Need help?Do you have a question about the ABB TPS 61D01 and is the answer not in the manual?
This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended.
Diagram and description of the turbocharger's main components and their function.
Details the turbocharger's design for diesel engines and precautions for gas engine use.
Provides guidance on storing new turbochargers and spare parts for up to 6 months and longer.
Covers organizational measures, safety, modifications, and personnel competence.
Explains symbols used in the manual and defines key terms like ABB Turbocharging.
Details the information found on the turbocharger rating plate.
Explains the meaning of the operational limits and replacement intervals on the rating plate.
Indicates the physical location of the rating plates on the turbocharger.
Provides contact details for ABB Turbocharging service stations and website.
Introduces safety aspects, residual risks, and responsibilities for safe operation.
States that ABB turbochargers comply with Directive 2006/42/EC on machinery.
Illustrates and defines mandatory safety signs for protective clothing and equipment.
Explains the meaning of WARNING and CAUTION symbols and their implications.
Describes the location and procedure for ordering new warning plates.
Provides instructions for safe work practices, area safety, and welding.
Guidelines for safe working practices and maintaining a safe work environment.
Specific precautions for performing welding operations near the turbocharger.
Procedures and precautions for disassembly, assembly, maintenance, and troubleshooting.
Safety warnings regarding mechanical tasks and the need for proper training.
Safety measures for shutting down and preparing the turbocharger for storage.
Details hazards like mechanical risks, noise, hot surfaces, and operating materials.
Risks associated with contact with rotating parts and improper operation.
Risks during maintenance due to improper handling or inadequate procedures.
Information on noise levels and the need for ear protection.
Risks of burns from hot surfaces and materials; precautions required.
Warnings about burns from uninsulated turbochargers and enginebuilder responsibility.
Risks from handling oils, greases, solvents; combustibility.
Hazards related to flammable materials and potential for explosion.
Precautions to prevent environmental contamination from spills.
Risks associated with dust and fibres from insulation materials.
Information on turbocharger resistance to deflagration and recommended inspections.
Risks associated with electrical components and requirements for trained personnel.
Guidelines for periodic checks of pressure vessels and operator responsibility.
Safety instructions for lifting loads, fastening gear, and avoiding suspended loads.
Details the requirements for a properly designed and installed oil supply system.
States that all lubricating oils used for engines are admissible.
Specifies permissible oil inlet temperatures and viscosities with a chart.
Defines required oil pressure values in front of the turbocharger for different operating statuses.
Emphasizes the importance of prelubrication before starting the engine.
Specifies limits for oil inlet temperature to prevent machine damage.
Lists permissible oil outlet temperatures based on operating status.
Details preventive visual checks, monitoring, and measuring work before and during commissioning.
Checks for monitoring devices, filter mat, lubricating system, and warning plates.
Checks for lubricating system and gas, air, oil lines after engine start.
Monitoring speed, pressure, and temperatures during engine run-up.
Guidance on cleaning or replacing lubricating oil filters after 100 hours.
Procedure for recommissioning the turbocharger after a period of inactivity.
Discusses noise levels, hazards, and necessary measures for noise reduction.
Outlines the importance of regular service for turbocharger performance and identifies key service tasks.
Emphasizes carrying out service work at specified time intervals to prevent failures.
Discusses factors leading to premature damage and the need for adjusted service intervals.
Recommendation for an inspection by a service station every 5 years.
Details routine service tasks like visual inspection and data recording.
Instructions on cleaning or replacing the oil filter as per engine manufacturer's guidance.
Long-term service tasks involving inspection of rotor and bearing parts by a service station.
Specifies operating data and measured values to be recorded in the engine logbook.
Provides recommended replacement intervals for rotating and non-rotating components.
Defines replacement intervals for compressor and turbine wheels based on operating conditions.
Defines replacement intervals for bearing parts and hot gas exposed components.
