Abb TPL76-C32 User Manual

4.3 (4)

Operation Manual

TPL76-C32

	ABB Turbo Systems Ltd
	CH 5401 Baden
Type	TPL76-C32	HT586989
nMmax	352	t Mmax	650
	1/s			°C
nBmax	337	t Bmax	650
	04070 kg	35	50	50
Year	2019	Application according to
Year	2019	the Operation Manual
	made in Switzerland

HZTL2485 English

Original Operation Manual

ABB Turbocharging

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspectionand replacement intervals for the components 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 current 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 / TPL76-C

Table of contents

Operation Manual
1	Preliminary remarks.................................................................................................	3
1.1	Purpose of this manual ..................................................................................................	3
1.2	Layout and function........................................................................................................	4
1.3	Intended use.....................................................................................................................	6
1.4	Deflagration on gas engines.........................................................................................	7
1.5	Storage of new turbochargers and spare parts .......................................................	8
1.6	Essential information...................................................................................................	10
1.7	Symbols and definitions ..............................................................................................	12
1.8	Turbocharger rating plate...........................................................................................	13
1.9	Contact information.....................................................................................................	14
2	Safety.......................................................................................................................	15
2.1	Introduction ...................................................................................................................	15
2.2	CE conformity ................................................................................................................	15
2.3	Definition of mandatory signs ...................................................................................	16
2.4	Definition of Safety instructions ...............................................................................	16
2.5	Warning plates on the turbocharger.........................................................................	17
2.6	Safe operation and maintenance...............................................................................	18
2.7	Hazards during operation and maintenance...........................................................	21
2.8	Periodic checking of the pressure vessel .................................................................	26
2.9	Lifting loads ...................................................................................................................	26
3	Commissioning......................................................................................................	28
3.1	Oil supply ........................................................................................................................	28
3.2	Inspection work.............................................................................................................	31
3.3	Commissioning after taking out of operation........................................................	33
4	Operation ...............................................................................................................	34
4.1	Noise emissions ............................................................................................................	34
4.2	Servicing work ...............................................................................................................	36
4.3	Replacement intervals for turbocharger components..........................................	39
4.4	Speed measurement ....................................................................................................	41
4.5	Stopping the engine ....................................................................................................	44
5	Maintenance ..........................................................................................................	45
5.1	Foreword to Maintenance ..........................................................................................	45
5.2	Cleaning the filter silencer..........................................................................................	46
5.3	Cleaning the compressor during operation ...........................................................	49
5.4	Cleaning turbine blades and nozzle ring in operation...........................................	55
5.5	Cleaning components mechanically.........................................................................	60

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Table of contents

6	Troubleshooting....................................................................................................	69
6.1	Malfunctions when starting.......................................................................................	69
6.2	Surging of the turbocharger.......................................................................................	70
6.3	Malfunctions during operation ..................................................................................	71
6.4	Malfunctions when stopping......................................................................................	74
6.5	Speed measurement system ......................................................................................	75
7	Removal and installation......................................................................................	76
7.1	Turbocharger weight....................................................................................................	76
7.2	Removing the turbocharger........................................................................................	77
7.3	Installing the turbocharger .........................................................................................	79
8	Disassembly and assembly ..................................................................................	80
8.1	Introduction ..................................................................................................................	80
8.2	Module weights .............................................................................................................	82
8.3	Removing and fitting filter silencer or air suction branch...................................	84
8.4	Axial clearance ..............................................................................................................	86
8.5	Removing cartridge group ..........................................................................................	87
8.6	Dismantling and installing the turbine diffuser and nozzle ring........................	94
8.7	Installing cartridge group...........................................................................................	98
8.8	Dismantling and fitting nozzle ring at turbine end.............................................	108
8.9	Table of tightening torques......................................................................................	116
9	Taking out of operation at short notice ...........................................................	118
9.1	Possibilities for emergency repair...........................................................................	118
9.2	Locking the rotor.........................................................................................................	119
9.3	Fit cover plate ..............................................................................................................	123
9.4	Blocking the inlets and outlets.................................................................................	127
9.5	Bypass the turbocharger ...........................................................................................	127
10	Mothballing the turbocharger ...........................................................................	128
10.1	Taking out of operation for up to 12 months........................................................	128
10.2	Taking out of operation for more than 12 months...............................................	129
11	Disposing of turbocharger components..........................................................	130
12	Spare parts............................................................................................................	131
12.1	Ordering spare parts..................................................................................................	131
12.2	View of turbocharger with part numbers ..............................................................	132

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1 Preliminary remarks / 1.1 Purpose of this manual

1 Preliminary remarks

1.1 Purpose of this manual

This Operation Manual belongs to the turbocharger with the identical serial number (01), see the cover sheet of the Operation Manual and the turbocharger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended.

