Page 1 Operation Manual TPL65-A30 Type TPL65-A30 HT846804 Mmax Mmax °C Bmax Bmax 01230 Application according to Year 2022 the Operation Manual ABB Turbocharging...
Page 2 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
Operation Manual / TPL65-A10 / -A30 Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................6 Storage of new turbochargers and spare parts ............7 Essential information.....................
Page 4 Operation Manual / TPL65-A10 / -A30 Table of contents Troubleshooting....................70 Malfunctions when starting..................70 Surging of the turbocharger..................71 Malfunctions during operation .................. 72 Malfunctions when stopping ..................75 Speed measurement system ..................76 Removal and installation..................77 Turbocharger weights....................77 Removing the turbocharger..................
Page 5: Operation Manual
Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Page 6: Layout And Function
Operation Manual / TPL65-A10 / -A30 1 Preliminary remarks / 1.2 Layout and function 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 7 Operation Manual / TPL65-A10 / -A30 1 Preliminary remarks / 1.2 Layout and function 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.
Page 8: Intended Use Of The Turbocharger
Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liab- ility for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.
Page 9: 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 from ABB Turbocharging 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 10 Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of turbochargers The turbochargers will be prepared for prolonged storage by ABB Tur- bocharging on request. The package is equipped with a hygrometer (see illustration).
Page 11: Essential Information
The malfunction must be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbochar- ging. © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E...
Page 12 Only use original parts from ABB. ABB 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 13 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not rel- evant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 14: Symbols And Definitions
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 Tur- bocharging. See also chapter Contact information →14. © Copyright 2020 . All rights reserved.
Page 15: Turbocharger Rating Plate
Operation Manual / TPL65-A10 / -A30 1 Preliminary remarks / 1.7 Turbocharger rating plate 1.7 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder.
Page 16: Contact Information
A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet cas- ing.
Page 17: Safety
2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...
Page 18: Definition Of Mandatory Signs
Operation Manual / TPL65-A10 / -A30 2 Safety / 2.3 Definition of mandatory signs 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to pro- tect against mechanical hazard and risk of fall- To be worn according to the specific work Safety glasses Safety goggles Safety gloves against...
Page 19: Warning Plates On The Turbocharger
Operation Manual / TPL65-A10 / -A30 2 Safety / 2.5 Warning plates on the turbocharger 2.5 Warning plates on the turbocharger Warning plates that must be observed are attached to the turbocharger. The warning plates must always be present in the intended locations and must be legible.
Page 20: Safe Operation And Maintenance
Operation Manual / TPL65-A10 / -A30 2 Safety / 2.6 Safe operation and maintenance 2.6 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
Page 21 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.6 Safe operation and maintenance Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area. Remove any obstacles and objects lying around. Before start-up / commissioning, check all pipes from and to tur- bocharger for damage and leaks.
Page 22 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.6 Safe operation and maintenance Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. Inform operating personnel about all service and repair work before beginning.
Page 23: Hazards During Operation And Maintenance
Operation Manual / TPL65-A10 / -A30 2 Safety / 2.7 Hazards during operation and maintenance 2.7 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly. WARNING Risk of injury Contact with rotating parts can lead to serious injuries.
Page 24 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.7 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful.
Page 25 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.7 Hazards during operation and maintenance WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 26 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the details in the material safety data sheets of the operat- ing and auxiliary materials.
Page 27 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.7 Hazards during operation and maintenance Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.
Page 28: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations. 2.8 Periodic checking of the pressure vessel The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 29 Operation Manual / TPL65-A10 / -A30 2 Safety / 2.9 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading. Fasten turbocharger assemblies / components as described in re- spective handling steps.
Page 30: Start-Up
Operation Manual / TPL65-A10 / -A30 3 Start-up / 3.1 Oil supply 3 Start-up 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation. The turbocharger is normally lubricated with oil from the engine oil cir- cuit.
