Turbo Charger, Air Coolers: 2006/09/09 © MAN Diesel A/S

TURBO CHARGER, AIR COOLERS
© MAN Diesel A/S 2006/09/09

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

Centrifugal stress
in Vibration mode stress distribution
blade and disk of the turbine blade

Unbalance TS
Bearing
Vibrations
Thrust
Dynamic
Forces
Weight
CS
Bearing Pulses
Compliments from ABB

Low frequency vibrations
Ö 3 < f < 100 Hz
Ö can lead to damages of the T/C
Ö max. admissible velocity RMS : < 50mm/sec (e.g. VTR454)
High frequency vibrations

Ö 100 < f < 1000 Hz
Ö give an indication of the running behaviour of the rotor
Ö if 10 mm/sec is exceeded, the rotor has to be balanced
(for more details consult ABB Service Stations)

Sulphur (in the exhaust
gas) and salt in the air
intake can cause
corrosion of the inducer
blades.
Pitting corrosion may lead
to notch effect, resulting
in high cycle fatigue
(HCF) failure.
=> Fluorescent penetrant
inspection of the blades is
recommended.

During standard operation
there is a slight
underpressure in the CS
bearing chamber.
If a plug is not tight
enough or an old gasket
is used, the
underpressure can cause
air to flow through the
bearing chamber to the
compressor.
Oil mist will be carried
away by this air flow,
resulting in oil loss.

THE UNIFLOW SCAVENGE SYSTEM
L/73043-7.0/0602 (2300/MCJ)

The Air/Gas Flow.
Exhaust gas receiver
Exhaust valve
Turbocharger
Cylinder liner
Scavenge air
receiver
Scavenge air
cooler
Water mist
catcher

WHAT IS A TURBOCHARGER?
A Turbocharger is a Turbine driven by the Exhaust

Gas and gives power to a Compressor positioned
on the same shaft as the Turbine.
This gives more air to the Combustion than normal
aspiration.
Normal aspiration about 1bar air pressure.
Turbocharged ”aspiration” 3.8 bar air pressure.

TURBOCHARGING

Performance.

Turbocharging.

Supercharging/Turbocharging.
Supercharging.
Turbocharging
S/K/L/MC, MC-C 3,5 – 3,8 ”

TURBOCHARGING

Introduction to Cylinder Condition
13,000 tons Nitrogen

2,000 tons Oxygen 12K98ME
860 tons CO2
350 tons H2O Fuel oil 250 tons
16 tons SO2 Sulphur 8 tons
1/4 tons H2SO4
s
t on
0 s
5,00 0 ton
r 1 0
3.0 3.00
0
Ai e n
yg en
1
Ox itrog
N
Cy
lin
de
r
Bore: 0.98 meter
oi
l1
.5
Stroke: 2.66 meter
to
ns
Speed: 94 rpm
Output: 93,360 Bhp / 68,640 kW
Cylinder Condition, the result of gigantic thermo-
Piston speed: 8.3 m/sec and chemical reactions

Exhaust Emissions.
Flow process Heat Exhaust gas
Air
13.0% O2
8.5 kg/kWh 75.8% N2
21% O2 5.2% CO2
79% N2 5.35% H2O
1500 vppm NOx

Fuel
600 vppm SOx
175 g/kWh 60 vppm CO
97% HC 180 vppm HC
3% S 120 mg/Nm3 Part
Lube
1 g/kWh
97% HC
2.5% Ca
0.5% S Work
TURBOCHARGER MAKER

ABB – VTR.

TCA TURBOCHARGER

TURBO CHARGER TCA

ABB TPL 91

TURBO POWER LARGE
Aug.99 © MAN Diesel A/S 2006/09/09

Bearing Arrangements.
inboard plain bearings

(MAN B&W turbochargers)
outboard roller bearings

(other makes)

TCA TURBOCHARGER
Compressor Wheel Turbine Wheel

ROTOR
Exhaust Gas to Exh. Gas Boiler
Air Intake
Gas
Pressure
Scavenge Pressure

MAN NA Charger.
Turbine Side.

MAN NA Charger.
Air Inlet.

Turbocharging.

