Operation Manual
A135-M65
HT593033 English
Original Operation Manual
Chapter |
Document-ID |
1 Introduction
HZTL4005_EN_F
2 Safety
HZTL4022_EN_E
3 Safety data sheet |
HT593033 |
4 Product description
HZTL4031_EN_H
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 |
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
Operation Manual / 1 Introduction
1 Introduction / 1.1 Purpose of the manual
Page 2 / 7
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 operation.
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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
Operation Manual / 1 Introduction
1 Introduction / 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 Contact information →7.
Page 3 / 7
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
Page 4 / 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 tighten- |
|
Measure |
|
ing angle |
|
|
|
Hand-tight, tighten without |
|
Note |
|
tools |
|
|
|
|
|
|
|
Oil |
|
Visually inspect |
|
|
|
|
|
Apply screw locking paste (e.g. |
|
Please note text for numbered |
|
Loctite) |
|
work step |
|
|
|
|
|
Apply high-temperature grease |
|
See document |
|
|
|
|
|
Apply other paste in accord- |
|
Dispose of in an environmentally |
|
ance with specifications |
|
compatible, professional way and |
|
|
|
in compliance with locally applic- |
|
|
|
Oil free, grease free and dry
able regulations
Table 1: Definition of pictograms
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
Operation Manual / 1 Introduction
1 Introduction / 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:
uObserve information in material safety data sheet
uEnsure proper space ventilation.
uDo not eat, drink or store food at the workplace while working with VCI.
uClean hands and face after working with VCI.
uFor more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6 months, the following mothballing measures are required:
uOpen package.
uRemove VCI corrosion protection emitter from package and replace with a new VCI corrosion protection emitter of the same kind. New VCI corrosion protection emitters can be obtained from www.branopac.com.
uOld VCI corrosion protection emitters must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations.
uClose package. The more tightly the package is sealed, the longer the protection duration.
Page 5 / 7
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
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).
Page 6 / 7
Fig. 3: Package with hygrometer
Every 6 months, the following measures are required:
uCheck 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.
uCheck 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:
¡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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
Operation Manual / 1 Introduction
1 Introduction / 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
© Copyright 2017 ABB. All rights reserved. |
HZTL4005_EN |
Revision F |
May 2017 |
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 |
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 2 / 18
Operation Manual / 2 Safety / A130 - A155
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 inspection work.
The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger.
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.
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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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 |
Respiratory mask to protect |
against |
against |
- Mechanical hazard |
- Dusts |
- Chemical hazard |
- Gases |
- Thermal hazard |
|
Safety helmet |
Ear protection |
Table 2: Personal protective equipment to be worn specific to the respective task
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.
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.
Page 3 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 4 / 18
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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.
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.
uOnly operate the turbocharger within the operating limits.
uOnly 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
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
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.
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
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder.
Page 6 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.8 Turbocharger rating plate
Fig. 2: Rating plate
Operating limits
01Turbocharger 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
09Turbocharger type
10Serial number
11Year of construction of turbocharger
12Manufacturing plant
Page 7 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 8 / 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.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended replacement intervals. In such a case, we recommend that you contact the nearest official service station of ABB Turbo Systems.
nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limit values can also be permitted during operation for special applications. Operation above nMmax and tMmax is not permitted.
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.
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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.10 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.
uLoads must always be fastened to properly functional lifting gear with a sufficient load limit.
uPay attention to the correct attachment of loads on the crane hook.
uPeople 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.
uBefore looping around the components of the turbocharger, let them cool down (maximum 80 °C).
uAttach components of the turbocharger as described in the respective action steps.
uUse a suitable edge guard if there are sharp edges.
uThe assembly devices must be completely screwed in and must not unscrew during use.
uUse assembly devices only for the described applications.
uPut down dismantled components of the turbocharger in such a way that they cannot tip over.
Page 9 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 10 / 18
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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.
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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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.
uWhen the engine is running, always wear ear protection.
uAlways 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.
uDo not touch hot surfaces. Observe the warning plate on the turbocharger.
uWear heat-resistant safety gloves and protective clothing.
uWait for the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
Page 11 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 12 / 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.
uCompliance with the instructions and specifications given by the enginebuilder to protect against hot turbocharger surfaces is compulsory.
Wear safety gloves to protect against thermal hazards.
