Abb TPS44-F33 User Manual

4.7 (6)

Operation Manual

ABB Turbocharging



ABB Turbo Systems Ltd

CH 5401 Baden

Type TPS44-F33 HT843982

Mmax

1165 t

Mmax

770

Bmax

1106 t

Bmax

770

1/s °C

SOLD06 00120 12 50 50

Year 2018

made in Switzerland

Application according to

the Operation Manual

HZTL2412 English

TPS44-F33

Original Operation Manual

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-

ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon

between the engine builder and ABB.

Note: Replacement intervals of components depends on the load proﬁ le, turbine inlet temperature, suction air temperature and

turbocharger speed. In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur-

rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,

high temperatures and high speed lower the life of components.

Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

Operation Manual / TPS44-F.. - TPS61-F..

Table of contents Page 1

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Table of contents

1 Preliminary remarks

1.1

Purpose of this manual

1.2

Layout and function

1.3

Intended use of the turbocharger

1.4

Storage of new turbochargers and spare parts

1.5

Essential information

1.6

Symbols and definitions

1.7

Turbocharger rating plate

1.8

Contact information

2 Safety

2.1

Introduction

2.2

CE conformity

Definition of mandatory signs

2.4

Definition of Safety instructions

2.5

Warning plates on the turbocharger

2.6

Safe operation and maintenance

2.7

Hazards during operation and maintenance

2.8

Deflagration on gas engines

2.9

Periodic checking of the pressure vess

2.10

Lifting loads

3 Start-up

3.1

Oil supply

3.2

Inspection work

3.3

Commissioning after taking out of operation

4 Operation

4.1

Noise emissions

4.2

Servicing work

4.3

Expected exchange intervals

4.4

Speed measurement

4.5

Stopping the engine

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5 Maintenance

5.1

Forewor

d to Maintenance

5.2

Cleaning the compressor during operation

5.3

Turbine cleaning during operation

5.4

Cleaning components mechanically

6 Troubleshooting

6.1

Malfunctions when starti

6.2

Surging of the turbocharger

6.3

Malfunctions during operation

6.4

Malfunctions when stopping

Speed measurement system

7 Removal and installation

7.1

Transport

7.2

Turbocharger weights

7.3

Remove the turbocharger

7.4

Installing the turbocharger

8 Disassembly and assembly

8.1

Introduction

8.2

Module weights

8.3

Disassembling and assembling turbocharger

8.4

Axial clearance A and radial clearance B

8.5

Radial clearances N and R

8.6

Table of tightening torques

9 Taking out of operation

9.1

Shutting down the turbocharger

10 Mothballing the turbocharger

10.1

Taking the engine out of operation for up to 12

months

10.2

Taking the engine out of operation for more than 12

months

11 Disposing of turbocharger components

12 Spare parts

12.1

Ordering spare parts

12.2

View of turbocharger showing part numbers

12.3

View of cartridge group showing part numbers

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Preliminary remarks 1

Purpose of this manual 1.1 Page 3

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Preliminary remarks

Purpose of this manual

1.1

This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-

charger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the turbo-

charger supplied by ABB Turbo Systems and to use it as intended.

It provides important information in order that the turbocharger can be op-

erated safely, correctly and efficiently.

This Operation Manual complements and expands existing national regu-

lations 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 in-

stalled 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.

1.1

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Preliminary remarks 1

Layout and function 1.2 Page 4

August 2017HZTL2412_ENRevision F

Layout and function

1.2

1 Suction branch / filter silencer 8 Gas outlet flange

2 Compressor casing 9 Nozzle ring

3 Diffuser 10 Turbine casing

4 Bearing casing 11 Turbine-end bearing flange

5 Axial thrust bearing 12 Compressor-end bearing flange

6 Radial plain bearing (visible only

at turbine end)

13 Compressor wheel

7 Turbine

1.2

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Preliminary remarks 1

Layout and function 1.2 Page 5

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Mode of operation

The turbocharger is a turbomachine consisting of the following main com-

ponents:

€ Turbine

€ Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine cas-

ing (10) and the nozzle ring (9) to impinge on the turbine (7).

