Turbo FQJ

MAN B&W Diesel
Turbocharging.
The Uni Flow

Scavenging System.
L/73043-7.0/0602 (2300/MCJ)
© MAN B&W Diesel

The Air/Gas Flow.
MAN B&W Diesel
Exhaust gas receiver
Exhaust valve
Turbocharger
Cylinder liner
Scavenge air
receiver
Scavenge air
cooler
Water mist
catcher
© MAN B&W Diesel <2>

Turbocharging.
MAN B&W Diesel
© MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Supercharging/Turbocharging.
MAN B&W Diesel
Supercharging.
Turbocharging
S/K/L/MC, MC-C 3,5 – 3,8 ”

MAN B&W Diesel
Turbocharging.

MAN B&W Diesel
Surging!
What is Surging?
Why does Surging occur?
What might be the reasons for Surging?

Surging
MAN B&W Diesel
• Surging is a phenomena that occur when pressure

and mass flow can not sustain each other.
• Surging occur when stage instability are allowed

to progress into system instability.
• System instability or surge occur when boundary

operational conditions no longer follow the normal
operational conditions based on the design criterias.
• Therefore large changes in ambient/system

conditions (TC and engine related systems), may
lead to the phenomena we commonly know as surging.

Surging of turbocharger
Surging at high load has to be

avoided !
Kinematics of rotor during surging

will lead to
damage of the rotating elements !
Speed of the rotating components may

momentary rise by some 15% !
© MAN B&W Diesel 2004/10/29 <9>

General.
MAN B&W Diesel
Turbocharger surging (stalling) can be divided into three main categories.
1) Restriction and fouling in the air/gas

system
2) Malfunction in the engine fuel system
3) Rapid variation in engine load
Modern turbochargers generally exhibit good stability, i.e. not prone to surging.
The reason for surging occurring are usually due to some kind of airflow
restriction, such as :
1) Dirty air filter silencer

2) Increased back pressure after turbine (dirty exhaust boiler or silencer)
3) Dirty air side of CAC
4) High CAC water inlet temperature
5) Contaminated nozzle ring or turbine
6) A ships hull being dirty, causing the engine to run at full torque /
reduced speed.
© MAN B&W Diesel < 10 >
Surging
MAN B&W Diesel
Ballon
Surge

Surging
MAN B&W Diesel
Pressure
Diffuser High pressure - Slow air speed

Operating point
Operating line
Low pressure - High air speed
Compressor
Under normal operating conditions,

the turbocharger follows the operating
line,
based on the criteria of :
• Pressure ratio
• Air volume flow
Volume • Turbocharger speed

Surging
MAN B&W Diesel
Air flow velocity resultant

angles
relative
tangential
Under normal operating conditions

the air flow follows the diffuser van directions.
During abnormal conditions, when for example the air flow is reduced
by a fouled air filter,charge air cooler or at rapid load changes.
The velocity angles are changing,causing the boundary layer breakdown.
The boundary layer breakdown, induces whirling

that will reduce the free flow area.
No diffusion takes place and the air speed
remains high i.e. no pressure is produced.

Surging
MAN B&W Diesel
Air speed high - pressure low
Surge occurred as the pressure down stream

the diffuser was higher than the diffuser pressure.
The frequency of this flow reversal, or surge

will depend on the level of flow restriction,
and system stability.
SURGE !
MAN B&W Diesel

MAN B&W Diesel

Surging
MAN B&W Diesel
Pressure
1) Normal operation
2) Boundary layer
breakdown.
Air speed not
converted into
pressure.
3) Compressor
flow reversal.
Volume
- Surge -
Possible causes:
MAN B&W Diesel
Fuel oil system: Exhaust system :

• Low circulating or supply pump pr. • Exhaust valve not opening correctly.
• Air in fuel oil. • Damaged or blocked protective
• Water in fuel oil. grating before turbine.
• Low pre-heating temperature. • Increased back pressure after turbine.
• Malfunctioning of deaerating valve
on top of venting tank.
Turbocharger : Scavenge air system :

• Fouled air filter box. • Fouled CAC, water mist catcher
• Fouled or damaged compressor side. and / or ducts.
• Fouled or damaged turbine side. • Fouled water circulation to CAC.
Miscellaneous :
• Hunting generator.
• Rapid changes in engine load.
• Too rapid rpm change .

Aerodynamic Noise.
MAN B&W Diesel
5
From time to time we experience sound
( Woof - woof - woof ) coming from the compressor during low
4,5 load conditions.
4
i.e. low compressor pressure ratio
3,5
3 The sound is NOT the initiation of Surge !

