Page 1 Operation Manual TPS48-F31 ABB Turbo Systems Ltd CH 5401 Baden Type TPS48-F31 HT845337 1009 Mmax Mmax °C Bmax Bmax SOLD08 00180 Application according to Year 2020 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Page 3: Table Of Contents
Operation Manual / TPS44-F.. - TPS61-F.. Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................6 Storage of new turbochargers and spare parts ............7 Essential information.....................
Page 4 Operation Manual / TPS44-F.. - TPS61-F.. Table of contents Troubleshooting....................67 Malfunctions when starting..................67 Surging of the turbocharger..................68 Malfunctions during operation ................. 69 Malfunctions when stopping ..................72 Speed measurement system ..................73 Removal and installation..................74 Transport ........................74 Turbocharger weights....................
Page 5: Operation Manual
Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Page 6: Layout And Function
Operation Manual / TPS44-F.. - TPS61-F.. 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 1Suction branch / filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing 4Bearing casing 11Turbine-end bearing flange 5Axial thrust bearing 12Compressor-end bearing flange 6Radial plain bearing (visible only...
Page 7 Operation Manual / TPS44-F.. - TPS61-F.. 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine consisting of the following main components: ¡ Turbine ¡ Compressor These are mounted on a common shaft. Exhaust gases from the diesel or gas engine flow through the turbine casing (10) and the nozzle ring (9) to impinge on the turbine (7).
Page 8: Intended Use Of The Turbocharger
Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liab- ility for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.
Page 9: 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 Turbocharging 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 10 Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of turbochargers The turbochargers will be prepared for prolonged storage by ABB Tur- bocharging on request. The package is equipped with a hygrometer (see illustration).
Page 11: Essential Information
The malfunction must be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbochar- ging. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G...
Page 12 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 13: Symbols And Definitions
ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Tur- bocharging. See also chapter Contact information →13. © Copyright 2020 . All rights reserved.
Page 14: Turbocharger Rating Plate
Operation Manual / TPS44-F.. - TPS61-F.. 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 15: Contact Information
One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. 1.8 Contact information Contact information for the official service stations of ABB Turbochar- ging is available online. Scan the QR code to access our website.
Page 16: 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 17: Definition Of Mandatory Signs
Operation Manual / TPS44-F.. - TPS61-F.. 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 Safety gloves against...
Page 18: Warning Plates On The Turbocharger
Warning plates are attached to the turbocharger at the following places: If warning plates are not present at the intended places or are not legible, then proceed as follows: Order new warning plates from ABB Turbocharging Service Stations. Remove unreadable warning plates. Clean and degrease surfaces provided for warning plates.
Page 19 Operation Manual / TPS44-F.. - TPS61-F.. 2 Safety / 2.6 Safe operation and maintenance Work safety and work area safety WARNING Risk of falling There is the risk that someone can fall when working on the turbochar- ger. Do not climb on the turbocharger or on parts attached to it or use these as climbing aids.
Page 20 2 Safety / 2.6 Safe operation and maintenance Safety during start-up / commissioning and operation WARNING The turbine casing insulation of the TPS44-F supplied by ABB is also burst protection Serious personal injuries or fatal accidents can occur, if the turbine cas- ing insulation of the TPS44-F supplied by ABB is removed.
Page 21 Operation Manual / TPS44-F.. - TPS61-F.. 2 Safety / 2.6 Safe operation and maintenance Inspect the electric cables for abrasion and damage before and after your cleaning work. Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals.
Page 22: Hazards During Operation And Maintenance
Operation Manual / TPS44-F.. - TPS61-F.. 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 23 Operation Manual / TPS44-F.. - TPS61-F.. 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 24 Operation Manual / TPS44-F.. - TPS61-F.. 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. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 25 Operation Manual / TPS44-F.. - TPS61-F.. 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 26 Operation Manual / TPS44-F.. - TPS61-F.. 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
Operation Manual / TPS44-F.. - TPS61-F.. 2 Safety / 2.9 Periodic checking of the pressure vessel 2.9 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". ¡...
