SA-10-026 Rev A 710 Light Load Operation and Inspection

SA#: 10-026
REVISION: A
REVISION DATE: 8/12/10
ISSUE DATE: 6/25/2010
AUTHOR: J. Balzer
Customer Engineering • Electro-Motive Diesel, Inc. • 9301 W. 55th Street • LaGrange, IL 60525
SERVICE ADVISORY - 710 Light Load Operation and Inspection

Form CEF-001 Rev B. 7/1/2006
Components Affected:
12, 16, and 20 cylinder Model 710 Turbocharged Engines in Generator Service or Synchronous Operation
Purpose:
To reiterate the consequences of light load operation and provide an inspection guideline for turbocharger
gear trains that have been subjected to excessive high driving torque
Background:
EMD engines, like other internal combustion engines, operate most efficiently when producing the power
for which they were designed. Under normal operating conditions load can vary based on environmental
conditions and equipment demands. Power Plant Load Management systems can and should be designed
to minimize the number of engines on line at any time in order to maximize load, optimize fuel economy,
and minimize any issues related to light load. The rapid response of the EMD two-cycle engine allows for
fewer engines to be on line at any time to meet transient power requirements*.
Under typical drilling operations EMD engines provide durable and reliable performance for operators.
Recent failures of EMD turbochargers with relatively low operating hours have identified a potential
problem which we believe to be attributed to extremely light load operation during the construction and
testing phases of equipment. The practice of using main engines for hotel power during construction in the
shipyards has been identified as a leading contributor to early wear of drive gears and turbocharger
failures.
Shipyard practices of running engines for hotel power during construction of the vessel/ drilling
unit should be avoided.
As a general rule load management systems for Model 710 turbocharged engines running at 750 or
900 RPM should not be less than 30% of the full load rating for optimum life. There is no
minimum load restriction for operation at lower engine speeds.
Page 1
Copyright © Electro-Motive Diesel, Inc.. All rights reserved. Neither this document, nor any part thereof, may be reproduced or reprinted without the prior written
consent of the Electro-Motive Diesel, Inc.. Contact EMD SDO office.
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
* EMD is available to assist in optimizing power plant load management systems with our two cycle
engines.
Under typical operating conditions it is normal for high driving torque to be transmitted through the turbo
gear train for a short time. As the engine load is applied, the power needed to mechanically drive the turbo
is proportionally decreased on the gear train by the turbine. The turbine uses exhaust gas energy to
decrease the gear train load. At approximately 70% of full rated load, the exhaust energy is sufficient to
drive the turbocharger rotating assembly without any gear train assist. At this operating condition, the
overrunning clutch allows the turbo to speed up and run independent of the gear train: the gears continue to
turn at their corresponding speed ratio to engine RPM without transmitting torque.
If engines are operated for extended periods at full speed with light loads, turbo gear train wear is
accelerated. At loads of 30% and above there is no significant wear on the drive gears and EMD expects
full turbocharger life. At loads below 30% wear rates gradually increase, however operating the engines
during construction where loads could easily be below 10% load for sustained periods of time the wear
rates could reduce the life of the drive gears to 3000 hours of operation.
EMD engines operated at full speed and less than 20% load can experience oil accumulation in the exhaust
system. Engines equipped with Low Lube Oil power assemblies or engines that carry a US EPA Tier 2
certification will experience less accumulation. The exhaust system can be cleaned out by operating the
engines at 70% load or more for at least 30 minutes. This should be performed after 8 hours of idling or
100 hours of continuous operation at synchronous speed with less than 20% load.
Recommended Action:
1. Change any operational activities that allow engines to operate at light loads for extended periods
of time such as construction.
2. If it is suspected that engines have already been operated under very lightly loaded conditions, it is
recommended that an inspection of the gears be made to insure the gears have not worn to a point
where a failure would ensue. The following can be indicators of early stage turbocharger gear train
failure due to light engine loading:
• Noise generated from worn involute turbo spur gears will be louder than a turbo with
unworn gears
• Visual wear on Turbo Spur Gears
Page 2
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
Inspection Procedure:
Recent inspections of turbochargers have shown that the turbo spur gears are failing as a result of
high turbocharger gear train loads. The gears at risk are the carrier drive, idler, and turbo drive gear, see
figure 1 below.
Inspect these 3 gears
Figure 1-Turbocharger Gear Train
Page 3
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
1. Ensure that the engine is not running and the appropriate lock outs are in place
2. Remove the aux gen cover plate on the RB side of the turbocharger as depicted in figure 2
below.
Remove
Aux Gen
Cover Plate
Figure 2
3. Use the exposed opening as an access point for viewing the gears as shown in figure 3
below.
Aux Gen
Cover Plate
Removed
Figure 3
The following can be indicators of early stage turbocharger gear train failure due to light engine loading:
• Visual wear on Turbo Spur Gears (Turbo Drive Gear, Turbo Idler Gear, Carrier Drive
Gears) See Figures 6 & 7 on page 6
• Loose, broken, or missing Oil Lube Jumper Bolts
Page 4
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
Due to space limitation, you may only be able to view of the turbo drive gear, idler gear, and the jumper
bolts (Reference Figures 4 & 5 below).
After removal of Aux

