34 ABB charge! 2|11

Tips for the operator

Protector of growth Safe working on site can save injuries, time and money. Benno Rüegg explains how.

Text Jonathan Walker, Photography ABB Turbo Systems

Health and safety at work or“operational health and safety”(OHS) is the subject of nationallegislation all over the world,

as well as regulations and guidelines fromvarious authorities. At ABB Turbochargingwe support and comply with all meas-ures aimed at preventing injuries.

Indeed, it is our policy not to serviceturbochargers where the safety of ourown technicians and our customers’ per-sonnel cannot be guaranteed.

Safety first – not just a sloganThe service business at ABB Turbo -

charging views compliance with OHSregulations as mandatory in all situa-tions. And, since our experience alsoshows that safe, orderly working is alsoefficient working, we look at OHS holisti-cally with other, interrelated aspects thatcan affect effective – and cost effective –working at the end user’s site. OHS hasthus become the subject of an open-ended project targeting continuousimprovement in our own practices andencouraging our business partners totake a proactive approach.

Experience shows that while thehuman aspects of safe working are para-mount, OHS represents a series of costsaving measures, because avoidableaccidents equal avoidable costs. At theextremes we are talking about avoidablerisks to life and limb, but even having tofish out a wrench dropped into anexhaust pipe when removing a turbo -charger can mean a costly delay.

Lifting gear should be in good working order and properly positioned.

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Tips for the operator

Structural Problems can be avoided by good

preparation and this starts in the designof an engine or engine room. Much of thefollowing may sound obvious, but every-thing mentioned here has been an actualproblem in the past.

Suitable access to the turbochargerand space for handling the removed turbocharger should be designed intothe layout of a ship’s engine room orpower station generator hall. Unfortu-nately, in the choice between a welldesigned, spacious engine room or morevessel payload, payload usually wins. Inmany cases we even find that to makespace to work on the turbocharger ortake it out of an engine room we have toremove unrelated equipment, with greatloss of time.

As well as leaving enough spacearound the engine to maneuver a turbo -charger on and off and in and out of theengine space, a crane (ideally) or otherlifting gear should be present whichallows direct vertical access of the hookto the turbocharger and permits it or itsheavy components to be moved exactlyinto position for refitting. The crane orhoist should, of course, be in good work-ing order, tested and have enough safeworking load (SWL).

In a power plant this should be anoverhead crane which gives the driver agood view of the turbocharger. In a ship’sengine room there should be a poweredhoist that can be moved on a track whichgoes directly over the turbocharger andextends over the engine room floor. It maysound obvious, but there should also beenough headroom for lifting the tur-bocharger completely clear of the engine.

Working at heightLooking at the engines themselves,

ABB service technicians often find thataccess platforms to the top of the enginedo not extend to the turbochargers. Theyare fine for removing cylinder heads andpulling pistons, but no use for removingand replacing turbochargers. In extremecases, engine rooms do not, typically,even have space to set up scaffoldingnext to the turbocharger.

It is certain that investment saved byleaving off a tracked hoist, installingshorter access platforms or cramming anengine into a confined space is not worth-while. Savings are already destroyed bythe extra time it takes ABB service techni-cians to set up temporary platforms andcreate a safe working environment.

Operational Good working practices are para-

mount to avoiding problems. Here aresome essentials involving little effort butavoiding big problems: – Always use personal protective equip-

ment (PPE: gloves, helmets, glasses). – Wear safety harnesses at all times

when working at height. – Ensure tools and parts are always

secured against being dropped.– Check the condition of hoists and

cranes do not exceed safe workingloads (SWL).

– Keep out of the danger zone when lift-ing and transporting loads.

– Provide correct strops and slings, etc.for lifting operations.

– Blank off open pipes and orifices tostop parts or tools falling in.

– Cover sharp edges, e.g. on compres-sor and turbine vanes and blades.

– Stay tidy – avoid tripping hazards onwalkways and platforms.

Planning and preparationThe end user can also save money by

correct scheduling of service and prepar-ing the worksite. Avoidable costs resultwhen a turbocharger cannot be workedon because other technicians are already /still on the engine.

A lot of time and money can also bewasted when, instead of the end users’staff, ABB technicians have to set uptemporary access platforms, they haveto go looking for equipment or they haveto clean the working area to make itsafe – for example removing slippery oilfilms, engine exhaust soot or other sub-stances hazardous to health or safeworking.

Go by the bookThere is often a temptation to impro-

vise. It may be satisfying to do some-thing inventive, but this often means mis-using something or using something notfit for purpose – e.g. hanging a load on anearby pipe.

In turbocharger servicing as in life:prevention is better than cure. Our holis-tic message is: Always follow guidelines,don’t take risks and – above all – usecommon sense!

Designing, preparing, planning and complying – the basis of safe working on site.

Engine platforms should always extend to the turbocharger.

Engine rooms should be designed for good turbocharger access.