Operation Manual
ABB Turbo Systems Ltd
CH 5401 Baden
Type
TPL85-B15
HT489493
n
Mmax200
t
Mmax550
n
Bmax190
t
Bmax520
1/s
°C
10620
36
100
100
Year
2008
made in Switzerland Application according to the Operation Manualkg
We herewith confi rm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to the „European Machinery Directives“.
We reserve all rights in this document and in the information contained herein.
Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.
© Copyright by ABB TURBO SYSTEMS Ltd 2004
Design and specifi cations are subject to change without notice.
Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.
The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of recycled cardboard.
These materials may be disposed with the domestic wastes or at a specialised collecting centre.
Note: Replacement intervals of components depends on the load profi le, turbine inlet temperature, suction air temperature and turbocharger speed. In case the operation conditions differs signifi cantly from what is considered to be normal for the cur-rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
List of contents Page 1 January 2008 HZTL2 491_EN
List of contents
1 Preliminary remarks 1.1 Purpose of manual 1.2 Layout and function1.3 Correct use of the turbocharger 1.4 Essential information
1.5 Abbreviations and symbols 1.6 Turbocharger rating plate 2 Safety
2.1 Basic safety instructions 2.2 General safety instructions 2.3 Special safety instructions
2.4 Safety instructions and hazard protection 2.5 Warnings on the turbocharger
3 Commissioning 3.1 Oil supply 3.2 Inspection work
3.3 Putting into operation after laying up 4 Operation
4.1 Servicing work
4.2 Expected exchange intervals 4.3 Monitoring
List of contents Page 2 January 2008 HZTL2 491_EN Version 5 6 Troubleshooting
6.1 Possible remedies for failures 7 Removal and installation 7.1 Turbocharger weights 7.2 Remove the turbocharger 7.3 Installing the turbocharger 8 Disassembly and assembly 8.1 Module weights
8.2 Removing and fitting filter silencer or air suction branch 8.3 Axial clearance
8.4 Dismantling the internal part of the compressor casing 8.5 Dismantling gas inlet casing
8.6 Fitting gas inlet casing
8.7 Fitting the internal part of the compressor casing 8.8 Table of tightening torques
9 Taking out of operation temporarily 9.1 Possibilities for emergency repair 9.2 Locking the rotor
9.3 Blocking the inlets and outlets 9.4 Bypass the turbocharger 10 Mothballing the turbocharger
10.1 Taking out of operation for up to 12 months 10.2 Taking out of operation for more than 12 months 11 Disposal
11.1 Environmentally compatible disposal of turbocharger components
12 Reserve and spare parts 12.1 Ordering spare parts 12.2 Directory of part numbers 12.3 General view of turbocharger 12.4 General view of cartridge group
Purpose of manual 1.1 Page 1 January 2008 HZTL2 491_EN
1 Preliminary remarks
1.1 Purpose of manual
This operation manual will help you to become familiar with your ABB Turbo Systems turbocharger and to use it to full effect in its intended ap-plication. You will find important instructions as to the safe, correct, and economical operation of the turbocharger.
The content of this operation manual is intended for persons such as en-gineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon. This operation manual includes helpful information on the following topics:
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
Early identification and avoidance of hazards. Minimizing repair costs and downtime.
This operating manual complements and extends existing national regula-tions on protection against accidents and accident prevention.
An operation manual must be available at all times at the site where the turbocharger is used. It is essential that this operation manual is read before beginning work by all persons working with or on the turbo-charger. Anyone who works only occasionally on the machine, e.g. dur-ing installation and maintenance, must also read and fully understand the operating manual before beginning work.
The instructions included in this operating manual must be followed with-out fail.
Operating manual
Target group
Content of operating ma-nual
Layout and function 1.2 Page 2
January 2008
HZTL2
491_EN
Version 5
1.2 Layout and function
1.2.
1 Filter silencer 7 Nozzle ring 2 Radial plain bearing 8 Turbine wheel 3 Thrust bearing 9 Bearing casing 4 Radial plain bearing 10 Diffuser
5 Gas outlet casing 11 Compressor wheel 6 Gas inlet casing 12 Compressor casing
Layout and function 1.2 Page 3
January 2008
HZTL2
491_EN
Working principle
The turbocharger is a turbo-machine and consists of the following main components:
Turbine Compressor
These are both mounted on a common shaft.
Exhaust gases from the diesel engine flow through the gas inlet casing (6) and the nozzle ring (7) to impinge on the turbine wheel (8).
The turbine wheel (8) uses the energy contained in the exhaust gas to drive the compressor wheel (11). The compressor draws in fresh air, compresses it and then forces it into the engine cylinders.
The exhaust gas escapes to free air through the exhaust manifold which is connected to the gas outlet casing (5).
The air, which is necessary for the operation of the diesel engine and compressed in the turbocharger, is drawn through the suction branch or the filter silencer (1) into the compressor wheel (11). This air then passes through the diffuser (10) and leaves the turbocharger through the com-pressor casing (12).
The rotor runs in two radial plain bearings (2/4), which are located in the bearing casing (9) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is normally supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (9).
The turbocharger is equipped with an emergency lubrication oil tank, which is integrated in the bearing casing. During an emergency stop
cau-Correct use of the turbocharger 1.3 Page 4
January 2008
HZTL2
491_EN
Version 5
1.3 Correct use of the turbocharger
This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charg-ing pressure required to operate the engine.
