TCR Project Guide

TCR Project Guide
Exhaust Gas Turbocharger
======
All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions.
Project Guide
Exhaust Gas Turbocharger TCR Series
1 General
Principles of Exhaust Gas Turbocharging Application Ranges of the TCR Series
1-1
1-1 1-2
Overview of Series
Dimensions and Weights Casing Positions
2-1
2-3 2-5
Design
Characteristics of the Assemblies Loads on Connections and Flanges Allowable Inclinations Allowable Vibration Accelerations Sound Level Diagram
3-1
3-1 3-7 3-10 3-11 3-12
Systems
Lube Oil System Lube Oil Pressure of the Exhaust Gas Turbocharger
4-1
4-1 4-3
Quality Requirements
Fuels Lubricating Oil and Additives Intake Air
5-1
5-1 5-4 5-4
Auxiliary Equipment
Compressor Cleaning Turbine Cleaning Jet Assist
6-1
6-1 6-1 6-4
Engine-Room Planning
Disassembly Dimensions for the Assemblies Turbocharger Suspension Device Exhaust Gas System
7-1
7-1 7-3 7-3
8 9
Emergency Operation in Case of Failure of an Exhaust Gas Turbocharger Calculations

Layout Calculation Efficiency of the Exhaust Gas Turbocharger
8-1 9-1
9-1 9-1
10
Speed Measurement, Adjustment, Checks

Speed Measurement Measurement of the Air Volume Matching Procedure Surge Stability Check
10-1
10-1 10-2 10-3 10-3
11 12
Quality Assurance Maintenance and Checking

Maintenance Personnel and Time Requirements Service Addresses
11-1 12-1
12-1 12-3 12-3
13 14 15 16
Transport Preservation Treatment and Packing Training and Documentation Ordering of Spare Parts
Spare Parts Reserve Parts and Tools
13-1 14-1 15-1 16-1

16-1 16-2
17 18 I
Tools Worldwide Turbocharger Service Index
17-1 18-1 I-1
Version 06/2006
TCR
Low Noise Levels Long Service Life of Wear Parts High Power/Load Ratio Extended Application Range Compact Design Easy Maintenance Simple Installation Safe Operation Low Weight
Turbine
New CFD-optimized components guarantee reliability and increased efciency: Rotor, nozzle ring as well as inlet and outlet casing Constant and pulse pressure turbocharging Mix-ow turbine design Compact gas-admission casing Optimized gas outlet diffuser
Maintenance
Long inspection intervals Reduced number of components
Bearings
High-grade thrust bearings for low mechanical losses Optimized shaft diameter for maximum efciency Compact design of bearings for optimized damping characteristics
Long Service Life of Wear Parts

Floating radial bearings Thrust bearings Nozzle ring Compressor wheel
Compressor
Optimized compressor wheel, diffuser and compressor casing Extended pressure ratio and ow rate Internal Flow Recirculation (IRC) for extended surge margins New compressor wheel xation for easy servicing
Casing Design for Easy Assembly

Uncooled casings Lubrication via engine oil-lubrication system Integrated oil pipe system No sealing air system
Safety
Containment-proven exhaust gas turbocharger
TCR
Version 06/2006
General
1
They can be operated on propulsion engines (diesel-mechanic and diesel-electric), on genset auxiliary engines, in stationary systems as well as on traction engines.
Characteristics of the TCR Series Exhaust Gas Turbocharger

Economic operation of modern engines without exhaust gas turbochargers is inconceivable. MAN Diesel turbochargers are equally tried and tested with marine main engines, auxiliary engines and in stationary systems under the most various operating conditions. Reliability, easy maintenance and long inspection intervals have been confirmed through-out decades of experience.
Principles of Exhaust Gas Turbocharging

The exhaust gas turbochargers of the TCR Series are intended for constant and pulse pressure turbocharging. Constant pressure turbocharging: With constant pressure turbocharging, the engine exhaust gases flow into a common exhaust manifold, are accumulated there and flow with minor pressure fluctuations to the exhaust turbine.
Exhaust gas turbochargers of the TCR Series can be used with two-stroke and four-stroke engines with constant and pulse pressure turbocharging and engine outputs from 450 kW to 6 700 kW.
With the new TCR Series, not only clear increases in efficiency, but also substantial improvements in reliability and service life are introduced.
Exhaust gas
Charge air
Fresh air
Constant pressure turbocharging

Charge air Exhaust gas
Pulse pressure turbocharging: With pulse pressure turbocharging, the engine exhaust gases of the individual cylinders are conducted together to several narrow exhaust gas pipes and transmit the outlet pressure pulses of the cylinders into the multi-socket gas-admission casing.
Fresh air
Exhaust gas
TCR on in-line engine The modular design of the TCR Series allows for optimal adaptation of the turbochargers to the conditions for both fourstroke as well as two-stroke engines.
Charge air
Fresh air
Engine Types and Operating Range

MAN Diesel turbochargers of the TCR Series are designed for HFO/MDO engines, dual fuel and gas engines. Pulse pressure turbocharging
Version 06/2006
TCR
Page 1-1
Type Plate
The type plate is attached on the pressure socket of the compressor casing. An additional type plate is located on the silencer or on the air intake casing:
Exhaust gas turbocharger

type max 1/min type-tested The type plate contains the following information: Turbocharger type, Works number (serial number), Max. allowable rotor speed, Max. allowable turbine inlet temperature, Unit of temperature for the turbine inlet temperature, Date of the type test, Year of ex-works delivery. W/No. t max year
Application Ranges of the TCR Series

The state-of-the-art exhaust gas turbochargers designed and manufactured by MAN Diesel can be used in a very wide range for the charging of diesel and gas engines per TC:
TCR12 TCR14 TCR16 TCR18 TCR20 TCR22 0 1000 2000 3000 4000 5000 6000 7000
Engine output per exhaust gas turbocharger in kW
Currently, the turbocharger types TCR14, TCR16, TCR18, TCR20 and TCR22 are available. Introduction date of the TCR12 on request.
Page 1-2
TCR
Version 06/2006
Performance Characteristics
The following operating lines are distinguished: Generator curve (constant engine speed), Standard propeller curve (variable engine speed), Propeller curve at reduced engine speed (high torque), Combinator curve (combination of generator and propeller curve), as well as vehicle engine curve. 5.5 Pressure ratio of compressor c tot 5.0 4.5 4.0 3.5 3.0 2.5 2.0 Regardless of the engines application purpose, a safety margin of all possible operating points to the surge line of the compressor is always required. This is ensured by the respective dimensioning of the compressor.
0 0.3
0.4
0.5
1.0
1.5
2.0
2.5 3.0
4.0 5.0
7.5
10.0
15.0
Flow rate of compressor Vc tot in m3/s High-pressure version

0.80
* TCR22-25 two-stroke version
Standard version
0.75 0.70
ETA TC tot
0.65
0.60
0.55 0.50 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5
Pressure ratio of compressor c tot
High-pressure version
Standard version
Version 06/2006
TCR
Page 1-3
Overview of Series
Type
TCR12
TCR14
TCR16
Technical Data Max. engine output per exhaust gas turbocharger Four-stroke engine (le 7 kg/kWh) in kW Two-stroke engine (le 8 kg/kWh) in kW Max. ow rate in m3/s Total pressure ratio Standard version up to High-pressure version up to Max. allowable rotor speed in rpm Max. allowable turbine inlet temperature in C1) Weight as shown
1) Higher temperature on request at MAN Diesel
760
1 100
1 600
1.26
1.84
2.67
4.7 5.2 71 300 650 100
4.7 5.2 59 100 650 165
4.7 5.2 49 100 650 260
Page 2-1
TCR
Version 06/2006
2
TCR20 TCR22 TCR22-25 Two-stoke version
TCR18
2 350 2 050 3.92
3 400 3 000 5.69
6 700 5 900 11.18
6 400 12.19
4.7 5.2 40 500 650 415
4.7 5.2 33 600 650 720
4.7 5.2 24 300 650 1 550
4.2
23 000 650
Version 06/2006
TCR
Page 2-2
Dimensions and Weights

B L
Type TCR14 TCR16 TCR18 TCR20 TCR22

1) With silencer 2) With air intake casing 3) With air intake pipe
L1) in mm 904 1 092 1 308 1 580 2 042
L2) in mm 963 1 238 1 400 1 713 2 234
L3) in mm 734 887 1 066 1 307 1 691
H in mm 530 658 792 953 1 244
B in mm 453 555 661 777 1 023
D in mm 490 590 714 854 1 104
Page 2-3
TCR
Version 06/2006
Weights of the Assemblies

Assemblies Gas outlet casing Gas-admission casing Cartridge Compressor wheel Rotor, complete Bearing casing Compressor casing Insert Compressor side Turbine side Silencer Air intake casing Air intake pipe Total weight1) (approx. value) TCR14 38 kg 24 kg 30 kg 2 kg 7 kg 23 kg 29 kg TCR16 57 kg 38 kg 50 kg 3 kg 12 kg 38 kg 43 kg TCR18 86 kg 59 kg 89 kg 6 kg 23 kg 66 kg 68 kg TCR20 144 kg 102 kg 152 kg 10 kg 39 kg 113 kg 132 kg TCR22 325 kg 233 kg 337 kg 22 kg 87 kg 250 kg 277 kg
8 kg 3 kg 14 kg 18 kg 11 kg 165 kg
13 kg 4 kg 27 kg 22 kg 14 kg 260 kg
17 kg 7 kg 45 kg 38 kg 24 kg 415 kg
35 kg 13 kg 76 kg 64 kg 42 kg 720 kg
75 kg 30 kg 156 kg 139 kg 90 kg 1 550 kg
1) Exhaust gas turbocharger with silencer and gas outlet casing
Version 06/2006
TCR
Page 2-4
Casing Positions
For the best possible adaptation to the engine, certain casing assemblies of the exhaust gas turbocharger can be adjusted continuously by up to 360 relative to the vertical position.
Compressor casing 0 V
Bearing casing 0 L
Gas-admission casing 0 Z
0 - 360
0 Further positions upon consultation with MAN Diesel
0 - 360
continuously adjustable
Air intake casing 0 A
Gas outlet casing 0 T
0 - 360
from -90 to +90
Note
All casing positions viewed from the turbine side.
Page 2-5
TCR
Version 06/2006
3 Design
3
Floating bearings Integrated lubricating oil pipe Proled turbine nozzle ring with long service life Standard anges on gas outlet casing and air intake casing Easy inspection through large maintenance hatch
Characteristics of the Assemblies

