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Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
List of contents
List of contents
1
Preliminary remarks
1.1
1.2
1.3
1.4
Essential information
1.5
1.6
Safety
2.1
2.2
2.3
2.4
2.5
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Operation
4.1
Servicing work
4.2
Monitoring
4.3
Surging of turbocharger
4.4
4.5
Maintenance
5.1
Foreword to Maintenance
5.2
5.3
5.4
5.5
Page 1
Operation Manual
6.1
7.1
Turbocharger weights
7.2
7.3
8.1
Module weights
8.2
8.3
Axial clearance
8.4
8.5
8.6
8.7
8.8
9.1
9.2
9.3
9.4
10
10.1
10.2
11
11.1
11.2
11.3
11.4
January 2007
Troubleshooting
HZTL2491_EN (TPL85-B14/-B15/-B16)
Page 2
Version 4
List of contents
Operation Manual
Preliminary remarks
1.1
Page 1
This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
1 Preliminary remarks
NOTE
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully understood the operating manual before beginning work.
Version 4
WARNING
Operation Manual
Preliminary remarks
1.2
Page 2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
1.2.
Filter silencer
Nozzle ring
Turbine wheel
Thrust bearing
Bearing casing
10
Diffuser
11
Compressor wheel
12
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Operation Manual
Preliminary remarks
1.2
Page 3
January 2007
Mode of operation
The turbocharger is a turbo-machine and consists of the following main
components:
Turbine
Compressor
The exhaust gases from the diesel engine flow through the gas inlet casing (6) and nozzle ring (7) to the turbine wheel (8).
HZTL2491_EN (TPL85-B14/-B15/-B16)
The turbine wheel (8) uses the energy contained in the exhaust gas to
drive the compressor wheel (11), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (5).
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 (11). It then
passes through the diffuser (10) and leaves the turbocharger through the
compressor outlet on the air outlet 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 on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is
normally supplied by the oil lubrication circuit of the engine. The oil outlet
is always at the lowest point of the bearing casing (9).
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Operation Manual
Preliminary remarks
1.3
Page 4
January 2007
The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
Latest technology
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.
The turbocharger must only be installed in a technically perfect condition,
corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual.
X Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
Version 4
Perfect condition
Operation Manual
Preliminary remarks
Essential information
1.4
Page 5
January 2007
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
1
Essential information
1.4
Page 6
January 2007
Preliminary remarks
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Version 4
CAUTION
Operation Manual
Preliminary remarks
Essential information
1.4
Page 7
January 2007
After-sales service
The Contact Information brochure contains an overview of official ABB
Turbo Systems Ltd. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Our service stations and agencies will gladly answer your questions relating specifically to your model.
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
Version 4
Operation Manual
Preliminary remarks
1.5
Page 8
January 2007
D Result
Basic Instructions
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
The term ABB Turbo Systems used in this manual signifies ABB Turbo
Systems Ltd.
Operation Manual
Preliminary remarks
1.6
Page 9
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00012
Operational limits
Version 4
3
4
5
Operation Manual
1
1.6
6
7
8
9
10
11
12
Page 10
January 2007
Additional specifications:
Preliminary remarks
CAUTION
Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
Operation Manual
Safety
2.1
Page 1
2 Safety
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
Operation Manual
Safety
2.2
Page 2
The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating
materials.
January 2007
stress.
Version 4
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Safety
2.3
Page 3
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
WARNING
Operation Manual
Safety
2.3
Page 4
operation materials.
You must wear protective clothing (see section General safety instructions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the following rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
January 2007
Before cleaning, protect the floor against unintended leaks of oil and
Version 4
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Safety
2.3
Page 5
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Safety
2.4
Page 6
Associated hazards may arise during operation of and work on the turbocharger:
January 2007
Mechanical influences
Personal injury
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
Version 4
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Safety
2.4
Page 7
Protective measures
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Causes
9
9
9
9
9
9
9
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environment if they penetrate soil or water.
