 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.

  • Page 88: Silencer Casing

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.3 Silencer casing 8.3 Silencer casing NOTICE Disassembly / assembly of the silencer casing This section is applicable only to turbochargers with a filter silencer casing. Only the assembly of the silencer casing is described in detail. Its disassembly is carried out in the reverse order of its assembly.
  • Page 89 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.3 Silencer casing Fitting NOTICE Screws on the silencer casing All silencer casing screws may be tightened only when assembly work is finished. Only then is it possible for all parts to be fitted. Do not tighten screws during assembly.
  • Page 90 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.3 Silencer casing Fit bottom part (2) to filter silencer using screws. Fit side parts (3) and (4) to filter silencer and to bottom part (1) using screws. Fit side parts (7) and (8) to filter silencer, to bottom part (2) and to side parts (3, 4) using screws.
  • Page 91 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.3 Silencer casing Insert flanges (10) and (11) from the side between side parts and fit screws. Fit circumferential part (5) using screws. Fit circumferential part (6) using screws. Fit circumferential part (9) using screws. ©...

  • Page 92: Removing And Installing The Filter Silencer

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.4 Removing and installing the filter si- lencer Tightening screws Tightening torques [Nm] Screws for fastening individual parts to Screws for fastening indi- the filter silencer vidual parts Tighten all screws of bottom parts (1) and (2). Tighten all screws of side parts (3, 4, 7 and 8) and flanges (10 and 11).
  • Page 93 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.4 Removing and installing the filter si- lencer Secure the shackle (90195) to a rib / fin on the filter silencer. Pass the lifting gear through the eyelets on the back side. Unscrew the nuts (74027) and remove them together with the wash- ers (74018).

  • Page 94: Axial Clearance

    Measure and note the axial clearance (A). Clearance A [mm] TPL85-B 0.54 … 0.79 CAUTION If the axial clearance A is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C...

  • Page 95: Removing Internal Part Of Compressor Casing

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.6 Removing internal part of com- pressor casing 8.6 Removing internal part of compressor casing CAUTION Locked safety segments (76080) during disassembly Observe the maximum tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (76080).
  • Page 96 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.6 Removing internal part of com- pressor casing Removing the compressor casing internal part Unscrew nuts (74027) and remove them together with washers (74018). Remove four studs (74026/74029) in the upper section and fit two guide studs (90320).
  • Page 97 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.6 Removing internal part of com- pressor casing Slightly raise the compressor casing internal part (76000) along with the wall insert and diffuser using the lifting device (90190). Use a second set of lifting gear to carefully move the compressor cas- ing internal part (76000) into a vertical position.
  • Page 98 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.6 Removing internal part of com- pressor casing Removing the diffuser Remove screws (76002). Loop lifting gear around diffuser (79000) and remove diffuser. Carefully press off the wall insert (77000) using the press-off screws (90900) and remove it using the swivel lifting eye (90230).

  • Page 99: Removing Gas Inlet Casing

    51087 840 Nm Screw-on variant If one of the screws (61044) breaks off when loosening, an ABB Tur- bocharging Service Station must be contacted. Loosen the screws (61044) and remove the gas inlet casing (51001) along with the nozzle ring (56001).
  • Page 100 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.7 Removing gas inlet casing Undo and remove screws (57005). Fit two guide studs (90320). Push away the cover ring (51085) using the press-off screws (90907) and remove it over the guide studs (90320). ©...

  • Page 101: Fitting Gas Inlet Casing

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.8 Fitting gas inlet casing 8.8 Fitting gas inlet casing If removed: Fit the cover ring (51085) with the help of the two guide studs (90320). CAUTION Positioning the cover ring Align the marking "TOP"...

  • Page 102: Fitting Internal Part Of Compressor Casing

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.9 Fitting internal part of compressor casing 8.9 Fitting internal part of compressor casing Fitting the diffuser Fit O-rings (77005, 77006) to wall insert (77000). Attach lifting gear and fit swivel lifting eyes (90230). Align wall insert (77000) with threaded holes in internal part (76000) of compressor casing using dog points on swivel lifting eyes (90230) and then lower it.
  • Page 103 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.9 Fitting internal part of compressor casing Fitting internal part of compressor casing Lift internal part (76000) of compressor casing complete with wall in- sert and diffuser using two sets of lifting gear. Carefully slacken lifting gear fastened to support angle (90025) until internal part (76000) of compressor casing is suspended only from lifting device (90190).
  • Page 104 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.9 Fitting internal part of compressor casing CAUTION Locked safety segments (76080) during assembly The safety segments (76080) are not in the operating position. Addi- tional axial securing of the two compressor casings (74000/76000) is not guaranteed.

  • Page 105: Dry-Cleaning Device

    Clearance A [mm] TPL85-B 0.54 … 0.79 CAUTION If the axial clearance A is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. Unscrew nuts (74027) and remove them together with washers (74018). Installing the filter silen-...
  • Page 106 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.10 Dry-cleaning device Brush the thread of the parts marked with *) with high-temperature grease. Fit the connecting plate (51511) onto the pressure vessel (51501) with hexagon-head screws (51518) and washers (51519). Mount the connecting plate (51511) onto the gas outlet casing with hexagon-head screws (51520).
  • Page 107 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.10 Dry-cleaning device © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...