Lists parameters that can affect component replacement intervals, such as fuel quality and load profile.
Describes the speed measuring system for continuous monitoring of turbocharger speed.
Guidelines for managing speed differences between multiple turbochargers on an engine.
Step-by-step instructions for replacing a speed sensor, including safety warnings.
Briefly mentions that reasons for failure are in the Troubleshooting chapter.
Provides procedures for stopping oil-cooled and water-cooled turbochargers safely.
Introduces general maintenance tasks like visual checks and cleaning for turbocharger upkeep.
Explains the process and consequences of compressor contamination and periodic cleaning.
Describes wet cleaning as a tested method for cleaning the compressor during operation.
Explains how water injection removes dirt through mechanical impact.
Detailed steps for wet cleaning using an external water pressure vessel (XC1).
Addresses turbine contamination from fuels like HFO and recommends periodic wet cleaning.
Defines general cleaning intervals for turbine components and contacts for engine-specific needs.
Describes wet cleaning as the method for turbine components approved by ABB.
Outlines two methods: short and long water injection times for turbine cleaning.
Describes the short injection time method for designs without C-rings.
Describes the long injection time method for designs with C-rings.
Details necessary precautions for turbine cleaning, including water quality and temperature.
Specifies the tested and approved operating conditions for turbine wet cleaning.
Step-by-step guide for performing short water injection time turbine cleaning.
Step-by-step guide for performing long water injection time turbine cleaning.
Introduces mechanical cleaning methods for turbocharger components and associated precautions.
Instructions for cleaning the filter silencer components: ring and absorption segments.
Steps for reassembling the filter silencer after cleaning.
Procedure for cleaning compressor casing, wall insert, and diffuser.
Procedure for cleaning turbine casing, gas outlet flange, and nozzle ring.
Describes soaking and brushing contaminated turbine parts in liquid.
Instructions for removing dirt from turbine parts using brushes or vacuum cleaners.
Warns about rotor unbalance from residual contamination and damage.
Covers issues like sluggish start-up, vibrations, and rubbing of rotating parts.
Lists possible causes and eliminations for sluggish turbocharger start-up.
Lists possible causes and eliminations for turbocharger vibrations.
Describes normal wear and when to contact a service station for rubbing issues.
Explains turbocharger surging, its causes, and potential damage.
Identifies causes like contaminated components or blocked air ducts for surging.
Warns about damage from prolonged surging and recommends service station contact.
Covers issues like low oil pressure, reduction/increase in speed, and high exhaust gas temperature.
Lists causes for low oil pressure and their remedies.
Lists causes for speed reduction and their remedies.
Lists causes for speed increase and their remedies.
Details causes for high exhaust gas temperature and their solutions.
Identifies causes for low charge air pressure and their respective repairs.
Covers issues like high charge air pressure, compressor fouling, and noises during run-down.
Lists causes for high charge air pressure and their remedies.
Addresses compressor fouling from ventilation gases and its consequences.
Lists possible causes and eliminations for noises heard during turbocharger run-down.
Troubleshooting for speed measurement issues like no signal, incorrect speed, or defective sensors.
Lists causes and solutions for a short turbocharger run-down time.
Troubleshooting for poor speed signal or amplitude, often due to fitting errors.
Guidance for issues related to defective speed sensors.
Troubleshooting for measured speeds being too high, often due to sensor tip contamination.
Troubleshooting for measured speeds being too low or other sources of error.
Illustrates suspension methods for insulated and uninsulated turbochargers during transport.
Provides weight specifications for different turbocharger models (TPS48 to TPS61).
Step-by-step instructions for disconnecting lines, insulation, and attaching lifting gear.
Details steps for installing the turbocharger, including oil connections, O-rings, and tightening torques.
Preconditions and general safety notes for turbocharger disassembly and assembly.
Note that the fitted oil orifice must not be removed during disassembly.
Emphasizes observing specified tightening torques for component connections.
