MB

=BLACKSTOhT
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 6
Contents
AIR INLET AND EXHAUST SYSTEMS

6.1. DESCRIPTION AND FLOW DIAGRAM ..................... 2

6.2. AIRFILTER ............................................ 3
63. TURBOCHARGER ....................................... 3
Turbocharger Maintenance ................................ 4
Turbocharger Replacement ................................ 4
Turbocharger Removal .................................... 4
Turbocharger Installation .................................. 5
6.4. INTERIM CLEANING OF TURBOCHARGERS .............. 5

e Introduction .............................................
Cleaning The Turbine Side Of The Turbocharger ..............
5
6
Equipment Required ..................................... 7
Washing Procedure ....................................... 7
6.5. AIR INLET AND EXHAUST DUCTING ..................... 9

6.6. HEATSHIELD ........................................... 9

6.7. TECHNICALDATA ...................................... 9

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 ESL 12 & 16 Mk2 Section 6
INSTRUCTION MANUAL
=BLACKSTONE
AIR INLETAND EXHAUST

Figure 124 - Air Inlet System Arrangement

1. Exhaust pipe adaptor 2. Water outlet pipe (one of two)
3. Water inlet pipe 4. Turbocharger mounting bolts
5. nrbocharger mounting bracket 6. Intercooler adaptor plate
7. Intercooler 8. Intercooler air duct
9. Adaptor plate 10. Intercooler air pipe
11. On-engine air filter

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Figure 125 - Exhaust Manifold Arrangement (12Cylinder Engine)

6.1. DESCRIPTION AND FLOW DIAGRAM
The engine has one turbocharger, which utilises exhaust gas energy to increase the mass of
air available to the engine, which, in turn, increases its power.

Inlet air enters through a filter into the turbocharger compressor and then passes through
the intercooler,where heat is transferred to the rawwater cooling system. In cool or humid
climates, condensation may occur here. This is removed via a drain plug fitted to the
turbocharger mounting bracket.

The air passes through the spring loaded butterfly valve which shuts off the air when the
mechanical overspeed trip is operated (page 11-1). The air then passes into the inlet
manifold (integrally cast in the crankcase) and into the cylinders.

The burnt exhaust gas passes into the exhaust manifolds and is fed to the turbocharger
turbine, after which it is discharged to atmosphere via the silencer assembly.

A heatshield covers the exhaust manifold to reduce heat radiation and noise, and for safety
reasons.

Instrument indications are provided for:-

a) The inlet manifold air pressure.

b) The inlet manifold air temperature.

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 ESL 12 & 16 Mk2 Section 6
INSTRUCTION MANUAL
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c) The exhaust gas temperature at the turbocharger outlets.

d) The exhaust gas temperature at each cylinder head.

e) (Optional only). Turbocharger tachometer.

See ’Instrumentation’, page 11-12 for further details.

6.2. AIR FILTER

The air filter(s) may be either mounted on-engine, as part of the turbochargers, or
off-engine.

For description and maintenance of:-

a) On-engine filters - see the turbocharger manufacturer’s manual.

b) Off-engine filters - see the filter manufacturer’s technical instructions.

63. TURBOCHARGER

P Q

Figure 126 - -01 turbocharger and pipework

1. Water jacket thermometer 2. Water manifold
3. Turbine oil filler 4. , Turbine oil level sight glass
5. Turbocharger water inlet pipe 6. Turbocharger water outlet pipe

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INSTRUCTION MANUAL
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a) n3hbQdusrMa
ar intenance

See the turbocharger manufacturer’s manual

Figure 127 - Exhaust Manifold Joint rig

b) Brbocharger Replacement

The turbochargers are positioned so that they can be serviced in L.U. Replacement should
only be necessary if mechanical damage is sustained.
CQUTION: Do not apply excessive loads to fhe turbocharger during replacement. Allfittings
should be correcuy aligned onfinal assembly to ensure that no stresses result when tightening
pipes and mounting-bolts.
SDares required;

I) 2 x exhaust manifold to turbocharger gaskets.

2) 2,Exhaurtpipe gasket.

3) 2 x intercoolerpipe to turbochatger gaskets.

4) Water inlet to turbocharger gasket.

Turbocharger weight See manufacturer’s specification.

Brbocharper Removd

1) Open the water manifold bleed screw and drain the fresh water system.
2) Remove the exhaust heatshield.

3) Disconnect and support the exhaust pipe above the turbocharger.

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= BLACXsTOh?E
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 6

Disconnect the intercooler air pipe at the turbocharger end.

Disconnect the water and lub oil pipes as necessary.

