Abb A135-H55 User Manual

Operation Manual

A135-H55

HT582518 English

Original Operation Manual

Chapter Document-ID

1 Introduction

2 Safety

3 Safety data sheet

4 Product description

HZTL4005_EN_F

HZTL4022_EN_E

HT582518

HZTL4030_EN_E

ABB Turbocharging

Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product.

Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpredictable component failures.

Operation Manual / 1 Introduction

Table of contents

Introduction

1 Introduction............................................................................................................ 2

1.1 Purpose of the manual.................................................................................................. 2

1.2 Symbols, definitions...................................................................................................... 3

1.3 Storage of new turbochargers and spare parts...................................................... 5

1.4 Contact information...................................................................................................... 7

Operation Manual / 1 Introduction

1 Introduction / 1.1 Purpose of the manual

1 Introduction

1.1 Purpose of the manual

Fig.1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), see chapter 3 (Safety data sheet) and the rating plate on the turbocharger.

Operation Manual

The Operation Manual explains the turbocharger and contains instructions for safe opera-

Page 2 / 7

tion.

The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read and fully understood the Operation Manual.

Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

u Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number.

Definition of Note

NOTICE

Note

The note provides advice which facilitates the work.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs are described in chapter Safety and must be complied with.

Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

ABB Turbo Systems

ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.

Official service stations of ABB Turbo Systems

Official service stations are identified in this document as ABB Turbocharging Service Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-

tact information →7.

Page 3 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

Definition of pictograms

The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning Pictogram Meaning

Tighten with specified torque Affix

Tighten over specified tightening angle

Hand-tight, tighten without tools

Oil Visually inspect

Apply screw locking paste (e.g. Loctite)

Apply high-temperature grease See document

Apply other paste in accordance with specifications

Oil free, grease free and dry

Table1: Definition of pictograms

Measure

Note

Please note text for numbered work step

Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations

Page 4 / 7

Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts for up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months from the date of delivery without additional mothballing measures, indicated by the VCI label on the package.

Fig.2: Volatile Corrosion Inhibitor (VCI)

Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can form, are suitable as storage locations.

Storage of new turbochargers and spare parts for more than 6 months

WARNING

Health protection when handling VCI

VCI products are not hazardous in terms of the Ordinance on Hazardous Substances. Nevertheless, the following points must be observed when handling VCI:

u Observe information in material safety data sheet

u Ensure proper space ventilation.

u Do not eat, drink or store food at the workplace while working with VCI.

u Clean hands and face after working with VCI.

u For more information, see www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

u Open package.

u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-

sion protection emitter of the same kind. New VCI corrosion protection emitters can be obtained from www.branopac.com.

u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-

ible, professional way and in compliance with locally applicable regulations.

Page 5 / 7

u Close package. The more tightly the package is sealed, the longer the protection dura-

tion.

Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

Long-term storage of replacement turbochargers or spare parts

The turbochargers or cartridge groups will be prepared for long-term storage if requested in the purchase order. The package is equipped with a hygrometer (see illustration).

Fig.3: Package with hygrometer

Every 6 months, the following measures are required:

u Check the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden

crate to enable you to perform this check. If the 70% indicator field has changed colour, the maximum admissible atmospheric humidity has been exceeded. In this case, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station.

u Check the package for damage. If the package is damaged, the turbocharger or cartridge

group must be checked and repackaged by an ABB Turbocharging Service Station.

After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station:

Page 6 / 7

¡ Checking the component

¡ Replacing the desiccant

¡ Repackaging the component.

NOTICE

Replacement components which are ready for operation

If the 70% field of the hygrometer(02) has not changed colour and the package is not damaged, the replacement turbocharger or replacement cartridge group can be put into operation without previously having been checked by an ABB Turbocharging Service Station.

Unpackaging replacement turbochargers or spare parts

Once the material has been unpackaged from the VCI package, the corrosion protection is no longer effective.

To prevent condensation, the temperature of the package contents must be the same as the ambient temperature.