The engine manufacturer has provided ABB Turbo Systems with infor-mation regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate.
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys-tems reserves the right to reject all claims under the warranty.
This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations.
Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine. The machine may only be ope-rated by trained personnel.
Correct use of the turbocharger also includes observation of the assem-bly, disassemassem-bly, operating, maintenance and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed.
The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in com-pliance with the Operation Manual.
X Malfunctions / defects which could affect safety must be eliminated
immediately.
The manufacturer shall not accept liability for damages resulting from un-authorised alterations to the turbocharger.
NOTE
Latest technology
WARNING
Essential information 1.4 Page 5 January 2008 HZTL2 491_EN
1.4 Essential information
Organisational measuresIn addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed.
This also applies to the provision and wearing of personnel protection e-quipment.
The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual.
X The turbocharger must be shut down immediately by stopping the
en-gine in the event of alterations affecting safety or of corresponding op-erating behaviour. The fault must be reported to the person or depart-ment responsible.
Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys-tems.
NOTE
Essential information 1.4 Page 6
January 2008
HZTL2
491_EN
Version 5
Original parts and safety
Original parts and accessories are especially designed for the turbo-charger supplied by ABB Turbo Systems.
We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us.
If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the techni-cal design specifications of the turbocharger.
Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories.
Qualification of personnel
The turbocharger must only be operated and maintained by trained and authorised personnel.
Work on mechanical components, such as bearings or rotors, may only be performed by qualified fitters from an official service station of ABB Turbo Systems.
It must be ensured that only authorised personnel work on the turbo-charger.
NOTE
WARNING
Essential information 1.4 Page 7
January 2008
HZTL2
491_EN
After-sales service
The Contact Information brochure contains an overview of official ABB Turbo Systems. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this oper-ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-ing specifically to your model.
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instruc-tions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the deliv-ery date.
Suitable storage locations are dry rooms where the relative humidity is be-tween 40-70% and no condensation can form.
X After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
Abbreviations and symbols 1.5 Page 8
January 2008
HZTL2
491_EN
Version 5
1.5 Abbreviations and symbols
The following abbreviations are used in this document:
Z Prerequisite X Work step D Result
9 Positive checkpoint (activity that must be carried out without fail) U Negative checkpoint (activity that must not be carried out under any
circumstances)
Basic Instructions
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbo-charger easier.
The note provides further essential information.
Reference to safety instructions
The warnings and cautions are described in the chapter Safety .
ABB Turbo Systems
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Sys-tems.
Official ABB Turbo Systems service station
The term Official ABB Turbo Systems service station used in this manual NOTE
Turbocharger rating plate 1.6 Page 9
January 2008
HZTL2
491_EN
1.6 Turbocharger rating plate
L_00012
1 Turbocharger operational limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer.
2 Turbocharger operational limits in service. Operational limits
Turbocharger rating plate 1.6 Page 10
January 2008
HZTL2
491_EN
Version 5
6 Customer part number
7 Field for special design designation 8 Weight of the turbocharger in kg 9 CE = Conformité Européenne 10 Turbocharger type
11 Series number
12 Year of construction of the turbocharger
Explanations of the rating plate
The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific.
Continuous running above the indicated nBmax, tBmax values may consid-erably reduce the recommended exchange intervals. In such cases, we recommend you contact the nearest official service station of ABB Turbo Systems.
nMmax , tMmax normally apply only when running at overload (110 %)
dur-ing trials on the engine test bed. These limits may also be permitted in service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-crease the risk of unpredictable component failure.
Additional specifications:
Basic safety instructions 2.1 Page 1
January 2008
HZTL2
491_EN
2 Safety
2.1 Basic safety instructions
The following symbols and terms are used for the safety instructions in this manual:
Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents.
Warning signs must be strictly observed at all times.
Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed.
Caution signs must be strictly observed at all times.
WARNING
General safety instructions 2.2 Page 2
January 2008
HZTL2
491_EN
Version 5
2.2 General safety instructions
The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associated operating materials.
The following safety instructions must be followed when operating and when working on the turbocharger.
Do not work on the turbocharger if you are under physical or mental
stress.
Wear protective clothing at all times.
Helmet Ear protection Protective glasses Protective suit
Oil and petrol resistant gloves Protective shoes
Attach individual parts and larger component modules carefully to
suit-able hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling. For overhead assembly work, use the steps and platforms provided for
this purpose. WARNING
Special safety instructions 2.3 Page 3
January 2008
HZTL2
491_EN
2.3 Special safety instructions
Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation
Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
once a day for visible damage and defects.
Report any damage or changes in operational performance to the
per-son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use. Safety when cleaning
When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, sto-rage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air
Special safety instructions 2.3 Page 4
January 2008
HZTL2
491_EN
Version 5
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
You must wear protective clothing (see section General safety
instruc-tions).
Handle operation materials and detergents with utmost caution. When handling solvents, wear protective clothing and observe the
fol-lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances. Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Safety during disassembly, assembly, maintenance and troubleshooting
Follow the prescribed maintenance and inspection schedules for all
ad-justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before
start-ing.
Ensure that absorbent materials are available to clean up any
opera-tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and
dis-posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled.
Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or ro-tors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.
Special safety instructions 2.3 Page 5
January 2008
HZTL2
491_EN
Safety when taking out of operation or putting into storage
Secure the rotor against turning.
Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger. Keep the work area clean and free of oil and operating materials. Remove any obstacles lying around on the floor.
Safety instructions and hazard protection 2.4 Page 6 January 2008 HZTL2 491_EN Version 5
2.4 Safety instructions and hazard protection
Associated hazards may arise during operation of and work on the turbo-charger:
from the turbocharger and its accessories. from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
Unconsciousness and injury due to:
crushing shearing cutting winding smashing drawing in knocking stabbing rubbing
Escape of liquids under high pressure and / or at high temperature slipping
tripping falling
WARNING
Safety instructions and hazard
protection 2.4 Page 7
January 2008
HZTL2
491_EN
sharp edges, pointed parts crush, shear and winding areas fragmentation / ejection of parts
fracture or rupture of parts due to overload
Elastic elements (springs), liquids and / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor
9 Wear leather protective gloves 9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection) 9 Wear face and eye protection
9 Wear protective shoes
9 Keep floor, equipment and the turbocharger clean
9 Ensure the availability of oil absorbing materials and have oil collector basins ready or in position
9 Eliminate leaks
Operation and process materials
Operation and process materials refer to chemical and hazardous sub-stances:
Oils Grease Coolants
Detergents and solvents Acids
Note that operation and process materials are harmful to the environ-ment if they penetrate soil or water.
Causes
Protective measures
Safety instructions and hazard protection 2.4 Page 8 January 2008 HZTL2 491_EN Version 5
The following injuries can be caused by operation and process materials:
Allergies Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids
Clothing wet or soaked with hazardous substances
Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials
9 Utmost caution when handling process and operation materials 9 Protective clothing must be worn
9 Avoid skin contact and inhalation
9 Ensure that the workroom is properly ventilated
9 Observe the hazard indications on the containers for operation and process materials
9 Seal the hazardous substance container tight immediately after use 9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-scribed, and disposed of as special waste in an environmentally com-patible manner
9 Ensure that containers with new / used operation materials are sealed tight
9 In the event of leaks or spills, immediately apply a suitable absorbent material and dispose of this in a technically and environmentally com-patible manner as special waste
Personal injury
Causes
Safety instructions and hazard
protection 2.4 Page 9
January 2008
HZTL2
491_EN
Handling insulating materials
9 Ensure that the work area is well ventilated 9 Keep the work area clean
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps 9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials 9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses 9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream Noise
The effects of noise above a legally permitted level can cause personal in-jury.
Loss of hearing Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances
Machine noise level above 85 dB (A)
9 Wear ear protection Heat hazard
When the turbocharger is operated, surfaces become very hot. Personal injury
Causes
Warnings on the turbocharger 2.5 Page 10
January 2008
HZTL2
491_EN
Version 5
2.5 Warnings on the turbocharger
Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Miss-ing or illegible warnMiss-ings must be replaced by new warnMiss-ings.
L_00227
Apply warnings so that they are clearly visible in the positions intended for that purpose. Please contact an official ABB Turbo Systems service station for further information.
Oil supply 3.1 Page 1 January 2008 HZTL2 491_EN
3 Commissioning
3.1 Oil supply
A carefully designed oil supply, which functions under all operating condi-tions, is an important precondition for trouble-free operation of the turbo-charger.
Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit.
Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature.
Oil filtration
A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for TPL ..-B turbochargers.
Oil pressure
The oil pressure in front of the bearings must be maintained precisely to ensure trouble-free operation.
The permissible oil pressures are specified in the following tables de-pendent on the lubrication (engine lubrication or separate lubricating sys-tem).
Oil supply 3.1 Page 2
January 2008
HZTL2
491_EN
Version 5
Kinetic viscosity 45 - 170 cST Oil pressure [bar] Inadmissible oil pressure range ->
Emergency shutdown (without time lag)
0.0 - 0.6
Oil pressure range permissible in short term (<1h) -> Alarm
0.6 - 0.8
Permissible oil pressure range for normal operation 0.8 - 2.5 Permissible oil pressure range during engine
warm-up phase 0.8 - 4.0
Kinetic viscosity 12 - 170 cST Oil pressure [bar] Inadmissible oil pressure range ->
Emergency shutdown (without time lag)
0.0 - 0.9
Oil pressure range permissible in short term (<1h) -> Alarm
0.9 - 1.1
Permissible oil pressure range for normal operation 1.1 - 2.5 Permissible oil pressure range during engine
warm-up phase 1.1 - 4.0
If a separate lubricating system has been designed for operation in the viscosity range of the engine lubrication system, i.e. 45 – 170 cSt, the oil pressure limits according to the engine lubrication information may be used for this system.
Oil temperature during normal operation
Oil entry temperature
[ °C ]
Engine load [ % ]
Oil entry pressure [bar] Oil exit temperature [ °C ] 45 100 1.5 - 2 70 - 90 70 100 1.5 - 2 90 - 110 Engine lubrication
Separate lubricating sys-tem
NOTE
Inspection work 3.2 Page 3
January 2008
HZTL2
491_EN
3.2 Inspection work
This inspection work includes preventive visual controls, as well as moni-toring and measurement to ensure the correct functioning of the turbo-charger. These serve as an aid to detecting anomalies before and during commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all
inspec-tion work.
3.2.1 Inspection before commissioning
X Check for correct functioning.
X Inspect for damage.
X Check that the oil filter is clean before commissioning.