2,5
The noise can be considered cosmetic
2 and have no influence on the performance
of neither the engine no the turbocharger.
1,5
0 2 4 6 8 10 12

Safety Valve at Aft End of
MAN B&W Diesel
Scavenging Reciever. 6L60MC.
Safety Valve.

MAN B&W Diesel
Safety Valve.

No. of cylinders.
MAN B&W Diesel
Compressor map
Surge line
Air receiver
MCR
Surge Air from
margin compressor
Air to engine cylinder

Pr.
Operating line CA
Surging are also related to number of cylinders and therefore also related
to receiver volume.
The receiver volume required, relative to the swept volume of the engine,
will reduce with increasing number of cylinders and will be more critical
with a 2-stroke engine than a 4-stroke,
i.e. less cylinders require more surge margin..
In case of the receiver volume is too small, or there are a small numbers
of cylinders, pressure will reduce toward the end of each induction process,
and since the compressor maintains almost constant speed, the compressor
may surge.
Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel
Compensators.

Turbocharging.
MAN B&W Diesel

MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel
Protection Grid

MAN B&W Diesel
Turbocharging.

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharger.
MAN B&W Diesel

Bearing Arrangements.
MAN B&W Diesel
inboard plain bearings

(MAN B&W turbochargers)
outboard roller bearings

(other makes)

Designation of Turbocharger.
MAN B&W Diesel
S = letter for designation O = without

A for "Axial of the design status (German: ohne)
Flow Turbine" (S = latest design) M = with
(German: mit)
damping wire
N
NAA 40
40 // S
SOO 1019
1019
40 for the
frame size
N for the German = nominal 1019 = Specification
word "Norm" outer dia- number (related to
meter of the the specific engine
compressor and the installed
wheel in cm flow components)

T/C Layout.
MAN B&W Diesel
NR12/S
NR14/S
NR17/S
NR20/S
NR24/S
NR29/S
NA29/S
NR34/S
NA34/S
NA40/S
NA48/S
NA57/T9
NA70/T9
0
5.000 10.000 15.000 20.000 25.000
engine output per turbocharger (kW)

Turbocharger Performance.
MAN B&W Diesel

NA 57 – T9
MAN B&W Diesel

NA Charger.
MAN B&W Diesel

MAN B&W Diesel
NA Charger.

MAN NA T9 Design Features.
MAN B&W Diesel
rotor running in
inboard plain bearings bearing casing
water cooled
all turbine casings

uncooled but
effectively heat
insulated
bearings lubricated by
the engine lube oil system

Example of bearing arrangement NA type
MAN B&W Diesel
Plain bearing
Locating bearing
Ring nut
Compressor Turbine
side side
Locating ring Thrust collar

Plain bearing.
MAN B&W Diesel

Checking locating bearing NA
MAN B&W Diesel
57/T9/T10
Length l < 6.50 mm (T9); 7.50 mm (T10)
Thrust bearing
Wedge surface
Contact line
Bearing contact face
Plane face
Bandwidth B < 31 mm (T9), 33mm (T10)
Wedge shape face 1:200

Assembly groups: 517
MAN B&W Diesel

NA Charger.
MAN B&W Diesel

MAN B&W Diesel
MAN NA Charger.
Turbine Side.

MAN B&W Diesel
NA Charger.

MAN B&W Diesel
NA Charger.

NA Charger.
MAN B&W Diesel
The technically
elaborate fir-tree root
connection provides
for a positive,
stressfree mounting of
the flow-optimised
blades in the turbine
disc. This solution
permits replacement of
individual blades.

MAN B&W Diesel
Rotor - NA Turbocharger.
Rotor of a NA
turbocharger supported
on inboard bearings.
The reliable inboard
bearing design has
been the proven
characteristic of MAN
B&W turbochargers for
decades.

