Page 1 Operation Manual TPL65-A36 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65-A36 HT566859 Mmax Mmax °C Bmax Bmax SISO20 01230 Application according to Year 2016 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2: Nmmax,
In case the operation conditions differs signiﬁ cantly 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.
Page 3: Table Of Contents
Periodic checking of the pressure vessel Lifting loads Commissioning Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement Stopping the engine Maintenance © Copyright 2016 ABB. All rights reserved.
Page 4 Possibilities for emergency repair Locking the rotor Fit cover plate Blocking the inlets and outlets Bypass the turbocharger Mothballing the turbocharger Taking the engine out of operation for up to 12 months 10.1 © Copyright 2016 ABB. All rights reserved.
Page 5 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of the turbocharger with part numbers 12.3 View of turbine cleaning system with part numbers (optional) © Copyright 2016 ABB. All rights reserved.
Page 7: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbo- charger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be op- erated safely, correctly and efficiently.
Page 8: Layout And Function
02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing © Copyright 2016 ABB. All rights reserved.
Page 9 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. © Copyright 2016 ABB. All rights reserved.
Page 10: Intended Use Of The Turbocharger
Any other use is considered to be a special application, which must first be clarified with ABB Turbo Systems. The manufacturer accepts no lia- bility for any other type of use. If the equipment is used for any other purpose, ABB Turbo Systems reserves the right to reject all warranty claims.
Page 11: 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).
Page 12: Year
Page 10 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 13: Essential Information
The fault must be reported to the person or depart- ment responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 14 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 15: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Turbo- charging Service Stations.
Page 16: Turbocharger Rating Plate
Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction Manufacturing plant © Copyright 2016 ABB. All rights reserved.
Page 17 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.
Page 18: Contact Information
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Contact information Page 16 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 19: Safety
Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
Page 20: Definition Of Mandatory Signs
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2016 ABB. All rights reserved.
Page 21: Warning Plates On The Turbocharger
Warning plates on the turbocharger Page 19 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.
Page 22: Safe Operation And Maintenance
Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2016 ABB. All rights reserved.
Page 23 Protect the floor against unintentional penetration of detergents or sol-  vents before starting cleaning operations. Wear appropriate protective clothing.  Inspect the electric cables for abrasion and damaged areas before and  after your cleaning work. © Copyright 2016 ABB. All rights reserved.
Page 24 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2016 ABB. All rights reserved.
Page 25: Hazards During Operation And Maintenance
Observe the general rules for occupational safety and prevention of  accidents. Ensure workplace safety.  Only perform operations that are described in this chapter.  Only perform operations for which you have previously received in-  struction or training. © Copyright 2016 ABB. All rights reserved.
Page 26 Wear safety gloves against thermal risks. Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
Page 27 The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can CAUTION lead to environmental damage. Handle operating and auxiliary materials carefully.  © Copyright 2016 ABB. All rights reserved.
Page 28 Wear safety gloves against chemical risks. Use only suitable, non-combustible insulating materials.  Ensure that the work area is well ventilated.  Wear suitable work clothing (safety glasses, respiratory mask).  Avoid stirring up dust.  © Copyright 2016 ABB. All rights reserved.
Page 29: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 30: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and se-  curely. © Copyright 2016 ABB. All rights reserved.
Page 32 A metering orifice is installed in the oil inlet of the turbocharger to en- sure these oil pressures. The orifice is installed by the enginebuilder NOTICE and it is fixed in place with a locking ring. © Copyright 2016 ABB. All rights reserved.