The following view indicates the advanced design principle of the TCR Series: High efciency Uncooled casings Silencer Optional: Internal Flow Recirculation (IRC) Easy-to-service, high efciency compressor wheel
Floating bearings Silencer Diffuser Nozzle ring Gas outlet casing
Compressor casing Compressor wheel Gas-admission casing The development of flow parts is carried out based on modern CFD calculation programs. Simulation of the complete turbine and compressor stage allows for realistic calculation of the operating performance and efficiency of the turbocharger. This enables a more compact design of many components as well as significantly improved adaptation to the engine operating curve. Turbine wheel
Version 06/2006
TCR
Page 3-1
Turbine Wheel
The turbine wheel, which is precision casted, consists of a high temperature nickel-based alloy and is connected to the rotor shaft by means of friction welding. CFD simulations, FEM calculations, as well as extensive operational testing with testbed load measurement ensure maximum reliability.
Internal Bearings
For 70 years MAN Diesel has been using plain bearings in turbochargers with great success. The huge experience resulting has been turned into a bearing concept with high longevity. The TCR Series combines tried and tested aspects of the axial and radial bearing concept of the NR Series with new detail solutions.
Bearings
The rotor shaft runs in plain bearings which enable precise centering of the rotor shaft. The centrally arranged thrust bearing handles the axial guidance and the axial thrust.
Turbine wheel
These bearings have ideal properties under extreme high axial and radial forces and ensure long service life. The high damping effect of the oil film make them insensitive to vibrations and imbalance.
The turbine is very well accessible for inspections and cleaning.
Compressor Wheel
The highly stressed compressor wheel is milled from a forged aluminum block. It builds up the charge pressure and supplies the engine with the necessary amount of air. The compressor wheel and the turbine are seated together on the rotor shaft. Internal radial bearings
Axial bearing
Internal bearings
Characteristics of the bearing concept: Floating bearings, Compressor wheel Compact bearing concept with center thrust bearing, Shaft sealing with piston rings and no sealing air. Easy assembly and disassembly of the bearings is ensured through housing of the radial bearings in the bearing bodies.
Page 3-2
TCR
Version 06/2006
Bearing Casing
The bearing casing is manufactured of cast iron with spheroid graphite. It contains the distribution ducts for the lube oil which is also used for cooling of the casing. For special applications, e.g., for gas engines with high exhaust gas temperatures, water-cooled bearing casings can be provided.
Diffuser
The diffuser raw part is manufactured of cast iron with spheroid graphite, from which the vane profile is then milled.
Diffuser
Bearing casing
Compressor Casing
The compressor casing is manufactured of cast iron with spheroid graphite. The standard design is with single outlet. It is fastened to the bearing casing with clamping claws.
Optimal adaptation of the compressor map to the engine takes place by changing the diffuser cross-section (see Page 10-3, Chapter Matching Procedure). This provides for optimal conversion of the speed component in pressure after the compressor wheel.
Compressor casing The casing position is adjusted continuously (see Table on Page 2-5). The newly calculated flow cross-sections and the large outlet surfaces ensure effective conversion of the kinetic energy into pressure. For special applications the compressor casing can be sound-insulated.
Version 06/2006
TCR
Page 3-3
Silencer with Air Filter

Exhaust gas turbochargers for marine engines, as a standard, are equipped with silencers that are surrounded by a filter mat. Silencer characteristics: High turbocharger efciency due to low pressure loss, especially at high air-ow, Effective sound level reduction, Low air-ow velocity at the silencer intake, Integrated cleaning device for compressor. The completely new developed silencer casing dampens the sound immission to less than 105 dB(A). Air filter mat characteristics: The effective ltration widely keeps the compressor, diffuser and charge-air cooler free from dirt particles, Easy replacement and installation, In case lter particles are drawn in, there is no danger of damage to any leading edges of the compressor, Cleaning of the air lter mat is required only every 250 operating hours (approx.).
Technical data according to ASHRAE (DIN 24 185): Average separation content............................................83% Efficiency .................................................................... < 20% Quality class (filtration class) ........................................... EU3 Dust-absorption capacity ....................................... 520 g/m3 Pressure loss.......................... 200 Pa (20 mm water column)
Air Intake Casing

The air intake casing is used during operation without air filter. It achieves constant distribution of pressure and velocity at the pressure intake owing to the optimized flow ducts. The air intake casing can be adjusted continuously from 0 to 360 relative to the bearing casing (see Table on Page 2-5). The air intake casing is available in the 90 as well as in the axial version:
Air intake casing 90/axial
Silencer
The plastic air filter mat is resistant to temperatures of up to 100 C, short-term even to 120 C. The relative humidity can be 100%. The behavior in fire is self-extinguishing. The filter mats can be fully regenerated. For this, rinse with warm water from inside to outside, vacuum or blow out with compressed air. If necessary, mild detergents can be added to the water. Avoid heavy mechanical stress such as wringing out or applying a hard water jet.
Page 3-4
TCR
Version 06/2006
Gas-Admission Casing
The gas-admission casing is manufactured from of silicidemolybdenum alloyed cast iron with spheroid graphite. The uncooled casing is heat-insulated with a covering.
Gas Outlet Casing

The gas outlet casing is manufactured from cast iron with spheroidal graphite. The casing is uncooled and is heat-insulated with a covering.
Gas-admission casing
Gas outlet casing An optimized, high-volume and very effective gas outlet diffuser is integrated in the gas outlet casing. It can be adjusted continuously from -90 to +90 relative to the bearing casing (see Table on Page 2-5). Waste Gate The gas outlet casing can be supplied with a waste gate connection:
The gas-admission casing is fastened to the bearing casing with clamping claws and can be adjusted continuously (se Table on Page 2-5). Optimized flow cross-sections keep the loss of flow at a low level. For pulse pressure turbocharging, the gas-admission casing can be provided with several gas-intake connections.
Turbine Nozzle Ring

The cast turbine nozzle ring with profiled vanes largely contributes to the excellent turbine efficiency of the TCR Series.
Turbine nozzle ring Gas outlet casing with waste gate Optimum adaptation of the turbocharger to the engine is achieved through nozzle-ring variants with different cross sections. Turbine nozzle rings are manufactured from an extremely resistant material which ensures long service life. The waste gate enables the exhaust gas to be bypassed in order to avoid the maximal turbocharger speed from being exceeded. The optimized waste-gate connection, which is in line with the turbocharger axis, allows for easy engine-side mounting.
Version 06/2006
TCR
Page 3-5
Gas Outlet Elbow

Exhaust gas turbochargers of the TCR Series can also be supplied with a gas outlet elbow.
Gas outlet elbow The gas outlet elbow is manufactured from cast iron with spheroidal graphite. As a result, the reduced space requirement and the lower weight are an advantage for assembly.
Containment Safety
With modern diesel engines, turbochargers are one of the components that are subject to the highest loads. The high speeds of turbocharger rotors lead to high centrifugal forces and high component temperatures at the same time. All assemblies of a MAN Diesel turbocharger are designed to provide optimal burst protection. Extensive calculations and operational testing ensure maximum safety. MAN Diesel turbochargers comply with the required containment safety according to the regulations of the classification societies so that particles cannot be expelled in case of damage.
Page 3-6
TCR
Version 06/2006
Loads on Connections and Flanges

All exhaust gas turbocharger casing flanges, with the exception of the turbine outlet, may be subject only to loads by the effected gas forces. The maximum values are to be observed under consideration of exterior forces and torque. This necessitates the use of compensators directly at the turbine inlet, at the turbine outlet as well as after the compressor. The compensators are to be pre-loaded in such a manner that thermal expansion of the pipes and casing do not effect forces or torque in addition to the air or gas forces. The mentioned parameters for the connections apply for radial and axial air intake casings. Forces and torques according to API Standard 617, Direction of effect transferred according to MAN Diesel Standard, Minimized anticipated loads as far as possible, Parameters include forces of masses and compensators.
Connections of the Charge Air Pipes

Mz Type TCR14 TCR16 TCR18 TCR20 TCR22 Fx in N 1 900 2 300 2 800 3 400 3 900 Fy in N 3 900 4 600 5 700 6 900 7 900 Fz in N 3 900 4 600 5 700 6 900 7 900 Mx in Nm 2 900 3 500 4 300 5 200 6 000 Mz in Nm 1 400 1 700 2 100 2 600 3 000 Mx Fx Fy
Mx
Fz
Compensator
Maximum loads Compensator fastened directly to the turbocharger ange Type TCR14 TCR16 TCR18 TCR20 TCR22 D in mm 150 180 231 280 370 d in mm 121 145 176 212 277 k in mm 167 200 220 265 350 Bolts 4 4 8 8 8 d k D Compressor casing connection
Version 06/2006
TCR
Page 3-7
Connection of the Exhaust Gas Pipe (Engine Side)

.
Type Mx TCR14 Mz Mx Fx Fy Mz TCR16 TCR18 TCR20 TCR22 Fz
Fx in N 1 700 2 100 2 600 3 100 3 800
Fy in N 3 500 4 300 5 200 6 300 7 700
Fz in N 3 500 4 300 5 200 6 300 7 700
Mx in Nm 2 700 3 200 3 900 4 700 5 800
Mz in Nm 1 300 1 600 1 900 2 300 2 900
Compensator
Maximum loads
Compensator fastened directly to the turbocharger ange Type TCR14 TCR16 TCR18 TCR20 TCR22 D in mm 150 180 233 275 360 d in mm 111 134 162 195 255 k in mm 164 195 215 260 340 Bolts 4 4 8 8 8
d k D
Connection of gas-admission casing
Page 3-8
TCR
Version 06/2006
Connection of the Exhaust Gas Pipe (System Side)

Mx Mz Type TCR14 TCR16 TCR18 TCR20 TCR22 Fx in N 3 400 3 800 4 100 4 400 5 000 Fy in N 6 800 7 700 8 300 8 900 10 200 Fz in N 6 800 7 700 8 300 8 900 10 200 Mx in Nm 5 200 5 800 6 300 6 800 7 700 Mz in Nm 2 600 2 900 3 100 3 400 3 800 Fx Fz Mx Mz Fy Compensator
Maximum loads
Compensator fastened directly to the casing ange Flange connection according to DIN 86044
D in mm 296 357 425 540 703
d in mm 212 256 310 373 487
k in mm 280 335 395 495 650
Bolts 8 12 12 16 20 d k D
Connection of gas outlet casing
Version 06/2006
TCR
Page 3-9
Allowable Inclinations
The exhaust gas turbochargers of the TCR Series require horizontal assembly with respect to the axis of the running equipment. For operation in ships, however, where the installation position is crosswise to the longitudinal axis, inclination angles occur that can influence the operating ability of the exhaust gas turbocharger. The following inclination angles can be handled by the exhaust gas turbocharger without problems. With the installation position in longitudinal direction of the ship, these limit values are not reached even under unfavorable exterior conditions. For certain individual cases, larger inclination angles are also possible. When required, please contact MAN Diesel SE in Augsburg.
Inclination
Continuous 15 10
Short-term 22.5 10
Page 3-10
TCR
Version 06/2006
Allowable Vibration Accelerations

During engine operation, the exhaust gas turbocharger is subject to stress through vibrations that are actuated by the engine (A) and the exhaust gas turbocharger (B) itself. The excitations starting from the engine lie within the low-frequency range. The resulting vibrations of the turbocharger structure stress the possibly mounted silencer and connecting elements between casing parts and turbocharger feet. The bearing load resulting from the engine excitation is negligible, as the rotors of the MAN Diesel exhaust gas turbocharger run in plain bearings. Vibrations actuated from the exhaust gas turbocharger itself are generated by forces of imbalance that are transmitted via the bearing onto the casings. The relevant frequency is in the high-frequency range. The vibrations resulting from the imbalance forces do not influence the structure of the exhaust gas turbocharger casing, but serve as an indicator for the balance condition of the rotor and thus for the running behavior. Imbalances occurring during operation can be caused through irregular dirt deposits, damaged vanes of the compressor and/or turbine wheel or residual imbalance. When erratic running of the turbocharger is observed during operation, the condition can be improved in most cases by cleaning of the compressor (see Page 6-1) and the turbine (see Page 6-1 ff.). If the running behavior is still not satisfactory after repeated cleaning, the rotor is to be inspected and a balance check is to be carried out. The maximum allowable vibration acceleration for both of the mentioned excitation types are listed in the following.
A: Frequency range 3 - 300 Hz,

excitation degree caused through engine Allowable Vibration Acceleration TCR14 - 16 TCR18 - 22 2.0 g effective 1.8 g effective Allowable Vibration Acceleration TCR14 - 16 TCR18 - 22 1.8 g effective 1.4 g effective
B: Frequency range 300 - 3100 Hz,

actuated through the first harmonic oscillation of the rotor speed; individual share. Allowable Vibration Acceleration TCR14 - 16 TCR18 - 22 0.8 g Amplitude 0.8 g Amplitude
Measuring Points for Vibration Acceleration

(
(1) At the front plate of the silencer (2) At the flange of the compressor casing/silencer (3) At the flange of the compressor casing/bearing casing, vertical to the turbocharger axis
Version 06/2006
TCR
Page 3-11
Sound Level Diagram

A completely new developed silencer was designed for the TCR exhaust gas turbocharger. Together with the insulations at the gas outlet casing, gas-admission casing and compressor casing of the turbocharger, sound immission values of below 105 dB (A) can be achieved on the engine. In the example, the sound level diagram is shown for the TCR 18 exhaust gas turbocharger, equipped with silencer and air filter. The third octave spectrum of the dampened airintake sound was measured. Sound pressure level in dB; speed: n = 37 980 rpm.
TCR18 1 m Sound pressure level Lp in dB on MDB-A TC-tested

