Technical Documentation

Exhaust Gas Turbocharger

Operating Manual C1

Exhaust gas turbocharger . . . . . . . . . . NR12/RS

D36 6667-- 1 E

MAN B&W Diesel Aktiengesellschaft : 86224 Augsburg, Germany : Phone +49 821 322 0 : Fax +49 821 322 3382

6667 C1--01 E 02.02 101/ 02

. 1999 MAN B&W Diesel AG

All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.

6667 C1--01 E 02.02 102/ 02

Table of contents

N 1 Introduction

: : : N 1.1 Preface
: : : N 1.2 Product Liability
: : : N 1.3 How the Operating Instruction Manual is organized, and how to use it
: : N 1.4 Addresses/Telephone numbers

N 2 Technical details

: : N 2.1.1 MAN B&W Diesel AG’s Scope of Supply/Technical Specification

: N 2.2.1 Exhaust gas turbocharger Brief description, function
: : N 2.4.1 Lube oil system
: : N 2.4.7 Acceleration system ”Jet Assist” (compressed--air auxiliary drive)
: : : N 2.5.1 Rating data
: : N 2.5.2 Operating data, temperatures, pressures
: : N 2.5.3 Weights
: : N 2.5.4 Dimensions
: : N 2.5.5 Gaps and clearances

N 3 Operation/Operating media

: : N 3.1.1 Prerequisites
: : N 3.2.1 Safety regulations
: : : N 3.2.2 Destination/suitability of the turbocharger
: : : N 3.2.3 Risks/dangers
: : : N 3.2.4 Safety instructions
: : N 3.4.1 Preparations for start, Starting, Stopping
: : N 3.5.1 Control the turbocharger
: : N 3.6.1 Faults/Deficiencies and their causes (Trouble Shooting)
: : N 3.6.3 Emergency operation on failure of one turbocharger
: : : N 3.6.7 Behaviour in case operating values are exceeded/ alarms are released

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 101 /02

: : N 3.7.1 Shut down/preserve the turbocharger

N 4 Maintenance/Repair

: : : N 4.1 General remarks

: : : N 4.2 Maintenance schedule (explanations)
: : N 4.3 Tools/Special tools
: : N 4.4 Spare Parts
: : N 4.6 Special services/Repair work
: : N 4.7 Maintenance schedule (signs/symbols)
: : N 4.7.3 Maintenance Schedule (Turbocharger)
: : N 4.8 Maintenance work
: : N 4.8.1 Cleaning
: : N 4.8.4 Checking the individual Components
: : N 4.8.7 Check list
: : N 4.8.9 Service Report

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 102 / 02

Introduction

1 Introduction

2 Technical details

3 Operation/
Operating media

4 Maintenance/Repair

5 Annex

6680 1--02 E 02.02 101/ 01

Table of contents

N 1 Introduction

: : : N 1.1 Preface
: : : N 1.2 Product Liability
: : : N 1.3 How the Operating Instruction Manual is organized, and how to use it
: : N 1.4 Addresses/Telephone numbers

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 101 /01

Preface 1.1

Characteristics of turbochargers, Turbochargers produced by MAN B&W Diesel AG have evolved from
justified expectations, periods of continuous, successful research and development work. They
prerequisites satisfy high standards or performance and have ample redundancy of
withstanding adverse or detrimental influences. However, to meet all the
requirements of practical service, they have to be used to purpose and
serviced properly. Only with these prerequisites can unrestricted efficiency
and long useful life be expected.

Purpose of the The operating manual as well as the work cards are thought to assist you
operating manual in becoming familiar with the turbocharger and the equipment. They are
and also thought to provide answers to questions that may turn up later on,
work cards and to serve as a guidance in your activities of engine operation, checking
and servicing. Furthermore, we attach importance to familiarising you with
the functions, relations, causes and consequences, and to conveying the
empirical knowledge we have. Not the least, in providing the technical
documentation including the operating manual and work cards, we comply
with our legal duty of warning the user of the hazards which can be caused
by the turbocharger or its components - in spite of a high level of
development and much constructive efforts - or which an inappropriate or
wrong use of our products involve.

Condition 1 The technical management and also the persons in charge of servicing
works (possibly on order) have to be familiar with the operating manual
and work cards. These should all times be available.

▲▲ Caution! Missing information and disregard for information

can cause injury to persons, damage to property and the
environment.
Please read the operating manual and work cards.

Condition 2 The servicing and overhaul of turbochargers will in each case require
previous training of the personnel in charge. The level of knowledge that is
acquired during such training is a prerequisite to using the operating
manual and work cards. No warranty claims can be derived from the fact
that a corresponding note is missing in these.

▲▲ Caution! Untrained persons can cause injury to persons,

damage to property and the environment.
Never give orders which may exceed the level of knowledge and
experience. Access must be denied to unauthorised personnel.

Condition 3 The technical documentation is valid for one certain order only. There can
be considerable differences to other plants. Informations valid in one case
can lead to problems in others.

▲ Attention! Technical documents are valid for one certain order

only. Using information of another order or from foreign sources can
lead to disturbances/damages.
Only use the correct information, never use information from foreign
sources.

6685 1.1--01 E 05.99 NR, NA 101/ 02

To be observed as well ... Please observe also the notes on product liability given in the following
section and the introductional passages and safety regulations in
Section 3.

6685 1.1--01 E 05.99 NR, NA 102/ 02

Product Liability 1.2

The reliable and economically efficient operation of a propulsion system

(inclusive turbocharger) requires that the operator has a comprehensive
knowledge. Similarly, proper performance can only then be restored by
maintenance or repair work if such work is done by qualified specialists
with the adequate expertise and skill. Rules of good workmanship have to
be observed, negligence is to be avoided.

This Technical Documentation complements these faculties by specific

information, and draws the attention to existing dangers and to the safety
regulations in force. MAN B&W Diesel AG asks you to observe the
following:

▲▲ Caution! Neglection of the Technical Documentation, and

especially of the Operating Instructions, Work Cards and Safety
Regulations, the use of the system for a purpose other than intended
by the supplier, or any other misuse or negligent application may
involve considerable damage to property, pecuniary damage and/or
personal injury, for which the supplier rejects any liability
whatsoever.

6685 1.2--01 E 05.99 NR, NA 101/ 01

How the Operating Instruction Manual
is organized, and how to use it 1.3

Instructions for use

The operating manual contains written and illustrated information that is

both generally useful and specially significant. This information is thought
to supplement the knowledge and faculties which the persons have who
are entrusted with
- the operation,
- the control and supervision,
- the maintenance and repair
of the engine. The conventional knowledge and practical experience alone
will not be adequate.

The operating instructions should be made available to these persons. The

people in charge have the task to familiarise themselves with the
composition of the operating manual so that they are able to find the
necessary information without lengthy searching.

We attempt to render assistance by a clearly organised composition and

by a clear diction of the texts.

Structure and special features

The operating instruction manual mainly consists of the sections

1 Introduction
2 Technical details
3 Operation/Operating media,
4 Maintenance/Repair

The operating manual is limited to the vital subjects. It mainly focuses on:
- Understanding the functions/coherences;
- operating it in routine and emergency modes;
- ensuring operational prerequisites on the turbocharger and the
peripheral systems, and
- Maintaining the operability of the turbocharger/engine,
carrying out preventive or scheduled maintenance work,
doing unsophisticated repair work, and contracting and supervising
more difficult work.

6685 1.3--01 E 03.02 NR, NA 101/ 02

 The manual does not deal with:
- The moving and erection of the turbocharger,
- Steps and checks when putting the engine into operation for the first
time,
- Difficult repair work requiring special tools, facilities and experience and
the
- Behaviour after fire, inrush of water, severe damage and average.

What is also of importance

The sheet “Scope of supply” The content of the operating manual and structural details of it can be
seen at a glance from the table of contents. We would like to draw your
particular attention to the sheet “Scope of supply” in Section 2. The sheet
named “Scope of supply” lists and briefly describes all the items that were
supplied by MAN B&W Diesel AG. This sheet shows for which
components you may expect to receive assistance and spare parts
supplies from us. This is the scope to which our information, our
maintenance schedules and specifications refer to. Where problems are
encountered with systems for which we have supplied but a few items, it
will possibly be more helpful to consult the system supplier directly, unless
MAN B&W’s scope of supply is mainly concerned, or similar, obvious
reasons apply.

Turbocharger design The operating manual will be continually updated, and matched to the
design of the engine as ordered. There may nevertheless be deviations
between the sheets of a primiarily describing/illustrating content and the
definite design.

Technical details Technical details of your engine are included in

- the “Technical Data” in Section 2,
- in the work cards in Volume C2, and
- the test run or commissioning certificate included in Volume C5.

Maintenance schedule/ The maintenance schedule (turbocharger) is closely related to the work
work cards cards of Volume C2. The work cards describe how a job is to be done, and
which tools and facilities are required for doing it. The maintenance
schedule, on the other hand, gives the periodical intervals and the average
requirements in personnel and time.

6685 1.3--01 E 03.02 NR, NA 102/ 02

Addresses/Telephone numbers 1.4

Addresses Table 1 contains the addresses of Works of the

MAN B&W Diesel Aktiengesellschaft.

The addresses of MAN B&W service centers, agencies and authorised

repair workshops can be looked up in the brochure
“Diesel and Turbocharger Service Worldwide”
from the MAN B&W Diesel Aktiengesellschaft.

