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Modernization of the lubrication system of the bearing unit of the internal combustion engine turbocharger
Maritime University of Szczecin, ul. Wały Chrobrego 12, 70-500 Szczecin, Poland
j.monieta@am.szczecin.pl
Abstract. Supervision of technical state is often limited to the thermodynamic parameters, so there are happening gradual
and sudden failures to leading a state of unfitness of the entire piston combustion engine. The article presents the results
of principal diagnostics investigations of turbochargers carried out in laboratory and ships conditions of three types of
four-stroke engines. In the preliminary investigations were aimed at choice of used work and residual processes, places of
the locations of sensors, domain of signal analysis and diagnostic symptoms. In assessing diagnostic symptoms were
checked for that sensitiveness to engine load, and the selected simulated technical states determined from reliability
investigations. Selected vibration and thermodynamic processes were examined. Selected diagnostic symptoms and
measures in preliminary examinations proved to be sensitive to the proposed locations of sensors, types and domains
INTRODUCTION
A turbocharger is an essential part of most modern diesel engines. From the condition of the engine boost system
elements depends on the filling of the cylinders filling. Centrifugal compressors are a key piece of equipment for
modern marine propulsion plants. It allows increase of engine power density through the downsizing concept,
control of exhaust emissions and reducing fuel consumption [1].
Turbocharged slow speed two stroke self ignition engines are among the most efficient thermal power plants,
with thermal efficiencies approaching or exceeding 50% [1]. Primary fields of application are marine propulsion and
stationary turbine drives. Turbochargers are important assembles too of marine self-ignition engines. During the
combustion of residual fuels of different qualities and compositions a large variety of particles are generated.
A certain amount of these particles condensates and deposits on the turbine surfaces with far-reaching
consequences for the turbocharger and the engine.
The turbocharger is a relatively simple, but very precisely made assembly working in hard conditions. Due to
hard working conditions, among others (large outlet temperatures, very high rotational speeds reaching up to
250,000 rpm [2], precise design and difficult assembly) turbochargers should be considered particularly subject to
damage and degradation failure. It is confirmed by data showing an increasing number of failures of such assembles,
which are caused, among others, by the increasing number of vehicles equipped with turbochargers.
Turbochargers supply for marine engines with a mixture of air, steam, precipitation droplets, sea aerosol
containing salts and biological particles, oil and exhaust gas vapours and from port and land areas also industrial
dust. Their supply into the turbocharger and engine flow ducts significantly affects the quality of energy conversion
and causes degradation of the technical state of sub-assembles of the engine supercharging system [3].
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DAMAGE OF THE TURBOCHARGER
According to literature data, 65% of centrifugal compressor unfitness states are closely related to blades. In
addition, about 40% of fatigue damage to the blades is not yet fully understood [4], [5]. The damage detection
problem is important as the 90% of the life wear of the blade and could result in catastrophic failure [6].
The most frequently occurring states of inability of supercharging systems of marine engines are [7]:
pollution of air filters and other parts of the airspace;
pollution of channels and gas turbine blades by deposits of salt and combustion products;
contamination of the radiator from the seawater side;
accumulation of deposits in flow channels, on blades and in seals labyrinth;
unbalance of the rotor;
erosive and corrosive wear of turbine blades;
corrosion of the turbine blades;
mass decrements and deformation of the blades by impacts by damaged engine components and sea water;
damage to the turbine rotor by a foreign body;
damage to the labyrinth seals;
bearing wear;
cracks of shafts and bodies.
Unbalance during operation is caused by impurities in the rotor vanes as a result of impacts of separated parts of
injector nozzles, fragments of sealing rings, starting valves, etc. The unwanted events, related to faulty functioning
of an antropotechnical couple human – engine they are a foreign body finds its way to the turbine or not renewed oil.
The filters during operation display the following unfitness:
– increase of the flow resistance,
– loss of filtering properties,
– loss of tightness.
During the filter operation, aerodynamic resistance increases and particles are torn away from the fibers. When
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The inlet and outlet channels should show as small flow resistance values, which is a prerequisite for a good
filling of the cylinder with a fresh charge and complete removal of the exhaust gas from them. Excessive
contamination of the outlet ducts brings about pressure increase of exhaust gas behind the turbine. As result, the gas
expansion degree in turbine is decreased, the turbocharger power output and turbo-blower speed are diminished.
With excessive axial run-out of the rotor shaft, rotor blades can be attached to the turbocharger hull which can
deform or break.
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vibration and acoustic signals analysis was sensitive on engine load and speed changes. The vibration and acoustic
signals have been processed in time and frequency domain.
The article [8] presents the results of preliminary diagnostics investigations of turbochargers carried out in
laboratory or operating in real vessel conditions of three types of four-stroke engines. Tests were aimed at choice of
used mainly residual processes, places of the locations of sensors, domain of signal analysis and diagnostic
symptoms. In assessing diagnostic symptoms were checked for that sensitiveness to engine load, and the selected
simulated technical states determined from reliability.
