Page 1 Operation Manual TPL85-B12 Type TPL85-B12 HT846086 Mmax Mmax °C Bmax Bmax 12000 Application according to Year 2021 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 / TPL73-B.. - 85-B11/ -B12 Table of contents Operation Manual Preliminary remarks....................4 Purpose of this manual ....................4 Layout and function......................5 Intended use of the turbocharger ................7 Storage of new turbochargers and spare parts ............8 Essential information....................
Page 4 Operation Manual / TPL73-B.. - 85-B11/ -B12 Table of contents Changing the filter strip on the filter silencer casing..........59 Cleaning the compressor during operation ............61 Cleaning turbine blades and nozzle ring in operation ........... 67 Troubleshooting....................80 Malfunctions when starting..................80 Surging of the turbocharger..................
Page 5 Operation Manual / TPL73-B.. - 85-B11/ -B12 Table of contents 12.2 View of turbocharger with part numbers .............. 148 12.3 View of cartridge group with part numbers............150 © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 6: 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 7: Layout And Function
Operation Manual / TPL73-B.. - 85-B11/ -B12 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 1 Filter silencer 8Nozzle ring 2 Radial plain bearing 9Turbine wheel 3 Thrust bearing 10Bearing casing 4 Bearing bush 11Diffuser 5 Radial plain bearing 12Compressor wheel 6 Gas outlet casing 13Compressor casing...
Page 8 Operation Manual / TPL73-B.. - 85-B11/ -B12 1 Preliminary remarks / 1.2 Layout and function 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. The exhaust gases from the diesel engine flow through the gas inlet cas- ing (07) and nozzle ring (08) to the turbine wheel.
Page 9: Intended Use Of The Turbocharger
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 10: Storage Of New Turbochargers And Spare Parts
1.4 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 11 70% level, the maximum 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 12: 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. HZTL2480_EN...
Page 13 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 14: 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 15: Turbocharger Rating Plate
Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 16: 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 17: 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 18: Definition Of Mandatory Signs
Operation Manual / TPL73-B.. - 85-B11/ -B12 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...
Page 19: Warning Plates On The Turbocharger
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 20: Safe Operation And Maintenance
Operation Manual / TPL73-B.. - 85-B11/ -B12 2 Safety / 2.6 Safe operation and maintenance 2.6 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 21 Operation Manual / TPL73-B.. - 85-B11/ -B12 2 Safety / 2.6 Safe operation and maintenance 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 tur- bocharger for damage and leaks.
Page 22 Operation Manual / TPL73-B.. - 85-B11/ -B12 2 Safety / 2.6 Safe operation and maintenance Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. Inform operating personnel about all service and repair work before beginning.
Page 23: Hazards During Operation And Maintenance
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 24 Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 25 Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 26 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 27 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 28: 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 29 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 30: Commissioning
Operation Manual / TPL73-B.. - 85-B11/ -B12 3 Commissioning / 3.1 Oil supply 3 Commissioning 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 31 Operation Manual / TPL73-B.. - 85-B11/ -B12 3 Commissioning / 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 32 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 33: Inspection Work
Operation Manual / TPL73-B.. - 85-B11/ -B12 3 Commissioning / 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 34 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 35: Commissioning After Taking Out Of Operation
Operation Manual / TPL73-B.. - 85-B11/ -B12 3 Commissioning / 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 36: Operation
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 37 Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.1 Noise emissions 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 ©...
Page 38: Admissible Air Inlet Temperature
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 39 4 Operation / 4.3 Servicing work CAUTION Unknown changes during operation The consequences can range from an impairment to a breakdown. Have unknown causes clarified by an ABB Turbocharging service sta- tion. © Copyright 2018 . All rights reserved. HZTL2480_EN...
Page 40 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 41 4.3.5 Service work every 36000 hours Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station. Damaged and worn out parts must be replaced with original ABB parts. Remove the filter silencer.
Page 42: Expected Exchange Intervals