TC Engineering Testing
TC-speed: n = 37980 rpm; tot , V = 4.4
100 95
1 m Sound pressure level Lp in dB
90 85 80 75 70 65 60
25 40 63 100 160 250 400 630 1000 1600 2500 4000 6300 10000 Overall A 31.5 50 80 125 200 315 500 800 1250 2000 3150 5000 8000 Overall L
1/3 Octave center frequency in Hz
Sound level diagram for TCR Series
Page 3-12
TCR
Version 06/2006
Systems
4
The connection for lube oil discharge is located between the two supply connections. The measuring point for the lube oil pressure is located at the top of the bearing casing.
Lube Oil System

The lube oil is conducted from the lube oil system of the engine to the exhaust gas turbocharger.
Lube Oil Connections

The exhaust gas turbocharger has two connections for lube oil supply at the bottom of the bearing casing. The connection not needed is to be plugged in the area of the turbocharger bracket. Type TCR14 TCR16 TCR18 TCR20 TCR22
Inner diameter of lube oil supply in mm 22 22 22 22 32
Inner diameter of lube oil outlet in mm 32 37 45 54 70
Function of the Lube Oil System

Lubrication and cooling of the highly stressed bearing points in the exhaust gas turbocharger is effected through a lube oil system which is integrated in the bearing casing of the turbocharger. The lube oil is conducted from the lube oil system (Lube oil diagram, see Page 4-2) of the engine via the supply pipe (1) to the lube oil system of the turbocharger. The orifice (2) mounted in the oil supply reduces the oil pressure to the required value. The lube oil is conducted to the radial and axial lubrication gaps of the turbocharger via the ring duct (3) and the bores in the bearings. A connection for the manometer (7) and/or the pressure controller (8) for controlling/monitoring of the lube oil pressure is located on the top of the bearing casing (4). The oil flows back into the engines lube oil system via the drain pipe (9).
Lube oil outlet Lube oil supply*
* Alternatively left or right
Lube oil connections The oil pressure is adjusted with an orifice. Alternatively, the provided orifice can also be mounted in the turbocharger bracket on the engine side.
Note
Ensure that only one orifice is mounted in the lube oil supply of the turbocharger.
Version 06/2006
TCR
Page 4-1
8
PSL
7
PI
Venting
Up to 0.2% of the intake air escapes with the lubrication oil through the drain pipe via the bearing casing. This air volume can lead to an inadmissible high increase of the prevailing pressure in the crankcase. To avoid this, the oil discharge must be vented. This must occur via a larger space/cavity that permits settling of the oil. The two possibilities are either via separate venting in the oil discharge or through sufficiently dimensioned crankcase venting. The cross section of the venting pipe should correspond with that of the oil drain pipe.
5 4 2
Note
For two-stroke engines, a bracket with integrated venting possibility can be supplied optionally from MAN Diesel.
9 10
Shaft Sealing
The oil chamber is sealed with piston rings on the turbine and compressor side. For this reason, TCR exhaust gas turbochargers do not require sealing air and can be pre-lubricated beyond limitation. The robust piston-ring sealing ensures ease of servicing.
* Delivery scope of the turbocharger 1 2 3 4 5 Supply pipe (engine) Orifice * Ring duct * Bearing casing* Thrust bearing* 6 Bearing bush* 7 Manometer 8 Pressure controller 9 Drain pipe 10 Motor bracket
Lube Oil Flow Rate

The flow rate of the lube oil depends on the viscosity (SAE class) and the temperature of the oil. The bearings are dimensioned to be operated with commercially available SAE 30 or SAE 40 engine oil. This enables direct linking of the lube oil supply to the lube oil circuit of the engine. High-alkaline cylinder oils are not suitable for the lubrication of the turbocharger bearings.
Lube oil diagram
Lube Oil Discharge

The drain pipe is to be installed with the maximum possible slope, sufficiently dimensioned and free of resistance and back-ups. For ship systems the inclination of the drain pipe must be at least 5 in excess of the largest possible slope of the ship, For stationary systems the drain pipe must have an inclination of at least 5.
Lube Oil Characteristics Viscosity Lube oil inlet temperature (min.) Lube oil inlet temperature (max.)
Parameter SAE 30 or SAE 40 40 C
Upon request, planning data can also be supplied for self-sufficient lube oil supply of the exhaust gas turbocharger, independent from the engine lubrication circuit. For more details please contact MAN Diesel in Augsburg directly. E-Mail: [email protected]
75 C
Page 4-2
TCR
Version 06/2006
The following Table applies for SAE 30 at 60 C: Flow Rate at 2.2 bar in m3/h 0.9 1.2 1.9 2.6 4.4 Flow Rate at 1.3 bar in m3/h 0.6 0.9 1.3 1.8 3.0 Discharged Heat in kW 7 9 11 14 21
Pre-lubrication
Before starting the engine, the bearing points of the exhaust gas turbocharger must be pre-lubricated. This takes place automatically together with the pre-lubrication of the engine, as the lube oil system of the turbocharger is connected to the lube oil system of the engine. Depending on the engine system, pre-lubrication occurs directly before starting. Pre-lubrication before starting: Duration < 10 minutes with an oil pressure of 1.3 - 2.2 bar. Continuous pre-lubrication: With an oil pressure of 0.3 to 0.6 bar.
Type
TCR14 TCR16 TCR18 TCR20 TCR22
Lube Oil Pressure of the Exhaust Gas Turbocharger

The required lube oil pressure of the turbocharger is adjusted by means of an orifice in the lube oil supply. Upon initial starting of operation, the oil pressure is set and checked at the measuring point connection (at the top of the bearing casing) (see Page 4-1). The lube oil pressure is to be set in such a manner that a pressure of 1.3 - 2.2 bar is given at this location under full load of the engine with the lube oil at operating temperature. The following parameters apply for the monitoring of the lube oil pressure: The alarm value is to be set at 1.0 bar for a pressure drop of the lube oil pressure, The limit value for load reduction to half load is at 0.8 bar, At 0.6 bar, the engine is to be stopped immediately. When starting the engine and during the warm-up phase of the engine with still cool lube oil, a short-term higher lube oil pressure is permitted. For differences in elevation between the pressure-measuring point and the center of the exhaust gas turbocharger, it is imperative to take the value of 0.1 bar per 1 meter of level difference into account. Example: If the manometer or the pressure controller is situated three meters below, then the manometer must indicate a value increased by 0.3 bar or the pressure controller must be set 0.3 bar higher than the required operating pressure. The required lube oil pressure is adjusted by means of a throttle device in the supply line. The indication of the active alarm and the reaction through the engine control must occur at the same time. Therefore, the engine control must at least correspond with category 3 according to DIN EN 954-1.
Post Lubrication
After an engine shut-down, the bearings of the turbocharger must be post lubricated for cooling purposes with a lube oil pressure of 0.3 to 0.6 bar (reference height: center axis of the exhaust gas turbocharger) for a period of 10 to 30 minutes.
Oil Pressures
Measuring Location Lube oil pressure during operation (40 - 75 C) Max. lube oil pressure in cold condition Continuous pre-lubrication Post lubrication, 10 to 30 minutes Alarm Points Alarm Direct load reduction of the engine (slow down) Engine stop (shut down) 1.0 0.8 0.6 Limit Value in bar 1.3 - 2.2
<6 0.3 - 0.6 0.3 - 0.6
Version 06/2006
TCR
Page 4-3
Filtration of Lube Oil

Additional lube oil filters are not necessary; the nowadays usual filtration for heavy fuel oil operation is sufficient, as far as the pass-through size of particles < 0.05 mm. Furthermore, it is assumed that the engine lube oil is continuously maintained by separation and is not enriched with residual matter exceeding 0.02 mm and water. Before the first starting of operation or after extended maintenance, the pipes between engine filter and exhaust gas turbocharger are to be thoroughly pickled, cleaned and flushed. Clean oil increases the service life of the plain bearings.
Changing the Oil

An oil change is required when the chemical/physical parameters of the oil filling have changed in such a manner that the lubricating, cleaning and neutralizing properties are no longer sufficient. In this, the limit values mentioned in the Table as well as a drop test can serve only as a reference.
Taking an Oil Sample

In order to receive a representative oil sample, the following requirements are to be met: Take oil sample only while the engine is running, Take oil sample in front of the exhaust gas turbocharger and always at the same location, Fill sample bottle only to 90%, Provide for a special sample removal cock.
Evaluation of the Lube Oil Condition

For exhaust gas turbochargers that are supplied with oil via the engine lube oil circuit, the assessment criteria of the engine manufacturer primarily apply for the evaluation of the lube oil condition. For exhaust gas turbochargers with their own lube oil system, regular checks of the lube oil condition are to be carried through. For routine inspections of the lube oil condition, the parameters in the Table below are sufficient. The mentioned limit values are empirical field values with orientation of the engine requirements toward the lubricating oil. In order to reach long storage service life, these limit values must not be exceeded. A binding statement on the further usability of the oil can only be derived from a full analysis where the values are to be determined according to standardized testing methods. Oil Parameters for Routine Inspections Viscosity Water content (% in weight) Total contamination in (% in weight) Limit Value one viscosity class < 0.2 (short-term to 0.5) 2.0
Page 4-4
TCR
Version 06/2006
Quality Requirements
5
Testing Method ISO-F Specication Total sediment content (% in weight) Water content in Vol.% Sulphur content (% in weight) Ash content (% in weight) Coke residue (MCR) (% in weight) Cetane number Copper strip test Vanadium content in mg/kg Aluminum and silicon content in mg/kg Visual check ISO CD 10307 ISO 8733 ISO 8754 Parameter DMB 0.10 < 0.3 < 2.0 DMC 0.10 < 0.3 < 2.0
Fuels
The quality of the fuel with which the engine is operated affects the composition of the exhaust gas that flows through the turbocharger. Impurities in the fuel can lead to residue in the exhaust gas which can effect the turbocharger in an abrasive or corrosive manner.
Marine Diesel Oil (MDO)

Marine Diesel Oil (MDO) is also known as diesel fuel oil, diesel oil, bunker diesel oil or marine diesel fuel. MDO is offered exclusively for shipping as a heavy distillate (ISO-F-DMB) or as a mixture of distillate and low quantities of residual oil (ISO-F-DMC). The term blended MDO is common for the dark brown to black colored mixture. MDO is produced from crude oil and must be free of organic acids. The usability of the fuel depends on the design of the engine and the cleaning device as well as if the characteristics mentioned below, which are based on the condition at the time of supply, are observed. The characteristics determined were based on ISO 8217-1996 and CIMAC-2003. The characteristics refer to the mentioned testing methods.
ISO 6245
< 0.01 < 0.05
ISO CD 10370 ISO 5165 ISO 2160 DIN 51790 T2
> 0.3 > 40 <1 0
< 2.5 > 40 <1 < 100
ISO CD 10478
0
1)
< 25
Testing Method Specication ISO-F Density at 15C in kg/m3 Kinematical viscosity at 40C in mm2/s=cSt Pour Point Winter quality in C Summer quality in C Flash point (Pensky Martens) in C ISO 3675
Parameter DMB 0.900 DMC 0.920
1) At room temperatures and with good lighting, the fuel should be clear and appear transparent.
ISO 3104
< 11
< 14
Other Specications British Standard BS MA 1001987 ASTM D 975
Parameter Class M2 2D No. 2 Class M3 4D No. 4
ISO 3016
<0 <6 > 60
<0 <6 > 60
ASTM D397
ISO 2719
Mixing fuels can lead to a reduction of quality. This can result in combustion with a higher degree of residuals which can cause heavy contamination of the turbocharger. Extreme contamination can damage the turbocharger.
Version 06/2006
TCR
Page 5-1
Therefore the following points are to be observed: In loading plants and during transportation, MDO is treated as residual oil. Mixing with, e.g., high-viscous fuel oil or interfuel remaining in a bunker vessel is possible and can lead to a considerable reduction in quality. Different bunker batches of blended MDO (ISO-F DMC) can be incompatible and therefore should not be mixed. For this reason, the respective fuel tank should be emptied to the greatest possible extent before a new batch is filled in. Ocean water in the fuel aides corrosion in the turbocharger and leads to high-residual combustion. Solid foreign matter increases the mechanical wear in the nozzle ring and the turbine of the turbocharger. Therefore the following is to be observed: If blended MDO (ISO-F DMC) is primarily being used, we recommend installing a centrifugal separator in front of the fuel filter. This widely separates solids particles (sand, rust catalyst residue, catfines) and water so that the cleaning intervals for the filter inserts can also be prolonged. Operating data: Separator admission 65% with reference to the rated ow rate capacity, Separation temperature 40 -50 C.
free engine operation. The following points are to be observed for this: Heavily abrasive inorganic, solid foreign substances (catnes, rust, sand) must be separated to the greatest possible extent. With an aluminum content >10 mg/kg, the abrasive wear in the turbocharger increases heavily. Use only separators of the latest generation which are fully effective over a large density range without any adjustment, and separate water with an HFO density of 1.01 g/ml at 15 C. The cleaning effect is monitored by the separator itself. The HFO purication is to be designed in such a manner that the characteristics in the Table are reached: Particle Size in m
Parameter Inorganic solid foreign particles (including catnes) Water
Quantity
<5
< 20 mg/kg1)
< 0.2 Vol.%
1) AlSi content < 15 mg/kg
Heavy Fuel Oil (HFO)

