Service Bulletin S – 5.

1
08.11.99
Technical Information to all Owners / Operators (Supersedes Bulletin
of Sulzer S20 Engines S–5 of 25.12.95)

ABB Type RR ..1 Turbocharger

Improvement for HFO Service

Contents: Page

1. Introduction 1
2. Bearing Loading and Overheating 1
3. RR ..1 Type Turbochargers 2
with Water Cooling
4. Avoiding Oil Leakage during 2
Stand By Periods
5. Further Hints when Working 3
on the Turbocharger
6. Conclusion 3
7. Service Bulletins Published for 4
S20 Type Engines
28.70.07.40 – Printed in Switzerland

Wärtsilä NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22

Wärtsilä NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wärtsilä NSD Suisse SA Switzerland Tlx 896 659 NSDL CH
1. INTRODUCTION
Following some reports some time ago of damage to ABB RR ..1 turbochargers fitted to
engines which are running on HFO (Heavy Fuel Oil).
Service Bulletin S-5 was issued about countermeasures introduced to alleviate the bearing
problems experienced.
Following changes have been made in this Service Bulletin S-5.1 regarding to the previous
Service Bulletin S-5. The clearance tables A" and B" have been limited to the Turbocharger
types used for these engines. The lubricating oil pressures at stand-by have been reduced
according to the turbocharger type.

This Service Bulletin should be kept in a separate file in the control room. The respective pages or
tables of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual
or Code Book should be copied and filed in the respective Manual or Book.

2. BEARING LOADING AND OVERHEATING

Some problems were recently experienced with damage to bearings of ABB RR ..1 type
turbochargers which could be traced back to an overheating problem of the turbine side
bearing.
The area around the bearing on the turbine side, which is presently cooled with oil, could be
heated up to such a degree, during normal operation and after engine shut down, that
carbonization can take place due to the high bearing temperature. This may result in starvation
of bearing lubricating oil and reduced flow of cooling oil. It can manifest itself in bearing
damage, excessive bearing wear, that the rotor runs in an outofbalance condition and may, in
extreme cases, lead to turbocharger destruction.
Due to the above mentioned reasons, we strongly recommend checking the condition of the
bearings at regular intervals. The necessary information and limiting values of bearing
clearance have been stated by ABB as follows:
Checking interval: 4'000 hours

Axial clearance "A" (RR..1) Radial clearance "B" (RR..1)

(See also WorkingInstructions RR..103002 (See also WorkingInstructions RR..103002
and Operation manual) and Operation manual)

~80 N ~80 N

RR .. RR ..
131 151 181 131 151 181

A max. 0.13 0.17 0.19 B max. 0.70 0.75 0.83

1/4 Service Bulletin S-5.1

3. RR ..1 TYPE TURBOCHARGERS WITH WATER COOLING

To avoid bearing problems the turbocharger housing is to be cooled by water for engines
running on HFO.
On the bearing housing NA2 the existing water inlet and outlet connections must be connected
in parallel with the cylinder cooling water supply and return pipes as shown on enclosures
S-5.1/1 for 4 S 20, S-5.1/2 for 6 S 20 and S-5.1/3 for 8 and 9 S 20 type engines.
On turbochargers with the previous bearing housing NA1, which has no water cooling
connections, the existing housing must be replaced with the bearing housing NA2 and the
water connections must be connected according to the enclosures S-5.1/1, S-5.1/2 or S-5.1/3.
On 4 S 20 type engines with ABB turbocharger RR 131 the existing bearing housing NA4 must
be machined in accordance with the ABB drawing on enclosure S-5.1/1a. It is advisable that
the modification (remachining) of the bearing housing is carried out through the local ABB
turbocharger service.
If it becomes necessary to replace the bearing housing NA4 the following number must be
quoted to ABB Turbo Systems Ltd. in order to receive the correctly modified housing:

Bearing Housing NA4, RR 131 SLGG 06 / HZTL 317733.

For installations where, due to operating profile, standby conditions or ambient condition (fuel
and lube oil quality), problems with RRTurbochargers have occurred, the introduction of the
water cooling is to be carried out at the earliest opportunity. This is also valid if abnormal
conditions are detected during the above mentioned regular checks.
A conversion to water cooling for S20 engines without turbocharger problems (regularly
checked) is recommended at the next engine overhaul.

4. AVOIDING OIL LEAKAGE DURING STAND-BY PERIODS

Tests on an RR 151 ABB turbocharger have shown that under certain conditions oil can leak
from the compressor side bearing housing into the internals of the turbocharger, during
standby periods, if the oil pressure before the turbocharger exceeds a certain level.
The above mentioned tests have shown that with a correctly sized orifice in the oil supply line to
the turbocharger, the oil pressure is maintained at a value where no oil leaks past the shaft seals
of the rotor shaft.

2/4 Service Bulletin S-5.1

The sketch and the table below inform you about the dimension and the correct diameter of the
orifice suitable for the turbocharger type fitted on your S20 type engine.

ORIFICE FOR OIL SUPPLY PIPE TO TURBOCHARGER

Pressure gauge connection M14x1.5 mm

countersunk Ø 20 mm, depth: till surface is clean

* All the bores must

be absolutely free
M22x1.5
of burrs.