The turbine (7) uses the energy contained in the exhaust gas to drive the

compressor wheel (13). The compressor draws in fresh air, compresses it

and then forces it into the engine's cylinders.

The exhaust gases escape into the ambient air through the exhaust gas

pipe, which is connected to the gas outlet flange (8).

The air, which is necessary for operation of the diesel or gas engine and

is compressed in the turbocharger, is drawn into the compressor wheel

(13) through the suction branch or filter silencer (1). It then passes

through the diffuser (3) and leaves the turbocharger through the outlet on

the compressor casing (2).

The rotor runs in two radial plain bearings (6), which are located in the

bearing flanges (11/12) between the compressor and the turbine. The axi-

al thrust bearing (5) is located between the two radial plain bearings.

The bearings are connected to a central lubricating oil duct which is sup-

plied by the engine's lubricating oil circuit. The oil outlet is always at the

lowest point of the bearing casing (4).

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Preliminary remarks 1

Intended use of the turbocharger 1.3 Page 6

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Intended use of the turbocharger

1.3

NOTICE

This turbocharger supplied by ABB Turbo Systems has been developed

for use on diesel engines to generate the volume of air and the charg-

ing pressure required to operate the engine.

The engine builder has provided ABB Turbo Systems with information

regarding the intended use of the engine, from which the operating lim-

its specific to the turbocharger shown on the rating plate (such as oper-

ating speeds, temperatures, exchange intervals / replacement intervals)

have been derived.

If it is used in conjunction with a gas engine, the engine must not be in-

stalled in a potentially explosive environment, and precautionary

measures must be taken to ensure that the machine room as a whole is

classified as not potentially explosive.

Any other use will be regarded as a special application which must first

be discussed with ABB Turbo Systems. The manufacturer accepts no

liability for other applications. If it is used otherwise, ABB Turbo Sys-

tems reserves the right to reject all warranty claims.

This turbocharger was built according to state-of-the-art technology and is

operationally safe according to recognised safety regulations.

WARNING

Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper

use may cause damage to the machine.

τ The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-

ing and repair conditions specified by the manufacturer. Disposal regula-

tions set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's manual.

It may be used only for the intended purpose and operated in compliance

with the operation manual.

τ Malfunctions which could affect safety must be eliminated immediately.

The manufacturer accepts no liability for any damage resulting from unau-

thorised alterations to the turbocharger.

1.3

State of the art

Perfect condition

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Preliminary remarks 1

Storage of new turbochargers and

spare parts

1.4 Page 7

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Storage of new turbochargers and spare

parts

1.4

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 Sub-

stances Ordinance. Nevertheless, the following points are to be ob-

served when handling VCIs:

τ Ensure good room ventilation.

τ Do not eat, drink or keep food at the workplace while working with

VCIs.

τ Wear safety gloves.

τ Clean hands and face after working with VCIs.

τ For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

τ Open the package.

τ Remove 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.

τ Dispose of the old VCI corrosion protection emitter in an environmen-

tally compatible manner, professionally and in accordance with local

regulations.

τ Seal the package. The better the external seal is designed, the more

permanent the protection.

1.4

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Preliminary remarks 1

Storage of new turbochargers and

spare parts

1.4 Page 8

August 2017HZTL2412_ENRevision F

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Tur-

bo Systems for prolonged storage. The package is equipped with a hyg-

rometer (see illustration).

The following measures are required every 6 months:

τ Check 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.

τ Inspect the package for damage. If the package is damaged, the tur-

bocharger or cartridge group must be inspected by an ABB Turbo-

charging 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 re-

placement cartridge group can be placed into operation without any pri-

or 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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Preliminary remarks 1

Essential information 1.5 Page 9

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Essential information

1.5

Organisational measures

In addition to this manual, the general, statutory regulations applicable in

the respective country for the prevention of accidents and the protection of

the environment must be observed.

This also applies to the provision and wearing of personnel protection

equipment.

NOTICE

The safety and risk consciousness of the personnel working on and

with the turbocharger must be checked regularly with reference to this

manual.