It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system.
We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.
X Check oil pressure in oil supply lines.
Monitoring equipment
Air filter mat
Lubrication system
Inspection work 3.2 Page 4
January 2008
HZTL2
491_EN
Version 5
3.2.2 Inspection after commissioning
X Check oil pressure in oil supply lines.
X Measure
X Measuring
X upstream/downstream from turbine, compressor and oil feed for
vari-ous engine speeds
X Check all gas, air, and oil lines for leaks after the engine has been
star-ted up.
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours af-ter commissioning. If further oily liquid continues to appear afaf-ter this pe-riod, an oil leak must be suspected. Then, the first step is to check for leakage of the oil supply to the turbocharger. If something wrong is de-tected, contact an official ABB Turbo Systems service station.
X Measure the speed, oil pressure, charging pressure and temperatures
before and after the turbine and the compressor at various engine speeds.
X Compare the measured values with those of the inspection report,
tak-ing into account the different operattak-ing conditions. Lubrication system
Charger speed
Charger pressure
Measure temperatures
Gas, air, and oil lines
Putting into operation after laying up 3.3 Page 5
January 2008
HZTL2
491_EN
3.3 Putting into operation after laying up
X Remove the cover plates (blind flanges) between the compressor
cas-ing outlet and the charge-air receiver, upstream of the gas inlet, down-stream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any
com-bustion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section
In-spection work before commissioning in the chapter entitled Commis-sioning.
X Commission the turbocharger.
Servicing work 4.1 Page 1 January 2008 HZTL2 491_EN
4 Operation
4.1 Servicing work
Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be car-ried out at the intervals indicated.
The pertinent safety instructions must be observed during all servicing work.
Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger.
4.1.1 Servicing work every 25 to 50 hours
X Record
X Record in the machine logbook
X In the event of significant deviations, establish the cause.
If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.
WARNING
CAUTION
Operation data
Servicing work 4.1 Page 2
January 2008
HZTL2
491_EN
Version 5
4.1.2 Entries in the machine logbook
Monitoring of the machine plant provides information about the perform-ance of the turbocharger.
The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book:
Output and speed of the engine Air intake temperature
Exhaust temperature before and after the turbine Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
Air temperature after compressor and after the charge-air cooler Speed of the turbocharger
Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions
X With the engine at standstill clean or replace oil filters
If provided
Servicing work 4.1 Page 3
January 2008
HZTL2
491_EN
4.1.4 Inspection work every 18,000 hours
X Remove filter silencer or air suction branch
X Clean filter silencer as far as accessible, and inspect for damage X Remove internal part of compressor casing
X Check clearance A (axial bearing play).
X Clean accessible parts (compressor wheel, diffusor, wall insert), and
inspect for damage
X Without removing turbine parts and using an endoscope, carry out a
visual check for possible soiling and damage (nozzle ring, turbine diffu-sor/cover ring, turbine blades). As an option, this inspection can be car-ried out after removal of gas inlet casing.
X Refit internal part of compressor casing X Re-install filter silencer or air suction branch.
This inspection work and checks must be carried out by an official ser-vice station of ABB Turbo Systems.
Servicing work 4.1 Page 4
January 2008
HZTL2
491_EN
Version 5
4.1.5 Servicing work every 36,000 hours
X Remove filter silencer or air suction branch
X Clean filter silencer as far as accessible, and inspect for damage X Remove internal part of compressor casing
X Check clearance A (axial bearing play).
X Clean accessible parts (diffusor, wall insert), and inspect for damage. X Take apart gas inlet casing and remove nozzle ring.
X Clean nozzle ring and check for damage or wear.
X Clean turbine diffusor / cover ring and check for damage or wear. X Replace radial bearing and thrust bearing with original parts from ABB
Turbo Systems.
X Inspect and assess rotor.
Replacement of the bearing parts as well as inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems ser-vice station.
Expected exchange intervals 4.2 Page 5
January 2008
HZTL2
491_EN
4.2 Expected exchange intervals
Turbocharger part HFO Gas inlet casing 50'000 … 100’000 Gas outlet casing 50'000 … 100’000 Nozzle ring 35'000 … 50’000 Turbine diffusor / cover ring 25'000 … 50’000
Other housings 100’000
Rotor components See rating plate for information Bearings See rating plate for information
HFO = Heavy Fuel Oil
The values indicated are for guidance only and are not guaranteed val-ues. These values may vary significantly for example due to inadequate servicing, frequent emergency stoppages as well as through the use of fuel or lubricating oil of inferior quality.
Expected replacement intervals [h]
Monitoring 4.3 Page 6 January 2008 HZTL2 491_EN Version 5
4.3 Monitoring
4.3.1 Measuring speed
9 1 2 3 5 6 8 10 7 11 L_012461 Bearing casing 7 Line amplifier (optional) 2 Thrust bearing 8 Speed transmitter 3 Guide in axial bearing 9 Auxiliary bearing
- - 10 Alternative for fitting speed transmitter
5 Screw plug 11 Tachometer (option) 6 Connecting cable (with
voltage limiting module) - -
The speed transmitter system for measuring the turbocharger speed also permits continuous remote monitoring of the turbocharger speed when it is used in conjunction with the corresponding measuring instruments and / or monitoring systems (not included in the scope of delivery). If the ma-chine installation is monitored continuously, the turbocharger speed can be used as a suitable control parameter. The line amplifier (7) can be pur-chased as an option to the described speed measuring system.
