ABB TPL76-C32 User manual
Operation Manual
ABB Turbocharging
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL76-C32 HT575927
nMmax 343 t Mmax 650
nBmax 326 t Bmax 620
1/s °C
04070 35 50 50
Year 2017 made in Switzerland
Application according to
the Operation Manual
kg
HZTL2485 English
TPL76-C32
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 / TPL76-C
Table of contents
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
Operation Manual
1 Preliminary remarks................................................................................................. 3
1.1 Purpose of this manual .................................................................................................. 3
1.2 Layout and function........................................................................................................ 4
1.3 Intended use..................................................................................................................... 6
1.4 Deflagration on gas engines......................................................................................... 7
1.5 Storage of new turbochargers and spare parts ....................................................... 8
1.6 Essential information................................................................................................... 10
1.7 Symbols and definitions .............................................................................................. 12
1.8 Turbocharger rating plate........................................................................................... 13
1.9 Contact information..................................................................................................... 14
2 Safety....................................................................................................................... 15
2.1 Introduction ................................................................................................................... 15
2.2 CE conformity ................................................................................................................ 15
2.3 Definition of mandatory signs ................................................................................... 16
2.4 Definition of Safety instructions ............................................................................... 16
2.5 Warning plates on the turbocharger......................................................................... 17
2.6 Safe operation and maintenance............................................................................... 18
2.7 Hazards during operation and maintenance........................................................... 21
2.8 Periodic checking of the pressure vessel ................................................................. 26
2.9 Lifting loads ................................................................................................................... 26
3 Commissioning...................................................................................................... 28
3.1 Oil supply ........................................................................................................................ 28
3.2 Inspection work............................................................................................................. 31
3.3 Commissioning after taking out of operation........................................................ 33
4 Operation ............................................................................................................... 34
4.1 Noise emissions ............................................................................................................ 34
4.2 Servicing work ............................................................................................................... 36
4.3 Replacement intervals for turbocharger components.......................................... 39
4.4 Speed measurement .................................................................................................... 41
4.5 Stopping the engine ..................................................................................................... 43
5 Maintenance .......................................................................................................... 45
5.1 Foreword to Maintenance .......................................................................................... 45
5.2 Cleaning the filter silencer.......................................................................................... 46
5.3 Cleaning the compressor during operation ........................................................... 49
5.4 Cleaning turbine blades and nozzle ring in operation........................................... 55
5.5 Cleaning components mechanically......................................................................... 60
Operation Manual / TPL76-C
Table of contents
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
6 Troubleshooting.................................................................................................... 69
6.1 Malfunctions when starting....................................................................................... 69
6.2 Surging of the turbocharger....................................................................................... 70
6.3 Malfunctions during operation .................................................................................. 71
6.4 Malfunctions when stopping ...................................................................................... 74
6.5 Speed measurement system ...................................................................................... 75
7 Removal and installation...................................................................................... 76
7.1 Turbocharger weight.................................................................................................... 76
7.2 Removing the turbocharger........................................................................................ 77
7.3 Installing the turbocharger ......................................................................................... 79
8 Disassembly and assembly .................................................................................. 80
8.1 Introduction .................................................................................................................. 80
8.2 Module weights ............................................................................................................. 82
8.3 Removing and fitting filter silencer or air suction branch................................... 84
8.4 Axial clearance .............................................................................................................. 86
8.5 Removing cartridge group .......................................................................................... 87
8.6 Dismantling and installing the turbine diffuser and nozzle ring ........................ 94
8.7 Installing cartridge group........................................................................................... 99
8.8 Dismantling and fitting nozzle ring at turbine end ............................................. 108
8.9 Table of tightening torques...................................................................................... 116
9 Taking out of operation at short notice ........................................................... 118
9.1 Possibilities for emergency repair........................................................................... 118
9.2 Locking the rotor......................................................................................................... 119
9.3 Fit cover plate .............................................................................................................. 123
9.4 Blocking the inlets and outlets................................................................................. 127
9.5 Bypass the turbocharger ........................................................................................... 127
10 Mothballing the turbocharger ........................................................................... 128
10.1 Taking out of operation for up to 12 months........................................................ 128
10.2 Taking out of operation for more than 12 months............................................... 129
11 Disposing of turbocharger components.......................................................... 130
12 Spare parts............................................................................................................ 131
12.1 Ordering spare parts.................................................................................................. 131
12.2 View of turbocharger with part numbers .............................................................. 132
Operation Manual / TPL76-C
1 Preliminary remarks / 1.1 Purpose of this manual
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
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
This Operation Manual enables you to familiarize yourself with the tur-
bocharger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be
operated safely, correctly and efficiently.
