Abb TPS 57D01 User Manual
Operation Manual
TPS 57D01
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPS 57D01 HT843552
n
Mmax
n
Bmax
SGAK02 00410 12 50 50
Year 2017
HZTL2410 English
Original Operation Manual
709 t
678 t
Mmax
1/s °C
Bmax
kg
made in Switzerland
650
620
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 / TPS48-D/E.. - TPS61-D/E..
Table of contents
© Copyright 2016 ABB. All rights reserved.
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
2.3
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 vessel
2.10
Lifting loads
3
Commissioning
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
Page 1
September 2016 HZTL2410_EN Revision E
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Table of contents
© Copyright 2016 A
5
Maintenance
5.1
Foreword 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 starting
6.2
Surging of the turbocharger
6.3
Malfunctions during operation
6.4
Malfunctions when stopping
6.5
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
Page 2
September 2016 HZTL2410_EN Revision E
BB. All rights reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Purpose of this manual
1.1
© Copyright 2016 ABB. All rights reserved.
Preliminary remarks
Purpose of this manual
Operation Manual
Target group
Availability of operation manual
1
1.1
Page 3
1.1
September 2016 HZTL2410_EN Revision E
This operation manual belongs to the turbocharger with the identical HT
number (01), see the cover sheet of the operation manual and the turbocharger rating plate.
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.
This Operation Manual is intended for engineers and qualified mechanics
who are responsible for operating the engine and the turbocharger installed on it.
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 / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Layout and function
1.2
© Copyright 2016 ABB. All righ
Layout and function
1.2
1.2
Page 4
September 2016 HZTL2410_EN Revision E
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
13 Compressor wheel
only at turbine end)
7
Turbine
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Layout and function
1.2
© Copyright 2016 ABB. All rights reserved.
Mode of operation
Page 5
The turbocharger is a turbomachine consisting of the following main components:
Turbine
September 2016 HZTL2410_EN Revision E
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).
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Intended use of the turbocharger
1.3
© Copyright 2016 ABB. All righ
Intended use of the turbocharger
NOTICE
This turbocharger supplied by ABB Turbo Systems has been developed
used
with a gas engine
not
explosive environment
not potentially explosive
WARNING
Improper operation and maintenance of the turbocharger can result in
1.3
State of the art
Perfect condition
1.3
Page 6
for use on diesel engines to generate the volume of air and the charging 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 limits specific to the turbocharger shown on the rating plate (such as operating speeds, temperatures, exchange intervals / replacement intervals)
have been derived.
If it is
stalled in a potentially
in conjunction
, the engine must
, and precautionary
be in-
measures must be taken to ensure that the machine room as a whole is
classified as
.
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 Systems reserves the right to reject all warranty claims.
September 2016 HZTL2410_EN Revision E
This turbocharger was built according to state-of-the-art technology and is
operationally safe according to recognised safety regulations.
danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine.
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.
Malfunctions which could affect safety must be eliminated immediately.
The manufacturer accepts no liability for any damage resulting from unauthorised alterations to the turbocharger.
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
© Copyright 2016 ABB. All rights reserved.
Storage of new turbochargers and spare
parts
Storage of new turbochargers and spare parts up to 6 months
V
Storage of new turbochargers and spare parts for more than 6 months (VCI)
WARNING
Protection of health when handling VCIs
1.4
Page 7
1.4
September 2016 HZTL2410_EN Revision E
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).
olatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
VCI products are not hazardous in the sense of the Hazardous Substances Ordinance. Nevertheless, the following points are to be observed when handling VCIs:
Ensure good room ventilation.
Do not eat, drink or keep food at the workplace while working with
VCIs.
Wear safety gloves.
Clean hands and face after working with VCIs.
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:
Open the package.
Remove the VCI corrosion protection emitter from the package and
Dispose of the old VCI corrosion protection emitter in an environmen-
Seal the package. The better the external seal is designed, the more
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at
www.branopac.com.
tally compatible manner, professionally and in accordance with local
regulations.
permanent the protection.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Storage of new turbochargers and
spare parts
1.4
© Copyright 2016 ABB. All righ
Long-term storage of replacement turbochargers or spare parts
NOTICE
Replacement components ready for operation
Unpacking replacement turbochargers or spare parts
Page 8
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).
