ABB XAC25847 User manual

Operation Manual

ABB Turbocharging 

Type TPR56-F XAC25847

nMmax 700 t Mmax 680

nBmax 686 t Bmax 650

1/s °C

00360 15 40 40

Year 2022 Application according to

the Operation Manual

HZTL2499 English

TPR56-F

Original Operation Manual

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-

ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon

between the engine builder and ABB.

Note: Replacement intervals of components depends on the load proﬁle, turbine inlet temperature, suction air temperature and

turbocharger speed. In case the operation conditions differs signiﬁcantly from what is considered to be normal for the cur-

rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,

high temperatures and high speed lower the life of components.

Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

Operation Manual / TPR56-F + TPR61-F

Table of contents

Operation Manual

1 Preliminary remarks................................................................................................. 3

1.1 Purpose of this manual .................................................................................................. 3

1.2 Layout and function........................................................................................................ 4

1.3 Intended use of the turbocharger .............................................................................. 6

1.4 Storage of new turbochargers and spare parts ....................................................... 7

1.5 Essential information..................................................................................................... 9

1.6 Symbols and definitions .............................................................................................. 11

1.7 Turbocharger rating plate ........................................................................................... 12

1.8 Contact information..................................................................................................... 13

2 Safety...................................................................................................................... 14

2.1 Introduction ................................................................................................................... 14

2.2 CE conformity ................................................................................................................ 14

2.3 Definition of mandatory signs ................................................................................... 15

2.4 Definition of Safety instructions ............................................................................... 15

2.5 Warning plates on the turbocharger......................................................................... 16

2.6 Safe operation and maintenance............................................................................... 17

2.7 Hazards during operation and maintenance........................................................... 20

2.8 Periodic checking of the pressure vessel ................................................................. 25

2.9 Lifting loads ................................................................................................................... 26

3 Start-up / commissioning .................................................................................... 27

3.1 Oil supply ........................................................................................................................ 27

3.2 Inspection work............................................................................................................ 30

3.3 Commissioning after taking out of operation........................................................ 32

4 Operation ................................................................................................................ 33

4.1 Noise emissions ............................................................................................................ 33

4.2 Servicing work ............................................................................................................... 35

4.3 Replacement intervals for turbocharger components.......................................... 37

4.4 Speed measurement .................................................................................................... 39

4.5 Stopping the engine ..................................................................................................... 42

5 Troubleshooting.................................................................................................... 43

5.1 Malfunctions when starting........................................................................................ 43

5.2 Surging of the turbocharger...................................................................................... 44

5.3 Malfunctions during operation ................................................................................. 45

5.4 Malfunctions when stopping...................................................................................... 47

5.5 Speed measurement system ..................................................................................... 48

Operation Manual / TPR56-F + TPR61-F

Table of contents

6 Removal and installation...................................................................................... 49

6.1 Turbocharger weights................................................................................................. 49

6.2 Removing the turbocharger....................................................................................... 49

6.3 Installing the turbocharger ......................................................................................... 52

7 Mothballing the turbocharger ............................................................................. 54

7.1 Taking the engine out of operation for up to 12months..................................... 54

7.2 Taking the engine out of operation for more than 12months ............................ 55

8 Disposing of turbocharger components............................................................ 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.1 Purpose of this manual

1 Preliminary remarks

1.1 Purpose of this manual

This Operation Manual belongs to the turbocharger with the identical

serial number (01), see the cover sheet of the Operation Manual and the

turbocharger rating plate.

Operation Manual

The Operation Manual explains the turbocharger and contains instruc-

tions for safe operation.

The Operation Manual is a complement to and expansion of existing na-

tional regulations for occupational safety, accident prevention and envir-

onmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics re-

sponsible for the proper operation of the engine and for the turbochar-

ger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read

and fully understood the Operation Manual.

Page 3 / 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.2 Layout and function

1.2 Layout and function

01 Suction branch / filter silencer 06 Gas inlet casing

02 Compressor wheel 07 Nozzle ring

03 Diffuser 08 Turbine

04 Bearing bush 09 Bearing casing

05 Gas outlet casing 10 Compressor casing

Page 4 / 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.2 Layout and function

Mode of operation

The turbocharger is a turbomachine consisting of two main compon-

ents, a turbine and a compressor. These components are mounted on a

common shaft and form the rotor.