It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.

This Operation Manual complements and expands existing national regulations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechanics who are responsible for operating the engine and the turbocharger installed on it.

Availability of operation manual

An operation manual must be available at all times at the place where the turbocharger is used.

Everyone who operates or works on the turbocharger must have first read and understood the operation manual.

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1Preliminary remarks / 1.2 Layout and function

1.2Layout and function

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01Filter silencer	08Nozzle ring
02Radial plain bearing	09Turbine wheel
03Thrust bearing	10Bearing casing
04Bearing bush	11Diffuser
05Radial plain bearing	12Compressor wheel
06Gas outlet casing	13Compressor casing
07Gas inlet casing

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1 Preliminary remarks / 1.2 Layout and function

Mode of operation

The turbocharger is a turbomachine and consists of the following main components:

¡Turbine

¡Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet casing (07) and nozzle ring (08) to the turbine wheel.

The turbine wheel (09) uses the energy contained in the exhaust gas to drive the compressor wheel (12). The compressor then draws in fresh air, compresses it and then forces it into the cylinders.

The exhaust gases escape to free air through an exhaust gas pipe which is connected to the gas outlet casing (06).

The air which is necessary for operation of the diesel engine and is compressed in the turbocharger is drawn through the suction branch or the filter silencer (01) into the compressor wheel (12). This air then passes through the diffuser (11) and leaves the turbocharger through the compressor casing (13).

The rotor runs in two radial plain bearings (02/05). One plain bearing is in the bearing bush (04), and the second one is in the axial thrust bearing (03) at the compressor end.

The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine's lubricating oil circuit. The oil outlet is always at the lowest point of the bearing casing (10).

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is provided with a compressor wheel cooling system. Compressor wheel cooling means that, after the charge air cooler at the engine end, cooled compressor air is delivered to the turbocharger to cool the compressor wheel.

Depending on the respective operating conditions, it is absolutely essential that the compressor wheel is cooled in order to guarantee its reliability and the replacement intervals. In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing.

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1Preliminary remarks / 1.3 Intended use

1.3Intended 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].

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 Turbo Systems 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

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

State of the art

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

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1 Preliminary remarks / 1.4 Deflagration on gas engines

Flawless condition

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

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

1.4 Deflagration on gas engines

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

ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the bracket. A crack inspection of the casings and the bellows is also recommended. The nearest ABB Turbocharging Service Station should be instructed to carry out this inspection and assessment.

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1 Preliminary remarks / 1.5 Storage of new turbochargers and spare parts

1.5 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).

Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and no condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6

months (VCI)

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Substances Ordinance. Nevertheless, the following points are to be observed when handling VCIs:

uEnsure good room ventilation.

uDo not eat, drink or keep food at the workplace while working with VCIs.

uWear safety gloves.

uClean hands and face after working with VCIs.

uFor further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

uOpen the package.

uRemove the VCI corrosion protection emitter from the package and replace it with a new, identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be obtained at www.branopac.com.

uDispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations.

uSeal the package. The better the external seal is designed, the more permanent the protection.

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Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration).

The following measures are required every 6 months:

uCheck the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maximum permissible humidity has been exceeded. In this case the turbocharger or rotor must be inspected by an ABB Turbocharging Service Station and repacked.

uInspect the package for damage. If the package is damaged, the turbocharger or cartridge group must be inspected by an ABB Turbocharging Service Station and repacked.

After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:

¡Inspect the components

¡Exchange the desiccant agent

¡Repackage the components.

NOTICE

Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour and the package is undamaged, the replacement turbocharger or replacement cartridge group can be placed into operation without any prior testing by an ABB Turbocharging Service Station.

Unpacking replacement turbochargers or spare parts

The corrosion protection effect ends after the material is unpacked from the VCI package.

To avoid the formation of condensation, the surroundings and the content of the package must have the same temperature during unpacking.