MAN Diesel turbochargers can be operated on engines that run on crude-oil based heavy fuel oil (HFO), when the engine and the processing system are designed accordingly. The fuels used must meet the fuel specifications. The respective limit values that are to be met are listed in the fuel specifications. The limit values that influence the engine operation are to be specified when ordering fuel, e.g., in the bunker or charter clause. Adding motor oil (waste oil), mineral-oil-foreign materials (e.g. coal oil) and remainders from refining or other processes (e.g. solvent) is prohibited! This ban is specifically to be pointed out in the fuel order, as it is not yet part of the standard fuel specifications. Such additions lead to combustion with high residue and increased wear and corrosion on components of the turbocharger. Adding motor oil (waste/old oil) is particularly critical as the lube oil additives cause emulsions to form and keep debris, water and catalyst particles finely distributed in poise. This impedes or prevents the required fuel cleaning. The heavy fuel oils ISO F-RMK 35/45/55, with a maximum density of 1010 kg/m3, can be used only when respectively modern separators are available. Thorough processing of heavy fuel oil is required for trouble-
With unfavorable vanadium-sodium ratio, the melting temperature of the HFO ash drops to the range of the exhaust valve temperature, which causes hot corrosion. By precleaning the HFO in the settling tank and in the centrifugal separators, the water and thus the water-soluble sodium compounds can be removed to the largest extent. With a sodium content exceeding 100 mg/kg, increasing salt deposits in the turbine are to be expected. This jeopardizes the turbocharger operation (among other things by pumping of the turbocharger). When using PTG the sodium content must be limited to 50 mg/kg. Under certain conditions, hot corrosion can be avoided with a fuel additive that increases the melting temperature of the HFO ash. Heavy fuel oils with a high ash content in form of foreign substances, e.g., sand, rust catnes, increase the mechanical wear in the turbocharger. Heavy fuel oils from catalytic cracking plants can contain catnes. These are generally aluminum silicate, which effects high wear in the turbocharger. The determined aluminum content multiplied by 5-8 (depending on catalyst composition) approximately amounts to the content of catalyst material in the HFO.
Page 5-2
TCR
Version 06/2006
Fuel Specication Heavy Fuel Oil (HFO)

Fuel Specication CIMAC 2003 BS MA-100 ISO F-RM System-relevant Parameters Viscosity (at 50 C)1) in mm2/s=in cSt Viscosity (at 100 C)1) in mm2/s=in cSt Density (at 15 C)1) in g/ml Flash point2) in C Pour point Summer1) in C Winter2) in C Engine-relevant Parameters Carbon residue1) (Conradson) (% in weight) Sulfur1) (% in weight) Ash1) (% in weight) Vanadium1) in mg/kg Water1) in Vol.% Sediment1) (potential) (% in weight) Supplementary Parameters Aluminum and silicium1) in mg/kg Asphaltenes1) (% in weight) Sodium1) in mg/kg 80 2/3 of the carbon residue (Conradson) Sodium < 1/3 vanadium, sodium < 100 Cetane number of the uid mixing component: min. 35 Fuel to be free of mineral-oil-foreign additives such as coal oil or vegetable oil. Free of creosote and lubricating oil (waste oil)
1) maximum 2) minimum
A30
B30/ C10 M4
D80 M5 D15
E/F 180 M7 E/F25
G/H3/ K50 8/9 G/H35
M8/ H/K45
H/K700 M9/ H/K55
A10
B/C10
40 10 0.975 60
40 10 0.981 60
80 15 0.985 60
180 25
380 35
500 45
700 55
0.991/1.010 60 60 60 60
6 0
24 24
30 30
30 30
30 30
30 30
30 30
10 3.5 0.10 150 0.5 0.1
10/14 3.5 0.10 150/ 300 0.5 0.1
14 4 0.10 350 0.8 0.1
15/20 5 0.15 200/ 500 1 0.1
18/22 5 0.15 300/ 600 1 0.1
22 5 0.20 600 1 0.1
22 5 0.20 600 1 0.1
Version 06/2006
TCR
Page 5-3
Lubricating Oil and Additives

Commonly, doped oils (HD oils) are used for gas oil and diesel-oil operation (MGO/MDEO), whereas semi-alkaline lubricating oils are used for heavy fuel oil operation (HFO). The base oil must meet the following limit values, particularly concerning the aging stability:
tives or the mixing of different lube oil brands also annuls the responsibility of the lube oil supplier company for the lube oil.
Intake Air
The quality as well as the condition of the intake air has a decisive influence on the performance of the turbocharger. Not only is the atmospheric condition of great importance, but also the degree of solid and gaseous impurities. Mineral dust particles in the intake air have a wear-increasing effect, whereas chemical/gaseous ingredients increase corrosion. For this reason, effective cleaning of the intake air and regular maintenance/cleaning of the silencer air filter mat is required.
Properties
Testing Method
Parameter Preferably parafn-based -15
Structure Behavior in cold, still uid in C Flash point according to Cleveland in C Ash content (oxide ash) (% in weight) Carbon residue according to Conradson (% in weight) Aging tendency after 100 h of heating (to 135 C) n-heptane insoluble (% in weight) Evaporation loss (% in weight) Spot test (lter paper)
ASTM-D2500
Intake Air Characteristics

The particle size in the intake air must not exceed 5 m after the silencer/air intake casing or ahead of the compressor inlet. The following maximum particle concentrations in the intake air may not be exceeded: Concentration in mg/Nm3 1) 5 1.5 1.25 15
ASTM-D92
> 200
ASTM-D482
< 0.02 Properties/Characteristics
ASTM-D189
< 0.05 Dust (sand, cement, CaO, Al203 etc.) Chlorine
MAN aging apparatus ASTM-D4055 or DIN 51592
Sulphur dioxide (SO2) Hydrogen sulphide (H2S)
< 0.2
1) Standard cubic meter in Nm3
<2 Visual check1)
When dimensioning the intake air system, pay attention not to exceed a total pressure loss (filter, silencer, piping) of 20 mbar. Exception: A pressure loss higher than 20 mbar has been taken into consideration for the layout (e.g. gas addition for gas engines).
MAN-Test
1) Sample must not show precipitation/parting of resinous and asphaltic aging
Additives must be dissolved in oil and structured in such a manner that as little as possible ash results upon combustion. The ash must have a soft structure. Otherwise, increased formation of residue in the bearing casing of the turbocharger must be taken into account. Hard additive ash enables increased mechanical wear. Additives may not aid a clogging of the filter inserts, neither in active nor in processed condition. Lubrication Oil Additives We strongly advise to refrain from subsequent addition of additives to the lube oil or mixing different lube oil brands, as this can interfere with the function of the additive package matched for itself and for the base oil. The addition of addi-
Page 5-4
TCR
Version 06/2006
Auxiliary Equipment
6
Dry Cleaning, Turbine x Therefore, we recommend carrying out the compressor cleaning every 100 to 200 operating hours. For this, cleaning equipment with a pressure sprayer is provided by MAN Diesel: Cleaning of the compressor is carried out with water during operation at full load, Cleaning is to be performed only with fresh water; do not use ocean water, chemical additives or detergents, Blow washing water in for approx. 30 seconds, The cleaning intervals for the compressor should be determined depending on the contamination degree of the respective system. The compressor cleaning equipment is connected at the silencer/air intake casing or at the corresponding connection coupling.
Cleaning Equipment
Wet Cleaning Turbine Heavy Fuel Oil operation Marine diesel oil/gas oil operation x x1) Compressor x
1) Depends on fuel ingredients such as vanadium, sodium and nickel
Compressor Cleaning
During operation, deposits and oily debris films increasingly form on the vanes of the compressor wheel and the diffuser. This contamination reduces the efficiency of the compressor.
1 4 B A
2 5 3
1 2 3 4 5
Handle Pressure sprayer Label with cleaning instructions Connection coupling Turbocharger (compressor)
A Overpressure valve B Hand valve
Diagram Wet cleaning of the compressor
Turbine Cleaning
From the initial starting of operation on, the exhaust gas turbochargers of engines in heavy fuel oil operation, marine diesel oil operation and gas oil operation must be cleaned in regular intervals in order to remove combustion residue from the blades of the turbine wheel and the turbine nozzle ring. Otherwise such deposits can impair the operating data or even lead to heavy vibrations of the turbine blades.
Version 06/2006
TCR
Page 6-1
The following two cleaning procedures are possible: Turbine wet cleaning, Turbine dry cleaning. Both cleaning procedures can be applied to the same exhaust gas turbocharger, whereby the advantages of both cleaning procedures complement one another. Observe the cleaning instructions on the instruction plate of the exhaust gas turbocharger and in the operating manual.
cleaning every 150 operating hours: Use fresh water without any chemical additives whatsoever, The washing duration for interval cleaning is: 10 x 0.5 minutes washing and drying for 1 minute each time. The washing water (1) flows through the three-way cock (A) (water pressure approx. 2 bar) into the gas-admission casing (4). The washing nozzle (2) sprays the water in the exhaust gas pipe before the turbine (3). The droplets of the washing water bounce against the turbine nozzle (5) ring and the turbine (6) where they wear off contamination. The washing water collects in the gas outlet casing. A large portion of the washing water evaporates in the gas outlet diffuser (7) due to the high flow velocity and is emitted outside via the flue flange as steam. The portion of washing water that does not evaporate drains through the washing water outlet (8) and the stop cock (B). The washing water is conducted to a sediment tank via the drain funnel (9) and collected there. The sealing air prevents clogging or rusting through of the piping. For this, a minor quantity of the air after the charge air cooler is used and continuously flows through the respective piping system. The sealing-air flow rate required for the turbine cleaning is 0.1 - 0.3% of the compressor flow rate. Advantages of turbine wet cleaning:
Wet Cleaning of the Turbine

Wet cleaning of the turbine is carried out during operation at strongly reduced engine load in order to avoid overstressing of the turbine materials (thermal shock):
Max. Exhaust Gas Temperature before the Turbine in C 320 320 320 320 320
Max. Turbocharger Speed in rpm 26 000 22 000 18 000 15 000 12 000
The cleaning frequency depends on the type of fuel and on the operating mode; we recommend carrying out turbine wet
3 2
Better cleaning effect and thus longer cleaning intervals.
4 5 1 2 3 4 5 6 7 8 9 10 A Washing water Washing nozzle Exhaust gas pipe before the turbine Gas-admission casing Turbine nozzle ring Turbine wheel Outlet diffuser Washing water outlet* Drain funnel* Plate with cleaning instructions Three-way cock with sealing air connection B Stop cock* C Manometer (recommended)* * Delivery scope of engine manufacturer
10 6 7 C A 8 1 Sealing air 9 B
Diagram Wet cleaning of the turbine
Page 6-2
TCR
Version 06/2006
Dry Cleaning of the Turbine

