Turbo Aircooler 2013

purposes only
For training
Turbochargers & Air Coolers
MAN Diesel & Turbo AAA-CPH / OFH Tools and Overhaul Procedures 15.01.2013 < 1 >
purposes only
For training
Turbochargers
Shaft Welding
 Movie
purposes only
For training
Turbochargers
Fir tree cutting
 Movie
purposes only
For training
Turbochargers
Blade Insert
 Movie
purposes only
For training
Turbochargers
Dampening Wire
 Movie
purposes only
For training
Turbochargers
Compressor Wheel Dismantling
 Movie
purposes only
For training
Turbochargers
(1) Tension rod

(2) Torque transmission splined
shaft sleeve
(3) Minimized stress level on 3
compressor wheel rear side 4
(4) „Super Bolt“ nut 1

2
»Mounting of compressor
wheel with standard tools«
purposes only
For training
Turbochargers
”SUPERBOLT”
purposes only
For training
Turbochargers
THE UNIFLOW SCAVENGE SYSTEM
purposes only
For training
Turbochargers
Pressure: 1.02 bar Pressure: 3.0 bar Pressure : 1.0 bar
Temp.: 315 C Temp.: 460 C Temp.: 25 C
Air density: 1,225 kg/m3
Pressure: 1.0 bar

Temp.: 25 C
Pressure: 3.75 bar

Temp.: 200 C
Air density: 2,7 kg/m3
Air Pressure: 3.73 bar
Temp.: 45 C
cooler Air density: 4,2 kg/m3
purposes only
For training
Turbochargers
 72 %
 14 %
 11%
3%
purposes only
For training
Turbochargers
14% 11%
72% 3%
purposes only
For training
Turbochargers
300 – 400 %
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
M/S Dorthe Mærsk, delivered to the

Danish company A. P. Møller by
Odense Steel Shipyard in 1952, is
the first ship to be powered by a
turbocharged two-stroke diesel
engine
Engine type: 674VTBF-160

Power: 7,500 BHP @ 115 r/min
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
SFOC g/kWh
210
Cylinder diameter 90 cm
200
190
180
170
160
Impulse TC Constant pressure TC
K-GF L-GF L-GFC L-GFCA L-GBE MC
150
1973 1976 1978 1979/80 1981/83 1983 1984 1985 1990 1995 2000 2005
purposes only
For training
Turbochargers
inboard plain bearings

(MAN Diesel Turbochargers)
outboard roller bearings

(other makers)
purposes only
For training
Turbocharger
Exhaust Gas to Exh. Gas Boiler
Air Intake
Gas
Pressure
Scavenge Pressure
purposes only
For training
Turbocharger
Unbalance TS
Bearing
Vibrations
Thrust
Dynamic
Forces
Weight
CS Bearing
Pulses
Compliments from ABB

purposes only
For training
Turbochargers
ABB TPL 91
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
Compressed air cushion secures
emergency lubrication for 15sec
after shut down of main lube oil

pump
purposes only
For training
New design
Current design
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
Floating bearing
Basic bearing arrangement Bearing disc
labyrinth ring
thrust ring
bearing disk
(made of bronze)
thrust ring
purposes only
For training
Turbochargers
1st possibility: modified floating bearing
floating bearing modified

floating
(actual) bearing
2
4
1
purposes only
For training
Turbochargers
2nd possibility: rigid bearing
Basic bearing arrangement
thrust bearing
labyrinth ring
1
3
thrust ring
retaining ring
purposes only
For training
Turbochargers
Chronology of the different Designs
New Gravity oil tank, thrust bearing with increased oil supply, new coated
steel bearing disc and 2 labyrinths on labyrinth ring
Variant „4+“
cut view
Product improvement Benefit