Page 33 > 160 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbo- charger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 34: Inspection Work
Failure of compressor wheel cooling system The service life of the compressor wheel will be impaired if the break- down of the compressor wheel cooling system lasts long. CAUTION Ensure supply of cooling air.  © Copyright 2016 ABB. All rights reserved.
Page 35 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 36: Commissioning After Taking Out Of Operation
/ commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  TPL65: Version with compressor wheel cooling system Remove screw plug on cooling air connection and fit cooling air line.  © Copyright 2016 ABB. All rights reserved.
Page 37: Operation
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must en- sure that equivalent acoustic insulating measures are taken. © Copyright 2016 ABB. All rights reserved.
Page 38 Operation Noise emissions Page 36 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line © Copyright 2016 ABB. All rights reserved.
Page 39: Servicing Work
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
Page 40  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2016 ABB. All rights reserved.
Page 41  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.
Page 42: Replacement Intervals For Turbocharger Components
Parameters influencing non-rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Load profile (thermal load changes, number of starts/stops)  Temperature level of exhaust gas  Turbine cleaning frequency  Procedure for turbine cleaning © Copyright 2016 ABB. All rights reserved.
Page 43 See the data on the rating plate replacement intervals [h] = Gas Engine = Marine Diesel Oil = Heavy Fuel Oil See Influencing The specified values are guides and not guaranteed. ( parameters NOTICE © Copyright 2016 ABB. All rights reserved.
Page 44: Speed Measurement
Cable connector for 86505 86526 F/I converter 86528 Tachometer 4.4.1 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ only slightly from each other in normal operation. © Copyright 2016 ABB. All rights reserved.
Page 45 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. 4.4.2...
Page 46 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  Failure of speed measuring system 4.4.4 Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2016 ABB. All rights reserved.
Page 47: Stopping The Engine
Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further 10  minutes before stopping. © Copyright 2016 ABB. All rights reserved.
Page 49: Maintenance
 The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2016 ABB. All rights reserved.
Page 50: Cleaning The Filter Silencer
Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut Insert unit = absorption segment + sheetmetal covering © Copyright 2016 ABB. All rights reserved.
Page 52 If the connecting rods (81269) are not correctly positioned in their re- cesses on the filter silencer unit (81135), the cover grid (81266) can twist and shift. There is then a risk of foreign matter and contamination getting into the compressor. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 53 (81272) alternately until the following maximum torque is reached: Screw Tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut Tightening torque [Nm] 81273 Fit filter strip (81265). If provided  © Copyright 2016 ABB. All rights reserved.
Page 54: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions. In general, cleaning should be carried out every 25 ... 100 op- erating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 55 Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. To clean the compressor stage during operation, water is injected in front...
Page 56 If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor Product...
Page 57 Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Engine load 50 ... 85% ...
Page 58 If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharg- ing Service Station. Cleaning parameters per turbocharger compressor...
Page 59: Cleaning Turbine Blades And Nozzle Ring In Operation
The interval between periodic cleaning is very dependent on the operating Wet cleaning interval conditions. As a rule, cleaning should be carried out every 50 to 200 op- erating hours. © Copyright 2016 ABB. All rights reserved.
Page 60 When cleaning the turbine components during operation, use wet clean- Cleaning method ing. This cleaning method has been tested and approved by ABB Turbo Systems. Prerequisites for wet cleaning are that the engine builder approves the process and his instructions are followed.
Page 61 Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap- proved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced ...
Page 62 The injection process has been completed.  Close drain hole (if provided) above drain pipe (08, 09).  After cleaning, wait with engine running for at least 10 minutes without  changing load to allow turbocharger to dry. © Copyright 2016 ABB. All rights reserved.
