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Monday, January 30, 2012

1.4 Essential information


Organisational measures
In 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 equipment.

NOTE

" The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual. "

  • The turbocharger must be shut down immediately in the event of alterations affecting safety or of corresponding operating behaviour. The fault should be reported to the person or department responsible.
NOTE

" Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems."

Original parts and safety
Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems Ltd.

NOTE

" If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer should be followed."


WARNING

" If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the technical 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 authorized personnel.

CAUTION

" Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems Ltd.!"


It must be ensured that only authorized personnel work on the turbocharger.

After-sales service
The Contact Information brochure contains an overview of official ABB Turbo Systems Ltd. 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 operating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relating
specifically to your model.

Accuracy of illustrations
The graphics and images shown in this operation manual are of a general nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.

Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems Ltd. can be stored without additional safeguarding measures for a period of 6 months after the delivery date.
Ensure that the storage area is dry with humidity of 40-70% and free of condensation.
  1. After 6 months, rust-proofing oil should be sprayed on exposed surfaces and all accessible areas of the turbocharger.
  2. To do this, the insulating materials must be removed.

NOTE

" Repeat the steps described for rust-proofing your turbocharger every 6 months."


          1. Purpose of the manual
          2. Layout and function
          3. Correct use of the turbocharger
          4. Essential information
          5. Abbreviations and symbols
          6. Turbocharger rating plate
          1. Basic safety instructions
          2. General safety instructions
          3. Special safety instructions
          4. Safety instructions and hazard protection
          5. Warnings on the turbocharger
          1. Oil supply
          2. Inspection work
          3. Putting into operation after laying up
          1. Servicing work
          2. Monitoring
          3. Emergency mode TPL..VA
          4. Surging of turbocharger
          5. Contact with rotating parts
          6. Shutting the engine down
          1. Foreword to MaintenanceServicing work
          2. Cleaning the filter silencer
          3. Cleaning the compressor during operation
          4. Cleaning turbines and guide blades in operation
          1. Possible remedies for failures
          1. Turbocharger weights
          2. Remove the turbocharger
          3. Installing the turbocharger
          1. Module weights
          2. Remove filter silencer/air suction branch and compressor casing
          3. Removing cartridge group
          4. Axial clearance
          5. Disassembling and assembling the turbine diffuser
          6. Dismantle the VTG unit together with the gas inlet casing
          7. Installing the VTG unit and gas inlet casing
          8. Installing the cartridge group
          9. Install filter silencer/air suction branch and compressor casing
          10. Table of tightening torques
          1. Possibilities for emergency repair
          2. Fitting the cover plate
          3. Blocking the inlets and outlets
          4. Bypass the turbocharger
          1. Taking out of operation for up to 12 months
          2. Taking out of operation for more than 12 months
          1. Ordering spare parts
          2. Directory of part numbers
          3. General view of turbocharger
          4. General view of cartridge group
          5. General view of VTG unit





1.3 Correct use of the turbocharger



NOTE

" This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.

The engine manufacturer has provided ABB Turbo Systems with information 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.
If it is used in conjunction with a gas engine, the engine must not be installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive.

 Any other usage shall be regarded as a special application which must be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty. "


Latest technology

This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations.

WARNING
" 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 operated by trained personnel. "

Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.

Perfect condition
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 compliance with the Operation Manual.
  • Defects which could affect safety must be eliminated immediately.

The manufacturer shall not accept liability for damages resulting from unauthorized alterations to the turbocharger.