Blade tip timing is an effective method for blade vibration measurements in turbomachinery. Different kinds of
sensors have been developed for blade tip timing, including optical, eddy current and capacitance sensors. The
signal model and process method was analyzed. Zero intermediate frequency structure was employed to maintain
timing accuracy and dynamic performance, and the received signal can also be used to measure tip clearance. The
timing method uses the increasing and falling edges of the signal and an auto-gain control circuit to reduce the effect
of tip clearance change.
To validate the accuracy of the system, it is compared experimentally with a fiber optic tip timing system. The
results show that the microwave tip timing system achieves good accuracy. Method is non-intrusive and is able to
measure the vibrations of all blades in real time [14].
The attempt to determine the technical state of turbocharger and the location of the operational damages is
associated with putting the engine out of operation with all the technical and economic consequences. For eliminate
this negative situation in the operation, one is forced to search for methods to conduct a reliable diagnostic test
during the maintenance, without disconnecting the turbocharger from the engine. Analysis of the cause and effect
relations in the diagnostic relations, acquired on the example of the turbocharger, justifies the need for establishing
diagnostic test based on previously studied relations [3]. The main problem is the detection of damages of blades
and bearings, which can be implemented by vibration methods.
The paper [10] presents an attempt to identify and systematize diagnostic relations in the turbocharged marine
engine, treated as a "responsible" machine. Structural decomposition of these parameters has been performed and
linear analytical model of dynamics for the engine, together with the system of turbochargers, has been elaborated.
The correct choice of symptoms to be measured has been confirmed and on this basis the minimal plan for
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Closed cycle and gas exchange was modelled using an existing multizone thermodynamic model. It is
demonstrated model's ability to predict engine response with load variation regarding turbocharger performance and
closed cycle parameters, possible it an effective tool for both engine diagnostic and optimization studies.
The article [3] justifies the need to analyze diagnostic relations for turbocharger operation purposes.
Turbocharger decomposition has been conducted on example in modern marine engines have been presented. The
influence of typical faults in respect to symptom value changes was worked out for each heat engine and sub-
system. Validation of selected cause and effect relations has been based on operational analysis in the technical.
The literature review shows that many problems have not been solved so far. The over most works do not
address the issue of damage development and focus on the identification and detection of damage at only one point.
OBJECTS OF INVESTIGATIONS
The objects of research were three four-stroke medium speed marine engines Sulzer 5BAH22 and 6AL20/24 and
4L20D2 type, driving the generators. The 5BAH22 engine with its turbocharger both installed in Institute of Marine
Power Plant Operation Laboratory in Maritime University of Szczecin. Engines 6AL20/24 types are equipped with
the turbocharger type VTR or C-045/c. Turbochargers for 4L20D2 engines are TPS type. They are adapted for
feeding with separating and residual fuels. Fig. 1 shows the turbocharging diagram of one of the tested internal
combustion engines. The charge air cooler is of tube type and is mounted between the air duct and air inlet piece.
During the periodic service, the turbine steering wheel of the internal combustion engine was removed from
using. The defective element was replaced with a new one.
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FIGURE 1. Scheme turbocharging of marine self-ignition investigated engine: A – outlet valve, B – inlet valve, C –
compressor, Cc – combustion chamber, E – air cooler, T – turbine
kc
f cg , (1)
4l
Sh v
f oc , (3)
l
where: Sh Strouhal number, v velocity gases, l the geometric dimension of the valve seat.
The turbine and the compressor are mounded on the same shaft as the turbine wheel.
The vibrations generated in bearings in the case of asymmetry and eccentricity about frequency fb [17]:
ns
fb , (4)
2
M t ( , , dI / d ) X Fn ( , , x, z, w) . (5)
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This can be written as and for the input quantities of the form:
di1 di2 di
M t ( , , , ,..., n )Y Fn ( , , x, y , z, w) . (6)
d d d
where: M t ( , , dQ/ d ) differential polynomial with time-varying coefficients, I(i1, i2, …, in), current time,
dynamic; exploitation resource, X{x1, x2, …, xn} – a state features vector, Y{y1, y2, …, yn} – vector of output
quantities Fn nonlinear function, Z{z1, z2, ..., zn, w1, w2, …, wn} – vector of random time functions characterizing
external disturbances and internal extortions. The input quantities are the fuel dose qf and the air mass qa.
Turbocharger is an energy accumulator, for which in the zero-dimensional model dynamics equation can be written
in the form of ordinary differential equations:
d
J tc M t , qmo , po M c , pa , (7)
d
where: Jtc reduced mass moment of inertia of the turbocharger, turbocharger shaft speed, qmo exhaust mass
flux, Mt turbine torque, Mc turbocharger compressor torque, po outlet pressure, pa air pressure.
The presented relationships suggest the desirability of conducting diagnostic experimental tests of turbochargers
cooperating with internal combustion engines together with their surroundings and simultaneous.
(a)
(b)
FIGURE 2. The time course of vibration accelerations signal of turbocharger (a) and the result of the time-frequency analysis (b)
Time sequences indicate that complex, not very repetitive and disturbed signals are generated. The time-
frequency map does not contribute much information too signals for steady-state conditions. Therefore, an attempt
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was made to decompose and denoise the signal [18]. Simulation of air filter contamination was performed by
covering the intake with a foil strangler with grading. This simulation was carried out for several engines.