In addition to wet cleaning of the turbine, dry cleaning of the turbine can also be performed. Dry cleaning of the turbine is carried out during operation at 75% - 100% operating load of the engine. Shorter cleaning intervals must be observed in regard to wet cleaning of the turbine, otherwise more intense deposits will not be removed. It is recommended to perform the cleaning with granulates every one to two days. When using HFO that produces heavy coverings, the cleaning interval should be increased to twice daily. Depending on the type of funnel, particles of soot can escape during the cleaning procedure. Special consideration should be taken for passenger ships. The granulate tank is fitted with an opening for filling, a compressed-air supply pipe and a pipe leading to the gas-admission casing. Type TCR14 TCR16 TCR18 TCR20 TCR22 Granulate Quantity1) in l 0.1 0.2 0.2 0.3 0.5
The compressed-air supply pipe and the further piping are both shut with a cock. The granulate tank is filled with cleaning granulate and shut tight. The stop cock (A) of the compressed-air supply (1) is opened and compressed air flows into the granulate tank (2). Afterwards the cock (B) of the pipe leading to the gas-admission casing (6) is opened. The compressed air blows the granulate out of the granulate tank into the gas-admission casing. There, the exhaust gas flow transports the granulate to the turbine wheel (8). The granulate particles bounce against the turbine nozzle ring (7) and the turbine wheel (8), and in this manner remove deposits and contamination. The exhaust flow forwards the granulate and the dirt particles out of the system. The granulate tank must be fastened at a suitable location and must not be positioned more than 1 m below the connection ange, The piping must not be longer than 6 m and must be supported against vibrations. Unhindered ow must be ensured, Maximum operating temperature of the stop cock (exhaust gas): 200 C, The piping should have as few bows as possible with large bend radius, The connection ange have to be attached on the exhaust gas pipe. The max. distance between injection point and gas-admission casing is the inlet diameter of the gasadmission casing d.
1) Granulate consisting of nut shells or activated carbon (soft) with a particle size of 1.0 mm (max. 1.5 mm)
5 9 10 3 7 6
2 A
B 1
1 Compressed-air supply pipe (5-8 bar)* 2 Granulate tank (filling volume approx. 0.5 l) 3 Screw plug 4 Piping 20 x 2 mm, lmax = 6 m 5 Connection flange 6 Gas-admission casing 7 Turbine nozzle ring 8 Turbine wheel 9 Gas outlet casing 10 Plate with cleaning instructions A Stop cock (compressed air) B Three-way cock with sealing air connection * Delivery scope of engine manufacturer
Sealing air
Diagram Dry cleaning of the turbine
Version 06/2006
TCR
Page 6-3
Jet Assist
The Jet Assist acceleration system is used when special requirements are made towards swift and possibly soot-free acceleration, and/or towards the load applications of the engine. In case of a sudden load increase, the Jet Assist system accelerates the rotor within an extreme short period by supplying auxiliary compressed air, which is conducted onto the compressor wheel through several nozzles in the compressor insert.
Jet Assist Connections

Jet Assist Air Pressure 4 bar Type Inner Diameter of the Connection Pipe in mm 20 20 40 40 50
TCR14 TCR16 TCR18 TCR20 TCR22
6 5
4 1 Starting-air bottle* 2 Solenoid valve* 3 Orifice 4 Insert 5 Compressor casing 6 Bore 2 1

30 bar
4 bar
* Delivery scope of engine manufacturer
Diagram Jet Assist
Connection Sizes for Pipes and Piping

Connections for Turbine Dry Cleaning
Type TCR14 TCR16 TCR18 TCR20 TCR22 Compressed-air Connection in mm 10 x 1.5 10 x 1.5 12 x 1.5 12 x 1.5 12 x 1.5
Sealing-air Connection for Turbine Cleaning

Dry cleaning: 6 x 1 mm Wet cleaning: 10 x 1 mm
2D connection drawings and 3D CAD models can be supplied on request. If required, please directly contact MAN Diesel in Augsburg. E-mail: [email protected]
Connections for Turbine Wet Cleaning

Water supply: 16 x 2 mm Drain-water connection: G 3/4
Page 6-4
TCR
Version 06/2006
Engine-Room Planning
Provide for hoisting rails with a traversable crane trolley in axial direction above the exhaust gas turbocharger in which a lifting tackle with the respective minimum carrying capacity for lifting is inserted, so that, e.g., maintenance can be carried out.
Disassembly Dimensions for the Assemblies

The disassembly dimensions C1 (compressor side) and C2 (turbine side) shown in the graphic are required to disconnect and remove assemblies from the exhaust gas turbocharger: We recommend planning additional 300 to 400 mm as working space. It must be ensured that the silencer and gas outlet casing can be removed and placed down either to the bottom, the top or to the side, so that the exhaust gas turbocharger is accessible for additional servicing. Pipes are not to be installed in these free spaces. The following Tables list the disassembly dimensions for turbochargers with air intake casing/air intake pipe and gas outlet elbow: Turbocharger with air intake casing Type TCR14 TCR16 Disassembly dimensions TCR18 TCR20 The following Table lists the disassembly dimensions for the turbocharger with silencer and gas outlet casing: Type TCR14 TCR16 TCR18 TCR20 TCR22 A in mm 445 535 645 750 880 B in mm 460 585 700 870 1 130 C1min in mm 100 120 120 130 150 C2min in mm 300 400 400 400 400 TCR 14 TCR 16 TCR 18 TCR 20 TCR 22 275 330 400 490 530 480 545 655 780 1 000 TCR22 A in mm 505 685 735 895 1 055 B in mm 480 545 655 780 1 000 C1min in mm 100 120 120 130 150 C2min in mm 120 120 120 130 150
C1
C2
Turbocharger with air intake pipe Type A in mm B in mm C1min in mm 100 120 120 130 150 C2min in mm 120 120 120 130 150
The minimum clearance of the silencer to a bulkhead or deck should not be less than 100 mm.
Version 06/2006
TCR
Page 7-1
Between the hoisting rails above the gas outlet casing and manifold, sufficient space must be provided for the exhaust gas system (make sure to observe the maximal possible dimension E).
Casing Positions
The gas outlet casing can be delivered assembled in various angle positions (also see Table on Page 2-5):
D E E
Hoisting rail dimensions Casing positions, gas outlet casing Type TCR14 TCR16 TCR18 TCR20 TCR22
1) 2) 3)
Dmin1) in mm 880 1 035 1 220 1 430 1 845
Dmin2) in mm 940 1 180 1 315 1 575 2 020
Dmin3) in mm 710 830 980 1 170 1 495
E in mm 150 180 215 270 355
For these cases, provide for sufficient clearance b between the flange/exhaust gas system and the engine-room walls!
Note
If required, please enquire about the flange clearances relative to the angle position at MAN Diesel in Augsburg.
with silencer with air intake casing with air intake pipe
Note
Weights of the assemblies, see Page 2-4.
Page 7-2
TCR
Version 06/2006
Turbocharger Suspension Device
Exhaust Gas System

Exhaust-gas resistance has a very large influence on the fuel consumption and the thermal load for the engine. The pipe diameter depends on:
2 2
the exhaust-gas volume, the length and arrangement of the pipe. Sharp bends result in very high resistance and are therefore to be avoided. Where this is not possible, use pipe bends with blade grids.
Note
The total resistance of the exhaust gas system must not exceed 30 mbar. The exhaust-gas velocity in the pipe must not exceed 40 m/s. Exception: A higher pressure loss has been taken into consideration for the layout (e.g. underwater exhaust gas system)
Turbocharger suspension device
The fastening point (1) of the endless sling for lifting the turbocharger is at the bearing casing; the auxiliary ropes (2) of the lifting tackle are to be fastened between silencer/air intake casing and compressor casing or gas outlet casing. Minimal Carrying Capacity of the endless Sling in kN 4
Feet
Exhaust gas silencer
Weight in kg 165 260 415 720 1 550
Loose-point support Fixed-point support
6 10 15 35
Exhaust-gas drum Drain Compensator
Example of an exhaust system
Version 06/2006
TCR
Page 7-3
Exhaust Gas System - Installation

The following points are to be observed when installing the exhaust gas system: The exhaust pipes of more than one engine may not be conducted together, The exhaust pipes must be able to expand. For this purpose, expansion pieces are installed between the xedpoint supports which are attached at suitable locations. A sturdy xed-point support is to be provided for directly above the compensator, as far as this is possible, in order to keep forces away from the exhaust gas turbocharger that result from the weight, the thermal expansion or the sideward axis displacement of the exhaust pipe. To keep the sound transmission in other parts of the vessel as low as possible, the exhaust pipes should be fastened exible or supported with the use of damping elements. Continuously opened drainages are to be provided for back-owing condensate and possible drum-leakage water.
Installation of Flexible Pipes

Apart from the engine movements caused by rough seas or swell in vertical, axial and transverse direction, the largest motion amplitudes of an elastically supported engine occur in transverse direction while starting and shutting down the engine. For reasons of improved motion absorption, we therefore recommend the installation of the pipes in axial or vertical direction, and not in transverse direction to the engine. For straight installation, the clearance of the flanges to each other is to be selected in such a manner that the hose can sag. It must not be subject to tensile stress during operation. For installation with 90 bend, the radii indicated in our drawing are minimum required radii, and must not be fallen below. Hoses may not be installed twisted, which is why the loose flanges on the hoses are designed rotatable. For screwed connections, the hexagon on the hose is to be counter-held with a wrench when tightening the nut.
Note
Observe the manufacturers instructions!
Page 7-4
TCR
Version 06/2006
Emergency Operation in Case of Failure of an Exhaust Gas Turbocharger

Exhaust gas turbochargers are highly stressed turbo machines. As with engines, malfunctions can occur despite careful operations management. If damage occurs to a turbocharger that cannot be corrected immediately, emergency operation is possible. For this, the cartridge is removed and the gas-admission casing is closed.
8
Auxiliary Device
For the turbocharger (delivery scope optional): Closing cover and foot for closing off the gas-admission casing and sealing off the lube oil supply and discharge.
Achievable Outputs
The following criteria limit the achievable engine load at emergency operation: Maximum exhaust gas temperature after cylinders, Maximum exhaust gas temperature before the turbocharger,
Maximum permitted speed of the still operative turbochargers (for engines with several turbochargers), Smoke number of exhaust gas.
Personnel and Time Requirements
2
Emergency Measure Turbocharger with closing device
Qualied Mechanic Required Time in h Mounting of the closing device 2.6
Assistant Required Time in h 2.6
Emergency Measure
In order to close the gas-admission casing, the silencer/air intake casing and the compressor casing must be removed first. The cartridge (bearing casing with turbine rotor) and the turbine nozzle ring are removed. Afterwards, the gas-admission casing is closed with the closing cover (1). The foot (2) is used to secure the casing and seal off the lube oil supply and discharge. In emergency operation, the turbocharger exhaust side is still flown through.
Version 06/2006
TCR
Page 8-1
Calculations
Layout Calculation
A layout calculation in accordance with the experience of MAN Diesel on the basis of ISO conditions (25 C/1000 mbar) enables safe engine operation at inlet air temperatures between 5 C and 45 C. For operation in arctic climate (< +5 C), a blow-off valve is to be provided for after the compressor in order to exclude exceeding charge air pressure and danger of surging. The maximum speed of the rotor mentioned on the type plate of the exhaust gas turbocharger is a constant value, regardless of the respective ambient temperature.
TC = T1 T3
. m L c pL . m G c pG
p2 1
p1
L - 1 L 1 G - 1 G
p4 p3
Note
At a given engine output, the pressure ratio of the compressor increases with decreasing inlet air temperature and decreases with increasing temperature.
Efciency of the Exhaust Gas Turbocharger