In the turbocharger shown in the illustration, the exhaust gas flows

through the gas inlet casing(06) and the nozzle ring(07) and arrives at

the turbine(08). The turbine utilises the energy contained in the exhaust

gas to drive the rotor. The exhaust gases then escape into the open air

through the gas outlet casing(05) and the exhaust gas pipe connected

to it.

The rotor runs in two radial plain bearings, which are located between

the compressor and the turbine in the bearing bush(04). The axial bear-

ing is also a plain bearing. The plain bearings are connected to a central

lubricating oil duct which is normally supplied by the lubricating oil cir-

cuit of the engine. The oil outlet is situated at the lowest point of the

bearing casing(09).

The compressor wheel(02) connected to the shaft draws in fresh air

through the filter silencer(01) or the air suction branch. The air is com-

pressed in the compressor and the downstream diffuser(03) and then

led to the charge air cooler via the compressor casing(10).

Page 5 / 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.3 Intended use of the turbocharger

1.3 Intended use of the turbocharger

The turbochargers supplied by ABB have been developed for use on in-

ternal combustion engines to generate the volume of air and the char-

ging pressure required to operate the engine.

The enginebuilder has provided ABB Turbo Systems with information re-

garding the intended purpose of use of the engine, from which the spe-

cific operating limits shown on the turbocharger rating plate (such as

speeds, temperatures and replacement intervals) have been determined.

This turbocharger is intended for railway applications.

Any other use, such as marine and stationary applications, is considered

to be a special application, which must first be clarified with ABB. The

manufacturer accepts no liability for any other type of use. If the equip-

ment is used for any other purpose, ABB reserves the right to reject all

warranty claims.

State of the art This turbocharger was built according to state-of-the-art technology

and is operationally safe according to recognised safety regulations.

WARNING

Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, im-

proper use may cause damage to the machine.

uThe machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / ser-

vicing and repair conditions specified by the manufacturer. Disposal reg-

ulations set down by local authorities must be observed.

Perfect condition The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's

manual. It may be used only for the intended purpose and operated in

compliance with the operation manual.

uMalfunctions which could affect safety must be eliminated immedi-

ately.

The manufacturer accepts no liability for any damage resulting from un-

authorised alterations to the turbocharger.

Page 6 / 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

1.4 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts can be stored in sealed packaging

without additional mothballing measures for up to 6months from the

date of delivery (marked by the VCI label on the package).

Fig.1: Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and

no condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6

months

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-

stances Ordinance. Nevertheless, the following points are to be ob-

served when handling VCIs:

uObserve specifications in the safety data sheet

uEnsure good room ventilation.

uDo not eat, drink or keep food at the workplace while working with

VCIs.

uClean hands and face after working with VCIs.

uFor further information refer to www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

The following mothballing measures are required every 6months:

uOpen the package.

uRemove the VCI corrosion protection emitter from the package and

replace it with a new, identical VCI corrosion protection emitter. New

VCI corrosion protection emitters can be obtained at www.brano-

pac.com.

uDispose of the old VCI corrosion protection emitter in an environ-

mentally compatible manner, professionally and in accordance with

local regulations.

uSeal the package. The better the external seal is designed, the more

permanent the protection.

Page 7 / 56

Operation Manual / TPR56-F + TPR61-F

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

Long-term storage of replacement turbochargers or spare parts

The turbochargers or cartridge groups will be prepared for prolonged

storage by ABB Turbo Systems on request. The package is equipped

with a hygrometer (see illustration).

Fig.2: Package with hygrometer

The following measures are required every 6months:

uCheck the hygrometer(02) in the sight-glass. There is an opening(01)

in the wooden crate which allows this check to be carried out. When

the display field has changed colour at the 70% level, the maximum

permissible humidity has been exceeded. In this case the turbochar-

ger or cartridge group must be inspected by an ABB Turbocharging

Service Station and repacked.

uInspect the package for damage. If the package is damaged, the tur-

bocharger or cartridge group must be inspected by an ABB Tur-

bocharging Service Station and repacked.

After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:

¡Inspect the components

¡Replace the desiccant agent

¡Repackage the components.

If the 70% display field of the hygrometer(02) has not changed colour

and the package is undamaged, the replacement turbocharger or re-

placement cartridge group can be placed into operation without any

prior testing by an ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from

the VCI package.

To avoid the formation of condensation, the surroundings and the con-

tent of the package must have the same temperature during unpacking.

Page 8 / 56

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