Page 31 Operation Manual / TPL65-A10 / -A30 3 Start-up / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
Page 32 Not permissible -> stop the engine > 165 If the turbocharger has been operated for a longer period of time out- side the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 33: Inspection Work
Operation Manual / TPL65-A10 / -A30 3 Start-up / 3.2 Inspection work 3.2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help de- tect changes to the turbocharger. Machine damage can be avoided. 3.2.1 Inspection before commissioning Monitoring devices Check for correct functioning.
Page 34 The first step is to check for leak- age of the oil supply to the turbocharger. If this is leaky, contact an offi- cial ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 35: Commissioning After Taking Out Of Operation
Operation Manual / TPL65-A10 / -A30 3 Start-up / 3.3 Commissioning after taking out of operation 3.3 Commissioning after taking out of operation If provided Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, before gas inlet and after gas outlet. Inspect exhaust gas duct / line in front of and after turbine for any combustion deposits, foreign matter or residual water.
Page 36: Operation
Operation Manual / TPL65-A10 / -A30 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running. When the sound pressure level is above 85 dB(A), always wear ear protection.
Page 37 Operation Manual / TPL65-A10 / -A30 4 Operation / 4.1 Noise emissions 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 ©...
Page 38: Servicing Work
NOTICE Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 39 Operation Manual / TPL65-A10 / -A30 4 Operation / 4.2 Servicing work 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the tur- bocharger performance. The following operating data and measured values must be entered reg- ularly in the engine manufacturer's engine logbook: ¡...
Page 40 Inspect and assess bearing parts and rotor. 4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger. Clearance measurement.
Page 41: Replacement Intervals For Turbocharger Components
Operation Manual / TPL65-A10 / -A30 4 Operation / 4.3 Replacement intervals for turbocharger components 4.3 Replacement intervals for turbocharger components Rotating components The recommended replacement intervals for the compressor and turbine wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components.
Page 42 Operation Manual / TPL65-A10 / -A30 4 Operation / 4.3 Replacement intervals for turbocharger components Parameters influencing rotating components exposed to exhaust ¡ Fuel quality (gas, MDO, HFO) ¡ Turbine cleaning frequency ¡ Procedure for turbine cleaning ¡ Load profile Expected replacement in- Component GAS / MDO...
Page 43: Speed Measurement
Operation Manual / TPL65-A10 / -A30 4 Operation / 4.4 Speed measurement 4.4 Speed measurement A speed measuring system permits continuous monitoring of the tur- bocharger speed. CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 44 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 Tur- bocharging Service Station. 4.4.2 Assembly...
Page 45 Operation Manual / TPL65-A10 / -A30 4 Operation / 4.4 Speed measurement 4.4.3 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C. Wear safety gloves when removing the cable connector and speed sensor.
Page 46: Stopping The Engine
Operation Manual / TPL65-A10 / -A30 4 Operation / 4.5 Stopping the engine 4.5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. Allow the engine to continue running at idling speed for a further 10 minutes before stopping.
Page 47: Maintenance
Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.1 Foreword to Maintenance 5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble-free.
Page 48: Cleaning The Filter Silencer
Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.2 Cleaning the filter silencer 5.2 Cleaning the filter silencer 5.2.1 Filter silencer with tension band 81265 Filter ring (if provided) 81138 Sheet-metal covering 81270 Tension band 81005 Screw plug 81271 Lock 81006 Gasket...
Page 49 Otherwise segments may be damaged or lose their shape. NOTICE Replace absorption segments which are heavily contaminated and the filter ring with original parts from ABB. Fitting the filter silencer Assemble the insert units (E) by inserting the absorption seg- ments (81136) into the sheet metal coverings (81137).
Page 50 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.2 Cleaning the filter silencer 5.2.2 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screw 81273...
Page 51 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated or damaged parts with original parts from ABB. © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E...
Page 52 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.2 Cleaning the filter silencer Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments (81136) into the sheet metal coverings (81137). Bend sheet metal coverings (81137) back to original shape. Insert the insert units (E) into slot guides in filter silencer unit (81135).