The efficiency is an important criteria for the evaluation of the turbocharger. The following formula shows how the efficiency of the turbocharger can be calculated. The specific thermal value cp and the isentropic exponent are temperature-dependent. The values for the exhaust gas G and cpG are also influenced by the gas composition.
T1 T3 m L m G cpL cpG p1 p2
= = = = = = =
Compressor inlet temperature in K Turbine inlet temperature in K Air flow in kg/s Exhaust gas mass flow (air and fuel in kg/s) Specific heat (air in J/kg.K) Specific heat (exhaust gas in J/kg.K) Air inlet pressure in bar Charge-air pressure in bar Turbine inlet pressure in bar Turbine outlet pressure in bar Isentropic exponent (air) Isentropic exponent (exhaust gas) Turbocharger efficiency Pressure ratio of compressor Pressure ration of turbine
= p3 = p4 = L = G = TC = p2/p1 = p3/p4 =
Page 9-1
TCR
Version 06/2006
Denition of the Efciency

MAN Diesel exhaust gas turbochargers are used by various engine manufacturers within and beyond the MAN Diesel Group. Traditionally, various efficiency definitions are customary for exhaust gas turbochargers.
Please note:
As various losses of the supercharger system are taken into account for the engine definition, this efficiency is always lower than the efficiency according to the turbocharger definition, despite the same thermodynamic capacity of the exhaust gas turbocharger.
Turbocharger Definition
The total efficiency is one of the most common characteristics for the thermodynamic properties of a turbocharger. The total pressures directly before and after the compressor and before the turbine as well as the total temperatures are to be put into the equation. The flow velocity in the turbine outlet casing is not taken into account as no further usage of the dynamic pressure is given; as a result, the static exhaust gas turbine outlet pressure is applied and not the total pressure.
The efficiencies are calculated with the help of measured operating values. In order to receive a meaningful comparison between exhaust gas turbochargers of varying specifications, sizes, designs and makes, it is always necessary to mention the definition used for the calculation of the efficiency. When a pressure or temperature value in the definition is unknown, then it is not possible to determine the efficiency of exhaust gas turbochargers. The following Table lists the main differences of the two definitions for calculation of the total efficiency of an exhaust gas turbocharger:
Engine Definition
The engine definition defines the turbocharging efficiency of the engine. Contrary to the turbocharger definition, p2 is assigned to the pressure in the air pipe ahead of cylinder plus the cooler-pressure drop. The pressure in the exhaust gas pipe after cylinder is assigned to p3.
Pressure Values for the Efciency Denition of Exhaust Gas Turbochargers Turbocharger Denition Pressure: p2 Pressure: p3 Total compressor outlet pressure Engine Denition Pressure of the air pipe plus cooler-pressure drop Pressure in the exhaust gas pipe
Total turbine inlet pressure
Version 06/2006
TCR
Page 9-2
10
10
Speed Measurement, Adjustment, Checks
Speed Measurement
For all exhaust gas turbochargers of the TCR Series, MAN Diesel supplies a speed transmitter for measuring of the rotor speed as standard. The speed transmitter is positioned in the bearing casing and delivers speed impulses. The alternating impulses are conducted via a 2-wire cable to the terminal box on the compressor casing.
From the terminal box, the impulse signal is conducted on to a frequency-current converter or to a digital speed indicator (both optional). The signal can additionally be indicated on a suitable analog measuring instrument. Transmission of the measured values is possible with both types of speed measurement equipment. MAN Diesel supplies the measuring instrument and the transmission system for the measured values on request.
1 bl re 2 2 x 0.75 mm 2 Rel-NC Rel-COM Rel-NO
1 bl re 2 2 x 0.75 mm2 Rel-NC Rel-COM Rel-NO 4 2 x 0.75 mm 2 (4...20 mA) + 5 5 2 x 0.75 mm2 (4...20 mA) + 4 5 Digital speed indicator Additional speed indicator (analog) and/or transmission of the measured values
24 V DC +-
+24 V DC
1 Speed transmitter 2 Terminal box 3 Frequency-current converter
Connection of the speed measurement equipment for the TCR Series
Page 10-1
TCR
Version 06/2006
Description of Components
Speed Transmitter
The speed transmitter (1) is screwed radial into the bearing casing. A retaining ring with two grooves on the circumference is seated on the rotor shaft to generate the speed impulses.
Measurement of the Air Volume

The measurement of the air volume is carried out via calibration of the compressor casing. The measuring method is based on the theory of gas flow in manifolds: The pressure difference between inner and outer wall is correlated to the second power of the flow velocity. The compressor casing is comparable to a manifold of variable cross-section area. At a certain, through numerous tests determined cross section, the static pressure difference hsp, is measured at two opposing wall locations. As during the testing of the TCR turbocharger both hsp as well as the air volume can be measured in the usual manner (with orifice) at the burner rig, a calibration curve can be derived. For the subsequent engine testing, this curve easily enables to determine the air volume when hsp, the spiral pressure hsp and the outlet temperature tsp are measured:
Speed transmitter The speed transmitter is screwed in with a gap clearance of approx. 1 mm to the retaining ring and secured.
Read-out devices
The read-out devices can be located in the switch cabinet or housed in the operating cabinet. A speed transmitter with terminal box is part of the MAN Diesel delivery scope. The following measuring transformers can be connected: Frequency-current converter, Digital tachometer with speed indicator. When using a frequency-current converter or a digital tachometer, the number of grooves on the retaining ring (number of impulses per revolution), the maximum rotor speed as well as the alarm points must be taken into account when programming the equipment. When using original MAN Diesel components this adjustment is factor-set.
255 A
t Sp
Note
Speed detection and speed indication must be exactly in tune with each other! It is therefore recommended to have the detection and indication system supplied completely through MAN Diesel.
hsp hsp
Analog speed indication/transmission of measured values

Both types of speed measurement equipment have a power output (4-20 mA) for connection of an additional analog speed measurement device and/or the measured value transmission.
Silencer
Section A-A
hsp in mm H2O hsp in mm Hg
Spiral pressure hsp, Outlet temperature tsp and hsp This calibration curve is not transferable to other turbochargers, even if the size and specification are the same. The accuracy of this method is approx. 1%. For diffuser flow areas other than the calibration curve has been derived for, correction factors are used. In order to ensure reliable
Version 06/2006
TCR
Page 10-2
measurement, all measuring hoses, extensions, threads, etc. must be absolutely airtight (check by spraying on a soap solution).
One of the following methods can be applied: Four-stroke-stroke engines: Reduce engine speed with constant fuel admission; a speed reduction of at least 15% should be possible without the occurrence of surging, Increase the charge air temperature at constant power output; a temperature increase of at least 50 C above the air temperature at the compressor inlet should be possible without the occurrence of surging. Two-stroke engines: Run the engine at 100% load, Reduce the load suddenly to 75%. If no surging occurs repeat the procedure, but this time reduce the load from 100% to 50%; if not more than one surge blast occurs, the stability above 50% load is good, Run the engine at part load and a scavenging air pressure of > 0.6 bar overpressure so that the auxiliary blowers no longer run. Pull the fuel pump of one cylinder suddenly to zero, and repeat this measure with other cylinders. If surging occurs in not more than one case, the stability is sufcient.
Matching Procedure
Each newly specified exhaust gas turbocharger for a new application is matched by MAN Diesel so that: It is optimized with the best possible ow cross-sections for the operating conditions of the engine, A sufcient surge margin is ensured across the complete operating range. Therefore, it is customary that different variants of nozzle rings and diffusers (matching parts) are provided for matching purposes.
Matching Steps
Test run of the engine with the exhaust gas turbocharger in the Condition of delivery, If the air pressure (as required by the engine manufacturer) before cylinder is too low or too high in the design point, the nozzle ring must be exchanged, The following applies for the air pressure before cylinder: In order to reach a higher air pressure, a smaller nozzle ring must be used. To reach a lower air pressure, a larger nozzle ring must be used. At the same time the surge margin must be checked. The following applies for the surge margin: When the surge margin is less than required, a smaller diffuser must be used (in rare cases even a smaller compressor wheel). The part-load range must also be checked for a sufficient surge margin.
Surge Stability Check

Surging describes the unstable operation of a compressor when the air flow of an engine operating point becomes too low for the given pressure ratio. In this case, the air flow stalls and air from the subsequent pipe system flows through the compressor in the opposite direction. After the sudden decrease of pressure, the air flow starts again in the normal direction until the surge procedure is repeated. In this process, the compressor wheel is highly stressed so that continuous surging can lead to damage. The air intake section of the engine system is to be dimensioned in such a manner that pressure blasts of at least 1 bar overpressure can be withstood.
Page 10-3
TCR
Version 06/2006
Characteristic Map Diagram

As a basic for the matching of each newly specified exhaust gas turbocharger, the corresponding compressor map as well as the turbine characteristics are provided through MAN Diesel.
Compressor Map
6.5
Pressure ratio, compressor totV
without IRC with IRC
6.0
5.5
5.0
4.5
Choke range Surge line

4.0
3.5
u2red = 550 m/s u2red = 525 m/s u2red = 500 m/s u2red = 475 m/s
3.0
2.5
u2red = 450 m/s
2.0
u2red = 400 m/s
u2red = 350 m/s
1.5
u2red = 300 m/s u2red = 250 m/s
1.0 0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
Reduced flow rate, compressor V tot Vred in m3/s Compressor map with and without IRC
Based on the characteristic parameters Pressure ratio and Air volume flow rate, all operating points can be plotted along the operating line reduced for elimination of influences of different intake conditions. Together with other parameter curves such as speeds and efficiencies, they provide information on the performance of the compressor. The distance of the operating line to the surge limit can be increased by means of the compressor-internal measure IRC (Internal Recirculation).
Version 06/2006
TCR
Page 10-4
Internal Recirculation (IRC)

The compressor map width usable for an engine operating line is increased using IRC through the following effects: Increase of the surge limit margin at low and medium pressure ratio, Extension of the choke limit at high pressure ratio. This means that at low and medium pressure ratio, the minimal flow rate required for stable compressor operation is reduced through an additional neutral portion of the air flow. This is effected through recirculation of the air flow around the inlet area of the compressor wheel blades (see figure below). In the opposite flow direction and with high pressure ratio, however, the maximal flow rate is increased owing to an additional portion of air flow that bypasses the inlet area.
Turbine Characteristic
Reduced flow rate, turbine
.112 .108 .104 .100 .096 .092 .088 .084 .080 .076 .072 .068 .064 .060 1.00
tot v T tot v T
in m3/ (s K)
Recirculation
Bypass
1.30 1.60 1.90 2.20 2.50
2.80 3.10 3.40
3.70 4.00
4.30 4.60 4.90
Pressure ratio, turbine T Turbine Characteristic
Internal Recirculation
Based on the characteristic parameters Pressure ratio and Exhaust gas volume flow rate, the respectively given exhaust gas volume and also the air volume - through subtraction of the fuel quantity - can be calculated back from the known plotted operation characteristic curve (clearly assigned to a turbine geometry), reduced for elimination of influences different ambient conditions. This serves as an alternative, when no calibration of the compressor casing is given for direct measurement of the air volume.
Page 10-5
TCR
Version 06/2006
11
Quality Assurance
11
An integrated quality and environmental management system is established at MAN Diesel which is certified according to ISO 9001 since 1991 and to ISO 14001 since 2001. This affords our customers the confidence that MAN Diesel turbochargers meet customer expectations to complete satisfaction, from development over production to dispatching.
Version 06/2006
TCR
Page 11-1
Page 11-2
TCR
Version 06/2006
Description of the Quality Criteria

