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ABB TPL65VA10 Operation Manual

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Operation Manual
Type TPL65VA10
n
Mmax
n
Bmax
Year
ABB Turbocharging
TPL65VA10
ABB Turbo Systems Ltd
CH 5401 Baden
503
1/s
478
01210
kg
2018
made in Switzerland
HT844106
t
650
Mmax
t
620
Bmax
35
50
50
Application according to
the Operation Manual
°C

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Summary of Contents for ABB TPL65VA10

  • Page 1 Operation Manual TPL65VA10 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65VA10 HT844106 Mmax Mmax °C Bmax Bmax 01210 Application according to Year 2018 the Operation Manual made in Switzerland ABB Turbocharging...
  • Page 2 In case the operation conditions differs signifi cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.

  • Page 3: Table Of Contents

    Operation Manual / TPL65VA10 / VA30 Table of contents Page 1 Table of contents Preliminary remarks Purpose of this manual Layout and function Intended use of the turbocharger Storage of new turbochargers and spare parts Essential information Symbols and definitions...
  • Page 4 Operation Manual / TPL65VA10 / VA30 Table of contents Page 2 Maintenance Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbines and guide vanes during operation Cleaning components mechanically Troubleshooting Malfunctions when starting Surging of the turbocharger...
  • Page 5 Operation Manual / TPL65VA10 / VA30 Table of contents Page 3 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months 10.2 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1...

  • Page 7: Preliminary Remarks

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

  • Page 8: Layout And Function

    Operation Manual / TPL65VA10 / VA30 Preliminary remarks Layout and function Page 6 Layout and function 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser...
  • Page 9 Operation Manual / TPL65VA10 / VA30 Preliminary remarks Layout and function Page 7 Mode of operation The turbocharger is a turbomachine and consists of the following main components:  Turbine  Compressor These are both mounted on a common shaft.
  • Page 10 Operation Manual / TPL65VA10 / VA30 Preliminary remarks Layout and function Page 8 Additional function TPL..V. These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring. © Copyright 2016 ABB. All rights reserved.

  • Page 11: Intended Use Of The Turbocharger

    Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys- tems reserves the right to reject all warranty claims.

  • Page 12: Storage Of New Turbochargers And Spare Parts

    Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
  • Page 13 Page 11 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.

  • Page 14: Essential Information

    The fault must be reported to the person or depart- ment responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2016 ABB. All rights reserved.
  • Page 15 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.

  • Page 16: 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 Turbo- charging Service Stations.

  • Page 17: Turbocharger Rating Plate

    Operation Manual / TPL65VA10 / VA30 Preliminary remarks Turbocharger rating plate Page 15 Turbocharger rating plate Operating limits Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the en- ginebuilder.
  • Page 18 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.

  • Page 19: Contact Information

    Operation Manual / TPL65VA10 / VA30 Preliminary remarks Contact information Page 17 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...

  • Page 21: Safety

    Page 19 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...

  • Page 22: Definition Of Mandatory Signs

    Operation Manual / TPL65VA10 / VA30 Safety Definition of mandatory signs Page 20 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear against mechanical hazards To be worn according to the specific work Safety glasses...

  • Page 23: Warning Plates On The Turbocharger

    Warning plates on the turbocharger Page 21 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.

  • Page 24: Safe Operation And Maintenance

    Operation Manual / TPL65VA10 / VA30 Safety Safe operation and maintenance Page 22 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
  • Page 25 Operation Manual / TPL65VA10 / VA30 Safety Safe operation and maintenance Page 23 Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area.  Remove any obstacles and objects lying around.  Before start-up / commissioning, check all pipes from and to turbo- ...
  • Page 26 Operation Manual / TPL65VA10 / VA30 Safety Safe operation and maintenance Page 24 Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as inspec-  tion work and observe inspection intervals. Inform operating personnel about all service and repair work before ...

