Operation Manual TPL69-A PDF

Turboch arging
Operation .Manual
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Operation Manual/ TPL 69-A.. - 80-A..
Table of contents
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.~0 1 Preliminary remarks
1.1 Purpose of manual.
1.2 Layout and functi()n
1.3 Correct use of the turbocharger
1.4 . Ess~ntial information.
1.5 Abbreviations and symbols
1.6 Turbocharger rating (:?late .
2 Safety
2.1 Basic safety instructions .
2.2 General safetyjnstructions .
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2.4 Safety instructions a11d hazard. protection
·l:::i 2.5
I Warnings on the turbocharger.
3 Start-up
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation ~fter laying up
4 Operation
4.1 Servicingwo_rk .
4.2 ~eplacement interval$ for.turboch~rger components
4.3 Measuring speed
4.4 Surging of turpocharger
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4.6 Shutting the engine down
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5 Maintenance
5.1 Foreword to Maintenance .
5.2 Cleaning the filtersilencer. ··
5.3 Cleaning the cpmpressordl;lring,pperatiol}.
5.4 Cleaning turbine blades and nozzle ring in operation
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Preliminary remarks .1
Purpose of manual · ... Lh.··.·
1 PreliminaryremarkS·
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1.1 Purpose of manual
Thl~~operation mahual will help you to become familiar with your ABB
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·~ Operating manual .
0 Turbo Systems turbocharger and to use it to full effect in its intended ap-
plication. You will find important instructions as to the safe, correct, and
~~onomi?al operation of the turbocharger.
Target group Thecqnt$ntolt11is operation manual is intended for persons such as en-
gin~ers;·rnarfn~mechanics and service technicians who are responsible
fortherunnl\lgofthe engine and the: turbocharger installed thereon .
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Content of Operating m8- Thi~'operaticm m~nyal.ilicludes helpful.information on the following topics:
nual '
: • · ·Information o6
the operation ofthe turbocharger and ways to prolong
the. turbocharger's ser\lice.life.
·• Early idemtificatigh and avoidahce of hazards.
• .. Minimizing repair costs arid downtime.
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· rhis operating manual complements and extends existing national regula-

tions on .p~otestionagainst accidents and accident prevention.
NOTE
The instructionsindudei:Hn this operating manoal must be followed

·without fail.
WARNING
If in doubt, consult the safety officer responsible and the person accoun-
table for protection against accidents In your domain.
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Preliminary remarks .1
Layout and function~ :
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Working principle
. The turbocharger is a turbo-machine and consists of the following main

components:. .. . .
• Turbine·
• CbmpreS?Or .
These are both mo.unted ona common shaft.
The exhaust gases from the diesel eng in~ flow through the gas inlet ca-
sing (7) and no.tile. ring (8)to the.:turbine -w~eel.
The turbine wheel· (9) use? the energy ccmtaihed in the exhaust gas to
· . drive the compressor wheeL( 12}-'The compressor draws in fresh air,
compresses it.and therrf()rCe? it intothe errgine cylinders.
The exhaust gas escapes to free air through the exhaust manifold which
is connected to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is•compressedintheturb()c;hargeris drawn through the suction
branch or the filter silencer: (1) into the,compressor wheel (12). It then
passes through the diffuser (11) and .leaves the turbocharger through the
air outlet casing (13).
. . ,
The rotor runs in.tW()radiaLplainbeafings (2/5). One plain bearing is in

the bearing bush (4} ahd one plain bearing is in the axialthrust bearing (3)
at the compressor end .. · . . . . .
The plain bearings are connected to a central lubricating oil channel which
is fed with oil from the engine lubrication circuit The oil outlet is always at
the lowest point ofthebearlng casing(10) ....
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Preliminary remarks
Essential information
1.4 Essential information
. Organisational me&$l1re5 . .
' ' ' • • ' 1; - • ' ' ,;___ • ~ •
In addition to· this m·anual', the gen~ral, statutory regulations applicable in

the respective country for the prevention of accidents and the protection of
the environment must be observed ..
This also appliesto the provision arid wearing of personnel·protection

equipment.
NOTE
..,.. The turbocharger must. be shut down immediately by stopping the en-
gine.in the event. of ~Iterations affecting safety or of corresponding ope-
rating behaviour. The fault must be reported to the person or depart-
ment responsible.
NOTE
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Preliminary remarks 1
Essential information . ',.\ · 1.4
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.0 The. Contactlnformation br:ochure,contains an overview of official ABB
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Turbo Systems. service stations worldwide.
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Design variants
. This operating manual. is valid fo~ various turbocharger design variants.
'fhi~means'thatsorhe;secti6ns:andcomponent descriptions in this opera-

ting manual do not apply to ym.ir ttiroocharger.
Our service stations and agencies will gladly answer your questions rela-
ting. 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 instructi-
ons, Differences,may~xist.in certain details.
Storage of new ttirbocharg~rs
New turbochargers supplied by ABB Turbo Systems can be stored without

additional safeguarding measures for a period of 6 months after the deli-
very date.
Suitable storage locations are dry rooms where the relative humidity is
between 40-70% and no condensation can form .
.,.. After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed \Nith. anticorrosive agent.
.,.. To do this, the insulating materials must be removed.
NOTE
Preliminary remarks
Turbocharger rating plate',;' ·. ; , . ,,, :1;6: '' Page 91
1.6 Turbocharger rating plate

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Operational limits 1 Turbocharger operational limits at engine overload ( 110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
2 Turbocharger operational limits during operation
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j;:j Recommended replace- 3 Replacement interval for the plain bearings in 1000 h
I ment intervals I change
4 Replacement interval for the compressor in 1000 h
periods for turbocharger
components 5 Replacement interval for the turbine in 1000 h
Additional specifications: 6 Customer part number

7 Description of the special design
8 Weight of turbocharger in kg
9 CE identification
10 Turbocharger type
11 Serial number
12 Year of turbocharger construction
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SafetY 2
Basic safety instructions ·• •'·
2 Safety·
, 2.t '.· Basic safety iostf;uCtioils
The following symbols and terms are used for the safety instructions in
this manual:
z CAUTION
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Safety 2
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SpeCial safety instructions - 2.3-
2.3 Special safety instructions
• Work only onJhose conoectjons.for which, you are qualified.