MAN B&W Diesel AG Company Address

Work Augsburg MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
Germany
Phone +49 821 322 0
Fax +49 821 322 3382
MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
-- Engine Service
Germany
Phone +49 821 322 3930
Fax +49 821 322 3838
MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
-- Turbocharger Service
Germany
Phone +49 821 322 3994
Fax +49 821 322 3998
Work Hamburg MAN B&W Diesel Aktiengesellschaft
Service Center Werk Hamburg
Rossweg 6
20457 Hamburg
Germany
Phone +49 40 7409 0
Fax +49 40 7409 104
Technical Branch Office Hamburg MAN B&W Diesel Aktiengesellschaft
Vertriebsbüro Hamburg
Admiralitätstraße
20459 Hamburg
Germany
Phone +49 40 378515 0
Fax +49 40 378515 10
Table 1. Companies and addresses of the MAN B&W Diesel Aktiengesellschaft

6685 1.4--01 E 02.02 NR, NA 101/ 01

Technical details

1 Introduction

2 Technical details

3 Operation/
Operating media

4 Maintenance/Repair

5 Annex

6680 2--02 E 07.97 101/ 01

Table of contents

N 2 Technical details

: : N 2.1.1 MAN B&W Diesel AG’s Scope of Supply/Technical Specification

: N 2.2.1 Exhaust gas turbocharger Brief description, function
: : N 2.4.1 Lube oil system
: : N 2.4.7 Acceleration system ”Jet Assist” (compressed--air auxiliary drive)
: : : N 2.5.1 Rating data
: : N 2.5.2 Operating data, temperatures, pressures
: : N 2.5.3 Weights
: : N 2.5.4 Dimensions
: : N 2.5.5 Gaps and clearances

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 101 /01

MAN B&W Diesel AG’s
Scope of Supply/Technical Specification 2.1.1

For all items supplied by us ... For all questions you have on items supplied by us, please contact
- MAN B&W Diesel AG in Augsburg,
and for typical service questions,
- MAN B&W service centers,
- agencies and
- authorised repair workshops all over the world.
For all items not supplied by us ... For all items not supplied by us, please directly contact the subsuppliers,
except the components/systems supplied by MAN B&W Diesel AG are
concerned to a major extent or similar, obvious reasons apply.

Technical Specification The order confirmation, technical specification related to order

confirmation and technical specification of the turbocharger contain
supplementary information.

6685 2.1.1--01 E 04.99 NR, NA 101/ 01

Exhaust gas turbocharger
Brief description, function 2.2.1

Figure 1. Exhaust gas turbocharger NR12/RS

Brief description Turbocharger with one radial--flow turbine stage and one radial--flow compressor stage.
Rotor supported on 2 floating bearing bushes and one locating bearing arranged inboard.
Turbine wheel (3) with shaft in one integral piece, compressor wheel (8) mounted on shaft.
Compressor (10) with one outlet socket.
Silencer (6), or air intake casing (if provided).
Bearing lubrication integrated in engine lube oil circuit.
No water cooling. Casings on turbine side with heat insulation.

Function In operation the engine exhaust gases drive the turbocharger rotor by converting the
exhaust gases into energy. The exhaust gases flow from the engine exhaust pipe
through the turbocharger via the gas--admission casing (1), turbine nozzle ring (2),
turbine wheel (3), insert (4) and gas outlet casing (5) with integrated gas outlet diffuser.
Simultaneously, fresh air is drawn in via the silencer (6) or air intake casing and
insert (7) and compressed via compressor wheel (8), diffuser (9) and compressor
casing (10). Via intercooler and charging air pipe the compressed air is pressed into the
engine cylinders.
Generally this process achieves a tremendous increase in the performance of the
engine. Flow areas and directions of flow are adjusted to the individual application.
The turbocharger Rotor is guided in radial direction through 2 floating bearing bushes
arranged between turbine wheel (3) and compressor wheel (8) in the bearing
casing (11). The locating bearing on the compressor side serves both for axial
positioning and for taking the axial thrust.
The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe. The lube oil serves as well for the cooling of the bearings.

6667 2.2.1--01 E 05.99 NR12/RS 101/ 01

Lube oil system 2.4.1

1 Feed pipe (engine) 6 Discharge pipe 10 Control air

2 Feed pipe (turbocharger) 7 Sight glass or 11 Charge air cooler
3* Orifice venting box 12 Pressure gauge
4* Bearing bush 8 Venting pipe 13 Pressure controller
5* Locating bearing 9 * Oil pressure valve 14 * Sealing air
* Scope of supply of turbocharger
Figure 1. Lube oil system NR12/RS

Lube oil system The turbocharger rotor is guided in radial direction through 2 floating bearing
bushes (4) arranged between turbine wheel and compressor wheel in the bearing
casing. The locating bearing (5) on the compressor side serves both for axial
positioning and for taking the axial thrust.
The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe (2). The necessary lube oil pressure is to be adjusted by an
installed orifice (3) at the entry of the bearing casing. The lube oil serves as well
for the cooling of the bearings.

6667 2.4.1--01 E 05.99 NR12/RS 101/ 03

 1 Feed pipe (engine) 6 Discharge pipe 10 Control air
2 Feed pipe (turbocharger) 7 Sight glass or 11 Charge air cooler
3* Orifice venting box 12 Pressure gauge
4* Bearing bush 8 Venting pipe 13 Pressure controller
5* Locating bearing 9 * Oil pressure valve 14 * Sealing air
* Scope of supply of turbocharger
Figure 2. Lube oil system NR12/RS (coincident as figure 1)

Lube oil pressure The measuring connection at the top of the bearing casing is to be used for
controlling and monitoring the lube oil pressure.
By adaption of the orifice (3), the lube oil pressure is to be adjusted so that a
pressure of 0.6 – 0.1 bar prevails at this point at a charge air pressure below 1 bar
(engine load lower than 25 %) and with the lube oil at service temperature (inlet
temperature max. 75 ƒ C).
The oil pressure valve (9) is adjusted to an opening pressure of 1 bar. If the charge
air pressure exceeds 1 bar by an increase of the engine load, this valve will be
opened through the control air (10).
At full engine load and with the lube oil at service temperature a lube oil pressure of
1.5 – 0.2 bar must then be available.
On start--up and during heating up of the engine, when the lube oil temperature is
relatively low, a lube oil pressure of up to 2.0 bar is admissible for a short period of
time.

Control air The control air should be taken off downstream of the charge air cooler (11). The
take--off point must be protected against the ingress of condensate and dirt.
Therefore, it should be located in the upper area of the charge air duct. The pipe
should extend about 30 mm into the charge air duct in order to avoid the entering
of dirt and water which is blown along the wall of the duct.

Differences in height Differences in height between the indicating instrument and turbocharger centreline
must be made allowance for with – 0.1 bar per 1 m difference.
Example: If the pressure gauge (12) and/or the pressure controller (13) is located
3 metres lower, the pressure gauge must indicate a by 0.3 bar higher pressure

6667 2.4.1--01 E 05.99 NR12/RS 102/ 03

 and/or the setting of the pressure controller must by 0.3 bar be higher than the
operating pressure specified above.

Alarm, engine shut--down With charge air pressures higher than 1 bar the alarm point for lube oil pressure is
to be adjusted to a value of 1.0 bar. When an alarm is triggered, the engine
performance has to be reduced simultaneously (without delay) to half load
(engine slow-down). If the oil pressure continues to drop, the engine is to be
stopped and the causes are to be remedied.
- Engine shut-down at 0.8 bar oil pressure, if charge air higher than 1 bar
- Engine shut-down at 0.4 bar oil pressure, if charge air below 1 bar
If it is not allowed to stop the engine for an important reason, damages of the
turbocharger are to be expected.

Lube oil flow rate The required lube oil flow rate depends on the viscosity of the lube oil and may
differ from that stated in the Operating data (see sheet 2.5.2).

Lube oil quality The plain bearings are rated for use of standard engine lube oils SAE30 or
SAE40 and can therefore be directly connected to the lube oil system of the
engine.

Lube oil filtration The turbocharger does not require its own lube oil filter. The filtration which
nowadays is the standard for engines is adequate, provided that the fineness is
smaller than/equal to 0.05 mm. A precondition is that the engine lube oil is
permanently treated by separation and excessive concentrations of water of more
than 0.2 % portion by weight and solid residues larger than 0.02 mm are avoided.
Prior to initial operation of the engine or after major servicing work, the pipes
between the filter and turbocharger are to be cleaned, pickled and flushed
carefully.

Priming Prior to engine start--up, the bearings of the turbocharger must be primed, which,
depending on the lube oil system of the engine system, is done by priming
immediately prior to start--up, or by interval or continuous priming.

Post lubrication For cooling the plain bearings, the turbocharger has to be lubricated after engine
stop with a lube oil pressure of min. 0.3 bar. The engine lube oil pumps or the
auxiliary pumps must therefore continue running for 10 ... 30 minutes.

Lube oil drain The discharge pipe (6) should have a gradient as steep as possible, and it should
be amply dimensioned and free of resistances and back pressures. On ships, the
inclination of the line should be not less than 5• more than the maximum possible
inclination of the vessel.
The oil discharge pipe must have a venting facility from a sufficiently large
compartment permitting the oil to settle down, e.g. a sight glass/venting box (7).
The cross section of the venting pipe (8) should be approximately that of the oil
discharge pipe (6).

Shaft sealing The oil space is sealed on the turbine and compressor sides by labyrinths fitted
on the rotor shaft. The radial labyrinth clearance should be such that the rotating
labyrinth tips slightly dig into the softer sealing cover layer. At higher speeds, the
rotor is slightly lifted corresponding to the lubricating film, so that the labyrinth tips
come clear. The rotor will be lowered when the turbocharger stops. The labyrinth
tips will then come down into the grooves in the sealing covers, providing better
sealing during priming. Local running--in grooves in the bore of the sealing covers
are therefore desirable and no reason for replacement of parts.

Sealing air For the shaft sealing on turbine side, sealing air (compressed air) is additionally
required:
- against entry of exhaust gas into the oil space,
- against trickle of lube oil into the turbine (oil coke)
During operation, the sealing air (14) is withdrawn downstream of the compressor
wheel and led to the labyrinth seal on the turbine side via ducts drilled into the
bearing casing.

6667 2.4.1--01 E 05.99 NR12/RS 103/ 03

Acceleration system
”Jet Assist” 2.4.7
-

1 Pressure reducing valve 5 Turbocharger

2 3/2--way solenoid valve
3 Control valve A Starting air bottle (30 bar)
4 Non--return valve C Compressor wheel

Figure 1. System “Jet Assist”

Accelerator The accelerator “Jet Assist” is used where special demands exist
“Jet Assist” regarding fast and virtually soot--free acceleration and/or load application.