September 2016 HZTL2410_EN Revision E
The following measures are required every 6 months:
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.
Inspect the package for damage. If the package is damaged, the tur-
bocharger 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.
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.
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.
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Essential information
1.5
© Copyright 2016 ABB. All rights reserved.
Essential information
Organisational measures
NOTICE
The manner in which personnel work on and with the turbocharger with
NOTICE
Any modifications, additions or conversions made to the turbocharger,
1.5
1.5
Page 9
In addition to the Operation Manual, the general statutory regulations for
September 2016 HZTL2410_EN Revision E
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.
regard to safety and risks is to be checked on a regular basis in accordance with the Operation Manual.
The turbocharger must be shut down immediately in the event of modi-
fications affecting safety or of corresponding operating behaviour by
stopping the engine. The fault should be reported to the person or department responsible.
which could impair safety, require the prior approval of ABB Turbo Systems.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Essential information
1.5
© Copyright 2016 ABB. All righ
Original parts and safety
WARNING
Use original parts
Competence of personnel
Page 10
Original parts and accessories are specially designed for the turbocharger
supplied by ABB Turbo Systems.
September 2016 HZTL2410_EN Revision E
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.
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.
The turbocharger must only be operated and serviced by trained and authorised personnel. Basic mechanical training is a prerequisite.
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Essential information
1.5
© Copyright 2016 ABB. All rights reserved.
Design variants
Accuracy of illustrations
Registered Trademarks
Page 11
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.
September 2016 HZTL2410_EN Revision E
ABB Turbocharging Service Stations will be happy to provide information
on questions regarding a design variant (see Contact information at
www.abb.com/turbocharging).
The illustrations in this document are general in nature and intended for
ease of understanding. Differences in detail are therefore possible.
Registered trademarks of external companies are used in this document.
The trademarks are marked with ®.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Symbols and definitions
1.6
© Copyright 2016 ABB. All righ
Symbols and definitions
Definition of notes
NOTICE
Note
Definition of mandatory signs
Definition of caution / warning
ABB Turbo Systems
Official ABB Turbo Systems Service Stations
1.6
1.6
Page 12
The following symbols are used in the documents:
Prerequisite
Step of a procedure
List, first level
- List, second level
[➙ ] Refers to a page number
September 2016 HZTL2410_EN Revision E
A note provides suggestions which facilitate the work on the product.
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.
The caution and warning signs are described in the chapter Safety.
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo
Systems.
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 [➙ 15].
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Turbocharger rating plate
1.7
© Copyright 2016 ABB. All rights reserved.
Turbocharger rating plate
06 Customer part number
07 Designation of the special design
08 Weight of turbocharger in kg
09 Turbocharger type
11 Year of construction of turbocharger
1.7
Operating limits
Recommended inspection
and replacement intervals
of turbocharger components
Further data
1.7
September 2016 HZTL2410_EN Revision E
Page 13
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
10 Serial number
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Turbocharger rating plate
1.7
© Copyright 2016 ABB. All righ
Explanation of the rating plate
Positions of the rating plates
1.7.1
1.7.2
Page 14
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
, t
can considerably shorten the
Bmax
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 tri-
Mmax
als on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above n
Mmax
and t
is not permitted.
Mmax
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
September 2016 HZTL2410_EN Revision E
One rating plate (01) each is attached on the left and the right side of the
turbocharger bearing casing.
ts reserved.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Preliminary remarks
1
Contact information
1.8
© Copyright 2016 ABB. All rights reserved.
Contact information
Contact information
1.8
1.8
Page 15
Contact information for the official service stations of ABB Turbo Systems
September 2016 HZTL2410_EN Revision E
is available online.
Scan the QR code to access our website.
ABB Turbo Systems Ltd
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Introduction
2.1
© Copyright 2016 ABB. All rights reserved.