Page 53 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.2 Cleaning the filter silencer Join connecting rods (81269) using screws (81272). When tightening the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten screws (81272) alternately until the following maximum torque is reached: Screw...
Page 54: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operat- ing conditions. In general, cleaning should be carried out every 25 ... 100 operating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbocharging. © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E...
Page 55 ¡ Wet cleaning This cleaning method is tested and approved by ABB Turbocharging. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer or the suction branch.
Page 56 Operating state prerequisites for wet cleaning XC3 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Engine load 50 … 85% Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3.
Page 57 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. Cleaning parameters per turbocharger compressor...
Page 58: Cleaning Turbine Blades And Nozzle Ring In Operation
Cleaning method When cleaning the turbine components during operation, use wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. Prerequisites for wet cleaning are that the enginebuilder approves the process and his instructions are followed.
Page 59 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion ¡ Erosion The dirt is removed by the mechanical action of the impacting water droplets. ¡ Solubility Water solubility of the contamination deposits in water. ¡...
Page 60 Prerequisites for wet cleaning of turbine The following operating state and prerequisites have been tested and approved by ABB Turbocharging for the cleaning process: The engine has just been started or the engine load has been reduced as far as possible (best cleaning is achieved at a load level of roughly 10 … 15%).
Page 61 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion Layout of cleaning pipes Wet cleaning procedure for turbine during operation Meet prerequisites and operating state requirements without fail be- fore cleaning! Make sure water supply (01) is connected, turned on and guaranteed.
Page 62 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 clarified by the operator.
Page 63: 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 64 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically 5.5.2 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. Do not breathe in these substances and avoid contact with the skin.
Page 65 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically Repeat the soaking and brushing if necessary. Completely remove any solvents from the parts in clean water. Dry components completely. Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger.
Page 66 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of compressed air. Lightly spray the gap between the compressor and the bearing casing with penetrating oil.
Page 67 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure two lifting loops with swivel lifting eyes in the lower push-off threads and suspend from a second crane. 3.
Page 68 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically Cartridge group with two side suspension points Or use two swivel lifting eyes at top. CAUTION Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time dur- ing rotation.
Page 69 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane. 5. Tighten chain block until entire cartridge group is suspended from first crane.
Page 70 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically NOTICE Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
Page 71 Operation Manual / TPL65-A10 / -A30 5 Maintenance / 5.5 Cleaning components mechanically Remove contamination manually with a soft brush or wire brush. CAUTION Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbochar- ger function may be impaired and parts in the cartridge group may be damaged.
Page 72: Troubleshooting
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 Turbochar- ging Service Station. © Copyright 2020 . All rights reserved.
Page 73: Surging Of The Turbocharger
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.
Page 74: Malfunctions During Operation
Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders...
Page 75 Exhaust counterpressure Clean or repair the boiler or ex- too high haust silencer Enlarged flow cross-section Contact an ABB Turbocharging of the nozzle ring due to de- Service Station formed blade trailing edges Damaged or eroded turbine Charge air...
Page 76 Contaminated filter silencer Clean it causing excessive loss of pres- sure Compressor / turbine contam- inated Damaged compressor / tur- Contact an ABB Turbocharging bine Service Station Exhaust counterpressure too Clean or repair the boiler or ex- high haust silencer...
Page 77: Malfunctions When Stopping
6 Troubleshooting / 6.4 Malfunctions when stopping 6.4 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbochar- Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbochar- Turbocharger contaminated...
Page 78: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service sta- tion. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 79: Removal And Installation
Operation Manual / TPL65-A10 / -A30 7 Removal and installation / 7.1 Turbocharger weights 7 Removal and installation 7.1 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible.
Page 80: Removing The Turbocharger
Operation Manual / TPL65-A10 / -A30 7 Removal and installation / 7.2 Removing the turbocharger 7.2 Removing the turbocharger Disconnect all gas, air and oil lines in accordance with the engineb- uilder’s instructions. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing.