System description In such cases, compressed air is drawn from the starting air bottles (A)
and reduced from 30 bar to a maximum pressure (gauge) of 4 bar, and
then passed into the compressor casing of the turbocharger (5) to be
admitted to the compressor wheel (C) via inclined bored passages of the
insert. In that way, additional air is supplied to the compressor which in
turn is accelerated, thereby increasing the charge air pressure.

Control Operation of the accelerator ”Jet Assist” is initiated by a control, and

limited to a fixed load range.

System “Jet Assist” System “Jet Assist”, please refer to the figure 1.

6685 2.4.7--01 E 03.02 NR, NA 101/ 01

Rating data 2.5.1

Relation of the Turbocharger/engine

Turbocharger Engine Rating Speed

Type Type [kW] [rpm]
NR12/RS01 5L 16/24 500 1 200
NR12/RS02 6L 16/24 540 1 000
NR12/RS03 6L 16/24 600 1 200
NR12/RS04 7L 16/24 630 1 000

Type plate of the turbocharger

Type NR12/RS01
NR12/RS02
NR12/RS03
NR12/RS04

Works--No. . . . . . . . . . . . . . . . . . . . . . . . refer to the type plate

(mounted at the pressure socket
of the compressor)

Maximum admissible speed n max . . . . . . . . . . 75,000 [rpm]

(operating limit)

Maximum admissible exhaust t max . . . . . . . . . . . . . . 650 [ ƒC ]

gas temperature before turbine
(operating limit)

Further data

Display range of the 0 ... 75,000 [rpm]

speed transmitter

Operating speed of the refer to the Acceptance Records of the turbocharger

turbocharger

Further operating data refer to the Acceptance Records and Operating Manual of the engine

6667 2.5.1--01 E 04.99 NR12/RS 101/ 01

Operating data,
temperatures, pressures 2.5.2

Lube oil

Selection of lube oil SAE-class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 30 or SAE 40

Filtration of lube oil grade of filtration smaller than . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm

Operating temperatures maximum permissible oil admission temperature

at full engine load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 ƒC

Operating pressure using SAE 30 at 60ƒ C or SAE 40 at 65ƒ C

(reference measuring point on turbocharger centreline)
with charge air pressure up to 1 bar . . . . . . . . . . . . . 0.6 “ 0.1 bar
with charge air pressure higher than 1 bar . . . . . . . . 1.5 “ 0.2 bar

Flow rate of lube oil using SAE 30 at 60ƒ C or SAE 40 at 65ƒ C . . . . . . . . . . . . . . 660 l/h

Further remarks refer also to the “Lube oil system”, sheet 2.4.1

6667 2.5.2--01 E 05.99 NR12/RS 101/ 01

Weights
2.5.3

Weights assigned to assemblies/components (approximate values)

500 Exhaust gas turbocharger, complete with silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 kg

501 Gas--admission casing, complete (with covering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 kg

506 Gas outlet casing, complete (with covering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 kg

513 Turbine nozzle ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 kg

517 Bearing casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 kg

520 Rotor complete (turbine rotor .... 2.7 kg, compressor wheel ... 1.0 kg) . . . . . . . . . . . . . . . . . . . . . . 4 kg

540 Insert, compressor side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kg

541 Insert, turbine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kg

542 Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 kg

544 Silencer, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 kg

546 Compressor casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 kg

599 Cartridge, complete (517 + 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kg

6667 2.5.3--01 E 04.99 NR12/RS 101/ 01

Dimensions 2.5.4

Pipe connections

Exhaust gas Entry at the gas--admission casing (501) . . . . . . . . . . . . . . . mm 105 dia.

Outlet at the gas outlet casing (506) . . . . . . . . . . . . . . . . . . . mm 290 x 135

Outlet at the gas outlet casing (506)

with counter flange (593) . . . . . . . . . . . . mm 276 dia.

Charge air Outlet at the compressor casing (546) . . . . . . . . . . . . . . . . . mm 88 dia.

Lube oil Inlet laterally at the bearing casing (517)

flange connection for pipe . . . . . . . . . . . mm 15 x 1.5

Drain laterally at the bearing casing (517)

flange connection for pipe . . . . . . . . . . . mm 30 x 2.0

Additional lubrication Inlet at the top of the bearing casing (517)

(if provided) for pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 6.0 x 1.0

Jet assist Connection laterally at the compressor casing (546)

(if provided) flange connection for pipe . . . . . . . . . . . mm 25 x 2.0

6667 2.5.4--01 E 04.99 NR12/RS 101/ 01

Gaps and clearances 2.5.5

Figure 1. Gaps and clearances

Item Designations Order No. When new Replace or

No. of parts remachine parts
min [mm] max [mm] min [mm] max [mm]
1 a) Compressor wheel (520.005)
Radial gap 0.30 0.40 0.20 0.50
Insert (540.001)
2 b) Compressor wheel (520.005)
Axials gap 0.15 0.30 0.10 0.40
c) Insert (540.001)
3 a) Turbine rotor (520.001)
Radial gap 0.30 0.40 0.20 0.50
Insert (541.001)
4 d) Turbine rotor (520.001)
Axials gap 0.05 0.60 ------ 0.70
Insert (541.001)
5 e) Locating bearing (517.002)
Axial clearance 0.19 0.21 ------ 0.28
Labyrinth ring (520.006)
6 admissible aberration from the plane of rotation
Compressor wheel (520.005)
(face runout) ................... 0.06 mm

a) Using feeler gauge, measure at 4 points on the circumference and calculate mean value.
b) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from calculated mean value with the rotor pushed up
in direction (B).
c) Adjustable by remachining or by shim at balance ring (S).
d) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from calculated mean value with the rotor pushed up
in direction (B).
e) Using the dial gauge, measure while vigorously moving the rotor in the directions (A) and (B). In case of
labyrinth seals already run in it might be possible that the measured value is smaller.

6667 2.5.5--01 E 03.02 NR12/RS 101/ 02

 Figure 2. Exact measurement of the axial clearance (5)

Exact mesurement of the axial clearance (5)

1. Measure the distance (K5) and note down.

2. Measure the width (B) of the locating bearing (517.002) and note
down.
3. Axial clearance (5): actual value = (K5) -- (B).

6667 2.5.5--01 E 03.02 NR12/RS 102/ 02

Operation/Operating media

1 Introduction

2 Technical details

3 Operation/
Operating media

4 Maintenance/Repair

5 Annex

6680 3--02 E 07.97 101/ 01

Table of contents

N 3 Operation/Operating media

: : N 3.1.1 Prerequisites
: : N 3.2.1 Safety regulations
: : : N 3.2.2 Destination/suitability of the turbocharger
: : : N 3.2.3 Risks/dangers
: : : N 3.2.4 Safety instructions
: : N 3.4.1 Preparations for start, Starting, Stopping
: : N 3.5.1 Control the turbocharger
: : N 3.6.1 Faults/Deficiencies and their causes (Trouble Shooting)
: : N 3.6.3 Emergency operation on failure of one turbocharger
: : : N 3.6.7 Behaviour in case operating values are exceeded/ alarms are released
: : N 3.7.1 Shut down/preserve the turbocharger

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 101 /01

Prerequisites 3.1.1

Prerequisites dating back into the past

Some of the prerequisites for successful operation of the engine/engine

plant are already dating back into the past when the phase of day-to-day
operation commences. Other prerequisites can, or have to be directly
influenced.

The factors that are no longer accessible to direct influence, are

- the source of the engine,
- qualified manufacture including careful controlling under the eyes of
control boards/classification societies,
- reliable assembly of the engine and its exact tuning during the trials.
The factors dating back into the past and having effects on future
performance also include
- the care invested in the planning, layout and construction of the
system,
- the level of cooperation of the buyer with the projecting firm and the
supplier, and
- the consistent, purpose activities during the commissioning, testing and
breaking-in phases.

Day-to-day prerequisites

The prerequisites directly required for day-to-day operation and to be

provided for again and again are, for example
- the selection of appropriate personnel and its instruction and training,
- the availability of technical documentation for the system, and of
operating instructions and safety regulation in particular,
- ensuring operational availability and reliability, in due consideration of
operational purposes and results,
- the organisation of controlling, servicing and repair work,
- the putting into operation of systems, ancillaries and engines in
accordance with a chronologically organised checklist, and
- definition of the operating purposes, compromising between expense
and benefit.
Detailed information on the above items is given in the following.

6685 3.1.1--01 E 04.99 NR, NA 101/ 01

Safety regulations 3.2.1

Preliminary remarks

Personell The engine and the systems required for its operation may only be started,
operated and stopped by authorised personell. The personell has to be
trained for this purpose, possess complete understanding of the plant and
should be aware of the existing potential risks.

Technical documentation The personnel must be familiar with the technical documentation of the
plant, in particular the operating manual of the engine, the turbocharger
and the accessories requiered for engine operation, particularly the safety
regulations contained therein.

Service log book It is advisable to keep a service log book into which all the essential jobs
and deadlines for their performance, the operating results and special
events can be entered. The purpose of this log book is that in the event of
a change in personnel the successors are in a position to duly continue
operation using this data log. Moreover, the log book permits to derive a
certain trend analysis and to trace back faults in operation.

Accident prevention regulations The accident prevention regulations applicable for the plant should be
observed during engine operation as well as during maintenance
operations and overhauls. It is advisable to post those regulations
conspicously in the engine room and to stress the danger of accidents
over and over again.

Warranty claims The given advices does not claim to be complete. Safety requirements
mentioned in other passages of the technical documentation are
supplementarily valid and are to be observed in the same way.
Please also note that incorrect behaviour might result in the loss of
warranty claims.

Containment safety

Extraordinary influences The turbocharger is one of the highest loaded components in modern
diesel engines. The high rotor speeds of a turbocharger result in high
centrifugal force stresses at simultaneous high component temperatures.
A consequence of additional extraordinary influences might be -- in
extremlely rare cases -- a failure of the components.

