ABB TPL65-A33 - User Manual

Operation Manual
ABB Turbocharging

Type TPL65-A33 HT608561
n
Mmax
499 t
Mmax
600
n
Bmax
474 t
Bmax
600
1/s °C
01230 36 50 50
Year 2021
Application according to
the Operation Manual
kg
HZTL2498 English
TPL65-A33
Original Operation Manual

Summary

Preliminary Remarks

Purpose of this Manual

Manual's purpose is to familiarize user with turbocharger, its safe and efficient operation.

Layout and Function

Details the internal and external components of the turbocharger and their roles.

Intended Use of the Turbocharger

Specifies turbocharger's design for diesel engines to generate air volume and charge pressure.

Storage of New Turbochargers and Spare Parts

Covers storage for up to 6 months and long-term storage with VCI.

Essential Information

Covers organizational measures, safety checks, and modification approvals.

Symbols and Definitions

Explains symbols, notes, mandatory signs, and terms used in the manual.

Turbocharger Rating Plate

Details the information on the rating plate: operating limits, intervals, and specifications.

Explanation of the Rating Plate

Explains the meaning of values like nMmax, tMmax, and the impact of non-observance.

Positions of the Rating Plates

Details the locations where rating plates are attached to the turbocharger.

Contact Information

Provides contact details for ABB Turbocharging service stations and website.

Safety

Introduction

Discusses residual risks during operation and maintenance, and personnel responsibilities.

CE Conformity

States that ABB turbochargers fulfill Directive 2006/42/EC on machinery.

Definition of Mandatory Signs

Illustrates and defines required personal protective equipment (PPE).

Definition of Safety Instructions

Explains the meaning of WARNING and CAUTION symbols and terms.

Warning Plates on the Turbocharger

Describes the warning plates attached to the turbocharger that must be observed.

Safe Operation and Maintenance

Provides instructions for safe operation, work area safety, and welding near the turbocharger.

Hazards During Operation and Maintenance

Identifies mechanical hazards, noise risks, and hot surfaces.

Periodic Checking of the Pressure Vessel

Covers legal regulations and responsibilities for safe operation of pressure vessels.

Lifting Loads

Provides warnings and instructions for safely lifting turbocharger components.

Commissioning

Oil Supply

Details requirements for the oil supply system, filtration, pressure, and temperature.

Inspection Work

Outlines preventive visual controls and monitoring before and during commissioning.

Commissioning After Taking Out of Operation

Provides steps for recommissioning the turbocharger after a period of inactivity.

Operation

Noise Emissions

Addresses noise levels, hazards, and measures for noise reduction.

Servicing Work

Outlines service intervals, inspections, and general servicing procedures.

Replacement Intervals for Turbocharger Components

Discusses recommended replacement intervals for rotating and non-rotating parts.

Speed Measurement

Describes the system for continuous monitoring of turbocharger speed.

Stopping the Engine

Instructs to allow the engine to idle for 10 minutes before stopping for heat dissipation.

Maintenance

Foreword to Maintenance

Explains the importance of visual checks and safety precautions during maintenance.

Cleaning the Filter Silencer

Details the procedure for removing, cleaning, and fitting the filter silencer components.

Cleaning the Compressor During Operation

Explains wet cleaning procedures for compressor contamination.

Cleaning Turbine Blades and Nozzle Ring in Operation

Explains contamination sources and the importance of cleaning turbine components.

Cleaning Components Mechanically

Covers procedures for mechanical cleaning of turbocharger components.

Troubleshooting

Malfunctions When Starting

Lists causes and eliminations for sluggish start-up, vibrations, and rubbing parts.

Surging of the Turbocharger

Covers causes and eliminations for turbocharger surging and its effects.

Malfunctions During Operation

Addresses issues like low oil pressure, reduced speed, and increased speed.

Malfunctions When Stopping

Addresses noises during run-down and short run-down times.

Speed Measurement System

Troubleshoots issues with signal amplitude, sensor tip, and speed readings.

Removal and Installation

Turbocharger Weights

Provides weight specifications for TPL65 and TPL69 models.

Removing the Turbocharger

Details steps for disconnecting lines, unplugging sensors, and lifting the turbocharger.

Installing the Turbocharger

Covers procedures for fitting the turbocharger, checking oil orifices, and connecting lines.

Disassembly and Assembly

Introduction

Emphasizes trained specialists for cartridge group work and checking assembly devices.

Module Weights

Provides weights for individual turbocharger assemblies and complete compressor casing.

Removing and Fitting Filter Silencer or Air Suction Branch

Details steps for removing and installing the air suction branch and filter silencer.

Axial Clearance

Explains how to measure axial clearance before and after fitting the cartridge group.

Removing Cartridge Group

Details steps for removing the cartridge group, including disconnection and casing removal.

Dismantling and Installing the Turbine Diffuser and Nozzle Ring

Details procedures for removing and installing the turbine diffuser and nozzle ring.

Installing Cartridge Group

Provides steps for installing the cartridge group, including securing and tightening.

Dismantling and Fitting Nozzle Ring at Turbine End

Describes procedures for removing and installing the nozzle ring at the turbine end.

Table of Tightening Torques

Provides a table of tightening torques for various components and positions.

Taking Out of Operation at Short Notice

Possibilities for Emergency Repair

Lists options like locking rotor, fitting cover plate, and blocking inlets/outlets.

Locking the Rotor

Details procedures and cautions for locking the turbocharger rotor.

Fit Cover Plate

Provides dimensions and instructions for manufacturing and fitting a cover plate.

Blocking the Inlets and Outlets

Instructs to shut off casing outlet, gas inlet, and gas outlet with cover plates.

Bypass the Turbocharger

Explains fitting a bypass around the turbocharger for engines with one turbocharger.

Mothballing the Turbocharger

Taking the Engine Out of Operation for Up to 12 Months

Details mothballing measures based on engine lubricating oil condition.

Taking the Engine Out of Operation for More Than 12 Months

Describes options for long-term storage, including component removal and sealing openings.

Disposing of Turbocharger Components

Spare Parts

Ordering Spare Parts

Lists data needed for inquiries and ordering, and how to order.

View of the Turbocharger with Part Numbers

Provides an exploded view of the turbocharger with numbered parts and their designations.

View of Turbine Cleaning System with Part Numbers (Optional)

Shows an exploded view of the turbine cleaning system with part numbers.

View of Cartridge Group with Part Numbers TPL65-A

Illustrates the TPL65-A cartridge group with numbered parts and their designations.

View of Cartridge Group with Part Numbers TPL69-A

Illustrates the TPL69-A cartridge group with numbered parts and their designations.

ABB TPL65-A33 Specifications

General

Power	Not available
Max Pressure	Not available
Free Air Delivery	Not available
Noise Level	Not available
Weight	Not available
Dimensions	Not available