Page 81 Operation Manual / TPL65-A10 / -A30 7 Removal and installation / 7.2 Removing the turbocharger Ribs (01) not in the middle at the top: Completely remove the bearing casing insulation (02) and place a sling around the bearing casing. Loosen the fixing screws at the foot. Lift the turbocharger off the engine and set it down to one side.
Page 82: Installing The Turbocharger
Operation Manual / TPL65-A10 / -A30 7 Removal and installation / 7.3 Installing the turbocharger 7.3 Installing the turbocharger Remove cover from oil connection. Inspect lifting gear. Fasten lifting gear to each of two bearing casing ribs provided for this purpose. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil...
Page 83: Disassembly And Assembly
For safety and product liability reasons, work on the cartridge group that is not described in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station. Unqualified work on the cartridge group can lead to total system failure and void the warranty.
Page 84 Use assembly devices only for the described applications. ¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E March 2020...
Page 85: Module Weights
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.2 Module weights 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value. Assemblies Weights [kg] Description TPL65 Radial air suction branch Axial air suction branch Silencer...
Page 86 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.2 Module weights Complete compressor casing Weights [kg] TPL65 NOTICE The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert. ©...
Page 87: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch 8.3 Removing and fitting filter silencer or air suction branch Removing the air suction Disconnect all air lines in accordance with the engine builder’s instruc- branch tions.
Page 88 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch Remove filter silencer. Remove insulation where necessary. Fit swivel lifting eye (90231) to filter silencer. Pass lifting gear through rib on filter silencer. Pass lifting gear through lugs at back.
Page 89: Axial Clearance
Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 90: Removing Cartridge Group
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.5 Removing cartridge group 8.5 Removing cartridge group Remove insulation. Disconnect oil lines in accordance with engine manufacturer's instruc- tions. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing.
Page 91 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.5 Removing cartridge group Turn compressor casing (72000) together with wall insert and dif- fuser and set them down with surface (F) on underlay. WARNING Tipping the compressor casing Make sure that the underlay does not slip.
Page 92 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.5 Removing cartridge group Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506). Remove the O-ring (42012). Remove the three screws (61059) together with their Verbus Ripp® washers (61058).
Page 93 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.5 Removing cartridge group Withdraw cartridge group and fit supports (90450). Remove screws (42054) together with flange (42044) and also remove possible contamination behind the flange. Cover the oil connections. ©...
Page 94: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring 8.6 Dismantling and installing the turbine diffuser and nozzle ring CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins. Before removing the turbine diffuser, secure the nozzle to prevent it from falling.
Page 95 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Position clamp (90921) over stud (61036) until it lies flat against inner radius of gas outlet casing. Insert extension (A) of torque spanner (B) through clamp hole and only loosen screws (61056) one after other.
Page 96 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Replace two screws (61056) in the gas outlet casing with two guide studs (90320) in the upper section of the turbine diffuser (63000). Fit clamps (90921) over the guide studs (90320) and the studs (61036).
Page 97 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Installing the turbine diffuser and nozzle ring Install the nozzle ring and turbine diffuser in the reverse order of re- moval.
Page 98: Installing Cartridge Group
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.7 Installing cartridge group 8.7 Installing cartridge group CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing. When the cartridge group, the bear- ing casing or the turbocharger-is being fitted to the engine, it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes.
Page 99 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.7 Installing cartridge group CAUTION If there is no or insufficient clearance between the rotor turbine blades and the turbine diffuser, the blades and the turbine diffuser (casing) can be damaged. Check that the blades do not rub on the turbine diffuser by rotating the rotor.
Page 100: Dismantling And Fitting Nozzle Ring At Turbine End
Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. 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 instructions.
Page 101 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Removing nozzle ring Remove insulation from gas inlet casing (51001). Loop rope around gas inlet casing and secure with lifting gear. CAUTION When looping the securing rope around the casing, make sure that no cleaning pipes are squashed or damaged.