SW 41
Øx

M22x1.5

(30.5) 15-
+0.3 27.5

73 TURBO-
CHARGER RR 131 RR 151 RR 181
23 Arrow for direction of oil TYPE
flow to be stamped in!
ORIFICE
DIAMETER 3.3 3.7 4.2
x in mm

OIL PRESSURE
Øx
IN OPERATION 2-6 2-6 2-6
bar

OIL PRESSURE
AT STANDBY 0.3 - 0.5 0.3 - 0.5 0.3 - 0.5
bar
Orifice Ø to be stamped in!

Note: All pressures mentioned in the above table are gauge pressures.
The above orifice for the oil supply line of the turbocharger of your engine can be obtained from
Wärtsilä NSD Switzerland Ltd or one of our Network Companies.

5. FURTHER HINTS WHEN WORKING ON THE TURBOCHARGER

As a reminder we would like to stress that the complete turbocharger should be removed from
the engine prior to any work which makes it necessary to remove the rotor shaft, in order to
avoid damage to the exhaust pipe expansion bellows.

6. CONCLUSION

By water cooling the bearing on the turbine side of the turbocharger, the thermal loading of the
bearing oil will be reduced and a safer operation of the turbocharger in heavy fuel oil service will
be guaranteed.
If, in addition to the modification to water cooling, the correct size of orifice is fitted into the
bearing oil supply pipe, the risk of bearing oil leaking into the combustion chamber of the
engine is ruledout and the possibility of additional secondary damage is therefore drastically
reduced.

3/4 Service Bulletin S-5.1

7. SERVICE BULLETINS PUBLISHED FOR S 20 TYPE ENGINES

We have so far published the following Service Bulletins which are valid for S 20 type engines:

S-1 dated 18.02.94 Undersized Bearings and Reconditioning of Crankshaft

S-2 dated 15.07.94 Cylinder Liner with a Fine Thread in the Upper Part of the Bore
S-3 dated 01.09.94 Tightening Sequence for the Fuel Stud and the Valve Housing
S-4 dated 18.10.94 Heavy Fuel Oil Concept Guide and System Adjustments for
S 20 Marine Auxiliary Engines
S-5.1 dated 08.11.99 ABB Type RR ..1 Turbocharger Improvement for HFO Service
S-6 dated 15.09.95 New Piston Ring Fitting Tool
S-7 dated 29.09.95 Oil Baffle on Driving End
S-8 dated 22.03.96 New Uncooled Fuel Injection Nozzle for MDO Operation
S-9.1 dated 31.03.96 Engine Starting Control System
S-10.2 dated 25.03.99 Exhaust Valve Seat Bore in the Cylinder Head
S-11 dated 31.01.97 Alphabetical Index of Topics of Service Bulletins
S-12 dated 16.05.97 Top Piston Ring
S-13 dated 19.09.97 Lubricating Oil Treatment and Systems
S-14 dated 30.01.98 Starting Air Valves
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact
your local Wärtsilä NSD representative for your copy.

Wärtsilä NSD Switzerland Ltd has issued this Service Bulletin with their best knowledge and
ability. However, Wärtsilä NSD Switzerland Ltd can not take any liability for any or all information
contained in this or any other Service Bulletin.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as
published by Wärtsilä NSD Switzerland Ltd, are not permitted.

ENCLOSURES: as mentioned in the text

4/4 Service Bulletin S-5.1

COOLING WATER PIPE CONNECTIONS
FOR 4 S20 TYPE ENGINES

Vent pipe
A

Service Bulletin Enclosure S–5.1/1

MODIFICATION TO BEARING HOUSING TYPE NA4
OF ABB TURBOCHARGER RR 131
FOR 4 S 20 TYPE ENGINES

The bearing housing NA4 of ABB turbocharger type RR 131 suitable for 4 S 20
type engines must be modified according to the above drawing before the
cooling water pipes can be connected.
We strongly recommend to contact the local ABB Turbocharger Service
Representative before the modification is carried out in order to avoid any
difficulties with the machining of the bearing housing.
IF A NEW BEARING HOUSING IS REQUIRED IT CAN BE ORDERED THROUGH
ABB TURBO SYSTEMS Ltd. QUOTING THE FOLLOWING ORDERING DETAILS:
BEARING HOUSING NA4, RR 131 SLGG 06 / HZTL 317733.

Service Bulletin Enclosure S–5.1/1a

 COOLING WATER PIPE CONNECTIONS
FOR 6 S20 TYPE ENGINES

Drawn for engines

with cooling water
outlet pipe connec
tion at free end.

Drawn for engines

with cooling water
outlet pipe connec
tion at driving end.

Service Bulletin Enclosure S–5.1/2

 COOLING WATER PIPE CONNECTIONS
FOR 8 and 9 S20 TYPE ENGINES

Drawn for engines

with cooling water
outlet pipe connec
tion at free end.

Drawn for engines

with cooling water
outlet pipe connec
tion at driving end.

Service Bulletin Enclosure S–5.1/3