Operation Manual / 1 Introduction

1 Introduction / 1.4 Contact information

1.4 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.

u Scan the QR code to access our website.

ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland

www.abb.com/turbocharging

Page 7 / 7

Operation Manual / 2 Safety / A130 - A155

Table of contents

Safety

1 Safety ...................................................................................................................... 2

1.1 Introduction .................................................................................................................... 2

1.2 CE conformity................................................................................................................. 2

1.3 Definition of mandatory signs .................................................................................... 3

1.4 Definition of safety instructions ................................................................................ 3

1.5 Intended use .................................................................................................................. 4

1.6 Deflagration on gas engines ....................................................................................... 5

1.7 Warning plates on the turbocharger......................................................................... 6

1.8 Turbocharger rating plate............................................................................................ 7

1.9 Periodic check of the pressure vessels..................................................................... 8

1.10 Lifting of loads .............................................................................................................. 9

1.11 Prerequisites for operation and maintenance....................................................... 10

1.12 Hazards during operation and maintenance ......................................................... 11

1.13 Safe operation.............................................................................................................. 13

1.14 Safe maintenance ........................................................................................................ 15

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.1 Introduction

1 Safety

1.1 Introduction

Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which:

¡ Are caused by the turbocharger itself or its accessories. ¡ Are caused by the operating equipment used or supplies and materials. ¡ Are a consequence of insufficient compliance with safety instructions. ¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-

spection work.

The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger.

Page 2 / 18

All instructions contained in this chapter must be observed for safe and trouble-free operation of the turbocharger and during all work on the turbocharger.

All further safety instructions contained and specifically identified in every chapter of this manual (Definition of safety instructions →3) must also be observed.

1.2 CE conformity

Information

ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g in this directive.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.3 Definition of mandatory signs

1.3 Definition of mandatory signs

To be worn at all times

Protective clothing Safety footwear to protect

against mechanical hazard and risk of falling

Table1: Personal protective equipment to be worn at all times

To be worn specific to the respective task

Safety glasses Safety goggles

Safety gloves to protect

against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Safety helmet Ear protection

Table2: Personal protective equipment to be worn specific to the respective task

Respiratory mask to protect against

- Dusts

- Gases

1.4 Definition of safety instructions

WARNING

Definition of Warning

Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents.

u Warning signs must always be observed.

Page 3 / 18

CAUTION

Definition of Caution

Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences.

u Caution signs must always be observed.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.5 Intended use

1.5 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging internal combustion engines.

To ensure compliance with the machinery directive 2006/42/EC when using on gas engines, the turbocharger must be operated in an engine room classified as "not at risk of explosion". This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT[1].

For use on pre-mix gas engines with ignitable propellents in the gas control system, the enginebuilder must implement appropriate safety measures for explosion protection [3] (such as flame barriers in the inlet system, for example) to assure that there is no transient pressure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagration.

The turbocharger supplies the engine with the air volume or air/gas mixture and the associated charging pressure required for operation.

Page 4 / 18

The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end.

The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate.

ABB accepts no liability and rejects all warranty claims for any non-intended uses.

[1] Euromot = The European Association of Internal Combustion Engine Manufacturers

[2] Directive 94/9/EC concerning equipment and protective systems intended for use in

potentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX Euromot Position 191103

[3] Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen,

1991

WARNING

Unapproved operation

Any operation of the turbocharger outside of its operating limits can be hazardous to personnel.

u Only operate the turbocharger within the operating limits. u Only trained personnel must operate the turbocharger.

The intended use of the turbocharger includes compliance with all regulations and conditions. In particular, the following must be observed:

¡ Operation Manual ¡ Instructions of the enginebuilder

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.6 Deflagration on gas engines

State of the art

The turbocharger is designed and manufactured according to the state of the art and is safe to operate.

Perfect condition

The turbocharger must only be used when it is in a technically flawless condition and operated in compliance with its intended use.

