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15 Turbocharging and Air Cooling version : 15-8604-03

15.1 Turbocharger

15.1.1 Description

The turbochargers are of the axial turbine type. The insert type charge air cooler is mounted in a welded housing which,
at the same time, serves as a bracket for the turbocharger. 12 and 16 cylinder V-engines have two identical cooler inserts
in a common housing.

The turbocharger is cooled with water and connected to the engine cooling system. The turbocharger has a lubricating oil
system of its own.

The air outlet casing is connected to the air duct and the exhaust pipes to the gas inlet casing through metal bellows. The
exhaust pipe after the turbocharger should be arranged according to the installation instructions.

figure: 15-1 Turbocharger and air cooler

Turbochargers for engines running on heavy fuel (22HF and 22HE) are equipped with cleaning devices for washing by
water of the compressor and the turbine.

Turbochargers for engines running on marine diesel fuel (22MD) are equipped with cleaning devices for washing by water
of the compressor.

15.1.2 Turbocharger maintenance

Normal overhauls can be carried out without removing the turbo-charger from the engine.

When dismantling, remove the connection pipes for water. Loosen the exhaust inlet and outlet pipes.

When reassembling, take care that all seals are intact. High temperature resistant lubricants are used for exhaust pipe
screws.

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Maintenance of the turbocharger is carried out according to section 15.1.3 and to the instructions of the turbocharger
manufacturer. It is recommended to use the service net of the engine manufacturer or the turbocharger manufacturer.

15.1.3 Water cleaning of turbine during operation (applies to engines running on heavy
fuel)

figure: 15-2 Water cleaning of turbine

15.1.3.1 Principles of the cleaning method

As practical experiences show, the dirt deposits on the turbine side can be reduced by periodic cleaning (washing) during
operation.

The principle is to employ water-droplet action to clean the guard, turbine nozzle and turbine blades of combustion
products while the engine is running at reduced power, by a combination of scouring action and partial dissolving of the
deposits.

Under no circumstances the turbine should be allowed to run long enough to become very heavily coated with deposits.

A fouled turbine can be recognized by abnormal exhaust gas tem-perature, charger speed and charge air pressure. In
some case it can lead to compressor surging. The bearings of the turbocharger are also sensitive to the imbalance caused
by the deposits.

The water supply is conveyed to an injector (1) with fixed size orifice, fitted into each branch of the engine exhaust gas
pipe. Turbochargers, which have one gas inlet, are provided with two injectors on the same pipe. The injectors are
connected to a quick-coupling (2).

15.1.3.2 Cleaning intervals

The optimum period between cleaning operations will obviously vary from one installation to another, and will depend on
the type of fuel used as well as on running conditions. Under "average" conditions, with engines running on residual fuels,
experience shows that cleaning intervals of about 200 hours are satisfactory.

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15.1.3.3 Water flow rates

The necessary water flow is basically dependent on the volume of gas and its temperature. The flow should be adjusted
so that about 50 to 70% of the water is evaporated and escapes through the exhaust gases, while the remaining water is
drained through the tap in the exhaust casing.

Recommended water flow rates:

Water cleaning of turbine

Turbocharger size ∆p (bar) Water flow (l/min)

VTR 161 1 2.0 - 3.0

VTR 201 1 3.0 - 4.5

VTR 251 1 4.5-7

Additives or solvents must not be used in the cleaning water. The use of salt water is out of question.

15.1.3.4 Cleaning procedure:

1 Record blower charge air pressure, cylinder exhaust gas tem-peratures, charger speed, for later use to
assess efficacy of cleaning.

2 Reduce engine load to between 10 and 20% of full load rating.

3 Open the valves (1), and check that they are not clogged.

4 Connect the water hose.

5 Open the drain valve (3) and check that it is clear of block-age.

6 Open the valve (5) and valves (1) completely.

7 The pressure control valve (4) must be adjusted to a pressure of 1 bar.

8 Check the water drains through the drain pipe.

9 Cleaning is terminated after about 10 min. The water supply valve (5) is closed.

10 After termination of water injection the engine must run for three minutes at constant load until all
parts are dry.

11 Shut all valves and disconnect the hose to ensure that no water can possibly enter the exhaust pipes except
during the cleaning periods.

12 Resume normal engine operation at higher output and, as soon as possible, repeat the readings taken
under step 1. for comparative purposes.

Water washing of the compressor side during operation, see

enclosed separate manual for the turbocharger.

15.2 Charge air cooler

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15.2.1 Maintenance of charge air cooler

Condensate from the air is drained through a small pipe (6) at the bottom of the cooler housing, after the insert. Exa-
mine regularly that the pipe is open by checking the air flow when running.

If water keeps on dripping or flowing from the draining pipe for a longer period (unless running all the time in condi-
tions with very high humidity) the cooler insert may be leak and must be dismantled and pressure tested.

At longer stops, the cooler should be either completely filled or completely emptied, as a half-filled cooler increases the
risk of corrosion. If there is a risk of sinking water level in the system when the engine is stopped, drain the cooler
completely. Open the air vent screw (3) to avoid vacuum when draining.

Clean and pressure test the cooler at intervals according to section 04 or if the receiver temperature cannot be held within
stipulated values at full load.

Always when cleaning, check for corrosion.

15.2.2 Cleaning cooler insert

A) Remove the cooling water pipes. Loosen the cooler insert flange screws and withdraw the insert until the thread
or the hole (7) for the lifting tool is visible. If necessary, use the screws in the two threaded extractor holes in
the flange.

B) Apply the lifting tool and lift off the insert.

C) Clean the air side with a degreasing liquid and blow pressure air or steam through the insert. See also section
18.5.3.

D) Remove the water boxed (4) and (5) to make the water side accessible.

E) Clean the water side according to the instructions for oil cooler in section 18.5.4.

F) Check the gaskets.

G) Reassemble the cooler insert and mount it on the engine. Check tightness when starting up.

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