ABB

Operation Manual

Table of Contents Page 1

ABB Turbo Systems Ltd ABB

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Table of Contents 1 Preliminary remarks 1.1 Purpose of the manual 1.2 Layout and function 1.3 Correct use of the turbocharger 1.4 Essential information 1.5 Abbreviations and symbols 1.6 Turbocharger rating plate 2 Safety 2.1 Basic safety instructions 2.2 General safety instructions 2.3 Special safety instructions 2.4 Safety instructions and hazard protection 2.5 Warnings on the turbocharger 3 Commissioning 3.1 Oil supply 3.2 Inspection work 3.3 Putting into operation after laying up 4 Operation 4.1 Servicing work 4.2 Monitoring 4.3 Surging of turbocharger 4.4 Contact with rotating parts 4.5 Shutting the engine down 5 Maintenance 5.1 Foreword to Maintenance 5.2 Cleaning the filter silencer 5.3 Cleaning the compressor during operation 5.4 Cleaning turbine blades and nozzle ring in operation

Operation Manual

Table of Contents Page 2


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6 Troubleshooting 6.1 Possible remedies for failures 7 Removal and installation 7.1 Turbocharger weights 7.2 Remove the turbocharger 7.3 Installing the turbocharger 8 Disassembly and assembly 8.1 Module weights 8.2 Removing and fitting the filter silencer or air suction branch 8.3 Removing cartridge group 8.4 Axial clearance 8.5 Dismantling and installing the turbine diffuser and nozzle ring 8.6 Installing the cartridge group 8.7 Turbine-end removal / fitting of the nozzle ring 8.8 Table of tightening torques 9 Taking out of operation temporarily 9.1 Possibilities for emergency repair 9.2 Locking the rotor 9.3 Fitting the cover plate 9.4 Blocking the inlets and outlets 9.5 Bypass the turbocharger 10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months 10.2 Taking out of operation for more than 12 months 11 Reserve and spare parts 11.1 Ordering spare parts 11.2 Directory of part numbers 11.3 General view of turbocharger 11.4 General view of cartridge group

Operation Manual Preliminary remarks 1

Purpose of the manual 1.1 Page 1


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1 Preliminary remarks 1.1 Purpose of the manual

This operation manual will help you to become familiar with your ABB Turbo Systems Ltd turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and economical operation of the turbocharger. The content of this operation manual is intended for persons such as en-gineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon. This operation manual includes helpful information on the following topics: Information on the operation of the turbocharger and ways to prolong

the turbocharger's service life. Early awareness and avoidance of hazards. Minimising repair costs and failure times. This operation manual is a complement to, and an extension of, existing national regulations on accident protection and prevention.

An operation manual must be available at all times at the site where the turbocharger is used. It is essential that this operation manual is read before beginning work by all persons working with or on the turbo-charger. Personnel who only work occasionally on the machine (e.g. during installation and maintenance) must also have read and fully un-derstood the operating manual before beginning work.

The instructions included in this operation manual must be followed under all circumstances.

This applies especially to the general and special safety instructions preceding and in the respective chapters. Ignoring hazards and the sa-fety instructions can lead to serious personal injury and damage to e-quipment.

In the event of doubt, consult the officer for safety and accident protection responsible for your area.

Operation manual

Target group

Content of operation ma-nual

NOTE

WARNING


Layout and function 1.2 Page 2


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1.2 Layout and function

00000_001

1 Filter silencer 8 Nozzle ring 2 Radial plain bearing 9 Turbine wheel 3 Thrust bearing 10 Bearing casing 4 Bearing bush 11 Diffuser 5 Radial plain bearing 12 Compressor wheel 6 Gas outlet casing 13 Air outlet casing 7 Gas inlet casing


Layout and function 1.2 Page 3


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Mode of operation The turbocharger is a turbo-machine and consists of the following main components: Turbine Compressor These are both mounted on a common shaft. The exhaust gases from the diesel engine flow through the gas inlet cas-ing (7) and nozzle ring (8) to the turbine wheel. The turbine wheel (9) uses the energy contained in the exhaust gas to drive the compressor wheel (12), whereby the compressor draws in fresh air, and the compressed air is forced into the cylinders. The exhaust gases escape through the exhaust pipe which is connected to the gas outlet casing (6). The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch or the filter silencer (1) into the compressor wheel (12). It then passes through the diffuser (11) and leaves the turbocharger through the compressor outlet on the air outlet casing (13). The rotor runs in two radial plain bearings (2/5) which are located in the bearing bush (4) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side. The plain bearings are connected to a central lubricating oil feed which is supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (10).


Correct use of the turbocharger 1.3 Page 4


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1.3 Correct use of the turbocharger

This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charg-ing pressure required to operate the engine. The engine manufacturer has provided ABB Turbo Systems with infor-mation regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate. If it is used in conjunction with a gas engine, the engine must not be in-stalled in a potentially explosive environment, and precautionary meas-ures must be taken to ensure that the machine room as a whole is clas-sified as not potentially explosive. Any other usage shall be regarded as a special application which must be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys-tems reserves the right to reject all claims under the warranty.

This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations.

Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine. The machine may only be ope-rated by trained personnel.

Correct use of the turbocharger also includes observation of the assem-bly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Regulations set out by local authorities must be ob-served when disposing of the turbine. The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in com-pliance with the Operation Manual. X Defects which could affect safety must be eliminated immediately. The manufacturer shall not accept liability for damages resulting from un-authorised alterations to the turbocharger.

NOTE

Latest technology

WARNING

Perfect condition


Essential information 1.4 Page 5


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1.4 Essential information Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed. This also applies to the provision and wearing of personnel protection e-quipment.

The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual.