> • "•' " ••• -, ";• ., •- \''" (, ''u' 2 • >, '
Safety when commissioning and during operation
• Before startiQgwork, m~ke avisual inspection of the working area.

• '-Herpove obstadesand any o_bjects lying-amund from the work area.
• Before commissioning check the turbocharger for damage and leaks.
• Retrain from any activitY which could compmmise safety while working
with the turbocharger.
• Inspect the turbocharger after about 12 hours of operation or at least
-once a-day for visiolerdamage and: defects.
• Report any damage or changes: in operational performance to the per-
z son/department responsible immediately:' -
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«> • In the event of damage, shut down the turbocharger immediately and
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s'ecl.lre u·against inadvertentor-u(laothorized use.
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Safety 2
Special safety instructions ..·. . 2.3. Page 51
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S~tety during disassembly, assembly, maintenance and troubleshooting

• Follow the prescribed maintenanceand inspection schedules for all ad-
justment, maintenance and inspection work.
• Inform operating personnel aboutspeCial work and repairs before star-
ting.
• Ensure that absorbent materials ar;e available to clean up any operati-
on materials~ that ~s~pe accidentally.
• Ensuresafe and environmentally-friendly drainage, collection and
disposal otoperating and auxiliary materials.
• Before opening a coverorr;~mqving.a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
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Safety when taking out of operation or putting into storage
• Secure the rotor against turning.

• Clean the turbocharger before mothballing.
• Wear protective clothing when mothballing the turbocharger.
• Keep the work area clean and free of oil and operating materials.
• Remove any obstacles lying around on the· floor.
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Operation Manual/ TPL 69-A.. - 8Q..A..
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Safety 2
Safety instructions:and hazard : Page 7

protection
Protective measl.lres ./ Weacleatherprotective:gloves·

./ Wear close:.fitting.protectiveclothing
./ Tie up long hait:.amd;beards'(wearhairprotection)
·. .(<Wear face.and.eye protection'
./ Wear pmtective shoes · ;1 :
./ Keep floor, equipment andJheJturbocharger clean
· './ .Ensuretheavailabilityof.oil·absorbing materials and have oil collector
:. ibasirisTeady·or in position
·./>Eliminate leaks ''
· Operation and· proCess materials
Operaft9~ . process rnat~fic:ll$

stances:. and refer te. chemical and hazardous sub-
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f .• : •· , ! ' : •. : ... · . . ,:•
• Oils
• Grease
• Coolants
• ;Detergents c:mc:l,solvents
• Acids
CAUTION
!'\, Personal injury The following injuries can be caused by operation and process materials:
• Allergies
• Skin disease
• Loss of consciousness
• Pdisoning or nausea after illhalation
causes • Inhalation of toxic gases, SfT10ke and vapours

• Skin contact with aggressive fluids • .
• Clothing wet or soaked with ,hazardc;>us substances
• Spilling and tipping over ofvessels containing substances used during
· operation • · ··· ·
• Escape (fue to leakage ·
• Tanks and,c()ll~ctorswhic!l qre n.e.tgqs~tight.and which do not comply,
with the regulations On hazardous·substances · .. ·. . · ·
• Burning cigarettes or openJ!ame inJhe,pr()ximity of operCition rna.terials
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Safety 2:''"
Safety instructions and hazard . , 2A Page9

protection
When the turbocharger is operated, surfaces become very hot.
PersOnal injury • Burns'
causes ,. MiSsing orincorrectlyfitted .insulatiqn, .
Protective measures ./ WearJeath,erprotective glqves.
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Start-up ;3 .·
Oil supply < 3.1
3 Start-up
3.1 ,Oil supply
A carefully designed' oil supply, which 'functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger. · ·
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
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Start-Up 3
Inspection work
3.2 Inspection work

This inspection work includes preventiVe visualcontrbl~·. as well as moni-
toring and measurement to.~.nsure the. correct functioning of the tur~o- .
charger. These serve as
an aid to detecting anomalies before and during .
commissioning, thus preventing possible damage to the machine.
• The safety instructions must be follow~d before and during all inspecti-.
on work. .· · · · ·
3.2.1 Inspection before commissioning·

Monitoring equipment .,. Check for correct functioning .
Air filter mat .,. Inspect for damage.
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Lubrication system ... Check that the oil filter is clean before commissioning.
CAUTION
... Check oil pressure in oil supply lines. · .
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Start-up 3
Putting into operation after laying up 3.3 Page5
3.3 Putting into operation after laying up

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0 If they are present ..,.. Remove the cover plates (blind flanges) between the compressor ca-
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sing outlet and the charge-air receiver, upstream of the gas inlet,
E downstream of the gas outlet.
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..,.. Inspect the exhaust-gas duct before and after the turbine for any com-
bustion residue, clean I remove .foreign bodies or residual water .
..,.. Inspect air supply line or filter silencer for any foreign bodies, clean I
remove .
..,.. Start up the turbocharger's engine end oil circulation system .
..,.. Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commissi-
oning .
..,.. Commission the turbocharger.
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Operation 4
Servicing work
4 Operation
4.1 Servicing work·
Se'rvicing{Work du'ring opera}i6n)pcludes,iisu~l ~checks, monitoring and
measuring as well as inspectiotfand.furiction 'checks in order to ensure
co~rectfunctioni11gof t~~ turpocl:larger .. Jtservesas an aid to detecting
. anomalies (juring oper~tion •. th~s preventi11gdamage to the machine.
The inspeCtion, measurement and servicing·O'perations listed must be car.,
ried out at the intervals
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indicated.
WARNING
CAUTION
4.1.1 Servicing work every 25 to 50 hours

