Page 1 Operation Manual TPL67-C33 ABB Turbo Systems Ltd CH 5401 Baden Type TPL67-C33 HT575281 Mmax Mmax °C Bmax Bmax 01330 Application according to Year 2017 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
Periodic checking of the pressure vessel Lifting loads Commissioning Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement Stopping the engine Maintenance © Copyright 2017 ABB. All rights reserved.
Page 4 Taking out of operation at short notice Possibilities for emergency repair Locking the rotor Fit cover plate Blocking the inlets and outlets Bypass the turbocharger Mothballing turbocharger 10.1 Taking out of operation for up to 12 months © Copyright 2017 ABB. All rights reserved.
Page 5 Taking out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of turbocharger with part numbers 12.3 View of turbine cleaning system with part numbers (optional) © Copyright 2017 ABB. All rights reserved.
Page 7: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbo- charger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be op- erated safely, correctly and efficiently.
Page 8: Layout And Function
02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing © Copyright 2017 ABB. All rights reserved.
Page 9 In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing. © Copyright 2017 ABB. All rights reserved.
Page 10: Intended Use
These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Man-...
Page 11 The turbocharger must only be used when it is in a technically flawless condition and operated in compliance with its intended use. ABB Turbo Systems excludes any liability for damage resulting from un- authorized modifications to the turbocharger or improper operation.
Page 12: 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 13 Page 11 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 14: Essential Information
The fault should be reported to the person or de- partment responsible. Any modifications, additions or conversions made to the turbocharger, which could impair safety, require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2017 ABB. All rights reserved.
Page 15 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems 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 16: 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 Turbo- charging Service Stations.
Page 17: Turbocharger Rating Plate
Replacement interval for turbine in 1000 h Further information Customer part number Designation of the special design Turbocharger weight in kg Turbocharger type Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2017 ABB. All rights reserved.
Page 18 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.
Page 19: Contact Information
Operation Manual / TPL67-C.. - TPL71-C.. Preliminary remarks Contact information Page 17 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 21: Safety
Page 19 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
Page 22: Definition Of Mandatory Signs
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2017 ABB. All rights reserved.
Page 23: Warning Plates On The Turbocharger
Warning plates on the turbocharger Page 21 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.
Page 24: Safe Operation And Maintenance
Keep flammable objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can enter the turbocharger. Wear personal protective equipment (PPE) for welding operations.  © Copyright 2017 ABB. All rights reserved.
Page 25 Observe the material safety data sheet for the cleaning agent or sol-  vent. Wear personal protective equipment (PPE) according to the material  safety data sheet. Inspect the electric cables for abrasion and damage before and after  your cleaning work. © Copyright 2017 ABB. All rights reserved.
Page 26 Clean the turbocharger before mothballing it.  Observe the material safety data sheet for the cleaning and mothball-  ing agents. Wear personal protective equipment (PPE) according to the material  safety data sheet. © Copyright 2017 ABB. All rights reserved.
Page 27: Hazards During Operation And Maintenance
Observe the general rules for occupational safety and prevention of  accidents. Ensure workplace safety.  Only perform operations that are described in this chapter.  Only perform operations for which you have previously received in-  struction or training. © Copyright 2017 ABB. All rights reserved.
Page 28 Do not touch hot surfaces and heed the warning plate on the turbo-  charger. Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.  Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved.
Page 29 Non-insulated turbochargers can cause serious injuries to personnel (burns). WARNING The turbocharger is supplied by ABB Turbo Systems without insulation depending on the order from the enginebuilder. If supply is without insu- lation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 30 In the event of leaks or after spilling, immediately spread a suitable  binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations. © Copyright 2017 ABB. All rights reserved.
Page 31 Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  Dispose of insulating materials properly and in an environmentally  compatible way in accordance with applicable local regulations. © Copyright 2017 ABB. All rights reserved.
Page 32: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 33: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and se-  curely. © Copyright 2017 ABB. All rights reserved.
Page 35: Commissioning
Filtration of the lubricating oil using a filter mesh size ≤ 0.034 mm is ade- quate for TPL67-C turbochargers and a mesh size ≤0.050 mm for TPL71-C turbochargers. This filtration can also be carried out using an additional self-cleaning fine filter. NOTICE © Copyright 2017 ABB. All rights reserved.