Page 29 Operation Manual / TPS44-F.. - TPS61-F.. 2 Safety / 2.10 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: Start-Up
Operation Manual / TPS44-F.. - TPS61-F.. 3 Start-up / 3.1 Oil supply 3 Start-up 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 / TPS44-F.. - TPS61-F.. 3 Start-up / 3.1 Oil supply Lubricant NOTICE All lubricating oils used for engines are admissible. Oil inlet viscosity and temperature The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet viscosities and oil-inlet temperatures are shown in the following chart. Kinematic viscosity (mm /s = cSt) Oil-inlet temperature (°C)
Page 32 Operation Manual / TPS44-F.. - TPS61-F.. 3 Start-up / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. Status for operation Oil pressure in front of turbocharger [bar] Normal operation 2.0 … 4.5...
Page 33 + 55 K oil,inlet If the turbocharger has been operated outside the permissible range for a prolonged period of time, ABB Turbocharging recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G...
Page 34: Inspection Work
Operation Manual / TPS44-F.. - TPS61-F.. 3 Start-up / 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 35 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 36: Commissioning After Taking Out Of Operation
Operation Manual / TPS44-F.. - TPS61-F.. 3 Start-up / 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 37: Operation
Operation Manual / TPS44-F.. - TPS61-F.. 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 38: Servicing Work
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 Turbochar- ging. © Copyright 2020 . All rights reserved.
Page 39 NOTICE Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 40 4.2.3 Service work in accordance with instructions on rating plate (In general, after 8000 … 16000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Tur- bocharging Service Station. The following work can be carried in prepar- ation.
Page 41: Expected Exchange Intervals
Operation Manual / TPS44-F.. - TPS61-F.. 4 Operation / 4.3 Expected exchange intervals 4.3 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 42 Operation Manual / TPS44-F.. - TPS61-F.. 4 Operation / 4.3 Expected exchange intervals Influencing parameters The specified values are only guide values and not guaranteed. The ac- tual values can deviate considerably from the guide values due, for ex- ample, to the following influences: ¡...
Page 43: Speed Measurement
Operation Manual / TPS44-F.. - TPS61-F.. 4 Operation / 4.4 Speed measurement 4.4 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 44 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 2020 . All rights reserved.
Page 45 Operation Manual / TPS44-F.. - TPS61-F.. 4 Operation / 4.4 Speed measurement 4.4.2 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 46: Stopping The Engine
Operation Manual / TPS44-F.. - TPS61-F.. 4 Operation / 4.5 Stopping the engine NOTICE Sealing of the speed sensor The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly. Connect cable connector to speed sensor. Switch on lubricating oil supply to turbocharger.
Page 47: Maintenance
To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbocharging recommends that the cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 48: Cleaning The Compressor During Operation
If the coating of dirt is very thick and hard, the compressor can only be cleaned manually when disassembled. This cleaning must be carried out by an ABB Turbocharging Service Station. Cleaning interval The interval between periodic cleaning is very dependent on the operat- ing conditions.
Page 49 Cleaning method Cleaning the compressor while in operation is carried out as wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. 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 or the suction branch.
Page 50 Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Run engine at load from 50 … 85 %.
Page 51 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...
Page 52: Turbine Cleaning During Operation
ABB Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vanadium contents. Consequences of contamination: ¡...
Page 53 NOTICE Choice of cleaning method If you need information about the choice of cleaning method (short / long), you can contact the engine builder or an official ABB Turbochar- ger service station. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G...
Page 54 This cleaning pro- cess is faster and the risk of turbocharger surging is reduced. Recommended operating state for turbine wet cleaning The following operating state is tested and approved by ABB Turbochar- ging: Characteristic / com-...
Page 55 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.3 Turbine cleaning during operation Characteristic / com- Conditions ponent short long Water injection time Water injection time Water supply ensured Water pressure (overpres- 2.0 bar 1.5 bar sure over atmosphere) p If necessary, engine performance must be reduced to maintain these conditions.