New Gravity oil tank No maintenance required
Six oil bores in thrust bearing Improved oil supply on blackout
DLC coated steel bearing disc Increased service-life time
purposes only
Turbochargers
For training
Improvement
• Pressurized lube oil tank • Pressurized lube oil tank with • Gravitation oil tank
• Air can diffuses in oil EPLS • No air oil diffusion
• Risk of no oil supply during a • Slows down the diffusion process • No service required
blackout • Necessary to reset the
system latest every six weeks
Free of charge change to
EPLS
purposes only
Turbochargers
For training
Bearing design “0” Bearing design 4plus
Additional
improvement
cut view cut view
Thrust bearing with two bores Thrust bearing with six bores
 Oil supply through two bores  Improved oil supply for the bearing
 Higher oil pressure needed  Less wear through harder surface
 Pressurized emergency lubrication  Running-in of the disc is avoided

tank is needed  Improved emergency lubrication
purposes only
Turbochargers
For training

a Bearing design 4plus
a) 2 labyrinths on labyrinth ring
c d b) 6 oil bores in thrust bearing
c) DLC coated steel bearing disc
b
d) Stress oriented design of the thrust ring
Benefit of Bearing design 4plus

 No reset of the lubrication system
 Improved sealing at the labyrinth ring
 Increased resistance against particles
 Longer service intervals
purposes only
For training
Turbochargers
 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.
 Compliments of ABB
purposes only
For training
Turbocharger
purposes only
For training
Turbochargers
 SMALLER  LARGER
purposes only
For training
Turbochargers
Surging
Balloon
Surge
purposes only
For training
Turbochargers
Compressor Map
Pressure
Under normal operating

conditions, the turbocharger
follows the operating line in
accordance with three criteria:
 pressure ratio
 air volume flow
 turbocharger speed
Volume
 Compliments of ABB
purposes only
For training
Turbochargers
Compressor Map
Pressure
Operating point
Diffuser High pressure - Slow air speed
Operating line
Low pressure - High air speed
Compressor
 Pressure ratio
 Air volume flow
Volume  Turbocharger speed
purposes only
For training
Turbochargers
High pressure – slow air speed
Low pressure – high air speed
The air flow follows

the directions
determined by the
diffuser vane.
Diffusion takes place
and speed is
converted into
pressure.
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
Pressure
1) Normal operation
2) Boundary layer
breakdown.
Air speed not
converted into
pressure.
3) Compressor
flow reversal.
Volume - Surge -
purposes only
For training
Turbochargers
Surging
 Movie
purposes only
For training
Turbochargers
Surging
 Movie
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
There are three main causes of surging:
 Flow restriction and fouling in the air/gas

system
 Malfunctioning of the engine fuel system
 Rapid variation in engine load
purposes only
For training
Turbochargers
Surging
Surging Caused By The Fuel Oil System

Low circulating or supply pump pressure.
Air or water in fuel oil
High viscosity
Damaged suction valve
Damaged or sticking fuel injector or fuel pump
Malfunction of de-airetaing valve on

top of ventig tank
purposes only
For training
Turbochargers
Surging
Surging Caused By The Exhaust System
Piston blow-by
Increased back pressure after turbine
Exhaust valve not operating correctly
Compensator failure in exhaust manifold
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
Turbocharger Efficiency
Fouled or damaged compressor side
Worn out shroud ring
If it is on MAN turbochargers the reason could be

heavy particles in the fuel oil, can be fixed
temporary by turning the shroud ring 180 degrees
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
Beyond a certain point, the

restriction (and therefore loss
of efficiency) reduces the free
gas flow, i.e. TC speed goes down.
purposes only
For training
Turbochargers
Surging
Scavenge Air System

Scavenge fire
Pressure fluctuations in the reciver
One clean and one dirty air cooler
Fouled air cooler on water or air side
Fouled water mist catcher
Auxilary fans running, in man mode
Coked scavenge ports

purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
purposes only
For training
Turbochargers
Surging
Timing
Wrong cam lead
Bad load distribution between cylinders
purposes only
For training
Turbochargers
Surging
Miscellaneous
Hunting governor
Rapid change in RPM or load
Comes into shallow water
purposes only
For training
Turbochargers
Surging
5
( Woof - woof - woof )
4,5
3,5
2,5
1,5
0 2 4 6 8 10 12
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
purposes only
For training
Turbochargers
FI LTE R
FI LTE R
FI LTE R
FI LTE R
FI LTE R
FI LTE R
18V P185
SPLIT CIRCUIT
AFTERCOOL ER COOLI NG JACKET
WATE R WATE R
OVERSPEED AIR LEGEND:

SHUTDOWN C COMPRESSOR
T T URBINE
MAN Diesel & Turbo UK Engine Range

AAA-CPH / OFH Tools and Overhaul Procedures 15.01.2013 < 107 >
purposes only
For training
Turbochargers
purposes only
For training
Air Cooler
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
purposes only
For training
Air Cooler
Air cooler Air cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
A
B
A
16 mm
20 mm
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
After-catcher
0.5 - 1.5%
Pre-catcher WMC
80 – 85 % 15 – 20 %
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
Water Mist Catcher Geometry.
Air flow
purposes only
For training
Air Cooler
Water Mist Catcher
Efficiency versus air velocity
MAN Diesel & Turbo AAA-CPH / OFH Tools and Overhaul Procedures 15.01.2013 < 131
< >
purposes only
For training
Air Cooler
Water Mist Catcher
Efficiency versus water amount
< >
purposes only
For training
Air Cooler
Water Mist Catcher
Efficiency versus air pressure
< >
purposes only
For training
Air Cooler
Water Mist Catcher
Differential pressure across WMC
< >
purposes only
For training
Air Cooler
Air Coolers with tube plates

made of steel
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
MAN Diesel & Turbo AAA-CPH / OFH Tools and Overhaul Procedures 15.01.2013 137>
< 137
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
Air flow
Air flow
purposes only
For training
Air Cooler
Water Mist Catcher
Air flow
Air flow
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
Water mist catcher arrangement

DIRECTION OF CONDENSED
WATER FLOW
WMC-ELEMENT
AIR BY-PASS
BOTTOM VIEW OF THE WMC ELEMENT
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Water Mist Catcher
Water mist catcher arrangement
1 1 1
9 8 7 6 5 4 3 2 1
2 1 0
Non return flaps
WMC incorrectly WMC correctly

mounted mounted
purposes only
For training
Air Cooler
Water Mist Catcher
Water mist catcher Optimized profile
Rigid frame
Better sealing
purposes only
For training
Air Cooler
Water Mist Catcher
purposes only
For training
Air Cooler
Ambient air conditions
Yellow fields - measured data
Green fields should not be changed!
Unit Data
Engine power MW 18.66
Calculated air amount kg/s 44.784
Measured Ambient temperature dg. C 25
Measured ambient pressure mbar 1000
Measured Ambient relative humidity % 80
Measured air temperature after cooler dg.C 45
Measure pressure after cooler mbar 3000
Assumed relative humidity after cooler % 100
Calculated amount of condensate - negative values means humidity<100% kg/h -882

purposes only
For training
Air Cooler
Unit Data
Calculated amount of condensate - negative values means humidity<100% kg/h 1089

purposes only
For training
Air Cooler
Unit Data
Calculated amount of condensate - negative values means humidity<100% kg/h 1917

purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
purposes only
For training
Air Cooler
 Investigation has shown that the pH value of the condensed humidity is

around 7 which is normal, but has in some cases changed to sulphuric acid,
even down to pH 4.5.
 The fact that the condensate contains sulphuric acid indicates that the fresh air intake is
polluted by exhaust gases. It could be the location of the fresh air intake or exhaust gas
leakage in the enige room.
 The paint of the air cooler reversing chamber is recommended to be of
a two component epoxy phenolic paint in order to effectively counteract
the descirbed corrosion problem.
Some recommended paints are:

 Interline 961 (International)
 Hempadur 85671 (Hempel)
 Tankguard Storage two component phenolic paint (Jotun)
purposes only
For training
Air Ways
Auxiliary Blowers
Auxilary Blower.
From Air inlet on

Turbo Charger.
purposes only
For training
Air Ways
Turbo Charger
Auxilary Blower.
From Turbo Charger
purposes only
For training
Variable Turbocharger
TCA Variable Turbine Area
purposes only
For training
Turbo Charger
VTA (Variable Turbine Area)
For TCR Turbochargers… …and for TCA Turbochargers

Variable Turbine Area (VTA)
open
closed
Movie
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
Actuator
Units
Control
Unit
Variable Turbine Inlet

Nozzle Ring Casing
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
TC Cut Out Concept
Low Load Operation - T/C Cut-out: Concept

