Operation Manual

TPL71-C34

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPL71-C34 HT842511

n Mmax 408 t Mmax 650
1/s °C
n Bmax 389 t Bmax 620

SFUS06 02040 kg 35 50 50
Application according to
Year 2016 the Operation Manual
made in Switzerland
Original Operation Manual
HZTL2488 English

ABB Turbocharging 

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.

Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly 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.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
 Operation Manual / TPL67-C.. - TPL71-C..

Table of contents Page 1

Table of contents
April 2016

1 Preliminary remarks
1.1 Purpose of this manual
1.2 Layout and function
1.3 Intended use of the turbocharger
1.4 Storage of new turbochargers and spare parts
1.5 Essential information
1.6 Symbols and definitions
1.7 Turbocharger rating plate
1.8 Contact information

2 Safety
HZTL2488_EN

2.1 Introduction
2.2 CE conformity
2.3 Definition of mandatory signs
2.4 Definition of Safety instructions
2.5 Warning plates on the turbocharger
2.6 Safe operation and maintenance
2.7 Hazards during operation and maintenance
2.8 Periodic checking of the pressure vessel
2.9 Lifting loads

3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Commissioning after taking out of operation
Revision C

4 Operation
4.1 Noise emissions
4.2 Servicing work
4.3 Replacement intervals for turbocharger components
4.4 Speed measurement
4.5 Stopping the engine

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..

Table of contents Page 2

5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer

April 2016
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation

6 Troubleshooting
6.1 Malfunctions when starting
6.2 Surging of the turbocharger
6.3 Malfunctions during operation
6.4 Malfunctions when stopping
6.5 Speed measurement system

7 Removal and installation

7.1 Turbocharger weights
7.2 Remove the turbocharger

HZTL2488_EN
7.3 Installing the turbocharger

8 Disassembly and assembly

8.1 Introduction
8.2 Module weights
8.3 Removing and fitting filter silencer or air suction branch
8.4 Axial clearance
8.5 Removing cartridge group
8.6 Dismantling and installing the turbine diffuser and nozzle ring
8.7 Installing cartridge group
8.8 Dismantling and fitting nozzle ring at turbine end
8.9 Table of tightening torques

9 Taking out of operation at short notice

Revision C

9.1 Possibilities for emergency repair

9.2 Locking the rotor
9.3 Fit cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..

Table of contents Page 3

10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
April 2016

11 Disposing of turbocharger components

12 Spare parts
12.1 Ordering spare parts
12.2 View of turbocharger with part numbers
12.3 View of turbine cleaning system with part numbers (optional)
HZTL2488_EN
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Maintenance 5

Foreword to Maintenance 5.1 Page 51

5 Maintenance
5.1 Foreword to Maintenance
April 2016

5.1

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:

HZTL2488_EN

 Filter silencer
 Compressor
 Turbine and nozzle ring
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Maintenance 5

Cleaning the filter silencer 5.2 Page 52

5.2
5.2 Cleaning the filter silencer

April 2016
5.2.1 Filter silencer and connecting rod

HZTL2488_EN
81265 Filter ring (if provided) 81136 Absorption segment
81269 Connecting rods 81137 Sheet-metal covering
81266 Cover grid 81135 Filter silencer body
81272 Screwdriver 81273 Lock nut
E Insert unit = absorption segment + sheet­metal covering
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Maintenance 5

Cleaning the filter silencer 5.2 Page 53

Removing and cleaning filter silencer

April 2016

If provided  Remove filter strip (81265).

 Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid
rough treatment (not a jet of water).

How dirty the filter strip (81265) is, depends on how clean the drawn-in
air is. Clean filter strip every 500 hours of service or more frequently if
necessary.
NOTICE

 Unscrew and remove lock nuts (81273).

 Unscrew and remove screws (81272) for connecting rods (81269).
 Remove connecting rods (81269).
 Carefully remove cover grids (81266).
HZTL2488_EN

 Pull out insert units (E), bend open sheet-metal coverings (81137) and
then remove absorption segments (81136).
 Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
Otherwise there is a risk of damage or deformation.

Replace heavily contaminated or damaged parts with original parts from

ABB Turbo Systems.

