Abb TPS52-F33 User Manual

Operation Manual

TPS52-F33

ABB Turbo Systems Ltd CH 5401 Baden

Type TPS52-F33 HT845348 n

Mmax

Bmax

SOLD06 00250 20 60 60 Year 2020

HZTL2412 English

Original Operation Manual

843 t 801 t

Mmax

1/s °C

Bmax

made in Switzerland

680 650

Application according to

the Operation Manual

ABB Turbocharging



Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and 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 proﬁ le, turbine inlet temperature, suction air temperature and

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

turbocharger speed. In case the operation conditions differs signiﬁ cantly 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.

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

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 of the turbocharger .............................................................................. 6

1.4 Storage of new turbochargers and spare parts ....................................................... 7

1.5 Essential information ..................................................................................................... 9

1.6 Symbols and definitions .............................................................................................. 11

1.7 Turbocharger rating plate ........................................................................................... 12

1.8 Contact information..................................................................................................... 13

2 Safety...................................................................................................................... 14

2.1 Introduction ................................................................................................................... 14

2.2 CE conformity ................................................................................................................ 14

2.3 Definition of mandatory signs ................................................................................... 15

2.4 Definition of Safety instructions ............................................................................... 15

2.5 Warning plates on the turbocharger......................................................................... 16

2.6 Safe operation and maintenance............................................................................... 16

2.7 Hazards during operation and maintenance........................................................... 20

2.8 Deflagration on gas engines....................................................................................... 25

2.9 Periodic checking of the pressure vessel ................................................................. 26

2.10 Lifting loads ................................................................................................................... 26

3 Start-up ................................................................................................................. 28

3.1 Oil supply ........................................................................................................................ 28

3.2 Inspection work ............................................................................................................. 32

3.3 Commissioning after taking out of operation ........................................................ 34

4 Operation ............................................................................................................... 35

4.1 Noise emissions ............................................................................................................ 35

4.2 Servicing work ............................................................................................................... 36

4.3 Expected exchange intervals ...................................................................................... 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 compressor during operation ........................................................... 46

5.3 Turbine cleaning during operation........................................................................... 50

5.4 Cleaning components mechanically.......................................................................... 56

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

Table of contents

6 Troubleshooting.................................................................................................... 67

6.1 Malfunctions when starting........................................................................................ 67

6.2 Surging of the turbocharger...................................................................................... 68

6.3 Malfunctions during operation ................................................................................. 69

6.4 Malfunctions when stopping ...................................................................................... 72

6.5 Speed measurement system ...................................................................................... 73

7 Removal and installation...................................................................................... 74

7.1 Transport ........................................................................................................................ 74

7.2 Turbocharger weights.................................................................................................. 75

7.3 Removing the turbocharger........................................................................................ 75

7.4 Installing the turbocharger ......................................................................................... 76

8 Disassembly and assembly .................................................................................. 78

8.1 Introduction ................................................................................................................... 78

8.2 Module weights ............................................................................................................. 81

8.3 Disassembling and assembling turbocharger ........................................................ 82

8.4 Axial clearance A and radial clearance B .................................................................. 96

8.5 Radial clearances N and R........................................................................................... 98

8.6 Table of tightening torques..................................................................................... 100

9 Taking out of operation .................................................................................... 101

9.1 Shutting down the turbocharger ............................................................................ 101

10 Mothballing the turbocharger ........................................................................... 105

10.1 Taking the engine out of operation for up to 12months.................................... 105

10.2 Taking the engine out of operation for more than 12months ......................... 106

11 Disposing of turbocharger components.......................................................... 108

12 Spare parts........................................................................................................... 109

12.1 Ordering spare parts .................................................................................................. 109

12.2 View of turbocharger showing part numbers ....................................................... 110

12.3 View of cartridge group showing part numbers .................................................. 112

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

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 helps familiarise the user with the turbocharger from ABB Turbocharging and how 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

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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.

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

1 Preliminary remarks / 1.2 Layout and function

1.2 Layout and function

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1Suction branch / filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing

4Bearing casing 11Turbine-end bearing flange 5Axial thrust bearing 12Compressor-end bearing

flange

6Radial plain bearing (visible only

at turbine end)

7Turbine

13Compressor wheel

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

1 Preliminary remarks / 1.2 Layout and function

Mode of operation

The turbocharger is a turbomachine consisting of the following main components:

¡ Turbine

¡ Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine casing (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 axial thrust bearing (5) is located between the two radial plain bearings.

The bearings are connected to a central lubricating oil duct which is supplied 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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Operation Manual / TPS44-F.. - TPS61-F..

1 Preliminary remarks / 1.3 Intended use of the turbocharger

1.3 Intended use of the turbocharger

NOTICE

This turbocharger supplied by ABB Turbocharging has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.

The enginebuilder has provided ABB Turbocharging with information regarding the intended use of the engine, from which the operating limits specific to the turbocharger shown on the rating plate, such as operating speeds, temperatures, exchange intervals / replacement intervals, have been derived.