Monitoring 4.3 Page 7
January 2008
HZTL2
491_EN
Possible reasons for failure of speed transmitter system:
Defects of the speed transmitter (8), connecting cable (6) and
connect-ing plug for the measurconnect-ing unit or on the measurconnect-ing unit or power sup-ply.
Turbocharger breakdown.
Failure of speed indicator
If the speed indicator fails, it is recommended that the engine output be reduced to idling and the engine then stopped.
X Investigate cause of failure and eliminate problem.
Fitting speed transmitter system
It is recommended that fitting or replacing a speed transmitter system on an in-place turbocharger be carried out only by an official ABB Turbo Systems service station.
A reduction in turbocharger speed can signify:
Damaged turbine or bearing Severe soiling of the turbine
CAUTION
Monitoring 4.3 Page 8
January 2008
HZTL2
491_EN
Version 5
4.3.2 Underpressure measurement on filter silencer
A U-tube manometer can be ordered from ABB Turbo Systems for meas-uring the negative pressure at the filter silencer.
This measuring can be used for the following purposes:
Measuring the correction factor for calculating the turbocharger
effi-ciency during engine acceptance
The use of a filter mat on the filter silencer can cause a loss of
pres-sure. More significant pressure loss is an indication of increased soiling of the filter material.
L_00003 L_00004
1 Felt discs
Monitoring 4.3 Page 9
January 2008
HZTL2
491_EN
All parts required for assembly are supplied in a separate package. Mechanical vibration of the U-tube manometer is reduced by the installa-tion of addiinstalla-tional felt discs (1).
The U-tube manometer must be exposed to minimum possible me-chanical shock or vibration.
X Fit U-tube manometer to filter silencer as shown in preceding
illustra-tion.
X Fill U-tube manometer with slightly coloured water to obtain best
legibil-ity.
Under as-new conditions (new or clean filter silencer and filter mat), the maximum pressure loss (A) is 120 mm H2O under full loading.
X Clean filter at latest as soon as loss of pressure (A) reaches a value of
200 mm H2O.
For better legibility of the pressure differential (A) on the U-tube ma-nometer, the measuring rod can be withdrawn to the level of the bottom water level.
NOTE
Surging of turbocharger 4.4 Page 10 January 2008 HZTL2 491_EN Version 5
4.4 Surging of turbocharger
Surging of the turbocharger can occur with certain engine operating sta-tes, such as rapid load removal or while manoeuvring. The direction of flow in the compressor is then briefly reversed. However, sporadic surging of this kind does not generally affect the safe operation of the
turbo-charger.
Prolonged or periodic surging
If surging is prolonged or occurs periodically, the following components may be damaged:
- Compressor wheel (vibration fractures, ...) - Turbine blades (cracks)
- Bearing (overheating) - Filter silencer
Action to be taken:
The operating safety of the turbocharger is no longer ensured with con-tinuous or periodically recurring surging. The operator must take imme-diate steps to correct the surging together with the closest official ABB Turbo Systems service station.
The components listed above must be inspected for damage by an offi-cial ABB Turbo Systems service station, and replaced in cases of doubt.
CAUTION
Contact with rotating parts 4.5 Page 11
January 2008
HZTL2
491_EN
4.5 Contact with rotating parts
Slight, uniform wear around the periphery of rotor components, caused by their just touching adjacent components locally, is not hazardous and permissible. This slightly reduces the length of the blades in the compres-sor and/or the turbine. Certain tolerances must be observed to avoid a significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo
Shutting the engine down 4.6 Page 12
January 2008
HZTL2
491_EN
Version 5
4.6 Shutting the engine down
Before shutting down the engine, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can take away heat from the turbocharger bearings.
Foreword to Maintenance 5.1 Page 1 January 2008 HZTL2 491_EN
5 Maintenance
5.1 Foreword to Maintenance
Maintenance and servicing work involves regular visual checks and clean-ing to ensure that the turbocharger and its attached units function trouble-free.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified intervals.
The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:
Filter silencer Compressor
Cleaning the filter silencer 5.2 Page 2
January 2008
HZTL2
491_EN
Version 5
5.2 Cleaning the filter silencer
5.2.1 Filter silencer with tension band
81136 L 81266 81135 81268 81265 81270 81271 81137 81266 81268 81270 L_01158
81265 Filter ring (if provided) 81266 Cover grids 81270 Tension ring 81136 Fleece segment 38271 Trap cover 81137 Cover panel
Cleaning the filter silencer 5.2 Page 3
January 2008
HZTL2
491_EN
Disassembling and cleaning filter silencer
X Remove filter ring (81265).
X Rinse filter ring (81265) with water using detergent or, if very dirty, soak
it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air is. Wash or replace the filter ring as necessary or every 500 service hours.
X Loosen clamping straps (81270) at tightening point (81271) and
re-move together with mesh covers (81266) and connecting bars (81268).
In the case of a slide-in module (E) when a cleaning container is at-tached to the filter silencer (available as option depending on turbo-charger type), the water injection line must first be removed (see also following section Disassembling cleaning line).
X Withdraw slide-in modules (E), bend open cover plates (81137) and
then take out fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that fleece segments (81136) are cleaned only with a weak jet of compressed air, a soft brush or damp cloth. Other-wise the segments may be damaged or lose their shape.