Page 56 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.3 Turbine cleaning during operation 5.3.3 Procedure for method with short water injection time Prerequisites have been fulfilled. Wait 10 minutes during a stabilising phase after reducing the engine load. Open the shut-off valve. Set the required water flow rate as specified in the table of cleaning parameters using the flowmeter and inject for 30 seconds.
Page 57 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.3 Turbine cleaning during operation Wait 10 minutes as a stabilising phase after reducing the engine load. Open the shut-off valve. Set the required water flow rate as specified in the table of cleaning parameters using a flowmeter and inject for 10 minutes.
Page 58: Cleaning Components Mechanically
Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4 Cleaning components mechanically 5.4.1 Introduction CAUTION Choosing cleaning tools Turbocharger components are sensitive to mechanical damage. The use of needle guns or other impact tools, for example, damages the components.
Page 59 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.2 Cleaning the filter silencer 81135Filter silencer body 81266Cover grid 81136Absorption segment 81270Tension band 81137Sheet-metal covering 81271Lock 81265Filter ring NOTICE Disassembly and assembly The procedure for disassembly and assembly of the filter silencer is de- scribed in the chapter entitled Disassembly and Assembly.
Page 60 Have absorption segments which are heavily contaminated replaced by an official ABB Turbocharging Service Station. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal cover- ings (81137).
Page 61 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.3 Compressor-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. Do not breathe in these substances and avoid contact with the skin.
Page 62 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.4 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. Do not breathe in these substances and avoid contact with the skin.
Page 63 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.5 Cartridge group Introduction CAUTION Corrosion If the cartridge group is not put into operation again immediately after cleaning, parts may corrode. Re-install and use the cartridge group immediately after cleaning. Compressor wheels or turbines may be heavily contaminated due to ex- haust gas deposits or coked oil.
Page 64 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically Cleaning the compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals. Only use pH-neutral cleaning agents that do not corrode metals. Observe the material safety data sheet.
Page 65 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically Cleaning the turbine end Soaking the dirt Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the tur- bine end. The contamination can be removed by soaking and brushing. The soaking of the layers of dirt as well as the cleaning of the turbine are described below.
Page 66 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health. Observe the information in the material safety data sheet.
Page 67 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically Removing the dirt WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract, this can be harmful to health. Avoid the formation of dust. Vacuum up dust with a suitable vacuum cleaner.
Page 68 Operation Manual / TPS44-F.. - TPS61-F.. 5 Maintenance / 5.4 Cleaning components mechanically CAUTION Water and dirt in the cartridge group If water or dirt gets into the cartridge group, the turbocharger function may be impaired and parts in the cartridge group may be damaged. Make sure that water or dirt does not get into the gap between the partition wall and turbine.
Page 69: 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 2020 . All rights reserved.
Page 70: 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 71: 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 Engine Defects of connected cylinders...
Page 72 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 73 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 74: 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 75: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact an ABB Turbocharging Service Sta- tion Measured Contaminated The sensor tip is magnetic and can thus at-...
Page 76: Removal And Installation
Operation Manual / TPS44-F.. - TPS61-F.. 7 Removal and installation / 7.1 Transport 7 Removal and installation 7.1 Transport Suspension of uninsulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas out- casing let casing Suspension of insulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas out- casing let casing...
Page 77: Turbocharger Weights
Operation Manual / TPS44-F.. - TPS61-F.. 7 Removal and installation / 7.2 Turbocharger weights 7.2 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. This standard value may deviate from the data on the rating plate depending on the specification.
Page 78: Installing The Turbocharger
Remove covers from oil connections. Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring gaskets for engine are not included in the scope of delivery of ABB). **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coeffi- cient µ...
Page 79 Operation Manual / TPS44-F.. - TPS61-F.. 7 Removal and installation / 7.4 Installing the turbocharger Fasten all gas, water and air lines in accordance with the engineb- uilder's instructions. If present: Fit speed sensor and plug in cable connector. Adapt and fit bearing casing insulation (A). Adapt and fit sheet metal (B) of bearing casing insulation.