X The turbocharger must be shut down immediately in the event of al-terations affecting safety or of corresponding operating behaviour. The fault should be reported to the person or department responsible.

Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys-tems.

NOTE

NOTE




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Original parts and safety Original parts and accessories are especially designed for the turbo-charger supplied by ABB Turbo Systems Ltd.

We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us.

If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the techni-cal design specifications of the turbocharger. Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine.

ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories.

Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel.

Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems Ltd.!

It must be ensured that only authorised personnel work on the turbo-charger.

NOTE

WARNING

CAUTION




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After-sales service The Contact Information brochure contains an overview of official ABB Turbo Systems Ltd. service stations worldwide.

Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this oper-ating manual do not apply to your turbocharger. Our service stations and agencies will gladly answer your questions relat-ing specifically to your model.

Accuracy of illustrations The graphics and images shown in this operation manual are of a general nature and are intended to assist understanding of the work steps and in-structions. Differences may exist in certain details.

Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems Ltd. can be stored without additional safeguarding measures for a period of 6 months after the delivery date. Ensure that the storage area is dry with humidity of 40-70% and free of condensation. X After 6 months, rust-proofing oil should be sprayed on exposed sur-

faces and all accessible areas of the turbocharger. X To do this, the insulating materials must be removed.

Repeat the steps described for rust-proofing your turbocharger every 6 months. NOTE


Abbreviations and symbols 1.5 Page 8


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1.5 Abbreviations and symbols The following abbreviations are used in this document: Z Prerequisite X Work step D Result 9 Positive checkpoint (activity that must be carried out without fail) U Negative checkpoint (activity that must not be carried out under any

circumstances)

Basic Instructions The following symbol is used for notes in this manual:

This note provides suggestions and tips to make work on the turbo-charger easier. The note provides further essential information.

ABB Turbo Systems The term used in this manual ABB Turbo Systems signifies ABB Turbo Systems Ltd.

Official ABB Turbo Systems service station The term used in this manual Official ABB Turbo Systems service station signifies ABB Turbocharger service stations, that have been tested and certified by ABB Turbo Systems Ltd.

NOTE


Turbocharger rating plate 1.6 Page 9


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1.6 Turbocharger rating plate

L_00012

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

In test rig operation only, unless otherwise agreed with the engine manufacturer.

2 Turbocharger operational limits in service.

3 Replacement interval for the plain bearings in 1000 h 4 Exchange interval for the compressor in 1000 h (no data for

100,000 h) 5 Exchange interval for the turbine in 1000 h (no data for

100,000 h)

Operational limits

Recommended replace-ment periods / exchange intervals for turbocharger components


Turbocharger rating plate 1.6 Page 10


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6 Customer part number 7 Field for special design designation 8 Weight of the turbocharger in kg 9 CE = Conformit Europenne 10 Turbocharger type 11 Series number 12 Year of construction of the turbocharger

Explanations of the rating plate The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific.

Continuous running above the indicated nBmax, tBmax values may consid-erably reduce the recommended exchange intervals. In such cases, we recommend you contact the nearest official service station of ABB Turbo Systems Ltd. nMmax , tMmax normally apply only when running at overload (110 %) dur-ing trials on the engine test bed. These limits may also be permitted in service for special applications. The operation over nMmax , tMmax is not permitted. Non-compliance with the recommended exchange intervals may in-crease the risk of unpredictable component failure.

Additional specifications:

CAUTION

Operation Manual Safety 2

Basic safety instructions 2.1 Page 1


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2 Safety 2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in this manual:

Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents. Warning signs must be strictly observed at all times.

Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed. Caution signs must be strictly observed at all times.

WARNING

CAUTION


General safety instructions 2.2 Page 2


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2.2 General safety instructions The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associated operating materials.

The following safety instructions must be followed when operating and when working on the turbocharger.

Do not work on the turbocharger if you are under physical or mental stress.

Wear protective clothing at all times. Helmet Ear protection Protective glasses Protective suit Oil and petrol resistant gloves Protective shoes

Attach individual parts and larger component modules carefully to suit-able hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity.

Do not stand under suspended loads. If welding work is to be carried out above the turbocharger, the air filter

must be covered to prevent damage to the filter mat. When working on the turbocharger, be aware of the risk of it falling. For overhead assembly work, use the steps and platforms provided for

this purpose.

WARNING


Special safety instructions 2.3 Page 3


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2.3 Special safety instructions Safety when connecting Work only on those connections for which you are qualified.

Safety when commissioning and during operation Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working

with the turbocharger. Inspect the turbocharger after about 12 hours of operation or at least

once a day for visible damage and defects. Report any damage or changes in operational performance to the per-

son/department responsible immediately. In the event of damage, shut down the turbocharger immediately and

secure it against inadvertent or unauthorized use.




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Safety when cleaning When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Follow directions regarding the environmentally compatible collection, sto-rage and disposal of these liquids.

Explosion hazard Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air circulation. Before beginning cleaning work in confined spaces, extin-guish naked flames (including cigarettes!) due to the risk of explosion.

Before cleaning, protect the floor against unintended leaks of oil and

operation materials. You must wear protective clothing (see section General safety instruc-

tions). Handle operation materials and detergents with utmost caution. When handling solvents, wear protective clothing and observe the fol-

lowing rules: Avoid skin contact with solvents. Avoid inhaling vapours under all circumstances. Do not allow solvents to soak protective clothing.

After cleaning, check electric cables for signs of wear or damage.

WARNING




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Safety during disassembly, assembly, maintenance and troubleshooting Follow the prescribed maintenance and inspection schedules for all ad-

justment, maintenance and inspection work. Inform operating personnel about special work and repairs before start-

ing. Ensure that absorbent materials are available to clean up any opera-

tion materials that escape accidentally. Ensure safe and environmentally-friendly drainage, collection and dis-

posal of operating and auxiliary materials. Before opening a cover or removing 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.

Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or ro-tors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.

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.

CAUTION


Safety instructions and hazard protection

2.4 Page 6


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2.4 Safety instructions and hazard protection Associated hazards may arise during operation of and work on the turbo-charger: from the turbocharger and its accessories. from the operating materials used. due to failure to comply with the safety instructions. from inadequate performance of maintenance and inspection work.

Mechanical influences

Mechanical influences can cause serious injury or even fatal injury.

Unconsciousness and injury due to: crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling sharp edges, pointed parts crush, shear and winding areas fragmentation / ejection of parts fracture or rupture of parts due to overload Elastic elements (springs), liquids and / or gases under pressure/in a

vacuum slippery, oily work area, obstacles on the floor

WARNING

Personal injury

Causes



2.4 Page 7


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9 Wear leather protective gloves 9 Wear close-fitting protective clothing 9 Tie up long hair and beards (wear hair protection) 9 Wear face and eye protection 9 Wear protective shoes 9 Keep floor, equipment and the turbocharger clean 9 Ensure the availability of oil absorbing materials and have oil collector

basins ready or in position 9 Eliminate leaks

Operation and process materials Operation and process materials refer to chemical and hazardous sub-stances: Oils Grease Coolants Detergents and solvents Acids

Note that operation and process materials are harmful to the environ-ment if they penetrate soil or water.

The following injuries can be caused by operation and process materials: Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids Clothing wet or soaked with hazardous substances Spilling and tipping over of vessels containing substances used during

operation Escape due to leakage Tanks and collectors which are not gas-tight and which do not comply

with the regulations on hazardous substances Burning cigarettes or open flame in the proximity of operation materials

Protective measures

CAUTION

Personal injury

Causes



2.4 Page 8


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9 Utmost caution when handling process and operation materials 9 Protective clothing must be worn 9 Avoid skin contact and inhalation under all circumstances 9 Ensure that the workroom is properly ventilated 9 Observe the hazard indications on the containers for operation and

process materials 9 Immediately after use, seal the hazardous substance container tight 9 Used operation materials must be collected safely in accordance with

the legal provisions, stored separately in suitable containers as pre-scribed, and disposed of as special waste in a technically and envi-ronmentally compatible manner

9 Ensure that containers for new / used operation materials are sealed tight

9 In the event of leaks or spills immediately apply a suitable absorbent material and dispose of this in a technically and environmentally com-patible manner as special waste

Handling insulating materials 9 Ensure that the work area is well ventilated 9 Keep the work area clean 9 Avoid disturbing dust 9 Dust-suppressing tools and processing steps 9 Remove from packaging only in the work area 9 Exercise particular care when removing old insulating materials 9 Dispose of insulating materials in a technically and environmentally

compatible manner 9 If large quantities of dust are created, wear protective glasses 9 Use half or quarter masks 9 Wear suitable work clothing and gloves 9 For sensitive skin, apply moisturising, protective barrier cream

Protective measures



2.4 Page 9


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Noise The effects of noise above a legally permitted level can cause personal in-jury. Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances Machine noise level above 85 dB (A) 9 Wear ear protection

Heat hazard When the turbocharger is operated, surfaces become very hot. Burns Missing or incorrectly fitted insulation. 9 Wear leather protective gloves.

Personal injury

Causes Protective measures

Personal injury Causes Protective measures


Warnings on the turbocharger 2.5 Page 10


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2.5 Warnings on the turbocharger Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Miss-ing or illegible warnings must be replaced by new warnings.

L_00227

Apply warnings so that they are clearly visible in the positions intended for that purpose. Please contact an official ABB Turbo Systems service station for further information. NOTE

Operation Manual Commissioning 3

Oil supply 3.1 Page 1


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3 Commissioning 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.

Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature.

3.1.1 Oil filtration A lubrication oil filter system with a mesh size 0.050 mmis adequate for TPL 73 - TPL 80 turbochargers.

3.1.2 Oil pressure The oil pressure before the bearings (measuring point in blind connection) must be exactly maintained to ensure fault-free operation.

NOTE


Inspection work 3.2 Page 2


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3.2 Inspection work This inspection work includes preventive visual controls, as well as moni-toring and measurement to ensure the correct functioning of the turbo-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 followed before and during all inspec-

tion work.

3.2.1 Inspection before commissioning X To be checked for correct functioning. X Inspect for damage. X Check oil filter for cleanliness before commissioning.

It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system. We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.

X Check oil pressure in oil supply lines.

Monitoring equipment

Air filter mat

Lubricating system

CAUTION


Inspection work 3.2 Page 3


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3.2.2 Inspection after commissioning X Check oil pressure in oil supply lines. X Measuring X Measuring X Measure upstream/downstream from turbine, compressor and oil feed

for various engine speeds X After the engine has been started up, check all gas, air and oil lines for

leaks.

Further must be observed:

Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours af-ter commissioning. If oily liquid continues to escape after this period, the cause must be treated as an oil leak and located. The first step in this process is to check the oil supply to the turbocharger for leaks. If this is not in order, contact an official ABB Turbo Systems service sta-tion.

X Measure the speed, oil pressure, charging pressure and temperatures before and after the turbine and the compressor at various engine speeds.

X Compare the measured values with those of the inspection report, tak-ing into account the different operating conditions.

3.2.3 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.

Lubricating system

Charger speed

Charger pressure

Temperatures

Gas, air, and oil lines

NOTE


Putting into operation after laying up 3.3 Page 4


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3.3 Putting into operation after laying up X Remove the cover plates (blind flanges) between the compressor cas-

ing outlet and charge-air receiver, upstream of the gas inlet, down-stream of the gas outlet.