Fig. 3 presents the results of the amplitude estimate and kurtosis values determined from time courses for the
same engine load. The simulated unfitness state significantly changes the values of the applied values.
The comparison of the spectrum with a clean filter and the simulation of air filter contamination indicate that
these are poly-harmonic and poly-periodic spectra (Fig. 4). Spectrum in case of throttling the inflow to the
compressor's air filter cause the decrease in amplitude values and a shift of components towards higher frequencies.
FIGURE 3. The influence of the technical state of turbochargers on the amplitude estimates and kurtosis acceleration vibration
signals: 2PM – the second turbocharger after periodic maintenance, 1PM – the first turbocharger after periodic maintenance,
3PO – turbocharger after 10,000 h of operation, 2SP – turbocharger of the second engine with damage simulation
To select the spectral components and link them to the theoretical source of bastards, the spectral analysis was
performed in third bands (Fig. 5). There can see significant components: rotary (500 Hz) and 8fo (related to the
number of compressor blades). When analyzing non-stationary processes, such as changing the rotational speed of
the turbocharger when changing the load, information about amplitude fluctuations of individual components is lost.
FIGURE 5. Average values of amplitudes in third 1/3 octave bands Haa: fa – central frequency
In recent years, dynamic development of previously used methods of time-frequency analysis and the search for
new, a more effective ones has been observed. The basic methods in this group include transformation [18, 19]:
short-time Fourier discretized Gabor, wavelet, distribution of Wigner-Ville, etc.
The article [18] presents the results of research on selected methods of analysis, such as the use of Daubechies
wavelet and approximation and detail for the separation of disturbances, the influence of the approximation level on
the values of wavelet measures and the continuous Haar wavelet transform. The Haar wavelet is the only wavelet
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which, having orthogonality property, also has an anti-symmetry axis, which means that the corresponding filter
does not introduce a non-linear phase shift between the input signal and the output signal:
1 0 0 .5
( ) . (8)
1 0 .5 1
In many studies, the level of decomposition or level of approximation is assumed based on literature or intuition.
Therefore, an attempt was made to investigate the effect of approximation level on the values of wavelet measures
of the vibration acceleration signal [18]. Fig. 6 presents an example of the time course of the vibration acceleration
signal for the turbocharger with simulated damage and the approximation results by means of the Haar wavelet
measures. On the Fig. 7, the results of the approximation reconstruction are presented on level 1 presents the
statistical values of Haara wavelet approximation measures for the level of approximation 1. It can be seen in the
histogram that the condition of simulated unfitness was significantly highlighted.
FIGURE 7. Values of statistical measures of Haar wavel approximation HVa for levels 1 and various technical states at level: SD
– standard deviation, MAD – mean obs. dev.
The global state of the turbocharger can be defined by the formula for the global function of the G response:
G (X, W, Z) = Y, (9)
The technical condition of the turbochargers tested can be determined globally on the basis of different state
features X for the determined and stationary the extortions W on the basis of Y output values and Z interference
minimization. Thus, the technical state features can be determined.
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SUMMARY
The following conclusions can be drawn on the basis of the analysis conducted:
1. The tests carried out of 5 auxiliary engines in the laboratory and marine ship conditions indicate the
existence of unambiguous trends in diagnostic parameters with the engine load and the technical state.
2. The symptoms values usually increase with increasing load, and throttling on the air filter usually reduces
them.
3. Analysis of diagnostic parameters in the fields of time, amplitude, frequency and wavelet allowed indicating
the most useful of them.
4. The conducted research has shown that they have more significant influence on the diagnostic parameters of
the technical state than the resource in operating hours.
5. It is required to introduce servicing according to the technical state, and not on the resource used so far.
6. Further research is planned with the simulation of subsequent technical states of turbochargers.
REFERENCES
1. N.F. Sakellaridis, S.I. Raptotasios, A.K. Antonopoulos, G.C. Mavropoulos and D.T. Hountalas,
Development and validation of a new turbocharger simulation methodology for marine two stroke diesel
engine modelling and diagnostic applications, Energy no. 91, 2015, pp. 952966.
2. M. Idzior, M. Karpiuk, M. Bieliński and T. Borowczyk, Failure’s identification of turbocharges of internal
combustion engines by means of multi-functional test stand, Journ. of KONES, vol. 20, 2013, no. 3, pp.
169175.
3. A. Adamkiewicz, An analysis of cause and effect relations in diagnostic relations of marine Diesel engine
turbochargers, Scien. Jour. of the Mar. Univ. of Szczecin, no. 31(103), 2012, pp. 513.
4. H. Li, X. Zhang and F. Xu, Experimental Investigation on Centrifugal Compressor Blade Crack
Classification Using the Squared Envelope Spectrum, Sensors DOI 10.3390/s130912548 online 2013.
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17. M. Hebda, S. Niziński and H. Pelc, Fundamentals of diagnostic vehicles (in Polish). (2nd ed.) WKiŁ,
Warsaw 1984.
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