Page 102 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end CAUTION When setting down the gas inlet casing to one side, use suitable under- lays and take care not to damage the brackets of the insulation. Remove (optional) gasket (61050).
Page 103: Table Of Tightening Torques
Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.9 Table of tightening torques 8.9 Table of tightening torques © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E March 2020...
Page 104 Operation Manual / TPL65-A10 / -A30 8 Disassembly and assembly / 8.9 Table of tightening torques Tightening torques [Nm] Position Part number TPL65 82005 M16x1.5 72002 72027 With washer 61036 72029 61044 61059 61056 61077 If provided 42059 42064 61037 61090 86505 M18x1.5...
Page 105: Taking Out Of Operation At Short Notice
45% of n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Ser- vice Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
Page 106: Fit Cover Plate
Operation Manual / TPL65-A10 / -A30 9 Taking out of operation at short notice / 9.2 Fit cover plate 9.2 Fit cover plate NOTICE The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 107 Operation Manual / TPL65-A10 / -A30 9 Taking out of operation at short notice / 9.2 Fit cover plate NOTICE Carry out the work as described in the chapter Removal and fitting. Remove cartridge group. © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E March 2020...
Page 108 Operation Manual / TPL65-A10 / -A30 9 Taking out of operation at short notice / 9.2 Fit cover plate Close off opening in gas outlet casing using cover plate. Fasten cover plate using spacer sleeves and nuts (61037). CAUTION Shut off the supply of lubricating oil to the turbocharger. ©...
Page 109 Operation Manual / TPL65-A10 / -A30 9 Taking out of operation at short notice / 9.2 Fit cover plate Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as a nat- urally-aspirated engine according to the engine builder's instructions.
Page 110: Blocking The Inlets And Outlets
Operation Manual / TPL65-A10 / -A30 9 Taking out of operation at short notice / 9.3 Blocking the inlets and outlets 9.3 Blocking the inlets and outlets CAUTION Shut off the lubricating oil supply to the turbocharger. Shut off compressor casing outlet, gas inlet and gas outlet by fitting cover plates.
Page 111: Mothballing The Turbocharger
Operation Manual / TPL65-A10 / -A30 10 Mothballing the turbocharger / 10.1 Taking the engine out of opera- tion for up to 12 months 10 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
Page 112 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. Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.
Page 113: Taking The Engine Out Of Operation For More Than 12 Months
The turbocharger casing remains mounted on the engine, but the ro- tor 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 114: Disposing Of Turbocharger Components
Operation Manual / TPL65-A10 / -A30 11 Disposing of turbocharger components / 11 Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts. Avoid the formation of dust.
Page 115: Spare Parts
Serial number (HT……) ¡ Designation 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 116 CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system. Have work on the turbine cleaning system carried out by an ABB Tur- bocharging Service Station. Quantity Description...
Page 117: View Of The Turbocharger With Part Numbers
Operation Manual / TPL65-A10 / -A30 12 Spare parts / 12.2 View of the turbocharger with part numbers 12.2 View of the turbocharger with part numbers © Copyright 2020 . All rights reserved. HZTL2482_EN Rev.E March 2020...
Page 118 Operation Manual / TPL65-A10 / -A30 12 Spare parts / 12.2 View of the turbocharger with part numbers Part number Description – Cartridge group 51001 Gas inlet casing 56001 Nozzle ring 61001 Gas outlet casing 61036 Stud 61043 (in customer spare part Verbus Ripp®...
Page 119: View Of Turbine Cleaning System With Part Numbers (Optional)
Operation Manual / TPL65-A10 / -A30 12 Spare parts / 12.3 View of turbine cleaning system with part num- bers (optional) 12.3 View of turbine cleaning system with part numbers (optional) Part number Description 51229 Cleaning pipe 52249 Holder complete 51255 (in spare parts set) Locking plate 52208 (in spare parts set)
Page 120  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

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