  • Page 108: Table Of Tightening Torques

    Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.11 Table of tightening torques 8.11 Table of tightening torques © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...
  • Page 109 Operation Manual / TPL85-B14/-B15/-B16 8 Disassembly and assembly / 8.11 Table of tightening torques Tightening torques [Nm] Item Part number TPL85-B 82005 M16 x 1.5 76002 74027 (with washer) 74026 / 74029 61044 51087 42059, 42064 86505 M22 x 1.5 56014 57005 90458 Screw in the screw (76002) as far as it will go and then un- screw it by ¼...

  • Page 110: Short-Term Turbocharger Shut-Down

    Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.1 Possibilities for emer- gency repair 9 Short-term turbocharger shut-down 9.1 Possibilities for emergency repair WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces. This can result in serious injuries to personnel or fatal accidents.

  • Page 111: Locking The Rotor

    Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.2 Locking the rotor 9.2 Locking the rotor 9.2.1 Preliminary remarks Attention must be paid to the version / design of the compressor wheel ”CV” for locking the rotor. The version / design is engraved in the com- pressor wheel near the holes for the balancing screws.
  • Page 112 Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.2 Locking the rotor 9.2.2 Fitting locking device Remove filter silencer and internal part of compressor casing com- plete with wall insert and diffuser. (See chapter Disassembly and as- sembly.) Fix partition wall using press-off tools (90920) and screws. Fit locking device (90020) in accordance with following illustrations.
  • Page 113 Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.2 Locking the rotor TPL85-B14/-B15/-B16 Compressor type CV11 Compressor type CV12, CV13, CV16 © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...

  • Page 114: Shutting Off Inlets And Outlets

    Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.3 Shutting off inlets and outlets 9.2.3 Further information for operation with locked rotor on 2-stroke engines 2-stroke engine with one No further measures are necessary. The engine can be operated with the turbocharger: auxiliary blower according to the manufacturer's instructions.

  • Page 115: Bypass The Turbocharger

    Operation Manual / TPL85-B14/-B15/-B16 9 Short-term turbocharger shut-down / 9.4 Bypass the turbocharger 9.4 Bypass the turbocharger CAUTION Shut off the lubricating oil supply to the turbocharger. This applies to engines with one turbocharger only: The connections are ready and pipes for the bypass are available. Fit bypass around turbocharger.

  • Page 116: Storing Turbocharger

    Remove turbocharger. Rotor and bearing parts must be removed by an official ABB Tur- bocharging service station and refitted afterwards. Clean all parts. Oil machined, bright surfaces of steel and cast parts using anticorros- ive oil.
  • Page 117 Operation Manual / TPL85-B14/-B15/-B16 10 Storing turbocharger / 10.2 Taking out of operation for more than 12 months ¡ The turbocharger casing remains mounted on the engine, but the ro- tor and the bearing parts are removed and stored separately. ¡...

  • Page 118: Disposing Of Turbocharger Components

    Operation Manual / TPL85-B14/-B15/-B16 11 Disposing of turbocharger components / ​ 11 Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts. Avoid the formation of dust.

  • Page 119: Spare Parts

    Serial number (HT……) ¡ Designation and part number. Spare parts can be ordered from an official ABB Turbocharging service station. If different design versions have not been taken into consideration in this document, please contact an ABB Turbocharging service station.
  • Page 120 Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.1 Ordering spare parts Customer spare part set (97070) for service work every 36000 h Quantity Description Part number O-ring 42012, 76040 Gasket 42041, 42069 Hexagon-head screw 42059, 42064 Gasket 42045 Hexagon-head screw 56014, 57005 Hexagon nut 61037...
  • Page 121 Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.1 Ordering spare parts © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...

  • Page 122: View Of Turbocharger With Part Numbers

    Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.2 View of turbocharger with part numbers 12.2 View of turbocharger with part numbers © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...
  • Page 123 Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.2 View of turbocharger with part numbers Part number Description Cartridge group 51001 Gas inlet casing 51085 Cover ring 51086 Threaded stud 51087 Hexagon nut 56001 Nozzle ring 61001 Gas outlet casing 61035 Hexagon-head screw 61037 (in customer spare part...

  • Page 124: View Of Cartridge Group With Part Numbers

    Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.3 View of cartridge group with part numbers 12.3 View of cartridge group with part numbers © Copyright 2018 . All rights reserved. HZTL2491_EN Revision C August 2018...
  • Page 125 Operation Manual / TPL85-B14/-B15/-B16 12 Spare parts / 12.3 View of cartridge group with part numbers Part number Description 21000 Shaft 25000 Compressor wheel 25008 Threaded stud 25009 Ring nut 32001 Thrust bearing 32101 Radial bearing at compressor end 32102 Radial bearing at turbine end 32104 Auxiliary bearing...
  • Page 126  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

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