Standards, Provisions and Regulations
Exhaust gas turbochargers of the MAN Diesel TCR Series meet the regulations of the guideline 98/37/EG (Machine Guideline). The following national and international standards were applied upon development and production: DIN EN 292-1 - Security of Machines; Basic Terms, General Design Guidelines; Part 1: Basic Terminology, Methodology DIN EN 292-2- Security of Machines; Basic Terms, General Design Guidelines; Part 2: Technical Guidelines and Specications DIN EN 1050 - Security of Machines; Guidelines for Risk Assessment DIN EN 62079 - Creating Manuals; Outline, Contents and Representation DIN 7168 - General Tolerances; Length and Angle Measures, Form and Position; not for new constructions DIN 6784 - Workpiece Edges DIN EN ISO 1302 - Geometric Product Specication (GPS) - Indication of the Surface Condition in the Technical Product Documentation Q11.09004-8500 - Turbocharger Quality Guidelines (List of the applied MAN Diesel Works Standards for turbochargers). imum allowable operating speeds. Measuring of bores and wheel exterior to ensure that all dimensions are still within tolerance. Crack testing by penetration method. All nishing performed according to specications. Checking/measuring of all machined surfaces and diameters. Re-balancing of nish-machined compressor wheels.
Turbine Wheel
The pre-machined precision cast turbine undergoes a crack detection test prior to welding to the shaft. Renewed crack detection test of the friction-weld seam after friction welding with the shaft. Turbine rotors are balanced and spin-tested at speeds far above the maximum allowable operating speeds. Finishing according to specications. Checking/measuring of all machined surfaces and diameters. Re-balancing of the nish-machined turbine rotor.
Service Life Periods

The following data is based on empirical values of MAN Diesel that have been manufactured with identical materials and manufacturing procedures. The mentioned service life periods are reference values that apply under normal operating conditions. They can be considerably reduced due to e.g., insufficient maintenance, frequent blackouts or use of low-quality fuel and lube oil. Operating Hours Plain bearings Nozzle ring Turbine rotor Compressor wheel Casing 1) Depends on: The intake air temperature, the charge pressure, the load prole of the engine, and may fall shorter in case of unfavorable values. up to 30 000 up to 30 000 up to 60 000 up to 60 000 1) no limitation
Acceptance by international Classication Associations

Each turbocharger type of the TCR Series receives a type acceptance which includes the following: A drawing check, an examination of the regulation conformity, the type test run at the burner rig with maximum speed and exhaust temperature. In addition to this, each individual turbocharger can be ordered and delivered with acceptance and IMO Certicate upon request. As the rst of its series, the TCR18 turbocharger is certied by the following international acceptance companies: ABS (American Bureau of Shipping), BV (Bureau Veritas), DNV (Det norske Veritas Classikation A.S.), GL (Germanischer LIoyd), LR (LIoyds Register of Shipping).
Compressor Wheel
The die-forged blanks will be crack- and ultrasonic-tested before milling. Each compressor-wheel blank carries a test ring on which the strength values will be checked. After milling and pre-machining, all compressor wheels will be balanced and spin-tested at speeds far above the max-
Version 06/2006
TCR
Page 11-3
12
12
Maintenance and Checking
When carrying out maintenance and inspection work, it is usually sufficient to remove only partial subassemblies of the exhaust gas turbocharger. Only for mayor overhauls, it can be required to remove the complete exhaust gas turbocharger. When primary components are repaired or for major overhauls, it is recommended to protocol the condition of the individual assemblies.
Components with traces of wear or damage that particularly influence the strength and smooth running of rotating parts must be replaced against original spare parts or be repaired by an authorized repair shop or the manufacturer. For shipping, pack and protect components against corrosion so that they remain intact during transportation.
Maintenance
Turbocharger on the Four-stroke Engine Inspection intervals (during operation) in h Check turbocharger for abnormal noise and vibrations Check turbocharger and system pipes for leakages (charge air, exhaust gas, lube oil) Check all fastening screws, casing bolts and piping connections for tight seating.
1) Inspection of new or overhauled components required (once, at the operating hours listed)
24 X X
150
250
3 000
12 000
18 000
X1)
Maintenance intervals (during operation) in h Dry cleaning1) of the turbine
24 X2)
150
250
3 000
12 000
18 000
Wet cleaning1) of the turbine Cleaning of compressor (during operation) Cleaning of air lter1)
1) if given 2) or more frequently, if required
X2) X2) X2)
Maintenance intervals (combined with an engine maintenance) in h Major overhaul every 12 000 ... 18 000 operating hours: Remove, clean and check all components of the turbocharger! Inspect gap upon assembly!
24
150
250
3 000
12 000
18 000
Page 12-1
TCR
Version 06/2006
Turbocharger on the Two-stroke Engine Inspection intervals (during operation) in h Check turbocharger for abnormal noise and vibrations Check turbocharger and system pipes for leakages (charge air, exhaust gas, lube oil) Check all fastening screws, casing bolts and piping connections for tight seating. 24 X X X1) X 150 250 3 000 24 000 30 000
1) Inspection of new or overhauled components required (once, at the operating hours listed)
Maintenance intervals (during operation) in h Dry cleaning1) of the turbine Wet cleaning1) of the turbine Cleaning of compressor (during operation) Cleaning of air lter1)
1) if given 2) or more frequently, if required
24 X2)
150
250
3 000
24 000
30 000
X2) X2) X2)
Maintenance intervals (combined with an engine maintenance) in h Major overhaul every 24 000 ... 30 000 operating hours: Remove, clean and check all components of the turbocharger! Inspect gap upon assembly!
24
150
250
3 000
24 000
30 000
Version 06/2006
TCR
Page 12-2
Personnel and Time Requirements

Cleaning Work:
Qualied Mechanic Turbine: Dry cleaning Wet cleaning Compressor Air lter 0.3 0.6 0.3 0.4 Assistant
Inspection Periods for Major Overhaul:

Together with an engine maintenance, the turbocharger is subject to a major overhaul every 12 000 to 18 000 operating hours (operation with four-stroke engines) or every 24 000 to 30 000 operating hours (operation on two-stroke engines). Here, all components of the turbocharger must be cleaned and checked, and the gaps and clearances must be inspected for dimensional accuracy.
Required Time in h Required Time in h
Removing and Refitting the Turbocharger:

The mounting time for removing and refitting of the turbocharger includes the connection of the charge air and exhaust gas pipes, Jet Assist, turbine cleaning, compressor cleaning, draining of dirt/condensate, lube oil pressure/temperature, speed measurement and misc. special connections. Qualied Mechanic Turbocharger to engine approx. 4.5 h Assistant
Approx. 15 man hours are estimated for the major overhaul of a TCR turbocharger.
Service Addresses
The current global MAN Diesel service address list can be obtained from: Turbocharger Service Office Phone.: +49 821-322-1198 Fax: +49 821-322-3998 E-mail: [email protected]
Required Time Required Time 1.0 h
Inspection of Bearings and Piston Rings:

To inspect the thrust bearing, the bearing bushes, the turbine rotor, the retaining ring and the piston rings, the following components must be removed or dismounted: Silencer and air intake casing, Insert on compressor side, Compressor casing, Cartridge. For a complete inspection of the bearings, the piston rings and the rotor, approx. 7.6 man hours are estimated: Qualied Mechanic Assistant
Required Time Required Time in h in h Silencer/air intake casing Insert Covering of compressor casing Compressor casing Cartridge Bearings and piston rings Total hours 0.4 0.4 0.6 0.6 0.6 4.0 6.6 0.4 0.6 1.0
Page 12-3
TCR
Version 06/2006
13
Transport
13
tackle is located on the bearing casing. Equalization ropes are fastened on the gas outlet casing (2) as well as between silencer/air intake casing and compressor casing (3).
The illustration shows the fixing points for transport of the complete exhaust gas turbocharger. Fixing point (1) for fixation of the endless sling of the lifting
1 3
Transport of the turbocharger
Note
For attachment of the lifting tackle to the bearing casing, use only the endless slings intended for this purpose. Ensure not to damage fixing point (1) in the bearing casing!
Version 06/2006
TCR
Page 13-1
14
14
Preservation Treatment and Packing

Corrosion Protection
The corrosion protection includes preservation and packing of the turbocharger in accordance with the transport and storage conditions to be expected. Corrosion protection criteria are the required duration, the transport conditions (land carriage, air or sea freight), the climatic conditions during the transport, the storage at the place of destination. Preservation is carried out already upon assembly of the exhaust gas turbocharger. In this, fitted surfaces (with the exception of tapered seats of the compressor wheel) are treated with anti-corrosion oil, e.g.: Fuchs Anticorit 1, Valvoline Tectil, Teco 6 SAE 30, Esso Rust Ban 335 or Cylesso 400, Shell Ensis Oil L. The rotor as well as the interior surfaces of the casings are treated with anti-corrosion agents with low flow properties, e.g.: Fuchs Anticorit 6120-42 E or Anticorit 15 N, Esso Rust Ban 391 or with moisture-displacing properties, e.g.: Fuchs Anticorit 6120-42 DFV, Valvoline Tectyl 511 M or Tectyl 472. When using these operating-media-consistent agents, removal of the preservation agent prior to starting operation is not required. Machined exterior surfaces are treated with anti-corrosion agents such as: Fuchs Anticorit BW 336, Valvoline Tectyl 846, Esso Rust Ban 397. These agents must be removed with diesel fuel or petroleum upon assembly prior to starting operation. After preservation, all openings on the exhaust gas turbocharger are sealed air-tight as far as this is possible.
Increased Corrosion Protection

Increased corrosion protection is achieved (e.g. for overseas, tropics, subtropics) when before closing the openings, vaporphase corrosion agent (e.g. Branorol 32-5) is sprayed into the gas-intake connection, gas-discharge connection and air-discharge connection at a ratio of 300 cm3 per 1 m3 interior space, or when drying agent (bag or block form) is attached to the interior sides of the closing covers. In such cases, the drying agents must be removed upon assembly prior to starting operation of the exhaust gas turbocharger and the casing must thoroughly be blown through with compressed air, otherwise toxic fumes can be set free when being heated up.
Packing
The packing must meet the required degree of corrosion protection and the conditions for transport and storage.
Seaworthy Packing
For oversea shipping and/or extended storage in tropical or subtropical areas, it can be required to additionally shrinkwrap the exhaust gas turbocharger in an aluminum-plastic compound foil, including a sufficient amount of desiccant bags and moisture indicators within the packing crate.
Instructions on the control measures to be carried out for corrosion protection or post preservation will be supplied or can be requested, as can be detailed instructions on corrosion protection. E-mail: [email protected]
Page 14-1
TCR
Version 06/2006
15
Training and Documentation
15
With the delivery of an exhaust gas turbocharger, our customers receive comprehensive technical documentation consisting of: Operating Manual Working Instructions (Work Cards) Spare Parts Catalog Reserve Parts List and Tool List Certicates Records The technical documentation can also be supplied electronically on request.
Training Programs
For engineers and qualied mechanics - Servicing the turbocharger, - Theoretical and practical training. Courses for groups are available on request For more information on our training programs, please directly contact MAN Diesel SE in Augsburg: [email protected].
Technical Documentation
Examples for Work Card and Spare Parts Catalog
Version 06/2006
TCR
Page 15-1
16
16
Ordering of Spare Parts
Maintenance and repair work can only be carried out properly when the required spare parts and reserve parts are available.
Spare Parts
The spare parts catalog is part of the operating manual. It comprises all primary components of the turbocharger. The pages of the spare parts catalog are organized according to the subassembly system of the turbocharger. Most subassemblies can be determined with help of the Overview of Subassemblies, in front of the spare parts catalog.
Order number of the gas outlet casing Ordinal number gas outlet casing
Assembly number of the gas outlet casing
Spare parts page with 6-digit order numbers
The order number consists of a 3-digit assembly number and a 3-digit position number. Assembly and position number are divided by a dot. Examples: Assembly number:
Assembly overview with 3-digit assembly number
506 (gas outlet casing) Order number: 506.001 (gas outlet casing) 506.038 (gasket)
The ordinal number consisting of the 3-digit assembly number and a 2-digit version number, is located at the top of the spare parts pages:
Page 16-1
TCR
Version 06/2006
Reserve Parts and Tools