Use in connection with a gas engine requires that the engine is not installed in a potentially explosive environment and that precautions are taken to ensure that the engine room as a whole is classified as non-ex- plosive.

Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liability for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.

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State of the art

Perfect condition

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.

u The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the installation / fitting, disassembly / removal, operating, maintenance / servicing and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed.

The turbocharger may be installed only when in technically perfect condition 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.

u Malfunctions which could affect safety must be eliminated immedi-

ately.

The manufacturer accepts no liability for any damage resulting from unauthorised alterations to the turbocharger.

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

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts

1.4 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 Turbocharging 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:

u Ensure good room ventilation.

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

VCIs.

u Wear safety gloves.

u Clean hands and face after working with VCIs.

u 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:

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u Open the package.

u 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.brano- pac.com.

u Dispose of the old VCI corrosion protection emitter in an environ-

mentally compatible manner, professionally and in accordance with local regulations.

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

1 Preliminary remarks / 1.4 Storage of new turbochargers and spare parts

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

permanent the protection.

Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Turbocharging on request. The package is equipped with a hygrometer (see illustration).

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The following measures are required every 6months:

u 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 must be inspected by an ABB Turbocharging Service Station and repacked.

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

bocharger 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 component

¡ Replace the desiccant agent

¡ Repackage the component.

NOTICE

Turbocharger ready for operation

If the 70% field of the hygrometer(02) has not changed colour and the package is undamaged, the turbocharger can be put into operation without any prior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

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.

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

1 Preliminary remarks / 1.5 Essential information

1.5 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulations for the prevention of accidents and protection of the environment are also to be observed.

This also applies for 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.

u If the turbocharger shows modifications affecting safety or any cor-

responding operating behaviour, it must be shut down immediately by stopping the engine. The malfunction must be reported to the person or department responsible.

NOTICE

Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbocharging.

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

1 Preliminary remarks / 1.5 Essential information

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

Page 10 / 113

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

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.

Registered Trademarks

Registered trademarks of external companies are used in this document. The trademarks are marked with ®.

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

1 Preliminary remarks / 1.6 Symbols and definitions

1.6 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 Turbocharging

ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document.

Official service stations of ABB Turbocharging

Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →13.

Page 11 / 113

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

1 Preliminary remarks / 1.7 Turbocharger rating plate

1.7 Turbocharger rating plate

Page 12 / 113

Operating limits

Recommended inspection and replacement intervals for turbocharger components

Further information

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 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 09 Turbocharger type

10 Serial number

11 Year of turbocharger construction

12 Manufacturing plant

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

1 Preliminary remarks / 1.8 Contact information

1.7.1 Explanation 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 n

Bmax

the recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. n

Mmax

and t

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

Mmax

trials on the engine test bed. Operation above n ted. Non-observance of the recommended replacement intervals increases the risk of unpredictable component failures.

1.7.2 Positions of the rating plates

One rating plate(01) each is attached on the left and the right side of the turbocharger bearing casing.

, t

can considerably shorten

Bmax

Mmax

and t

is not permit-

Mmax

Page 13 / 113

1.8 Contact information

Contact information for the official service stations of ABB Turbocharging is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland

www.abb.com/turbocharging

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

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 instruc-

tions

¡ are the consequence of unsatisfactory and improper execution of

maintenance and inspection work.

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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.

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

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-

To be worn according to the specific work

Safety glasses Safety goggles

tect against mechanical hazard and risk of falling

Safety gloves against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

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.

Respiratory mask

against

- Dusts

- Gases

Page 15 / 113

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.

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

2 Safety / 2.5 Warning plates on the turbocharger

2.5 Warning plates on the turbocharger

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

Page 16 / 113

If warning plates are not present at the intended places or are not legible, then proceed as follows:

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove unreadable warning plates.

u Clean and degrease surfaces provided for warning plates.

u 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.

2.6 Safe 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.

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

2 Safety / 2.6 Safe operation and maintenance

Work safety and work area safety

WARNING

Risk of falling

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

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

these as climbing aids.

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

platforms suitable for this purpose.

u Observe all general regulations for the prevention of accidents.

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

stress.

u Work only with suitable tools as well as equipment and working ma-

terials that are in perfect condition.

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

be damaged.

u Keep the workplace clean, clear away loose objects and remove

obstacles on the floor.

u Keep the floor, equipment and the turbocharger clean.

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

ready or in position

u Eliminate leaks.

u Keep fire-protection materials and fire-extinguishing equipment

ready.

Welding work close to the turbocharger

u If welding work is being carried out in the vicinity of the turbocharger,

cover the filter silencer so that the filter mat is not damaged.

u Remove combustible objects and substances out of the range of fly-

ing sparks.

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

can get into the turbocharger.