140
130 SFOC ≤ -3.5 g/kWh

120
110
100
3 Turbochargers operating
2 Turbochargers operating
90 Pcomp = 25bar
80
bar abs
70
60
50
40
30
20
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
deg a BDC
↑ Pscav => Pcomp ↑ => Pmax ↑ by enhanched T/C performance

purposes only
For training
Turbo Charger
TC Cut Out Concept
Turbo Charger Cut Out, Cutting one T/C - 2 ways to do it
T/C Cut Out with blind-plates T/C Cut Out with valves
T/C rotor can either be in or outside T/C T/C rotor must always be inside T/C
– better possible preservation/storage – risk of T/C bearing problems due to
vibration
T/C Cut in/out takes long time (4 – 24 Very easy to Cut T/C In/Out (2
hours) minutes)
Low installation costs High installation costs
purposes only
For training
Turbo Charger
TC Cut Out Concept
purposes only
For training
Turbo Charger
TC Cut Out Concept
Low Load Operation TC Cut-out: Conclusions
IMO cycle value and type of engine limits potential fuel oil
consumption benefit.
Bearing load must be checked
Torsional vibration issues must be checked
At 25% power a SFOC reduction of 5 g/kWh per 0.2 bar increase of
scavenge air pressure can be expected
At 50% power a SFOC reduction of 5 g/kWh per 0.5 bar increase of
scavenge air pressure can be expected
Turbine outlet temperature can drop up to 30 degrees
ROI below one year on a large engine
purposes only
For training
Turbo Charger
Sequential Turbo Charging
Sequential turbocharging?
Engine load:
75-100%: TC#L+S
< 75%: TC#L
Effect:
At low load the effective turbine area is
smaller and therefore
the scavenge air pressure higher
Engine scope:
A dynamic TC cut-out system for engines
with 1-2 turbochargers and a competitive
product to VT, EGB and to some extent TC
cut-out.
purposes only
For training
Turbo Charger
purposes only
For training
Turbo Charger
Test result from Mitsui on 6S60MC6

Relative change on SFOC and NOx
with TC#L and 2 x MET53SD
… but turbocharging efficiency could be improved for the DuET system and additional 1-2
g/kWh benefit is expected (likewise higher NOx).
purposes only
For training
Good co-operation
purposes only
For training
Stick together
purposes only
For training
Thank you for your attention.
purposes only
For training
Disclaimer
All data provided in these training materials 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.

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Turbochargers & Air Coolers

Fir tree cutting

Compressor Wheel Dismantling

(1) Tension rod

compressor wheel rear side 4

(4) „Super Bolt“ nut 1

Pressure: 1.0 bar

Pressure: 3.75 bar

M/S Dorthe Mærsk, delivered to the

Engine type: 674VTBF-160

inboard plain bearings

outboard roller bearings

Compliments from ABB

Compressed air cushion secures

emergency lubrication for 15sec

after shut down of main lube oil

1st possibility: modified floating bearing

floating bearing modified

2nd possibility: rigid bearing

Basic bearing arrangement

Product improvement Benefit

Chronology of the different Designs

Chronology of the different Designs

Bearing design “0” Bearing design 4plus

cut view cut view

 Higher oil pressure needed  Less wear through harder surface

 Pressurized emergency lubrication  Running-in of the disc is avoided

Chronology of the different Designs

Benefit of Bearing design 4plus

 During standard operation

Under normal operating

Low pressure - High air speed

High pressure – slow air speed

Low pressure – high air speed

The air flow follows

There are three main causes of surging:

 Flow restriction and fouling in the air/gas

 Malfunctioning of the engine fuel system

 Rapid variation in engine load

Surging Caused By The Fuel Oil System

Air or water in fuel oil

Damaged suction valve

Damaged or sticking fuel injector or fuel pump

Malfunction of de-airetaing valve on

Surging Caused By The Exhaust System

Increased back pressure after turbine

Exhaust valve not operating correctly

Compensator failure in exhaust manifold

Fouled or damaged compressor side

Worn out shroud ring

If it is on MAN turbochargers the reason could be

Beyond a certain point, the

Scavenge Air System

Pressure fluctuations in the reciver

One clean and one dirty air cooler

Fouled air cooler on water or air side

Fouled water mist catcher

Auxilary fans running, in man mode

Coked scavenge ports

Wrong cam lead

Bad load distribution between cylinders

Rapid change in RPM or load