  • Page 27: Hazards During Operation And Maintenance

    Operation Manual / TPL65VA10 / VA30 Safety Hazards during operation and Page 25 maintenance Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the turbo- charger if it has been installed properly.
  • Page 28 Operation Manual / TPL65VA10 / VA30 Safety Hazards during operation and Page 26 maintenance Hazards due to noise The development of noise during operation is influenced by the installation and operating conditions. Noise with a sound pressure level exceeding 85 dB(A) is harmful.
  • Page 29 Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
  • Page 30 Operation Manual / TPL65VA10 / VA30 Safety Hazards during operation and Page 28 maintenance Risk of fire, explosion Combustible or easily ignited operating and auxiliary materials can burst into flame, or vapours from them can cause explosions. WARNING Observe specifications in the safety data sheets of the operating and ...
  • Page 31 Operation Manual / TPL65VA10 / VA30 Safety Hazards during operation and Page 29 maintenance Hazards when handling insulating materials 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 WARNING hazard.
  • Page 32 Operation Manual / TPL65VA10 / VA30 Safety Hazards during operation and Page 30 maintenance Hazards due to electrical components Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by ...

  • Page 33: Periodic Checking Of The Pressure Vessel

    Page 31 vessel Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.

  • Page 34: Lifting Loads

    Operation Manual / TPL65VA10 / VA30 Safety Lifting loads Page 32 Lifting loads Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. WARNING Loads must always be fastened to technically perfect lifting gear with ...

  • Page 35: Start-Up

    Operation Manual / TPL65VA10 / VA30 Start-up Oil supply Page 33 Start-up Oil supply A carefully designed and installed oil supply, which functions in all possi- ble operational conditions, is an important prerequisite for trouble-free tur- bocharger operation. The turbocharger is normally lubricated with oil from the engine oil circuit.
  • Page 36 Operation Manual / TPL65VA10 / VA30 Start-up Oil supply Page 34 Oil pressure The oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
  • Page 37 > 165 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbo- charger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.

  • Page 38: Inspection Work

    Operation Manual / TPL65VA10 / VA30 Start-up Inspection work Page 36 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.
  • Page 39 The first step is NOTICE to check the seal for the oil supply to the turbocharger. If this is not in proper condition, contact an official ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.

  • Page 40: Commissioning After Taking Out Of Operation

    Operation Manual / TPL65VA10 / VA30 Start-up Commissioning after taking out of Page 38 operation Commissioning after taking out of operation Remove cover plates (blind flanges) between compressor casing out- If provided  let and charge air duct, before gas inlet and after gas outlet.

  • Page 41: Operation

    Operation Manual / TPL65VA10 / VA30 Operation Noise emissions Page 39 Operation Noise emissions Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. WARNING Always wear ear protection when the engine is running.
  • Page 42 Operation Manual / TPL65VA10 / VA30 Operation Noise emissions Page 40 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line © Copyright 2016 ABB. All rights reserved.

  • Page 43: Servicing Work

    Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
  • Page 44 Operation Manual / TPL65VA10 / VA30 Operation Servicing work Page 42 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the turbo- charger performance. The following operating data and measured values must be entered regu- larly in the engine manufacturer's engine logbook: ...
  • Page 45 (Customer Part Exchange) programme. 4.2.5 Service work every 30000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.

  • Page 46: Replacement Intervals For Turbocharger Components

    Operation Manual / TPL65VA10 / VA30 Operation Replacement intervals for turbocharger Page 44 components Replacement intervals for turbocharger com- ponents The recommended replacement intervals for the compressor and turbine Rotating components wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components.
  • Page 47 Operation Manual / TPL65VA10 / VA30 Operation Replacement intervals for turbocharger Page 45 components Parameters influencing rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Turbine cleaning frequency  Procedure for turbine cleaning  Load profile...

  • Page 48: Speed Measurement

    Operation Manual / TPL65VA10 / VA30 Operation Speed measurement Page 46 Speed measurement A speed measuring system permits continuous monitoring of the turbo- charger speed. Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
  • Page 49 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
  • Page 50 Operation Manual / TPL65VA10 / VA30 Operation Speed measurement Page 48 4.4.2 Assembly If the speed sensor is not fitted on the turbocharger, the following proce- dure must be adopted to fit it: Engine and turbocharger are not running. ...
  • Page 51 Operation Manual / TPL65VA10 / VA30 Operation Speed measurement Page 49 4.4.3 Replacing the speed sensor 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.

  • Page 52: Emergency Operation Tpl

    Operation Manual / TPL65VA10 / VA30 Operation Emergency operation TPL..VA Page 50 Emergency operation TPL..VA Detail A In the event of failure of the control system or the drive, the variable tur- bine geometry module can be fixed by clamping the ring lever (B) using at least 3 washers (C) spaced around the circumference.