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 43 Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.4 Expected exchange intervals 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 44: Speed Measurement
Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.5 Speed measurement 4.5 Speed measurement A speed measuring system permits continuous monitoring of the tur- bocharger speed. CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 45 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 46 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 47: 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 48: Operation Without Emergency Oil Supply
Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.7 Operation without emergency oil supply 4.7 Operation without emergency oil supply If a leak occurs in the emergency oil system during operation and imme- diate repair is not possible, the turbocharger can be operated without an emergency oil supply until a repair is possible.
Page 49: Flexible Cut-Out
Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.8 Flexible cut-out 4.8 Flexible cut-out At low load, an engine that is being charged by several turbochargers can be operated with one turbocharger shut down. Flexible shutting down or switching on of a turbocharger is called “flexible cut-out“. In flexible systems, slide valves or flaps are installed upstream of the gas inlet and downstream of the air outlet of the turbocharger.
Page 50: Stopping The Engine
Operation Manual / TPL73-B.. - 85-B11/ -B12 4 Operation / 4.9 Stopping the engine NOTICE Contamination with closed flaps To limit the deposits of dirt when operating with closed flaps, we re- commend you open them at least every 500 hours of operation. 4.9 Stopping the engine CAUTION Before shutting down the engine, it must be allowed to idle for about 3...
Page 51: Maintenance
Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 52: Cleaning The Filter Silencer
Operation Manual / TPL73-B.. - 85-B11/ -B12 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...
Page 53 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. HZTL2480_EN...
Page 54 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 55 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.2 Cleaning the filter silencer 5.2.2 Filter silencer and connecting rod 81265Filter ring (if provided) 81136Absorption segment 81269Connecting rods 81137Sheet-metal covering 81266Cover grid 81135Filter silencer body 81272Screw 81273Lock nut EInsert unit – absorption segment / sheet-metal covering fitted ©...
Page 56 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated absorption segments, filter ring and damaged connecting rods with original parts from ABB Turbo Systems. © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D...
Page 57 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 (81137) back into the original shape. Insert the insert units (E) into the slot guides in the filter silencer body (81135).
Page 58 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.2 Cleaning the filter silencer Screw lock nuts (81273) onto screw (81272) and tighten to following torque: Lock nut Tightening torque [Nm] 81273 If provided Fit filter ring (81265). © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 59 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.2 Cleaning the filter silencer 5.2.3 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 60 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 61: Changing The Filter Strip On The Filter Silencer Casing
Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 62 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 63: 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. HZTL2480_EN Revision D...
Page 64 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 65 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 66 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 67 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 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 Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
Page 69: Cleaning Turbine Blades And Nozzle Ring In Operation
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 ©...
Page 70 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Principle of wet cleaning Wet cleaning makes use of various effects. Depending on the composi- tion of the contamination, the individual effects with their different levels of intensity have a varying influence on the cleaning result: ¡...
Page 71 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 72 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 73 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Points to remember when ¡ When cleaning, water must be drained from the gas outlet casing via cleaning the drain pipe (8). ¡...
Page 74 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 75 Operation Manual / TPL73-B.. - 85-B11/ -B12 5 Maintenance / 5.5 Cleaning turbine blades and nozzle ring in opera- tion Operating the integrated dry cleaning device Granulate container (51502) 07 Combined air valve / Pressure-re- lief valve (51504) 02 Cover cap (51503) 08 Clamp (51515) 03 Compressed air supply [4 to 10 09 Pipe elbow (51521)
Page 76 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 77 Operation Manual / TPL73-B.. - 85-B11/ -B12 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.