Surging
Ballon
Surge

Pressure Under normal operating
conditions, the turbocharger
follows the operating line in
accordance with three criteria:
pressure ratio
air volume flow
turbocharger speed
Volume

Surging
Pressure
Diffuser High pressure - Slow air speed

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

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

Surging
Air flow velocity resultant

angles
relative
tangential
Under normal operating conditions

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

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

Surging
Air speed high - pressure low
Surge occurred as the pressure down stream

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

will depend on the level of flow restriction,
and system stability.
SURGE !
Surging
Pressure
1) Normal operation
2) Boundary layer
breakdown.
Air speed not
converted into
pressure.
3) Compressor
flow reversal.
Volume
- Surge -
COMPLIMENTS FROM ABB TURBO

Surging!
What is Surging?
Why does Surging occur?
What might be the reasons for
Surging?

Possible causes:
Fuel oil system: Exhaust system :

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

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

Surging of turbocharger
Surging at high load has to be

avoided !
Kinematics of rotor during surging

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

momentary rise by some 15% !

Aerodynamic Noise.
5
From time to time we experience sound
( Woof - woof - woof )
4,5 coming from the compressor during low
load conditions.
4
i.e. low compressor pressure ratio
3,5
3 The sound is NOT the initiation of Surge !
2,5
The noise can be considered cosmetic
2 and have no influence on the performance
of neither the engine no the turbocharger.
1,5
0 2 4 6 8 10 12

No. of cylinders
Compressor map
Air receiver
Surge line Air from
Surge MCR compressor
margin
Air to engine cylinder
Pr.
CA
Operating line
Surging are also related to number of cylinders and therefore also related
to receiver volume.
The receiver volume required, relative to the swept volume of the engine,
will reduce with increasing number of cylinders and will be more critical
with a 2-stroke engine than a 4-stroke,
i.e. less cylinders require more surge margin..
In case of the receiver volume is too small, or there are a small numbers
of cylinders, pressure will reduce toward the end of each induction process,
and since the compressor maintains almost constant speed, the compressor
may surge.

AIR INLET FILTER

AIR INLET FILTER

INLET FILTER?

Turbocharging.

ROTOR

Turbocharging.
Protection Grid

Turbocharging.

Turbocharging.

Damaged T/C grid.

NA 70 Turbocharger.
Unit forWater Washing of

Compressor Side.

Dry Cleaning on 6L60MC.
Dry Cleaning.

Temperature
Exhaust gas temperature
Charging pressure
as new condition
Pressure
without cleaning
1. cleaning
2. cleaning
3. cleaning
4. cleaning
5. cleaning
overhaul
Time

The cleaning frequency is influenced by the following
conditions:
Ambient conditions
Fuel quality and fuel separation
Load profile
Cleaning efficiency
Engine condition
Manual overhauls are still necessary to remove deposits
which the cleaning in operation does not remove.

Cleaning the compressor with fitted
tank
• Clean compressor wheel every 150 working hours. The

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

Wet cleaning the turbine
• Clean every 150 working hours

• 15 min before cleaning, reduce engine load to idle speed
• wash with 2 bar until clear water is coming out of drain pipe
• wait again 10 min to dry the turbocharger
• increase engine load

Turbocharging.

Turbocharging.

Turbocharging.

Scavenge Air Receiver
New design with Previous

increased stiffness design

Engine Acoustics,
T.C. Noise, Countermeasures
Add absorption
to hull side
Reduce source
strength
Add insulation
Reduce transmission
Rockwool marine wired mat.
Aluminium foil faced
Scav. air
receiver Insulation
pins and clips
Galv. plate
Air cooler
Acoustic
insulation
Frame
Add insulation Water mist catcher

Cylinder Frame Design
L/74061-0.0/0302 (2410/SBJ)
Scavenge Air Receiver.

MAN HOLE COVER

SAFETY VALVE SCAVENING RECIEVER

SAFETY VALVE

Design Features.
Previous design Improved design
Precatcher guide
Air cooler
plate provides 80% Air cooler
water separation
before normal
water mist catcher
element
Inspection covers
are fitted before Water Precatche
Water r
and after the air mist mist
guideplate
cooler element catcher catcher
Improved drains (to

prevent re-entry of
water)
Water Mist Sensor
3333690.2006.03.25 (2300/SBJ) © MAN Diesel A/S 2006/09/09

AIR COOLER

Improved
Water Mist Catcher Geometry.
Air flow

AIR COOLER DRAIN
Sight glass
Level switch
Outlet from air cooler

to chemical tank AL
Drain from water mist catcher

FOR CLEANING THE AIR COOLER ELEMENT

7 times magnified and 22 times

Damaged water mist catcher element.

Air cooler box inside, reversing
chamber, acceptable paint condition!