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CAUTION
Operation Manual
2
2.4
Page 8
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Causes
Protective measures
9
9
9
9
9
9
9
Version 4
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Personal injury
Safety
Operation Manual
Safety
2.4
Page 9
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
9
9
9
9
Noise
The effects of noise above a legally permitted level can cause personal injury.
Loss of hearing
Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Personal injury
Causes
Protective measures
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Burns
Causes
Protective measures
Operation Manual
Safety
2.5
Page 10
L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Version 4
NOTE
Operation Manual
Commissioning
Oil supply
3.1
Page 1
3 Commissioning
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Oil filtration
A lubrication oil filter system with a mesh size 0.050 mm is adequate for
TPL ..-B turbochargers.
Oil pressure
The oil pressure before the bearings must be maintained precisely to ensure fault-free operation.
The permissible oil pressures are specified in the following tables dependent on the lubrication (engine lubrication or separate lubricating system).
Version 4
Engine lubrication
0.0 - 0.6
0.6 - 0.8
0.8 - 2.5
0.8 - 4.0
Operation Manual
3
Oil supply
3.1
Page 2
0.0 - 0.9
0.9 - 1.1
1.1 - 2.5
1.1 - 4.0
January 2007
Commissioning
Oil inlet
temperature
[ C ]
Engine load
[%]
Oil outlet
temperature
[ C ]
45
100
1.5 - 2
70 - 90
70
100
1.5 - 2
90 - 110
Version 4
Engine lubrication
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Commissioning
Inspection work
3.2
Page 3
This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspec-
tion work.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Lubricating system
Version 4
Operation Manual
Inspection work
3.2
Page 4
Charger speed
X Measuring
Charger pressure
X Measuring
Temperatures
X After the engine has been started up, check all gas, air and oil lines for
leaks.
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Commissioning
NOTE
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, taking into account the different operating conditions.
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Operation Manual
Commissioning
3.3
Page 5
January 2007
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combusX
X
X
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Operation
Servicing work
4.1
Page 1
4 Operation
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
X must be recorded
X Enter in the machine logbook
X In the event of significant anomalies, establish the cause
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CAUTION
Operation Manual
4
Servicing work
4.1
Page 2
January 2007
Operation
If provided
Version 4
Oil filters
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
4
Servicing work
4.1
Page 3
January 2007
This inspection work and the checks are to be carried out by an official
service station of ABB Turbo Systems Ltd.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation
Operation Manual
Servicing work
4.1
Page 4
The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
Version 4
NOTE
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation
Operation Manual
Operation
Monitoring
4.2
Page 5
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
4.2 Monitoring
Version 4
86505_001
Bearing casing
Connecting cable
Axial bearing
Speed transmitter
Gasket ring
Screw plug
Operation Manual
Operation
Monitoring
4.2
Page 6
Defects in the speed transmitter, the connecting cable and plug to the
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation Manual
Operation
Monitoring
4.2
Page 7
January 2007
U-tube manometer
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00003
L_00004
Felt discs
A [mm H2O]
Operation Manual
Operation
Monitoring
4.2
Page 8
Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1).
The U-tube manometer must be exposed to minimum possible mechanical shock or vibration.
January 2007
NOTE
X Fit the U-tube manometer to the filter silencer as shown in the preced-
ing description.
X For best readability, the U-tube manometer can be filled with slightly
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
X Clean the filter as soon as the loss of pressure (A) reaches a value of
For better readability of the pressure differential (A) on the U-tube manometer, the measuring rod can be withdrawn to the level of the lower
water level indicators.
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
coloured water.
Operation Manual
Operation
Surging of turbocharger
4.3
Page 9
Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbocharger.
Prolonged or periodic surging
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Action to be taken:
Version 4
The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.
Operation Manual
Operation
4.4
Page 10
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Operation
4.5
Page 11
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation Manual
Maintenance
Foreword to Maintenance
5.1
Page 1
January 2007
5 Maintenance
5.1 Foreword to Maintenance
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
Filter silencer
Compressor
Turbine and nozzle ring
Operation Manual
Maintenance
5.2
Page 2
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
81265
81266
Cover grids
81270
Tension ring
81136
Fleece segment
38271
Trap cover
81137
Cover panel
81268
Connecting strip
81135
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L_00210
Operation Manual
Maintenance
5.2
Page 3
January 2007
If provided
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.