Page 78 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 79 Operation Manual / TPL73-B.. - 85-B11/ -B12 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...
Page 80 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 81 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 the non-integrated dry-cleaning device...
Page 82: 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 83: 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 84: 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 85 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 86 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 87: 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 88: 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 89: Removal And Installation
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 90 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 the support for the turbocharger is not provided or unsuitable, the turbocharger could tip over during installation and removal work and cause serious or fatal injuries.
Page 91: Installing The Turbocharger
Operation Manual / TPL73-B.. - 85-B11/ -B12 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. Ensure that ropes do not touch emer- gency oil tank.
Page 92: 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 93 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 94: Module Weights
Operation Manual / TPL73-B.. - 85-B11/ -B12 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] TPL..-B Item Description Filter silencer Compressor casing internal part...
Page 95 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.2 Module weights Compressor casing internal part assembly Weights [kg] TPL73-B TPL77-B TPL80-B 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 96: Silencer Casing
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 97 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 98 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 99 Operation Manual / TPL73-B.. - 85-B11/ -B12 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 100 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.3 Silencer casing 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 101: Removing And Installing The Filter Silencer
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.4 Removing and installing the filter si- lencer 8.4 Removing and installing the filter silencer Removing filter silencer Remove insulation where necessary. Pass lifting gear through rib on filter silencer and through eyelets at rear.
Page 102 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.4 Removing and installing the filter si- lencer Removing the filter silen- Remove insulation where necessary. cer TPL77 - 91-B Secure the shackle (90195) to a rib / fin on the filter silencer. Pass the lifting gear through the eyelets on the back side.
Page 103: Axial Clearance
Measure and note the axial clearance (A). CAUTION If the axial clearance (A) is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. Axial clearance A [mm] TPL73-B...
Page 104: Removing Cartridge Group
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group 8.6 Removing cartridge group Remove insulation where necessary. Disconnect oil pipes in accordance with enginebuilder's instructions. Open the oil drain screw (42245) at the pipe to the emergency lubric- ating oil tank and collect any residual oil that might be in it into a bucket.
Page 105 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group Control dimension u [mm] Dimension TPL73-B TPL77-B TPL80-B TPL85-B 18.6 19.0 19.6 27.6 The compressor casing internal part has now been detached from the compressor casing external part (74000) and can be removed.
Page 106 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group Compressor casing in- ternal part Fit support angle (90025). Place the compressor casing internal part (76000) with the wall insert (77000) and the diffuser (79000) down on the support angle and an underlay.
Page 107 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group 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 108 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group Removing the compressor casing external part Fasten the lifting device (90190) with shackle (90195) to the com- pressor casing external part (74000) and secure it to the crane. Unscrew and remove nuts (61037).
Page 109 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group Removing the cartridge group 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 washers (61058).
Page 110 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.6 Removing cartridge group CAUTION If the turbine blades on the rotor have insufficient or no clearance, the blades and the casing may be damaged. Check that the blades do not rub on the turbine diffuser (63000) by rotating the rotor.
Page 111: Inspection And Assessment Of Valve Block
If necessary, replace O-ring seal (2). NOTICE If scratches are found on the valve seat or the valve flap jams, the valve block should be replaced. If in doubt, contact an ABB Turbocharging Service Station. © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D...