Operating data ~ Recording and entering in the machine logbook
~ Establish cause of major anomalies in parameters.
CAUTION
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Operation '4,,
Seriticing work ! ·
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4.1.4 Servicing work every 8,000- 12,000 hOur$
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..c ......... ·Di.smantleJhe tLJrppcharge~:
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0 ..,.. .'Cieall'tl.Jrblne(a'llc:l~'confpressor casings and check for any cracks and
', erosion'/ corrosion ; •, ' •
.. ~JJ> Glean. ~earir;1g ,casing, :blo~· through oil ~~ott~·
..... Clean nozzie ring and inspect for cracks and erosion
· ·..,.. .· Inspect an·d.assess rotor·and• beari.hg parts
NOTE
..zwI 4.1.5 Servicing work every 36,000 hours

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....J ..,.. Dismantle the turbocharger
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..,.. Clean tu'rbine·and cOITlpressorcasingsalld check for any cracks and
erosion I corrosion · ·. ···
· ..,.. Clean beat-ing t:asfng, blow thrOugh oil ports
..... Clean nb:izlefring ahd inspekitfor cracks and erosion
..,.. Inspect and assess rotor
..,.. Replace. the. plain- .bearings with original pa~tsfrom ABB Turbo Systems
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Operation :4
Replacement intervals for turbocharger 4.2 Page 5

components
Expected replacement
intervals [h]
35'000 ... 100'000

25'000. ~.50'000
25'000 ... 50'000
ring
Other casings . 100'000 100'000
Axial bearing compo~ 36.'000 36'000
nents.
24'000 ... 36'000
;::: 12'000
Recommended! replace- See data on rating plate.

ment intervals [h]
..
GAS '=·Gas engine.
..
= Marine Diesel Oil

..
MOO
HFO = Hea.yy.Fuel Oil
NOTE
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Operation 4
Measuring speed ·. 4:3 ...
4.3.1 Assembly
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If the speed sensor is not fitted on the turbocharger, the following proce-
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E l> Engine and turboc~arger are not running.
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'~ C> The turbo~l:l~·rg~r 'lubri~ating system is switched off.
· ,· ~ Remove.sq~~ Riug'(42o47)trori,bearing' casing.
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NOTE
. ~ $crewir speed ?ellsor(8~505)asJaras it will go and tighten to torque

· specified,in table. (See chapter Table of tightening torques.)
~ Connect:'speedser;~sortpc?ble,corn.~ctorj86515) or power amplifier
(86525). . ' •'
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4:3.2 ·Replacement ·
If the speed sensor has to be replaced, proceed as follows:
[> Engine ~no turbocharger ar~.,not running ..

[> The supply of lubricating oil to the turbocharger is switched off.
~ Disconnect cable connector (86515) or power amplifier (86525) from
(\ speed sersor (86505).
~ Screw out defective speed sensor. .
liJl. Screw innewspeed sensor as far''as it will, go and tighten ito specified
·torquei.(See(:;hapterT~ble,of tighte~ing torques.)
.~ Connect new speed sensor to cable connector or power amplifier.
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Operation :4.
Surging of turbocharger' ;: :: ~.: •. 4.4·
4.4 Surging of turbocharger:

Turbocharger surging can.occur.during certain engine operating states,
such as rapid load removal or. ~henmanoeuvring. The direction of flow in
··the COITlpressoristheobrieflyreversed: Sporadic surging of this kind, ho-
wever; doesnotgenerally.impairsafe.operation of the turbocharger.
CAUTION
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Operation 4
Shutting the engine down 4.6 Page 11;
4.6 Shutting the engine down

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Operation Manual/ TPL 69..-A.. - 80-A..
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Maintenance 5
Foreword to Maintenance · 5.1: Page 1
5.1 Foreword to Maintenance

Maintenance and servicing work involves regular visual checks and clea-
ning to ensure that the turbocharger and its attached units function trou-
ble-fre~, ·
. • The externe3l conqitio11 and howgirty the cleaning points specified in

this chapter are, mustoe established by visual checks at the specified
intervals. ·
• The s~fety precautions must be observed during all maintenance and
i servicing work.. ,
The qleaning:points.d~sctibedin t~efollo~ing are:
· • Filtersilencer
• Compr~ssor .·
• Turbine and nozzle ring
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Maintenance 5
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Cleaning the filter silencer · ; . ·
Removing and cleaning filter silencer
If provided ~ Remove filter strip (81265).

.·.·~ Rinse filtefstrip ·(8(1265) 'V\dtli Water using detergent or, if very dirty, so-
ak it. Squeeze out carefully;"Rinse in cold water. Avoid rough treatment
Uetof water) ..
NOTE
~ Unscrew clamping straps (81270) at tightening points (81271) andre-

move together witt'l mesh covers (81266) and connecting strips
'(81268). . ·.. . ·.·· ; .. '
NOTE
~ Take out insert units (E), bend open cover plates (81137) and then
take out fleece segments (81136).
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~ Clean fleece segments (81136).
When cleaning, ensure that fleece segments (81136) are cleaned only
with a weak jet of compressed air, a soft brush or damp cloth. Otherwi-
se, segments might be damaged or lose their shape.
NOTE
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Maintenance 5.
Cleaning the filter silencer> · ·. . .. 5.2 . Page 51
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5.2.2 Filter silencer arid conneCting iod
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81272
'81.273
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81265 ,Filter strip (if provided) 81136 Fleece segment (Insert unit)
81269 !connecting rods 81137 Cover plate
81266 IM~shcov,er . ·..... c •· · 811~ . Filter silencer body
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81272 !screw . . : •.• , .. 81273 Lock nut
E ·/lnsert·unit.= fleece segmemt :+•cover plate
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Maintenance 5 '
Cleaning the filter silencer 5:2 •.
Mounting ~Iter silencer
~ As~emble insert units (E) by p.utti~g tieece segments (81136) into co-
ver plates(81137). . .
1J1- Bend pack cover panels {81137) to their original shape.
_..<Put insert'units· (E):into slot g~:Jides ii1filter ~ilencer body (81135).
!Jt"" :Pt.Wmeshco\/ers {81266)'uriiformly into~correct position.