Page 63 The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clari- fied by the operator.
Page 64 Wet cleaning parameters for turbine and nozzle ring Table of cleaning Product Maximum tempera- Injection time Water flow rate per parameters ture at start of turbocharger [min] cleaning process with p = 2 bar Water [°C] [l/min] TPL65-A32/33/36 TPL69-A32/33 © Copyright 2016 ABB. All rights reserved.
Page 65: Cleaning Components Mechanically
(see chapter entitled Service work). Professional overhauling of the components by an ABB Turbocharging Service Station is required, preferably using the cleaning method de- scribed in the following.
Page 66 Brush off the contamination or remove it with a steam cleaner.  Repeat the soaking and brushing if necessary.  Completely remove any solvents from the parts in clean water.  Dry components completely.  © Copyright 2016 ABB. All rights reserved.
Page 67 If water or contamination penetrates the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge CAUTION group. Make sure that no water or contamination can enter into the cartridge  group. © Copyright 2016 ABB. All rights reserved.
Page 68 Cartridge group with a central suspension point Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation. CAUTION Choose appropriate lifting gear length.  © Copyright 2016 ABB. All rights reserved.
Page 70 2. Attach third lifting loop with swivel lifting eye to thread of oil outlet flange. 3. Rotate the cartridge group into a horizontal position by lifting. © Copyright 2016 ABB. All rights reserved.
Page 71 Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the tank with soaking liquid.  Only immerse the cartridge group until all blades are covered with  cleaning agent. © Copyright 2016 ABB. All rights reserved.
Page 72 Wear a respiratory mask to protect against particles (P1 or P2 mask).  Wear safety goggles.  Wear safety goggles. Wear a respiratory mask to protect against particles. Wear safety gloves against mechanical risks. Raise the cartridge group and align horizontally.  © Copyright 2016 ABB. All rights reserved.
Page 73 Cleaning the cartridge group on the turbine end [➙ 66]). Dispose of contaminated water and cleaning agent in accordance with  the specifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 75: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 76: Surging Of The Turbocharger
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser-  vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 77: Malfunctions During Operation
Defects such as leaks in the Make repairs exhaust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging charger ring (with 4-stroke application) Service Station © Copyright 2016 ABB. All rights reserved.
Page 78 Charge air Cooler contaminated Clean it cooler Cooling water volume too Top up the water Entry temperature of cooling Inspect / clean the cooling sys- water too high Inadequate ventilation Improve the ventilation © Copyright 2016 ABB. All rights reserved.
Page 79 Engine Malfunctioning injection system Repair it or contact the manufac- turer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbo- Manometer display wrong Replace the manometer charger © Copyright 2016 ABB. All rights reserved.
Page 80: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2016 ABB. All rights reserved.
Page 81: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 83: Removal And Installation
The following weight specification is the heaviest variant possible. This standard value may deviate from the data on the rating plate depending on the specification. Weights [kg] TPL65-A32/-A33/ -A36 TPL69-A32 / -A33 1230 1780 © Copyright 2016 ABB. All rights reserved.
Page 84: Removing The Turbocharger
Remove air supply line. (See also chapter entitled Preliminary remarks  / Layout and functionality) Inspect the lifting gear.  Fasten separate lifting gear to each of the two ribs on the bearing cas-  ing provided for this purpose. © Copyright 2016 ABB. All rights reserved.
Page 85 WARNING rious or even fatal injury. Support the turbocharger at a suitable point.  If possible secure it using lifting gear.  Wear safety helmet. Cover the oil connection.  © Copyright 2016 ABB. All rights reserved.
Page 86: Installing The Turbocharger
TPL65: Version with compressor wheel cooling system Fit air supply line. (See also chapter Preliminary remarks / Layout and  functioning.) Refit removed parts of insulation.  Plug in cable connector on speed sensor.  © Copyright 2016 ABB. All rights reserved.
Page 87: Disassembly And Assembly
CAUTION Only carry out those tasks that are described in this chapter.  Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
Page 88 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 89: Module Weights
