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ABB TPS48-F33 User Manual

ABB TPS48-F33
132 pages
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Operation Manual
ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS48-F33 HT564922
n
Mmax
990 t
Mmax
680
n
Bmax
940 t
Bmax
650
1/s °C
00180 12 50 50
Year 2016
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2412 English
TPS48-F33
Original Operation Manual

Table of Contents

Questions and Answers:

ABB TPS48-F33 Specifications

General IconGeneral
BrandABB
ModelTPS48-F33
CategoryIndustrial Equipment
LanguageEnglish

Summary

Operating condition and replacement intervals

1 Preliminary remarks

1.1 Purpose of this manual

Explains the manual's objective and its role in understanding turbocharger operation.

1.2 Layout and function

Details the physical components and operational flow of the turbocharger.

1.3 Intended use of the turbocharger

Specifies the approved applications and limitations for the turbocharger.

1.4 Storage of new turbochargers and spare parts

Provides guidelines for storing turbochargers and spare parts to maintain their condition.

1.5 Essential information

Covers general safety, organizational measures, and personnel competence for turbocharger use.

1.6 Symbols and definitions

Explains symbols, notes, and definitions used throughout the manual for clarity.

1.7 Turbocharger rating plate

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

1.8 Contact information

Lists contact details for ABB Turbo Systems and service stations.

2 Safety

2.1 Introduction

Introduces safety aspects, residual risks, and operator responsibilities for turbocharger safety.

2.2 CE conformity

States that ABB turbochargers comply with the Machinery Directive 2006/42/EC.

2.3 Definition of mandatory signs

Illustrates and explains mandatory safety signs for personnel protection.

2.4 Definition of Safety instructions

Explains warning and caution symbols and their significance in safety instructions.

2.5 Warning plates on the turbocharger

Shows the location and purpose of warning plates attached to the turbocharger.

2.6 Safe operation and maintenance

Details general safety rules for operation, work area, and specific tasks like welding.

2.7 Hazards during operation and maintenance

Identifies mechanical, noise, heat, and material hazards during operation and maintenance.

2.8 Deflagration on gas engines

Describes turbocharger tolerance to deflagration and recommended checks after an event.

2.9 Periodic checking of the pressure vessel

Outlines requirements for periodic checks of simple pressure vessels used for cleaning.

2.10 Lifting loads

Provides safety guidelines and procedures for lifting turbocharger components.

3 Start-up

3.1 Oil supply

Covers the importance of oil supply, filtration, viscosity, temperature, and pressure.

3.2 Inspection work

Details inspection steps before, during, and after commissioning the turbocharger.

3.3 Commissioning after taking out of operation

Outlines procedures for recommissioning a turbocharger after a period of inactivity.

4 Operation

4.1 Noise emissions

Discusses noise hazards and requirements for noise insulation of the turbocharger.

4.2 Servicing work

Explains various servicing tasks, intervals, and recording operational data.

4.3 Expected exchange intervals

Provides guide values for replacement intervals of turbocharger components.

4.4 Speed measurement

Describes the speed measuring system, its components, and replacement procedures.

4.5 Stopping the engine

Details procedures for stopping the engine for both oil-cooled and water-cooled turbochargers.

5 Maintenance

5.1 Foreword to Maintenance

Introduces maintenance tasks for ensuring trouble-free turbocharger functioning.

5.2 Cleaning the compressor during operation

Explains wet cleaning method for the compressor to remove deposits.

5.3 Turbine cleaning during operation

Describes wet cleaning methods for turbine components to remove fuel oil contamination.

5.4 Cleaning components mechanically

Covers mechanical cleaning of specific components like filter silencer and cartridge group.

6 Troubleshooting

6.1 Malfunctions when starting

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

6.2 Surging of the turbocharger

Explains causes and remedies for turbocharger surging and its potential damage.

6.3 Malfunctions during operation

Details causes and solutions for issues like low oil pressure, speed changes, and temperature variations.

6.4 Malfunctions when stopping

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

6.5 Speed measurement system

Covers troubleshooting for signal issues, incorrect speed readings, and other errors.

7 Removal and installation

7.1 Transport

Shows methods for suspending and transporting insulated and uninsulated turbochargers.

7.2 Turbocharger weights

Provides weight specifications for different turbocharger models for lifting gear selection.

7.3 Remove the turbocharger

Details the step-by-step procedure for removing the turbocharger from the engine.

7.4 Installing the turbocharger

Outlines the steps for installing the turbocharger onto the engine, including torque values.

8 Disassembly and assembly

8.1 Introduction

Sets preconditions for disassembly and assembly, and highlights safety precautions.

8.2 Module weights

Lists weights for individual turbocharger components and assemblies.

8.3 Disassembling and assembling turbocharger

Provides detailed instructions for disassembling and reassembling turbocharger components.

8.4 Axial clearance A and radial clearance B

Explains how to measure axial and radial clearances for proper rotor assembly.

8.5 Radial clearances N and R

Defines and details the measurement of radial clearances N and R for component fit.

8.6 Table of tightening torques

Lists specified tightening torques for various screws and connections.

9 Taking out of operation

9.1 Shutting down the turbocharger

Describes procedures for shutting down the turbocharger for emergency repairs.

10 Mothballing the turbocharger

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

Provides mothballing measures for turbochargers when the engine is out of operation for up to 12 months.

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

Details mothballing procedures for turbochargers when the engine is out of operation for over 12 months.

11 Disposing of turbocharger components

12 Spare parts

12.1 Ordering spare parts

Explains how to order spare parts, including required information.

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 components of the cartridge group with their respective part numbers.

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