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Service Bulletin

VTR..4 TurbochargersAfter Sales Service Informationissued by ABB

RL7.218.05.99

(Supersedes BulletinRL-7.1 of 19.09.97)

28.7

6.0

7.4

0PrintedinSwitzerland

Technical Information to all Owners / Operatorsof Sulzer RL Diesel Engines

Wrtsil NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22Wrtsil NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17Wrtsil NSD Suisse SA Switzerland Tlx 896 659 NSDL CH

Contents: Page

1. Introduction 1

2. Contents of Service Information 1

3. Service Bulletins Published for 2Large Bore RLType Engines

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After Sales Service Information 1 / 96 Date: 96-07-26

ABB Turbo Systems Ltd CH- 5401 Baden, Switzerland Page 1 of 1

VTR 454E32 VTR 454-32 STLK16 1 / 96VTR 564E32 VTR 564-32 STLK12VTR 714E32 VTR 714-31 STLK21VTR 714E33

EXTERNAL PROTECTION COVER FOR TURBOCHAR-GERS WITH ONE PIECE E-TYPE COMPRESSORWHEEL AND GREY CAST IRON CASINGS

Field experiences have shown in a very few cases burst of compressor wheels.

Such a compressor wheel burst can be caused by the following reasons:- overspeed- extremly high ambient air temperature- repeated surging

- unusual severe operating conditions which will reduce life time of thecompressor wheel due to creep load and/or low cycle fatigue

In such an exceptional case it could be possible, that parts are ejected in radialdirection from the Turbocharger.

For Turbochargers with one piece E-type compressor wheel according to separatelist, the installation of an external protection cover is necessary for safety reasons.

ABB Turbo Systems Ltd. are prepared to deliver free of charge the required sets of external protection cover from: 96-07-26 for VTR 714...

96-08-16 for VTR 564...96-09-06 for VTR 454...

within one week after receipt of proforma order and delivery address.

ABB Turbo Systems Ltd. strongly recommend to fit the external protection cover as soon as the parts have arrived at site.

The easy fitting of the various parts of the external protection cover has to becarried out by plant staff in accordance with the attached Enclosures 1 and 2.

Serial-nos. of Turbochargers with one piece compressor wheel (of E-, D- or P-type) which are not mentioned in the separate list do not require an external

protection cover because in a further development step they have been equippedfrom the very beginning with gas -and air casings of better material.

In general, the Instructions on safety and hazards (updated version), accordingto attached Enclosures 3 and 4, have to be observed.

Remark

Detailed information hasbeen distributed only toinvolved Servicestations,Engine builders and End-users.

INTRODUCTION

ACTION

OPERATION MANUAL

ABB - Turbochargers

After Sales ServiceInformation

ABB

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After Sales Service Information 4 / 98 (1 / 98 is cancelled by this document) Date: 98-11-23


VTR354-11/A-11 VTR354-32/A-32 4 / 98VTR454-11/A-11 VTR454-32/A-32 VTR454E-32VTR564-11/A-11 VTR564-32/A-32 VTR564E-32

VTR714-32/A-32 VTR714E-32/-33

TURBOCHARGER SPEED / LIFETIME OF THE RO-TOR COMPONENTS / EXPLANATION OF RATINGPLATE

In recent years, advances achieved in engine output, but also requirements fromthe market have led to increased turbocharger pressure ratios and higher turbo-charger speeds. The centrifugal forces acting on rotating parts of the turbocharger have risen considerably.Speed control in turbocharger operations is a key factor for reliable service. For applications at high engine room temperatures and continuous operation approach-ing or meeting full load of the engine, it is necessary to monitor compressor wheellifetime.

Every turbocharger has a rating plate with information concerning the maximumallowable speeds and gas inlet temperatures. These operating limits are explainedin enclosures 1 and 2.Earlier turbochargers have only one limit for the speed ( n max ) whereas those deliv-ered after 1993 have normally two speed parameters ( n Bmax and n Mmax ) on the rat-ing plate. The value for n Bmax is 95% of n max ( resp. n Mmax ).Important: n Bmax is the relevant speed limit for this subject

ABB has developed new techniques to calculate optimal replacement intervals for the rotor parts (i.e. compressor/turbine) in specific applications. The replacementintervals for compressor and turbine are indicated on the rating plate and in theoperation manual. Please refer to enclosures 1 and 2. Replacement intervals were

not included on the rating plates of earlier turbochargers. The turbocharger opera-tion manual or your ABB Service Station can supply you this information.Important: If the turbocharger is operated above n Bmax and the air intake tempera-ture exceeds 35C (95 F) a reduction of the replacement intervals of the rotor components must be expected. For certain applications the turbocharger is speci-fied for higher air intake temperatures.