  • Page 53: Stopping The Engine

    Operation Manual / TPL65VA10 / VA30 Operation Stopping the engine Page 51 Stopping the engine Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further ...

  • Page 55: Maintenance

    Operation Manual / TPL65VA10 / VA30 Maintenance Foreword to Maintenance Page 53 Maintenance 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 specified intervals.

  • Page 56: Cleaning The Filter Silencer

    Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the filter silencer Page 54 Cleaning the filter silencer 5.2.1 Filter silencer with tension band 81265 Filter ring (if provided) 81138 Sheet-metal covering 81270 Tension band 81005 Screw plug 38271 Lock 81006 Gasket...
  • Page 57 Otherwise segments may be damaged or lose their shape. Replace absorption segments which are heavily contaminated and the filter ring with original parts from ABB Turbo Systems. NOTICE Fitting the filter silencer Assemble the insert units (E) by inserting the absorption seg- ...
  • Page 58 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the filter silencer Page 56 5.2.2 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body...
  • Page 59 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the filter silencer Page 57 Unscrew and remove lock nuts (81273).  Unscrew and remove screws (81272) for connecting rods (81269).  Remove connecting rods (81269).  Carefully remove cover grids (81266).
  • Page 60 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the filter silencer Page 58 Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments  (81136) into the sheet metal coverings (81137). Bend sheet metal coverings (81137) back to original shape.
  • Page 61 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the filter silencer Page 59 Join connecting rods (81269) using screws (81272). When tightening  the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten...

  • Page 62: Cleaning The Compressor During Operation

    Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning the compressor during Page 60 operation Cleaning the compressor during operation These instructions for wet cleaning only apply when cleaning is carried out Approval by enginebuilder with clean water and under the precondition that the enginebuilder ap- proves the process.
  • Page 63 Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. To clean the compressor stage during operation, water is injected in front...
  • Page 64 Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Engine load 50 ... 85% ...
  • Page 65 If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharg- ing Service Station. Cleaning parameters per turbocharger compressor...

  • Page 66: Cleaning Turbines And Guide Vanes During Operation

    Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning turbines and guide vanes Page 64 during operation Cleaning turbines and guide vanes during operation HFO applications The TPL65VA.. has not been released for HFO applications. Wet clean- ing of the turbine blades and guide vanes during operation is thus nei- NOTICE ther required nor planned.

  • Page 67: Cleaning Components Mechanically

    (see chapter entitled Service work). Professional overhauling of the components by an ABB Turbocharging Service Station is required, preferably using the cleaning method de- scribed in the following.
  • Page 68 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 66 Turbine-end, non-rotating parts 5.5.2 Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. WARNING Do not breathe in these substances and avoid contact with the skin.
  • Page 69 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 67 Cartridge group – General 5.5.3 Corrosion If the cartridge group is not put into operation again immediately after cleaning, parts may corrode. CAUTION Re-install and use the cartridge group immediately after cleaning.
  • Page 70 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 68 Cleaning the cartridge group on the turbine end 5.5.5 Soaking the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end. The contamination can be removed by soaking and brushing.
  • Page 71 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 69 4. When the cartridge group is horizontal, secure one chain block from one of the upper push-off threads using a swivel lifting eye and sus- pend from the second crane.
  • Page 72 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 70 Cartridge group with two side suspension points Or use two swivel lifting eyes at top. Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation.
  • Page 73 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 71 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane. 5. Tighten chain block until entire cartridge group is suspended from first crane.
  • Page 74 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 72 Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. NOTICE Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
  • Page 75 Operation Manual / TPL65VA10 / VA30 Maintenance Cleaning components mechanically Page 73 Remove contamination manually with a soft brush or wire brush.  Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbocharger...

  • Page 77: Troubleshooting

    Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.

