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ABB TPL67-C34 User Manual

ABB TPL67-C34
128 pages
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Operation Manual
ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL67-C34 HT842294
n
Mmax
482 t
Mmax
650
n
Bmax
479 t
Bmax
620
1/s °C
01330 35 50 50
Year 2016
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2488 English
TPL67-C34
Original Operation Manual

Table of Contents

Questions and Answers:

ABB TPL67-C34 Specifications

General IconGeneral
BrandABB
ModelTPL67-C34
CategoryIndustrial Equipment
LanguageEnglish

Summary

Operating Condition and Replacement Intervals

Preliminary Remarks

Purpose of this Manual

Explains the manual's objective and scope for turbocharger operation.

Layout and Function

Details the turbocharger's components and operational principles.

Intended Use of the Turbocharger

Specifies the correct application and limitations of the turbocharger.

Storage of New Turbochargers and Spare Parts

Guides on proper storage of new and spare turbocharger components.

Essential Information

Covers crucial safety and organisational measures for turbocharger operation.

Symbols and Definitions

Explains symbols and defines key terms used in the manual.

Turbocharger Rating Plate

Describes the information presented on the turbocharger's rating plate.

Contact Information

Provides details on how to contact ABB for support.

Safety

Introduction

Introduces safety aspects, residual risks, and operator responsibilities.

CE Conformity

States the turbocharger's compliance with relevant directives.

Definition of Mandatory Signs

Explains mandatory safety signs and required personal protective equipment.

Definition of Safety Instructions

Clarifies terms and symbols used for safety warnings and cautions.

Warning Plates on the Turbocharger

Details warning plates attached to the turbocharger and their meaning.

Safe Operation and Maintenance

Provides guidelines for safe operational practices and maintenance procedures.

Hazards During Operation and Maintenance

Identifies potential mechanical, noise, heat, and material hazards.

Periodic Checking of the Pressure Vessel

Covers safety requirements for periodic checks of pressure vessels.

Lifting Loads

Specifies safety regulations and procedures for lifting turbocharger components.

Commissioning

Oil Supply

Details requirements and specifications for the turbocharger's oil supply.

Inspection Work

Outlines inspection tasks performed before and during commissioning.

Inspection before Commissioning

Details specific checks to perform before the initial commissioning.

Check after Start-up (Engine at Idling Speed)

Specifies checks to perform after engine start-up at idling speed.

Check When Running Up Engine

Details checks to conduct while the engine is being run up.

Inspection after 100 Service Hours

Outlines inspections required after the first 100 service hours.

Commissioning after Taking Out of Operation

Procedures for recommissioning the turbocharger after inactivity.

Operation

Noise Emissions

Discusses noise levels and measures to mitigate them.

Servicing Work

Details routine servicing tasks and their importance for turbocharger longevity.

Entries in Engine Logbook

Specifies data to be recorded in the engine logbook for performance monitoring.

Servicing Work According to Engine Manufacturer's Instructions

Emphasizes following manufacturer's specific servicing instructions.

Service Work Every 8000 … 12000 Hours

Outlines major service tasks required at 8000-12000 hour intervals.

Service Work Every 24000 … 36000 Hours

Outlines major service tasks required at 24000-36000 hour intervals.

Replacement Intervals for Turbocharger Components

Provides recommended intervals for replacing turbocharger components.

Speed Measurement

Describes the turbocharger speed measurement system and its components.

Speed Differences with Multiple Turbochargers per Engine

Addresses speed differences between multiple turbochargers on a single engine.

Assembly

Details the assembly procedure for the speed sensor.

Replacing the Speed Sensor

Provides instructions for replacing a faulty speed sensor.

Failure of Speed Measuring System

Lists potential reasons for failure of the speed measuring system.

Stopping the Engine

Explains the correct procedure for stopping the engine and turbocharger.

Maintenance

Foreword to Maintenance

Introduces the importance of maintenance and safety precautions.

Cleaning the Filter Silencer

Details the procedure for cleaning the filter silencer.

Filter Silencer and Connecting Rod

Describes the components of the filter silencer for cleaning.

Cleaning the Compressor During Operation

Explains how to clean the compressor while the engine is running.

Wet Cleaning with Orifice Plate on Filter Silencer (XC2)

Details wet cleaning procedure using an orifice plate.

Wet Cleaning Using External Water-Pressure Vessel (XC3)

Details wet cleaning procedure using an external water-pressure vessel.

Cleaning Turbine Blades and Nozzle Ring in Operation

Describes the method for cleaning turbine blades and nozzle ring during operation.

Wet Cleaning Turbine and Nozzle Ring During Operation

Details wet cleaning procedures for turbine and nozzle ring.

Troubleshooting

Malfunctions When Starting

Lists possible causes and solutions for starting issues.

Surging of the Turbocharger

Addresses turbocharger surging, its causes, and remedies.

Malfunctions During Operation

Covers various malfunctions that can occur during turbocharger operation.

Malfunctions When Stopping

Details issues that may arise during the engine stopping process.

Speed Measurement System

Helps diagnose problems with the turbocharger speed measurement system.

Removal and Installation

Turbocharger Weights

Provides weight specifications for lifting and handling.

Remove the Turbocharger

Step-by-step instructions for safely removing the turbocharger.

Installing the Turbocharger

Step-by-step instructions for safely installing the turbocharger.

Disassembly and Assembly

Introduction

Introduces disassembly and assembly procedures and safety considerations.

Module Weights

Lists the weights of individual turbocharger components.

Removing and Fitting Filter Silencer or Air Suction Branch

Explains how to remove and fit the filter silencer and air suction branch.

Axial Clearance

Describes the measurement and importance of axial clearance.

Removing Cartridge Group

Outlines the steps for removing the turbocharger's cartridge group.

Dismantling and Installing the Turbine Diffuser and Nozzle Ring

Covers procedures for dismantling and installing turbine diffuser and nozzle ring.

Installing Cartridge Group

Details the procedure for installing the turbocharger's cartridge group.

Dismantling and Fitting Nozzle Ring at Turbine End

Explains how to dismantle and fit the nozzle ring at the turbine end.

Table of Tightening Torques

Provides a table of specified tightening torques for assembly.

Taking Out of Operation at Short Notice

Possibilities for Emergency Repair

Outlines options for emergency repairs and safety measures.

Locking the Rotor

Details how to lock the rotor for safety during specific operations.

Fit Cover Plate

Describes how to fit a cover plate for securing the turbocharger.

Blocking the Inlets and Outlets

Explains how to block turbocharger inlets and outlets.

Bypass the Turbocharger

Instructions for bypassing the turbocharger if needed.

Mothballing Turbocharger

Taking Out of Operation for up to 12 Months

Steps for taking the turbocharger out of operation for up to 12 months.

Taking Out of Operation for More Than 12 Months

Steps for taking the turbocharger out of operation for over 12 months.

Disposing of Turbocharger Components

Spare Parts

Ordering Spare Parts

Details on how to inquire about and order spare parts.

View of Turbocharger with Part Numbers

Illustrated view of the turbocharger with part numbers.

View of Turbine Cleaning System with Part Numbers (Optional)

Illustrated view of turbine cleaning system parts.

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