Precautions MAN B&W turbochargers correspond to the required containment safety

according to the rules stipulated by the classification societies so that the
state of the art prevents fragments from escaping. In extrem cases,
particularly if the turbocharger has not been sufficiently or properly
maintained, there may be the risk of damages to persons or property in
vicinity of the turbocharger. To eliminate residual risks we kindly ask you to
observe following rules:
- Persons are by no means allowed to stay without any reason near the
operating turbocharger.
- Turbine and compressor are to be cleaned at regular intervals as speci-
fied in the operating manual.

6685 3.2.1--01 E 10.03 NR, NA 101/ 03

 - The maintenance of the turbocharger must be carried out by trained
personnel as well as in the maintenance intervals as stipulated in the
operating manuals.
- Inadmissible operating conditions, such as frequent load releases,
compressor surging, excessive turbocharger speeds, must be avoided.
- Corrosive and erosive media in the intake air are to be avoided.

Precautions

Opening of pipes/pressure Before opening pipes, flanges, screwed connections or fittings, check if
vessels the system is depressurised respectively emptied.

▲ Attention! Disregarding this means: risk of burns when hot

fluids are involved, fire hazard in case of fuel, injuries caused by
flung-out screw plugs or similar objects when loosening same under
pressure.

Disassembling/assembling In case of disassembly, all pipes to be reinstalled, especially those for fuel
pipelines oil, lube oil and air, should be carefully locked. New pipes to be fitted
should be checked whether clean, and flushed if necessary. It should in
each case be avoided that any foreign matter gets into the system. All
parts involved have to be subjected to preservation treatment for
prolonged storage.

Removing/refitting of heavy When removing or detaching heavy engine components it is imperative to

engine components ensure that the transportation equipment is in perfect condition and has
the adequate capacity of carrying the load. The place selected for
depositing must also have the appropriate carrying capacity. This is not
always the case with platforms, staircase landings or gratings.

Coverings Following assembly work, check whether all the coverings over moving
parts and laggings over hot parts have been mounted in place again.
Engine operation with coverings removed is only permissible in special
cases, e.g. if the valve rotator is to be checked for proper performance.

▲ Attention! Loose clothing and long hair might get entangled.

Spontaneous supporting against moving parts when loosing ones
balance may result in serious injury. In addition, there is the risk of
burning and/or fire.

Use of cleaning agents When using cleaning agents, observe the suppliers instructions with
respect to use, potential risks and disposal.

▲ Attention! Disreagarding this means: danger of caustic skin and

eye injury, and also of the respiratory tract if vapours are produced.

▲ Attention! Using Diesel fuel for cleaning purposes involves the

risk of fire or even explosion. Otto fuel (petrol) or chlorinated
hydrocarbons must not be used for cleaning purposes.

Use of high-pressure cleaning When using high-pressure cleaning equipment, be careful to apply this
equipment properly. Air filters, shaft ends including ones with lip seal rings,
controllers, splash water protected monitoring equipment, cable entries
and sound/heat insulating parts covered by water-permeable materials
have to be appropriately coverd or excluded from high-pressure cleaning.

Fire hazard The use of fuel and lube oils involves an inherent fire hazard in the engine
room. Fuel and lube oil pipes must not be installed in the vicinity of
unlagged, hot engine components (exhaust pipe, turbocharger). After
carrying out overhaul work on exhaust gas pipes and turbochargers, all
insulations and coverings must be carefully refitted completely. The

6685 3.2.1--01 E 10.03 NR, NA 102/ 03

 tightness of all fuel oil and oil pipes should be checked regularly. Leaks are
to be repaired immediately.

Fire extinguishing equipment must be available and is to be inspected

periodically.

In case of fire, the supply of fuel and lube oil must be stopped immediately
(stop the engine, stop the supply pumps, shut the valves), and the fire
must be attempted to be extinguished using the portable fire-fighting
equipment. Should these attempts be without success, or if the engine
room is no longer accessible, all openings are to be locked, thus cutting off
the admission of air to quench the fire. It is a prerequisite for success that
all openings are efficiently sealed (doors, skylights, ventilators, chimney as
far as possible). Fuel oil rquires much oxygen for combustion, and the
isolation from air is one of the most effective measures of fighting the fire.

▲▲▲ Danger! Carbon dioxide fire extinguishing equipment must

not be used until it has been definitely ensured that no one is in the
engine room. Ignoring this means danger of life!

6685 3.2.1--01 E 10.03 NR, NA 103/ 03

Destination/suitability
of the turbocharger 3.2.2

Use in accordance with the destination

The delivered turbocharger is destined for (firstly) operation under the

marginal conditions stipulated
- under Technical Data, Section 2.5,
- in the scope of supply/technical specification and
- in the order confirmation.
Furthermore destined for (secondly)
- operation using the specified operating media,
- taking into consideration the design/layout of the supply, measuring,
control and regulating systems as well as laying down of the marginal
conditions (e.g. removal space/crane capacities) in accordance with the
recommendations of MAN B &W Diesel AG or according to the state of
the art.
Furthermore destined for (thirdly)
- start, operation and stopping of the engine in accordance with the usual
organisational rules, exclusively by authorised, qualified, trained
persons who are familiar with the plant.

With restrictions destined/suitable for

The turbocharger is with restrictions destined/suitable for:

- operation at operating values resulting in an alarm situation,
- operation in case of failure of supply equipments,
- operation at reduced maintenance expenditures,
- speeded-up acceleration/abrupt loading/unloading to a moderate
extent,

Not destined/suitable for

The Turbocharger is not destined/suitable for:

- operation at operating values due to which engine stop or load
reduction was effected,
- operation in case of failure of supply equipments,
- operation within barred speed ranges,
- operation without appropriate surveillance/supervision,
- operation without maintenance expenditures or if they have been
reduced to a great extent,
- unauthorised modifications,
- use of other than original spare parts,
- long-term shut-down without taking preservation measures.

6685 3.2.2--01 E 04.99 NR, NA 101/ 01

Risks/dangers 3.2.3

Dangers due to deficiencies concerning personnel/level of training

Expectations in case of vessel Propeller operation/generator operation (normal operation/operation in

plants road stead):
Chief engineer on board. Operational control by technical officer.

Maintenance work/repair work in the port:

To be carried out by engine operator, technical assistants or technicians
and helpers. For instructions and in difficult cases: technical officer or chief
engineer.

Generator operation (in port):

Operational control by technical officer.

Maintenance work/repair work in port:

As mentioned above.

Supplementary, the following Persons responsible for the operational control must be in possession of a
applies qualification certificate/patent which is in accordance with the national
requirements and international agreements (STCW). The number of
required persons and their minimum qualification are, as a rule, specified
by national requirements, otherwise by international agreements (STCW).

Expectations in case of During operation:

stationary plants (power plants) Plant manager (engineer) available. Operational control/supervision of the
engine and the belonging supply systems by trained and specially
instructed engine operator or technical assistant.

Maintenance work/repair work:

Execution by engine operator, technical assistants or technicians and
helpers. For instructions and in difficult cases: engineer or chief engineer.

Supplementary, the following For persons responsible for the operational control and for persons
applies carrying out/supervising maintenance and repair work, proof must be
furnished in Germany in accordance with the power economy law
(Energiewirtschaftsgesetz = EnWG) that, among other things, the
technical operation is ensured by a sufficient number of qualified
personnel. In other countries, comparable laws/guidelines are to be
observed. Deficiencies regarding personnel/level of training cannot be
compensated by other efforts.

Dangers due to components/systems

Certain dangers do of course originate from technical products and from

certain operating conditions or actions taken. This also applies to engines
and turbochargers in spite of all efforts in development, design and
manufacturing. They can be safely operated in normal operation and also
under some unfavourable conditions. Nevertheless, some dangers
remain, which cannot be avoided completely. Some of them are only
potential risks and some do only occur under certain conditions or in case
of unforeseen actions. Others do absolutely exist.

6685 3.2.3--01 E 04.99 NR, NA 101/ 02

Dangers due to emissions

Emission Danger Preventive/protective measure

Treated cooling water, lube oil, Harmful to skin and noxious, Use/dispose in accordance with the
hydraulic oil, fuel polluts water instructions of the
manufacturers/suppliers
Cleaning agents and aids According to the manufacturers’ Use/dispose in accordance with the
specification instructions of the
manufacturers/suppliers
Exhaust gas with the dangerous Noxious, has a negative effect on Carry out maintenance work
constituents NOx, SO2, CO, HC, soot the the environment in case the according to the maintenance
limit values are exceeded schedule, maintain danger--oriented
operational control, critically
observe operating results
Sound Noxious, has a negative effect on Wear ear protection, restrict
the environment in case the limit exposure to the necessary
values are exceeded minimum

Planned working places

Engines are usually operated under remote control. Regular rounds

according to the rules of “observation--free operation” are required. In this
connection, measurement, control and regulating devices as well as other
areas of the plant, which require special attention, are preferably checked.
A continuous stay in the immediate vicinity of the running engine/
turbocharger is not planned.

Personal protective measures

The regulations for prevention of accidents (Unfallverhütungsvorschriften =

UVV) and other regulations of the proper trade association or other
comparable institutions are to be observed without restriction.

This includes wearing of protective working clothing and safety shoes, the
use of a safety helmet, safety goggles, ear protection and gloves.

The relevant sections of the technical documentation must be read and

comprehended.

6685 3.2.3--01 E 04.99 NR, NA 102/ 02

Safety instructions 3.2.4

Characterisation/danger scale

Characterisation According to the relevant laws, guidelines and standards, attention must
be drawn to dangers by means of safety instructions. This applies to the
marking used on the product and in the technical documentation. In this
connection, the following information is to be provided:

- type and source of danger,

- imminence/extent of danger,
- possible consequences,
- preventive measures.