X Inspect the exhaust pipe before and after the turbine for any combus-

tion residue, clean / remove foreign bodies or residual water. X Inspect air supply line or filter silencer for any foreign bodies, clean /

remove. X Start up the turbocharger's engine end oil circulation system. X Prepare the turbocharger for operation as instructed in the section In-

spection work before commissioning in the chapter entitled Commis-sioning.

X Start up the turbocharger.

If provided

Operation Manual Operation 4

Servicing work 4.1 Page 1


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4 Operation 4.1 Servicing work

Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be car-ried out at the intervals indicated.

The pertinent safety instructions must be observed during all servicing work.

Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger.

4.1.1 Servicing work every 25 to 50 hours X must be recorded X Enter in the machine logbook X In the event of significant anomalies, establish the cause

If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.

WARNING

CAUTION

Operation data

CAUTION




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4.1.2 Entries in the machine logbook Monitoring of the machine plant provides information about the perform-ance of the turbocharger. The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book: Output and speed of the engine Air intake temperature Exhaust temperature before and after the turbine Pressure of the charge-air Pressure drop in the charge-air cooler Lubricating oil pressure, lubricating oil temperature Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter

4.1.3 Servicing work according to the engine manufacturer's instructions X With the engine at standstill clean or replace oil filters

If provided

Oil filters




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4.1.4 Servicing work every 8,000 - 12,000 hours X Dismantle the turbocharger X Clearance measurement X Clean turbine- and compressor casings and check for any cracks and

erosion / corrosion. X Clean bearing casing, blow through oil ports X Clean nozzle ring and check for cracks and erosion X Inspection and assessment of the rotor and bearing parts

The inspection and assessment of the rotor and bearing parts must be performed by an official ABB Turbo Systems service station.

4.1.5 Servicing work every 35,000 hours X Dismantle the turbocharger X Clearance measurement X Clean turbine- and compressor casings and check for any cracks and

erosion / corrosion. X Clean bearing casing, blow through oil ports X Clean nozzle ring and check for cracks and erosion X Inspection and assessment of the rotor X Replacement of the plain bearings with original parts from ABB Turbo

Systems

The replacement of the bearing parts as well as the inspection and as-sessment of the rotor must be carried out by an official ABB Turbo Sys-tems service station.

NOTE

NOTE


Monitoring 4.2 Page 4


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4.2 Monitoring

4.2.1 Speed measurement

L_278

1 Bearing casing 6 Connecting cable 2 Axial bearing 7 Line amplifier (option) 3 Guide in the axial bearing 8 Speed transmitter 4 Gasket ring 9 Installation variant of the

speed transmitter 5 Screw plug


Monitoring 4.2 Page 5


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The speed transmitter system for the measurement of the turbocharger speed also permits, in conjunction with the corresponding measuring in-struments and/or monitoring systems (not included in the scope of deliv-ery), a constant remote monitoring of the turbocharger speed. With con-tinuous monitoring of the machine installation, the turbocharger speed can be used as a suitable control parameter. The line amplifier can be pur-chased as an optional addition to the described speed measuring system.

Possible reasons for failure of the speed indicator: Defects in the speed transmitter, the connecting cable and plug to the

measuring unit, in the measuring unit itself or the power supply. Turbocharger damage.

Failure of the speed indicator If the speed indication fails, it is recommended that the engine output be reduced to idling speed and the engine stopped. The cause of the failure should then be determined.

We recommend that subsequent assembly or replacement of the speed transmitter system should be carried out only by an official ABB Turbo Systems service station.

A reduction in speed of a charger can signify: Damaged turbine or bearing Defects in the connected pulse charging cylinders Severe soiling of the turbine

Increased turbocharger speed With 4-stroke applications, heavy fouling of the turbine can also be a cause of an increase in the turbocharger speed.

CAUTION

NOTE

NOTE


Surging of turbocharger 4.3 Page 6


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4.3 Surging of turbocharger Surging of the turbocharger can occur with certain engine operating sta-tes, such as rapid load removal or while manoeuvring. The direction of flow in the compressor is then briefly reversed. However, sporadic surging of this kind does not generally affect the safe operation of the turbo-charger.

Prolonged or periodic surging If surging is prolonged or occurs periodically, the following components may be damaged: - Compressor wheel (vibration fractures, ...) - Turbine blades (cracks) - Bearing (overheating) - Filter silencer

Action to be taken: The operating safety of the turbocharger is no longer ensured with con-tinuous or periodically recurring surging. The operator must take immedi-ate steps to correct the surging together with the closest official ABB Turbo Systems service station. The components listed above must be inspected for damage by an official ABB Turbo Systems service station, and replaced in cases of doubt.

CAUTION


Contact with rotating parts 4.4 Page 7


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4.4 Contact with rotating parts Mild, uniform wear around the circumference of rotor components, caused by slight local grazing against adjacent components, is non-hazardous and permissible. This slightly reduces the length of the blades in the com-pressor and/or the turbine. Certain tolerances must be observed to avoid significant loss of efficiency. X A check on dimensions must be carried out by an official ABB Turbo

Systems service station.


Shutting the engine down 4.5 Page 8


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4.5 Shutting the engine down

Before shutting the engine down, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can dissipate the heat in the turbocharger bearings. CAUTION

Operation Manual Maintenance 5

Foreword to Maintenance 5.1 Page 1


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5 Maintenance 5.1 Foreword to Maintenance

Cleaning work includes regular visual checks and washing to ensure the correct functioning of the turbocharger and its auxiliary appliances. The external condition and the degree of contamination of the cleaning

points specified in this chapter must be established by visual checks at the intervals indicated.