Page 36 A metering orifice is installed in the oil inlet of the turbocharger to en- sure these oil pressures. The orifice is installed by the enginebuilder NOTICE and it is fixed in place with a locking ring. © Copyright 2017 ABB. All rights reserved.
Page 37 > 160 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbo- charger inspected by an ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 38: Inspection Work
CAUTION Activate prelubrication device before starting engine.  Check whether the warning plates are present and legible. Warning plates on  turbocharger Check whether the protective sheets have been removed.  © Copyright 2017 ABB. All rights reserved.
Page 39 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 40: Commissioning After Taking Out Of Operation
Start up turbocharger oil circulation system at engine end.  Prepare turbocharger for operation as instructed in section "Inspection  work before start-up / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  © Copyright 2017 ABB. All rights reserved.
Page 41: Operation
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must en- sure that equivalent acoustic insulating measures are taken. © Copyright 2017 ABB. All rights reserved.
Page 42 Operation Noise emissions Page 40 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 © Copyright 2017 ABB. All rights reserved.
Page 43: Servicing Work
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
Page 44  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2017 ABB. All rights reserved.
Page 45  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.
Page 46: Replacement Intervals For Turbocharger Components
Parameters influencing non-rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Load profile (thermal load changes, number of starts/stops)  Temperature level of exhaust gas  Turbine cleaning frequency  Procedure for turbine cleaning © Copyright 2017 ABB. All rights reserved.
Page 47 See the data on the rating plate replacement intervals [h] = Gas Engine = Marine Diesel Oil = Heavy Fuel Oil See Influencing The specified values are guides and not guaranteed. ( parameters NOTICE © Copyright 2017 ABB. All rights reserved.
Page 48: Speed Measurement
If you pull the speed measurement cables too hard, contacts can be pulled out. CAUTION Do not tension the speed measurement cables.  Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer © Copyright 2017 ABB. All rights reserved.
Page 49 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  Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 50 Screw in speed sensor (86505) as far as it will go and tighten to torque  specified in table. (See chapter Table of tightening torques.) Connect speed sensor using cable connector (86515).  © Copyright 2017 ABB. All rights reserved.
Page 51 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.4 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2017 ABB. All rights reserved.
Page 52: Stopping The Engine
Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further  10 minutes before stopping. © Copyright 2017 ABB. All rights reserved.
Page 53: Maintenance
 The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2017 ABB. All rights reserved.
Page 54: Cleaning The Filter Silencer
Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut Insert unit = absorption segment + sheetmetal covering © Copyright 2017 ABB. All rights reserved.
Page 56 If the connecting rods (81269) are not correctly positioned in their re- cesses on the filter silencer unit (81135), the cover grid (81266) can twist and shift. There is then a risk of foreign matter and contamination getting into the compressor. CAUTION © Copyright 2017 ABB. All rights reserved.
Page 57 (81272) alternately until the following maximum torque is reached: Screw Tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut Tightening torque [Nm] 81273 Fit filter strip (81265). If provided  © Copyright 2017 ABB. All rights reserved.
Page 58: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions. In general, cleaning should be carried out every 25 ... 100 op- erating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2017 ABB. All rights reserved.
Page 59 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. To clean the compressor stage during operation, water is injected in front Principle of wet cleaning of the compressor wheel.
Page 60 Not more than three cleaning cycles should be conducted consecutively. Cleaning parameters per turbocharger compressor Product Engine Water Water injection Water Ø orifice load pressure time temperature [mm] [bar] [sec] [°C] TPL67-C 50 … 5 … 50 100% TPL71-C © Copyright 2017 ABB. All rights reserved.
Page 61 (see section Wet cleaning tur- bine and nozzle ring during operation). In this case, the water injection time for cleaning the compressor can be increased from ten to forty seconds. © Copyright 2017 ABB. All rights reserved.
Page 62 Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Engine load 50 ... 85% ...
Page 63 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
Page 64: Cleaning Turbine Blades And Nozzle Ring In Operation
The interval between periodic cleaning is very dependent on the operating Wet cleaning interval conditions. As a rule, cleaning should be carried out every 50 to 200 op- erating hours. © Copyright 2017 ABB. All rights reserved.
Page 65 When cleaning the turbine components during operation, use wet clean- Cleaning method ing. This cleaning method has been tested and approved by ABB Turbo Systems. Prerequisites for wet cleaning are that the engine builder approves the process and his instructions are followed.
Page 66 Prerequisites for wet cleaning of turbine The following operating state and prerequisites have been tested and ap- proved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced ...