The statements in Section 3.2.3 follow this regulation, just as the other
safety instructions in the technical documentation do.
Danger scale The imminence/extent of danger is characterised by a five--step scale as
follows:

▲▲▲ Danger! Imminent danger

Possible consequences:
Death or most severe injuries,
total damage to property

▲▲ Caution! Potentially dangerous situation

Possible consequences: Severe injuries

▲ Attention! Possibly dangerous situation

Possible consequences: Slight injuries,
possible damage to property

Important! For calling attention to error sources/handling errors

Tip! For tips regarding use and supplementary information

6685 3.2.4--01 E 04.99 NR, NA 101/ 01

Preparations for start,
Starting, Stopping 3.4.1

Preparations for start

Turbocharger Prior to engine start--up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine system, is done by
priming immediately prior to start--up, or by interval or continuous priming.

Engine/Turbocharger Ensure that the shut--off elements of the systems have been set to
in--sevice position.
Check the lube oil pressure upstream of the turbocharger.

Starting

Turbocharger The turbocharger is driven by the exhaust gases and starts automatically
on engine start.

Stopping

Turbocharger The rotor of the turbocharger continues rotating for some more time on
engine shut--down, due to the flywheel effect. The run--down time of the
rotor is indicative of the mechanical condition of the turbocharger.
An early stop suggests mechanical damage to the bearings, a touching of
the compressor or turbine wheel, a solid object that has got caught
somewhere or the like.

Post lubrication Refer to the lube oil system 2.4.1 of the turbocharger.

6685 3.4.1--01 E 06.99 NR, NA 101/ 01

Control the turbocharger 3.5.1

Monitoring the turbocharger/routine checks

General State-of-the-art engine systems are operated automatically as a rule,

using intelligent control and regulation systems. Dangers and damage are
precluded to a large extent by internal testing routines and monitoring
equipment. Regular checks are necessary nevertheless so as to recognise
the cause of potential problems as early as possible, and to take remedial
action in due time. Moreover, the necessary maintenance work should be
done as and when required.

It is the operator’s duty to carry out the checks listed below, at least during
the warranty period. However, they should be continued on expiry of the
warranty term. The expense in time and costs is low as compared to that
for remedying faults or damage not recognised in time. Results, observa-
tions and actions taken in connection with such checks should be entered
in an engine log book. Reference values should be defined so as to make
an objective assessment of findings possible.

Regular checks The regular checks should include the following measures:
on the turbocharger
- Turbine speed
- Lube oil pressure upstream of turbocharger
- Lube oil temperature upstream of turbocharger
- Lube oil temperature downstream of turbocharger
- Exhaust gas pressure upstream of turbine
- Exhaust gas temperature upstream of turbine
- Charge air pressure downstream of compressor
- Charge air temperature downstream of compressor
- Exhaust gas, charge--air and oil--carrying pipes and conduits for tightness
- Air filter mat on the silencer for dirt accumulation / saturation
- Turbocharger for quiet running
- Rotor for unimpeded running
Quiet running Damage to the rotor and bearings is in most cases announced by irregular
running due to imbalance or contact of rotating parts. Listening to the run-
ning noise of the turbocharger in many cases permits to recognise irregu-
lar running at an early time.

Speed Provided the air ducts of the compressor are properly clean, a specific
charge--air pressure is related to every turbine rotor speed. Therefore it is
possible to conclude the rotor speed from the charge--air pressure as a
rough method of speed control.

6685 3.5.1--01 E 03.02 NR, NA 101/ 01

Faults/Deficiencies
and their causes (Trouble Shooting) 3.6.1

Preliminary conditions

Operating faults Operating faults normally manifests itself by abnormal readings (exhaust
gas temperature, charge--air pressure and speed), by distinct running
noice or by leaks in the oil pipes.

Possible consequential Should anomalies turn up on the turbocharger on starting or during engine
damage operation, the cause is to be traced immediately, if possible, and the fault
is to be eliminated. Otherwise, there will be risk of minor initial faults
causing consequential damage to the turbocharger, and also to the
engine.

First preparations In case of faults, the engine load should be reduced, if possible, or the
engine should be shut down completely and not be restarted before the
cause of faults has been eliminated.

Important! Unsystematic trying out should be avoided because it

will lead to success in rare cases only.

Fault--finding chart The fault--finding chart (refer to page 2) is thought to contribute to reliably
recognising trouble that turns up and finding the cause it is due to, and to
taking prompt remedial action.

6685 3.6.1--01 E 05.00 NR, NA 101/ 02

Exhaust gas temperature before turbine too high
Charge air pressure too low TROUBLES
Charge air pressure too high EXPERIENCED
Speed too low
Speed too high
Lubricating oil pressure too low
Lubricating oil losses
Sluggish starting or short run--down time
Abnormally high noise level
Turbocharger developing vibrations
Compressor surging

POSSIBLE CAUSES
Silencer or air filter fouled
Compressor fouled
Turbine wheel heavily fouled
Turbine nozzle ring slightly fouled / narrowed
Turbine nozzle ring heavily fouled / narrowed
Trust ring, labyrinth ring or locating ring damaged
Labyrinth seals defective
Seals damaged, leaking connections
Defective bearings, imbalance of the rotor
Rotor rubbing
Foreign bodies before or in turbine
Foreign bodies before or in compressor
Turbine or compressor wheel damaged
Sealing air ineffective, oil coke behind turbine wheel
Large erosion on turbine wheel/shroud ring, nozzle ring
High air inlet temperature
Low air inlet temperature
Intercooler fouled
Leaking charge air pipe
Charge air temperature too high
Lubricating oil inlet temperature too high
Lubricating oil pressure too high
Dirty lubricating oil filter
Lubricating oil pressure gauge disturbed
Excessive pressure in oil discharge or crankcase
Deposits on inlet or exhaust valves / slots of engine
Leaking exhaust gas pipe
Exhaust gas backpressure after turbine too high
Fuel injection system on engine disturbed

6685 3.6.1--01 E 05.00 NR, NA 102/ 02

Emergency operation on failure
of one turbocharger 3.6.3

Preliminary remarks

Turbochargers are turbo machines subjected to high stresses which must

reliably ensure the entire gas renewal performance of the engine at very
high speeds and relatively high temperatures and pressures. Like the
engine, the turbocharger can also suffer disturbances, despite careful
system operation, and emergency operation is also possible in most cases
unless the damage can be repaired immediately.

Means available The following means are availabe for emergency operation of the engine
with the turbochargers defective:

NR turbochargers: refer to work card 500.05 in Volume C2

- End cover to close the turbine rear side with the rotor and bearing
housing removed (cartidge)
NA turbochargers: refer to work cards 500.05 in Volume C2
- Arresting key to block the rotor from the compressor side (the suction
cross-sectional opening remains unclosed) -- such a key is also
available for NR 34/S,
- end cover to close the compressor and turbine rear side with the rotor
dismantled.
All of these elements are so designed that the flow is not obstructed on the
air side and exhaust side of the turbocharger.

Means for use on the engine:

- Cover piece (protection grid) for the far end of the turbocharger
charge-air pipe (remove the charge-air bypass pipe before if required).
This cover piece serves to facilitate suction.
- Blind flange for the exhaust gas pipe at the end opposite the
turbocharger (if there is a charge-air bypass). The blind flange serves
to lock the exhaust pipe during suction, with the bypass removed.
- In the case of V-type engines, depending on the layout of charge-air
and exhaust pipes on the engine, blind flanges for the charge-air pipe
socket and exhaust pipe socket (charge air side: downstream of the
compressor, exhaust gas side: upstream of the turbine). These blind
flanges serve to prevent wrong switching/backflow/leakage in
emergency operation.
Emergency operation with one The following possibilities exist if the rotor of the turbocharger can no
or both turbochargers failing longer rotate freely, or must be prevented from rotating. Please refer to
Table 1.

6685 3.6.3--01 E 05.02 NR, NA 101/ 03

Emergency measures Supplementary measures/
provisiones

Code number
Engine stop not permitted for compulsory reasons
Nothing is changed on the turbocharger 1-3
Engine may be stopped (temporarily)
NR turbocharger
● Dismantle the rotor and bearing housing (cartridge), mount the end cover on 1-7
the rear of the turbine (see turbocharger operating manual and relevant work
cards). Gas renewal of the engine is through the partly stripped turbocharger
on the air side and exhaust side.

This possibility exists in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine
NA turbocharger
● Measure A
Block the rotor from the compressor side using the arresting key (suction 1-4, 7
opening remains open). Subsequently re-assemble intake air silencer or intake (5-7 depending on
casing. Please refer to turbocharger operating manual and work card 500.05. situation and required)
Take measure A only if measure B cannot be taken for reasons of time.
Consequential damage possible.
● Measure B
Dismantle the rotor with bearings, block the bearing casing by mounting end
covers on the compressor and turbine sides. Reassemble the silencer/intake
casing and the turbine inlet casing, if applicable. Please refer to the 1-7
turbocharger operating manual and work card 500.05.

Possibilities in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine
Table 1. Emergency operation with one or both turbochargers failing (continued from preceding page)

Explanations

Code number Supplementary measures/provisions

1 Reduce the engine output. The maximum exhaust gas temperatures

downstream of the cylinders and upstream of the turbocharger and (on
engines equipped with two turbochargers) the maximum admissible
turbocharger speed must not be exceeded. Observe the exhaust gas for
discolouration.

2 Use all the endeavours that appear appropriate to reduce consequential

damage.

3 With the rotor arrested or dismantled, cut off the lube oil supply to avoid
fouling and fire hazards.

4 The engine has to be operated in the naturally aspirated mode, (if

equipped with two turbochargers) with reduced super-charging.

6685 3.6.3--01 E 05.02 NR, NA 102/ 03

 Code number Supplementary measures/provisions

5 In-line engines:

Cover pieces (protection girds) have to be mounted on the charge-air pipe.

On engines equipped with a charge-air bypass, it is also necessary to
mount the blind flange at the exhaust gas side connection.

6 V-type engines

On V-type engines having a common charge-air pipe, a blind flange is to

be mounted on the compressor outlet of the defective turbocharger so as
to avoid air losses.

7 V-type engines

Separate the exhaust gas inlet side of the defective turbocharger from the
gas flow of the second turbocharger by fitting a blind flange.