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

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

2 Safety / 2.6 Safe operation and maintenance

Safety during start-up / commissioning and operation

WARNING

The turbine casing insulation of the TPS44-F supplied by ABB is also burst protection

Serious personal injuries or fatal accidents can occur, if the turbine casing insulation of the TPS44-F supplied by ABB is removed. The burst protection is integrated into the turbine casing insulation of the TPS44F supplied by ABB.

Separate burst protection is fitted to TPS44-F turbochargers that have been ordered from ABB without insulation.

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

ABB with insulation if this insulation from ABB is not in place.

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

tion from ABB is not in place, the separate burst protection (57200) must be fitted before operation (see View of turbocharger showing

part numbers →110).

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

u Remove any obstacles and objects lying around.

u Before start-up / commissioning, check all pipes from and to tur-

bocharger for damage and leaks.

u Don't work in any way that could impair safety when working on tur-

bocharger.

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

turbocharger for visible damage and defects.

u Immediately report any damage or changes in operational perform-

ance to person responsible.

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

cure it against inadvertent or unauthorized use.

u 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.

u Observe the material safety data sheet for the cleaning agent or

solvent.

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

safety data sheet.

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

2 Safety / 2.6 Safe operation and maintenance

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

your cleaning work.

Safety during disassembly, assembly, maintenance and troubleshooting

u Always perform the specified adjustments, servicing as well as in-

spection work and observe inspection intervals.

u Inform operating personnel about all service and repair work before

beginning.

u Before opening a cover or removing a protective device on a tur-

bocharger, the engine must be switched off and the turbocharger must have come to a standstill.

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

oil supply.

u 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.

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

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

Safety when taking out of operation or preparing for mothballing

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

the force of the stack draught.

u Clean the turbocharger before mothballing it.

u Observe the material safety data sheet for the cleaning and moth-

balling agents.

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

safety data sheet.

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

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.

u Operate the turbocharger in accordance with instructions.

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

tation.

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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.

u Observe the general rules for occupational safety and prevention of

accidents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

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

struction or training.

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

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.

u Always wear ear protection when the engine is running.

u 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 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.

u Do not touch hot surfaces and heed the warning plate on the tur-

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

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

Wear safety gloves to protect against thermal hazards.

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

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.

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

ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Page 22 / 113

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.

u Avoid inhalation and contact with the skin.

u Ensure good ventilation.

u Observe details in the safety data sheets of the operating and auxili-

ary materials.

u 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..

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.

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

ing and auxiliary materials.

u Comply with local legislation.

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

work.

u Carry out cleaning in the open or provide sufficient 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.

u Handle operating and auxiliary materials carefully.

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

on the containers of the operating and auxiliary materials.

u Wear appropriate protective clothing.

u Avoid inhalation and contact with the skin.

u Ensure that the work space is adequately ventilated.

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

u Collect used working and auxiliary materials safely, store them separ-

ately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regulations.

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

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.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

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Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Wear suitable work clothing (safety glasses, respiratory mask).

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

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

2 Safety / 2.8 Deflagration on gas engines

Hazards due to electrical components

WARNING

Hazards due to electrical components

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

u All work on or with electrical components may only be performed by

trained specialists.

u Heed any country-specific regulations.

2.8 Deflagration on gas engines

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

ABB Turbocharging recommends that, following a deflagration event, the turbocharger undergoes an inspection of the following points:

¡ 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. This inspection and evaluation must be carried out by an ABB Turbocharging Service Station.

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

2 Safety / 2.9 Periodic checking of the pressure vessel

2.9 Periodic 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.

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2.10 Lifting loads

WARNING

Suspended loads

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

u Loads must always be fastened to technically perfect lifting gear

with sufficient loading capacity.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

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

2 Safety / 2.10 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.

u Fasten turbocharger assemblies / components as described in re-

spective handling steps.

u Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).

u Use suitable protection at sharp edges.

u Completely screw in assembly / fitting devices without fail so that

they cannot work loose during use.

u Use assembly / fitting devices only for applications described.

u Make sure removed turbocharger components stand safely and se-

curely.

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

3 Start-up / 3.1 Oil supply

3 Start-up

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. If a separate lubricating system is used, then emergency lubrication is also to be provided.

u Heed the instructions of the engine builder when selecting the lubric-

ating oil and oil-change intervals.

Oil filtration

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CAUTION

Depending on the turbine specifications and bearings used, varying amounts of contaminants have to be filtered out of the lubricating oil to avoid dangerous wear of the bearing parts.

The standard oil filter specification for the turbocharger is 34µm. This means that contaminants larger than 0.034mm must be filtered out of the oil with a separation efficiency >99%.

u Fit an accessory filter if engine oil filter is not efficient enough.

u If the engine is started cold and the flow resistance rises to above 0.5

bar due to deposits of dirt in the accessory filter, a bypass must open which ensures that oil flows to the turbocharger by circumventing the filter.

u Check that oil filters are clean before commissioning.

NOTICE

Also follow the enginebuilder's instructions regarding filter mesh and separation efficiency.

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