Page 67 The injection process has been completed.  Close drain hole (if provided) above drain pipe (08, 09).  After cleaning, wait with engine running for at least 10 minutes without  changing load to allow turbocharger to dry. © Copyright 2017 ABB. All rights reserved.
Page 68 The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clari- fied by the operator.
Page 69: Cleaning Components Mechanically
(see chapter entitled Service work). Professional overhauling of the components by an ABB Turbocharging Service Station is required, preferably using the cleaning method de- scribed in the following.
Page 70 Brush off the contamination or remove it with a steam cleaner.  Repeat the soaking and brushing if necessary.  Completely remove any solvents from the parts in clean water.  Dry components completely.  © Copyright 2017 ABB. All rights reserved.
Page 71 If water or contamination penetrates the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge CAUTION group. Make sure that no water or contamination can enter into the cartridge  group. © Copyright 2017 ABB. All rights reserved.
Page 72 Cartridge group with a central suspension point Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation. CAUTION Choose appropriate lifting gear length.  © Copyright 2017 ABB. All rights reserved.
Page 74 2. Attach third lifting loop with swivel lifting eye to thread of oil outlet flange. 3. Rotate the cartridge group into a horizontal position by lifting. © Copyright 2017 ABB. All rights reserved.
Page 75 Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the tank with soaking liquid.  Only immerse the cartridge group until all blades are covered with  cleaning agent. © Copyright 2017 ABB. All rights reserved.
Page 76 Wear a respiratory mask to protect against particles (P1 or P2 mask).  Wear safety goggles.  Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Raise the cartridge group and align horizontally.  © Copyright 2017 ABB. All rights reserved.
Page 77 Cleaning the cartridge group on the turbine end [➙ 70]). Dispose of contaminated water and cleaning agent in accordance with  the specifications in the safety data sheet. © Copyright 2017 ABB. All rights reserved.
Page 79: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  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 Turbocharging Service Station.
Page 80: Surging Of The Turbocharger
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser-  vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 81: Malfunctions During Operation
Defects such as leaks in the Make repairs exhaust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging charger ring (with 4-stroke application) Service Station © Copyright 2017 ABB. All rights reserved.
Page 82 Charge air Cooler contaminated Clean it cooler Cooling water volume too Top up the water Entry temperature of cooling Inspect / clean the cooling sys- water too high Inadequate ventilation Improve the ventilation © Copyright 2017 ABB. All rights reserved.
Page 83 Engine Malfunctioning injection system Repair it or contact the manufac- turer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbo- Manometer display wrong Replace the manometer charger © Copyright 2017 ABB. All rights reserved.
Page 84: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2017 ABB. All rights reserved.
Page 85: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 87: Removal And Installation
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. Weights [kg] TPL67-C TPL71-C 1330 2040 © Copyright 2017 ABB. All rights reserved.
Page 88: Removing The Turbocharger
Remove air supply line. (See also chapter entitled Preliminary remarks /  Layout and functionality) Inspect the lifting gear.  Attach one lifting gear each to the two ribs of the bearing casing pro-  vided for this purpose. © Copyright 2017 ABB. All rights reserved.
Page 89 WARNING rious or even fatal injury. Support the turbocharger at a suitable point.  If possible secure it using lifting gear.  Wear safety helmet. Cover the oil connection.  © Copyright 2017 ABB. All rights reserved.
Page 90: Installing The Turbocharger
Fit the air supply line (also see the chapter entitled Preliminary re-  marks / Layout and functioning). Refit the parts of insulation which had been removed.  Plug in the cable connector on the speed sensor.  © Copyright 2017 ABB. All rights reserved.
Page 91: Disassembly And Assembly
Disassembly and assembly Introduction Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station. CAUTION Only carry out those tasks that are described in this chapter. ...
Page 92 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2017 ABB. All rights reserved.
Page 93: Module Weights
Assemblies Weights [kg] Description TPL67-C TPL71-C Filter silencer Radial air suction branch Compressor casing Wall insert Diffuser Cartridge group Turbine diffuser Nozzle ring Radial gas inlet casing Segment Axial gas inlet casing © Copyright 2017 ABB. All rights reserved.
Page 94 Page 92 Complete compressor casing Weight [kg] TPL67-C TPL71-C The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2017 ABB. All rights reserved.