ABB excludes any liability for damage resulting from unauthorized modifications to the turbocharger or improper operation.

1.6 Deflagration on gas engines

ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12bar.

After a deflagration event ABB Turbo Systems recommends verifying the following points on the turbocharger:

¡ Position of the turbine and compressor casings to the bearing casing ¡ Shifting of the bearing casing in relation to the bracket ¡ Cracks in casings

If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.

Page 5 / 18

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.7 Warning plates on the turbocharger

1.7 Warning plates on the turbocharger

Warning plates are attached to the turbocharger, which must be observed. The warning plates must always be present in the intended locations and must be legible.

Fig.1: Warning plate

If warning plates are not present in the intended locations or are not legible, they must be replaced with new warning plates. The necessary information can be found in the Operation Manual, Chapter 4 Product description.

Page 6 / 18

Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.8 Turbocharger rating plate

1.8 Turbocharger rating plate

Fig.2: Rating plate

Operating limits

01 Turbocharger operating limits at engine overload (110%).

In test rig operation only, unless otherwise agreed with the enginebuilder.

02 Turbocharger operating limits during operation

Recommended inspection and replacement intervals of turbocharger components

03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h

Further data

06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 Manufacturing plant

Page 7 / 18

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.9 Periodic check of the pressure vessels

Explanations regarding the rating plate

The recommended inspection and replacement intervals and the corresponding operating limits are jointly defined with the enginebuilder. This information is specific to the system.

Page 8 / 18

Operation above the indicated values n

Bmax

, t

can considerably shorten the recommended

Bmax

replacement intervals. In such a case, we recommend that you contact the nearest official service station of ABB Turbo Systems.

, t

Mmax

normally apply only when running at overload (110%) during trials on the engine

Mmax

test bed. These limit values can also be permitted during operation for special applications. Operation above n

Mmax

and t

is not permitted.

Mmax

Non-observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures.

Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description.

1.9 Periodic check of the pressure vessels

The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels

must be observed.

¡ The operating company is responsible for the safe operation of the pressure vessel.

WARNING

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in proper working condition and monitor them. Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken.

u Pressure equipment must not be operated if defects are present.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.10 Lifting of loads

1.10 Lifting of loads

WARNING

Suspended loads

Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.

u Loads must always be fastened to properly functional lifting gear with a

sufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook. u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Fig.3: Attachment of loads on the crane hook

Fig.4: Attachment angle

If there are two or more suspension points, the attachment angle of 45° must not be exceeded. This prevents excessive loading due to diagonal pull.

u Before looping around the components of the turbocharger, let them cool down (max-

imum 80°C).

u Attach components of the turbocharger as described in the respective action steps. u Use a suitable edge guard if there are sharp edges. u The assembly devices must be completely screwed in and must not unscrew during use.

Page 9 / 18

u Use assembly devices only for the described applications. u Put down dismantled components of the turbocharger in such a way that they cannot tip

over.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.11 Prerequisites for operation and maintenance

1.11 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorised personnel work on the turbocharger, who:

¡ Are versed in the general and locally applicable regulations for occupational safety and

accident prevention

¡ Are equipped with the prescribed personal protective equipment ¡ Have read and understood the Operation Manual ¡ Have been instructed in the use of the turbocharger.

The safety-conscious work of the personnel and adherence to the Operation Manual must be checked periodically.

Suitable working materials and personal protective equipment must be kept in a perfect condition.

Page 10 / 18

Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running.

Competence of personnel

The turbocharger must only be operated and serviced by trained and authorised personnel. Basic mechanical training is a prerequisite.

Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB Turbo Systems.

WARNING

Use original parts

Operation of the turbocharger with non-original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel.

u Only use original parts from ABB Turbo Systems.

Original parts and accessories are specially designed by ABB Turbo Systems for the ABB turbochargers.

ABB accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.12 Hazards during operation and maintenance

1.12 Hazards during operation and maintenance

Noise hazards

The turbocharger's noise emission during operation is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.

