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ABB TPS52 Series User Manual

ABB TPS52 Series
132 pages
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Operation Manual
ABB Turbocharging

ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS 48E01 HT576697
n
Mmax
1000 t
Mmax
680
n
Bmax
950 t
Bmax
650
1/s °C
SOLD08 00180 12 60 60
Year 2017
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2410 English
TPS 48E01
Original Operation Manual

Table of Contents

Questions and Answers:

ABB TPS52 Series Specifications

General IconGeneral
BrandABB
ModelTPS52 Series
CategoryIndustrial Equipment
LanguageEnglish

Summary

Preliminary Remarks

Purpose of this Manual

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

Layout and Function

Details the turbocharger's main components and their operational roles and interactions.

Intended Use of the Turbocharger

Specifies the turbocharger's application on diesel engines and critical safety precautions.

Storage of New Turbochargers and Spare Parts

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

Essential Information

Covers organizational measures, safety practices, and personnel competence for safe operation.

Symbols and Definitions

Explains the meaning of symbols and terms used throughout the manual for clarity.

Turbocharger Rating Plate

Describes the information presented on the turbocharger's rating plate, including operating limits.

Explanation of the Rating Plate

Details the meaning of each item on the turbocharger rating plate.

Positions of the Rating Plates

Indicates the physical locations where the rating plates are attached to the turbocharger.

Contact Information

Provides details on how to contact ABB Turbo Systems for service and support.

Safety

Introduction

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

CE Conformity

States the compliance of ABB turbochargers with relevant EU machinery directives.

Definition of Mandatory Signs

Explains the meaning of mandatory safety signs requiring specific personal protective equipment.

Definition of Safety Instructions

Clarifies the meaning of warning and caution symbols used to indicate hazards and precautions.

Warning Plates on the Turbocharger

Identifies the locations and purpose of warning plates affixed to the turbocharger.

Safe Operation and Maintenance

Outlines essential safety practices for operating and maintaining the turbocharger.

Hazards during Operation and Maintenance

Details potential mechanical, noise, heat, chemical, and electrical hazards.

Deflagration on Gas Engines

Addresses turbocharger tolerance and checks required after a deflagration event.

Periodic Checking of the Pressure Vessel

Emphasizes statutory regulations for periodic checks of pressure vessels.

Lifting Loads

Provides safety guidelines for lifting and suspending loads involving turbocharger components.

Commissioning

Oil Supply

Details requirements for a reliable oil supply system for turbocharger operation.

Inspection Work

Describes preventive visual controls and measurements before and during commissioning.

Commissioning After Taking Out of Operation

Outlines procedures for recommissioning a turbocharger after it has been out of service.

Operation

Noise Emissions

Discusses noise levels and measures to mitigate them during turbocharger operation.

Servicing Work

Covers visual checks, monitoring, and functional checks for maintaining the turbocharger.

Expected Exchange Intervals

Provides guide values for the service life and replacement of turbocharger components.

Speed Measurement

Explains the system for continuous monitoring of turbocharger speed.

Stopping the Engine

Details procedures for safely stopping the engine with oil-cooled or water-cooled turbochargers.

Maintenance

Foreword to Maintenance

Introduces general maintenance tasks including visual checks and cleaning for trouble-free function.

Cleaning the Compressor During Operation

Describes the wet cleaning process for the compressor stage to remove deposits.

Turbine Cleaning During Operation

Explains methods for cleaning turbine components to prevent contamination and maintain efficiency.

Cleaning Components Mechanically

Covers manual cleaning procedures for various turbocharger components.

Troubleshooting

Malfunctions When Starting

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

Surging of the Turbocharger

Addresses causes and consequences of turbocharger surging and sporadic surge blows.

Malfunctions During Operation

Covers issues like low oil pressure, speed reduction/increase, and high exhaust gas temperature.

Malfunctions When Stopping

Details causes and eliminations for noises during run-down and short run-down times.

Speed Measurement System

Troubleshoots issues with speed sensors, signal amplitude, and measurement readings.

Removal and Installation

Transport

Illustrates methods for suspending and transporting turbochargers safely.

Turbocharger Weights

Provides a guide to the weights of different turbocharger models for lifting gear selection.

Remove the Turbocharger

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

Installing the Turbocharger

Outlines the process for correctly installing the turbocharger onto the engine.

Disassembly and Assembly

Introduction

Sets preconditions and general advice for disassembly and assembly work.

Module Weights

Lists the weights of individual turbocharger parts and assemblies for handling.

Disassembling and Assembling Turbocharger

Provides detailed instructions for dismantling and reassembling the turbocharger.

Axial Clearance A and Radial Clearance B

Explains how to measure axial and radial clearances and provides tolerance values.

Radial Clearances N and R

Describes measurement of radial clearances using feeler gauges and provides theoretical values.

Table of Tightening Torques

Lists specified tightening torques for various screw fittings on the turbocharger.

Taking Out of Operation

Shutting Down the Turbocharger

Describes procedures for shutting down the turbocharger for short-term emergency repairs.

Mothballing the Turbocharger

Taking the Engine Out of Operation for up to 12 Months

Details measures for mothballing the turbocharger when the engine is out of service temporarily.

Taking the Engine Out of Operation for More Than 12 Months

Outlines alternatives and procedures for long-term engine out-of-service storage of the turbocharger.

Disposing of Turbocharger Components

Spare Parts

Ordering Spare Parts

Specifies data required for inquiring about or ordering spare parts.

View of Turbocharger Showing Part Numbers

Provides an exploded view of the turbocharger with part numbers for identification.

View of Cartridge Group Showing Part Numbers

Shows an exploded view of the cartridge group with part numbers for identification.

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