Disconnect the exhaust manifolds from the turbocharger.

Fit the liftinggear, take theweight of the turbocharger and remove the mounting bolts. Lift
the turbocharger clear.

Plug all exposed holes on the turbocharger and engine to prevent the ingress of dirt. For
further turbocharger details, see the manufacturer’s manual.

Turbochareer Installation
1) Remove all plugs from the turbocharger and engine.

Lift the turbocharger into position and loosely fit the mounting bolts. (This will allow the
turbocharger to be moved to facilitate pipe connection, if necessary).

3) Loosely connect the exhaust manifold, the exhaust pipe and the intercooler air pipe to the
turbocharger, using new gaskets.

4) Loosely connect the turbocharger water and lub oil pipes, if fitted, using new gaskets where
necessary.

5) Tighten all pipes and manifolds. Tighten the turbocharger securing bolts to 310 Nm (230
1bf.ft).

Fill the fresh water cooling system. Slacken the turbocharger water outlet pipe at the water
manifold and tighten when an air-free flow of water is obtained.
W m N G : Care must be taken duringthis stage, due to the high operating temperature of the
exhaust system.
When the engine is next run, ensure that all disturbed connections do not leak.

Fit the exhaust manifold heatshield as soon as these connections are checked.

INTERIM CLEANING OF TURBOCHARGERS

Jntroduction

Under certain operating conditions or with certain fuels, it may be necessary to regularly
clean the turbochargers internal components.
NOTE: The equipment is not supplied unless specifically stated in the engine supply documents.

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Engines which normally run using light diesel fuel and have a clear exhaust discharge, will
not produce any accumulationof deposits in the turbocharger exhaust nozzle ring blading or
turbine wheel blading so do not usually need the water washing equipment. n e
turbocharger is cleaned sufficientlyfrequentlywhen mechanical considerations necessitate
stripping and dismantling of the turbocharger to fit new bearings, or even when other
turbocharger maintenance is necessary.
Engines running on heavy fuel have a higher incidence of accumulation of deposits due to
constituentsof the fuelwhich arenot total1yconsumed.These act as abindingagent and can
result in adherence and accumulation of deposits on the turbocharger exhaust nozzle
blading and turbine wheel blades. Similarly lubricating oil additives can also act as a binding
agent when an engine has a high lubricating oil consumption.

Running the engine when it is in poor condition or when it has developed a high lubricating
oil consumption, when a smoky exhaust discharge is also usually apparent, will also result in
some accumulation of deposits at the exhaust end of the turbocharger. Under these
conditions it is important to develop a suitable frequency of turbine cleaning. In most cases,
water washing is the best technique.
Generally a high load on the engine, preferably above 75% will result in a minimum of
incidence of turbocharger fouling. Due to high heat and gas velocity levels, combustion
products mostly remain in the gas stream and are discharged through to atmosphere.
clean in^ The 'hrbine Side Of The 'hrboc h a r w

QbiSxt
Practical experience has shown that for engines running on heavy fuels it is necessary to
periodically wash deposits off the turbine side of the turbocharger. The frequency of
cleaning depends upon operating conditions, and the quality of the fuel being consumed.
When insufficient washing has resulted in heavy fouling of the inlet nozzle ring and of the
turbine blading this will be denoted by marginally increased cylinder outlet exhaust
temperatures and probably higher boost air pressures and also higher turbine speeds, as
compared to clean or as new engine/turbocharger performance. Cleaning of the turbine end
should then be employed. Generally, if cleaning is adopted it should be carried out at
intervals appropriate for the class of fuel in use. Initial trials should err on the side of
over-frequent as cleaning will not remove long established deposits. It is important that
the procedure should be started early in the life of a turbocharger and should be done
frequently. Depending on the quality of fuel in use, the starting point may have to be as IOW
as every 24 hours. If the fouling rate is low the intervals may be extended by trial and error
possibly up to 150 hours. The condition of the outlet water is a useful guide. If still dirty
after 5 or 6 minutes of washing, the frequency should be increased. After cleaning, a
complete set of engine and turbocharger performance data should be taken at the same
load conditions for direct comparison and for long term trend analysis.

0
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INSTRUCTION MANUAL,
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A general log should be kept of engine and turbocharger performance data at full load or
at as high a load as possible at regular intervals, but at the same load on each occasion, and
where possible at the same barometric air intake atmospheric pressure and air manifold
temperature.
Cleaning must not be carried out on a turbine that is suspected to be very heavily fouled.
Dislodging of deposits unevenly could result in dynamic out of balance of the rotor
assembly. Under such conditions the turbocharger must be dismantled and cleaned.
Similarly if there is any incidence of turbocharger vibration before or after water washing
the turbocharger must be completely dismantled and cleaned.
2) Eq uipment Required (See Fip.2)
1) The equipment required is obtained from Mirrlees Blackstone Limited and is engineered to

e 2)
suit both the engine and turbocharger type.
The system most commonly supplied by Mirrlees Blackstone Limited uses water to wash
deposits off the turbine and consists of an engine mounted water supply system to the
turbocharger gas inlet.