WARNING

Danger due to noise

Exposure to noise can harm the hearing system, impair health and the psychological state and may lead to lack of attention and irritation.

u When the engine is running, always wear ear protection. u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot during operation. The surface temperature depends on the efficacy of the existing insulation. The temperature may rise to a level that can cause burns.

WARNING

Danger of burns

Touching hot surfaces or contact with hot operating fluids can cause burns.

u Do not touch hot surfaces. Observe the warning plate on the turbochar-

ger.

u Wear heat-resistant safety gloves and protective clothing. u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

Page 11 / 18

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.12 Hazards during operation and maintenance

WARNING

Hot surfaces on the non-insulated turbocharger

Non-insulated turbochargers can cause serious injuries to personnel (burns). The turbocharger is supplied with or without insulation in accordance with

the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.

u Compliance with the instructions and specifications given by the en-

ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Hazards due to rotating parts

Page 12 / 18

WARNING

Physical hazards

Contact with rotating parts can cause severe injury. The turbocharger must never be used without the filter silencer or the air suction branch. With the engine stopped, the rotor can rotate due to the stack draught alone.

u Operate the turbocharger in compliance with the specifications. u Secure the rotor against unintentional rotation during maintenance.

Wear safety gloves to protect against mechanical hazards.

Hazards due to electrical installations (if present)

WARNING

Dangers during work on electrical installations

Electrical installations use voltages that can lead to severe injury to personnel or accidents resulting in fatalities.

At the same time, electrical or electronic components and parts can also be damaged or destroyed.

u Only specially trained personnel should perform work on, or with, elec-

trical components.

u Observe national regulations.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.13 Safe operation

WARNING

Absence of grounding on electrical installations

Missing or incorrectly fitted grounding conductors can lead to severe injury to personnel or accidents resulting in fatalities.

Electric shock or elevated electromagnetic disturbances can damage or destroy electrical and electronic components.

u Ground electrical installations properly with grounding conductors. u Check the grounding connections on a regular basis and make sure they

are properly connected.

u Switch off the power supply before working on any electrical installations. u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge

and hot components to cool down.

u Ensure the power supply is switched off when working on electrical installations. u Do not carry out any tests with regard to insulation resistance or voltage on the electrical

components.

1.13 Safe operation

Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it has been properly installed.

Safety during commissioning and operation

u Visually inspect your working environment before starting work. u Remove any obstacles and objects littering the workplace. u Check all pipes to and from the turbocharger for damage and leaks before commission-

ing.

u Check turbocharger for recognisable damage or defects every 12 hours of operation or at

least once a day.

u Report any damage and any alterations of operational characteristics to the responsible

department immediately.

u In case of damage, take the turbocharger out of operation immediately and safeguard

against accidental/unauthorised use.

u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-

tention to the risks that may occur as a consequence of this energy input.

Page 13 / 18

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.13 Safe operation

WARNING

Burst protection and insulation

Operation without burst protection and insulation or with the wrong combination of burst protection and insulation can cause serious injuries to persons or even fatal accidents.

u Only operate the turbocharger with burst protection fitted and insulation

fitted in one of the following, permitted variants.

Fig.5

Page 14 / 18

Variant A Insulation(01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection(03) and insulation (02)from ABB Turbo Systems. Variant C Burst protection(03) from ABB Turbo Systems with appropriate insulation

from the enginebuilder.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

1.14 Safe maintenance

Occupational safety

WARNING

Injuries to persons

Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedures or non-compliance with safety and health standards.

u When working on the turbocharger always wear safety footwear and pro-

tective clothing to protect against mechanical hazards.

u Keep personal protective equipment in perfect condition. u Obey mandatory signs. u Observe the general rules for occupational safety and prevention of acci-

dents.

u Only perform operations that are described in this manual. u Only perform operations for which you have received instruction or train-

ing.

Wear safety footwear to protect against mechanical hazard and risk of falling.

Wear protective clothing.