  • Page 78: Surging Of The Turbocharger

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

  • Page 79: Malfunctions During Operation

    Operation Manual / TPL65VA10 / VA30 Troubleshooting Malfunctions during operation Page 77 Malfunctions during operation Lubricating oil pressure too low Possible causes Elimination Engine Oil filter heavily contaminated Clean it Defective oil pump in lubricating Check / replace it system...
  • Page 80 Operation Manual / TPL65VA10 / VA30 Troubleshooting Malfunctions during operation Page 78 Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Elimination Engine Malfunctioning injection Repair it or contact the manufac- system turer Turbocharger Air starvation, for example...
  • Page 81 Operation Manual / TPL65VA10 / VA30 Troubleshooting Malfunctions during operation Page 79 Charge air pressure too low Engine performance and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Air receiver leaking Make repairs Gas piping between the engine...

  • Page 82: Malfunctions When Stopping

    Operation Manual / TPL65VA10 / VA30 Troubleshooting Malfunctions when stopping Page 80 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger...

  • Page 83: Speed Measurement System

    Operation Manual / TPL65VA10 / VA30 Troubleshooting Speed measurement system Page 81 Speed measurement system Possible causes Elimination Signal Fitting error The screw plug for the sensor is fitted with a amplitude non gasket. existent or When fitting the speed sensor, this gasket poor must be removed.

  • Page 84: Variable Turbine Geometry

    Operation Manual / TPL65VA10 / VA30 Troubleshooting Variable Turbine Geometry Page 82 Variable Turbine Geometry Variable Turbine Geometry (VTG) not adjustable Possible causes Elimination Turbocharger Heavy turbine Contact an ABB Turbocharging contamination Service Station VTG bearing damaged Drive unit No drive energy...

  • Page 85: Removal And Installation

    Operation Manual / TPL65VA10 / VA30 Removal and installation Turbocharger weights Page 83 Removal and installation Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and in- stalling the turbocharger. The following weight specification is the heaviest variant possible.

  • Page 86: Removing The Turbocharger

    Operation Manual / TPL65VA10 / VA30 Removal and installation Removing the turbocharger Page 84 Removing the turbocharger Disconnect all gas, air and oil lines in accordance with the en-  ginebuilder’s instructions. Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing.
  • Page 87 Operation Manual / TPL65VA10 / VA30 Removal and installation Removing the turbocharger Page 85 Ribs (01) not in the middle at the top:  Completely remove the bearing casing insulation (02) and place a  sling around the bearing casing.

  • Page 88: Installing The Turbocharger

    Operation Manual / TPL65VA10 / VA30 Removal and installation Installing the turbocharger Page 86 Installing the turbocharger Remove cover from oil connection.  Inspect lifting gear.  Fasten lifting gear to each of two bearing casing ribs provided for this ...

  • Page 89: Disassembly And Assembly

    CAUTION Only carry out those tasks that are described in this chapter.  Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
  • Page 90 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.

  • Page 91: Module Weights

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Module weights Page 89 Module weights The specified weights of individual parts or assemblies are guides round- ed off to the next highest value. Assemblies Weights [kg] Item Description TPL65VA10/30 Radial air suction branch...
  • Page 92 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Module weights Page 90 Complete compressor casing Weight [kg] TPL65VA10/30 The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert.

  • Page 93: Removing And Fitting Filter Silencer Or Air Suction Branch

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing and fitting filter silencer or air Page 91 suction branch Removing and fitting filter silencer or air suc- tion branch Remove insulation where necessary. Remove filter silencer.  Fit swivel lifting eye (90231) to filter silencer.
  • Page 94 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing and fitting filter silencer or air Page 92 suction branch Disconnect all air lines in accordance with the engine builder’s instruc- Removing the air suction  tions. branch Dismantle the insulation where necessary.

  • Page 95: Axial Clearance

    Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.

  • Page 96: Removing Cartridge Group

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing cartridge group Page 94 Removing cartridge group Remove insulation.  Disconnect oil lines in accordance with engine manufacturer's instruc-  tions. Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing.
  • Page 97 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing cartridge group Page 95 Turn compressor casing (72000) together with wall insert and diffuser  and set them down with surface (F) on underlay. Tipping the compressor casing Make sure that the underlay does not slip.
  • Page 98 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing cartridge group Page 96 Unplug cable connector (86515) and unscrew speed sensor (86505)  with O-ring (86506). Remove the O-ring (42012).  Remove the three screws (61059) together with their Verbus Ripp®...
  • Page 99 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing cartridge group Page 97 Withdraw cartridge group and fit supports (90450).  Remove screws (42064), flange (42044) and gasket (42045) and  clean oil space. Cover the oil connections. ...