The safety instructions must be observed during all cleaning work. The cleaning points described in the following are: Filter silencer Compressor Turbine and nozzle ring


Cleaning the filter silencer 5.2 Page 2


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5.2 Cleaning the filter silencer

5.2.1 Filter silencer with tension band

L_00210

81265 Filter ring (if provided) 81266 Cover grids 81270 Tension ring 81136 Fleece segment 38271 Trap cover 81137 Cover panel 81268 Connecting strip 81135 Filter silencer body E Slide-in module = fleece segment + cover panel installed




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Disassembling and cleaning the filter silencer X Remove filter ring (81265). X Rinse filter ring (81265) with water using detergent or, if very dirty, so-

ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-cal stress (water jet).

The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 ser-vice hours.

X Loosen tension bands (81270) on trap covers (81271) and carefully

remove cover grid (81266) from connecting strips (81268).

In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger ty-pe) the water injection line must first be removed (see also following section Disassembling the cleaning line).

X Pull the slide-in modules (E) out, bend the cover panels (81137) open,

and then take out the fleece segments (81136). X Clean fleece segments (81136).

When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air, a soft brush or damp cloth. Oth-erwise the segments may be damaged or lose their shape.

Heavily soiled fleece segments and filter ring as well as damaged con-necting strips should be replaced with original parts from ABB Turbo Systems.

If provided

NOTE

NOTE

NOTE




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Assembling the filter silencer X Assemble the slide-in modules (E) by inserting fleece segments

(81136) in the cover panels (81137). X Bend the cover panels back to their original shape. X Insert slide-in modules (E) in the grooves in the filter silencer body

(81135).

With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).

X When fitting, insert the cover grid (81266) into the connecting strips

(81268). X Fit the tension bands (81270) and tighten on the trap covers (81271). X Fit filter ring (81265).

NOTE

If provided




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5.2.2 Filter silencer and connecting rod

L_00185

81265 Filter ring (if provided) 81136 Fleece segment 81269 Connecting rods 81137 Cover panel 81266 Cover grids 81135 Filter silencer body B Screw N Locknut E Slide-in module = fleece segment + cover panel




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Disassembling and cleaning the filter silencer X Remove filter ring (81265).

Rinse filter ring (81265) with water using detergent or, if very dirty, so-ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-cal stress (water jet).

The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 ser-vice hours.

X Loosen and remove locknuts (N). X Loosen and remove screws (B) on connecting rods (81269). X Remove connecting rods (81269). X Carefully remove the cover grid (81266).

In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger ty-pe) the water injection line must first be removed (see also following section Disassembling the cleaning line).

X Withdraw the slide-in modules (E), bend open the cover panels (81137) and then take out the fleece segments (81136).

X Clean fleece segment (81136). When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air and a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.

Heavily soiled fleece segments and filter ring as well as damaged con-necting rods should be replaced with original parts from ABB Turbo Systems.

If provided

NOTE

NOTE

NOTE




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Assembling the filter silencer X Assemble the slide-in modules (E) by inserting fleece segments

(81136) in the cover panels (81137). X Bend cover panels (81137) back to their original shape. X Insert slide-in modules (E) in the grooves in the filter silencer body

(81135).

With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).

X Place cover grids (81266) evenly in the correct position. X Push the connecting rods (81269) through the clips on the cover grids

(81266).

If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover grid (81266) can twist and shift. This can allow foreign bodies and dirt to get into the compressor.

L_00232

NOTE

CAUTION




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L_00234

X Connect the connecting rods (81269) with screws (B). While tightening the screws (B), ensure that the connecting rods (81269) are located correctly in the recesses in the filter silencer body (81135). Now tighten screws (B) alternately to the following max. tightening torque:

Screw Tightening torque B 20 Nm

X Fit locknuts (N) on screw (B) and tighten to the following torque: Locknut Tightening torque N 40 Nm

X Fit filter ring (81265). If provided




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5.2.3 Removing / installing the cleaning line

L_00192

1 Injection pipe 2 Pipe 3 Guide tube

Removing the cleaning line X Disconnect the line (2) at the injection pipe (1) and remove the screw

coupling from the pipe. X Withdraw the pipe (2) from the guide tube (3).




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L_00193

X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16 mm) and withdraw it.

Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems.

Punch out the guide tube

NOTE




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Installing the cleaning line

L_00194

X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-caulk it.

X Fit the pipe (2) and screw to the injection pipe (1).


Cleaning the compressor during operation

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5.3 Cleaning the compressor during operation

These guidelines for wet cleaning apply exclusively for cleaning with clean water and are subject to permission for the procedure being ob-tained from the engine manufacturer.

The dirt in the compressor stage (compressor wheel and diffuser) de-pends on the cleanness of the air drawn in and the operating point. A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air: Oil or saline mist Solid combustion residues Dust of various kinds Soiling of the compressor stage has a negative effect on compressor effi-ciency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consump-tion by the engine. Contamination of the compressor also increases the rotor imbalance. Periodic cleaning of the compressor in operation prevents or retards a se-vere increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is completely dismantled. The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 25 to 100 operating hours.

Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems.

NOTE

Interval between clea-nings

NOTE



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Cleaning method The compressor is cleaned while operating using the cleaning method de-scribed in the following. This method has been tested and is approved by ABB Turbo Systems: Wet cleaning Water is injected before the compressor wheel via an injection pipe fitted in the filter silencer or the suction branch in order to clean the compressor stage in operation. The water does not act as a solvent in the process, but the deposit is re-moved by the mechanical impact of the drops. The process is ideal, pro-vided the soiling is not too advanced.

Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling addi-tives, which could form deposits in the flow ducts.