τ The turbocharger must be shut down immediately by stopping the en-

gine in the event of alterations affecting safety or of corresponding op-

erating behaviour. The fault must be reported to the person or depart-

ment responsible.

NOTICE

Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-

tems.

1.5

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Preliminary remarks 1

Essential information 1.5 Page 10

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Original parts and safety

Original parts and accessories are specially designed for the turbocharger

supplied 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.

τ Only use original parts from ABB Turbo Systems.

ABB Turbo Systems accepts no liability for any damage resulting from the

use of non-original parts and corresponding accessories.

Competence of personnel

The turbocharger must only be operated and serviced by trained and au-

thorised personnel. Basic mechanical training is a prerequisite.

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Preliminary remarks 1

Essential information 1.5 Page 11

August 2017HZTL2412_ENRevision F

Design variants

This document is valid for different design variants of turbochargers.

There may be sections and descriptions of components that are not rele-

vant 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.

Registered Trademarks

Registered trademarks of external companies are used in this document.

The trademarks are marked with ®.

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Preliminary remarks 1

Symbols and definitions 1.6 Page 12

August 2017HZTL2412_ENRevision F

Symbols and definitions

1.6

The following symbols are used in the documents:

ϖ Prerequisite

τ Step of a procedure

€ List, first level

- List, 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 Turbo-

charging Service Stations. They are inspected and certified regularly by

ABB Turbo Systems. See also chapter Contact information [➙ 15].

1.6

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Preliminary remarks 1

Turbocharger rating plate 1.7 Page 13

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Turbocharger rating plate

1.7

01 Turbocharger 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 Inspection interval of plain bearings in 1000 h

04 Replacement interval of compressor in 1000 h

05 Replacement interval of turbine in 1000 h

06 Customer part number

07 Designation of the special design

08 Weight of turbocharger in kg

09 Turbocharger type

10 Serial number

11 Year of construction of turbocharger

1.7

Operating limits

Recommended in

spection

and replacement intervals

of turbocharger compo-

nents

Further data

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Preliminary remarks 1

Turbocharger rating plate 1.7 Page 14

August 2017HZTL2412_ENRevision F

Explanation of the rating plate

The recommended replacement intervals and the corresponding opera-

tional limits are jointly defined with the engine manufacturer. This informa-

tion is specific to the system.

Operation above the indicated values n

Bmax

, t

Bmax

can considerably shorten the

recommended replacement intervals. In such cases, we recommend that you

contact the nearest official ABB Turbocharging service station.

Mmax

and t

Mmax

normally apply only when running at overload (110%) during tri-

als on the engine test bed. These limits can also be permitted during operation

for special applications. Operation above n

Mmax

and t

Mmax

is not permitted.

Non-observance of the recommended replacement intervals can increase the

risk of unpredictable component failures.

Positions of the rating plates

One rating plate (01) each is attached on the left and the right side of the

turbocharger bearing casing.

1.7.1

1.7.2

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Preliminary remarks 1

Contact information 1.8 Page 15

August 2017HZTL2412_ENRevision F

Contact information

1.8

Contact information

Contact information for the official service stations of ABB Turbo Systems

is available online.

τ Scan the QR code to access our website.

ABB Turbo Systems Ltd

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

1.8

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Safety 2

Introduction 2.1 Page 17

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Safety

Introduction

2.1

Turbochargers manufactured by ABB Turbo Systems 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 opera-

tion 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 instruc-

tions

€ are the consequence of unsatisfactory and improper execution of

maintenance and inspection work

The operator is responsible for access to the turbocharger as well as the

organisational measures which regulate the safe handling of the turbo-

charger by his personnel.

All instructions in this chapter must be observed to ensure safe and trou-

ble-free turbocharger operation and during work on the turbocharger.

In the same vein, all other specially marked safety instructions in every

chapter of this manual must be observed (see the section entitled Defini-

tion of safety instructions).

2.1

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Safety 2

CE conformity 2.2 Page 18

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CE conformity

2.2

Information

ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con-

sidered partly completed machinery in the sense of Article 2 g.