Hazards due to rotating parts
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.
uOperate the turbocharger in compliance with the specifications.
uSecure 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.
uOnly specially trained personnel should perform work on, or with, electrical components.
uObserve national regulations.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
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.
uGround electrical installations properly with grounding conductors.
uCheck the grounding connections on a regular basis and make sure they are properly connected.
uSwitch off the power supply before working on any electrical installations.
uAfter switching off the power supply, wait for 5 minutes to allow capacitors to discharge and hot components to cool down.
uEnsure the power supply is switched off when working on electrical installations.
uDo not carry out any tests with regard to insulation resistance or voltage on the electrical components.
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
uVisually inspect your working environment before starting work.
uRemove any obstacles and objects littering the workplace.
uCheck all pipes to and from the turbocharger for damage and leaks before commissioning.
uCheck turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day.
uReport any damage and any alterations of operational characteristics to the responsible department immediately.
uIn case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use.
uWhen switching on operating energy supplies (hydraulics, pneumatics, electricity), pay attention to the risks that may occur as a consequence of this energy input.
Page 13 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
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.
uOnly operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants.
Page 14 / 18
Fig. 5
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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 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.
uWhen working on the turbocharger always wear safety footwear and protective clothing to protect against mechanical hazards.
uKeep personal protective equipment in perfect condition.
uObey mandatory signs.
uObserve the general rules for occupational safety and prevention of accidents.
uOnly perform operations that are described in this manual.
uOnly perform operations for which you have received instruction or training.
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.
uDo not climb onto the turbocharger or onto attached parts and do not use them as climbing aids.
uUse suitable climbing aids and working platforms for work above body height.
uComply with the general accident prevention regulations.
uOnly perform work on the turbocharger when you are in a physically and psychologically stable condition.
uOnly work with suitable tools, equipment and appliances that function properly.
uPower tools must be grounded and cables must be undamaged.
uKeep the workplace clean; clear away any loose objects and obstacles on the floor.
uKeep the floor, equipment, and turbocharger clean.
uHave oil binding agents ready and provide or keep oil pans at hand.
uClean up any spills.
uHave fire protection means and extinguishing agents available.
Page 15 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.14 Safe maintenance
Welding work in the vicinity of the turbocharger
uWhen performing welding work in the vicinity of the turbocharger, always cover the filter silencer to prevent the filter mat from being damaged.
uKeep flammable objects and substances out of the vicinity of flying sparks.
uCover all connections on the turbocharger so that no foreign objects can enter the turbocharger.
uWear 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.
uObserve the material safety data sheet for the cleaning agent or solvent.
uWear personal protective equipment (PPE) according to the material safety data sheet.
uInspect the electric cables for abrasion and damage before and after your cleaning work.
/ 18 |
Safety during disassembly, assembly, maintenance and repair |
u Observe the procedures for set-up, service and inspection work and the inspection inter- |
|
16 |
vals. |
|
|
Page |
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.
uOnly perform operations that are described in this manual.
uOnly perform operations for which you have received instruction or training.
Safety when taking out of operation or preparing for mothballing
uSecure rotor against turning. The rotor can rotate due to the stack draught alone.
uObserve the material safety data sheet for the cleaning and mothballing agents.
uWear personal protective equipment (PPE) according to the material safety data sheet.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
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.
uObserve the general rules for occupational safety and prevention of accidents.
uEnsure workplace safety.
uOnly perform operations that are described in this chapter.
uOnly perform operations for which you have previously received instruction 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.
uDo not breathe in these substances and avoid contact with the skin.
uEnsure proper ventilation.
uObserve the information in the material safety data sheet for the operating materials and supplies.
uWear personal protective equipment (PPE) according to the material safety data sheet.
uComply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
Page 17 / 18
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Page 18 / 18
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.
uObserve the information in the material safety data sheet for the operating materials and supplies.
uComply with local legislation.
uDo not allow any exposed flame or ignition source during cleaning work.
uCarry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
uObserve the information in the material safety data sheet for the operating materials and supplies.
uComply with local legislation.
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.
uOnly use suitable and non-combustible insulation materials.
uEnsure good ventilation at the workplace.
uAvoid whirling up dust.
uUse dust-free tools and working methods.
uRemove package at the workplace only.
uProceed with particular care when removing old insulation materials.
uDispose of insulation materials properly and in an environmentally compatible 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.
© Copyright 2017 ABB. All rights reserved. |
HZTL4022_EN |
Revision E |
May 2017 |
Operation Manual / A135-M65 / Safety data sheet
Page 1 / 1
Safety data sheet
A135-M65 |
HT593033 |
A135-M65 |
HT593033 |
|
|
893 |
|
630 |
|
873 |
|
600 |
|
150634-18013 |
|
|
|
300 |
8 |
50 |
50 |
2020 |
|
|
|
© Copyright 2020 ABB. All rights reserved. |
HT593033 |
February 2020 |