15. Turbocharging and Air Cooling 15.1 1. Botowe 2.Arcuct 8. Avent screw 4 Header 5 Header 6.Drain pe 7-Thrsod hole for tting toot Description ‘The turbochargers are ofthe axial turbine type. The insert type change air cooler is mounted in a welded housing, which, at the same time, serves a a brecket for the turbocharger. The housing is fastened to the engine block by screws, normally atthe free end of the engine. V-en- ‘ines have two identical cooler inserts in a common housing. ‘The gas inlet and outlet housings ofthe turbocharger are cooled with ‘water and cornected to the engine cooling system. The turbocharger hhas its own lubrieating ol system. "The outlet is connected to the air duct (2) through a piece of metal bellows (1). The exhaust pipes from the engine are also connected to the charger through metal bellows, The exhaust pipe after the turbo- charger shoul! be arranged according to the installation instructions. ‘The turbocharger is equipped with cleaning devices for cleaning both the compresecr and the turbine by water injection. “Materials ofthe tubes and water boxes ofthe air cooler depend on the cooling medium used. ‘Turbocharger and al cooler AA Fig 15-1 ie15.3 eee eee) Turbocharger maintenance Normal overhauls can be carried out without removing the turbo charger from the engine. When dismantling, remove the protecting covers and the connection pipes for water. Loosen the exhaust inlet and outlet pipes. "When reassembling, take care thatall seals areintact. High tempera ‘ture resistant lubricants are used for exhaust pipe screws. ‘Maintenance of the turbocharger is carried out according to section 153 and to the instructions of the turbocharger manufacturer, Its recommended ta use the service net ofthe engine manufacturer or the turbocharger manufacturer. Water cleaning of turbocharger during operation 15.3.1 Water cleaning of turbine ‘As practical experiences show, the dirt deposits on the turbine side can ‘be reduced by periodic cleaning (washing) during operation. The over- hhaul periods can be extended. Dirty turbines cause higher tempera- tures of the exhaust gas and higher stresses of the bearings due to imbalances. Usually, though, washing of the turbine side is necessary only when running on heavy fue. ‘During long periods of operation, periodic water cleaning provents the build-up of significant deposits on the turbine blades and nozzle blades. This cleaning method does not work on very dirty turbines ‘which have not been washed regularly. If the normal water cleaning of the turbine does not effect much on ‘the exhaust gas temperature level, hard deposits have probably built up on the nozzle ring and the turbine blades in the turbocharger, and they have to be cleaned mechanically. For that purpose, the rotor and the nozzle ring have to be removed from the turbocharger. ‘The water must be injected into the exhaust system with the engine running at reduced output (see 16.3.2, step 2). The disadvantages of reducing the output occasionally is not significant compared with the ‘advantages of cleaning. ‘The necessary water flow is basically dependent upon the volume of {gas and its temperature, The fow should be adjusted so that the major ppartof the water is evaporated and eseapes through the exhaust, while ‘the remaining water drains from the exhaust casing through the valve, ‘Additives or colvents must not be used in the cleaning water. The use ‘of salt water is prohibited Housings with several gas inlets are provided with an inlet valve (1) for each exhaust pipe. The engine 4R32 is provided with two valves on ‘the same pipe in ease it has only one gas inlet (generating sets). The valves are connoctod to a quiel-coupling 2).1-inet valve 2. auck-couping 3.Vove 4 Pow mater S.vove mene Le ‘The water washing of the turbine should be done as described in section 15.32. The water flow is controlled by flow meter (4) to a suitable value, see table below. ing deaning, the exhaust hosing i drained through the valve ‘leaning should take place regularly every 250 operating hours. Depending on the results blained the interval bebween bwo washings ‘maybe increased or reduced Water cleaning of turbine Fig 15-2 pol 15.3.2 Cleaning procedure [Hi Record blower charge ait pressure, cylinder exhaust gas temperatures, charger speed for later use to assess ficiency ofthe sleoning, 15-8Note! Note! Reduce engine load corresponding to « receiver pressure of 05...0.6 bar at nominal speed or reduce speed to between 400 and 600 RPM with a fixed propeller. Run the engine for five minutes on this load before the washing is started. Maximum exhaust gas temperature after cylinder is 880°C! ‘Open valves (1), and check that they are not clogged. II Measure the exhaust gas pressure, Ii Connect water hote. {Gi Open drain valve (3) and check that it is clear of