1 turbocharger failing In-line engine V-type engine

Fixed-pitch propeller 15% up to 50%
of the rated output at the
corresponding speed
Controllable-pitch 20% up to 50%
propeller/generator service of the rated output at the rated speed
Table 2. Output/speed that can be reached

6685 3.6.3--01 E 05.02 NR, NA 103/ 03

Behaviour in case
operating values are exceeded/
alarms are released 3.6.7

General remarks

Operating values/limit values Operating values, e.g. temperatures, pressures, flow resistances and all
other safety--relevant values/characteristics, must be kept within the range
of nominal values. Limit values must not be exceeded.

Alarms, reduction and stop Depending on the extent to which values are exceeded and on the
signals potential risks, alarms, reduction or stop signals are released for the more
important operating values. This is effected by means of the alarm system
and the safety controls. Reduction signals cause a reduction of the engine
output on vessel plants. This is effected by reducing the pitch of
controllable--pitch propeller plants. Stop signals cause an engine stop.

Behaviour in emergency cases -- Acoustic or visual warnings can be acknowledged. The displays remain
technical possibilities active until the malfunction is eliminated. Reduction or stop signals can in
the case of vessel plants be suppressed by means of the override function
of the valuation “ship takes precedence over engine”. For stationary
plants, this possibility is not provided. For these, there is also no reducing
function.

Fixing alarm and limit values For fixing the alarm and the safety--relevant limit values, the requirements
of the classification societies and the own assessment are decisive.

Legal situation

Alarm, reduction and safety signals serve the purpose of warning against
dangers or of avoiding them. Their causes are to be traced with the
necessary care. The sources of malfunctions are to be eliminated
consistently. They must not be ignored or suppressed, except on
instructions from the management or in cases of a more severe danger.

▲▲ Caution! Ignoring or suppressing of alarms, the cancellation of

reduction and stop signals is highly dangerous, both for persons
and for the technical equipment.

Liability claims for damages due to exceeded nominal values and

supressed or ignored alarm and safety signals respectively, can in no case
be accepted.

6685 3.6.7--01 E 04.99 NR, NA 101/ 01

Shut down/preserve the turbocharger 3.7.1

The instructions given for the Diesel engine (refer to the Diesel engine op-
erating manual) also apply correspondingly to a preservation and pro-
longed storage of the turbocharger.

6685 3.7.1--01 E 06.99 NR, NA 101/ 01

Maintenance/Repair

1 Introduction

2 Technical details

3 Operation/
Operating media

4 Maintenance/Repair

5 Annex

6680 4--02 E 11.97 101/ 01

Table of contents

N 4 Maintenance/Repair

: : : N 4.1 General remarks

: : : N 4.2 Maintenance schedule (explanations)
: : N 4.3 Tools/Special tools
: : N 4.4 Spare Parts
: : N 4.6 Special services/Repair work
: : N 4.7 Maintenance schedule (signs/symbols)
: : N 4.7.3 Maintenance Schedule (Turbocharger)
: : N 4.8 Maintenance work
: : N 4.8.1 Cleaning
: : N 4.8.4 Checking the individual Components
: : N 4.8.7 Check list
: : N 4.8.9 Service Report

Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management

6667 02.04 NR12/RS 101 /01

General remarks 4.1
Purpose of maintenance work/ Similarly to regular checks, maintenance work belongs to the user’s
prerequisites duties. Both serve the purpose of maintaining the reliable and safe
serviceability of the system. Maintenance work should be done by qualified
personnel and at the times defined by the maintenance schedule.
Maintenance work is of support to the engine operators in their
endeavours to recognise future failures at an early stage. It provides
useful notes on overhaul or repair becoming due, and is of influence on
the planning of downtimes.
Maintenance and repair work can only be carried out properly if the
necessary spare parts are available. It is advisable besides these spare
parts to keep an inventory of parts in reserve for unforeseen failures.
Please request MAN B&W Diesel AG to submit a quotation whenever
required.

Maintenance schedule/ The jobs to be done are shown in the maintenance schedule
maintenance intervals/ (Turbocharger) 4.7.3,
personnel and time required which contains
- a brief description of the job,
- the intervals of repetition,
- the personnel and time required, and it makes reference to
- the corresponding work cards/instructions.

Work cards in Volume C2 The work cards, comprised in Part C2 of the technical documentation,
respectively contain brief descriptions of
- the purpose of jobs to be done.
They contain
- information on the tools/appliances required, and
- detailed descriptions and drawings of the operating sequences and
steps required.

6685 4.1--01 E 03.99 NR, NA 101/ 01

Maintenance schedule (explanations) 4.2

Preliminary remarks

General The maintenance schedule of the turbocharger comprises works to be

done on components/subassemblies of the turbocharger (see 4.7 and
4.7.3).

Binding character and adaptabilities

Validity of the maintenance The maintenance schedule (turbocharger) 4.7.3 is a summary of all the
schedule maintenance and inspektion works up to a major overhaul of the
turbocharger after an operating period of

- 12,000 --18,000 hours for NR--turbochargers,

- 12,000 --18,000 hours for NA--turbochargers

at four--stroke engines,

- 24,000 -- 30,000 hours for NA--turbochargers

at two--stroke engines.

Whenever major overhaul of the turbocharger has been carried out, for
practical considerations in common with an engine maintenance being
doe, the maintenance schedule is to be started anew.

A major overhaul comprises the disassembly of the complete turbocharger

for the inspection of the actual condition, careful cleaning and checking of
all parts.

▲ Attention! In consideration of the operational safety of the

turbocharger and engine, the maintenance works should be carried
out as timely as possible and not later than scheduled.

6685 4.2--01 E 09.01 NR, NA 101/ 02

Adaption of the maintenance The maintenance schedule has been drawn up for standard operating
schedule conditions and an operation of 6,000 hours per year. After a critical
evaluation of the operating values and conditions shorter intervals may
become necessary provided external operating conditions as timetable/
timetable of ships/inspection time for plants allow it.

Favourable operating conditions are:

- constant load within the range of 60% to 90% nominal load,
- observing the specified temperature and pressure of the operating
media,
- using the specified lube oil and fuel quality,
- as well as a proper separation of the fuel and lube oil.

Adverse operating conditions are:

- long-term operation at maximum or minimum load; prolonged idling
times; frequent, drastic load changes,
- frequent engine starting and repeated warming-up phases without
adequate preheating,
- higher loading of the engine before the specified cooling water and lube
oil temperatures are reached,
- lube oil, cooling water and charge air temperatures that are too low,
- using inappropriate fuel qualities and insufficient separation,
- inadequate combustion air filtering (e.g. on stationary engines).

6685 4.2--01 E 09.01 NR, NA 102/ 02

Tools/Special tools 4.3

Tools for turbochargers

Commercial tools are not included in the delivery scope of the

Inventory tools
turbocharger. It is expected that these tools are contained in the inventory
of the plant.

Standard tools If included in the delivery scope, the turbochargers are equipped with a set
of standard tools. For a plant with several turbochargers, 1 set of
standard tools is generally sufficient. These standard tools and the
inventory tools permit the usual maintenance work to be carried out.

The tools set intended for the turbocharger(s) is contained in one box (or
in several boxes), and a table of contents is also included.
A list specifying the extent and designations of these tools is also
contained in Volume C6 of the Technical Documentation.

Tools on customer’s request In particular case, such tools/devices are supplied on request.
MAN B&W Diesel AG will gladly submit an offer, if desired.

Special tools Certain jobs, which are rather repair jobs than maintenance jobs, require
special expert knowledge, experience and supplementary
equipment/auxiliary means. Further special tools are made available to our
service bases, and possibly also our authorised workshops, for such
purposes. We therefore recommend that you consult these partners, or
entrust them to do jobs for you whenever the own capacities in terms of
time, qualification or personnel are inadequate.

6685 4.3--01 E 04.99 NR, NA 101/ 01

Spare Parts 4.4

Since it is so important, we are repeating below a sentence which we have

used already:

Tip Maintenance and repair work can only be carried out properly if
the necessary spare parts are available.

The information given below is thought to assist you in quickly and reliably
finding the correct information source in case of need.

Spare parts for turbocharger

Spare parts for the turbocharger can be identified by means of the spare
parts catalogue contained in Volume C3 of the technical documentation.
For this purpose, illustration and text sheets with order numbers are
available. An order number consists of a three--digit subassembly number
and a three--digit item number, which are separated by a dot. The spare
parts catalogue is arranged in the order of the subassemblies.
The order numbers, however, can also be looked up in the respective work
cards contained in Volume C2.

Spare parts for tools/ordering of tools (turbocharger)

Complete or individual tools for turbochargers can be ordered with the aid
of the list of contents for tools, stating the respective order numbers. This
list of contents is included in the tool box for the turbocharger. An order
number is composed of a three--digit subassembly number 596 (=
subassembly for tools) and a three--digit item number, which are separated
by a dot.
The order numbers, however, can also be looked up in the respective work
cards contained in Volume C2.

6685 4.4--01 E 05.99 NR, NA 101/ 01

Special services/Repair work 4.6

No matter whether routine cases or really intricate problems are

concerned,
- MAN B&W Diesel AG, Augsburg works,
- MAN B&W Diesel AG, Service Center Hamburg,
- MAN B&W Diesel Pte. Ltd., Service Center Singapore,
- service bases and authorised repair workshops
are readily available to offer you a wide spectrum of services and expert
advice, ranging from spare parts supplies, consultation and assistance in
operating, maintenance and repair questions, ascertaining and settling
cases of damage through to the assignment of fitters and engineers all
over the world. Some of these services are doubtless the standard offered
by suppliers, shipyards, repair workshops or specialist firms. Some of this
whole range of services, however, can only be rendered by someone who
can rely on decades of experience in Diesel engine systems. The latter are
considered as a part of the expert commitment towards the users of our
engines and for our products.

Please note the supplementary information contained in the printed

publications of Volume A1 of the Technical Documentation. In these, you
will also find the addresses and telephone numbers of the nearest service
bases which you can approach whenever required.