This Operation Manual complements and expands existing national reg-
ulations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechan-
ics who are responsible for operating the engine and the turbocharger
installed on it.
Availability of operation manual
An operation manual must be available at all times at the place where
the turbocharger is used.
Everyone who operates or works on the turbocharger must have first
read and understood the operation manual.
Page 3 / 133
Operation Manual / TPL76-C
1 Preliminary remarks / 1.2 Layout and function
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
1.2 Layout and function
01Filter silencer 08Nozzle ring
02Radial plain bearing 09Turbine wheel
03Thrust bearing 10Bearing casing
04Bearing bush 11Diffuser
05Radial plain bearing 12Compressor wheel
06Gas outlet casing 13Compressor casing
07Gas inlet casing
Page 4 / 133
Operation Manual / TPL76-C
1 Preliminary remarks / 1.2 Layout and function
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
Mode of operation
The turbocharger is a turbomachine 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 (07) and nozzle ring (08) to the turbine wheel.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air,
compresses it and then forces it into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
The air which is necessary for operation of the diesel engine and is com-
pressed in the turbocharger is drawn through the suction branch or the
filter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the com-
pressor casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is
in the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is al-
ways at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is
provided with a compressor wheel cooling system. Com-
pressor wheel cooling means that, after the charge air
cooler at the engine end, cooled compressor air is de-
livered to the turbocharger to cool the compressor
wheel.
Depending on the respective operating conditions, it is
absolutely essential that the compressor wheel is cooled
in order to guarantee its reliability and the replacement
intervals. In the case of the turbocharger version with
compressor wheel cooling, the cooling air is supplied
through the side connection (15) in the bearing casing.
Page 5 / 133
Operation Manual / TPL76-C
1 Preliminary remarks / 1.3 Intended use
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
1.3 Intended use
Use on internal combustion engines in general
ABB turbochargers are intended for turbocharging internal combustion
engines.
To ensure compliance with the machinery directive 2006/42/EC when
using on gas engines, the turbocharger must be operated in an engine
room classified as "not at risk of explosion". This is in accordance with
the position paper [2] relating to ATEX issued by EUROMOT[1].
The turbocharger supplies the engine with the air volume or air/gas mix-
ture and the associated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise dir-
ection of rotation as viewed from the turbine end.
The specific operating limits of the turbocharger were determined on
the basis of information from the enginebuilder about the intended use.
These data are given on the rating plate.
ABB Turbo Systems accepts no liability and rejects all warranty claims
for any non-intended uses.
[1]Euromot = The European Association of Internal Combustion Engine
Manufacturers
[2]Directive 94/9/EC concerning equipment and protective systems in-
tended for use in potentially explosive atmospheres (ATEX) The Eur-
omot Position as of November 2003, ATEX Euromot Position 191103
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be
hazardous to personnel.
uOnly operate the turbocharger within the operating limits.
uOnly trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regu-
lations and conditions.
In particular, the following must be observed:
¡Operation Manual
¡Instructions of the enginebuilder
State of the art
The turbocharger is designed and built according to the state of the art
and is safe to operate.
Page 6 / 133
Operation Manual / TPL76-C
1 Preliminary remarks / 1.4 Deflagration on gas engines
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
Flawless condition
The turbocharger must only be used when it is in a technically flawless
condition and operated in compliance with its intended use.
ABB Turbo Systems excludes any liability for damage resulting from un-
authorized modifications to the turbocharger or improper operation.
1.4 Deflagration on gas engines
ABB turbochargers can tolerate a deflagration with a transient pressure
increase of 12bar.
ABB Turbo Systems recommends subjecting the turbocharger to a visual
inspection after a deflagration event. As part of the inspection, the posi-
tion of the turbine casing and the position of the compressor casing to
the bearing casing must be checked, and the bearing casing must be ex-
amined to see if it has shifted in relation to the bracket. A crack inspec-
tion of the casings and the bellows is also recommended. The nearest
ABB Turbocharging Service Station should be instructed to carry out this
inspection and assessment.
Page 7 / 133
Operation Manual / TPL76-C
1 Preliminary remarks / 1.5 Storage of new turbochargers and spare
parts
© Copyright 2017 . All rights reserved. HZTL2485_EN Revision E July 2017
1.5 Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts from ABB Turbo Systems can be
stored in sealed packaging without additional mothballing measures for
up to 6 months from the date of delivery (marked by the VCI label on the
package).
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 (VCI)
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:
uEnsure good room ventilation.
uDo not eat, drink or keep food at the workplace while working with
VCIs.
uWear safety gloves.
uClean hands and face after working with VCIs.
uFor further information refer to www.branopac.com.
Wear safety gloves to protect against chemical hazards.
The following mothballing measures are required every 6months:
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 8 / 133
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