Version 4
Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo
Systems.
NOTE
Operation Manual
Maintenance
5.2
Page 4
January 2007
(81135).
X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).
Version 4
If provided
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Maintenance
5.2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation Manual
Version 4
L_00192
Injection pipe
Guide tube
Pipe
Page 5
Operation Manual
Maintenance
5.2
Page 6
X Disconnect the line (2) at the injection pipe (1) and remove the screw
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
NOTE
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Operation Manual
Maintenance
5.2
Page 7
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
Version 4
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Operation Manual
Maintenance
5.3
Page 8
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
January 2007
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point.
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers.
This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the
rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Operation Manual
Maintenance
5.3
Page 9
Cleaning method
January 2007
The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
Operation Manual
5
5.3
Page 10
5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)
NOTE
The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage
charging).
January 2007
Maintenance
Z Engine warm from running (engine under full loading as far as possi-
Version 4
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.3
Page 11
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00198
Version 4
Screw plug
Valve lever
Operation Manual
5
5.3
Page 12
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
January 2007
Maintenance
Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
0.4
4 ... 15
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
Version 4
TPL 91-B
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.3
Page 13
January 2007
Z Engine warm from running (engine under full loading as far as possi-
HZTL2491_EN (TPL85-B14/-B15/-B16)
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.
Version 4
L_00197
Cleaning container
2 Pipe
Injection pipe
4 Cleaning instructions
Cover
6 Valve
Operation Manual
5
5.3
Page 14
If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer
should be followed.
NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Maintenance
Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
4 ... 15
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
TPL 91-B
Version 4
Operation Manual
Maintenance
5.4
Page 15
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Operation Manual
Maintenance
5.4
Page 16
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:
January 2007
Cleaning methods
Wet cleaning
Dry cleaning
During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
During dry cleaning using dry solid particles in granulate form, the deposit
is removed by the mechanical impact of the grains hitting the surface.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
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NOTE
January 2007
Operation Manual
5
5.4
Page 17
NOTE
CAUTION
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Maintenance
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger turbines with nozzle rings one after the other.
Operation Manual
5
5.4
Page 18
5.4.1 Wet cleaning the turbine and nozzle ring during operation at partial
power
The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
January 2007
Maintenance
Z After the engine has been started or during operation, the engine
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.4
Page 19
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HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00394
Drainage line
Regulating valve
Drain cock
Manometer
10
Outflow
11
21
Other turbochargers
Position 1
Injection pipe
Position 2
X Check that the water supply (1) is open and ensured, and also con-
Operation Manual
5
5.4
Page 20
January 2007
Maintenance
NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.4
Page 21
January 2007
5.4.2 Integrated dry cleaning of the turbine and nozzle ring during operation
This cleaning method is not suitable for removing thick dirt deposits and
must therefore be carried out more often (see chapter Cleaning turbine
blades and nozzle ring in operation).
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.4
Page 22
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
ON/OFF valve
Trap-cover
Safety valve
Cleaning instructions
Version 4
L_00094
January 2007
Operation Manual
Maintenance
5.4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Page 23
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
Version 4
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
Operation Manual
Maintenance
5.4
Page 24
Selection of materials
January 2007
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
TPL 69BA
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
TPL 91-B
1.0
1.0
1.5
2.0
3.0
3.5
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
The average grain size of the cleaning granulate must be between 1.2
and 2.0 mm.