Air cooler box inside, reversing
chamber, paint condition!

Water mist catcher
New MBD design
Rigid frame
Optimized profile
Efficient sealing

Aux. Blower.
From Air inlet on

Turbo Charger.

Aux. Blower.
From Turbo Charger

PRESSURE GAUGES FOR SCAV.
AIR AND EXHA,GAS RECIVER

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

Input
Ambient Pressure 1.0Bar a
Ambient Air temperature 36.0C
Relative humidity of ambient air 70% 0-100%, only
Scav. Air Pressure 3.20Bar a

Scav. Air Temp. 50.0C
Engine load 20000.0kW It is assumed that air flow is 8.7 kg/kWh
Max. Partial Pressure at intake temp. 0.0595Bar

Absolute Humidity in intake air 0.0270kg/kg
Max. Partial Pressure at scav. air temp. 0.1234Bar

Max. water content 0.0250kg/kg
Specific Amount of drain water 0.0021kg/kg

Amount of drain water 357.7112kg/h
Thank you for your attention.

SEMI CLEAN FILTER

Axial Vibration Damper Monitor.

Design.
Drain pipes from air flow

Improvements:
reversing chamber Four drain lines for condensed water i.e. two before,
one below and after the water mist catcher element
K90MC-C K98MC-C

SAFETY VALVE

Turbocharging.

Turbocharging.

Manoeuvring.

TPL 69-85
See TPL Operation Manual

TPL 69-85
OBS!!!!
Use only
one time!!
See TPL Operation Manual © MAN Diesel A/S 2006/09/09

TPL 69-85

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

TPL 69-85

TPL 69-85

TPL 69-85

TPL Improvements
New design
12 wedges on one side
Oil supply groove
Aug.99 © MAN Diesel A/S 2006/09/09

VTR Charger

VTR Charger

TCA
(1) Tension rod

(2) Torque transmission
splined shaft sleeve
(3) Minimized stress level
on compressor wheel 3
4
rear side
2 1
(4) „Super Bolt“ nut
»Mounting of
compressor wheel
with standard tools«

TCA
New compressor
wheel connection

TCA
»Torque »Mounting of
transmission by compressor wheel
splined shaft sleeve« with standard tools«

The ” SUPERBOLT”.
8 Undercut Bolts The ”Superbolt”. Disc.

Rotor Shaft.

The ” SUPERBOLT”.
Undercut Bolts
Rotor Shaft

TCA Development Highlights
Separate thrust and

journal bearing
Reduction of bearing
diameter - therefore
reduced mechanical
losses
Floating journal bearing
bushes
Thrust bearing inspection
without dismantling of the
shaft

Turbo Charger, Air Coolers: 2006/09/09 © MAN Diesel A/S

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TURBO CHARGER, AIR COOLERS

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

Compliments from ABB

High frequency vibrations

 Compliments from ABB

 Compliments from ABB

 Compliments from ABB

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

A Turbocharger is a Turbine driven by the Exhaust

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

S/K/L/MC, MC-C 3,5 – 3,8 ”

© MAN Diesel A/S 2006/09/09

13,000 tons Nitrogen

© MAN Diesel A/S 2006/09/09

1500 vppm NOx

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

Aug.99 © MAN Diesel A/S 2006/09/09

inboard plain bearings

outboard roller bearings

© MAN Diesel A/S 2006/09/09

Compressor Wheel Turbine Wheel

© MAN Diesel A/S 2006/09/09

Exhaust Gas to Exh. Gas Boiler

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

 Compliments from ABB

Diffuser High pressure - Slow air speed

Under normal operating conditions,

© MAN Diesel A/S 2006/09/09

Air flow velocity resultant

Under normal operating conditions

The boundary layer breakdown, induces whirling

© MAN Diesel A/S 2006/09/09

Air speed high - pressure low

Surge occurred as the pressure down stream

The frequency of this flow reversal, or surge

© MAN Diesel A/S 2006/09/09

© MAN Diesel A/S 2006/09/09

Fuel oil system: Exhaust system :

Turbocharger : Scavenge air system :

© MAN Diesel A/S 2006/09/09

Surging at high load has to be

Kinematics of rotor during surging

Speed of the rotating components may

© MAN Diesel A/S 2006/09/09

3 The sound is NOT the initiation of Surge !

Compliments from ABB

Compliments from ABB

Compliments from ABB

Compliments from ABB

Compliments from ABB

Compliments from ABB

Improved drains (to