Related Manuals for ABB XAC25849
Summary of Contents for ABB XAC25849
- Page 1 Operation Manual TPR56-F Type TPR56-F XAC25849 Mmax Mmax °C Bmax Bmax 00360 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 / TPR56-F + TPR61-F 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 / TPR56-F + TPR61-F Table of contents Removal and installation..................49 Turbocharger weights....................49 Removing the turbocharger..................49 Installing the turbocharger ..................52 Mothballing the turbocharger ................54 Taking the engine out of operation for up to 12 months........54 Taking the engine out of operation for more than 12 months ......
-
Page 5: Operation Manual
Operation Manual / TPR56-F + TPR61-F 1 Preliminary remarks / 1.1 Purpose of this manual 1 Preliminary remarks 1.1 Purpose of this manual This Operation Manual belongs to the turbocharger with the identical serial number (01), see the cover sheet of the Operation Manual and the turbocharger rating plate. -
Page 6: Layout And Function
Operation Manual / TPR56-F + TPR61-F 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function Suction branch / filter silencer Gas inlet casing Compressor wheel Nozzle ring Diffuser Turbine Bearing bush Bearing casing Gas outlet casing Compressor casing ©... - Page 7 Operation Manual / TPR56-F + TPR61-F 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine consisting of two main compon- ents, a turbine and a compressor. These components are mounted on a common shaft and form the rotor. In the turbocharger shown in the illustration, the exhaust gas flows through the gas inlet casing (06) and the nozzle ring (07) and arrives at the turbine (08).
-
Page 8: Intended Use Of The Turbocharger
ABB. The manufacturer accepts no liability for any other type of use. If the equip- ment is used for any other purpose, ABB reserves the right to reject all warranty claims. -
Page 9: Storage Of New Turbochargers And Spare Parts
Operation Manual / TPR56-F + TPR61-F 1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts 1.4 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package). - Page 10 Long-term storage of replacement turbochargers or spare parts The turbochargers or cartridge groups will be prepared for prolonged storage by ABB Turbo Systems on request. The package is equipped with a hygrometer (see illustration). Fig. 2: Package with hygrometer The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
-
Page 11: Essential Information
The fault should be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger, which could impair safety, require the prior approval of ABB Turbo Sys- tems. © Copyright 2018 . All rights reserved. HZTL2499_EN... - 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: 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 Tur- bocharging Service Stations. -
Page 14: Turbocharger Rating Plate
Operation Manual / TPR56-F + TPR61-F 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 15: 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 16: 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 17: Definition Of Mandatory Signs
Operation Manual / TPR56-F + TPR61-F 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 18: Warning Plates On The Turbocharger
Operation Manual / TPR56-F + TPR61-F 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 19: Safe Operation And Maintenance
Operation Manual / TPR56-F + TPR61-F 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 20 Operation Manual / TPR56-F + TPR61-F 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 21 Operation Manual / TPR56-F + TPR61-F 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 22: Hazards During Operation And Maintenance
Operation Manual / TPR56-F + TPR61-F 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 23 Operation Manual / TPR56-F + TPR61-F 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 24 Operation Manual / TPR56-F + TPR61-F 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 25 Operation Manual / TPR56-F + TPR61-F 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 26 Operation Manual / TPR56-F + TPR61-F 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 27: 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 28: Lifting Loads
Operation Manual / TPR56-F + TPR61-F 2 Safety / 2.9 Lifting loads 2.9 Lifting loads WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. Loads must always be fastened to technically perfect lifting gear with sufficient loading capacity. -
Page 29: Start-Up / Commissioning
Operation Manual / TPR56-F + TPR61-F 3 Start-up / commissioning / 3.1 Oil supply 3 Start-up / commissioning 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. - Page 30 Operation Manual / TPR56-F + TPR61-F 3 Start-up / commissioning / 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 31 Not admissible -> stop engine > 155 If the turbocharger has been operated for a longer period of time out- side the admissible range, ABB Turbo Systems recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2018 . All rights reserved.