If several turbochargers are installed on one engine, we recommend clea-ning the turbocharger compressors one after the other. For V-engines with several turbochargers on each engine, we recommend parallel cleaning of the compressors. This cleaning process is faster and avoids the risk of engine surging. With register supercharging it must be ensured that both turbocharger compressors are cleaned regularly, especially following periods of opera-tion in the lower performance range.

Principle of wet cleaning

CAUTION

Cleaning more than one turbocharger compressor

V-engines

Register supercharging



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5.3.1 Wet cleaning the compressor with external pressurised water con-tainer (XC3)

The water feed with the externally mounted dosing vessel is only suit-able for applications with underpressure upstream of the compressor wheel (cannot be used for: Blower connected upstream of the com-pressor or high-pressure compressor stage in the case of two-stage charging).

Operating state preconditions for cleaning compressors with XC3

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met: Z Engine warm from running (engine under full loading as far as possi-

ble) Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-

cedure for wet cleaning with XC3.

NOTE

NOTE



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Procedure for compressor wet cleaning with XC3

L_00198

X Screw plug Y Valve lever

X The Operating state preconditions for cleaning compressors with XC3

must be met before cleaning can begin. X Remove the screw plug (X). X Fill the vessel with pure water. X Tighten screw plug (X). X Actuate valve lever (Y) against the spring and hold it for 10 to 15 sec-

onds until all the water has been injected. X After cleaning, a waiting time of at least 5 minutes is necessary to allow

the turbocharger to dry.

Operating the pressure water vessel



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If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-mes. If cleaning is still unsuccessful after three attempts and the engine op-erating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service sta-tion.

Cleaning parameters for XC3 for each turbocharger compressor Turbocharger type Turbocharger

speed Contents of the dosing vessel

[dm3] Water injection

time t1 [s]

TPL65-A TPL69-A

0.4

TPL73-A 1.0 TPL77-A 1.0 TPL80-A

If possible nBmax

2.0

415

NOTE



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5.3.2 Wet cleaning compressors with water vessel (XC4)

Operating state preconditions for cleaning compressors with XC4

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met: Z Engine warm from running (engine under full loading as far as possi-

ble) Z High turbocharger speed X Cleaning cycle started according to the following description in Pro-

cedure for wet cleaning with XC4.

NOTE



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Procedure for compressor wet cleaning with XC4

L_00197

1 Cleaning container 2 Pipe 3 Injection pipe 4 Cleaning instructions 5 Cover 6 Valve

If the cleaning container on the filter silencer is used, the detailed clean-ing instructions provided on the plate (4) fitted to the filter silencer should be followed.

X The Operating state preconditions for cleaning compressors with XC4

must be met before cleaning can begin. X Open filling cap (5) on cleaning container (1). X Fill with clean water. X Screw filling cap (5) back into place. X Open valve (6) for about 3 minutes. X Close valve (6) and check that all the water has been sucked out. X After cleaning, a waiting time of at least 5 minutes with the engine run-

ning must be allowed so that the turbocharger can dry.

NOTE

Use of cleaning container



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If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-mes. If cleaning is still unsuccessful after three attempts and the engine op-erating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service sta-tion.

Cleaning parameters for XC4 for each turbocharger compressor Turbocharger type Turbocharger

speed Contents of the dosing vessel

[dm3] Water injection

time t1 [s]

TPL65-A TPL69-A

0.4

TPL73-A TPL77-A

2

TPL80-A

If possible nBmax

3

415

NOTE


Cleaning turbine blades and nozzle ring in operation

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5.4 Cleaning turbine blades and nozzle ring in operation Combustion of heavy fuel oil in diesel engines causes soiling of the tur-bine blades and nozzle rings of the turbochargers. The deposits on the turbine components are caused by the following products of combustion: Soot Molten ash Cinders Incompletely burned fuel Sodium vanadyl vanadate Therefore, it is advantageous to use fuels with a low content of ash, sul-phur, sodium and vanadium. The fuel must also be stored, prepared and handled correctly.

We recommend the use of fuels with a mass ratio of vanadium to so-dium less than 3:1, so that the melting point of the sodium vanadyl va-nadate is as high as possible.

Soiling increases with time, so that regular and properly performed clean-ing is important to remove the accumulated deposits. The charging pressure can rise somewhat if the turbine profile is con-stricted due to fouled turbine components. Contamination causes loss of performance in the turbine and the engine temperature after the cylinders can increase. This may mean that the engine output has to be reduced. A soiled turbine also results in rotor unbalance. Severe soiling can lead to impermissibly high rotor imbalance. Experience in operation has shown that despite periodic cleaning during operation, it is impossible to dispense with overhauls during which the tur-bine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended.

NOTE



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The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours.

Cleaning method The turbine and nozzle ring are cleaned while operating using the clean-ing method described in the following. This method has been tested and is approved by ABB Turbo Systems: Wet cleaning

The dry cleaning method may be used as an alternative to wet clean-ing. However, this is not the preferred method, and must be approved by an official ABB Turbo Systems service station.

During wet cleaning using droplets of water, the water does not act as a solvent. Instead, the deposit is removed by the mechanical impact of the drops.

Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling addi-tives, which could form deposits in the flow ducts.

Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems.

Wet cleaning interval

NOTE Principle of wet cleaning

CAUTION

NOTE



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Cleaning of the turbine-side components begins after engine start or reduction of engine load. The exhaust temperature must not exceed the value specified in the corresponding cleaning instructions (see the re-spective section Operating state preconditions).

Failure to maintain the prescribed exhaust temperature upstream of the turbine, and to allow the minimum stabilising time before and between cleaning procedures and the drying time after cleaning in accordance with the pertinent cleaning instructions will shorten the expected service life of the components significantly.

For V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers. This cleaning process is faster and avoids the risk of engine surging. We recommend conducting tests to find the most suitable method. With register supercharging it must be ensured that both turbocharger tur-bines and nozzle rings are cleaned regularly, especially following periods of operation in the lower performance range.