··~ ·pu~h,copnecting:roos(81269):tt"imugh clips on mesh covers (81266).
CAUTION
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Maintenance
Cleaning the filter silencer_· •....·... · · · ·, : ·.• 5;2 ··· · Page 91
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5.2.3 Removing I installing the qleaning line
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Removing cleaning line
.,.. Disconnect line (2) at injection pipe (1) and remove connector from pi-
pe .
.,.. Withdraw pipe (2) from guide tube (3).
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Maintenance
Cleaning the filter:silencer' Page 11
.._Aft~rinstalling.iriserf0nits,(Ej, refifgUide tq.be (3) andre-peen it.

·.._ ·Fit line (2) ~~d ~cr~\IV fasten to iniettlon. pipe (1 ).
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Maintenance 5
Cleaning the compressor,during -. Page 13

operation
Cleaning method
. clea~in~fofthe c6rl1pres~or dL~i'h9 operation is tarried out using the clea-

ning method described in the following:
• Wet cleaning··-··
This cleaning method has been tested and approved by ABB. Turbo Sys-
tems. · ·
Principle of wet cleaning To clean the compressor stage. while in bperation, water is injected in .front
· of the compressor wheel from an injection pipe that is built in "the filter si-
lencer or suction branch. · · ··· · ··
' The water does not act C!S a solvent in the" process, but the deposit is re-
moved by the mec:hanical·impactofthe d~ops. This is a very suitable pro-
cess, provided that the build-up of deposits is not too advanced.
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V-engihes For V -engines With several turbochargers on each engine, yve· recommend
parallel cleaning of the compres~ors. This Cleaning process.is faster and
the. dsk of tlJrboyharger_:;lJrging is reduced.
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Maintenance
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Cleaning the compressor during Page 15

operation
5.3.2 Wet cleaning using external water.;pressure vessel (XC3)
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Operating.;state PrecOrtditions .for cleaning cam pressors with XC3
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.Procedure'forcompressorwetCieanilig wiitfxca
Operating the water pres-

sure vessel .,.. The Operating state prerequisites for cleaning compressors with XC3
must be met before cleaning can begin .
.,.. Screw out screw plug (X) .
.,.. Fill container with clean water.
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Maintenance 5
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Cleaning the compressor during .. · Page 17
operation
5.;3~3 Wefcleaning using vac1.1um cleaning device on filter silencer (XC4}
Operating-state preconditions for cleaning compressors with XC4
Procedure. tor .col!lJ>ressor wet deanif1g with XC4
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1. Cleaning container ''
,2 Pipe
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3 Injection pipe · 4 Cleaning instructions
5 Cover 6 Valve
Operation Manual/ TPL 69-A .. - 80-A ..
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Maintenance .5
Cleaning .turbiriebladesand nozzle ring· 5o4 Page 19

in operation
5.4 Cleanif1Q. tQrbil'le: bla-d~.s and nozzle ring· in ·

operation · · · · · · ·
The combustion of heavy fuel oil in diesel engines leaves dirty deposits on
the turbocharger turbine blades'andnozf:letring~; These deposits on the
turbine components are caused by the following products of combustion:
Ill! Soot . ·
• Cinders
• Incompletely burned fuel
• Sodium vanadyl vanadate
·· It is therefore an adva'rlta'ge if fuels are usec:l which have a low content of

ash, sulphur, sodium and vanadium. The fuel; furthermore, must also be
stored, prepared and handled correctly.
NOTE
The dirty deposits increase with time so that regular and proper cleaning
>is impqrtant to remove what he3S accumul~te~.
The chc(rging pre!;>Sure.ccm/i#~.sgooewhC3tifthe turbine cross-section is

reduced by dirty turbine compcments. The dirty .deposits ca.use a drop in
turbine efficiency and arise in Emgine temperatures after the cylinders.
This may mean that the engine output has to be reduced.
In addition, a dirty turbine results in rotor unbalance. Heavy deposits of

dirt can lead to unacceptably high rotor imbalance.
Experience wittl turbqcharger operation s.hows that, despite periodic clea-

. ning:while the installaticm is rljnning, overnauls during which turbine and
nozzle ring are Cleaned mechanically cannot l:;>e dispensed with. If clea-
ning is carried out correc;tly and the cleaning system is propercly sized,
however, the intervals betvlfeenoverhauls can be extended.
-------------------------------------
Maintenance . 5
Cleaning turbine blades and ,nozzle ring Page 21

in operation
5.4.1 Wet cleaning turbine and nozzle ring during operation
P~requisites for turbine wet cleaning
CAUTION
Recommended operating state for turbine.wet cleaning
The following operating state and prerequisites have been tested and ap-
provedbyABB Turbo
' "" ·'· '
Systems for
. _," ,, the·c.leaningprocess:
. ,,_'
_,,., __
.._ Start·eogine or reduce engine loadJo as low a level as possible (best

· cleaning is achieved ataJoadlevel of roughly 15 to 20%) .
..,_ As soon as turbine inlet temperature is stable .and below 430°C, wait a
further :10 minutes for charg~rparts to cool down.
· ..,. Start gleaning cycl~ (:)ccordiqg tq following description in Wet cleaning
ProcediJre ·
----------------------~------------
Maintenance 5
Cleaning turbine blades and;nozzle ring 5A Page 23

in operation
~· After {rijectin'greiw'i~ed vo.IJ~'gofwater, shut off the water supply again