If provided
NOTE
Cleaning the filter silencer 5.2 Page 4
January 2008
HZTL2
491_EN
Version 5
Mounting filter silencer
X Assemble slide-in modules (E) by inserting fleece segments (81136) in
cover plates (81137).
X Bend cover plates back to their original shape.
X Insert slide-in modules (E) in grooves in filter silencer body (81135).
When the cleaning container is fitted to the filter silencer (available as option depending on turbocharger type), the water injection line must be re-installed (see also following section Assembling cleaning line).
X Fit mesh covers (81266) and connecting bars (81268) onto filter
si-lencer body (81135).
X Pass clamping straps (81270) through eyelets in connecting bars (see
detail L in illustration L_01158).
X Tension all clamping straps at tightening points (81271).
X Fit filter ring (81265).
NOTE
Cleaning the filter silencer 5.2 Page 5
January 2008
HZTL2
491_EN
5.2.2 Removing / installing the cleaning line
L_00192
1 Injection pipe 2 Pipe 3 Guide tube
Cleaning the filter silencer 5.2 Page 6
January 2008
HZTL2
491_EN
Version 5
Disassembling the cleaning line
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Pull line (2) out of the guide tube(3).
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and pull it out.
Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems.
Punching out the guide tube
Cleaning the filter silencer 5.2 Page 7
January 2008
HZTL2
491_EN
Installing the cleaning line
L_00194
X After fitting the slide-in modules (E), fit the guide tube (3) and
re-caulk it.
Cleaning the compressor during operation 5.3 Page 8 January 2008 HZTL2 491_EN Version 5
5.3 Cleaning the compressor during operation
These guidelines for wet cleaning apply exclusively for cleaning with clean water and are subject to permission for the procedure being ob-tained from the engine manufacturer.
The contamination of the compressor stage (compressor wheel and dif-fuser) depends on the cleanness of the air drawn in.
A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air:
Oil or saline mist
Solid combustion residues Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor effi-ciency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consump-tion by the engine. Contaminaconsump-tion of the compressor also increases the rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a se-vere increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is completely dismantled.
The interval between periodic cleaning depends considerably on the op-erating conditions. In general, cleaning should be carried out every 25 to 100 operating hours.
Should the prescribed cleaning intervals prove incompatible with the operation of the engine, please contact ABB Turbo Systems.
NOTE
Interval between clea-nings
Cleaning the compressor during operation 5.3 Page 9 January 2008 HZTL2 491_EN Cleaning method
The compressor is cleaned while operating using the cleaning method de-scribed in the following. This method has been tested and is approved by ABB Turbo Systems:
Wet cleaning
Water is injected before the compressor wheel via an injection pipe fitted in the filter silencer or the suction branch in order to clean the compressor stage in operation.
The water does not act as a solvent in the process, but the deposit is re-moved by the mechanical impact of the drops. The process is ideal, pro-vided the soiling is not too advanced.
Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling addi-tives, which could form deposits in the flow ducts.
If several turbochargers are installed on one engine, we recommend clea-ning the turbocharger compressors one after the other.
Principle of wet cleaning
CAUTION
Cleaning more than one turbocharger compressor
Cleaning the compressor during operation 5.3 Page 10 January 2008 HZTL2 491_EN Version 5
5.3.1 Wet cleaning the compressor with external pressurised water
con-tainer (XC3)
The supply of water with the externally fitted dosing vessel is only suit-able for applications with underpressure before the compressor wheel (not applicable for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).
Operating state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met:
Z Engine loading as full as possible Z High turbocharger speed
X Cleaning cycle started according to the following description in
Pro-cedure for wet cleaning with XC3.
NOTE
Cleaning the compressor during
operation 5.3 Page 11
January 2008
HZTL2
491_EN
Procedure for compressor wet cleaning with XC3
L_00198
X Screw plug Y Valve activator
X The Operating state preconditions for cleaning the compressor with
XC3 must be met before cleaning can begin.
X Remove screw plug (X).
Operating the pressurised water container
Cleaning the compressor during operation 5.3 Page 12 January 2008 HZTL2 491_EN Version 5
If the cleaning operation was not successful, it can be repeated up to 2 times.
If cleaning is still not successfulafter three attempts and the engine op-erating values are unsatisfactory, we recommend that you have the tur-bocharger checked and cleaned by an official ABB Turbo Systems ser-vice station.
Cleaning parameters for each turbocharger compressor
Turbocharger type Turbocharger
speed Contents of the dosing vessel [dm3] Water injection time t1 [s] TPL 69BA 0.4 TPL 73-B TPL 77-B 1 TPL 80-B TPL 85-B TPL 91-B Possible nBmax 2 4 ... 15 NOTE
Cleaning the compressor during
operation 5.3 Page 13
January 2008
HZTL2
491_EN
5.3.2 Wet cleaning compressors using water vessel (XC4)
Operating state preconditions for cleaning compressors with XC4
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met:
Z Engine loading as full as possible Z High turbocharger speed
X Cleaning cycle started according to the following description in
Pro-cedure for wet cleaning with XC4.
Procedure for compressor wet cleaning with XC34 NOTE
Cleaning the compressor during operation 5.3 Page 14 January 2008 HZTL2 491_EN Version 5
If the cleaning container on the filter silencer is used, the detailed clean-ing instructions provided on the plate (4) fitted to the filter silencer should be followed.
X The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin.