Stabilising and drying time

NOTE

CAUTION

V-engines

Register supercharging



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5.4.1 Wet cleaning the turbine and nozzle ring during operation The maximum exhaust gas temperature specified by the engine manufac-turer and the TMmax temperature as shown on the turbocharger rating plate must not be exceeded under any circumstances. During wet cleaning, the turbine is braked and the turbocharger operates at reduced speed. As a result, less air is supplied to the engine and the temperature after the en-gine cylinder and exhaust valve rises.

Operating state preconditions for wet cleaning the turbine and nozzle ring during operation

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met: Z After the engine is started up or the engine load has been reduced to

the lowest possible level Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-

perature is stable and less than 430C. X Cleaning cycle started according to the following description in Pro-

cedure for wet cleaning

NOTE



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Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)

L_00203

L_00204

In engines with one turbo-charger (TL 1)

In V-engines with two turbochargers (TL 1 and 2)



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1 Water supply (freshwater only) 6 Other turbochargers 2 Regulating valve 7 Injection pipe 3 Manometer 8 Drainage line 4 Air supply with 3-way-valve 9 Drain cock 5 Stainless steel piping 10 Outflow 11 Baffle (optional, can be integrated in the nozzle)

Z The Operating state preconditions must have been fulfilled before

cleaning is begun! X Check that the water supply (1) is connected, open and reliable. X Open the drain pipe (8, 9) on the gas outlet casing. X Connect the water supply (1) to the regulating valve (2) upstream of

the turbocharger. X Slowly open the 3-way-valve (4) first, then the regulating valve (2) until

the manometer (3) shows a pressure of 2 0.2 bar. X Inject water for 10 minutes. X Check whether the exhaust-gas temperature after the turbine drops. X Close the regulating valve (2) and the 3-way-valve (4). X Close the drain pipe (8, 9) on the gas outlet casing. X The water supply connection (1) must be isolated at the regulating val-

ve (2). X After cleaning, a waiting time of at least 10 minutes with the engine

running must be allowed so that the turbocharger can dry.

The repeating of cleaning cycles directly one after the other is to be a-voided, since this can lead to a high mechanical load and consequently to a reduction in the service life of the components. If the cleaning process is unsuccessful, the time of this can be ex-tended. With an extension of the injection time it must be ensured, that no unacceptable quantity of water collects in the gas outlet casing. For this purpose, a drainage system for the gas outlet casing must be in-stalled and be open during the cleaning. If no drainage system is pre-sent, the injected quantity of water can be controlled with a flow meter in the water supply. What maximum quantity of water is permitted in in-dividual cases, is to be established with an official ABB Turbo Systems service station. The influence of the cleaning water on the peripheral aggregates (such as e.g. Boiler) must be clarified by the operator.

Operating the wet clea-ning system

NOTE



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The gas outlet casing must be drained of water via the drain pipe (8) when cleaning.

The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150C).

Outflow can (but need not) take place through the drain-pipe, depend-ing on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all.

If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the begin-ning with lower water pressure or higher engine load.

Points to remember when cleaning



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Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)

L_00252

L_00253





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1 Water supply (freshwater only)

6 Other turbochargers

2 Regulating valve 7 Injection pipe 3 Manometer 8 Drainage line 4 Air supply with 3-way-valve 9 Drain cock 5 Stainless steel piping 10 Outflow 11 Baffle (optional, can be integrated in the nozzle)

Z The Operating state preconditions must have been fulfilled before

cleaning is begun! X Check that the water supply (1) is connected, open and reliable. X Open the drain pipe (8, 9) on the gas outlet casing. X Connect the water supply (1) to the regulating valve (2) upstream of

the turbocharger. X Slowly open the 3-way-valve (4) first, then the regulating valve (2) until

the manometer (3) shows a pressure of 2 0.2 bar. X Inject water for 10 minutes. X Check whether the exhaust-gas temperature after the turbine drops. X Close the regulating valve (2) and the 3-way-valve (4). X Close the drain pipe (8, 9) on the gas outlet casing. X The water supply connection (1) must be isolated at the regulating val-

ve (2). X After cleaning, a waiting time of at least 10 minutes with the engine




NOTE



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The gas outlet casing must be drained of water via the drain pipe (8) when cleaning.



If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the begin-ning with lower water pressure or higher engine load.




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Operating state preconditions for wet cleaning the turbine and nozzle ring (3 nozzles)

In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met: Z Reduction of engine loading to the lowest possible level X The best cleaning effect is achieved at a loading level of 20 to 30%. Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-

perature is stable and less than 430C. X Cleaning cycle started according to the following description in Pro-

cedure for wet cleaning

NOTE



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Procedure for wet cleaning the turbine and nozzle ring (3 nozzles)

L_00200

L_00201





5.4 Page 32


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1 Water supply (freshwater only) 6 other turbochargers 2 Regulating valve 7 3 injection nozzles 3 Manometer 8 Drainage line 4 Air supply with 3-way-valve 9 Drain cock 5 Water pipe made from stainless

steel 10 Outflow

X The operating state preconditions must be met before cleaning can

begin! X Ensure that the water supply (1) is connected, turned on and constant. X Open the drainage line (8,9). X First open the 3-way valve (4), then open the regulating valve (2) slow-

ly until the pressure gauge (3) indicates a pressure of 2.5 bar. X Inject water for 10 minutes. Check whether the exhaust gas tempera-

ture falls after the turbine. X Close the regulating valve (2). X This completes the cleaning process. The water supply must be dis-

connected from the gas inlet casing. X Switching the 3-way-valve (4) for the water supply to blow-out mode

with compressed air. X Close drain hole (at 8) above drainage line (8,9). X After cleaning, a waiting time of at least 10 minutes with the engine




NOTE



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The gas outlet casing should be drained via the drainage line (8) during cleaning.



