CIAC - 3 - Operation & Maintenance

 

   & &  n  n     & &  n   o o  e  e   i o  a  n  c  e  r     t  t   i  e  r    a     t a  t  n  a  n  c  p    e e  p    e e   t   t  O  O  M    i   i   n   M  a   i i n  nn    a ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Indication of Replacement Intervals on VTR..4 Turbocharger Rating Plates today

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Example: 12 / 50 / -

Replacement intervals (in 1'000h) for  Replacement (3) bearings (4) compressor wheel (5) shaft with turbine blades ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Indication of Maximum Operating Limits on VTR..4 Turbocharger Rating Plates today

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Maximum T/C speed [rps] & max. exhaust temp. [°C]: (1) max. allowed speed: nMmax & temp. before TC: tMmax  (including max.10h at 110% for test bed & acceptance runs only)

(2)  max. operating limits in service (at MCR): nBmax , tBmax (2) ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Today's rating plate with further inscriptions

(6) customer part-number (e.g. from Caterpillar) (7) designation of special design (e.g. SWEL08) (8) weight of T/C [kg] ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Maintenance Recommendation Routine Maintenance

   t    t   s   s    i    i    l    l   a   a    i    i   c   c   e   e   p   p    S    S    C    C    /    /    T    T    B    B    B    B    A    A

Compressor Cleaning

Turbine Cleaning

Oil change

Standard Standard   Overhaul Overhaul

Extended Overhaul

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

Bearings exchange

Pumps exchange

(Rotor  balancing)

Oil change

Dismantling -Assembly

Inspection - Cleaning

Rotor  balancing

Part(s) exchange

   f    f    f    f   a   a    t    t    S    S   r   r   e   e   m   m   o   o    t    t   s   s   u   u    C    C

ABB

 

Lists of Approved Lubricating Oils Mean oil  temperature o

Cooling water  temperature  Air inlet  outlet temp.

C ( oF)

C ( oF)

o

o

PERIOD OF OIL CHANGES (hours)

C ( oF)

List 1

List 2

List 3

< 110 (230)

< 90 (194)

< 40 (104)

1’000

3’000

5’000

< 120 (248)

< 100 (212)

< 55 (131)

500

1’500

2’500

< 130 (266)

< 110 (230)

750

1’250

List List11 : :

Mineral Mineraloils oils

List 2a : : List2a List List2b 2b : :

Special Specialmineral mineraloils oils Special Specialsynthetic syntheticoils oilsfor forhighly highlyloaded loadedT/Cs T/Cs

List List3a 3a : : List List3b 3b : :

Synthetic Syntheticoils oils Special Specialsynthetic syntheticoils oilsfor forhighly highlyloaded loadedT/Cs T/Cs

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Special Approval for Lubricants Entered in Lists 2 and 3  Synthetic oils:

'Stirring Ageing Test', developed by ABB, simulates the oil ageing process in a turbocharger with ball and roller bearings.  Special synthetic oils for highly loaded T/Cs:

Additional testing in a real turbocharger with bearing temperature measurement.

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Oil Testing Equipment Viscometer 

 Analyser 

Stirring Ageing Test

Titrator 

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

ABB

 

Special Synthetic Oils for Heavily Loaded Turbochargers 

VTR..4P, VTR..4P,VTR..4D, VTR..4D,VTR..4E VTR..4E



VTR..4: VTR..4:ififthe the permissible permissiblespeed speedat at100% 100%load load exceeds the values specified in the table and/or exceeds the values specified in44the table and/or the ratio exceeds thecompression compression ratio exceeds VTR

184 214 254 304 354 454 564 714

nBmax [rps] >

726 611 514 433 364 289 230 183

e.g. BP Enersyn TC-S 68, Castrol Aircol SR 68, Elf Barelf SM 68, Esso Compressor Oil RS 68, Mobil Rarus SHC1026, Shell Corena AS 68,... ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

ABB

 

Cleaning in Operation e.g. 2-stroke engine temperature

   d   n   a

 .   e   r   p   u   m   s   t   s   e   e   r   s   p   a   g   g   t   n   s    i   u   g   r   a   a   h    h   x   c   e

as new condition  pressure

without cleaning    g   n    i   n   a   e    l   c  .    1

  g   n    i   n   a   e    l   c  .    2

  g   n    i   n   a   e    l   c  .    3

  g   n    i   n   a   e    l   c  .    4

  g   n    i   n   a   e    l   c  .    5

   l   u   a    h   r   e   v   o

time

Regular cleaning improves/maintains the performance between overhauls ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

ABB

 

Cleaning Frequency in Operation? Parameters Fuel Ambient Conditions

Load Profile

Cleaning Frequency ? 2...20 days / 1...2 days

Engine Condition

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

Cleaning Efficiency

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Water Cleaning Procedure Summary  Frequency: 2 to 2 to 20 days  By start of the journey and not n ot before

switching off the engine  Reduce engine load: - temperature before turbine / start of cleaning  

( in in brackets: values during cleaning)   T < 430 o C - boost pressure > 0.3 bar

( < 500o C  ) ( > 0.2 bar)

 Stabilisation time: 5 to 10 min  Cleaning time: 5 to 10 min

- quantity in accordance with instruction, make sure that water is injected!  - possibly the return of water

use only fresh water without additives!

 Drying time: 5 to 10 min

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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Dry Cleaning Procedure Summary 

Frequency:  1 to 2 days



Exhaust gas temperature before turbine: < 590 O   C 



Boost pressure: > 0.5 bar 



Granulated Materials: natural core granules, soft blast media or activated charcoal particles (diameter 1,2-2 mm)



Quantity: depending on T/C size



Air supply pressure: 5-6 bar 



Injection time: 30-60 sec .

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

ABB

 

Turbine Cleaning Methods Comparison Wet Cleaning  Exhaust gas temperature

before turbine : T < 430 o C   Boost pressure > 0.3 bar   Material: Fresh water  

without additives

Dry Cleaning  Exhaust gas temperature before

turbine : T < 590 o C   Boost pressure > 0.5 bar    Materials: natural core granules

soft blast media or activated charcoal particles (Ø1,2-2 mm)  Cleaning frequency :

 Cleaning frequency :

every 1 to 2 days

every 2 to 20 days

Cleaning by mechanical abrasion Cleaning by thermal shock on deposits and mechanical abrasion ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

ABB

 

Compressor Cleaning in Operation  Regular Regularcleaning cleaningin inoperation operation

extends extendsthe thetime timebetween between overhauls overhauls  Frequency: Frequency: 11to to33days days  Engine Engineat at full fullload. load.

turbocharger turbochargerat at full fullspeed  speed 

 Pure Purewater wateronly  only   Injection Injectiontime time44... ...10 10sec sec

ABB Turbochargers Code —H:\Powerpoint\CIAC_3_Operation& Maintenance /1999.09.01 /Hä

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