·CO by switching over the 3-way valve (4) to scavenging air mode.
0
0
N ~ This completes the injection procedure. · · ·
~ Close drain hole (if provided) above drain pipe {8,9).
Qj
..c
E
·~
Q)
~ After cleaning, wait atleast 1Q minutes with engine running to allow
Cl turbocharger to dry. ·
Recommendation for To obtain therwater flow rates specified in the table of cleaning parame-
water pressure ters, a water pipe pressure of 2 bar is necessary. If a lower water pressu-
re is available, the water flow rate specifiec:lin .the table will not be obtai-
ned. In this case, cleaning will nQt be so good. An improvement can be
achieved by reducing the load to ..below 10%. ·
NOTE
Points to remember when The following must be observed where drainage of the gas outlet casing is
deaning concerned:
• The exhaust-gas temperature after the turbocharger drops significantly

when cleaning (by 50 to 150°C}.
• Water might (but need not necessarily) flow out of the drain, depending
on the engine load. This outflow might not start for 2 - 3 minutes, or it
may not occur at all.
• If drainage of the gas outlet casing is dispensed with, the turbocharger
speed and I or the gas inlet temperature must be monitored during the
cleaning process. If the load is too low, water can collect in the gas out-
let casing. Signs of this are a sudden drop in turbocharger speed or ve-
ry strong increase in the gas inlet temperature. In such cases, cleaning
must be stopped immediately and the cleaning cycle repeated from the
beginning with lower water pressure or higher engine load.
--------------------------~-------
Troubleshooting ·. ·6.
Possible remedies forJailures ·. Page 1
6 Troubleshogting
6.1 Possible:remediesJorJailures
Exhaust temperature too high
Engine output and speed unchangeg

' ,._ ' - ,~ < " '
n Engine t> Malfunctio~ iri:ttle injection sy$h:im

~ Repair, or contact the manufacturer.
Turbocharger [> Air starvation, e.g. air filter clogged with dirt
~Clean
.z
.w [> Compressor I turbine soiled
I
~Clean
t> Exhaust counterpressure. too high

~ Clean or repair boiler orexhaust silencer
[>Turbine damagecfor worn ·. . ._

~ Contact an official ABB Turbo Systems-service station.
Charge-air cooller [> Cooler soiled

~Clean
[> Insufficient coolant water quantity

~ Replenish " . ...
N [>Coolant water inlet temperature too hot

~ Clean/illspedcooling system
-<"i
c:
. 0
"iii
iii
> [> Ventilation inadequate
~ Improve ventilation
--~--------------------------------
Troubleshooting .6
Possible remedies forfailures . Page3
Charge-air pressure too high<

CX)
0
'0
N
Q;
Engine output and speed unchanged
D
E
2l Intake condition normal
·~
Engine [> MalfunctiOr:Hn ·the ihjebtion system

.. ..,.:• Correct adjustment
[> Engine output higher than expected

..,. Check engine output
[> Injection misadjusted

..,. Correct adjustment
zw Turbocharger [> Manometerdispl<:w falJity

.... Replace ~anometer' ·. •
I
<Xi
·. '<!' ,. _ ,' ,---.. .. ' . '• - -·" -' ··';:c.:·
~- ~
N
...J
I-
N
I
Vibrations
Turbocharger [> Rotor imbalance due to heavy fouling of C,Qmpressor/turbine

[> Turbine or compressofdama'g~d '
[> Bearing defective
..,. Contac;~ anofficiC)h~BB).I,JfQO Sy~te111s service station.
Turbocharger [> Turbocharger dirty

..,. Clean
N
C\i
c:
r> Bearing .damaged•
0
-~ l> Rotorgrazing • \ ·
~ [> Foreign bodies in the turbocharger
..,. Contact an official ABB Turbo Systems service station.
------------------------------------
Troubleshooting 6
Possible remedies for failures 6.1 Page 5
Constant surging of the turbocharger

00
0
0
N
Engine [> Exhaust pressure to the turbine elevated because boiler or exhaust si-
~ lencer is dirty
~
Q) [> Trap dirty
a
..,.. Clean
Turbocharger [> Charge-air filter or silencer dirty

[> Heavy deposits of contamination in the turbine
..,.. Clean
NOTE
(\
N
N
c
0
-~
Q)
>
----------------------------------
Removal and installation . 7
0.
Turbocharger weights . L ' 'O .• .' •7.1 Page 1 i
7 Removal and;:installation ·
·co
0
0
N
7.1 TUr6ocHargerweights
ilE
·~
···~
Complete turbocharsj$r unit .without silencer or air suction branch
Weights [kg)
C'!
.N
Complete turbocharger unit with silencer
§
-~ Weights [kg]
Q)
·>
CQmplete
'
turbocharger
.· :· ',·· '
llnit with air",- suction
c-.. -_-, "
branch
Weights [kg)
Removal and installation
Remove the turbocharger' .. · -·· >f,·;: ' ' 7:2.
co
0
0
N
·~~
'Q)
0 "-.WARNING
... Unscrew fixing screws in foot.

..,. Liftturbocharger.off engine arid putit down to one side.
WARNING-
..,. Support turbocharger at a suitable point.

..,. Cover oil cqrmection.
~~--~~------------------
Disassembly and assembly, ' ,' ;8 ,;
Module weights ' 8.1 ' ,.
8 Disassembly and assembly