Lube oil system NA /T9
MAN B&W Diesel
Flow rate: max 8,000 l/h

SAE 30 (55°C)
SAE 40 (60° C)
max. temp: 70° C
Filtration < 0,05 mm

Oil supply with post lubrication tank
MAN B&W Diesel
To post lubrication Tank. In case of ”Black-Out”.
Lube oil supply to the bearing
Lube oil from the engine

NA Charger.
MAN B&W Diesel

NA Charger.
MAN B&W Diesel

NA Turbocharger.
MAN B&W Diesel
1 Turbine rotor with shaft

2 Compressor wheel
3 Bearing casing
4 Plain bearings
5 Gas inlet casing
6 Nozzle ring
7 Gas outlet diffusor
8 Compressor volute
9 Diffusor
10 Silencer

Turbocharger Design Features.
MAN B&W Diesel
rotor running in
inboard plain bearings
bearing casing
water free
all turbine casings

uncooled but
bearings lubricated by the effectively heat
engine lube oil system insulated

MAN B&W Diesel
Lube oil system NA 48/S
Flow rate: max 7.000 l/h

SAE 30 (55°C)
SAE 40 (60° C)
max. temp: 70° C
Filtration < 0,05 mm

Post lubrication tank on NA 48/S
MAN B&W Diesel
overflow
Post lubrication tank
compressor bearing cs bearing ts

side
bearing turbine side
supply bearing supply
lube oil supply from the engine

Checking locating bearing NA
MAN B&W Diesel
Length l
Thrust bearing
Wedge surface
Contact line
Bearing contact face
Bandwidth B
Plane face
l
Wedge shape face 1:200

Cleaning air filter mat
MAN B&W Diesel
Filter
mat
Lashing straps
Clean or replace filter mat every 250 – 500 working hours.

The turbocharger should be turned off during work
TCA Turbochargers
The New Generation
MAN B&W Diesel
»Enjoy the
benefits of
TCA Turbo-
chargers«

Benefits of TCA Turbochargers
MAN B&W Diesel
»Reduced
noise
emission«

Introduction of TCA
Turbochargers
MAN B&W Diesel
TC for Turbocharger 88 = approx.

outer dia-
meter of the
compressor
wheel in cm 0 = design status
TCA88–20017
017 = Specification
2 for two-stroke number (related to
engine applications, the specific engine
A for Axial turbine, (4 for four-stroke and the installed
(R for Radial turbine) engine applications) flow components)

MAN B&W Diesel
Larger compressor volute for reduced flow speed and low

noise emission
New patented silencer with axially mounted curved damping
plates

Applications TCA
MAN B&W Diesel
Two-stroke
engines
2-Stroke
engine
7S50MC-C
with TCA77-2

TCA Turbochargers
MAN B&W Diesel

Introduction of TCA
Turbochargers
MAN B&W Diesel

TCA Turbochargers
MAN B&W Diesel
New developed wide-chord turbine

blades without damping wire for
increased efficiency
Enlarged fir-tree root profile (4 roots)
for reduced centrifugal stresses
New turbine cast
nozzle ring
Optimized turbine
outlet diffuser
Optimized turbine
inlet casing
Easy replacement of
turbine blades

Introduction of TCA
Turbochargers
MAN B&W Diesel

TCA Turbochargers
MAN B&W Diesel

TCA Development Highlights
MAN B&W Diesel
Development steps in turbine balde design

New turbine blade: Wide-chord design without damping wire »More
also for four-stroke applications efficiency«
original S3 blade NA29/S blade
© MAN B&W Diesel

New design < 73 >
MAN B&W Diesel
Nozzle Ring »Extended

life time«
New designed cast iron nozzle ring
with extended life time
New blade profile for higher efficiency

Lube oil supply and post lubrication (III)
filling the tank
MAN B&W Diesel
Level 3:
Tank is filled to max.
air under pressure
Tank pressure is equal Level 3
to filling pressure orifice to reduce
Full overflow overflow
Level 2
3 mm
Level 2:
Tank is filled
without overflow
Level 0 ov
Level 0: er
Tank is filled via the flo
drilled hole in the w
non return valve pi
pe
supply pipe
Non return valve:
spring removed
with drilled hole
MAN B&W Diesel
TCA rotor assembly

Complete rotor TCA 77
MAN B&W Diesel

TCA
MAN B&W Diesel
»Easy maintenance«
New compressor
NA/S and NA/T9 wheel connection
compressor wheel connection

Compressor wheel connection
MAN B&W Diesel

Bearing arrangement (I)
MAN B&W Diesel
Floating bearing disc
Counter thrust bearing
Thrust bearing Bearing body
Thrust ring Turbine rotor
Tension rod

MAN B&W Diesel
Floating journal bearing bushes

for ideal damping behaviour
Decreased shaft diameter for reduced

mechanical losses
High performance thrust bearing

with minimised mechanical losses
Floating thrust bearing disk

TCA
Radial Plate Type Air Intake
MAN B&W Diesel
Silencer
»Whispering
silencer«
Patented axially
inserted damping
plates