Safety
Introduction
2
2.1
Page 17
2.1
September 2016 HZTL2410_EN Revision E
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 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
The operator is responsible for access to the turbocharger as well as the
organisational measures which regulate the safe handling of the turbocharger by his personnel.
All instructions in this chapter must be observed to ensure safe and trouble-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 Definition of safety instructions).
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
CE conformity
2.2
© Copyright 2016 ABB. All rights reserved.
CE conformity
Information
2.2
2.2
Page 18
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are considered partly completed machinery in the sense of Article 2 g.
September 2016 HZTL2410_EN Revision E
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Definition of mandatory signs
2.3
© Copyright 2016 ABB. All rights reserved.
Definition of mandatory signs
To be worn at all times
Protective clothing
Safety footwear
To be worn according to the specific work
Safety glasses
Safety goggles
Safety gloves to protect
Respiratory mask to protect
Safety helmet
Ear protection
2.3
2.3
Page 19
to protect
against mechanical hazard
and risk of falling
September 2016 HZTL2410_EN Revision E
against
- Mechanical hazard
- Chemical hazard
against
- Dusts
- Gases
- Thermal hazard
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Definition of Safety instructions
2.4
© Copyright 2016 ABB. All rights reserved.
Definition of Safety instructions
WARNING
Definition of warning
WARNING
Warning signs must be observed at all times.
CAUTION
Definition of caution
CAUTION
Caution signs must be observed at all times
2.4
2.4
Page 20
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol
and the word
are either not followed or not followed precisely.
Serious machine or property damage may occur if work and operating
instructions marked with this symbol and the word
are either
not followed or not followed precisely.
.
September 2016 HZTL2410_EN Revision E
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Warning plates on the turbocharger
2.5
© Copyright 2016 ABB. All rights reserved.
Warning plates on the turbocharger
Uninsulated turbochargers
2.5
2.5
Page 21
Warning plates are attached to the turbocharger at the following places:
September 2016 HZTL2410_EN Revision E
If warning plates are not present at the intended places or are not legible,
then proceed as follows:
Order new warning plates from ABB Turbocharging Service Stations.
Remove unreadable warning plates.
Clean and degrease surfaces provided for warning plates.
Attach new warning plates.
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.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Safe operation and maintenance
2.6
© Copyright 2016 ABB. All rights reserved.
Safe operation and maintenance
Work safety and work area safety
WARNING
Risk of falling
Welding work in the vicinity of the turbocharger
2.6
2.6
Page 22
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.
September 2016 HZTL2410_EN Revision E
There is the risk that someone can fall when working on the turbocharger.
Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
Observe all general regulations for the prevention of accidents.
Do not work on the turbocharger if you are under physical or mental
stress.
Work only with suitable tools as well as equipment and working mate-
rials that are in perfect condition.
Electric tools must be solidly earthed, and connecting cables may not
be damaged.
Keep the workplace clean, clear away loose objects and remove ob-
stacles on the floor.
Keep the floor, equipment and the turbocharger clean.
Have oil binding materials ready at hand and keep oil catch pans
ready or in position
Eliminate leaks.
Keep fire-protection materials and fire-extinguishing equipment ready.
When performing welding work in the vicinity of the turbocharger, al-
ways cover the filter silencer to prevent the filter mat from being damaged.
Keep flammable objects and substances out of the range of flying
sparks.
Cover all connections on the turbocharger so that no foreign objects
can enter the turbocharger.
Wear personal protective equipment (PPE) for welding operations.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Safe operation and maintenance
2.6
© Copyright 2016 ABB. All rights reserved.
Safety during start-up / commissioning and operation
Safety during cleaning
Page 23
Before starting work, carry out visual inspection of working area.
Remove any obstacles and objects lying around.
Before start-up / commissioning, check all pipes from and to turbo-
September 2016 HZTL2410_EN Revision E
charger for damage and leaks.
Don't work in any way that could impair safety when working on turbo-
charger.
After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
Immediately report any damage or changes in operational perfor-
mance to person responsible.