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1 Preliminary remarks / 1.6 Essential information

1.6 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulations for the prevention of accidents and for environmental protection in the country of use must also be observed.

This also applies to the provision and wearing of personal protective equipment.

NOTICE

The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accordance with the Operation Manual.

uThe turbocharger must be shut down immediately in the event of modifications affecting safety or of corresponding operating behaviour by stopping the engine. The fault should be reported to the person or department responsible.

NOTICE

Any modifications, additions or conversions made to the turbocharger, which could impair safety, require the prior approval of ABB Turbo Systems.

Original parts and safety

Original parts and accessories are specially designed for the turbocharger supplied by ABB.

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.

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

Competence of personnel

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

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Design variants

This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant.

ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible.

Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the delivery date.

Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form.

uAfter expiry of the 6 months, all surfaces and accessible areas of the turbocharger should be sprayed with anticorrosive agent.

uTo do this, the insulating materials must be removed.

NOTICE

Repeat the described measures every 6 months to keep your turbocharger free from rust.

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1 Preliminary remarks / 1.7 Symbols and definitions

1.7 Symbols and definitions

The following symbols are used in the documents:

w Prerequisite

u Work step

¡ Enumeration, first level

- Enumeration, second level

→ Refers to a page number

Definition of notes

NOTICE

Note

A note provides suggestions which facilitate the work on the product.

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

The caution and warning signs are described in the chapter Safety.

ABB Turbo Systems

In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo

Systems.

Official ABB Turbo Systems Service Stations

In this document, official service stations are referred to as ABB Turbocharging Service Stations. They are inspected and certified regularly by ABB Turbo Systems. See also chapter Contact information →14.

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1Preliminary remarks / 1.8 Turbocharger rating plate

1.8Turbocharger rating plate

Operating limits

Recommended replacement intervals for turbocharger components

Further information

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

Only when operating in the test rig unless otherwise agreed with the enginebuilder.

02 Turbocharger operating limits during operation

03 Replacement interval for plain bearings in 1000 h

04 Replacement interval for compressor in 1000 h

05 Replacement interval for turbine in 1000 h

06 Part number for customer

07 Designation of special design

08 Turbocharger weight in kg

09Turbocharger type

10Serial number

11Year of turbocharger construction

12Manufacturing plant

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1Preliminary remarks / 1.9 Contact information

1.8.1Explanation of the rating plate

The recommended replacement intervals and the corresponding operational limits are jointly defined with the engine manufacturer. This information is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shorten the recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. nMmaxand tMmax normally apply only when running at overload (110%) during trials on the engine test bed. These limits can also be permitted during operation for special applications. Operation above nMmax and tMmax is not permitted.

Non-observance of the recommended replacement intervals can increase the risk of unpredictable component failures.

1.8.2Positions of the rating plates

A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet casing.

1.9 Contact information

Contact information for the official service stations of ABB Turbo Systems 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

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2 Safety / 2.1 Introduction

2 Safety

2.1 Introduction

Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger operation and when working on the turbocharger, residual risks can exist which:

¡originate from the turbocharger itself and its accessories

¡originate from the operating and auxiliary materials used

¡are the consequence of insufficient observance of the safety instructions

¡are the consequence of unsatisfactory and improper execution of maintenance and inspection work.

The operating company is responsible for access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel.

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 (see section Definition of Safety Instructions) must also be observed.

2.2 CE conformity

Information

ABB turbochargers fulfil Directive 2006/42/EC on machinery and are considered partly completed machinery in the sense of Article 2 g.

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2 Safety / 2.3 Definition of mandatory signs

2.3 Definition of mandatory signs

To be worn at all times

Protective clothing	Safety footwear to pro-
	tect against mechanical
	hazard and risk of fall-
	ing

To be worn according to the specific work

Safety glasses

Safety goggles

Safety gloves against	Respiratory mask
- Mechanical hazard	against
- Chemical hazard	- Dusts
- Thermal hazard	- Gases

Safety helmet	Ear protection

2.4 Definition of Safety instructions

The following symbols and terms used in this manual concern safety or refer to possible hazards:

WARNING

Definition of warning

Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed precisely.

u Warning signs must be observed at all times.

CAUTION

Definition of caution

Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either not followed or not followed precisely.

u Caution signs must be observed at all times.