Notes on securing screws and nuts of assembly devices.
Safety warnings regarding lifting gear, load limits, and personnel safety.
Details the swivel lifting eye required for safe lifting of loads.
Provides weights for individual turbocharger parts and assemblies, rounded to the next highest value.
Detailed instructions for disassembling and assembling the turbocharger.
Steps for disconnecting air lines and removing the compressor casing and filter silencer.
Instructions on removing insulation plates from the turbocharger.
Specific steps for removing the wall insert from a TPS61 turbocharger.
Instructions for refitting the compressor casing and wall insert.
Steps for safely removing the cartridge group, including bearing casing and nozzle ring.
Instructions for installing the cartridge group with lamellar sealing rings, nozzle ring, and C-ring.
Procedure for calculating the press fit of the nozzle ring for single inlet turbine casings.
Procedure for calculating the press fit of the nozzle ring for multiple inlet turbine casings.
Steps for fitting the diffuser, O-ring, and securing the cartridge group.
Detailed instructions for fitting the cartridge group, including sealing rings and nozzle ring.
Procedure for measuring axial and radial clearances of the cartridge group.
Procedure for measuring radial clearances N and R using feeler gauges.
Explains how to measure radial clearances N and R and the permissible values.
Lists the specified tightening torques for various screw fittings on the turbocharger.
Procedure for shutting down the turbocharger, especially for short-term emergency repairs.
Instructions for fitting a cover plate to close the turbine casing opening.
Provides dimensions and material specifications for manufacturing a cover plate.
Guidance on mothballing the turbocharger when the engine is out of operation for up to 12 months.
Outlines alternatives for turbocharger storage when the engine is out of service for over 12 months.
Instructions for checking mothballed parts for corrosion and renewing protection.
Details the information required for ordering spare parts and where to order them.
Illustrates the turbocharger with numbered components and their corresponding part numbers.
Illustrates the cartridge group components with their respective part numbers.
This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended.
Diagram and description of the turbocharger's main components and their function.
Details the turbocharger's design for diesel engines and precautions for gas engine use.
Provides guidance on storing new turbochargers and spare parts for up to 6 months and longer.
Covers organizational measures, safety, modifications, and personnel competence.
Explains symbols used in the manual and defines key terms like ABB Turbocharging.
Details the information found on the turbocharger rating plate.
Explains the meaning of the operational limits and replacement intervals on the rating plate.
Indicates the physical location of the rating plates on the turbocharger.
Provides contact details for ABB Turbocharging service stations and website.
Introduces safety aspects, residual risks, and responsibilities for safe operation.
States that ABB turbochargers comply with Directive 2006/42/EC on machinery.
Illustrates and defines mandatory safety signs for protective clothing and equipment.
Explains the meaning of WARNING and CAUTION symbols and their implications.
Describes the location and procedure for ordering new warning plates.
Provides instructions for safe work practices, area safety, and welding.
Guidelines for safe working practices and maintaining a safe work environment.
Specific precautions for performing welding operations near the turbocharger.
Procedures and precautions for disassembly, assembly, maintenance, and troubleshooting.
Safety warnings regarding mechanical tasks and the need for proper training.
Safety measures for shutting down and preparing the turbocharger for storage.
Details hazards like mechanical risks, noise, hot surfaces, and operating materials.
Risks associated with contact with rotating parts and improper operation.
Risks during maintenance due to improper handling or inadequate procedures.
Information on noise levels and the need for ear protection.
Risks of burns from hot surfaces and materials; precautions required.
Warnings about burns from uninsulated turbochargers and enginebuilder responsibility.
Risks from handling oils, greases, solvents; combustibility.
Hazards related to flammable materials and potential for explosion.
Precautions to prevent environmental contamination from spills.
Risks associated with dust and fibres from insulation materials.
Information on turbocharger resistance to deflagration and recommended inspections.
Risks associated with electrical components and requirements for trained personnel.