For each turbocharger a set of reserve parts and tools can be ordered optionally. Reserve parts and tools are each packed in a box. The contents in the boxes are itemized in lists. The assemblies number for reserve parts is 595 for tools 596. For reordering, the same guidelines apply as for the spare parts.
Ordering
Please direct your order to: MAN Diesel SE 86224 Augsburg Phone: Fax: E-mail: +49 8 21-322-1198 +49 8 21-322-3998 [email protected]
To avoid questions and confusion, the following information are required upon ordering: 1. Type of exhaust gas turbocharger 2. Works number of the exhaust gas turbocharger (type plate) 3. Order number of the component 4. Quantity 5. Shipping address.
Version 06/2006
TCR
Page 16-2
17
17
Tools
For each turbocharger a set of tools can be ordered optionally. A set of tools consists of assembling/disassembling devices, suspension devices, holding devices and equipment for emergency operation. These tools ensure that damage can not occur to the turbocharger in the course of maintenance and repair work, and that the work can be carried out swiftly and effectively. The tools are packed in a box. The contents of the box is itemized in the enclosed list.
Suspension Devices
In most cases, standard suspension devices such as shackles and lifting eye bolts are used. These are fastened in the threads or in special bores of the components. Some heavy components are moved away from the turbocharger by means of specially designed suspension devices: Gas-admission casing Compressor casing
Assembling/Disassembling Devices
Components that can not be removed and installed by simply loosening the screw connections are removed and installed with guide rods, forcing-off devices or holding devices. These are: Cartridge Bearing bodies Insert Turbine wheel.
Suspension device
Assembling/disassembling device
Page 17-1
TCR
Version 06/2006
Emergency Operation
For emergency operation in case of a turbocharger failure, a closing device is provided for the gas-admission casing. In emergency operation, the gas-admission casing as well as the lube oil supply and discharge are closed and sealed off with this closing device. The cartridge is removed for this.
Emergency operation with closing device
General
The assemblies number for tools 596. For reordering, the same guidelines apply as for the spare parts and reserve parts.
Version 06/2006
TCR
Page 17-2
18
18
Worldwide Turbocharger Service

Augsburg Works MAN Diesel SE 86224 Augsburg Phone:+49 821-322-0 Fax: +49 821-322-33 82 Hamburg Works MAN Diesel SE Service Center, Hamburg Works Rossweg 6 20457 Hamburg Germany Phone:+49 40-7409-0 Fax:+49 40-7409-104 MAN Diesel Singapore Pte. Ltd. 29 Tuas Avenue 2 Singapore 639460 Phone: +65 6349-1600 Fax:+65 6862-1409 Fax: +65 6861-8590 (Service) Authorized Repair Shops (ARS) Qualified repair shops with MAN Diesel trained service engineers. Agents Independent companies with close contact to MAN Diesel. Over 150 service bases worldwide. Swift supply of high-grade OEM spare parts. 24 hour around-the-clock service. Fast, reliable and competent assistance from experienced, highly-skilled service engineers and qualied mechanics. Centralized, computer-controlled spare parts stock in Augsburg.
North America
Channelview Cleveland Fort Lauderdale Jacksonville Mexico City Montreal New Orleans New York Pointe Claire Port Colborne Tampa Vancouver Wilmington L.A.
Asia
Bangkok Colombo Dubai Africa Hong Kong Casablanca Jakarta Cairo Kobe Cape Town Keelung Durban Shanghai Harare Singapore Mazara del Pusan Vallo Tehran Sandton Tunis
Central America
Bogota Caracas Guayaquil Quito Mexico City Puerto Cabello Willemstad
Europe
Almada , Antwerpen Augsburg , Copenhagen, Frederikshavn/Holeby Gteborg Dublin, Genova Gustavsburg/Duisburg Hamburg Istanbul Le Havre London , Madrid Malta , Marseille Marihamn, Oslo Paris, Reykjavik Schiedam St. Petersburg Godynia , Zoetemeer Lisaboa
Australia
Brisbane Brookwale Melbourne Sydney Salisbury
South America
Buenos Aires Lima Montvideo Rio de Janeiro Santiago
Page 18-1
TCR
Version 06/2006
Index
I
Connection Compressor casing 3-7 Gas outlet casing 3-9 Gas-admission casing 3-8 Constant pressure turbocharging 1-1 Corrosion protection increased 14-1
A
ABS (American Bureau of Shipping) 11-3 Additional equipment Dry cleaning of the turbine 6-3 Jet Assist 6-4 Wet cleaning of the compressor 6-1 Wet cleaning of the turbine 6-2 Addresses Augsburg Works 18-1 Hamburg Works 18-1 MAN Diesel (Singapore) 18-1 Ordering spare parts 16-2 Service Addresses 12-3 Air intake casing 3-4 Air volume Measurement 10-2 Alarm points 4-3 Anti-corrosion agents 14-1 Anti-corrosion oil 14-1 Appliances 8-1 Assemblies 16-1 Air intake casing 3-4 Bearing casing 3-3 Compressor wheel 3-2 DIffuser 3-3 Gas outlet casing 3-5 Gas outlet elbow 3-6 Gas-admission casing 3-5 Silencer/air filter 3-4 Turbine 3-2 Turbine nozzle ring 3-5 Assembly number 16-1
D
Definition Engine 9-2 Turbocharger 9-2 Dimensions 2-3 DNV (Det norske Veritas Classifikation A.S.) 11-3
E
Efficiency Formula 9-1 Emergency operation 8-1 Achievable outputs 8-1 Personnel and time requirements 8-1 Engine Definition 9-2 shut down 4-3 slow down 4-3 Engine control 4-3 Engine-room planning Disassembly dimensions 7-1 Minimum clearance 7-1 Exhaust gas system Example 7-3 Exhaust-gas velocity 7-3 Installation 7-4 Total resistance 7-3
B
Bearing casing 3-3 BV (Bureau Veritas) 11-3
F
Flanges 3-7 Fuel 5-1
C
Casing positions Air intake casing 2-5 Bearing casing 2-5 Compressor casing 2-5 Gas outlet casing 2-5 Gas-admission casing 2-5 Characteristics of the TCR Series 1-1 Climate, arctic Operating performance 9-1 Climate, tropical Packing 14-1 Compressor 3-3 Compressor casing 3-3 Compressor cleaning 6-1 Compressor map 10-4
G
Gas-admission casing 3-5 GL (Germanischer LIoyd) 11-3
H
Heavy Fuel Oil 5-2 Specification 5-3 HFO (Heavy Fuel Oil) 5-2
I
IMO Certificate 11-3 Inclinations of the turbocharger 3-10
Version 06/2006
TCR
Page I-1
Inspection Four-stroke engine 12-1 Two-stroke engine 12-2 Internal Recirculation (IRC) 10-5 IRC 10-5 ISO 14001 11-1 ISO 9001 11-1
R
Read-out devices Speed measurement 10-2 Regulations 11-3 Reserve parts 16-2 Rotor speed, max. allowable 2-1
J
Jet Assist Diagram 6-4 Dimensioning of pipes 6-4
S
Shipping, overseas Packing and storage 14-1 Sound level diagram 3-12 Spare parts 16-1 Speed measurement 10-1 Speed transmitter 10-2 Standards 11-3 Surge margin Check 10-3 Four-stroke engines 10-3 Two-stroke engines 10-3 Surge stability 10-3 Suspension devices, turbocharger 7-3
L
Load reduction 4-3 LR (LIoyds Register of Shipping) 11-3 Lube oil condition, evaluation 4-4 Lube oil filtration 4-4 Lube oil pressure 4-3 Lube oil system 4-1
M
Maintenance Combined with an engine maintenance 12-1 During operation 12-1 Four-stroke engine 12-1 Two-stroke engine 12-2 Marine Diesel Oil 5-1 Testing method 5-1 Matching 10-3 Matching procedure Air pressure 10-3 Surge margin 10-3 Turbocharger to engine 10-3 MDO (Marine Diesel Oil) 5-1
T
Technical documentation 15-1 Time requirements Checking bearings and piston rings 12-3 Cleaning 12-3 Emergency operation 8-1 Major overhaul 12-3 Turbocharger assembly and removal 12-3 Tools 16-2 Turbine characteristic 10-5 Turbine dry cleaning 6-3 Connection size of compressed-air connection 6-4 Diagram 6-3 Granulate quantity 6-3 Turbine inlet temperature, max. allowable 2-1 Turbine wet cleaning 6-2 Connections 6-4 Diagram 6-2 Turbocharger speed 6-2 Turbocharger Definition 9-2
N
Number of order 16-1
O
Oil change 4-4 Oil sample 4-4 Operating performance Arctic climate 9-1 Normal conditions 9-1 Order number 16-1 Overview of series 2-1
V
Venting 4-2 Vibration accelerations 3-11
P
Packing 14-1 Performance characteristics 1-2 Performance range 1-2 Piping Installation, flexible 7-4 Position number 16-1 Pre-lubrication 4-3 Before starting 4-3 Continuous lubrication 4-3 Pressure ratio, total 2-1 Provisions 11-3 Pulse pressure turbocharging 1-1
W
Weights 2-3
Page I-2
TCR
Version 06/2006
CopyrightMAN Diesel & Turbo Subject to modification in the interest of technical progress. D2366421EN Printed in Germany GMC-AUG-05100.5
MAN Diesel & Turbo 86224 Augsburg, Germany Phone +49 821 322-0 Fax +49 821 322-3382 [email protected] www.mandieselturbo.com

TCR Project Guide

Uploaded by

Copyright:

Available Formats

TCR Project Guide

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TCR Project Guide

Uploaded by

Copyright:

Available Formats

What are the main components of an exhaust gas turbocharger?

What are the main components of an exhaust gas turbocharger?

What are the main design features of the TCR series exhaust gas turbocharger?

What are the main design features of the TCR series exhaust gas turbocharger?

TCR Project Guide

Exhaust Gas Turbocharger

Emergency Operation in Case of Failure of an Exhaust Gas Turbocharger Calculations

Speed Measurement, Adjustment, Checks

Quality Assurance Maintenance and Checking

13-1 14-1 15-1 16-1

Tools Worldwide Turbocharger Service Index

17-1 18-1 I-1

Long Service Life of Wear Parts

Casing Design for Easy Assembly

Characteristics of the TCR Series Exhaust Gas Turbocharger

Principles of Exhaust Gas Turbocharging

Constant pressure turbocharging

Engine Types and Operating Range

Exhaust gas turbocharger

Application Ranges of the TCR Series

Engine output per exhaust gas turbocharger in kW

Flow rate of compressor Vc tot in m3/s High-pressure version

* TCR22-25 two-stroke version

Pressure ratio of compressor c tot

4.7 5.2 71 300 650 100

4.7 5.2 59 100 650 165

4.7 5.2 49 100 650 260

2 350 2 050 3.92

3 400 3 000 5.69

6 700 5 900 11.18

4.7 5.2 40 500 650 415

4.7 5.2 33 600 650 720

4.7 5.2 24 300 650 1 550

Dimensions and Weights

Type TCR14 TCR16 TCR18 TCR20 TCR22

L1) in mm 904 1 092 1 308 1 580 2 042

L2) in mm 963 1 238 1 400 1 713 2 234

L3) in mm 734 887 1 066 1 307 1 691

H in mm 530 658 792 953 1 244

B in mm 453 555 661 777 1 023

D in mm 490 590 714 854 1 104

Weights of the Assemblies

75 kg 30 kg 156 kg 139 kg 90 kg 1 550 kg

1) Exhaust gas turbocharger with silencer and gas outlet casing

0 Further positions upon consultation with MAN Diesel

Air intake casing 0 A

Gas outlet casing 0 T

from -90 to +90

Characteristics of the Assemblies

Floating bearings Silencer Diffuser Nozzle ring Gas outlet casing

The turbine is very well accessible for inspections and cleaning.

Silencer with Air Filter

Air Intake Casing

Air intake casing 90/axial

Gas Outlet Casing

Turbine Nozzle Ring

Gas Outlet Elbow

Loads on Connections and Flanges

Connections of the Charge Air Pipes

Connection of the Exhaust Gas Pipe (Engine Side)