NOTICE
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Maintenance 5

Cleaning the filter silencer 5.2 Page 54

Fitting the filter silencer

 Assemble the insert units (E) by inserting the absorption segments

(81136) into the sheet metal coverings (81137).

April 2016
 Bend sheet metal coverings (81137) back to original shape.
 Insert the insert units (E) into slot guides in filter silencer unit (81135).

HZTL2488_EN
 Uniformly place cover grids (81266) in correct position.
 Push connecting rods (81269) through lugs of cover grids (81266).

If the connecting rods (81269) are not correctly positioned in their re-
cesses on the filter silencer unit (81135), the cover grid (81266) can
twist and shift. There is then a risk of foreign matter and contamination
getting into the compressor.
CAUTION

 Join connecting rods (81269) using screws (81272). When tightening

the screws (81272), ensure that connecting rods (81269) are located
correctly in recesses in filter silencer body (81135). Now tighten
screws (81272) alternately until the following maximum torque is
Revision C

reached:
Screw Tightening torque [Nm]
81272 20

 Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice 9

Fit cover plate 9.3 Page 109

9.3
9.3 Fit cover plate
The cover plate (material: General structural steel, in accordance with
April 2016

DIN EN 10025-2) must be manufactured in-house according to the

drawing.
NOTICE
HZTL2488_EN

Cover plate dimensions

Product B1 B2 B3 B4 B5 B6 B7 B8
[mm]
TPL67-C 13 325 30 30 8 10 6 70
TPL71-C 13 385 30 30 8 10 6 84

Product Ø1 Ø2 Ø3 Ø4 Ø 5 min. Ø 6 min.

Revision C

TPL67-C 616 694 660 16 22 15

TPL71-C 726 818 779 18 25 15

Product ⍺1 ⍺2 ⍺3
TPL67-C 4 x 90° 37.5° 24 x 15°
TPL71-C 4 x 90° 37.5° 24 x 15°

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice 9

Fit cover plate 9.3 Page 110

April 2016
HZTL2488_EN
Carry out the work as described in the chapter Disassembly and As-
sembly.

NOTICE

 Removing the cartridge group

Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice 9

Fit cover plate 9.3 Page 111

April 2016
HZTL2488_EN

 Close opening in gas outlet casing using cover plate.

 Fasten cover plate using spacer sleeves and nuts (61037).

Shut off the supply of lubricating oil to the turbocharger.

CAUTION
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Taking out of operation at short notice 9

Fit cover plate 9.3 Page 112

Further measures and information for operation with a turbocharger with

cover plate on 4-stroke engines

April 2016
4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.

4-stroke engine with several turbochargers

Separate receivers No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.

Common receiver The air line must be closed off at the engine end because the undamaged
turbochargers build up a receiver pressure.

HZTL2488_EN
The engine can be operated according to the engine builder's instruc-
tions. Attention must always be paid to the speed of the undamaged
turbocharger. The speed limit nBmax given on the rating plate must not
be exceeded.
CAUTION

Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Spare parts 12

View of turbocharger with part numbers 12.2 Page 122

12.2
12.2 View of turbocharger with part numbers

April 2016
HZTL2488_EN
Revision C

© Copyright 2016 ABB. All rights reserved.

 Operation Manual / TPL67-C.. - TPL71-C..
Spare parts 12

View of turbocharger with part numbers 12.2 Page 123

Part number Description

42012 (in customer spare part set) O-ring
51001 Gas inlet casing
April 2016

51012 Segment
56001 Nozzle ring
61001 Gas outlet casing
61037 (in customer spare part set) Hexagon nut
61044 Hexagon-head screw
61050 (if provided) Gasket
61056 (in customer spare part set) Hexagon-head screw
61057 (in customer spare part set) Verbus Ripp® Washer
61058 (in customer spare part set) Verbus Ripp® Washer
61059 (in customer spare part set) Hexagon-head screw
63000 Turbine diffuser
68001 Foot at compressor end
68002 Foot at turbine end
HZTL2488_EN

68003 Slide plate

68006 Cup spring
68007 Bush
72000 Compressor casing
77000 Wall insert
77005 (in customer spare part set) O-ring
79000 Diffuser
81000 Filter silencer
82000 Radial air suction branch
Revision C

© Copyright 2016 ABB. All rights reserved.