If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these cases, the washing op-eration must be terminated and the washing cycle begun again with a lower water pressure or higher engine loading.


Operation Manual Troubleshooting 6

Possible remedies for failures 6.1 Page 1


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6 Troubleshooting 6.1 Possible remedies for failures

Exhaust temperature too high Engine output and speed unchanged Z Malfunction in the injection system X Repair, or contact the manufacturer. Z Air starvation, e.g. air filter clogged with dirt X Clean Z Compressor / turbine soiled X Clean Z Exhaust counterpressure too high X Clean or repair boiler or exhaust silencer Z Turbine damaged or worn X Contact an official ABB Turbo Systems service station. Z Cooler soiled X Clean Z Insufficient coolant water quantity X Replenish Z Coolant water inlet temperature too hot X Clean/inspect cooling system Z Ventilation inadequate X Improve ventilation

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Turbocharger

Charge-air cooler




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Charge-air pressure too low Engine output and speed unchanged Intake condition normal Z Air receiver leaking X Repair Z Gas line between engine and turbine leaking X Repair Z Injection misadjusted X Correct adjustment Z Valve control misadjusted X Correct adjustment Z Manometer display faulty X Replace manometer Z Leak in line to the manometer X Repair leak Z Air filter dirty, causing excessive loss of pressure X Clean Z Compressor / turbine soiled X Clean Z Compressor / turbine damaged X Contact an official ABB Turbo Systems service station. Z Excessive exhaust counterpressure X Clean boiler or exhaust silencer

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Turbocharger




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Charge-air pressure too high Engine output and speed unchanged Intake condition normal Z Malfunction in the injection system X Correct adjustment Z Engine output higher than expected X Check engine output Z Injection misadjusted X Correct adjustment Z Manometer display faulty X Replace manometer

Vibrations Z Rotor imbalance due to heavy fouling of compressor/turbine Z Turbine or compressor damaged Z Bearing defective X Contact an official ABB Turbo Systems service station.

Noises during run-out Z Turbocharger dirty X Clean Z Bearing damaged Z Rotor grazing Z Foreign bodies in the turbocharger X Contact an official ABB Turbo Systems service station.

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Turbocharger

Turbocharger

Turbocharger




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Run-out time too short Z Turbocharger dirty X Clean Z Bearing damaged Z Rotor grazing Z Foreign bodies in the turbocharger X Contact an official ABB Turbo Systems service station.

Sluggish start-up Z Turbocharger dirty X Clean Z Bearing damaged Z Rotor grazing Z Foreign bodies in the turbocharger X Contact an official ABB Turbo Systems service station.

Lubricating oil pressure too low Z Oil filter heavily soiled X Clean Z Oil pump in the lubricating system defective X Inspect Z Manometer provides false reading X Replace manometer Z Axial clearance of the rotor too big X Contact an official ABB Turbo Systems service station.

Turbocharger

Turbocharger

Engine

Turbocharger




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Constant surging of the turbocharger Z Exhaust pressure after the turbine elevated because boiler or exhaust

silencer is dirty Z Trap dirty X Clean Z Charge-air cooler or silencer dirty Z Heavy deposits of contamination in the turbine X Clean

If it is not possible to determine the reason for the surging, contact an official ABB Turbo Systems service station.

Engine

Turbocharger

NOTE

Operation Manual Removal and installation 7

Turbocharger weights 7.1 Page 1


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7 Removal and installation 7.1 Turbocharger weights

Attach individual parts and larger component modules carefully to suit-able hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury. X Select a suitable rope taking into account the weight of the turbo-

charger parts. X Cross and loop the rope over the crane hook X Do not stand under suspended loads.

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For the safety of loads on the crane hook, the ropes must be sus-pended crossed over each other. See also previous illustration.

WARNING

WARNING


Turbocharger weights 7.1 Page 2


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Turbocharger complete unit without silencer/air suction branch TPL 73 TPL 77 TPL 80 2080 3200 4920

Turbocharger complete unit with silencer

TPL 73 TPL 77 TPL 80 2324 3604 5496

Turbocharger complete unit with air suction branch

TPL 73 TPL 77 TPL 80 2220 3355 5162

Weights [kg]

Weights [kg]

Weights [kg]


Remove the turbocharger 7.2 Page 3


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7.2 Remove the turbocharger X Disconnect all gas, air, and oil lines in accordance with the engine ma-

nufacturers instructions.

The two oil supply channels in the bearing casing are fitted with one ori-fice each. In order to obtain the required oil pressure, the of this ori-fice has been individually adjusted by the engine builder. Whenever these orifices are removed, or if the bearing casing or the complete tur-bocharger is replaced, it is essential to ensure that the orifice with the correct is fitted into the oil-conducting oil-inlet channel.

X Remove the insulating shell from the bearing casing. X Check the lifting equipment. X Secure lifting equipment to the suspension lugs on the bearing casing.

Observe weight of the turbocharger.

NOTE

CAUTION




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During removal, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury. Z If the bearing casing is not provided with a reinforced suspension lug

(lugs are flush with external diameter of the flange), the complete charger must be secured by the air outlet casing and gas inlet cas-ing. See following illustration.

X Select a suitable rope taking into account the weight of the turbo-charger.

Turbocharger without reinforced suspension lug

WARNING




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X Release the fixing screws on the foot. X Lift the turbocharger from the engine and place it aside.

If the support for the turbocharger is missing or defective, the turbo-charger may tip over during installation and removal and can cause se-rious or even fatal injury.

X Support turbocharger in a suitable location. X Cover oil connector.

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