Operation Manual
Maintenance
5.4
Page 25
January 2007
5.4.3 Non-integrated dry cleaning device for the turbine and nozzle ring
during opration
As an alternative to the built-in dry cleaning system, a non-integrated dry
cleaning device can be installed upstream of the gas inlet casing by the
engine manufacturer.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.4
Page 26
L_00208
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
January 2007
Operation Manual
Maintenance
5.4
Page 27
Trap-cover G2
Double nipple G2
Copper gasket
10
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Version 4
X
X
X
X
X
X
X
X
X
X
Operation Manual
5
5.4
Page 28
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
January 2007
Maintenance
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
Turbocharger type
Amount of granulate
[dm3]
Container size
TPL 69BA
1.0
II
TPL 73-B
1.0
II
TPL 77-B
1.5
II
TPL 80-B
2.0
II
TPL 85-B
3.0
III
TPL 91-B
3.5
III
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
5.5
Page 29
Manufacturer
Country
Address
ABB Service
Australia
20 Queen Street
Revesby Sydney
NSW 2212
Germany
Tel. +49,621,727 69 -0
Fax. +49 621 717 6988
Email: vertrieb@auer-strahltechnik.de
BRIGANTINE
Service Ltd.
Hong Kong
Netherlands
Barnsteenstraat 1
NL-7554 TC Hengelo
The Netherlands
GUYSON
International Ltd.
UK
DASIC
International Ltd.
UK
Winchester Hill
Romsey SO51 7YD
United Kingdom
PAN
Abrasives (Pte) Ltd.
Singapore
Pioneer Sector 2
Jurong
628382 Singapore
Sweden
Valtersang 9
S-442 49 Kungalv
Sweden
Korea
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation Manual
Troubleshooting
6.1
6 Troubleshooting
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Engine
Turbocharger
Charge-air cooler
Z Cooler soiled
X Clean
Z Insufficient coolant water quantity
X Replenish
Version 4
Page 1
Operation Manual
Troubleshooting
6.1
Page 2
Engine
January 2007
Z Injection misadjusted
X Correct adjustment
Z Valve control misadjusted
X Correct adjustment
Turbocharger
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
Operation Manual
Troubleshooting
6.1
January 2007
Engine
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger
Vibrations
Turbocharger
Z
Z
Z
X
Z Turbocharger dirty
X Clean
Version 4
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
Page 3
Operation Manual
Troubleshooting
6.1
Page 4
Turbocharger
Z Turbocharger dirty
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
January 2007
Turbocharger
Z Turbocharger dirty
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Contact an official ABB Turbo Systems service station.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Sluggish start-up
Turbocharger
Version 4
Operation Manual
Troubleshooting
6.1
Page 5
January 2007
Engine
silencer is dirty
Z Trap dirty
X Clean
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger
Operation Manual
Removal and installation
Turbocharger weights
7.1
Page 1
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
L_00082
Operation Manual
Removal and installation
Turbocharger weights
7.1
Page 2
Weight [kg]
TPL 85-B
9745
January 2007
TPL 85-B
10700
Weight [kg]
TPL 85-B
Version 4
10035
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Removal and installation
7.2
Page 3
X Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturers instructions.
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the of this orifice has been individually adjusted by the engine builder. Whenever
these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the
correct is fitted into the oil supplying oil-inlet channel.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
7.2
Operation Manual
7
7.2
Page 4
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
January 2007
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Removal and installation
7.3
Page 5
January 2007
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X
X
X
X
X
Operation Manual
Disassembly and assembly
Module weights
8.1
Page 1
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
L_00082
Operation Manual
Disassembly and assembly
Module weights
8.1
Page 2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Modules
Version 4
8.1
Operation Manual
Disassembly and assembly
Module weights
8.1
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Weights [kg]
Page 3
Description
TPL 85-B
290
Filter silencer
955
550
Wall insert
850
Diffuser
225
1200
Cartridge group
3000
Cover ring
145
Nozzle ring
95
10
495
TPL 85-B
1625
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.
Version 4
NOTE
Operation Manual
8
Page 4
January 2007
NOTE
L_00011
X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
instructions.
Operation Manual
Disassembly and assembly
8
Page 5
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00226
X Sling lifting gear through the loops at the rear and secure to the
X The filter silencer or air suction branch is installed in the reverse se-
quence.
Operation Manual
Disassembly and assembly
Axial clearance
8.3
Page 6
8.3
X Before disassembly and after assembly of the internal part of the com-
pressor casing, as well as of the gas inlet casing (if dismantled), the
axial clearance (A) must be measured.
