ABB HT609723 - Page 2

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Table of Contents3
Operation Manual / TPS44-H6
Introduction6
Purpose of the Manual6
Fig. 1: Serial Number (01) on the Rating Plate6
Contact Information7
Essential Information7
Registered Trademarks7
Layout and Function of the Turbocharger8
Fig. 2: Layout and Function of the Turbocharger8
Symbols, Definitions9
Table 1: Definition of Pictograms11
Storage of New Turbochargers and Spare Parts12
Fig. 3: Volatile Corrosion Inhibitor (VCI)12
Fig. 4: Package with Hygrometer13
Safety14
Introduction14
CE Conformity14
Definition of Mandatory Signs15
Definition of Safety Instructions15
Table 2: Personal Protective Equipment to be Worn at All Times15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task15
Intended Use16
Deflagration on Gas Engines17
Warning Plates on the Turbocharger18
Fig. 5: Warning Plate Locations18
Turbocharger Rating Plate19
Fig. 6: Rating Plate19
Fig. 7: Position of the Rating Plate20
Lifting of Loads21
Fig. 8: Attachment of Loads on the Crane Hook21
Fig. 9: Attachment Angle21
Prerequisites for Operation and Maintenance22
Hazards During Operation and Maintenance23
Safe Operation25
Safe Maintenance26
Removing and Installing30
Turbocharger Weight and Transportation30
Fig. 10: Swivel Lifting Eyes30
Table 4: Gesamtgewicht30
Table 5: Swivel Lifting Eyes to be Used30
Removing the Turbocharger31
Fig. 11: Removing the Turbocharger32
Installing the Turbocharger33
Fig. 12: Inserting Gaskets into the Bracket33
Fig. 13: Inserting Threaded Rods into the Bracket34
Fig. 14: Requirements for Threaded Rods34
Table 6: Requirements for Threaded Rods34
Fig. 15: Placing the Turbocharger on the Bracket35
Table 7: Tightening Torque for Standard Nuts35
Commissioning36
Oil Supply36
Inspection Procedures37
Commissioning after Taking out of Operation39
Monitoring Operation40
Oil Pressure, Oil Temperature40
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger40
Table 9: Lubricating Oil Temperature at the Inlet42
Table 10: Lubricating Oil Temperature at the Outlet42
Exhaust Gas Temperature before Turbine43
Turbocharger Speed43
Fig. 16: Layout and Overview of the Speed Measurement System44
Fig. 17: Fitting the Speed Sensor46
Table 11: Tightening Torque (86505)46
Operation and Service47
Noise Emission47
Fig. 18: Noise Insulation, Bellows48
Service Work49
Expected Replacement Intervals52
Table 12: Expected Replacement Intervals53
Stopping the Engine54
Periodic Maintenance Work55
Foreword to Maintenance55
Cleaning Components Mechanically55
Table 13: Maintenance Table55
Fig. 19: Cleaning the Filter Silencer56
Fig. 20: Cleaning the Compressor Casing, Diffuser Mechanically58
Fig. 21: Cleaning the Nozzle Ring, Turbine Casing Mechanically59
Fig. 22: Soaking Contamination of the Turbine61
Table 14: Dimensions of the Cleaning Container61
Eliminating Malfunctions65
Malfunctions When Starting65
Table 15: Malfunctions When Starting - Delayed Start-Up65
Table 16: Malfunctions When Starting - Vibrations65
Table 17: Malfunctions When Starting - Rotating Parts Rubbing65
Malfunctions During Operation66
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low66
Table 19: Malfunctions During Operation - Speed Reduces66
Table 20: Malfunctions During Operation - Speed Increases66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low67
Table 23: Malfunctions During Operation - Charge Air Pressure too High68
Table 24: Malfunctions During Operation - Engine Performance Losses68