8~1 Module weights
WARNING
, N
''N
c:
0
·~
' Q)
>
~------------------------------------
Disassembly and assembly 8
Module weights .•
.. Compte~ in~mat
c ' ' ~ '
part of ~mpressor;C?Ssing
' • ' >
•• ' • ' t, l . . '
Weights [kg]
NOTE
I
I
!
'i .'~
------------------~-----------------
Disassembly and ass~illbly•
·' 8
Rem6\ting and fitting filter. sil~ncer • 8:2 Page 5

or air suction branch
TPL n..-ao>
~ Fit safety lifting eye bolt (90231) in bearing plate (P) on filter silencer.
z
w
. ~1 TPL n-80
co
"""
~
+-
N
I
N
N
c:
0
·u; ~ Secure shackle (90195) to rib I fin on filter silencer.
iii
>
WARNING
----------~------------~---------
Disassembly and assembly, 8
\ /
Axial clearance
8.3 AxiaLcle~rance;
at
. ..,. Screw on least four nuts (74027) complet13 with washers (74018)
· equC)IIyfspaceclaround circumference apd tighten to secure partition
waiLaxiC)IIy ....·.
..- Measure:ard not~ axial cleara.nce(A)..
Clearance A [mm]
CAUTION
----------------------------------~
Disassembly and assembly .. c:8
Removing cartridge group >< · ·· .....· · • 8:4. · ·
If provided:
Detach safety ~enb; ..,. Take nuts (90458) out of the toolbox and fit them on the threaded pins
on the compi"EtSS()r :C:asing · ... of the safety segments (Y) on the internal part of the compressor ca-
internal part · .sing (76900).
90458 90458
z ..,. Tighten the. nuts (90458) with the corresponding tightening torque (see
·w table). · · · ·
......I
CIO
'<!"
::!
~
I
NOTE'
Ch~ d!IT!ension IJ[mm] .
N
t'oi
·C:
0
-~
>
The internal part of the compressor casing is now detached from the ex-
ternal part of the compressor casing (74000) and can be removed.
--------------------------------------
Disassembly and ass~rribly. :'> ,·.8
.n
Removing cartridge group··· .··•· ' •.•. · .··:8!4•:.:··· Page 111
Internal part of compres-

sor casing
90190/90195
·~ Secure lifting device to rear side. of flange (F).

~ Turn the internal part ofthe compressor casing with wall insert and dif-
fuser carefully over the support bracket (90025) and set down with the
front side of the flange (F) on the underlay.
•N
C\i CAUTION
·c:
0
·u;
~·
----------------------------~----~
Removing cartridge group .8.4 . •.
External part of compres-

sor casing
~co
.Q
0
,]4000
N
0
~
~ Jflstem lifting devic~(~0190) compl~te1'tJith shackle (90195) to external

· part of cotnpressorcasing'(74000) and secure to crane .
...,. Loosen nuts (61037); press off'exte~nalpart of compressor casing
evenly with the three press-off nuts (61037) and remove.
N
N
c::
0
"iii
~
--------------------------------------
Removing cartridge groljp , Page 151
00
0
0
'•C'\1
, .21
CAUTION
·~
~
"": Extract cartridge group and fit supports (90450).
... Cover oil connections.
CAUTION
C'\1
N
§
·~
(J)
>
--------------~-------------------
Disassembly and assembly.' 8
Dismantling and installirlQ Page 17

the turbine diffysen:mdnozzle.ring~
Rerrioving turbine .diffuser . .·/~~:·~~,"'

.
.
.
'
.·
'
""...
.,:.. !nupper section·ofturbine diffuser (63000), replace two screws

(6t056) and Verbusripp wast1ers.(61057) with two guide bolts (90320).
Pass guide bolt througtlhole)n Clamp (90921) each time .
. IJII. Sc~ew on hexagon nots (9Q178) to secure .
.. .-·.,
Secure diffuser
'N
·N
·c::
0
-~
Q)
>
.,.. Before dismantling the turbine diffuser, if possible the nozzle ring
should be secured against falling with a clamping set and a wooden
block.
--------------------------~---------
Disassembly and assembly .. 8
Dismantling and installing.·.. Page 19

the turbine diffuser and nozzle ring
·'..,_ Pull
. forwardnoZz.lering
. .
(56001), fasten to lifting gear and remove.
:Fitting turbine diffuser .and nozZle ring

'• . . . •. ' •,
0. Fitting •..,. .Fit nozzle rir)g

.
and turbine diffuser in reverse order to removal.
IJJi>; Align nozzle ring with holes in gas inlet casing and fit it using screws,
· ·nuts and sleeves.
N
N NOTE
c::
0
-~
·.~
CAUTION
--------------------~-------------
Disassembly and assembly ·.· ~ 8.
Installing cartridge group: ·· Page 211
CAUTION
If provided:
~ Screw in speed seo~o; t86505) complete with 0-ring seal (86506) and
plug in cable connector: (86515).
' ~· ' ' <
C'!
N
..,. Attach lifting device (90190) complete with shackle (90195) tp external
c
0
part of compressor casing (74000) and secure to crane. ·
"iii
. lii ..,. Fit external part of compressor casing (74000) and secure using nuts
> (61037).
------------------------------------
Disassembly and assembly~ <8 '
Installing cartridge group' Page 23
90190/90195
..,. .L}ttach the 'lifting device (90t9p)and shackle (90195} securely to the
qack side of flange (F). , ,. ,• · , . ,
..,. iurn the internC)I pC)rtof compressor ca~irig with wall insert and diffuser
carefullyover the supportbracke((90025} to the vertical position and
~et down on the :sllim ahd stipport!bracket
~·
I
j ',
'·
ii
------------------------------------
Disassembly and assembty ·· · -8 .
Installing cartridge group Page 251
..,. Scr~wonat lea9tfollrJ1uts;(440?7)wit~washers (74018) equally

spaced around circumference and tighten to secure internal part of
compressor casing and partition wall axially .
Engage safety segments ..,. Unscrew the nuts (90458) on threaded pins of safety segments (Y) on
on the
eompressorcasing ; internalipart~otcompr:essor·casing (76000).
internal part
· ¢ The intern.al part of ,the compressor casing (76000) is now secured re-
. iative tC> the external part otthe,.co,rl1p~~ssor casing (7 4000).
~..... / ...
~\ 90458
NOTE
Check dimension s [mm]
(\_
..,. Put nuts (90458) back into toolbox .
..,. Measure and note the axial clearance
·~ Clearance A [mm]
c::
0
·u;
"i Q3
·>
CAUTION
------------------------------------
0,8
Disassembly and assembly
Turbine-end rerrioiJaljofitting of the Page 27