Page 80: Disassembly And Assembly
Incorrectly performed disassembly and assembly of the cartridge group can lead to serious machine damage. ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Sta- tion. Mark the casing position for assembly.
Page 81 Use assembly devices only for the described applications. ¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G March 2020...
Page 82 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.1 Introduction Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely (not supplied by ABB). Swivel lifting eye Product Thread Length Minimum...
Page 83: Module Weights
Operation Manual / TPS44-F.. - TPS61-F.. 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. TPS44 TPS48 TPS52 TPS57 TPS61 Description [kg] [kg]...
Page 84: Disassembling And Assembling Turbocharger
Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger 8.3 Disassembling and assembling turbocharger Removing the compressor casing WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns.
Page 85 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Removing the insulation If provided Loosen and remove the screws for the insulation plates (1, 2). If provided: Remove the insulation plates (1, 2). Remove the remaining screws for the insulation (3).
Page 86 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Slightly loosen the screws (72011) and turn the compressor casing (72000) until the swivel lifting eye can be fastened to the lifting gear. (77006* only provided with the wall insert with acceleration aid.) NOTICE If the compressor casing cannot be removed easily, it can be pressed...
Page 87 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger TPS61 wall insert removal Fasten lifting beam (90258) to wall insert. Fasten swivel lifting eye (a) to lifting beam. Remove wall insert (77000) using lifting gear. Disassembly of diffuser TPS..-F31/32 / FV31/32 Loosen screws (72041) and remove them together with lockwashers...
Page 88 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger NOTICE O-rings Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts). Fitting the diffuser Refit diffuser in reverse order.
Page 89 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Removing the cartridge group Check the lifting gear and fasten it to bearing casing (42001). If provided Disconnect all lines in accordance with the engine builder's instruc- tions, remove the insulation, remove the turbocharger and com- pressor casing together with the filter silencer (also see the previous chapter).
Page 90 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Withdraw nozzle ring (56001) using two extraction devices (90070) and withdraw bottom part of service support (90012). If provided Remove C-ring (51105). Disassembly of diffuser TPS..-F33 Mount the cartridge group on the service support (90012) and bolt it down firmly.
Page 91 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Installing the cartridge group NOTICE O-rings Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts). NOTICE Protruding insulation The insulation on the turbine casing may protrude at the gas outlet...
Page 92 Calculate the press fit (PD) as shown. single inlet turbine casing NOTICE If the calculated value (PD) is less than 0.1 mm, an official ABB Tur- bocharging Service Station must be contacted. Measure the axial and radial clearances (see the section Axial and ra- dial clearances).
Page 93 Calculate the press fit (PD) as shown. multiple inlet turbine cas- NOTICE If the calculated value (PD) is outside ±0.2 mm, an official ABB Tur- bocharging Service Station must be contacted. Measure the axial and radial clearances (see the section Axial and ra- dial clearances).
Page 94 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Assembly of diffuser TPS..-F33 Fasten diffuser (79000) and O-ring (42012) using screw (42008). Check lifting gear and fasten to bearing casing (42001). Unscrew the cartridge group and lift it out of the service support (90012).
Page 95 Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Fasten the cartridge group using fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) (also see the chapter entitled Table of tightening torques). Fasten the bearing casing (42001) using the fixing screws (C).
Page 96 (see also preceding chapter). Loop lifting gear around gas outlet manifold (51100). Remove gas outlet manifold (51100) and gasket (52406). Only gas outlet manifolds from ABB have the gasket (52406). Remove gas outlet flange (52400) and, if fitted, C-ring (52408). © Copyright 2020 . All rights reserved.
Page 97 Fitting the gas outlet flange and gas outlet manifold If provided, fit the C-ring (52408). Fit the gas outlet flange (52400). For gas outlet manifolds (51100) from ABB: always replace the gasket (52406) (see the chapter entitled Spare parts). Apply high-temperature grease to contacting surfaces and threads.
Page 98: Axial Clearance A And Radial Clearance B
Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.4 Axial clearance A and radial clear- ance B 8.4 Axial clearance A and radial clearance B Following removal and before installation of the cartridge group, the axial clearance A and radial clearance B must be measured and noted. NOTICE In order to correctly measure the axial clearance A, the turbine must be raised slightly.