01 Radial air suction branch 02 Axial air suction branch 03 Filter silencer 04 Compressor casing 05 Wall insert 06 Diffuser 07 Cartridge group 08 Turbine diffuser 09 Nozzle ring 10 Gas inlet casing, radial © Copyright 2016 ABB. All rights reserved.
Page 90 TPL65-A32 / -A33 / -A36 TPL69-A32 / -A33 Complete compressor casing The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 91: Removing And Fitting Filter Silencer Or Air Suction Branch
Unscrew the nuts (72027) and remove them together with the washers  (72018). Remove the air suction branch and set it down to one side.  Fit the air suction branch in reverse order. Installing the air suction  branch © Copyright 2016 ABB. All rights reserved.
Page 92 Unscrew nuts (72027) and remove them together with washers  (72018). Remove filter silencer and set it down to one side.  Install filter silencer in reverse order. Installing the filter silencer  © Copyright 2016 ABB. All rights reserved.
Page 93: Axial Clearance
Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 94: Removing Cartridge Group
Loosen nuts (61037).  Evenly press off compressor casing (72000) using the three press-off  nuts (61090). Slightly lift and pull out compressor casing (72000).  Remove the O-ring (42012).  © Copyright 2016 ABB. All rights reserved.
Page 95 Check the underlay and adjust it if necessary.  Remove the screws (72002).  Remove the diffuser (79000).  Remove the wall insert (77000) using swivel lifting eyes (90235).  Remove the O-ring (77005) from the wall insert.  © Copyright 2016 ABB. All rights reserved.
Page 96 If the blades have insufficient or no clearance between the rotor and the casing, this can lead to damage to the blades and the casing. Turn rotor to check that blades do not rub against turbine diffuser.  CAUTION © Copyright 2016 ABB. All rights reserved.
Page 97 Disassembly and assembly Removing cartridge group Page 95 Withdraw cartridge group and fit supports (90450).  Remove screws (42064), flange (42044) and gasket (42045) and  clean oil space. Cover the oil connections.  © Copyright 2016 ABB. All rights reserved.
Page 98: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Before removing the turbine diffuser, secure the nozzle to prevent it  CAUTION from falling. Before disassembling the turbine diffuser, if possible secure the nozzle  ring against falling with a lashing strap and a wooden block. © Copyright 2016 ABB. All rights reserved.
Page 99 Insert extension (A) of torque spanner (B) through clamp hole and only  loosen screws (61056) one after other. Do not yet remove the screws (61056) and Verbus Ripp® washers  (61057). © Copyright 2016 ABB. All rights reserved.
Page 100 Install the nozzle ring and turbine diffuser in the reverse order of re-  moval. Coat the screw threads with high-temperature grease.  Align nozzle ring with holes or cams in gas inlet casing.  © Copyright 2016 ABB. All rights reserved.
Page 101: Installing Cartridge Group
(61058) to the specified tightening torque (see chapter Table of tightening torques). Evenly tighten screw (61059) together with Verbus Ripp® washers TPL69-A32/33  (61058) and two nuts (61037) to the specified tightening torque (see chapter Table of tightening torques). © Copyright 2016 ABB. All rights reserved.
Page 102 Align and fit the wall insert (77000) using the centring screw (90187).  Place the diffuser (79000) in position using the swivel lifting eye  (90235). Remove the swivel lifting eye (90235).  Fit the screws (72002).  © Copyright 2016 ABB. All rights reserved.
Page 103 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s ...
Page 104: Dismantling And Fitting Nozzle Ring At Turbine End
Remove two hexagon-head screws (61044) together with Verbus  Ripp® washers (61043) from the bottom section and replace them with two studs (90177). To secure, screw hexagon nuts (90178) onto studs (90177).  © Copyright 2016 ABB. All rights reserved.
Page 105 Replace the studs (90177) with hexagon-head screws (61044) and  Verbus Ripp® washers (61043). Remove lifting gear from gas inlet casing (51001).  Secure the insulation to the gas inlet casing (51001).  © Copyright 2016 ABB. All rights reserved.
Page 106: Table Of Tightening Torques
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 104 Table of tightening torques © Copyright 2016 ABB. All rights reserved.
Page 107 Tightening torques [Nm] Position Part number TPL65-A32 / -A33 / -A36 TPL69-A32 / -A33 82005 M16x1.5 M16x1.5 72027 with washer 72029 61044 61059 61071 (TPL69-A32/33) 61056 61036 61037 61090 86505 M18x1.5 M18x1.5 72002 © Copyright 2016 ABB. All rights reserved.
Page 109: Taking Out Of Operation At Short Notice
If the diesel engine must be capable of operation again as soon as possi- ble after damage to the turbocharger (emergency repair), the following possibilities are available:  Locking turbocharger rotor  Fitting the cover plate  Shutting off inlets and outlets  Turbocharger bypass © Copyright 2016 ABB. All rights reserved.
