ABB HT565079 Bedienungsanleitung

Operation Manual

ABB Turbocharging 

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPL65-A32 HT565079

nMmax 509 t Mmax 650

nBmax 509 t Bmax 620

1/s °C

01230 35 50 50

Year 2016 made in Switzerland

Application according to

the Operation Manual

HZTL2498 English

TPL65-A32

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 / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Table of contents

Page 1

September 2014HZTL2498_ENRevision A

Table of contents

Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Correct 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 address and after-sales service

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

Commissioning

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

Replacement intervals for turbocharger components

4.4

Speed measurement

4.5

Stopping the engine

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

ble of contents

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September 2014HZTL2498_ENRevision A

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

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

Removing and fitting filter silencer or air suction branch

8.4

Axial clearance

8.5

Removing cartridge group

8.6

Dismantling and installing the turbine diffuser and nozzle ring

8.7

Installing cartridge group

8.8

Turbine-end removal / fitting of the nozzle ring

8.9

Table of tightening torques

Taking out of operation at short notice

9.1

Possibilities for emergency repair

9.2

Locking the rotor

9.3

Fit cover plate

9.4

Blocking the inlets and outlets

9.5

Bypass the turbocharger

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Table of contents

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September 2014HZTL2498_ENRevision A

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

Ordering spare parts

12.2

View of the turbocharger with part numbers

12.3

View of cartridge group with part numbers TPL65-A32 / -A33 / -

A36

12.4

View of cartridge group with part numbers TPL69-A32 / -A33

12.5

View of turbine cleaning system with part numbers (optional)

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Preliminary remarks

Purpose of this manual

1.1

Page 5

September 2014HZTL2498_ENRevision A

Preliminary remarks

Purpose of this manual

1.1

This operation manual belongs to the turbocharger with the identical HT

number (1), see the cover sheet of the operation manual and the

turbocharger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the

turbocharger 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.

This Operation Manual complements and expands existing national

regulations 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

installed 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 / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Preliminary remarks

Layout and function

1.2

Page 6

September 2014HZTL2498_ENRevision A

Layout and function

1.2

Filter silencer 8

Nozzle ring

Radial plain bearing 9

Turbine wheel

Thrust bearing 10

Bearing casing

Bearing bush 11

Diffuser

Radial plain bearing 12

Compressor wheel

Gas outlet casing 13

Compressor casing

Gas inlet casing

1.2

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Preliminary remarks

Layout and function

1.2

Page 7

September 2014HZTL2498_ENRevision A

Working principle

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

components:

Turbine

Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet

casing (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.

The exhaust gases escape to free air through the exhaust manifold 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 diffusor (11) and leaves the turbocharger through the

compressor casing (13).

The rotor runs in two radial plain bearings (2/5). One plain bearing is

situated in the bearing bush (4) and one plain bearing is situated in the

axial thrust bearing (3) at the compressor side.

The plain bearings are connected to a central lubricating oil channel which

is fed with oil from the engine lubrication circuit. The oil outlet is always at

the lowest point of the bearing casing (10).

Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33

Preliminary remarks

Layout and function

1.2

Page 8

September 2014HZTL2498_ENRevision A

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is

provided with a compressor wheel cooling system.

ompressor wheel cooling means that, after the charge air

cooler at the engine end, cooled compressor air is

delivered to the turbocharger to cool the compressor

wheel.

In view of the respective operating conditions, it is

absolutely essential that the comp

ressor wheel is cooled in

order to guarantee its reliability and replacement intervals.

In the case of the turbocharger version with compressor

wheel cooling, the cooling air is supplied through the side

connection (15) in the bearing casing.

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