TCA Variable Turbine Geometry
(optional)
MAN B&W Diesel
Operation on 6L48/60
Patented, variable nozzle ring design test engine under HFO
conditions
Efficiency-optimised
Pro/E-model »Patented«

TCA Performance
MAN B&W Diesel

TCA Dimensions
MAN B&W Diesel
type length width height weight

[mm] [mm] [mm] [kg]
TCA 33 1784 957 1244 1137
TCA 44 2123 1150 1494 1970
TCA 55 2527 1364 1772 3287
TCA 66 2971 1620 2106 5515
TCA 77 3524 1925 2691 9250
height
TCA 88 4166 2286 2971 15490
TCA 99 4586 2508 3259 20453
th
length
wid
ABB Charger – VTR.
MAN B&W Diesel

VTR Charger
MAN B&W Diesel

VTR Charger
MAN B&W Diesel

MAN B&W Diesel

VTR Charger
MAN B&W Diesel

VTR Charger
MAN B&W Diesel

The new TPL Turbocharger
MAN B&W Diesel
P owerL arge
T urbo

TPL
MAN B&W Diesel
Volume flow range of TPL turbochargers

5.30
5.10
Compressor Pressure Ratio Πc
F-Version
4.90
4.70
4.50
E-Version
4.30
4.10
D-Version
3.90
TPL61 TPL65 TPL69 TPL73 TPL77 TPL80 TPL85
3.70
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
Air Flow V298 [m3/s]
TPL
MAN B&W Diesel
9000 Expected Weight incl. Filter/Silencer

8900
8000
7000
6000
4900
5000
4000 3230
3000 2090
2000 1320
830
520
1000
0
TPL61 TPL65 TPL69 TPL73 TPL77 TPL80 TPL85
TPL 69-85
MAN B&W Diesel

TPL 69-85
MAN B&W Diesel

TPL 69-85
MAN B&W Diesel
OBS!!!!
To be used
only once!

TPL 69-85
MAN B&W Diesel

TPL 69-85
MAN B&W Diesel

MAN B&W Diesel
TPL 69 / 85
Apply Molykote
on the friction
surface !!!!
The trust
bearing can also
be heated to
max 110°C
to simplify
fitting (put it in
hot water) But it
must
be fully cooled
before further
fitting
operations.

TPL 69-85
MAN B&W Diesel

TPL 69-85
MAN B&W Diesel

TPL 69-85
MAN B&W Diesel

ABB TPL Charger at 6L60MC.
MAN B&W Diesel

MAN B&W Diesel
ABB TPL Charger.
Air Inlet
Filter.

ABB TPL 91
MAN B&W Diesel

MET-Charger.
MAN B&W Diesel

MET-Charger.
MAN B&W Diesel

MET-Charger.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Turbocharging.
MAN B&W Diesel

Maintenance.
MAN B&W Diesel
© MAN B&W Diesel

Maintenance.
MAN B&W Diesel

Maintenance.
MAN B&W Diesel

MAN B&W Diesel
Wet cleaning the turbine
• Clean every 150 working hours.

• 15 min before cleaning, reduce engine load to idle speed.
• wash with 2 bar until clear water is coming out of drain pipe.
• wait again 10 min to dry the turbocharger.
• increase engine load slowly.
Dry Cleaning on 6L60MC.
MAN B&W Diesel
Dry Cleaning.

Dry cleaning the turbine.
MAN B&W Diesel

Dry cleaning the turbine.
MAN B&W Diesel
For cleaning you can use granulate from nutshells,

or activated charcoal.
Clean turbine every day.

MAN B&W Diesel
Maintenance.

Maintenance.
MAN B&W Diesel
Cleaning of
Compressor Side.

Cleaning the compressor
MAN B&W Diesel
with fitted tank.
• Clean compressor wheel every 150 working hours.

• The cleaning intervalls depend on degree of contamination.
• Use exclusively fresh water.
• Cleaning must be made with warm engine and running at full load.
• Let the engine still run a short period after cleaning.
MAN B&W Diesel
Maintenance.

MAN B&W Diesel
Maintenance.
Charge Air Cooler.
Mist Catcher.

Maintenance.
MAN B&W Diesel
Water Mist Catcher.
Cooler Element.

Maintenance.
MAN B&W Diesel
Cleaning system.
Cooler Element.
Position of Mist Catcher.
Drain from Mist Catcher.

MAN B&W Diesel
Maintenance.
Chemical Tank
for cleaning the
Air Cooler element.