X Measure and note the axial clearance A.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
Clearance A [mm]
TPL 85-B
0.54 0.79
Version 4
CAUTION
Operation Manual
Disassembly and assembly
8.4
Page 7
January 2007
X Take nuts (90458) from the toolbox and fit them on the threaded pins
of the three safety segments (Y) in the internal part of the compressor
casing (76000).
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00269
from the external part of the compressor casing (74000) and can be
removed.
Version 4
Dimension
u
TPL 85-B
27.6
Operation Manual
Disassembly and assembly
8.4
Page 8
gear.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
8.4.2
X
X
X
X
off screws (90900) so far, until the lifting device (90190/90195) can be
fitted.
Fit the lifting device to the internal part of the compressor casing
(76000).
Remove internal part of the compressor casing (76000) with wall insert
and diffuser.
Fit support angle (90025).
Set down internal part of compressor casing (76000) in a horizontal
position.
Version 4
X Press off the internal part of the compressor casing (76000) with press-
Operation Manual
January 2007
If necessary
8.4
Page 9
X Attach two shackles (90195) to the support angle (90025) and fasten a
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
X Rest the internal part of the compressor casing only on flange (F).
X Check shim and adjust as necessary.
Operation Manual
Disassembly and assembly
8.4
Page 10
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Remove diffuser
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Version 4
8.4
Operation Manual
Disassembly and assembly
8.5
Page 11
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
Version 4
X
X
X
X
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Operation Manual
Disassembly and assembly
8.6
Page 12
X Fit cover ring (51085) with the help of the two guide bolts (90320) and
If removed:
January 2007
X Mount nozzle ring (56001) on the gas inlet casing (51001) with screws
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
8.7
Page 13
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation Manual
Version 4
8.4
Operation Manual
Disassembly and assembly
8.7
Page 14
through this bring the internal part of the compressor casing (76000) to
a horizontal position.
X Remove support bracket (90025) with shackle (90195).
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
X Carefully slacken the lifting gear on the support bracket (90025) and
8.4.2
X Seat O-ring gasket (76040) to the internal part of the compressor cas-
insert and diffuser over the guide bolts (90320) into the external part of
the compressor casing (74000).
X Remove the lifting device (90190/90195).
X Insert the internal part of the compressor casing as far as it will go.
X Remove guide bolts (90320) and fit studs (74026).
Version 4
ing (76000).
Operation Manual
Disassembly and assembly
8.7
Page 15
X Release the nuts (90458) on the threaded pins of the three safety
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00276
Dimension
TPL 85-B
18.5
Version 4
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
CAUTION
Clearance A [mm]
TPL 85-B
0.54 0.79
Operation Manual
8
8.7
Page 16
and Verbus washers (76028) (see section Removing and installing the
filter silencer or air suction branch).
X Connect all air lines in accordance with the engine manufacturers instructions.
X Install all insulation that has been removed.
January 2007
X Fit the filter silencer or air suction branch and secure with nuts (76027)
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Disassembly and assembly
8.8
Page 17
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
L_00059
Version 4
Operation Manual
8.8
1)
Page 18
Part number
TPL 85-B
42059, 42064
M12
110
56014
M16
160
57005
M16
160
61044
M24
480
74026
M24
80
74027
M24
300
76002
M20
- 1)
82005
M16 x 1.5
50
86505
M22 x 1.5
220
90458
M12
30
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
86505
L_00228
Operation Manual
Taking out of operation temporarily
9.1
Page 1
CAUTION
If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following
possibilities are available:
Lock the turbocharger rotor
Blocking the inlets and outlets
Bypass the turbocharger
Those emergency repairs that can be performed fastest are to be performed first.
Version 4
NOTE
Operation Manual
Taking out of operation temporarily
9.2
Page 2
January 2007
CAUTION
NOTE
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
NOTE
CAUTION
Various intermediate rings are provided with the locking device for different compressor wheels. The compressor wheel type CV (for the
balancing screw holes) must be noted. The space between the locking
flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.
During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures
and information for operation with a locked rotor for 2-stroke engines).