blockage. Open valve (5) slowly within 10 s and increase the water flow ‘until the correct flow is reached according tothe table shown above, ‘After about 3 min washing of all gas inlets the best cleaning effect is achieved ifone inlet at atime is opened and washed. No water or a very Ile waters coming out from the drain pipe. BB tre woshing time is about 10 min, The ceaning procedurecan te repeated if necessary after one to two hours of normal operating. After termination of water injection the engine must run for three minutes at an unchanged loed until all parts are dry TB) shut alt valves and disconnect the hose to ensure that no ‘ater can possibly enter exhaust pipes except during the cleaning Teriods TI] Resume normal engine operation at higher output and, as son az possible, repeat the readings taker in step 1 above for comparative purposes. Run the engine for 100.20 min. more after the _ turbo- harger has been cleaned by water, Doing soit is ensured that all the pars in the exhaust system are completa dry. Coan the turbine (exhaust side) of the turbocharger at low loads (G0 50% of ull rated load). 15.3.3 Water cleaning of compressor or water washing ofthe compressor side during operation, see turbo- charger instruction manual, ection 2.0.6.Ea 15.4 15.5 Note! Note! SEI ene ‘loan the comprewor de) othe Kxbosharger a os figh a (God ce poste tated ooo, eae Allowable operation with damaged turbocharger Incase of a serious breakdown of the turbocharger, a blanking device ‘ora rotor locking device can be fitted according to the instructions in the turbocharger manual, section 3.1 ‘When the Vasa engines are in an emergency situation like this, they are able to operate temporarily at 20% output. The thermal overload, is a limiting factor on the diesel engine. Therefore, the exhaust gas temperatures must be carefully watched during operation with a locked roto. "Theexhaust gas temperature after the cylinder cover must notexceed 500°C, Both of he turbochargers on a V-engine must be locked orblanked fone of them fas, Maintenance of charge air cooler 1 General maintenance Il Condensate from the air is drained through a small hole! pipe (6), Fig 16-1, at the bottom of the cooler housing, after the insert, and at the opposite end plate of the air manifold, Bxamine regularly that the pipe is open by checking the air flow when running. lt water keeps on dipping or flowing from the draining pipe for a longer period (unlessrunning allthe ime in conaiifons with very high hhumidiy), the cooler insert may be leaky and must be dismantiad ‘and pressure tested. Ei Atlongerstops, the cooler should be either completely filled Gr completly eiaply, as « hellfled cooler increases the visk of corrosion, Irthere is risk of sinking water levelin the eystem when the engineis stopped, drain the cooler completely. Open the air vent screw @) to avold vacuum when draining, 88-6 Note! Turbocharging and P= Clean and pressure test the cooler at intervals according to chapter 04, or, ifthe receiver temperature cannot be held within stipulated values, at full lad. Always when cleaning, check for corrosion. 18.8.2 Cleaning of air cooler Cleaning ofthe water and air side heat exchange sufacesis imperative fora legend touble Bee operstin ofthe euge abd must be dane at regula terval HD kemove ne cooing woterpipes, Loosen the cooler tange terew tron an inline engine witha the codler untl te three tr the la (1 for tho iting ton vse, On te Vengine, withdraw the coor about 800 min and Ht th tool 9284002. Ser on the tao ty ning four of the air ole festering screws. Then, withdraw the Cooler completely towards the tol stp, necessary, use screws inthe two threaded extrector bales i the ange to ooen Ue cone App the titing fol and i of the cooler EX Clean the air side of the cooler by immersing it in a cher cal cleaning bath for at least 24 hours. Recommend cleaning deter- gents, see section 02.4. We recommend that cleaning tank should be equipped with perforated pipes on the bottom for the best clean- ing effet, see Fig 15-3. During cleaning steam or pressurised air should be connected to the pipes to get a good circulation. ‘When cleaning is completed, the cooler should be flushed thor- oughly by water. These of ahighpressurowaterjot for fushing, should be avoided thwlpack the ait into the middle of the cooler. “the rd of damaging the cooler fins Is great. Both of above wif resull In an Increased pressure drop over the cooler. ‘Clean the water side by detaching the headers (4) and (6) from the cooler bundle and immersing the tube bundle into a chemical cleaning bath for at least 24 hours. Upon completion, follow the direction given for the air side, Ei check the gaskets before reassembling the headers. 1G Mount the cooler on the engine.Alt cooler clecning tank Steam rat Perforated pes Cooler rset