X Open lid (5) of the cleaning container (1). X Fill with clean water.
X Screw lid (5) closed.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out. X After cleaning, the turbocharger must be allowed to dry for at least 5
minutes with the engine running before any further activity.
If the cleaning operation was not successful, it can be repeated up to 2 times.
If cleaning is still not successfulafter three attempts and the engine op-erating values are unsatisfactory, we recommend that you have the tur-bocharger checked and cleaned by an official ABB Turbo Systems ser-vice station.
Cleaning parameters for each turbocharger compressor
Turbocharger type Turbocharger
speed Contents of the dosing vessel [dm3] Water injection time t1 [s] TPL 69BA TPL 73-B TPL 77-B 2 TPL 80-B TPL 85-B TPL 91-B Possible nBmax 3 4 ... 15 NOTE
Operation of the cleaning container
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 15
January 2008
HZTL2
491_EN
5.4 Cleaning turbine blades and nozzle ring in
operation
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-bine blades and nozzle rings of the turbochargers.
Soiling increases with time, so that regular and properly performed clean-ing is important to remove the accumulated deposits.
The exhaust gas temperature downstream of the cylinders can rise and the charging pressure at the air receiver can fall if turbine components be-come soiled.
A soiled turbine also results in rotor unbalance. Severe soiling can lead to impermissibly high rotor imbalance.
Experience in operation has shown that despite periodic cleaning during operation, it is impossible to dispense with overhauls during which the tur-bine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended.
The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 50 to 500 operating hours.
The interval between periodic cleaning depends considerably on the op-erating conditions. In general, cleaning should be carried out every 20 to 50 operating hours.
Wet cleaning interval
Cleaning turbine blades and nozzle ring in operation 5.4 Page 16 January 2008 HZTL2 491_EN Version 5 Cleaning methods
Several methods are possible for cleaning the turbine and nozzle ring dur-ing operation. The cleandur-ing methods described in the followdur-ing have been tested and are recommended by ABB Turbo Systems:
Wet cleaning Dry cleaning
During wet cleaning using droplets of water, the water does not act as a solvent. Instead, the deposit is removed by the mechanical impact of the drops.
Due to the risk of corrosion, only clean water may be used and on no account salt water. Furthermore, the water should contain no cooling additives, which could form deposits in the flow ducts.
During dry cleaning using dry solid particles in granulate form, the deposit is removed by the mechanical impact of the grains hitting the surface.
Wet and dry cleaning are equally effective. However, it may be useful to apply both methods together.
Principle of wet cleaning
CAUTION Principle of dry cleaning
Cleaning turbine blades and nozzle ring in operation 5.4 Page 17 January 2008 HZTL2 491_EN
Components at the turbine end are not cleaned until the engine has been started or the engine load reduced. The exhaust temperature must not exceed the value specified in the pertaining cleaning instruc-tions (see respective section Operating state prerequisites).
Failure to maintain the specified exhaust temperature in front of the tur-bine, the minimum stabilising time before as well as between cleaning operations and the drying time after cleaning in accordance with the pertaining cleaning instructions will drastically shorten the expected service life of the components.
If several turbochargers are installed on one engine, we recommend clea-ning the turbocharger turbines with nozzle rings one after the other. NOTE
CAUTION
Cleaning more than one turbocharger turbine
Cleaning turbine blades and nozzle ring in operation 5.4 Page 18 January 2008 HZTL2 491_EN Version 5
5.4.1 Wet cleaning turbine and nozzle ring during operation
The maximum exhaust gas temperature specified by the engine manufac-turer and the TMmax temperature shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning the turbine delivers less power to the shaft and the turbocharger speed sinks. As a result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
Operating state precondition for wet cleaning
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-conditions must be met:
Z After the engine has been started or during operation, the engine
output must be adjusted until the scavenging air pressure pscav is
within the range of 0.3 – 0.6 bar (gauge pressure).
Z Wait 10 to 15 minutes (stabilising time), until the exhaust
tempera-ture at the turbine inlet is stable and below 430°C, the auxiliary blower must also be operating.
X Cleaning cycle started according to the following description in
Pro-cedure for wet cleaning.
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 19
January 2008
HZTL2
491_EN
Procedure for wet cleaning
L_00394
1 Water supply (fresh water
only) at least 6.0 bar 8 Drain pipe 2 Regulating valve 9 Drain cock 3 Manometer 10 Outflow
4 Air supply with 3-way-valve 11 Orifice (integrated in turbo-charger)
5 Stainless-steel pipe 21 Air duct from compressor cas-ing
6 Other turbochargers A Position 1 7 Injection nozzle B Position 2
Cleaning turbine blades and nozzle ring in operation 5.4 Page 20 January 2008 HZTL2 491_EN Version 5
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
valve (2) until the manometer (3) shows a pressure of 1 ± 0.2 bar.
X Inject water for 5 minutes at constant engine output.
X Check whether the exhaust-gas temperature after the turbine drops. X Close the regulating valve (2) and the 3-way-valve (4).
X Set drain cock (9) of the drain pipe (8) on the gas outlet casing to
Posi-tion 2, in order to keep the drain pipe clean with air from the compres-sor casing (21).
X The water supply connection (1) to the regulating valve (2) must be
disconnected.
X After cleaning, wait at least 10 minutes with engine running to allow
turbocharger to dry.
If the cleaning operation was not successful, it can be repeated up to 2 times.