Page 95: Removing And Fitting Filter Silencer Or Air Suction Branch
Unscrew the nuts (72027) and remove them together with the washers  (72018). Remove the air suction branch and set it down to one side.  Fit the air suction branch in reverse order. Installing the air suction  branch © Copyright 2017 ABB. All rights reserved.
Page 96 Unscrew nuts (72027) and remove them together with washers  (72018). Remove filter silencer and it set down to one side.  Install filter silencer in reverse order. Installing the filter silencer  © Copyright 2017 ABB. All rights reserved.
Page 97: Axial Clearance
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an  ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 99 Unscrew and remove nuts (61037).  Uniformly press off compressor casing (72000) using three press-off  nuts (61090) fitted on bearing casing side. Slightly lift and pull out compressor casing (72000).  Remove the O-ring (42012).  © Copyright 2017 ABB. All rights reserved.
Page 100 Check underlay and adjust if necessary.  WARNING Remove screws (72002).  Remove diffuser (79000) using swivel lifting eyes (90235).  Remove wall insert (77000) using swivel lifting eyes (90235).  Remove O-ring (77005) from wall insert.  © Copyright 2017 ABB. All rights reserved.
Page 101 Withdraw cartridge group.  Fit supports (90450) using screws and put down cartridge group.  Remove screws (42064) together with flange (42044). Also remove  possible contamination behind the flange. Cover the oil connections.  © Copyright 2017 ABB. All rights reserved.
Page 102: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Pass extension (A) of torque spanner (B) through hole in clamp and  only loosen screws (61056) one after other. Do not yet remove the screws (61056) and Verbus Ripp® washers  (61057). © Copyright 2017 ABB. All rights reserved.
Page 103 Loop the lifting gear around the turbine diffuser (63000) and secure it  to a crane. Remove the nuts (61037) and clamps (90921) from the stud.  Withdraw the turbine diffuser all the way and remove it.  Remove guide stud (90320).  © Copyright 2017 ABB. All rights reserved.
Page 104 Install the nozzle ring and turbine diffuser in the reverse order of re-  moval. Coat the screw threads with high-temperature grease.  Align nozzle ring with holes or cams in gas inlet casing.  © Copyright 2017 ABB. All rights reserved.
Page 106 Uniformly tighten the three screws (61059) with Verbus Ripp® wash-  ers (61058). Remove the lifting gear.  Screw in the speed sensor (86505) together with the O-ring (86506)  and plug in the cable connector (86515). © Copyright 2017 ABB. All rights reserved.
Page 107 Align the wall insert (77000) using the centering screw (90187) and fit  Put the diffuser (79000) in place using the swivel lifting eyes (90235).  Remove the swivel lifting eyes (90235).  Fit screws (72002).  © Copyright 2017 ABB. All rights reserved.
Page 108 (61037). Secure the three press-off nuts (61090) against the compressor casing  (72000) with the appropriate tightening torque (see chapter Table of tightening torques). Remove lifting device (90190).  © Copyright 2017 ABB. All rights reserved.
Page 109 Measure and note the axial clearance (A) (see the section on axial  clearance). If the axial clearance (A) is out of tolerance, an ABB Turbocharger ser- vice station must be contacted. CAUTION Connect oil pipes and all air lines in accordance with enginebuilder ...
Page 110: Dismantling And Fitting Nozzle Ring At Turbine End
CAUTION The nozzle ring hangs loosely on the gas inlet casing and can fall down. CAUTION Mark the positions of the gas inlet casing and the segments. NOTICE © Copyright 2017 ABB. All rights reserved.
Page 111 Remove gas inlet casing and put it down.  Use suitable underlays when putting down gas inlet casing. CAUTION Remove spiral-wound gasket (61050). 1) If present  © Copyright 2017 ABB. All rights reserved.
Page 112 Brush screw threads (61044) with high temperature grease.  Position segments (51012) using screws (61044). Segment connection  Make sure that collars (C) of segments (51012) rest in groove (S). Checking Position screws (61044). Flange connection  © Copyright 2017 ABB. All rights reserved.
Page 113 Checking the tightening  ing tightening torque from step 3. torque Remove lifting gear from gas inlet casing (51001).  Connect cleaning line (if provided) and fasten insulation to gas inlet  casing (51001). © Copyright 2017 ABB. All rights reserved.
Page 114: Table Of Tightening Torques
Operation Manual / TPL67-C.. - TPL71-C.. Disassembly and assembly Table of tightening torques Page 112 Table of tightening torques © Copyright 2017 ABB. All rights reserved.