Information on turbochargers, see also Volume C1 of the Technical

Documentation, Page 1.4.

6685 4.6--01 E 03.99 NR, NA 101/ 01

Maintenance schedule (signs/symbols) 4.7

Explanation of signs and symbols

The heading of the maintenance schedule shows symbols instead of

entries in two languages. They have the following meaning:

Serial number of the maintenance work.

1, 2, 3 The series shows gaps for changes/up-dates which could become
necessary.

Brief description of the job

Related work cards.

The work cards listed contain detailed information on the work steps
required.
A No Work card required/available

Relation between working cards.

x These notes are of particular significance within the maintenance
system CoCoS. They give you information on the jobs with a temporal
y connection to the work in question.

Required personnel

Time required in hours per person

per Relational term to indicate the time required

Repetition intervals given in operating hours

24 ... 18,000 24 ... 18,000 (NR)
24 ... 18,000 (NA, at the four--stroke engine)
24 ... 30,000
24 ... 30,000 (NA, at the two--stroke engine)

Signs used in the columns of intervals.

Their meaning is repeated in each sheet.
X, 1, 2
We assume that the signs and symbols used in the head are sufficiently
pictorial and that it is not necessary to repeat them constantly.

Table 1. Explanation of signs and symbols of the maintenance schedule

6685 4.7--01 E 03.00 NR, NA 101/ 01

Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger) 4.7.3

1, x

12000
18000
per

1500
3000
6000
2,

150
250
y

24
50
3

Inspektion (während des Betriebes) œ Inspection (during operation)

901 Turbolader auf abnormale Geräusche Check turbocharger for unusual noise A 1 0.1 Turbo-- X
und Vibrationen kontrollieren and vibrations lader
Turbo--
charger
903 Turbolader und Systemleitungen auf Check turbocharger and system pipes A 1 0.2 Turbo-- X
Leckagen kontrollieren (Sperrluft, for leakages (sealing air, charge air, lader
Ladeluft, Abgas, Schmieröl) exhaust gas, lube oil) Turbo--
charger
905 Alle Befestigungsschrauben, Check all the fixing screws, casing 500.10 1 1 Turbo-- 2 X
Gehäuseschrauben und screws and pipe connections for tight fit lader
Rohrleitungsanschlüsse auf festen Sitz Turbo--
prüfen charger

Wartung (während des Betriebes) œ Maintenance (during operation)

911 Turbine reinigen (im Schwerölbetrieb) Clean the turbine (in HFO operation) 500.07 1 0.3 Turbo-- 1
-- Trockenreinigung, falls vorhanden -- Dry cleaning, if provided lader
Turbo--
charger
913 Turbine reinigen (im Schwerölbetrieb) Clean the turbine (in HFO operation) 500.07 1 0.6 Turbo-- 1
-- Naßreinigung, falls vorhanden -- Wet cleaning, if provided lader
Turbo--
charger

X Wartungsarbeit fällig X Maintenance work is necessary

1 Nach Bedarf/Zustand 1 As required/depending on condition
2 Kontrolle neuer oder überholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column

6667 4.7.3--01 E 04.00 NR12/RS 101 /02

Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger) 4.7.3

1, x

12000
18000
per

1500
3000
6000
2,

150
250
y

24
50
3
915 Verdichter reinigen Clean the compressor 500.08 1 0.3 Turbo-- 1
(im Betrieb) (in operation) lader
Turbo--
charger
917 Luftfilter reinigen Clean the air filter 500.11 1 0.4 Turbo-- 1
(falls vorhanden) (if provided) lader
Turbo--
charger

Wartung (gemeinsam mit einer Motorwartung) œ Maintenance (in common with an engine maintenance)
931 Verdichtergehäuse, Einsatzstück, Clean and check (visually check) the 500.10 2 4 Turbo-- X
Nachleitapparat und Verdichterrad compressor casing, insert, diffuser and 500.14 lader
reinigen und kontrollieren compressor wheel. Turbo--
(Sichtkontrolle). Restore the turbocharger for operation charger
Betriebsbereitschaft des Turboladers
wieder herstellen
951 Grundüberholung Major overhaul 000.31 931 2 20 Turbo-- X
12 000 ...18 000 Betriebsstunden: 12,000 ... 18,000 operating hours: 500.06 lader
Alle Komponenten des Turboladers Remove, clean and check all 500.10 Turbo--
abbauen, reinigen und kontrollieren. components of the turbocharger. Check 500.16 charger
Spalte und Spiele beim Zusammenbau gaps and clearances on reassembly 500.24
kontrollieren 500.27

X Wartungsarbeit fällig X Maintenance work is necessary

1 Nach Bedarf/Zustand 1 As required/depending on condition
2 Kontrolle neuer oder überholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column

6667 4.7.3--01 E 04.00 NR12/RS 102 /02

Maintenance work 4.8

General To keep the exhaust gas turbocharger in a good, reliable condition, it is to

be subjected to inspection and checking at various points and at specific
intervals as specified in the maintenance schedule.

Depending on the special conditions in the engine room, the best way of
disassembly has to be chosen. To perform maintenance and control jobs,
it will in most cases be sufficient to strip subassemblies of the
turbocharger. Dismounting the complete turbocharger from the engine
normally will only be required for basic overhaul.

For basic overhaul of the turbocharger, or for repair work involving

essential components, it is recommended to note down the condition of
the individual subassemblies and to include this information in the engine
operating records. A form sheet ”Check list” (4.8.7 for NR--Turbochargers
or 4.8.8 for NA--Turbochargers) has been enclosed herein as a sample.

Spare parts Wear and damage suffered, specifically if affecting the strength or balance
precision and hence the running smoothness of rotating parts, require
replacement by original spare parts or repair in an authorised repair shop
or at the works. Rotor components sent out for repair have to be
appropriately packed and protected against corrosion to prevent further
damage in transit.

For ordering original spare parts, please refer Volume C3 (Technical

Documentation - Exhaust Gas Turbocharger - Spare Parts Catalogue).

Screwed connections Where screws and nuts cannot be loosened straight away because they
have seized, avoid applying excessive force because the components
might be destroyed in this way and would have to be replaced. It may also
become necessary to bore broken bolts out of casings and to retap the
bored--out threads. Seizures can in most cases be slackened by
lubricating the threads with Diesel fuel oil or low-viscosity special lubricants
(such as Caramba or Omnigliss) and by slightly tapping the bolt head with
a hammer. Such solvents should be applied liberally and allowed to act
upon the bolted or screwed joint for some time (1/2 hour or longer) so that
they will be able to penetrate right down into the threads. The
recommendations issued by the suppliers of such solvents should be
observed.

Screws, nuts and lockwashers used in joints on the turbine side and
exposed to elevated temperatures are made of non-scaling materials. In
order to prevent such non-scaling screws and nuts from being mixed up
with normal ones, they are identified by markings on their face (SM, VM or
4923, Z1 or 4828). During disassembly, such elements should therefore
be put down somewhere separately until being reassembled.
All the lockwasher pairs used on the turbocharger are of non-scaling
material but not marked.

To prevent screws and nuts from sticking, thereby facilitating later

disassembly, screwed connections and seats should be made sure to be
treated with a high-temperature lubricant (such as Molykote HSC) prior to
every reassembly. Before applying this lubricant, clean the threads
carefully. Threads of stud screws remain untreated.

6685 4.8--01 E 03.02 NR, NA 101/ 02

 All the bolted and screwed connections of the turbocharger must be in an
unobjectionable condition on assembly, or replacement is necessary.
Inappropriately tightened and secured screws and nuts may come loose
by vibratory effects and be drawn into the turbocharger by the air or gas
flow, causing severe damage.

When assembling the lockwasher pairs (one pair consisting of 2 identical

washers), make sure that the long wedged surfaces (B) contact each other
(on the inside), otherwise the securing effect will be lost.

6685 4.8--01 E 03.02 NR, NA 102/ 02

Cleaning 4.8.1

Air filter

Air filter mat The air intake opening of the silencer is covered by a air filter mat of high
filtering effect. The silencer, compressor and charge-air cooler are therefore
effectively protected against fouling. To maintain this efficiency, timely
cleaning or replacement of the air filter mat is necessary and is definitely
due when the inside of the air filter mat starts getting dark, a reliable sign
that the absorbing capacity of the air filter mat is exhausted and dirt begins
to appear at the filter. Taking the pressure differential as an indicator is not
reliable because it depends on the rate of air flow as prevailing, which is to
say on the service point and the position in the map.

Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.7.3) and work card (500.11).

Compressor

Cleaning during operation In the case of NR turbochargers, dirt depositing on the blades of the
by injecting water compressor wheel and on the nozzle ring vanes may cause a measurable
loss in efficiency, because of the relatively small dimensions.
We therefore recommend a compressor washing device, especially in cases
of extremely dirt-laden intake air. Freshwater is to be used exclusively. Sea
water and chemical additives and cleansers are not permitted. Cleaning
agents for the charge-air cooler have to be introduced downstream of the
compressor.
Cleaning should be carried out with the engine being at operating
temperature and under full load.

Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.7.3) and work cards (500.08).

Versions available A portable water container with accumulator to be connected to the

cleaning opening on the compressor casing, silencer or air intake casing.

A syringe is provided for small frame sizes such as NR12.

As an alternative, a water tank can be installed at a fixed, easily

accessible point. The tank is to be located not less than 600 mm lower
than the point of injection to avoid that the water is prematurely extracted
by a vacuum in the compressor as the tank is topped up with water. The
air required to draw the water out of the tank should be withdrawn
downstream of the charge-air cooler.

Mechanical cleaning Dirt that has deposited on the compressor wheel, the air diffuser and
compressor volute can be removed during maintenance periods by means
of the steam jet. A further possibility is the soaking in Diesel fuel or other
liquid cleansers and the subsequent brushing off of the dirt deposits.
Chlorous cleaning agents may attack the aluminium alloy (of the
compressor wheel) and must therefore not be used.

6685 4.8.1--01 E 02.02 NR 101/ 02

 It should in each case be avoided that some of the cleaning agent or
dissolved dirt gets into the lube oil system. It is not allowed to use
high-pressure cleaners.

