ABB TPL85-B14 Bedienungsanleitung

Operation Manual

ABB Turbocharging 

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPL85-B14 HT842305

nMmax 203 t Mmax 550

nBmax 193 t Bmax 520

1/s °C

12000 36 100 100

Year 2016 made in Switzerland

Application according to

the Operation Manual

HZTL2491 English

TPL85-B14

Original Operation Manual

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-

ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon

between the engine builder and ABB.

Note: Replacement intervals of components depends on the load proﬁle, turbine inlet temperature, suction air temperature and

turbocharger speed. In case the operation conditions differs signiﬁcantly 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.

Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

Operation Manual / TPL85-B14/-B15/-B16

Table of contents

Page 1

reserved.

May 2016HZTL2491_ENRevision B

Table of contents

Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Intended use of the turbocharger

1.4

Storage of new turbochargers and spare parts

1.5

Essential information

1.6

Symbols and definitions

1.7

Turbocharger rating plate

1.8

Contact information

Safety

2.1

Introduction

2.2

CE conformity

2.3

Definition of mandatory signs

2.4

Definition of Safety instructions

2.5

Warning plates on the turbocharger

2.6

Safe operation and maintenance

2.7

Hazards during operation and maintenance

2.8

Periodic checking of the pressure vessel

2.9

Lifting loads

Start-up

3.1

Oil supply

3.2

Inspection work

3.3

Commissioning after taking out of operation

Operation

4.1

Noise emissions

4.2

Servicing work

4.3

Expected exchange intervals

4.4

Speed measurement

4.5

Underpressure measurement on filter silencer

4.6

Flexible cut-out

Operation Manual / TPL85-B14/-B15/-B16

Table of contents

Page 2

May 2016HZTL2491_ENRevision B

4.7

Stopping the engine

Maintenance

5.1

Foreword to Maintenance

5.2

Cleaning the filter silencer

5.3

Changing the filter strip on the filter silencer casing

5.4

Cleaning the compressor during operation

5.5

Cleaning turbine blades and nozzle ring in operation

Troubleshooting

6.1

Malfunctions when starting

6.2

Surging of the turbocharger

6.3

Malfunctions during operation

6.4

Malfunctions when stopping

6.5

Speed measurement system

Removal and installation

7.1

Turbocharger weights

7.2

Remove the turbocharger

7.3

Installing the turbocharger

Disassembly and assembly

8.1

Introduction

8.2

Module weights

8.3

Silencer casing

8.4

Removing and installing the filter silencer

8.5

Axial clearance

8.6

Removing internal part of compressor casing

8.7

Removing gas inlet casing

8.8

Fitting gas inlet casing

8.9

Fitting internal part of compressor casing

8.10

Dry-cleaning device

8.11

Table of tightening torques

Short-term turbocharger shut-down

9.1

Possibilities for emergency repair

9.2

Locking the rotor

9.3

Shutting off inlets and outlets

9.4

Bypass the turbocharger

Operation Manual / TPL85-B14/-B15/-B16

Table of contents

Page 3

reserved.

May 2016HZTL2491_ENRevision B

Storing turbocharger

10.1

Taking out of operation for up to 12 months

10.2

Taking out of operation for more than 12 months

Disposing of turbocharger components

Spare parts

12.1

Ordering spare parts

12.2

View of turbocharger with part numbers

12.3

View of cartridge group with part numbers

Operation Manual / TPL85-B14/-B15/-B16

Prelimi

nary remarks

Purpose of this manual

1.1

Page 5

May 2016HZTL2491_ENRevision B

Preliminary remarks

Purpose of this manual

1.1

This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-

charger rating plate.

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.

This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-

stalled on it.

Availability of operation manual

An operation manual must be available at all times at the place where the

turbocharger is used.

Everyone who operates or works on the turbocharger must have first read

and understood the operation manual.

1.1

Operation Manual / TPL85-B14/-B15/-B16

Preliminary remarks

Layout and function

1.2

Page 6

May 2016HZTL2491_ENRevision B

Layout and function

1.2

1 Filter silencer 7

Nozzle ring

2 Radial plain bearing 8

Turbine wheel

3 Thrust bearing 9

Bearing casing

4 Radial plain bearing 10

Diffuser

5 Gas outlet casing 11

Compressor wheel

6 Gas inlet casing 12

Compressor casing

1.2

Operation Manual / TPL85-B14/-B15/-B16

Prelimi

nary remarks

Layout and function

1.2

Page 7

May 2016HZTL2491_ENRevision B

Mode of operation

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

components:

Turbine

Compressor

These are both mounted on a common shaft.

Exhaust gases from the diesel engine flow through the gas inlet casing (6)

and the nozzle ring (7) to impinge on the turbine wheel (8).

The turbine wheel (8) uses the energy contained in the exhaust gas to

drive the compressor wheel (11). The compressor draws in fresh air,

compresses it and then forces it into the engine cylinders.

The exhaust gas escapes to free air through the exhaust gas pipe which

is connected to the gas outlet casing (5).

The air, which is required for operation of the diesel engine and com-

pressed in the turbocharger, is drawn through the filter silencer (1) into the

compressor wheel (11). This air then passes through the diffuser (10) and

leaves the turbocharger through the compressor casing (12).

The rotor runs in two radial plain bearings (2/4), which are located in the

bearing casing (9) between the compressor and the turbine. The axial

thrust bearing (3) is at the compressor end.

The plain bearings are connected to a central lubricating oil duct which is

normally supplied by the lubricating oil circuit of the engine. The oil outlet

is always at the lowest point of the bearing casing (9).

The turbocharger is equipped with an emergency lubrication oil tank,

which is integrated in the bearing casing. During an emergency stop

caused by a failure of the lubrication oil system, this emergency lubrica-

tion unit supplies oil to the bearings until the rotor comes to a standstill.

Operation Manual / TPL85-B14/-B15/-B16

Preliminary remarks

Intended use of the turbocharger

1.3

Page 8

May 2016HZTL2491_ENRevision B

Intended use of the turbocharger

1.3

NOTICE

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.

The engine builder has provided ABB Turbo Systems with information

regarding the intended use of the engine, from which the operating lim-

its specific to the turbocharger shown on the rating plate (such as

speeds, temperatures and replacement intervals) have been derived.

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.

This turbocharger was built according to state-of-the-art technology and is

operationally safe according to recognised safety regulations.

WARNING

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 be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-

ing and repair conditions specified by the manufacturer. Disposal regula-

tions set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's manual.

It may be used only for the intended purpose and operated in compliance

with the operation manual.

Malfunctions which could affect safety must be eliminated immediately.

The manufacturer accepts no liability for any damage resulting from unau-

thorised alterations to the turbocharger.

1.3

State of the art

Perfect condition

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