Page 115 Table of tightening torques Page 113 Tightening torques [Nm] Part number TPL67-C TPL71-C 82005 M16x1.5 M16x1.5 72002 72027 with washer 72029 with washer 61037 61090 61036 61059 42059 61044 61056 86505 M18x1.5 M18x1.5 © Copyright 2017 ABB. All rights reserved.
Page 117: Taking Out Of Operation At Short Notice
If the diesel engine must be capable of operation again as soon as possi- ble after damage to the turbocharger (emergency repair), the following possibilities are available:  Locking turbocharger rotor  Fitting the cover plate  Shutting off inlets and outlets  Turbocharger bypass © Copyright 2017 ABB. All rights reserved.
Page 118: Locking The Rotor
4-stroke CAUTION engines.) Otherwise components that are still intact can be damaged through overheating. Shut off the oil supply in the event of lubricating oil leaking from the tur- bocharger. © Copyright 2017 ABB. All rights reserved.
Page 119 (72027) complete with washers (72018) onto studs (72026) and then tightening to values shown in preceding Table of tightening torques. Make sure all components are clean and free from grease. CAUTION © Copyright 2017 ABB. All rights reserved.
Page 120 0.5 bar overpressure. Attention must always be paid to the speed of the undamaged turbo- charger. The speed limit n given on the rating plate must not be ex- Bmax ceeded. CAUTION © Copyright 2017 ABB. All rights reserved.
Page 122 Operation Manual / TPL67-C.. - TPL71-C.. Taking out of operation at short notice Fit cover plate Page 120 Carry out the work as described in the chapter Disassembly and As- sembly. NOTICE Removing the cartridge group  © Copyright 2017 ABB. All rights reserved.
Page 123 Page 121 Close opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger. CAUTION © Copyright 2017 ABB. All rights reserved.
Page 124 The engine can be operated according to the engine builder's instruc- tions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating plate must not Bmax be exceeded. CAUTION © Copyright 2017 ABB. All rights reserved.
Page 125: Blocking The Inlets And Outlets
This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2017 ABB. All rights reserved.
Page 127: Mothballing Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of opera- tion: Remove turbocharger.  Rotor and bearing parts must be removed by an official ABB Turbo-  charging service station and refitted afterwards. Clean all parts. ...
Page 128: Taking Out Of Operation For More Than 12 Months
40 to 70 % and no condensation can form. Condition of the mothballed turbocharger Check the mothballed turbocharger parts for corrosion every year.  If there are signs of rust: Clean parts thoroughly and renew protection  against corrosion. © Copyright 2017 ABB. All rights reserved.
Page 129: Disposing Of Turbocharger Components
 Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2017 ABB. All rights reserved.
Page 131: Spare Parts
 Turbocharger type  Serial number (HT……)  Description 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 132 Part number Locking plate 51255 Gasket 52200 Hexagon-head screw 52204 Hexagon-head screw 52205 Nozzle 52208 Nozzle 52209 Nozzle 52210 Locking plate 52213 Hollow (banjo) screw 52219 Hexagon-head screw 52257 Verbus Ripp® Washer 52258 © Copyright 2017 ABB. All rights reserved.
Page 134: View Of Turbocharger With Part Numbers
Operation Manual / TPL67-C.. - TPL71-C.. Spare parts View of turbocharger with part numbers 12.2 Page 132 12.2 View of turbocharger with part numbers 12.2 © Copyright 2017 ABB. All rights reserved.
Page 135 Foot at turbine end 68003 Slide plate 68006 Cup spring 68007 Bush 72000 Compressor casing 77000 Wall insert 77005 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch © Copyright 2017 ABB. All rights reserved.
Page 136: View Of Turbine Cleaning System With Part Numbers (Optional)
52200 (in spare part set) Gasket 52204 (in spare part set) Hexagon-head screw 52205 (in spare part set) Hexagon-head screw 52208 (in spare part set) Nozzle 52257 (in spare part set) Hexagon-head screw © Copyright 2017 ABB. All rights reserved.
Page 137 52210 (in spare part set) Nozzle 52213 (in spare part set) Locking plate 52219 (in spare part set) Hollow screw 52257 (in spare part set) Hexagon-head screw 52258 (in spare part set) Verbus Ripp® washer © Copyright 2017 ABB. All rights reserved.
Page 138 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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ABB HT575281 Operation Manual

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