2.2

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Safety 2

Definition of mandatory signs 2.3 Page 19

August 2017HZTL2412_ENRevision F

Definition of mandatory signs

2.3

To be worn at all times

Protective clothing Safety footwear to protect

against mechanical hazard

and risk of falling

To be worn according to the specific work

Safety glasses Safety goggles

Safety gloves to protect

against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Respiratory mask to protect

against

- Dusts

- Gases

Safety helmet Ear protection

2.3

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Safety 2

Definition of Safety instructions 2.4 Page 20

August 2017HZTL2412_ENRevision F

Definition of Safety instructions

2.4

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.

τ 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.

τ Caution signs must be observed at all times.

2.4

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Safety 2

Warning plates on the turbocharger 2.5 Page 21

August 2017HZTL2412_ENRevision F

Warning plates on the turbocharger

2.5

Warning plates are attached to the turbocharger at the following places:

If warning plates are not present at the intended places or are not legible,

then proceed as follows:

τ Order new warning plates from ABB Turbocharging Service Stations.

τ Remove unreadable warning plates.

τ Clean and degrease surfaces provided for warning plates.

τ Attach new warning plates.

Uninsulated turbochargers

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.

2.5

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Safety 2

Safe operation and maintenance 2.6 Page 22

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Safe operation and maintenance

2.6

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 turbo-

charger.

τ Do not climb on the turbocharger or on parts attached to it or use

these as climbing aids.

τ When working at levels above the head, use climbing aids and work

platforms suitable for this purpose.

τ Observe all general regulations for the prevention of accidents.

τ Do not work on the turbocharger if you are under physical or mental

stress.

τ Work only with suitable tools as well as equipment and working mate-

rials that are in perfect condition.

τ Electric tools must be solidly earthed, and connecting cables may not

be damaged.

τ Keep the workplace clean, clear away loose objects and remove ob-

stacles on the floor.

τ Keep the floor, equipment and the turbocharger clean.

τ Have oil binding materials ready at hand and keep oil catch pans

ready or in position

τ Eliminate leaks.

τ Keep fire-protection materials and fire-extinguishing equipment ready.

Welding work in the vicinity of the turbocharger

τ When performing welding work in the vicinity of the turbocharger, al-

ways cover the filter silencer to prevent the filter mat from being dam-

aged.

τ Keep flammable objects and substances out of the range of flying

sparks.

τ Cover all connections on the turbocharger so that no foreign objects

can enter the turbocharger.

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

2.6

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Safety 2

Safe operation and maintenance 2.6 Page 23

August 2017HZTL2412_ENRevision F

Safety during start-up / commissioning and operation

WARNING

The turbine casing insulation of the TPS44-F supplied by ABB Turbo

Systems is also burst protection.

Serious personal injuries or fatal accidents can occur, if the turbine cas-

ing insulation of the TPS44-F supplied by ABB Turbo Systems is re-

moved. The burst protection is integrated into the turbine casing insula-

tion of the TPS44-F supplied by ABB Turbo Systems.

Separate burst protection is fitted to TPS44-F turbochargers without in-

sulation that have been ordered from ABB Turbo Systems.

τ Never operate TPS44-F turbochargers that have been supplied by

ABB Turbo Systems with insulation if this insulation from ABB Turbo

Systems is not in place.

τ Never operate turbochargers without burst protection. If the insula-

tion from ABB Turbo Systems is not in place, the separate burst pro-

tection (57200) must be fitted before operation. (See View of tur-

bocharger showing part numbers [➙ 126].)

τ Before starting work, carry out visual inspection of working area.

τ Remove any obstacles and objects lying around.

τ Before start-up / commissioning, check all pipes from and to turbo-

charger for damage and leaks.

τ Don't work in any way that could impair safety when working on turbo-

charger.

τ After about every 12 hours of operation or at least once a day, inspect

turbocharger for visible damage and defects.

τ Immediately report any damage or changes in operational perfor-

mance to person responsible.

τ If damage is discovered, immediately shut down turbocharger and se-

cure it against inadvertent or unauthorized use.

τ When 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.

τ Observe the material safety data sheet for the cleaning agent or solvent.

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Safety 2

Safe operation and maintenance 2.6 Page 24

August 2017HZTL2412_ENRevision F

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

safety data sheet.