Gen Cover Plate, take
pictures on the gear
within the range
shown in illustration.
Use this area

for camera
placement
Set digital camera in

MMacro setting and
capture the active profile
condition on both sides of
the idler gear teeth.
Figure 4
NOTE: See Figure 5 and 6 to see field inspection photos.
Page 5
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
This side is the

Rest hand here engine gear,
when taking not the turbo
photograph gears
Figure 5
Ensure that both sides of the
active profile of the idler
Inspect teeth on turbo idler gear are inspected and
gear photographed
Figure 6
4. Inspect at the surface of the gear flanks (called involute). On the involute check for signs of
pitting/scoring/scuffing. (Reference Figure 7 & 8 below)
Page 6
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
Scuffing at the tip
Pitting above the

pitch line area
accompanied by
scuffing near the tip
Pitting on the pitch

line on one side of
the gear face farther
away from the
impeller
Figure 7
Pitting above the

pitch line area
accompanied by Scuffing near the
scuffing near the root (dedendum)
root
Figure 8
5. Replace the aux gen cover plate on the RB side of the turbocharger.
6. If light loading damage is confirmed as outlined in this document it is recommended that

the engines not be operated to avoid more serious failures that can damage the entire gear
train. Contact your licensed EMD distributor for resolution.
Page 7
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
NOTE: If you suspect a problem, please fill out this form and send it your distributor.
Customer Order Number: Date: Page

Unit: MWH: 1of 2
Engine Model:
Hours:
In-Service Date:
Equipment Description:
No Description of Check Results

1 Ensure that the engine is not running and the appropriate lock outs are in place.
2 Remove the aux gen cover plate on the RB side of the turbocharger as depicted.
3 Use the exposed opening as an access point for viewing the gears.
• Visual wear on Turbo Spur Gears

• Loose, broken, or missing Oil Lube Jumper bolts.
4 Inspect at the surface of the gear flanks. On the involute check for signs of
pitting/scoring/scuffing.
5 Replace the aux gen cover plate on the RB side of the turbocharger.
Insert Inspection Pictures Below
Insert Pictures Here Insert Pictures Here
Page 8
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
Customer Order Number: Date: Page

Unit: MWH: 2of 2
Engine Model:
Hours:
In-Service Date:
Equipment Description:
Insert Inspection Pictures Below
Remarks:
Completed By Approved By Accepted By Completions
Company:
Signature:
Print Name:
Date:
Page 9
SA#: 10-026
REVISION: A
AUTHOR: J. Balzer

Form CEF-001 Rev B. 7/1/2006
(For EMD Office Use Only)
Approvals (Required):
Approval Approver Approved Approved By Date

Needed
Y N
Y N
CES/CEM Chris Harkness 8/12/2010
Warranty
Marketing
Service Advisory – General Classification (Select All that Apply):

GENERAL INFORMATION: This document is being issued to provide general information to the Customer Care Field Organization.
REQUEST FOR FIELD SUPPORT: This document is being issued to request Customer Care Field resources for the purpose of information/data
collection in support of a current field issue investigation.
PRELIMINARY: This document is being issued to provide notable preliminary findings with regard to a current field issue. It will be followed by the
issuance of an appropriate revision, or revisions, as the investigation progresses through closure, or more information becomes available.
FINAL: This document is being issued to provide final findings and recommendations on the proper handling of a current field issue. This document is
intended to provide official closure of the subject field issue.
Page 10

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SA#: 10-026

SERVICE ADVISORY - 710 Light Load Operation and Inspection

SERVICE ADVISORY - 710 Light Load Operation and Inspection

SERVICE ADVISORY - 710 Light Load Operation and Inspection

Inspect these 3 gears

Figure 1-Turbocharger Gear Train

SERVICE ADVISORY - 710 Light Load Operation and Inspection

SERVICE ADVISORY - 710 Light Load Operation and Inspection

After removal of Aux

Use this area

Set digital camera in

NOTE: See Figure 5 and 6 to see field inspection photos.

SERVICE ADVISORY - 710 Light Load Operation and Inspection

This side is the

SERVICE ADVISORY - 710 Light Load Operation and Inspection

Pitting above the

Pitting on the pitch

Pitting above the

6. If light loading damage is confirmed as outlined in this document it is recommended that

SERVICE ADVISORY - 710 Light Load Operation and Inspection

Customer Order Number: Date: Page

No Description of Check Results

• Visual wear on Turbo Spur Gears

Insert Pictures Here Insert Pictures Here

Insert Pictures Here Insert Pictures Here

SERVICE ADVISORY - 710 Light Load Operation and Inspection

Customer Order Number: Date: Page

Insert Inspection Pictures Below

Insert Pictures Here Insert Pictures Here

Insert Pictures Here Insert Pictures Here

SERVICE ADVISORY - 710 Light Load Operation and Inspection

(For EMD Office Use Only)

Approval Approver Approved Approved By Date

Service Advisory – General Classification (Select All that Apply):

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