3) The engine mounted system terminates in a l/2 BSP coupling to which is coupled a suitable
clean water supply. Down stream of this is an isolating valve followed by a three way valve
which controls the supply of either water or bleed air into the wash system. The system when
not in use is kept free from carbon build up in the spray nozzles and pipework, by aconstant
air bleed from the compressor side of the turbocharger.

4) A drain cock is provided to drain the exhaust casing. It must be possiblc to inspect and
measure the quantity of fluid drained during the washing operation.

5) Aclean, fresh (not salt) water supply at a pressure of 3.5 to 5 bar (50 to 75 lb/in2) is required
from a suitable source. The supply should be coupled to the engine with thc flexible hose to
a enable easy removal.

6) During the washing operation most of the water evaporates and escapes with the engine
exhaust. The remainder drains out of the exhaust casing (0.1 litre per minute). The water
discharge is important because the deposits are removed not only by dissolving them but
also by the mechanical action of the water droplets impinging upon the affected areas. If
water does not discharge for the required length of time, the wash has not becn successfully
carried out and the turbocharger will foul prematurely.
4 WashlngErocedure

1) Ensure water supply is available.

2) Turn the threeway valve in the engine mountedpipework, to close off the air blced and open
the system to water operation.

e
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 Section 6 ESL 12 & 16 Mk2
INSTRUCITON MANUAL MB
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- BLACKSTONE
Fit a length of flexible hose between the engine and the fresh water supply.

Reduce the load on the engine (engine output) untik-

1) The steady state temperature of the exhaust gas immediately before the turbine is a
maximum of 430°C (81OOF) but preferably higher than 35OoC (66OOF).
OR
2) If there are no pyrometers at the turbine inlet, the average cylinder outlet tempera-
ture prefered minimum should not exceed 34OoC (650%).
NOTE: Time should be allowedfor the metal temperatures to fall before washing, in order to
avoid fherkk of cracking lurbocharger components.
Each turbine will have a 4 entry casings, with a water supply into two pipes only. Before
completing the full wash procedure, verify that water is available and the drain clear. If
water does not appear, there is a problem which should be cleared before attempting the
full wash.

&&open the main valve upstream of the removable pipe until the correct water flow is
achieved i.e. ensuring that water is draining from the exhaust casing at 0.1 litres minimum
0.5 litres maximum, per minute. Care should be taken to avoid excessive flow, as this can
flood the labyrinth seal and contaminate the oil in the turbine bearing with risk of
subsequent failure. The valve should be opened slowly to minimise thermal shock.

If the required water flow cannot be achieved i.e. less than 0.1 litres per minute, the load on
the engine should be reduced a little further to reduce the evaporation rate.

When the water draining out of the casing appears clean, probably after 5 to 10 minutes,
turn off the main cock.
a
Disconnect the flexible supply pipe.

Change the engine mounted three way valve back to the 'air bleed'position to blow out any
water residue and prevent carbon formation.

Continue running the engine for 10minutesat or above the power set by4) above, to ensure
that all the washing water is evaporated to avoid bearing contamination and turbine
corrosion.

If it is considered that cleaning is incomplete the washing can be repcated.

The water supply connection to the wash system must be disconnected after completion.
There must be no possibility of any unsupervised water supply into the exhaust system.

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MB
=BUCFSTOArE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 6

6.5. AIR INLET AND EXHAUST DUCTING

See figures 124,125 and 126. It is recommended that all exhaust system bolt threads are
coated with 'Coppaslip' or similar compound on installation, to ease subsequent removal.

6.6. HEATSHIELD

The heatshield covers are held in place by toggle-fasteners. The end-plates are bolted
directly to the crankcase. See the Parts Manual for further details.
CAUTION: Do not run the engine for prolonged periods with the flywheel end heatshield
end-plate removed, or the governor may be overheated.
6.7. TECHNICAL DATA - See Engine Test Data for details of air manifold temperature
Maximum difference in exhaust temperatures
between any 2 cylinders at full load 3OoC (54OF)
Maximum difference in exhaust temperatures
between any 2 cylinders at no load 120oc (2160F)
Minimum exhaust temperature at no load lO0OC (212OF)

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