Turbocharger Is Surging69
Table 25: Malfunction - Turbocharger Pumping69
Table 26: Malfunction - Sporadic Surge Blows69
Malfunctions When Stopping70
Table 27: Malfunctions When Stopping - Runout Noises70
Table 28: Malfunctions When Stopping - Runout Time too Short70
Speed Measurement System71
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude71
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High71
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low71
Dismantling and Fitting72
Introduction72
Material Required73
Fig. 23: Swivel Lifting Eyes73
Table 32: Swivel Lifting Eyes to be Used73
Fig. 24: Ring Nuts74
Table 33: Ring Nuts to be Used (VRM)74
Weights of Individual Parts75
Fig. 25: Overview of Assemblies75
Table 34: Weights of the Assemblies [Kg]75
Removing the Gas Outlet Casing76
Fig. 26: Removing the Gas Outlet Casing76
Removing Air Inlets77
Fig. 27: Removing Air Inlets77
Removing the Compressor Casing78
Fig. 28: Removing the Compressor Casing (1/2)78
Fig. 29: Removing the Compressor Casing (2/2)78
Removing the Cartridge Group79
Fig. 3079
Fig. 31: Do Not Loosen Screw Plugs79
Fig. 32: Removing the Cartridge Group (1)80
Fig. 33: Removing Cartridge Group 280
Fig. 34: Rotating the Cartridge Group and Fitting the Service Support81
Removing Nozzle Ring82
Fig. 35: Removing the Nozzle Ring82
Measuring Clearance a and B83
Fig. 36: Measuring Clearance a and B83
Table 35: Permissible Clearances a and B83
Nozzle Ring Compression PD84
Fig. 37: Measuring Nozzle Ring Compression84
Table 36: Nozzle Ring Compression PD84
Fitting the Diffuser85
Fig. 38: Fitting the Diffuser85
Table 37: Tightening Torque (72041)85
Installing the Cartridge Group86
Fig. 39: Lifting the Cartridge Group and Rotating It86
Fig. 40: Fitting the Cartridge Group87
Table 38: Tightening Torque (72011)87
Installing the Nozzle Ring88
Fig. 41: Installing the Nozzle Ring88
Fitting the Turbine Casing89
Fig. 42: Fitting the Turbine Casing89
Table 39: Tightening Torque (51007)89
Turning the Turbocharger90
Fig. 43: Rotating the Turbocharger90
Measuring Radial Clearances N and R91
Fig. 44: Measuring Clearances N and R91
Table 40: Permissible Clearances N and R91
Installing the Gas Outlet Casing92
Fig. 45: Fitting the Gas Outlet Casing92
Table 41: Tightening Torque (51008)92
Installing Air Inlets93
Fig. 46: Installing the Air Inlets93
Table 42: Tightening Torque (72020)93
Table of Tightening Torques94
Fig. 47: Overview of Tightening Torques94
Table 43: Overview of Tightening Torques94
Taking out of Operation at Short Notice95
Possible Emergency Repairs95
Mothballing the Turbocharger96
Taking the Engine out of Operation for up to 12 Months96
Taking the Engine out of Operation for more than 12 Months97
Material and Disposal98
REACH and Rohs Compliance Declaration for Products98
Disposing of Turbocharger Components99
Spare Parts100
Ordering Spare Parts100
Required Customer Spare Part Set (97070)100
Table 44: Customer Spare Part Set (97070)100
Spare Part - Illustrations101
Table 45: Spare Parts - Cartridge101
Table 46: Spare Parts - Turbine Casing102
Table 47: Spare Parts - Compressor Casing103
Table 48: Spare Parts - Filter Silencer104
Table 49: Spare Parts - Air Suction Branch Radial105
Table 50: Spare Parts - Air Suction Brach Axial106
Table 51: Spare Parts - Gas Outlet Casing107
Table 52: Spare Parts - Speed Measurement System108
Tools109
Table 53: TPS-H Tool109
Figures110
Tables111

ABB HT609723 - Page 2

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