τ Inspect the electric cables for abrasion and damage before and after

your cleaning work.

Safety during disassembly, assembly, maintenance and troubleshooting

τ Always perform the specified adjustments, servicing as well as inspec-

tion work and observe inspection intervals.

τ Inform operating personnel about all service and repair work before

beginning.

τ Before opening a cover or removing a protective device on a turbo-

charger, the engine must be switched off and the turbocharger must

have come to a standstill.

τ Ensure that the supply of oil is interrupted, especially with an external

oil supply.

τ Put 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.

τ Perform only those tasks that are described in this manual.

τ Perform work only for which training has been carried out.

Safety when taking out of operation or preparing for mothballing

τ Secure the rotor so it cannot turn. The rotor can turn on its own from

the force of the stack draught.

τ Clean the turbocharger before mothballing it.

τ Observe the material safety data sheet for the cleaning and mothball-

ing agents.

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

safety data sheet.

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Safety 2

Hazards during operation and

maintenance

2.7 Page 25

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Hazards during operation and maintenance

2.7

Mechanical hazards during operation

During normal operation, no mechanical hazards emanate from the turbo-

charger if it has been installed properly.

WARNING

Risk of injury

Contact with rotating parts can lead to serious injuries. The turbo-

charger 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.

τ Operate the turbocharger in accordance with instructions.

τ During maintenance work, secure the rotor against unintentional ro-

tation.

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 hazards

Severe injuries to personnel or fatal accidents can be caused by me-

chanical influences as a consequence of hazardous and inadequate

operational procedures.

τ Observe the general rules for occupational safety and prevention of

accidents.

τ Ensure workplace safety.

τ Only perform operations that are described in this document.

τ Only perform operations for which you have previously received in-

struction or training.

2.7

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Safety 2

Hazards during operation and

maintenance

2.7 Page 26

August 2017HZTL2412_ENRevision F

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 disturb-

ances, diminished attention and irritation.

τ Always wear ear protection when the engine is running.

τ When 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 op-

erating materials (lubricating oil) become hot. The surface temperature is

dependent on the effectiveness of the insulation being used. The tem-

perature 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.

τ Do not touch hot surfaces and heed the warning plate on the turbo-

charger.

τ Wear heat-resistant safety gloves and protective clothing.

τ Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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Safety 2

Hazards during operation and

maintenance

2.7 Page 27

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WARNING

Hot surfaces on the non-insulated turbocharger

Non-insulated turbochargers can cause serious injuries to personnel

(burns).

The turbocharger is supplied by ABB Turbo Systems without insulation

depending on the order from the enginebuilder. If supply is without insu-

lation, the enginebuilder is responsible for providing the turbocharger

with proper insulation and for providing protection against contact with

hot surfaces.

τ 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 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. Operat-

ing 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.

τ Avoid inhalation and contact with the skin.

τ Ensure good ventilation.

τ Observe details in the safety data sheets of the operating and auxil-

iary materials.

τ Observe local laws.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Operation Manual / TPS44-F.. - TPS61-F..

Safety 2

Hazards during operation and

maintenance

2.7 Page 28

August 2017HZTL2412_ENRevision F

WARNING

Risk of fire, explosion

Flammable and combustible operating materials and supplies can catch

fire or resulting vapours can lead to an explosion.

τ Observe the details in the material safety data sheets of the operat-

ing and auxiliary materials.

τ Comply with local legislation.

τ Do not allow any exposed flame or ignition source during cleaning

work.

τ Carry out cleaning in the open or provide sufficient aeration and ven-

tilation.

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.

τ Handle operating and auxiliary materials carefully.

τ Heed the instructions for use, safety data sheets and hazard notices

on the containers of the operating and auxiliary materials.

τ Wear appropriate protective clothing.

τ Avoid inhalation and contact with the skin.

τ Ensure that the work space is adequately ventilated.

τ Seal containers tightly immediately after use and put them away.

τ Collect used working and auxiliary materials safely, store them sepa-

rately in suitable containers and dispose of them properly and in an

environmentally compatible manner in accordance with statutory regu-

lations.

τ In 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.

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