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2 Safety / 2.5 Warning plates on the turbocharger

2.5 Warning plates on the turbocharger

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

Part number	Size [mm]	Product
81080	105 x 74	TPL / TPR

When uninsulated turbochargers are delivered to the engine builder, the warning plates must be subsequently attached to the insulation. This is the responsibility of the engine builder.

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2Safety / 2.6 Safe operation and maintenance

2.6Safe operation and maintenance

The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.

Work safety and work area safety

WARNING

Risk of falling

There is the risk that someone can fall when working on the turbocharger.

uDo not climb on the turbocharger or on parts attached to it or use these as climbing aids.

uWhen working at levels above the head, use climbing aids and work platforms suitable for this purpose.

uObserve all general regulations for the prevention of accidents.

uDo not work on the turbocharger if you are under physical or mental stress.

uWork only with suitable tools as well as equipment and working materials that are in perfect condition.

uElectric tools must be solidly earthed, and connecting cables may not be damaged.

uKeep the workplace clean, clear away loose objects and remove obstacles on the floor.

uKeep the floor, equipment and the turbocharger clean.

uHave oil binding materials ready at hand and keep oil catch pans ready or in position

uEliminate leaks.

uKeep fire-protection materials and fire-extinguishing equipment ready.

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 range 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.

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Safety during start-up / commissioning and operation

uBefore starting work, carry out visual inspection of working area.

uRemove any obstacles and objects lying around.

uBefore start-up / commissioning, check all pipes from and to turbocharger for damage and leaks.

uDon't work in any way that could impair safety when working on turbocharger.

uAfter about every 12 hours of operation or at least once a day, inspect turbocharger for visible damage and defects.

uImmediately report any damage or changes in operational performance to person responsible.

uIf damage is discovered, immediately shut down turbocharger and secure it against inadvertent or unauthorized use.

uWhen switching on auxiliary power sources (hydraulics, pneumatics, electricity, water), keep an eye open for any hazards resulting from supplying these power sources.

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 and auxiliary materials" 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.

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2 Safety / 2.6 Safe operation and maintenance

Safety during disassembly, assembly, maintenance and

troubleshooting

uAlways perform the specified adjustments, servicing as well as inspection work and observe inspection intervals.

uInform operating personnel about all service and repair work before beginning.

uBefore opening a cover or removing a protective device on a turbocharger, the engine must be switched off and the turbocharger must have come to a standstill.

uEnsure that the supply of oil is interrupted, especially with an external oil supply.

uPut the engine into operation only after all parts have been refitted properly.

CAUTION

Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.

uPerform only those tasks that are described in this manual.

uPerform work only for which training has been carried out.

Safety when taking out of operation or preparing for mothballing

uSecure the rotor so it cannot turn. The rotor can turn on its own from the force of the stack draught.

uClean the turbocharger before mothballing it.

uObserve the material safety data sheet for the cleaning and mothballing agents.

uWear personal protective equipment (PPE) according to the material safety data sheet.

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2 Safety / 2.7 Hazards during operation and maintenance

2.7 Hazards during operation and maintenance

Mechanical hazards during operation

During normal operation, no mechanical hazards emanate from the turbocharger if it has been installed properly.

WARNING

Risk of injury

Contact with rotating parts can lead to serious injuries. The turbocharger must never be operated without a filter silencer or an air suction branch. When the engine is at a standstill, the rotor can turn on its own because of stack draught.

uOperate the turbocharger in accordance with instructions.

uDuring maintenance work, secure the rotor against unintentional rotation.

Mechanical hazards when working on the turbocharger

During maintenance work, various risks can occur through the improper handling of components, through the non-observance of work instructions, due to inadequate care or as a consequence of insufficient training.

WARNING

Mechanical hazard

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.

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2 Safety / 2.7 Hazards during operation and maintenance

Hazards due to noise

The development of noise during operation is influenced by the installation and operating conditions. Noise with a sound pressure level exceeding 85 dB(A) is harmful.

WARNING

Hazards due to noise

Noise can cause impaired hearing, damage to health, mental disturbances, diminished attention and irritation.

uAlways wear ear protection when the engine is running.

uWhen the sound pressure level is above 85 dB(A), always wear ear protection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well as operating materials (lubricating oil) become hot. The surface temperature is dependent on the effectiveness of the insulation being used. The temperature can become high enough so that it falls into ranges where burns are possible.