If cleaning is still not successfulafter three attempts and the engine op-erating values are unsatisfactory, we recommend that you have the tur-bocharger checked and cleaned by an official ABB Turbo Systems ser-vice station.
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
Outflow can (but need not) take place through the drain-pipe,
depend-ing on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these cases, the wet cleaning operation must be terminated and the wet cleaning cycle begun again with a lower water pressure or higher engine loading.
NOTE
Points to remember when cleaning
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 21
January 2008
HZTL2
491_EN
5.4.2 Integrated dry cleaning of turbine and nozzle ring during operation
This cleaning method is not suitable for removing thick dirt deposits and must therefore be carried out more often (see chapter Cleaning turbine blades and nozzle ring in operation).
Operating mode prerequisites for integrated dry cleaning device
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-requisites must be met:
Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature upstream of the turbine must be below 590°C.
Otherwise, there is considerable danger that the dry cleaning agent will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for integrated dry cleaning device.
NOTE
Cleaning turbine blades and nozzle ring in operation 5.4 Page 22 January 2008 HZTL2 491_EN Version 5
Operation of integrated dry cleaning device
L_00094
1 Container for granulated
mate-rial 5 ON/OFF valve 2 Trap-cover 6 Safety valve 3 Compressed air supply [4 to 10
bar] 7 Combined air valve/pressure relief valve 4 Pipe made from stainless steel 8 Cleaning instructions
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 23
January 2008
HZTL2
491_EN
Z The Operating mode prerequisites for integrated dry cleaning must be
satisfied before cleaning begins.
X Ensure that the ON/OFF valve (5) is closed.
X Check that combined air valve/pressure relief valve (7) is in pressure
relief position.
X Carefully open trap cover (2).
X Fill container (1) with specified amount of granulate. X Close and seal trap cover (2).
X Open air valve (7). X Open safety valve (6).
X Open ON/OFF valve (5) and leave it open for approx. 1 minute to clean
turbine.
X Close ON/OFF valve (5). X Close safety valve (6).
X Set the combined air valve/pressure relief valve (7) to the pressure
re-lief position.
X Check whether exhaust gas temperature after turbine has dropped.
In order to obtain the best possible cleaning effect, it is essential that the prescribed quantity of granulate is blown in.
The drain openings in the gas outlet casing must remain closed while the turbine is being cleaned. Careless handling can cause incompletely combusted soot particles to escape.
If the cleaning operation was not successful, it can be repeated up to 2 Operation of the dry
cleaning device
Cleaning turbine blades and nozzle ring in operation 5.4 Page 24 January 2008 HZTL2 491_EN Version 5
Cleaning parameters for integrated dry cleaning device
The following materials are suitable for use when dry cleaning:
Hard, granulated materials, such as natural core granulates Softblast media
Activated carbon particles
The mean grain size of the cleaning granulate must be between 1.2 and 2.0 mm.
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
TPL 85-B 3.0
The cleaning granulate must be stored in a dry, clean place in order to avoid clogging the pipes during cleaning.
The table in chapter Suppliers of dry cleaning agents lists possible sup-pliers of dry cleaning agents.
Selection of materials
Amount of granulate per turbocharger [litres]
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 25
January 2008
HZTL2
491_EN
5.4.3 Non-integrated dry cleaning device for turbine and nozzle ring
dur-ing operation
As an alternative to the built-in dry cleaning system, a non-integrated dry cleaning device can be installed in front of the gas inlet casing by the en-gine manufacturer.
Operating mode prerequisites for non-integrated dry cleaning device
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre-requisites must be met:
Z High engine output (50 to 100%) and high turbocharger speed. Z Gas inlet temperature in front of the turbine must be below 590°C.
Otherwise, there is considerable danger that the dry cleaning agent will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for non-integrated dry cleaning device.
Cleaning turbine blades and nozzle ring in operation 5.4 Page 26 January 2008 HZTL2 491_EN Version 5
Operation of non-integrated dry cleaning device
Cleaning turbine blades and nozzle ring
in operation 5.4 Page 27
January 2008
HZTL2
491_EN
1 Trap cover G2“ 6 Strap for securing the container 2 Poss. copper gasket 7 Safety valve with ventilation 3 Double nipple G2“ 8 Compressed air shut-off valve 4 Copper gasket 9 Compressed air pipe
(internal diameter 8mm) 5 Friction cock or slide controller
G1'' 10 Compressed air max. 6 bar
The air system must be protected against overpressure (> 6 bar).
Z The Operating mode prerequisites for non-integrated dry cleaning
de-vice must be satisfied before cleaning begins.
Z Friction cock or slide controller (5) closed and safety valve with
ventila-tion (7) open.
X Close safety valve with ventilation (7). X Tighten trap cover (1).
X Open compressed air shut-off valve (8) so that deposits and any
con-densation are blown off.
X Close compressed air shut-off valve (8) again after about 3 minutes. X Close friction cock / slide controller (5).
X Open safety valve with ventilation (7) to blow out exhaust gases. X Carefully open trap cover (1) on granulate container.
X Fill granulate container with specified quantity of granulate. X Close and seal trap cover (1).
X Close safety valve with ventilation (7). X Open compressed air shut-off valve (8).
X Open friction cock or slide controller (5) for approx. 1 minute. X Close friction cock or slide controller (5).
CAUTION
Operation of the dry cleaning device