Page 99 Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 100: Radial Clearances N And R
Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.5 Radial clearances N and R 8.5 Radial clearances N and R N and R These are the theoretical values of the radial clearance between the com- pressor wheel and the wall insert and / or turbine wheel and the gas out- let flange.
Page 101 Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 102: Table Of Tightening Torques
Operation Manual / TPS44-F.. - TPS61-F.. 8 Disassembly and assembly / 8.6 Table of tightening torques 8.6 Table of tightening torques The following tightening torques must be observed for the specified bolted connections: Tightening torques [Nm] Position Part num- TPS44 TPS48 TPS52 TPS57...
Page 103: Taking Out Of Operation
Operation Manual / TPS44-F.. - TPS61-F.. 9 Taking out of operation / 9.1 Shutting down the turbocharger 9 Taking out of operation 9.1 Shutting down the turbocharger If the turbocharger is damaged and the engine can be shut down for only a short time for emergency repairs, proceed as follows: Fit the cover plate.
Page 104 Operation Manual / TPS44-F.. - TPS61-F.. 9 Taking out of operation / 9.1 Shutting down the turbocharger Fitting the cover plate Close the opening in the turbine casing using the cover plate (A). Fasten the cover plate on the turbine casing (51000) using the fasten- ing strips (51002), Verbus Ripp®...
Page 105 9 Taking out of operation / 9.1 Shutting down the turbocharger Cover plate drawing The cover is not included in the scope of delivery of ABB and must be manufactured by the operator according to the following drawing. Material: Common structural steel, in compliance with DIN EN 10025-2 Product ±0.5...
Page 106 *) Diameter for turbine casing designs for optional C-ring sealing NOTICE Information about the turbine casing design (with / without C-ring sealing) can be requested from an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G...
Page 107: Mothballing The Turbocharger
Operation Manual / TPS44-F.. - TPS61-F.. 10 Mothballing the turbocharger / 10.1 Taking the engine out of opera- tion for up to 12 months 10 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
Page 108: Taking The Engine Out Of Operation For More Than 12 Months
Dismantle the turbocharger. The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards. Clean all parts. Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.
Page 109 Operation Manual / TPS44-F.. - TPS61-F.. 10 Mothballing the turbocharger / 10.2 Taking the engine out of oper- ation for more than 12 months Condition of the mothballed turbocharger Check the mothballed turbocharger parts for corrosion once per an- num. If there are signs of rust: Clean parts thoroughly and renew protection against corrosion.
Page 110: Disposing Of Turbocharger Components
Operation Manual / TPS44-F.. - TPS61-F.. 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 111: Spare Parts
O-ring 42012 Gasket 52406 * O-ring 77005 Counter-sunk screw 72041 O-ring 81010/ 82010 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G March 2020...
Page 112: View Of Turbocharger Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. 12 Spare parts / 12.2 View of turbocharger showing part numbers 12.2 View of turbocharger showing part numbers (……) only available in customer spare part set (97070). © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G March 2020...
Page 113 Operation Manual / TPS44-F.. - TPS61-F.. 12 Spare parts / 12.2 View of turbocharger showing part numbers Part number Description 10900 Cartridge group 42008 (in customer spare part set) Socket screw 42012 (in customer spare part set) O-ring 51000 Turbine casing 51002 Fastening strips 51100...
Page 114: View Of Cartridge Group Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. 12 Spare parts / 12.3 View of cartridge group showing part numbers 12.3 View of cartridge group showing part numbers © Copyright 2020 . All rights reserved. HZTL2412_EN Rev.G March 2020...
Page 115 Operation Manual / TPS44-F.. - TPS61-F.. 12 Spare parts / 12.3 View of cartridge group showing part numbers Part number Description 21000 Shaft 21002 Piston ring 25000 Compressor wheel 32101 Plain bearing bush 32103 Locking ring 32105 Thrust ring 32106 Thrust bearing 32108 Piston ring...
Page 116 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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