nozzle ring
8.7 Turbine-end removal/ fitting of the nozzle

oring
NOTE
Removing nozzle ring .,._ Remove insulation from gas inlet casing (51001).
.,._ Securethe gasoinlet casingowithshackle (90195) and a suspension ro-
eN
pe:
N .,._ Remove two hexagon-:head screws (61 044) together with Verbusripp
§
-~ washers (61043) from bottom section and replace them with two studs
>
Q)
(90177).
.,._ To secure, fit hexagon nuts (90178) onto the studs (90177) .
.,._ Loosen and remove the remaining screws {61044) and Verbusripp
washers (61043) on the gas inlet casing flange (61001) .
.,.. Withdraw the gas inlet casing with the nozzle ring from the gas outlet
casing until holder (90175) can be fitted from outside with screws
(61044) and Verbusripp washers (61043) .
.,._ Unscrew hexagon nuts .(90178) from studs .
.,._ Fully withdraw gas inlet casing and remove.
-----------------------------------
Table of tightening torque~,, '8.8 Page 29
8.8 ·. Table oftightening torques

·:·,>
00
0
0
N
".8E
.(g
Q)
0
f'\,
.. N
N
§
-~
Q)
>
The following tightening torques must be adhered to for the specified

screw connections:
\
'-__...·
----------------------------------
Short-term turbocharger shiJi-:down:: · . 9 ·
Possibilities for emergency repair· Page 1
9 Short-term turbocharger shut~down

00
0
.0
.N
9.1 .Possibilities for emergency repair
~ . ' .. ' ., -; . ~ . ( -'
E
I
I
:!ll
'Q.l
,o
, ..
WARNING·
.I .
.I
I
·········· T
.. I . .
CAUTION·
If the diesel engine must be capable of operation again as soon as pos-

I sible after damage. to the turbocharger (emerg~ncy repair), the "following
II possibili~ie~ ?r~ av,ailable: · · ·
.I i'•'-
··I'..· . • Lock the turbocharger rotor .·'·

• Blocking the inlets and outlets
• Bypass the turbocharge( .
• Fit cover plate
. ~ ., '
I
I
' '
N
N
c
.0
:"iii
..~
--------------------------------------~
ShorPterm turbocha'rger shljt;;:dowri' 9' :
Locking the rotor Page31
z
w
-,~
I
<Xl
'I-
""
N
...J
N
,:r;
Table of tightening tor•

ques[Nm]
(\ 135'
" '
94006 1\118 M10
25 25 25 45
94007 M8 M8 M8 M10
15 15 15 35
NOTE
~ Remove silencer or air suction branch and internal part of compressor

casing complete with wall insert and diffuser.
~ Fit partition wall clamp (94005) with screws (90442).
-----------------------------------
Short:.term turbochargershpt.,.down- 9
Locking the rotor
Compressor type cv 20
.,.. Push the intermediate rings (94001 and/or 94002) and assembly-
clisassembl}rdeviC:e (90020) onto the lockif:lg flange (94003) in the cor-
rect sequence;· · · ·· ·
.,.. Now' push 6n the other· remaining intermediate rings (94001 and/or
\ 94002).- . ·-. .. . .
- .,.. Tighte11 i.ntermeciiat~ ri~'gs, a~$eh161y-disassembly device (90o2o) and
. locking flange (94003)- with the screws (94006) according to the values
shown in the preceding Table of tightening torques .
N
N
.,.. Now. tighte_n theassembly-/dispssembly device onto the compressor
c
0
· ·· casin'g with the huts (7 4027) arid the studs according to the values
-~ ·shown in the preceding'Tigbtening torques table. ·
~
(\
----------------------------------~
Short.:;term turbochatger:sbut-:down' 9
Fit cover plate ·•··.· 9 ..3
9.3 Fit cover plate
NOTE
(\
I
N~
aH
'
.··6]
I
~
00
"'N...J"
N
I
(\
Cover plate dimensions

[mm]
TPL69 13 385 30 30 8 10 6 84
TPL 73 450 50 50 9 12 8 94
TPL 77 535 9 12 107
fN TPL80 623 11 15 136
N
·c
0
"iii
Q; TPL69 726 818 779 18 25 15
>
TPL 73 844 948 905 20 28 20
TPL 77 1003 1124 1075 22 30
TPL80 1164 1300 1248 24 32
--------------~----------------------
Short""term turbocharger shut~down :~ ·9 :
Fit co\ler plate .. 9.3 .··· Page91
··co
0
0.
N
.(jj
.I:l
E
0
~
IJilll> Close off opening in· gas outleLcasing using cover plate.
IJilll> Fasten cover plate using spacer sleeves and nuts (61037).
CAUTION
N
c-.i
§
"iii
(jj
>
Short-term turbocharger shl]t-down
Blocking the inlets and outl~ts 9A. Page 11
9.4 Blocking ·the inlets and outlets

00
0
··~
iii
·.0
J 0
CAUTION
NOTE
.w
z
I
·~
00
'<I"
N
....1
N
:::c
N
C\i
§
. -~
• (!)
·>
-----------------------------------
Storing turbocharger (. .•.10
Taking out of operation .fonupto :12 JQ.t. Page 1

months
·10 ;storingturbothargeri::
10. 1 '"-:-:i--TaKing
_ ,_,-;
out
;;:'~--~:-::,
pf operation for up
( ",',' ,'_,;··}·.•<·. ,;
to 12 months ~-·-';,:~~ -~~;·' ~::,~·:.__ --~
· If a turbqch?rgerp~(9l1t6lus~ for upto12;m6nths, any possible special

turbocharger stora'ge measures depend primarily on the condition of the
lubricating oil before the shut-down.
'. " -- '". , <
- • . .-· ~ . -. ' . ' ' "5 ;. - ,< ' ~ '"• • -'
lftheTotal AciCfNumber(TAN)fs·loWerthali'2rng KOH/g no special

measures need to be taken. If, however, the Total Acid Number is greater,
the turbocharger must be dismantled after its .shut-down, ciE3aned and
bright parts oiled with protectiv~ oiL · ·
If the turbocharger is left niouiltecl. on the engi~e and the engine ~il is re-
placed by protective oiJ which is circulated by the pre-lubrica,ti()n, pump
prior to the shut-down, no measures need to be taken with the turbochar-
ger. The remains of the old engine oil will be washed away and the sensi-
tive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
'C\1
·c-.j
·.· c
0
"P2
• Q)
>
f\,
---------------------------------
Disposal 11
(~
Environmentally compatible disposal of 11.1 Page 1
turbocharger components
11 Disposal
11.1 Environmentally compatible disposal of tur-
bocharger components
NOTE
..,.. Dispose of metals by melting down and recycling .