MAN B&W Diesel
Maintenance.
Supplied
Cleaning System.
by engine
Specified in the
builder.
Project Guide.
Supplied by
Ship Yard.

MAN B&W Diesel
NA 57 Charger.
Air Inlet
Filter.

MAN B&W Diesel
Cleaning air filter mat.
Filter
mat
Lashing straps
Clean or replace filter mat every 250 – 500 working hours.

The turbocharger should be turned off during work
Two-stroke Design update for
Small Bore Engine.
MAN B&W Diesel
Drain from air cooler

Sight glass
Introduced
on:
S50MC-C
Level switch
S46MC-C
S42MC-C
S35MC-C Outlet from air cooler
S26MC-C to chemical tank AL
Drain from water mist catcher

Two-stroke Design update for
Small Bore Engine.
MAN B&W Diesel
7S50MC-C, aft
Introduced
on:
S50MC-C
S46MC-C
S42MC-C
S35MC-C
S26MC-C
Precatcher
Stop plate
After wmc
Before wmc
© MAN B&W Diesel Under wmc < 132 >
MAN B&W Diesel
Aux. Blowers.
Auxiliary Blowers

Aux. Blower.
MAN B&W Diesel

Aux. Blower.
MAN B&W Diesel

Aux. Blower.
MAN B&W Diesel

MAN B&W Diesel

MAN B&W Diesel

Aux. Blower.
MAN B&W Diesel

Tirbocharging.
MAN B&W Diesel

MAN B&W Diesel

Aux. Blowers – 6L60MC.
MAN B&W Diesel

MAN B&W Diesel
Maintenance.
Exhaust Gas Boiler.

Maintenance.
MAN B&W Diesel
Burned Exh. Gas Boiler – 11K90MC-C

MAN B&W Diesel
Maintenance.
Melted Boiler Pipes.

Maintenance.
MAN B&W Diesel

MAN B&W Diesel
Maintenance.

Polar Resolution.
MAN B&W Diesel
© MAN B&W Diesel

Turbo FQJ

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Turbo FQJ

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MAN B&W Diesel

The Uni Flow

© MAN B&W Diesel

Exhaust gas receiver

© MAN B&W Diesel <2>

© MAN B&W Diesel

© MAN B&W Diesel <4>

S/K/L/MC, MC-C 3,5 – 3,8 ”

© MAN B&W Diesel <6>

Why does Surging occur?

What might be the reasons for Surging?

© MAN B&W Diesel <7>

• Surging is a phenomena that occur when pressure

• Surging occur when stage instability are allowed

• System instability or surge occur when boundary

• Therefore large changes in ambient/system

© MAN B&W Diesel <8>

Surging at high load has to be

Kinematics of rotor during surging

Speed of the rotating components may

© MAN B&W Diesel 2004/10/29 <9>

Turbocharger surging (stalling) can be divided into three main categories.

1) Restriction and fouling in the air/gas

1) Dirty air filter silencer

© MAN B&W Diesel < 11 >

Diffuser High pressure - Slow air speed

Under normal operating conditions,

© MAN B&W Diesel < 12 >

Air flow velocity resultant

Under normal operating conditions

The boundary layer breakdown, induces whirling

© MAN B&W Diesel < 13 >

Air speed high - pressure low

Surge occurred as the pressure down stream

The frequency of this flow reversal, or surge

© MAN B&W Diesel < 15 >

© MAN B&W Diesel < 16 >

Fuel oil system: Exhaust system :

Turbocharger : Scavenge air system :

© MAN B&W Diesel < 18 >

3 The sound is NOT the initiation of Surge !

© MAN B&W Diesel < 19 >

© MAN B&W Diesel < 20 >

© MAN B&W Diesel < 21 >

Air to engine cylinder

© MAN B&W Diesel < 23 >

© MAN B&W Diesel < 24 >

© MAN B&W Diesel < 25 >

© MAN B&W Diesel < 26 >

© MAN B&W Diesel < 27 >

© MAN B&W Diesel < 28 >

© MAN B&W Diesel < 29 >

© MAN B&W Diesel < 30 >

© MAN B&W Diesel < 31 >

© MAN B&W Diesel < 32 >

© MAN B&W Diesel < 33 >

© MAN B&W Diesel < 34 >

inboard plain bearings

outboard roller bearings

© MAN B&W Diesel < 35 >

S = letter for designation O = without

© MAN B&W Diesel < 36 >

engine output per turbocharger (kW)

© MAN B&W Diesel < 38 >

Larger compressor volute for reduced flow speed and low

New developed wide-chord turbine