-
Page 32: Inspection Work
Operation Manual / TPR56-F + TPR61-F 3 Start-up / commissioning / 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 33 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 34: Commissioning After Taking Out Of Operation
Operation Manual / TPR56-F + TPR61-F 3 Start-up / commissioning / 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 35: Operation
Operation Manual / TPR56-F + TPR61-F 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 36 Operation Manual / TPR56-F + TPR61-F 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 37: Servicing Work
Despite observance of the service intervals, unusual loads, such as sev- eral start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys- tems. NOTICE... - Page 38 4.2.4 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. Clean the turbine and compressor wheels and inspect for damage.
-
Page 39: Replacement Intervals For Turbocharger Components
Operation Manual / TPR56-F + TPR61-F 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 40 Operation Manual / TPR56-F + TPR61-F 4 Operation / 4.3 Replacement intervals for turbocharger components Expected replacement in- Component Service hours [h] tervals Gas inlet casing 50000 … 100000 Gas outlet casing 50000 … 100000 Nozzle ring 35000 … 75000 Turbine diffuser / cover ring 35000 …...
-
Page 41: Speed Measurement
Operation Manual / TPR56-F + TPR61-F 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 42 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 43 Operation Manual / TPR56-F + TPR61-F 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 44: Stopping The Engine
Operation Manual / TPR56-F + TPR61-F 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 45: 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 2018 . All rights reserved. -
Page 46: 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 47: 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 48 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 49: Malfunctions When Stopping
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 50: 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 51: Removal And Installation
Operation Manual / TPR56-F + TPR61-F 6 Removal and installation / 6.1 Turbocharger weights 6 Removal and installation 6.1 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 52 Operation Manual / TPR56-F + TPR61-F 6 Removal and installation / 6.2 Removing the turbocharger 6.2.1 TPR56-F/ TPR61-F (without support) Disconnect all gas, air and oil pipes in accordance with the engineb- uilder’s instructions. If provided Unscrew the cable connector (86515) on the speed sensor. Inspect the lifting gear.
- Page 53 Operation Manual / TPR56-F + TPR61-F 6 Removal and installation / 6.2 Removing the turbocharger 6.2.2 TPR56-F28/TPR61-F66 (with support) Disconnect all gas, air and oil pipes in accordance with the engineb- uilder’s instructions. If provided Unscrew the cable connector (86515) on the speed sensor. Inspect the lifting gear.
-
Page 54: Installing The Turbocharger
Operation Manual / TPR56-F + TPR61-F 6 Removal and installation / 6.3 Installing the turbocharger 6.3 Installing the turbocharger Oil orifice plate There is an orifice in each of the two oil inlet channels of the bearing cas- ing. The diameter of this orifice has been individually adapted by the en- ginebuilder for the purpose of adjusting the oil pressure. - Page 55 Operation Manual / TPR56-F + TPR61-F 6 Removal and installation / 6.3 Installing the turbocharger Attach all gas, air, water and oil pipes in accordance with the engineb- uilder's instructions. 6.3.2 TPR56-F/ TPR61-F (without support) Remove the cover from the oil connection. Product Tightening torque for fixing screws 01...
-
Page 56: Mothballing The Turbocharger
Operation Manual / TPR56-F + TPR61-F 7 Mothballing the turbocharger / 7.1 Taking the engine out of opera- tion for up to 12 months 7 Mothballing the turbocharger 7.1 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 57: Taking The Engine Out Of Operation For More Than 12 Months
Operation Manual / TPR56-F + TPR61-F 7 Mothballing the turbocharger / 7.2 Taking the engine out of opera- tion for more than 12 months If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of opera- tion: Dismantle the turbocharger. -
Page 58: Disposing Of Turbocharger Components
Operation Manual / TPR56-F + TPR61-F 8 Disposing of turbocharger components / 8 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 59 ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...