          1. Purpose of the manual
          2. Layout and function
          3. Correct use of the turbocharger
          4. Essential information
          5. Abbreviations and symbols
          6. Turbocharger rating plate
          1. Basic safety instructions
          2. General safety instructions
          3. Special safety instructions
          4. Safety instructions and hazard protection
          5. Warnings on the turbocharger
          1. Oil supply
          2. Inspection work
          3. Putting into operation after laying up
          1. Servicing work
          2. Monitoring
          3. Emergency mode TPL..VA
          4. Surging of turbocharger
          5. Contact with rotating parts
          6. Shutting the engine down
          1. Foreword to MaintenanceServicing work
          2. Cleaning the filter silencer
          3. Cleaning the compressor during operation
          4. Cleaning turbines and guide blades in operation
          1. Possible remedies for failures
          1. Turbocharger weights
          2. Remove the turbocharger
          3. Installing the turbocharger
          1. Module weights
          2. Remove filter silencer/air suction branch and compressor casing
          3. Removing cartridge group
          4. Axial clearance
          5. Disassembling and assembling the turbine diffuser
          6. Dismantle the VTG unit together with the gas inlet casing
          7. Installing the VTG unit and gas inlet casing
          8. Installing the cartridge group
          9. Install filter silencer/air suction branch and compressor casing
          10. Table of tightening torques
          1. Possibilities for emergency repair
          2. Fitting the cover plate
          3. Blocking the inlets and outlets
          4. Bypass the turbocharger
          1. Taking out of operation for up to 12 months
          2. Taking out of operation for more than 12 months
          1. Ordering spare parts
          2. Directory of part numbers
          3. General view of turbocharger
          4. General view of cartridge group
          5. General view of VTG unit






1.2 Layout and function


Layout of ABB TC

1
Filter silencer
8
Nozzle ring
2
Radial plain bearing
9
Turbine wheel
3
Thrust bearing
10
Bearing casing
4
Bearing bush
11
Diffuser
5
Radial plain bearing
12
Compressor wheel
6
Gas outlet casing
13
Air outlet casing
7
Gas inlet casing




Mode of operation
The turbocharger is a turbo-machine and consists of the following main components:
  1. Turbine
  2. Compressor
These are both mounted on a common shaft. The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel.

The turbine wheel (9) uses the energy contained in the exhaust gas to drive the compressor wheel (12), whereby the compressor draws in fresh air, and the compressed air is forced into the cylinders.

The exhaust gases escape through the exhaust pipe which is connected to the gas outlet casing (6).

The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch or the filter silencer (1) into the compressor wheel (12). It then passes through the diffuser (11) and leaves the turbocharger through the compressor outlet on the air outlet casing (13).

The rotor runs in two radial plain bearings (2/5) which are located in the bearing bush (4) 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 supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (10).

These turbocharger types are equipped with adjustable guide vanes instead of a nozzle ring.



          1. Purpose of the manual
          2. Layout and function
          3. Correct use of the turbocharger
          4. Essential information
          5. Abbreviations and symbols
          6. Turbocharger rating plate
          1. Basic safety instructions
          2. General safety instructions
          3. Special safety instructions
          4. Safety instructions and hazard protection
          5. Warnings on the turbocharger
          1. Oil supply
          2. Inspection work
          3. Putting into operation after laying up
          1. Servicing work
          2. Monitoring
          3. Emergency mode TPL..VA
          4. Surging of turbocharger
          5. Contact with rotating parts
          6. Shutting the engine down
          1. Foreword to MaintenanceServicing work
          2. Cleaning the filter silencer
          3. Cleaning the compressor during operation
          4. Cleaning turbines and guide blades in operation
          1. Possible remedies for failures
          1. Turbocharger weights
          2. Remove the turbocharger
          3. Installing the turbocharger
          1. Module weights
          2. Remove filter silencer/air suction branch and compressor casing
          3. Removing cartridge group
          4. Axial clearance
          5. Disassembling and assembling the turbine diffuser
          6. Dismantle the VTG unit together with the gas inlet casing
          7. Installing the VTG unit and gas inlet casing
          8. Installing the cartridge group
          9. Install filter silencer/air suction branch and compressor casing
          10. Table of tightening torques
          1. Possibilities for emergency repair
          2. Fitting the cover plate
          3. Blocking the inlets and outlets
          4. Bypass the turbocharger
          1. Taking out of operation for up to 12 months
          2. Taking out of operation for more than 12 months
          1. Ordering spare parts
          2. Directory of part numbers
          3. General view of turbocharger
          4. General view of cartridge group
          5. General view of VTG unit



Sunday, January 29, 2012

1.1 Purpose of the manual


Operation manual
This operation manual will help you to become familiar with your ABB Turbo Systems Ltd turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and economical operation of the turbocharger.

Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon.

Content of operation manual
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 awareness and avoidance of hazards.
  •     Minimizing repair costs and failure times.

This operation manual is a complement to, and an extension of, existing national regulations on accident protection and prevention.

IMPORTANT

" 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 turbocharger. Personnel who only work occasionally on the machine (e.g. during installation and maintenance) must also have read and fully understood the operating manual before beginning work. "

The instructions included in this operation manual must be followed under all circumstances.



WARNING

" This applies especially to the general and special safety instructions preceding and in the respective chapters. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. "



          1. Purpose of the manual
          2. Layout and function
          3. Correct use of the turbocharger
          4. Essential information
          5. Abbreviations and symbols
          6. Turbocharger rating plate
          1. Basic safety instructions
          2. General safety instructions
          3. Special safety instructions
          4. Safety instructions and hazard protection
          5. Warnings on the turbocharger
          1. Oil supply
          2. Inspection work
          3. Putting into operation after laying up
          1. Servicing work
          2. Monitoring
          3. Emergency mode TPL..VA
          4. Surging of turbocharger
          5. Contact with rotating parts
          6. Shutting the engine down
          1. Foreword to MaintenanceServicing work
          2. Cleaning the filter silencer
          3. Cleaning the compressor during operation
          4. Cleaning turbines and guide blades in operation
          1. Possible remedies for failures
          1. Turbocharger weights
          2. Remove the turbocharger
          3. Installing the turbocharger
          1. Module weights
          2. Remove filter silencer/air suction branch and compressor casing
          3. Removing cartridge group
          4. Axial clearance
          5. Disassembling and assembling the turbine diffuser
          6. Dismantle the VTG unit together with the gas inlet casing
          7. Installing the VTG unit and gas inlet casing
          8. Installing the cartridge group
          9. Install filter silencer/air suction branch and compressor casing
          10. Table of tightening torques
          1. Possibilities for emergency repair
          2. Fitting the cover plate
          3. Blocking the inlets and outlets
          4. Bypass the turbocharger
          1. Taking out of operation for up to 12 months
          2. Taking out of operation for more than 12 months
          1. Ordering spare parts
          2. Directory of part numbers
          3. General view of turbocharger
          4. General view of cartridge group
          5. General view of VTG unit





List of contents (ABB Turbocharger)



1.0  Preliminary remarks


1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate

2.0 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


3.0 Commissioning

3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up

4.0 Operation

4.1 Servicing work
4.2 Monitoring
4.3 Emergency mode TPL..VA
4.4 Surging of turbocharger
4.5 Contact with rotating parts
4.6 Shutting the engine down

5.0 Maintenance

5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbines and guide blades in operation

6.0 Troubleshooting

6.1 Possible remedies for failures


7.0 Removal and installation

7.1 Turbocharger weights
7.2 Remove the turbocharger
7.3 Installing the turbocharger

8.0 Disassembly and assembly

8.1 Module weights
8.2 Remove filter silencer/air suction branch and compressor casing
8.3 Removing cartridge group
8.4 Axial clearance
8.5 Disassembling and assembling the turbine diffuser
8.6 Dismantle the VTG unit together with the gas inlet casing
8.7 Installing the VTG unit and gas inlet casing
8.8 Installing the cartridge group
8.9 Install filter silencer/air suction branch and compressor casing
8.10 Table of tightening torques


9.0 Taking out of operation temporarily

9.1 Possibilities for emergency repair
9.2 Fitting the cover plate
9.3 Blocking the inlets and outlets
9.4 Bypass the turbocharger


10.0 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

11.0 Reserve and spare parts

11.1 Ordering spare parts
11.2 Directory of part numbers
11.3 General view of turbocharger
11.4 General view of cartridge group
11.5 General view of VTG unit



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