Otherwise components that are still intact can be damaged by overheating.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Operation Manual
Taking out of operation temporarily
9.2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Version 4
L_00261
Page 3
Operation Manual
9
9.2
Page 4
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Remove the filter silencer or air suction branch and the compressor
January 2007
casing internal part together with the wall insert and the diffuser.
Part number
TPL85-B
94006
M12
75
94007 / 94008
M12
60
X Fit the locking flange (94003) with screws (94007 or 94008, using the
Version 4
longest possible screws) as well as the adjustment ring (94004) and intermediate ring (94031).
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation Manual
Taking out of operation temporarily
9.2
Page 5
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
94000_15
Version 4
It must be ensured that all components are clean and free from grease.
CAUTION
flange (94003).
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
Operation Manual
Taking out of operation temporarily
9.2
Page 6
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
94000_012
It must be ensured that all components are clean and free from grease.
CAUTION
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
Version 4
Operation Manual
Taking out of operation temporarily
9.2
Page 7
January 2007
Further measures and information for operation with a locked rotor for 2stroke engines
2-stroke engine with one
turbocharger:
No further measures are necessary. The engine can be operated with the
auxiliary blower according to the instructions of the manufacturer.
9 The lubrication oil system must remain connected and turned on.
HZTL2491_EN (TPL85-B14/-B15/-B16)
air duct blocked at the engine end, as undamaged turbochargers develop a receiver pressure.
X The operating limit of the engine can be raised by additionally blocking
the gas inlet, as the exhaust gas is then used to drive the undamaged
turbocharger. The loading and temperature of the locked rotor are also
reduced.
If the gas inlet cannot be blocked, the following operating limits must be
observed:
The pressure in the charge-air receiver must not exceed 1 bar over-
pressure.
Max. permissible engine load: 50%.
Version 4
CAUTION
Operation Manual
Taking out of operation temporarily
9.3
Page 8
January 2007
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Operation Manual
Taking out of operation temporarily
9.4
Page 9
January 2007
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Mothballing the turbocharger
10
10.1
Page 1
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
Version 4
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Operation Manual
10
Page 2
January 2007
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
Check mothballed turbochargers yearly for corrosion.
In the event of rust, clean and renew the corrosion protection.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Operation Manual
Reserve and spare parts
11
11.1
Page 1
January 2007
Our service stations and agents accept orders for spare parts.
X If special variants/cases are not addressed in these general instruc-
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Reserve and spare parts
11
11.1
Page 2
NOTE
Quantity
Description
Part number
O-ring gasket
42012, 76040
Gasket
42041, 42069
12
42059, 42064
Gasket
42045
56014, 57005
Hexagon nut
61037
Gasket
61041
O-ring gasket
77005, 77006
O-ring gasket
86506
All spare parts that were ordered with the turbocharger should be kept
as a complete set and ready for use.
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
To carry out the work described in this manual, you need a set of spare
parts (97070). These spare parts in this set are available only as a
complete set.
January 2007
Spare-parts set
Version 4
Operation Manual
Reserve and spare parts
11
11.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Part number
Description
Cartridge group
51001
51085
Cover ring
56001
Nozzle ring
61001
61035
Hexagon nut
68000
Foot
74000
76000
O-ring gasket
76080
Safety segment
77000
Wall insert
O-ring gasket
O-ring gasket
79000
Diffuser
81000
Filter silencer
82000
Operation Manual
11.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25008
Threaded pin
25009
Ring nut
32001
Thrust bearing
32101
32102
32104
Auxiliary bearing
32105
Floating disc
32106
Axial bearing
42001
Bearing casing
42002
Hood
42011
O-ring gasket
O-ring gasket
42015
Sealing cover
Gasket
Gasket
42295
Non-return valve
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
O-ring gasket
Page 4
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
11
Version 4
Operation Manual
Reserve and spare parts
11
11.3
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
11.3_page1
Page 5
L_00906
43005
42012
42059
86505
January 2007
11.4
86506
42064
42295
HZTL2491_EN (TPL85-B14/-B15/-B16)
42041
42001
42002
21000
11
Version 4
25000
43001
32001
25008
42011
25009
32104
32101
32106
32105
42045
32102
42015
Operation Manual
Page 6