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ABB TPS48-F Series - User Manual

ABB TPS48-F Series
116 pages
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Operation Manual
ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS48-F32 HT594937
n
Mmax
1033 t
Mmax
680
n
Bmax
981 t
Bmax
650
1/s °C
SOLD06 00180 16 60 60
Year 2020
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2412 English
TPS48-F32
Original Operation Manual

Table of Contents

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ABB TPS48-F Series Specifications

General IconGeneral
BrandABB
ModelTPS48-F Series
CategoryIndustrial Equipment
LanguageEnglish

Summary

Operating condition and replacement intervals

1 Preliminary remarks

1.1 Purpose of this manual

Explains the manual's scope and objective for users.

1.2 Layout and function

Details the turbocharger's components and their arrangement.

1.3 Intended use of the turbocharger

Specifies the turbocharger's application and limitations.

1.4 Storage of new turbochargers and spare parts

Provides guidelines for storing turbochargers and parts.

1.5 Essential information

Covers organizational measures, safety and operational notices.

1.6 Symbols and definitions

Explains symbols and terms used throughout the document.

1.7 Turbocharger rating plate

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

1.8 Contact information

Provides contact details for ABB Turbocharging service stations.

2 Safety

2.1 Introduction

Introduces residual risks and responsibilities during turbocharger operation.

2.2 CE conformity

States compliance with relevant EU directives for machinery.

2.3 Definition of mandatory signs

Explains the meaning and use of safety signs.

2.4 Definition of Safety instructions

Defines warning and caution symbols and terms used in the manual.

2.5 Warning plates on the turbocharger

Illustrates warning plate locations and procedures for replacement.

2.6 Safe operation and maintenance

Outlines safety instructions for personnel during operation and maintenance.

2.7 Hazards during operation and maintenance

Details hazards like noise, hot surfaces, and operating materials.

2.8 Deflagration on gas engines

Addresses turbocharger behavior and inspection after deflagration events.

2.9 Periodic checking of the pressure vessel

Specifies requirements for periodic checks of pressure vessels.

2.10 Lifting loads

Provides safety instructions for lifting turbocharger components.

3 Start-up

3.1 Oil supply

Details requirements for oil supply, filtration, viscosity, and pressure.

3.2 Inspection work

Lists inspection tasks before, during, and after start-up.

3.3 Commissioning after taking out of operation

Outlines procedures for recommissioning after a period of shutdown.

4 Operation

4.1 Noise emissions

Discusses noise levels and necessary insulation measures.

4.2 Servicing work

Covers visual checks, monitoring, and functional checks during operation.

4.3 Expected exchange intervals

Provides guide values for component replacement intervals based on operating hours.

4.4 Speed measurement

Explains the speed measuring system and troubleshooting.

4.5 Stopping the engine

Details procedures for stopping oil-cooled and water-cooled turbochargers.

5 Maintenance

5.1 Foreword to Maintenance

Introduces general maintenance tasks for ensuring trouble-free operation.

5.2 Cleaning the compressor during operation

Describes wet cleaning methods for the compressor stage.

5.3 Turbine cleaning during operation

Explains wet cleaning methods for turbine components.

5.4 Cleaning components mechanically

Details mechanical cleaning procedures for various parts.

6 Troubleshooting

6.1 Malfunctions when starting

Lists possible causes and eliminations for starting issues.

6.2 Surging of the turbocharger

Addresses causes and consequences of turbocharger surging.

6.3 Malfunctions during operation

Covers issues like low oil pressure, reduction in speed, and high temperatures.

6.4 Malfunctions when stopping

Details potential problems during the engine run-down phase.

6.5 Speed measurement system

Troubleshoots issues related to the speed sensor and measurement system.

7 Removal and installation

7.1 Transport

Shows methods for suspending turbochargers for transport.

7.2 Turbocharger weights

Lists the weights of different turbocharger models for lifting.

7.3 Removing the turbocharger

Provides step-by-step instructions for removing the turbocharger.

7.4 Installing the turbocharger

Details the procedure for installing the turbocharger onto the engine.

8 Disassembly and assembly

8.1 Introduction

Preconditions and general notes for disassembly and assembly tasks.

8.2 Module weights

Lists the weights of individual turbocharger parts and assemblies.

8.3 Disassembling and assembling turbocharger

Step-by-step guide for taking apart and reassembling the turbocharger.

8.4 Axial clearance A and radial clearance B

Instructions and values for measuring axial and radial clearances.

8.5 Radial clearances N and R

Details how to measure and permissible values for radial clearances.

8.6 Table of tightening torques

Specifies tightening torques for various bolted connections.

9 Taking out of operation

9.1 Shutting down the turbocharger

Procedure for shutting down the turbocharger, including emergency measures.

10 Mothballing the turbocharger

10.1 Taking the engine out of operation for up to 12 months

Mothballing measures for short-term engine shutdown.

10.2 Taking the engine out of operation for more than 12 months

Mothballing procedures for long-term engine shutdown.

11 Disposing of turbocharger components

12 Spare parts

12.1 Ordering spare parts

Information required when inquiring about or ordering spare parts.

12.2 View of turbocharger showing part numbers

Illustrates turbocharger components with their corresponding part numbers.

12.3 View of cartridge group showing part numbers

Shows the cartridge group components with their part numbers.

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