Guidelines for periodic checks of pressure vessels and operator responsibility.
Safety instructions for lifting loads, fastening gear, and avoiding suspended loads.
Details the requirements for a properly designed and installed oil supply system.
States that all lubricating oils used for engines are admissible.
Specifies permissible oil inlet temperatures and viscosities with a chart.
Defines required oil pressure values in front of the turbocharger for different operating statuses.
Emphasizes the importance of prelubrication before starting the engine.
Specifies limits for oil inlet temperature to prevent machine damage.
Lists permissible oil outlet temperatures based on operating status.
Details preventive visual checks, monitoring, and measuring work before and during commissioning.
Checks for monitoring devices, filter mat, lubricating system, and warning plates.
Checks for lubricating system and gas, air, oil lines after engine start.
Monitoring speed, pressure, and temperatures during engine run-up.
Guidance on cleaning or replacing lubricating oil filters after 100 hours.
Procedure for recommissioning the turbocharger after a period of inactivity.
Discusses noise levels, hazards, and necessary measures for noise reduction.
Outlines the importance of regular service for turbocharger performance and identifies key service tasks.
Emphasizes carrying out service work at specified time intervals to prevent failures.
Discusses factors leading to premature damage and the need for adjusted service intervals.
Recommendation for an inspection by a service station every 5 years.
Details routine service tasks like visual inspection and data recording.
Instructions on cleaning or replacing the oil filter as per engine manufacturer's guidance.
Long-term service tasks involving inspection of rotor and bearing parts by a service station.
Specifies operating data and measured values to be recorded in the engine logbook.
Provides recommended replacement intervals for rotating and non-rotating components.
Defines replacement intervals for compressor and turbine wheels based on operating conditions.
Defines replacement intervals for bearing parts and hot gas exposed components.
Lists parameters that can affect component replacement intervals, such as fuel quality and load profile.
Describes the speed measuring system for continuous monitoring of turbocharger speed.
Guidelines for managing speed differences between multiple turbochargers on an engine.
Step-by-step instructions for replacing a speed sensor, including safety warnings.
Briefly mentions that reasons for failure are in the Troubleshooting chapter.
Provides procedures for stopping oil-cooled and water-cooled turbochargers safely.
Introduces general maintenance tasks like visual checks and cleaning for turbocharger upkeep.
Explains the process and consequences of compressor contamination and periodic cleaning.
Describes wet cleaning as a tested method for cleaning the compressor during operation.
Explains how water injection removes dirt through mechanical impact.
Detailed steps for wet cleaning using an external water pressure vessel (XC1).
Addresses turbine contamination from fuels like HFO and recommends periodic wet cleaning.
Defines general cleaning intervals for turbine components and contacts for engine-specific needs.
Describes wet cleaning as the method for turbine components approved by ABB.
Outlines two methods: short and long water injection times for turbine cleaning.
Describes the short injection time method for designs without C-rings.
Describes the long injection time method for designs with C-rings.
Details necessary precautions for turbine cleaning, including water quality and temperature.
Specifies the tested and approved operating conditions for turbine wet cleaning.
Step-by-step guide for performing short water injection time turbine cleaning.
Step-by-step guide for performing long water injection time turbine cleaning.
Introduces mechanical cleaning methods for turbocharger components and associated precautions.
Instructions for cleaning the filter silencer components: ring and absorption segments.
Steps for reassembling the filter silencer after cleaning.
Procedure for cleaning compressor casing, wall insert, and diffuser.
Procedure for cleaning turbine casing, gas outlet flange, and nozzle ring.
Describes soaking and brushing contaminated turbine parts in liquid.
Instructions for removing dirt from turbine parts using brushes or vacuum cleaners.
Warns about rotor unbalance from residual contamination and damage.
Covers issues like sluggish start-up, vibrations, and rubbing of rotating parts.
Lists possible causes and eliminations for sluggish turbocharger start-up.
