ABB HT607125 User manual
Turbocharging
Operation Manual / TPS52-H32
HT607125
Document identification
Document number HZTL4037
Revision G
Language English
Original Operation Manual
Product identification
Serial number HT607125
Customer part number X00076992
Delivery date (yyyy-mm-dd) 2022-01-11
Weight 250 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 868 1/s
Speed limit during operation nBmax 850 1/s
Gas inlet temperature limit in test rig operation only tMmax 710 °C
Gas inlet temperature limit during operation tBmax 680 °C
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Registered trademarks................................................................................................. 5
1.5 Layout and function of the turbocharger ................................................................ 6
1.6 Symbols, definitions...................................................................................................... 7
1.7 Storage of new turbochargers and spare parts .................................................... 10
2 Safety .................................................................................................................... 12
2.1 Introduction .................................................................................................................. 12
2.2 CE conformity............................................................................................................... 12
2.3 Definition of mandatory signs .................................................................................. 13
2.4 Definition of safety instructions .............................................................................. 13
2.5 Intended use ................................................................................................................. 14
2.6 Deflagration on gas engines ..................................................................................... 15
2.7 Warning plates on the turbocharger........................................................................ 16
2.8 Turbocharger rating plate.......................................................................................... 17
2.9 Lifting of loads ............................................................................................................. 19
2.10 Prerequisites for operation and maintenance...................................................... 20
2.11 Hazards during operation and maintenance ......................................................... 21
2.12 Safe operation.............................................................................................................. 23
2.13 Safe maintenance ....................................................................................................... 24
3 Removing and Installing...................................................................................... 28
3.1 Turbocharger weight and transportation ............................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger........................................................................................ 31
4 Commissioning .................................................................................................... 34
4.1 Oil supply ...................................................................................................................... 34
4.2 Inspection procedures............................................................................................... 35
4.3 Commissioning after taking out of operation....................................................... 37
5 Monitoring operation .......................................................................................... 38
5.1 Oil pressure, oil temperature.................................................................................... 38
5.2 Exhaust gas temperature before turbine ............................................................... 41
5.3 Turbocharger speed.................................................................................................... 41
6 Operation and service ......................................................................................... 45
6.1 Noise emission ............................................................................................................ 45
6.2 Service work................................................................................................................. 47
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
6.3 Expected replacement intervals .............................................................................. 50
7 Stopping the engine ............................................................................................ 52
8 Periodic maintenance work ................................................................................ 53
8.1 Foreword to maintenance......................................................................................... 53
8.2 Cleaning components mechanically ....................................................................... 53
9 Eliminating malfunctions.................................................................................... 63
9.1 Malfunctions when starting...................................................................................... 63
9.2 Malfunctions during operation ................................................................................ 64
9.3 Turbocharger is surging............................................................................................ 67
9.4 Malfunctions when stopping.................................................................................... 68
9.5 Speed measurement system.................................................................................... 69
10 Dismantling and fitting....................................................................................... 70
10.1 Introduction ................................................................................................................. 70
10.2 Material required.......................................................................................................... 71
10.3 Weights of individual parts........................................................................................ 73
10.4 Removing the gas outlet casing .............................................................................. 74
10.5 Removing air inlets ...................................................................................................... 75
10.6 Removing the compressor casing........................................................................... 76
10.7 Removing the cartridge group.................................................................................. 77
10.8 Removing nozzle ring ................................................................................................. 80
10.9 Measuring clearance A and B..................................................................................... 81
10.10 Nozzle ring compression PD..................................................................................... 82
10.11 Fitting the diffuser ..................................................................................................... 83
10.12 Installing the cartridge group .................................................................................. 84
10.13 Installing the nozzle ring ........................................................................................... 86
10.14 Fitting the turbine casing ......................................................................................... 87
10.15 Turning the turbocharger.......................................................................................... 88
10.16 Measuring radial clearances N and R ...................................................................... 89
10.17 Installing the gas outlet casing................................................................................ 90
10.18 Installing air inlets ....................................................................................................... 91
10.19 Table of tightening torques...................................................................................... 92
11 Taking out of operation at short notice ........................................................... 93
11.1 Possible emergency repairs...................................................................................... 93
12 Mothballing the turbocharger............................................................................ 94
12.1 Taking the engine out of operation for up to 12months ................................... 94
12.2 Taking the engine out of operation for more than 12months.......................... 95
13 Material and Disposal.......................................................................................... 96
13.1 REACH and RoHS Compliance Declaration For Products ................................... 96
13.2 Disposing of turbocharger components ............................................................... 97
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
14 Spare parts ........................................................................................................... 98
14.1 Ordering spare parts.................................................................................................. 98
14.2 Required customer spare part set (97070)............................................................ 98
14.3 Spare part - Illustrations............................................................................................ 99
15 Tools .................................................................................................................... 107
Figures................................................................................................................. 108
Tables .................................................................................................................. 109
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.1 Purpose of the manual
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
1 Introduction
1.1 Purpose of the manual
Fig.1: Serial number(01) on the rating plate
This Operation Manual belongs to the turbocharger with the identical serial number(01), see
the Operation Manual title page and the rating plate on the turbocharger.
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger 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 4 / 109
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.2 Contact information
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
1.2 Contact information
Contact information for the ABB Turbocharging Service Stations is available online.
uScan the QR code to access our website.
ABB Switzerland Ltd, Turbocharging
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
1.3 Essential information
Design variants
This document is valid for different design variants of turbochargers. There may be sections
and descriptions of components that are not relevant for a specific turbocharger variant.
Please contact an ABB Turbocharging Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
1.4 Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 5 / 109
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
1.5 Layout and function of the turbocharger
Fig.2: Layout and function of the turbocharger
01 Air suction branch / filter silencer 07 Plain bearing bush
02 Compressor casing 08 Turbine
03 Diffuser 09 Nozzle ring
04 Bearing casing 10 Turbine casing
05 Axial thrust bearing 11 Compressor wheel
06 Gas outlet casing
Page 6 / 109
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.6 Symbols, definitions
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡Turbine
¡Compressor.
These components are installed on a common shaft and form the rotor (see Fig.2: Layout
and function of the turbocharger →6).
The exhaust gases of the internal combustion engine flow through the turbine casing(10)
and the nozzle ring(09) onto the turbine(08). The turbine(08) uses the energy contained in
the exhaust gas to drive the rotor and thus the compressor wheel(11). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet cas-
ing(06).
The compressor wheel(11) sucks in air or a mixture of air and gas through the air suction
branch(01) or the filter silencer. In the compressor wheel(11), the energy required for build-
ing up the pressure is transferred to the air. By flowing through the diffuser(03) and the
compressor casing(02), the air is compressed further and is then directed to the engine cyl-
inders.
The rotor runs in a radial plain bearing bush(07) which is located in the bearing casing(04)
between the compressor and the turbine. The axial thrust bearing(05) is located in front of
the radial plain bearing bush.
The bearings are connected to a central lubricating oil duct which is normally supplied by the
lubricating oil circuit of the engine. The oil outlet lies at the deepest point of the bearing cas-
ing(04).
1.6 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
→Refers to a page number
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Page 7 / 109
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.6 Symbols, definitions
© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.
Definition of Caution / Warning
Caution and warning signs are described in chapter Safety.
ABB Turbocharging
ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document.
Official service stations of ABB Turbocharging
Official service stations are regularly audited and certified by ABB Turbocharging. See also
chapter Contact information →5.
Page 8 / 109
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