WARNING

Risk of falling

When working on the turbocharger, there is a risk of falling.

u Do not climb onto the turbocharger or onto attached parts and do not

use them as climbing aids.

u Use suitable climbing aids and working platforms for work above body

height.

u Comply with the general accident prevention regulations. u Only perform work on the turbocharger when you are in a physically and psychologically

stable condition.

u Only work with suitable tools, equipment and appliances that function properly. u Power tools must be grounded and cables must be undamaged. u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

Page 15 / 18

u Keep the floor, equipment, and turbocharger clean. u Have oil binding agents ready and provide or keep oil pans at hand. u Clean up any spills. u Have fire protection means and extinguishing agents available.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter

silencer to prevent the filter mat from being damaged.

u Keep flammable objects and substances out of the vicinity of flying sparks. u Cover all connections on the turbocharger so that no foreign objects can enter the tur-

bocharger.

u Wear personal protective equipment (PPE) for welding operations.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section Hazards due to operating materials and supplies must be observed.

u Observe the material safety data sheet for the cleaning agent or solvent. u Wear personal protective equipment (PPE) according to the material safety data sheet.

Page 16 / 18

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-

vals.

u Inform the operating staff before starting any service or repair work. Make sure the en-

gine is not started while work is being conducted on the turbocharger.

u Before taking off any cover or removing any guard from the turbocharger, switch off the

engine and wait until the turbocharger has come to a standstill.

u Make sure that the oil supply is interrupted, especially with an external oil supply. u Only restart the engine after all parts have been properly fitted again and oil supply is en-

sured.

CAUTION

Mechanical operations on the turbocharger

Components of the turbocharger can be damaged or destroyed as a result of improper procedures.

u Only perform operations that are described in this manual. u Only perform operations for which you have received instruction or train-

ing.

Safety when taking out of operation or preparing for mothballing

u Secure rotor against turning. The rotor can rotate due to the stack draught alone. u Observe the material safety data sheet for the cleaning and mothballing agents. u Wear personal protective equipment (PPE) according to the material safety data sheet.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

Mechanical hazards when working on the turbocharger

WARNING

Physical hazards due to rotating parts

The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury.

u Secure rotor against turning.

WARNING

Mechanical hazards

Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedures.

u Observe the general rules for occupational safety and prevention of acci-

dents.

u Ensure workplace safety. u Only perform operations that are described in this chapter. u Only perform operations for which you have previously received instruc-

tion or training.

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation of the turbocharger or for the performance of maintenance work. Oils, greases, coolants, detergents and solvents, acids and similar substances can be classified as hazardous substances.

WARNING

Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin. u Ensure proper ventilation. u Observe the information in the material safety data sheet for the operat-

ing materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Page 17 / 18

Wear a respiratory mask to protect against gases.

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

WARNING

Danger of fire or explosion

Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion.

u Observe the information in the material safety data sheet for the operat-

ing materials and supplies.

u Comply with local legislation. u Do not allow any exposed flame or ignition source during cleaning work. u Carry out cleaning in the open or provide sufficient ventilation.

CAUTION

Environmental hazard

Improper handling of operating materials and supplies can lead to environmental damage.

u Observe the information in the material safety data sheet for the operat-

ing materials and supplies.

u Comply with local legislation.

Page 18 / 18

Hazards due to the handling of insulation materials

WARNING

Danger from insulation materials

Dust or fibres from insulation materials can have adverse effects on the health or cause irritations. Unsuitable and combustible insulation materials are a fire hazard.

u Only use suitable and non-combustible insulation materials. u Ensure good ventilation at the workplace. u Avoid whirling up dust. u Use dust-free tools and working methods. u Remove package at the workplace only. u Proceed with particular care when removing old insulation materials. u Dispose of insulation materials properly and in an environmentally com-

patible manner in compliance with the legal regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

Operation Manual / A135-H55 / Safety data sheet

Safety data sheet

A135-H55 HT582518

Page 1 / 1

891 680 843 650

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2018

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