  • Page 100: Removing And Fitting Turbine Diffuser

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Removing and fitting turbine diffuser Page 98 Removing and fitting turbine diffuser Replace two screws (61032) with two studs (90903) in upper section  of turbine diffuser. Screw out the remaining screws (61032), press off the turbine diffuser ...

  • Page 101: Removing Variable Turbine Geometry Module With Gas Inlet Casing

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

  • Page 102: Fitting The Variable Turbine Geometry Module And The Gas Inlet Casing

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Fitting the variable turbine geometry Page 100 module and the gas inlet casing Fitting the variable turbine geometry module and the gas inlet casing Push variable turbine geometry module (56100) over studs ...
  • Page 103 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Fitting the variable turbine geometry Page 101 module and the gas inlet casing Fit sealing air line (56501) to semi-circular section of line (A).  © Copyright 2016 ABB. All rights reserved.

  • Page 104: Installing Cartridge Group

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Installing cartridge group Page 102 Installing cartridge group Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing. When the cartridge group, the...
  • Page 105 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Installing cartridge group Page 103 If there is no or insufficient clearance between the rotor turbine blades and the turbine diffuser, the blades and the turbine diffuser (casing) can be damaged.
  • Page 106 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s ...
  • Page 107 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Installing cartridge group Page 105 © Copyright 2016 ABB. All rights reserved.

  • Page 108: Table Of Tightening Torques

    Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Table of tightening torques 8.10 Page 106 8.10 Table of tightening torques 8.10 © Copyright 2016 ABB. All rights reserved.
  • Page 109 Operation Manual / TPL65VA10 / VA30 Disassembly and assembly Table of tightening torques 8.10 Page 107 Tightening torques [Nm] Item Part number TPL65VA10/30 82005 M16x1.5 72027 With washer 72002 * 1) 61037 61090 61036 61041 72029 61059 42059 42064 61056...

  • Page 111: Taking Out Of Operation At Short Notice

    Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Possibilities for emergency repair Page 109 Taking out of operation at short notice Possibilities for emergency repair Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.

  • Page 112: Fit Cover Plate

    Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Fit cover plate Page 110 Fit cover plate The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
  • Page 113 Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Fit cover plate Page 111 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2016 ABB. All rights reserved.
  • Page 114 Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Fit cover plate Page 112 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger.
  • Page 115 Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Fit cover plate Page 113 Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as a naturally-aspirated engine according to the engine builder's instructions.

  • Page 116: Blocking The Inlets And Outlets

    Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Blocking the inlets and outlets Page 114 Blocking the inlets and outlets Shut off the lubricating oil supply to the turbocharger. CAUTION Shut off compressor casing outlet, gas inlet and gas outlet by fitting ...

  • Page 117: Bypass The Turbocharger

    Operation Manual / TPL65VA10 / VA30 Taking out of operation at short notice Bypass the turbocharger Page 115 Bypass the turbocharger Shut off the lubricating oil supply to the turbocharger. CAUTION This applies to engines with one turbocharger only: ...
  • Page 119 Operation Manual / TPL65VA10 / VA30 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 117 up to 12 months Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months 10.1 Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
  • Page 120 Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
  • Page 121  The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station.  The turbocharger is removed completely, either as a whole or in indi- vidual parts.
  • Page 123 Operation Manual / TPL65VA10 / VA30 Disposing of turbocharger components Taking the engine out of operation for 10.2 Page 121 more than 12 months Disposing of turbocharger components 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.
  • Page 125  Turbocharger type  Serial number (HT……)  Description and part number Spare parts can be ordered from an official ABB Turbocharging Service Station. If different design versions have not been taken into consideration in  this document, please contact an ABB Turbocharging Service Station.
  • Page 126 Operation Manual / TPL65VA10 / VA30 Spare parts View of turbocharger with part numbers 12.2 Page 124 12.2 View of turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
  • Page 127 Operation Manual / TPL65VA10 / VA30 Spare parts View of turbocharger with part numbers 12.2 Page 125 Part number Description Cartridge group 56100 Variable turbine geometry module 51001 Gas inlet casing 61001 Gas outlet casing 61035 Hexagon-head screw 61037 (in customer spare part set)
  • Page 128 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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