The provided document is an operation manual for an ABB Turbocharging TPS 57E01 turbocharger.
Function Description:
The turbocharger is a turbomachine composed of a turbine and a compressor mounted on a common shaft. Its primary function is to generate the required volume of air and charging pressure for diesel or gas engines. Exhaust gases from the engine flow through the turbine casing and nozzle ring, impinging on the turbine. The turbine uses this energy to drive the compressor wheel. The compressor draws in fresh air, compresses it, and then forces it into the engine's cylinders. Exhaust gases then escape into the ambient air through the gas outlet flange. The rotor runs in two radial plain bearings located in the bearing flanges between the compressor and the turbine, with an axial thrust bearing positioned between the two radial plain bearings. The bearings are connected to a central lubricating oil duct supplied by the engine's lubricating oil circuit, with the oil outlet at the lowest point of the bearing casing.
Important Technical Specifications:
The rating plate provides key operational limits and intervals:
- Type: TPS 57E01
- HT Number: 842589
- Maximum rotational speed (nMmax): 716 1/s
- Maximum operational speed (nBmax): 680 1/s
- Maximum turbine inlet temperature (tMmax): 650 °C
- Maximum operational turbine inlet temperature (tBmax): 620 °C
- Weight (STPS16): 410 kg
- Year of construction: 2016
- Inspection interval of plain bearings: 12,000 to 24,000 hours (depending on fuel type)
- Replacement interval of compressor: 50,000 hours (depending on fuel type)
- Replacement interval of turbine: 50,000 hours (depending on fuel type)
Oil Specifications:
- Oil inlet temperature: Permissible range 30-105 °C. Temporarily permissible (< 1h) up to 105 °C (alarm), not permissible > 110 °C (stop engine). Not permissible < 30 °C (preheat oil before starting). Minimum oil inlet temperature must never be less than 10 °C.
- Oil outlet temperature: Permissible ≤ 160 °C. Temporarily permissible > 160 °C (alarm), not permissible > 180 °C (stop engine). Permissible ≤ Toil,inlet + 55 K. Temporarily permissible > Toil,inlet + 55 K (alarm).
- Oil pressure in front of turbocharger:
- Normal operation: 2.0 – 4.5 bar
- Engine start (cold oil, max 15 min): ≤ 8.0 bar
- Engine idling: ≥ 0.2 bar
- Pre- and post-lubrication (engine stopped): ≤ 1.0 bar
- Oil filtration: Standard oil filter specification is 34 µm, meaning contaminants larger than 0.034 mm must be filtered with a separation efficiency > 99%.
Speed Measurement System:
The turbocharger is equipped with a speed measuring system for continuous monitoring. The difference between the highest and lowest turbocharger speed on a multi-turbocharger engine must not exceed 3% relative to the speed limit nBmax. Speed sensors (86505(A) and 86505(B)) are used, with cable connectors (86515(A) and 86515(B)) and an F/I converter (86526) and tachometer (86528). The tightening torque for the speed sensor (86505) is 15 Nm for all TPS models (48, 52, 57, 61).
Usage Features:
- Intended Use: Designed for diesel engines to generate air volume and charging pressure. Use with gas engines requires installation in a non-explosive environment and adherence to safety measures. Any other use is considered special and requires discussion with ABB Turbo Systems.
- Operational Limits: Adherence to the limits specified on the rating plate (nBmax, tBmax, nMmax, tMmax) is crucial. Operating outside these limits can significantly shorten component life and may void warranty claims.
- Safety: The manual emphasizes strict adherence to safety instructions, including wearing personal protective equipment (PPE) such as safety gloves, goggles, respiratory masks, and helmets. It warns against hot surfaces, rotating parts, noise exceeding 85 dB(A), and improper handling of operating materials.
- Commissioning: Requires checking oil supply, oil filtration, and oil pressure/temperature. Prelubrication is essential before starting the engine. Initial inspection after 100 service hours includes cleaning or replacing oil filters.
- Stopping the Engine: For oil-cooled versions, post-lubrication for 15-20 minutes at 0.5-1.0 bar oil pressure is required to dissipate heat. For water-cooled versions, cooling water should run for 15-20 minutes after stopping, and oil lubrication should continue until the rotor stops.
Maintenance Features:
- Service Intervals: Service work should be carried out at specified time intervals to prevent excessive contamination, wear, and operating failures. A service inspection after 5 years is recommended.
- Routine Inspections (25-50 hours): Visual inspection for leaks (air, exhaust gas, water, oil), recording operating data in the engine logbook, and clarifying any variances.
- Mechanical Cleaning: Recommended only once within the service interval to avoid damage and corrosion. Soft tools (cloths, brushes) should be used.
- Compressor Cleaning (Wet Cleaning): Performed during operation using clean fresh water injected in front of the compressor wheel. Cleaning intervals are typically 25-100 operating hours. Engine load should be 50-85% during cleaning.
- Turbine Cleaning (Wet Cleaning): Performed during operation to prevent or delay excessive contamination, especially with heavy fuel oil (HFO). Cleaning intervals are typically 50-200 operating hours. Two methods are described: short water injection (3x30 seconds) and long water injection (10 minutes). Recommended operating conditions for cleaning include engine load (20-40%), turbine inlet temperature (350-430 °C), and water pressure (1.5-2.0 bar).
- Disassembly and Assembly: Detailed instructions are provided for removing the compressor casing, insulation, and cartridge group. O-rings must always be replaced with new ones. Specific tightening torques for components are provided (e.g., 15 Nm for speed sensor, 230-780 Nm for bearing casing fixing screws depending on TPS model).
- Clearance Measurement: Axial clearance (A) and radial clearance (B, N, R) must be measured and noted before and after installation of the cartridge group. Out-of-tolerance clearances require assessment and potential replacement by an ABB Turbocharging Service Station.
- Mothballing: For storage up to 6 months, new turbochargers and spare parts can remain in sealed VCI packaging. For longer storage (over 6 months), VCI emitters need to be replaced every 6 months. If the engine lubricating oil's total acid number (TAN) is greater than 2 mg KOH/g, the turbocharger must be dismantled, cleaned, oiled with anticorrosive oil, and reassembled. All openings should be closed with wooden covers and paraffin paper. Mothballed parts should be checked for corrosion annually.
- Disposal: Components must be disposed of in an environmentally compatible and professional manner, adhering to local regulations. Metals for recycling, non-metallic materials as waste, lubricants as waste oil, electronic components as electronic waste, and thermal insulation as hazardous waste.
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