Turbine

Cleaning during operation Depending on the fuel oil grade and the engine operating mode, residues
from combustion may accumulate on the vanes / blades of the nozzle ring
and turbine. The progressing build-up of dirt deposits and the considerable
deterioration of operating performance involved may lead to compressor
surging or to the excitation of dangerous vibrations of the turbine wheel
blades due to uneven fouling of the nozzle ring. Incipient fouling is indicated
by a rising charge-air pressure as a result of the narrower nozzle ring cross
section. The charge-air pressure will drop as fouling proceeds, and the
exhaust gas temperature will rise as a result.
Contrary to the HFO-operated engines, gas engines or engines using gas oil
do not need a cleaning device.

Turbochargers of HFO-operated engines require cleaning at regular intervals

from initial operation onwards.

Cleaning intervals For recommended intervals of cleaning, please refer to the maintenance
schedule (4.7.3) and work card (500.07). Depending on the fuel oil grade
and engine operating mode, other intervals may be appropriate.

Two methods are available for cleaning the turbine during operation:

Wet cleaning The engine has to be brought down to approx. 10 ... 15% output for this
purpose so as to avoid an overloading of the turbine blades (thermo shock).
The medium used for cleaning is freshwater introduced without any
chemical additives upstream of the turbine.

Dry cleaning Granulates of nut shells or activated charcoal (soft) of a grain size of
1 ... 1.5 mm are introduced upstream of the turbine, under normal engine
service load and using compressed air from the board mains.
The engine loading need not be reduced for this purpose.
The cleaning device is designed to introduce the necessary amount of
granulate over a period of 20 to 30 seconds rather than at a time. This will
prevent a sudden speed drop and surging of the compressor, especially
where several turbochargers are operated in parallel.

The required granulate can be ordered by:

MAN B&W Diesel Aktiengesellschaft
Turbocharger Service Dept.
86224 Augsburg, Germany

Mechanical cleaning During maintenance work, severe fouling (such as heavy fuel oil deposits or
oil coke) accumulated on the nozzle ring and turbine wheel can be soaked in
water treated with standard domestic detergents and subsequently brushed
off. If necessary, the process has to be repeated several times. Soaking can
be done in an appropriate vessel over several hours.

It must be made absolutely sure that the water and dissolved dirt cannot
get into the lube oil system.

6685 4.8.1--01 E 02.02 NR 102/ 02

Checking the individual Components 4.8.4

The following notes and questions are intended for guidance, e.g. for

- judging the condition of the turbocharger

- recording engine operating data and preparing checklists
- checking, reusing, repairing and replacing components

Oil coke downstream of the Sealing air bore in the bearing casing clogged
turbine wheel Shaft seal on turbine side damaged
Priming pressure too high

Touching marks over the entire Check of the bearings (refer to work card 500.06)
circumference (turbine rotor, Check of gaps and clearances (refer to sheet 2.5.5)
compressor wheel, inserts)

Touching marks in sections of Signs of imbalance

circumference (turbine rotor,
compressor wheel, inserts)

Crack detection tests on the By acoustic testing or fluorescent dye penetration method
blades (turbine rotor,
compressor wheel)

Gaps and clearances For admissible limits, refer to sheet 2.5.5

Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains solids of small size
(e.g. ”Cat fines”) which have an erosive effect especially at the outlet of
the turbine nozzle ring, where gas velocities and concentrations of these
particles are high. Moreover, there is a very pronounced deflection of the
flow in circumferential direction, and the particles are furthermore subject
to the centrifugal effect.

“Cat Fines” Where do these erosive solid particles come from?

As a result of the refining process, and depending on the quality, heavy
fuel oil contains ”Cat fines”, fine-grained and very hard powdered solids
(indicators are the Al and Si concentrations), and other impurities of
abrasive effect. Amply dimensioned, heated settling tanks and adequate
separation are means to reduce their concentration.

Admixtures Of a particularly negative effect is the admixing of used engine lube oil,
characterised by more-than-normal Ca and Fe concentrations. Used
engine lube oil not only contains wear residues but specifically ”detergent
dispersant additives”. Fine-grained solids are bound by these additives so
that ”Cat fines” and other impurities cannot be extracted by separating.
Much more severe erosion damage is the result of blending the fuel with
”Waste oil”.
Residues from incomplete combustion may also have an erosive effect.
Clean combustion should therefore be ensured.

6685 4.8.4--01 E 04.99 NR 101/ 02

Casings Which casings are heavily fouled by soot, oil or oil coke?
Were the casings tight, especially at the joints and connecting flanges?
Did the casings have cracks?
Had bolts broken off?
Had all the bolts and nuts been firmly tightened and secured?
Were any sealing air or oil ducts in the bearing casing clogged?
Are the seals in order?

Silencer, if provided What is the condition of the air filter mat?

What is the condition of the felt linings?
Have cracks formed on components?

Electronic speed measuring Was the speed transmitter or the speed indicator defective?
device Were the two pole plates on the speed transmitter deformed?

Compressor wheel Are blades affected by cracks or pronounced wear?

Do the blades show impact marks at the leading edge, caused by solid
objects drawn in?
Are traces of touching found?
What is the seat of the compressor wheel?
Is the seating surface bright, or does it show fretting corrosion?

Turbine rotor Have blades been damaged or are blades affected by pronounced wear or
erosion on the edges?
Are blades affected by cracks?
Are any traces of touching found on blades, on the wheel or shaft?
Concentricity of the shaft?
Condition of the bearing points?
Have the labyrinth tips of the locating ring been severly worn?
Are the seating faces bright or do they show fretting corrosion?

Inserts Are there any signs of touching?

Thrust ring, labyrinth ring Are there traces of fretting or pronounced wear?
Are the seating faces bright or do they show fretting corrosion?

Bearings Check the bearings (refer to work card 500.06)

Wear diagonally across on both bearings suggests rotor imbalance.

Sealing cover Does the pattern of labyrinth tip running-in appear normal?

Turbine nozzle ring Are there vanes that have been bent?
Have vanes suffered serious erosive wear?
Have foreign objects got jammed in the ducts?
Are there traces that are indicative of foreign objects?
Are cracks found on the vanes?

6685 4.8.4--01 E 04.99 NR 102/ 02

Check list 4.8.7
Relating to service report of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Name of customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger . . . . . . . . . . . . . . . . . . . . .

Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No. . . . . . . . . . . . . . . . . . . . . . . .
Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type . . . . . . . . . . . . . . . . . . . . . .
Ship’s name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No.. . . . . . . . . . . . . . . . . . . . . . .

Turbocharger inspected / overhauled on . . . . . . . . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Last inspection / overhaul on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. of operating hours since last inspection / overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h
No. of operating hours since commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h

Air intake casing, if provided Compressor casing Turbine rotor

P fouled P fouled P fouled
by . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . .
Silencer, if provided P cracks signs of touching
P damage by foreign object
air filter mat P radial
P replaced Diffuser P over the entire circumference
P in sections of circumference
reason: ................ P used P replaced
P fouled blades
felt linings
by . . . . . . . . . . . . . . . . . . . . . . P bent
P fouled
P with cracks
P wavy P vanes bent
P erosion
P separated P vanes with incipient cracks
P damage by foreign objects
P damage by foreign object
bearing points
Speed transmitter, if provided
Compressor wheel P fretting marks
P defective
P wear
P pole plates deformed P fouled
seating faces
by . . . . . . . . . . . . . . . . . . . . .
Speed indicator, if provided P fretting corrosion
signs of touching
P defective labyrinth tips
P axial
P radial P oil coke
Insert on compressor side P over the entire circumference P wear
P in sections of circumference
P used P replaced
P fouled blades
Labyrinth ring
by . . . . . . . . . . . . . . . . . . . . . P bent
P with cracks P used P replaced
signs of touching
P damage by foreign object P fretting marks
P radial
P over the entire circumference bore P wear
P in sections of the circumference P fretting corrosion P fretting corrosion

6685 4.8.7--01 E 03.02 NR 101/ 02

 Thrust ring Bearing bush turbine side Insert turbine side
P used P replaced P used P replaced P used P replaced
P fretting marks P fretting marks P fouled
P wear P wear P erosion
P fretting corrosion P outside diameter
signs of touching
P inside diameter
Bearing casing P over the entire circumference
P in section of the circumference
P fouled
Sealing cover compressor side
by . . . . . . . . . . . . . . . . . . . . .
P used P replaced Gas-admission casing
P cracks
P abnormal running--in pattern P fouled
sealing air bores P wear
by . . . . . . . . . . . . . . . . . . . . . .
P clogged P cleaned P signs of touching
P cracks
oil bore Sealing cover turbine side
P erosion
P clogged P cleaned
P used P replaced P damage by foreign object
seals
P abnormal running--in pattern screwed connections
P replaced
P wear
P slack
Locating bearing P oil coke P cleaned
P torn off
P used P replaced Cover disc P replaced
P fretting marks P used P replaced
P wear Gas outlet casing
P axial face, compressor side P wear
P oil coke P cleaned P fouled
P axial face, turbine side
P inside diameter by . . . . . . . . . . . . . . . . . . . . .
Bearing bush compressor side Turbine nozzle ring P cracks
P used P replaced P damage by foreign object
P used P replaced
P vanes bent screwed connections
P fretting marks
P vanes with incipient cracks P slack
P wear
P damage by foreign object P torn off
P outside diameter
P erosion P replaced
P inside diameter

P
X please tick the appropriate box

Gaps and clearances, (for admissible values refer to sheet 2.5.5)

Item 1 Compressor wheel / insert (radial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 2 Compressor wheel / insert (axial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 3 Turbine rotor / insert (radial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 4 Turbine rotor / insert (axial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 5 Locating bearing / labyrinth ring (axial clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 6 Face runout, compressor wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

Remarks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6685 4.8.7--01 E 03.02 NR 102/ 02

Service Report 4.8.9

6685 4.8.9--02 E 07.02 NR/S 101/ 01