Lists possible causes and eliminations for turbocharger vibrations.
Describes normal wear and when to contact a service station for rubbing issues.
Explains turbocharger surging, its causes, and potential damage.
Identifies causes like contaminated components or blocked air ducts for surging.
Warns about damage from prolonged surging and recommends service station contact.
Covers issues like low oil pressure, reduction/increase in speed, and high exhaust gas temperature.
Lists causes for low oil pressure and their remedies.
Lists causes for speed reduction and their remedies.
Lists causes for speed increase and their remedies.
Details causes for high exhaust gas temperature and their solutions.
Identifies causes for low charge air pressure and their respective repairs.
Covers issues like high charge air pressure, compressor fouling, and noises during run-down.
Lists causes for high charge air pressure and their remedies.
Addresses compressor fouling from ventilation gases and its consequences.
Lists possible causes and eliminations for noises heard during turbocharger run-down.
Troubleshooting for speed measurement issues like no signal, incorrect speed, or defective sensors.
Lists causes and solutions for a short turbocharger run-down time.
Troubleshooting for poor speed signal or amplitude, often due to fitting errors.
Guidance for issues related to defective speed sensors.
Troubleshooting for measured speeds being too high, often due to sensor tip contamination.
Troubleshooting for measured speeds being too low or other sources of error.
Illustrates suspension methods for insulated and uninsulated turbochargers during transport.
Provides weight specifications for different turbocharger models (TPS48 to TPS61).
Step-by-step instructions for disconnecting lines, insulation, and attaching lifting gear.
Details steps for installing the turbocharger, including oil connections, O-rings, and tightening torques.
Preconditions and general safety notes for turbocharger disassembly and assembly.
Note that the fitted oil orifice must not be removed during disassembly.
Emphasizes observing specified tightening torques for component connections.
Notes on securing screws and nuts of assembly devices.
Safety warnings regarding lifting gear, load limits, and personnel safety.
Details the swivel lifting eye required for safe lifting of loads.
Provides weights for individual turbocharger parts and assemblies, rounded to the next highest value.
Detailed instructions for disassembling and assembling the turbocharger.
Steps for disconnecting air lines and removing the compressor casing and filter silencer.
Instructions on removing insulation plates from the turbocharger.
Specific steps for removing the wall insert from a TPS61 turbocharger.
Instructions for refitting the compressor casing and wall insert.
Steps for safely removing the cartridge group, including bearing casing and nozzle ring.
Instructions for installing the cartridge group with lamellar sealing rings, nozzle ring, and C-ring.
Procedure for calculating the press fit of the nozzle ring for single inlet turbine casings.
Procedure for calculating the press fit of the nozzle ring for multiple inlet turbine casings.
Steps for fitting the diffuser, O-ring, and securing the cartridge group.
Detailed instructions for fitting the cartridge group, including sealing rings and nozzle ring.
Procedure for measuring axial and radial clearances of the cartridge group.
Procedure for measuring radial clearances N and R using feeler gauges.
Explains how to measure radial clearances N and R and the permissible values.
Lists the specified tightening torques for various screw fittings on the turbocharger.
Procedure for shutting down the turbocharger, especially for short-term emergency repairs.
Instructions for fitting a cover plate to close the turbine casing opening.
Provides dimensions and material specifications for manufacturing a cover plate.
Guidance on mothballing the turbocharger when the engine is out of operation for up to 12 months.
Outlines alternatives for turbocharger storage when the engine is out of service for over 12 months.
Instructions for checking mothballed parts for corrosion and renewing protection.
Details the information required for ordering spare parts and where to order them.
Illustrates the turbocharger with numbered components and their corresponding part numbers.
Illustrates the cartridge group components with their respective part numbers.
General| Brand | ABB |
|---|---|
| Model | TPS 61D01 |
| Category | Wind Turbines |
| Language | English |
To Next Page