..,.. Dispose of non-metallic materials as waste .
..,.. Dispose of lubricant left-overs and residues as used oil.
..,.. Dispose of electronic components as electrical I electronic scrap.
WARNING
N
N
c:
0
-~
~
..,.. Dispose of thermal insulation as special waste.
Reser\te and spare parts::~
-
Ordering spare parts ;
,-,"'~
; ~
-,' '
···•· '· 12·.'1·.
12 ·Reserve and spare:parts:

12.1 Or(jering spar~fP@-1~.,. · .·
' .··- ,,,, .. _·.-·~ '·"·f,"·~:>" ·c.': '":'·;-~ 0 '
When making inquiries or ordering $pqre p~rts, the following data should
be speCified: ·
• Turbocharger type
• HT number
• Description and· part mi~·ber: .
.· bur service stations and agents take orders for spare parts.
IJI- Contact an official ABB Turbo Systems service station or an ABB agent
if special versions I cases are not addressed in these general instructi-
ons.
IJI- Dispose of replaced, unusable parts in a technically and environmen-

tally compatible way.
Reserve and spare parts
Ordering spare parts 12.1. Page 31
TPLn-A
.61037
42041
2
2
TPL80-A
z
.•UJ
<>~
I
.·~
:N
._J
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I
.:~
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.i!?
Q)
~>
Reserve and spare parts"
Directory of part numbers ", ;~ · •.i • •· 122· ·.
Csrbidge group- screwed

connection
Com pressor wheel · ·

Screw plug
Thrust bearing
Radial bearing, 'compressor end
Radial bearing, tUrb_ine end
Auxiliary bearing
Floating disc
32106 Thrust bearing
32107 Bearing bush
42001
42002:
42011
42012 (in spare parts set}
42015
42045 (in spare parts set} .

42058 (in spare parts set} ·
42059 (in sppre parts set}
N
N
"C
0
·~
"Q)
">
(_) Version 2.2 (
/)
--
..
i-iirL2481_EN ( _) Deeember' 2008
)
74000
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61043 61044
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~
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CT
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61057
61056
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Operation Manual TPL69-A PDF

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Turboch arging

Type TPL ?q~A$0

Purpose of manual · ... Lh.··.·

· rhis operating manual complements and extends existing national regula-

The instructionsindudei:Hn this operating manoal must be followed

Layout and function~ :

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

These are both mo.unted ona common shaft.

The rotor runs in.tW()radiaLplainbeafings (2/5). One plain bearing is in

1.4 Essential information

In addition to· this m·anual', the gen~ral, statutory regulations applicable in

This also appliesto the provision arid wearing of personnel·protection

Essential information . ',.\ · 1.4

. This operating manual. is valid fo~ various turbocharger design variants.

'fhi~means'thatsorhe;secti6ns:andcomponent descriptions in this opera-

Storage of new ttirbocharg~rs

New turbochargers supplied by ABB Turbo Systems can be stored without

Turbocharger rating plate',;' ·. ; , . ,,, :1;6: '' Page 91

1.6 Turbocharger rating plate

Operational limits 1 Turbocharger operational limits at engine overload ( 110 %).

Additional specifications: 6 Customer part number

Basic safety instructions ·• •'·

SpeCial safety instructions - 2.3-

2.3 Special safety instructions

• Work only onJhose conoectjons.for which, you are qualified.

Safety when commissioning and during operation

• Before startiQgwork, m~ke avisual inspection of the working area.

Special safety instructions ..·. . 2.3. Page 51

' - .~-- ·. - -: ' ' ~ '

S~tety during disassembly, assembly, maintenance and troubleshooting

• Secure the rotor against turning.

Safety instructions:and hazard : Page 7

Protective measl.lres ./ Weacleatherprotective:gloves·

· Operation and· proCess materials

Operaft9~ . process rnat~fic:ll$

causes • Inhalation of toxic gases, SfT10ke and vapours

Safety instructions and hazard . , 2A Page9

When the turbocharger is operated, surfaces become very hot.

PersOnal injury • Burns'

causes ,. MiSsing orincorrectlyfitted .insulatiqn, .

Protective measures ./ WearJeath,erprotective glqves.

Oil supply < 3.1

3.2 Inspection work

3.2.1 Inspection before commissioning·

Air filter mat .,. Inspect for damage.

... Check oil pressure in oil supply lines. · .

Putting into operation after laying up 3.3 Page5

3.3 Putting into operation after laying up

4.1.1 Servicing work every 25 to 50 hours

..zwI 4.1.5 Servicing work every 36,000 hours

Replacement intervals for turbocharger 4.2 Page 5

35'000 ... 100'000

Recommended! replace- See data on rating plate.

= Marine Diesel Oil

Measuring speed ·. 4:3 ...

. ~ $crewir speed ?ellsor(8~505)asJaras it will go and tighten to torque

[> Engine ~no turbocharger ar~.,not running ..

Surging of turbocharger' ;: :: ~.: •. 4.4·

4.4 Surging of turbocharger:

Shutting the engine down 4.6 Page 11;

4.6 Shutting the engine down

Foreword to Maintenance · 5.1: Page 1

5.1 Foreword to Maintenance