Page 110: Locking The Rotor
4-stroke CAUTION engines.) Otherwise components that are still intact can be damaged through overheating. Shut off the oil supply in the event of lubricating oil leaking from the tur- bocharger. © Copyright 2016 ABB. All rights reserved.
Page 111 Turn compressor wheel so that locking flange hexagon aligns with  hexagon in assembly / disassembly device (90020). Tighten nuts (74027) complete with washers (72018) on compressor  casing as specified in following Table of tightening torques. © Copyright 2016 ABB. All rights reserved.
Page 112 Locking the rotor Page 110 Table of tightening Part number TPL65-A32 / -A33 / -A36 torques 72027 75 Nm 94007 25 Nm Make sure all components are clean and free from grease. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 113 Push intermediate ring (94001) and assembly-disassembly device  (90020) onto locking flange (94003) in correct order. As specified in following Table of tightening torques, tighten intermedi-  ate ring, assembly-disassembly device (90020) and locking flange (94003) using screws (94006). © Copyright 2016 ABB. All rights reserved.
Page 114 Table of tightening torques. Table of tightening Part number TPL69-A32 / -A33 torques 72027 105 Nm 94006 10 Nm 94007 10 Nm Make sure all components are clean and free from grease. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 115 0.5 bar overpressure. Attention must always be paid to the speed of the undamaged turbo- charger. The speed limit n given on the rating plate must not be ex- Bmax ceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 117 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 115 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2016 ABB. All rights reserved.
Page 118 Page 116 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 119 The engine can be operated according to the engine builder's instruc- tions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating plate must not Bmax be exceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 120: Blocking The Inlets And Outlets
This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 121: Mothballing The Turbocharger
Observe the information in the material safety data sheet for the op-  erating materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2016 ABB. All rights reserved.
Page 122: Taking The Engine Out Of Operation For Up To 12 Months
Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
Page 123: Taking The Engine Out Of Operation For More Than 12 Months
 The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station.  The turbocharger is removed completely, either as a whole or in indi- vidual parts.
Page 125: Disposing Of Turbocharger Components
 Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2016 ABB. All rights reserved.
Page 127: Spare Parts
 Turbocharger type  Serial number (HT……)  Description and part number Spare parts can be ordered from an official ABB Turbocharging Service Station. If different design versions have not been taken into consideration in  this document, please contact an ABB Turbocharging Service Station.
Page 128 42045 Verbus Ripp® washer 42058 / 42063 / 61043 / 61057 / 61058 Hexagon-head screw 42059 / 42064 / 61044 / 61056 / 61059 Hexagon nut 61037 Gasket 77005 O-ring (speed sensor) 86506 © Copyright 2016 ABB. All rights reserved.
Page 129 Work on turbine cleaning system should be carried out only by an  ABB Turbocharging service station. Quantity Description Part number Locking plate 51255 Nozzle 52208 Sleeve 52212 Locking plate 52213 Strain bolt 52217 52218 © Copyright 2016 ABB. All rights reserved.
Page 130 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 128 numbers 12.2 View of the turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 131: View Of The Turbocharger With Part Numbers
Compressor casing 72018 Washer 72027 Hexagon nut 72029 Stud 77000 Wall insert 77005 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch 82000 Axial air suction branch © Copyright 2016 ABB. All rights reserved.
Page 132: View Of Turbine Cleaning System With Part Numbers (Optional)
Locking plate 52208 (in spare parts set) Nozzle 52212 (in spare parts set) Bush 52213 (in spare parts set) Locking plate 52217 (in spare parts set) Strain bolt 52218 (in spare parts set) © Copyright 2016 ABB. All rights reserved.
Page 133 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

ABB TPL65-A36 Operation Manual

1 Preliminary Remarks

2 Safety

3 Commissioning

4 Operation

5 Maintenance

6 Troubleshooting

7 Removal and Installation

8 Disassembly and Assembly

9 Taking out of Operation at Short Notice

10 Mothballing the Turbocharger

11 Disposing of Turbocharger Components

12 Spare Parts

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