If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
supplying these power sources.
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.
Observe the material safety data sheet for the cleaning agent or sol-
vent.
Wear personal protective equipment (PPE) according to the material
safety data sheet.
Inspect the electric cables for abrasion and damage before and after
your cleaning work.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Safe operation and maintenance
2.6
© Copyright 2016 ABB. All rights reserved.
Safety during disassembly, assembly, maintenance and troubleshooting
CAUTION
Mechanical work on the turbocharger
Safety when taking out of operation or preparing for mothballing
Page 24
Always perform the specified adjustments, servicing as well as inspec-
tion work and observe inspection intervals.
Inform operating personnel about all service and repair work before
beginning.
September 2016 HZTL2410_EN Revision E
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.
Ensure that the supply of oil is interrupted, especially with an external
oil supply.
Put the engine into operation only after all parts have been refitted
properly.
Possible damage to or destruction of components on the turbocharger.
Perform only those tasks that are described in this manual.
Perform work only for which training has been carried out.
Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
Clean the turbocharger before mothballing it.
Observe the material safety data sheet for the cleaning and mothball-
ing agents.
Wear personal protective equipment (PPE) according to the material
safety data sheet.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Hazards during operation and
maintenance
2.7
© Copyright 2016 ABB. All rights reserved.
Hazards during operation and maintenance
Mechanical hazards during operation
WARNING
Risk of injury
Mechanical hazards when working on the turbocharger
WARNING
Mechanical hazards
2.7
2.7
Page 25
September 2016 HZTL2410_EN Revision E
charger if it has been installed properly.
During normal operation, no mechanical hazards emanate from the turbo-
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.
Operate the turbocharger in accordance with instructions.
During maintenance work, secure the rotor against unintentional ro-
tation.
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.
Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate
operational procedures.
Observe the general rules for occupational safety and prevention of
accidents.
Ensure workplace safety.
Only perform operations that are described in this document.
Only perform operations for which you have previously received in-
struction or training.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Hazards during operation and
maintenance
2.7
© Copyright 2016 ABB. All rights reserved.
Hazards due to noise
WARNING
Hazards due to noise
Hazards due to hot surfaces and substances
WARNING
Risk of burning
Page 26
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.
Noise can cause impaired hearing, damage to health, mental disturb-
September 2016 HZTL2410_EN Revision E
ances, diminished attention and irritation.
Always wear ear protection when the engine is running.
When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
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.
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
Wear heat-resistant safety gloves and protective clothing.
Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Hazards during operation and
mainten
2.7
© Copyright 2016 ABB. All rights reserved.
WARNING
Hot surfaces on the non-insulated turbocharger
Hazards due to operating and auxiliary materials
WARNING
Handling operating and auxiliary materials
Page 27
ance
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-
September 2016 HZTL2410_EN Revision E
lation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with
hot surfaces.
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.
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.
Ingestion or inhalation of vapours of operating and auxiliary materials or
contact with such can cause damage to health.
Avoid inhalation and contact with the skin.
Ensure good ventilation.
Observe details in the safety data sheets of the operating and auxil-
iary materials.
Observe local laws.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
Operation Manual / TPS48-D/E.. - TPS61-D/E..
Safety
2
Hazards during operation and
maintenance
2.7
© Copyright 2016 ABB. All rights reserved.
WARNING
Risk of fire, explosion
CAUTION
Risk of environmental damage
Page 28
Flammable and combustible operating materials and supplies can catch
fire or resulting vapours can lead to an explosion.
Observe the details in the material safety data sheets of the operat-
ing and auxiliary materials.
Comply with local legislation.
Do not allow any exposed flame or ignition source during cleaning
September 2016 HZTL2410_EN Revision E
work.
Carry out cleaning in the open or provide sufficient aeration and ven-
tilation.
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.
Handle operating and auxiliary materials carefully.
Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
Wear appropriate protective clothing.
Avoid inhalation and contact with the skin.
Ensure that the work space is adequately ventilated.
Seal containers tightly immediately after use and put them away.
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 regulations.
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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