Page 112: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.8 Dismantling and installing the tur- bine diffuser and nozzle ring 8.8 Dismantling and installing the turbine diffuser and nozzle ring CAUTION The nozzle ring (56001) must be secured to prevent it from falling be- fore pulling out the turbine diffuser (63000).
Page 113 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.8 Dismantling and installing the tur- bine diffuser and nozzle ring Place the clamp (90921) over the stud (61036) until the clamp is lying flat against the inner radius of the gas outlet casing. Insert the extension (A) of the torque spanner (B) through the hole in the clamp and loosen the screws (61056) one after another.
Page 114 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.8 Dismantling and installing the tur- bine diffuser and nozzle ring Turbine diffuser Replace two screws (61056) in the gas outlet casing with two guide studs (90320) in the upper section of the turbine diffuser (63000). Fit clamps (90921) over the guide studs (90320) and fit the studs (61036).
Page 115 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.8 Dismantling and installing the tur- bine diffuser and nozzle ring Nozzle ring Attach the holder (90490) to the gas outlet casing. On the TPL85, raise the holder (90490) with the lifting gear and secure it. Pull the nozzle ring (56001) forwards, attach it to the lifting gear and remove it.
Page 116: Installing Cartridge Group
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group 8.9 Installing cartridge group If removed: Install the nozzle ring and turbine diffuser. NOTICE These operations must be carried out as described in the section Re- moving and installing the turbine diffuser and nozzle ring.
Page 117 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group Fitting cartridge group Carefully insert cartridge group (42001). CAUTION If the turbine blades on the rotor have insufficient or no clearance, the blades and the casing may be damaged. Check that the blades do not rub on the turbine diffuser (63000) by rotating the rotor.
Page 118 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group Fitting the compressor casing external part Attach lifting device (90190/90195) to compressor casing external part (74000) and secure to a crane. Screw the press-off nuts (61090), evenly distributed around the cir- cumference of the bearing casing, onto the studs up to the end of the thread.
Page 119 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group Fitting the diffuser Fit the O-rings (77005, 77006) to the wall insert (77000). Fit the swivel lifting eyes (90230) and attach lifting gear. Align the wall insert (77000) with the threaded holes in the com- pressor casing internal part (76000) using the dog points at the swivel lifting eyes (90230) and lower it.
Page 120 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group Compressor casing in- ternal part Secure the lifting device (90190) and the shackle (90195) to the rear of the flange (F). Carefully rotate the compressor casing internal part (76000) with wall insert (77000) and diffuser (79000) about the support angle (90025) and set it down on the underlay.
Page 121 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group Fitting compressor casing internal part Fit the oil drain screw (42245). Attach the lifting device (90190/90195) to the front of the flange of the compressor casing internal part (76000). Fit O-ring (76040).
Page 122 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.9 Installing cartridge group 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 123 Wear safety gloves. Wear safety gloves to protect against mechanical hazards. Measure and note the axial clearance (A). CAUTION If the axial clearance A is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. Axial clearance A [mm] TPL73-B...
Page 124: Dismantling And Fitting Nozzle Ring At Turbine End
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.10 Dismantling and fitting nozzle ring at turbine end 8.10 Dismantling and fitting nozzle ring at turbine If only the nozzle ring needs to be removed, this can be done at the tur- bine end.
Page 125 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.10 Dismantling and fitting nozzle ring at turbine end CAUTION When setting down the gas inlet casing to one side, use suitable under- lays and take care not to damage the brackets of the insulation. Unscrew the holder (90175) and remove the nozzle ring (56001) using suitable lifting gear.
Page 126 490 Nm 665 Nm 840 Nm If a threaded stud (51086) breaks off when loosening, an ABB Turbo Sys- tems service station must be contacted. If a threaded stud (51086) becomes loose when the nut (51087) is re- moved, after disassembling the gas outlet casing it must be screwed back into the gas inlet casing hand-tight as far as it will go.
Page 127 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.10 Dismantling and fitting nozzle ring at turbine end Withdraw the gas inlet casing and remove it. CAUTION When setting down the gas inlet casing to one side, use suitable under- lays and take care not to damage the brackets of the insulation.
Page 128: Dry-Cleaning Device
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.11 Dry-cleaning device 8.11 Dry-cleaning device The assembly of the dry-cleaning device is described below. 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).
Page 130: Table Of Tightening Torques
Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.12 Table of tightening torques 8.12 Table of tightening torques © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 131 Operation Manual / TPL73-B.. - 85-B11/ -B12 8 Disassembly and assembly / 8.12 Table of tightening torques Tightening torques [Nm] Item Part number TPL73-B TPL77-B TPL80-B TPL85-B 82005 M16x1.5 76002 74027 With washer 61036 74026 / 74029 61056 61059 61044 51087 42059 42064 61037 61090...
Page 132: Shut-Down At Short Notice
Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.1 Possibilities for emergency repair 9 Shut-down at short notice 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 133: Locking The Rotor
Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 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 134 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 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.) If provided: Fix partition wall using clamps (94005) and screws (90442).
Page 135 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.2 Locking the rotor TPL73-B Compressor type CV11 Compressor type CV12, CV13, CV14 © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 136 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.2 Locking the rotor TPL77-B & TPL80-B Compressor type CV11 Compressor type CV12, CV13, CV14 © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 137 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.2 Locking the rotor TPL85-B11/ -B12 If possible, use the longer hexagon-head screws (94008) when fitting the locking flange (94003). Compressor type CV11 Compressor type CV12, CV13, CV16 ©...
Page 138 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.2 Locking the rotor 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 139: Shutting Off Inlets And Outlets
Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.3 Shutting off inlets and outlets 9.3 Shutting off inlets and outlets CAUTION Shut off the lubricating oil supply to the turbocharger. This applies only to engines with several turbochargers and common air as well as exhaust gas receivers.
Page 140: Fit Cover Plate
Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.5 Fit cover plate 9.5 Fit cover plate NOTICE The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 141 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.5 Fit cover plate NOTICE Carry out the work as described in the chapter Removal and fitting. Remove cartridge group. © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 142 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.5 Fit cover plate Close off opening in gas outlet casing using cover plate. Fasten cover plate using spacer sleeves and nuts (61037). CAUTION Shut off the supply of lubricating oil to the turbocharger. ©...
Page 143 Operation Manual / TPL73-B.. - 85-B11/ -B12 9 Shut-down at short notice / 9.5 Fit cover plate Further measures and information for operation with a turbocharger with cover plate in 2-stroke engines 2-stroke engine with one turbocharger: No further measures are necessary. The engine can be operated with the auxiliary blower according to the manufacturer's instructions.
Page 144: Preserving 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 145: Taking Out Of Operation For More Than 12 Months
Operation Manual / TPL73-B.. - 85-B11/ -B12 10 Preserving turbocharger / 10.2 Taking out of operation for more than 12 months 10.2 Taking out of operation for more than 12 months If the engine is taken out of service, the following can be done with the turbocharger: ¡...
Page 146: Disposing Of Turbocharger Components
Operation Manual / TPL73-B.. - 85-B11/ -B12 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 147: 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 148 Operation Manual / TPL73-B.. - 85-B11/ -B12 12 Spare parts / 12.1 Ordering spare parts Customer spare part set (97070) for service work every 36,000 h TPL73-B / TPL80-B Quantity Description Part number Hexagon-head screw 42059 / 42064 Verbus Ripp® washer 42058 / 42063 Hexagon-head screw 61044 / 61056 / 61059...
Page 150 Operation Manual / TPL73-B.. - 85-B11/ -B12 12 Spare parts / 12.2 View of turbocharger with part numbers 12.2 View of turbocharger with part numbers © Copyright 2018 . All rights reserved. HZTL2480_EN Revision D July 2018...
Page 151 Operation Manual / TPL73-B.. - 85-B11/ -B12 12 Spare parts / 12.2 View of turbocharger with part numbers Part number Description Cartridge group 42052 (in customer spare part set) O-ring 51001 Gas inlet casing 56001 Nozzle ring 51086 Threaded stud 51087 Hexagon nut 61001...
Page 152 Operation Manual / TPL73-B.. - 85-B11/ -B12 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. HZTL2480_EN Revision D July 2018...
Page 153 Operation Manual / TPL73-B.. - 85-B11/ -B12 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...
Page 154  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

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Ht846086

ABB TPL85-B12 Operation Manual

Operation Manual

1 Preliminary Remarks

2 Safety

3 Commissioning

4 Operation

5 Maintenance

6 Troubleshooting

7 Removal and Installation

8 Disassembly and Assembly

9 Shut-Down at Short Notice

10 Preserving Turbocharger

11 Disposing of Turbocharger Components

12 Spare Parts

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