WARNING

Risk of burning

Touching hot surfaces or contact with hot operating materials can lead to serious burns.

uDo not touch hot surfaces and heed the warning plate on the turbocharger.

uWear heat-resistant safety gloves and protective clothing.

uAllow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (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 operating and auxiliary materials

Operating and auxiliary materials are substances used for operation or the execution of maintenance work. Oils, greases, coolants, cleaning agents and solvents, acids, etc. can be regarded as hazardous materials. Operating and auxiliary materials can be combustible and easily ignited.

WARNING

Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials or contact with such can cause damage to health.

uAvoid inhalation and contact with the skin.

uEnsure good ventilation.

uObserve details in the safety data sheets of the operating and auxiliary materials.

uObserve local laws.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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Operation Manual / TPL76-C

2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Risk of fire, explosion

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

uObserve the details in the material safety data sheets of the operating and auxiliary materials.

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 aeration and ventilation.

CAUTION

Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can lead to environmental damage.

uHandle operating and auxiliary materials carefully.

uHeed the instructions for use, safety data sheets and hazard notices on the containers of the operating and auxiliary materials.

uWear appropriate protective clothing.

uAvoid inhalation and contact with the skin.

uEnsure that the work space is adequately ventilated.

uSeal containers tightly immediately after use and put them away.

uCollect used working and auxiliary materials safely, store them separately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regulations.

uIn the event of leaks or after spilling, immediately spread a suitable binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations.

HZTL2485_EN

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April 2018

Operation Manual / TPL76-C

2 Safety / 2.7 Hazards during operation and maintenance

Hazards when handling insulating materials

WARNING

Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.

uUse only suitable, non-combustible insulating materials.

uEnsure that the work area is well ventilated.

uAvoid stirring up dust.

uUse tools and processes which keep dust to a minimum.

uRemove packing materials only in the work area.

uTake particular care when removing old insulating materials.

uDispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

uUse only suitable, non-combustible insulating materials.

uEnsure that the work area is well ventilated.

uWear suitable work clothing (safety glasses, respiratory mask).

uAvoid stirring up dust.

uUse tools and processes which keep dust to a minimum.

uRemove packing materials only in the work area.

uTake particular care when removing old insulating materials.

uDispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations.

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Operation Manual / TPL76-C

2 Safety / 2.8 Periodic checking of the pressure vessel

Hazards due to electrical components

WARNING

Hazards due to electrical components

Electrical components operate with voltages which can present hazards to humans.

uAll work on or with electrical components may only be performed by trained specialists.

uHeed any country-specific regulations.

2.8Periodic checking of the pressure vessel

The pressure vessels used by ABB, 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 carried out without delay and the required safety precautions must be taken.

u Pressure equipment must not be operated if it has defects.

2.9Lifting loads

WARNING

Suspended loads

Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences.

uLoads must always be fastened to technically perfect lifting gear with sufficient loading capacity.

uMake sure the load is suspended properly on the crane hook.

uDo not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

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April 2018

Operation Manual / TPL76-C

2 Safety / 2.9 Lifting loads

In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading.

uFasten turbocharger assemblies / components as described in respective handling steps.

uBefore attaching slings, allow turbocharger components to cool down (maximum 80°C).

uUse suitable protection at sharp edges.

uCompletely screw in assembly / fitting devices without fail so that they cannot work loose during use.

uUse assembly / fitting devices only for applications described.

uMake sure removed turbocharger components stand safely and securely.

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Operation Manual / TPL76-C

3 Commissioning / 3.1 Oil supply

3 Commissioning

3.1 Oil supply

A carefully designed and installed oil supply, which functions in all possible operational conditions, is an important prerequisite for troublefree turbocharger operation.

The turbocharger is normally lubricated with oil from the engine oil circuit.

NOTICE

With regard to the oil supply, please observe the engine builder's specifications for lubricating oil selection, oil change intervals, oil filtration, oil pressure and oil temperature.

Oil filtration

A lubrication oil filter system with a mesh size ≤0.050 mm is adequate for TPL76-C turbochargers.

NOTICE

This filter system can also be achieved by using an additional self-clean- ing fine filter.

HZTL2485_EN

Revision F

April 2018

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