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ABB TPS61-F32 User Manual

ABB TPS61-F32
130 pages
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Operation Manual
Turbocharging
ABB Turbo Systems Ltd

ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS61-F32 HT563251
n
Mmax
595 t
Mmax
650
n
Bmax
565 t
Bmax
620
1/s °C
00650 8 50 50
Year 2016
made in Switzerland
Application according to
the Operation Manual
kg
HZTL2412 English
TPS61-F32
Original Operation Manual

Table of Contents

Questions and Answers:

ABB TPS61-F32 Specifications

General IconGeneral
BrandABB
ModelTPS61-F32
CategoryIndustrial Equipment
LanguageEnglish

Summary

Preliminary Remarks

Purpose of this manual

Explains the manual's objective and intended use for familiarization and correct operation.

Layout and function

Details the turbocharger's main components and their arrangement in a diagram.

Intended use of the turbocharger

Specifies the correct applications, limitations, and state-of-the-art technology.

Storage of new turbochargers and spare parts

Provides guidelines for storing turbochargers and spare parts up to and beyond six months.

Essential information

Covers organizational measures, safety consciousness, and handling of alterations.

Symbols and definitions

Explains symbols, notes, mandatory signs, and abbreviations used in the manual.

Turbocharger rating plate

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

Contact address and after-sales service

Provides contact details for ABB Turbo Systems and information on after-sales service.

Safety

Introduction

Outlines residual risks, operator responsibilities, and general safety instructions.

CE conformity

States compliance with Directive 2006/42/EC on machinery.

Definition of mandatory signs

Explains required safety equipment and signs to be worn.

Definition of Safety instructions

Clarifies the meaning of warning and caution symbols used in the manual.

Warning plates on the turbocharger

Identifies the location and purpose of warning labels on the turbocharger.

Safe operation and maintenance

Details general safety rules for work safety, area safety, and maintenance.

Hazards during operation and maintenance

Lists potential hazards like mechanical, noise, thermal, and material risks.

Use of ABB turbochargers on gas engines

Addresses specific safety considerations for turbochargers used on gas engines.

Periodic checking of the pressure vessel

Covers regulations and operator responsibilities for pressure vessel checks.

Lifting loads

Provides safety guidelines and procedures for lifting turbocharger components.

Start-up

Oil supply

Details requirements for lubrication system, filtration, and oil parameters.

Inspection work

Outlines checks before, during, and after commissioning the turbocharger.

Commissioning after taking out of operation

Steps for restarting the turbocharger after a period of inactivity.

Operation

Noise emissions

Discusses noise levels, measurement, and necessary insulation measures.

Servicing work

Details routine checks, intervals, and tasks for maintaining the turbocharger.

Expected exchange intervals

Provides recommended replacement times for various turbocharger components.

Speed measurement

Explains the system for monitoring turbocharger speed and replacing sensors.

Stopping the engine

Describes procedures for safely stopping oil-cooled and water-cooled turbochargers.

Maintenance

Foreword to Maintenance

Introduces general maintenance tasks, visual checks, and cleaning procedures.

Cleaning the compressor during operation

Details methods for cleaning the compressor without disassembly using wet cleaning.

Turbine cleaning during operation

Explains procedures for cleaning turbine components during operation with wet cleaning methods.

Cleaning components mechanically

Covers cleaning methods for various parts requiring disassembly and specific tools.

Troubleshooting

Malfunctions when starting

Lists common issues during start-up like sluggishness, vibration, and rubbing.

Surging of the turbocharger

Addresses the phenomenon of turbocharger surging and its potential causes and remedies.

Malfunctions during operation

Covers problems like low oil pressure, speed reduction, and high exhaust gas temperatures.

Malfunctions when stopping

Discusses issues that may arise during engine shut-down, such as noises.

Speed measurement system

Troubleshoots problems related to speed sensors, signal amplitude, and accuracy.

Removal and installation

Transport

Shows methods for suspending turbochargers during transport using lifting gear.

Turbocharger weights

Lists weights for different turbocharger models to aid in selecting lifting gear.

Remove the turbocharger

Step-by-step guide for detaching the turbocharger from the engine.

Installing the turbocharger

Step-by-step guide for mounting the turbocharger onto the engine.

Disassembly and assembly

Introduction

Prerequisites and general advice for disassembly and assembly tasks.

Module weights

Provides weights for individual turbocharger components to aid handling.

Disassembling and assembling turbocharger

Detailed procedures for dismantling and reassembling the turbocharger components.

Axial clearance A and radial clearance B

Instructions for measuring critical axial and radial bearing clearances.

Radial clearances N and R

Details how to measure radial clearances in turbine and compressor areas.

Table of tightening torques

Lists specified torque values for various screw connections in Nm.

Taking out of operation

Shutting down the turbocharger

Procedures for safely shutting down the turbocharger and fitting protective covers.

Mothballing the turbocharger

Taking the engine out of operation for up to 12 months

Measures for preserving the turbocharger during short-term engine inactivity.

Taking the engine out of operation for more than 12 months

Procedures for long-term storage and preservation of the turbocharger.

Disposing of turbocharger components

Handling damaged thermal insulation

Safety precautions for dealing with damaged thermal insulation materials.

Spare parts

Ordering spare parts

Information needed for ordering replacement parts and storage advice.

View of turbocharger showing part numbers

Illustrated breakdown of the turbocharger with part numbers.

View of cartridge group showing part numbers

Illustrated breakdown of the cartridge group with part numbers.

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