If the turbocharger is operated above n Bmax or above the specified air intake tem-perature, we recommend you to complete annex A with information about your turbocharger operations and to contact your ABB Service Station for a review.

Analysis of these data by ABB will reveal the impact on the replacement intervalsfor your specific operations. We will gladly relay this valuable information to youwithout delay.

INTRODUCTION

RATING PLATE

REPLACEMENTINTERVALS

RECOMMENDATION

(SUPERSEDING 1/98)

ABB - Turbochargers

After Sales ServiceInformation

ABB

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Operating limits:

n Mmax , t Mmax : Turbocharger - operating limitsat engine overload (110%),For test trials only, if nototherwise agreed with theengine manufacturer.

n Bmax , t Bmax : Turbocharger - operating limitsin service

n = Turbocharger speedt = Exhaust gas temperature before turbine

Replacement intervals for turbochargercomponents:

Replacement interval for the bearings in 1000h

Replacement interval for the compr. wheel in 1000hUnless otherwise stated: 100'000h

Replacement interval for the bladed shaft in 1000hUnless otherwise stated: 100'000h

Further descriptions:

Weight of the turbocharger in kg

Space for the special design designation

Betriebsgrenzen:

n Mmax , t Mmax : Turbolader - Einsatzgrenzen bei Motorberlast (110%),Nur im Prfstandbetrieb,wenn nicht anders mit demMotorenbauer vereinbart.

n Bmax , t Bmax : Turbolader - Einsatzgrenzenim Betrieb

n = Turbolader - Drehzahlt = Abgastemperatur vor Turbine

Wechselzeiten von Turboladerkom-ponenten:

Wechselzeit der Lager in 1000h

Wechselzeit des Verdichters in 1000hOhne Angaben: 100'000h

Wechselzeit der Turbine in 1000hOhne Angaben: 100'000h

Weitere Angaben:

Gewicht des Turboladers in kg

Feld fr die Sonderausfhrungs Bezeichnung

11Leistungsschild Turbolader

made in Switzerland

t Mmax

t Bmax

HT

n Mmax

Typ VTR

n Bmax

H Z T L 4 2 8

P 1

Application according toOperation Manual

ABB Turbo Systems LtdABB Turbocharger

C1s

11Rating plate Turbocharger

kg

Seite / Page 10 ABB Turbocharger VTR..4

Vorbemerkungen Kap. / Chap. 0 Preliminary remarks

10017 ABB Turbo Systems Ltd- D -

Enclosure 1

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Angaben auf dem Leistungsschild

Vorsicht ! Der Turbolader darf nur bis zu den auf demLeistungsschild angegebenen EinsatzgrenzennBmax , t Bmax betrieben werden. Diese sind mitdem Motorenbauer anwendungsspezifischfestgelegt.Einsatzgrenzen n Mmax , tMmax sind, wenn nichtanders vereinbart, nur im Prfstandbetriebzulssig.

Die Wechselzeiten der angegebenen Turbo-laderkomponenten sind unbedingt einzuhalten!Turboladerkomponenten mit abgelaufener Betriebsdauer drfen unter keinen Umstn-den weiter verwendet werden!

Caution ! The turbocharger is to be used only up tothe operating limits specified on the rating

plate n Bmax , tBmax . These are determined withthe engine manufacturer for the specificapplication.Unless otherwise agreed operating limitsnMmax , tMmax are allowed for test trials only.

The replacement times for the turbocharger components specified must be observedwithout fail!Turbocharger components whose permis-sible operating times have expired may not

be used again under any circumstances!

Rating plate information

n MmaxTypType

HT t Mmax

n Bmax

t Bmax

1s[ ]

[C ]

Wechselzeit der Lager Replacement interval for the bearings

Wechselzeit des VerdichtersRepl. interval for the compr. wheel

Wechselzeit der TurbineRepl. interval for the bladed shaft

Angaben in 1000 hDescriptions in 1000 h

Ambient air pressureAir intake temperatureCooling water inlet temp. at charge air cooler

Umgebungsdruck Ansauglufttemperatur

Khlwasser-Eintrittstemp. zum Ladeluftkhler

p 0 = 100 kPa (1 bar)t 0 = 25 C (298 K)tKWE = 25 C (298 K)

Note The conditions agreed with the enginemanufacturer apply to the values stated onthe rating plate with regard to operatinglimits and replacement times. Otherwise theconditions according to ISO 3046/1:

[C ]

[ ]1s

Hinweis Fr die auf dem Leistungsschild angegebe-nen Werte bezglich Einsatzgrenzen, undWechselzeiten gelten die mit dem Motoren-

bauer vereinbarten Bedingungen. Andern-falls die Bedingungen nach ISO 3046/1:

ABB Turbocharger VTR..4 Seite / Page 11

Vorbemerkungen Kap. / Chap. 0 Preliminary remarks

ABB Turbo Systems Ltd 10017- D -

Enclosure 2

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After Sales Service Information 5 / 98 (2 / 98 is cancelled by this document) Date: 98-11-23


VTR354-11/A-11 VTR354-32/A-32 5 / 98VTR454-11/A-11 VTR454-32/A-32VTR564-11/A-11 VTR564-32/A-32

VTR714-32/A-32

ADDITIONAL INFORMATION CONCERNING SAFETYPRECAUTIONS FOR TURBOCHARGERS

with two piece compressor wheels

with grey cast iron casings delivered ex works (Baden/Switzerland) before

Feb.1997

Field experience has shown that critical operating conditions may occur if the defined values/limits stated in the operation manuals are not strictlyobserved.In rare cases, this could lead to irregular situations, for example acompressor wheel burst.

Such critical situations could arise due to: Overspeed: T/C-speed > n Bmax

Overspeed can be caused by operating the turbocharger under ab-normal or unforeseen conditions, as well as by operations beyond theinitial specification limits.

Continuous surging at high engine load Air intake temperature to turbocharger higher than 35 C (95 F) if

not otherwise specified

Therefore, compliance with the operating instructions and safety

precautions defined in the operation manual (see enclosures 1 and2) is essential.

If there is any doubt on the part of the engine manufacturer or the operator/owner of the turbocharger that prevailing operating conditions could, infact, create a critical situation, provision of an external protection cover would be an additional precaution measure.

ABB Turbo Systems Ltd is prepared to supply all necessary drawings andinstructions required to manufacture and install such an external protectioncover. Alternatively, ABB Turbo Systems Ltd. can assist you in purchasingthis additional safety item.

For further assistance, please contact your ABB Service Station.

INTRODUCTION

RECOMMENDATION

(SUPERSEDING 2/98)

ABB ABB - TurbochargersAfter Sales ServiceInformation

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Enclosure 2 Seite / Page 8 ABB Turbocharger

Sicherheits- und Gefahrenhinweise Kap. / Chap. 1 Instructions on safety and hazards

10002 ABB Turbo Systems Ltd- B -

Protective measures

- Wear leather protective gloves

- Wear close-fitting protective clothing- Tie up long hair and beards, wear hair protection

- Wear face and eye protection

- Wear protective shoes

- Keep floor, equipment and the turbocharger clean

- Ensure the availability of oilabsorbing materials andhave oil collector basins ready or in position

- Eliminate leaks

- Do not stay neither close nor radially to theturbocharger while engine is running at > 85% ratedoutput.

3.2

Operation andprocess materials

This includes all substances such as oil, grease, coolant,detergents and solvents, acids and other hazardoussubstances.

Physical injury and damage to property

Warning ! Allergies, skin disease, unconsciousness,poisoning or nausea after inhalation

Injury by scalding and burning of the skin

Burning by vapours or contact with acidsor alkalis

Schutzmglichkeiten

- Leder-Schutzhandschuhe tragen.

- Eng anliegende Schutzkleidung tragen.- Lngere Bart- und Kopfhaare zusammenbinden, Haar-

schutz tragen.

- Gesichts- und Augenschutz tragen.

- Sicherheitsschuhe tragen.

- Boden, Gerte und Turbolader sauberhalten.

- labsorbentien bereithalten und lauffangwannen be-reitstellen oder aufstellen.

- Leckagen beseitigen.

- Aufenthalt nahe oder radial neben dem Turbolader bei Betrieb > 85% Motorlast ist zu vermeiden.

3.2Werk- undArbeitsstoffe

Das sind chemische Substanzen wie le, Fette, Khl-flssigkeit, Reinigungs- und Lsungsmittel, Suren undandere Gefahrenstoffe.

Krper- und Sachschden

Warnung ! Allergien, Hautschden, Bewusstlosigkeit,Vergiftung oder Benommenheit nach Ein-atmen.

Verletzungen durch Verbrhen und Ver-brennen der Haut.

Vertzungen durch Dmpfe oder Sure-und Laugenkontakt.

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VTR..4 6 / 98 All series (except VTR 714)

Introduction of advanced types of compressor-endantifriction bearings LA36 for all types of VTR..4turbochargers(LA37 with vibration monitoring)

The new antifriction bearing is made of a special material, resistant to heat and

wear, with double-side guided, high-strength steel ball retaining cages. Thedevelopment of this bearing was accomplished in very close cooperation with our bearing supplier.The first LA36 bearings were installed in early 1996. This new bearing generationhas performed excellently, proving outstanding reliability. Based on these results,

ABB has decided to discontinue the LA34 and introduce the new bearing generationas standard supply for all production turbochargers and field service operations(exception: VTR714 only with LA70).

New generation antifriction bearings: LA36

INTRODUCTION

NOTE !

The new LA36 bearing induces a slight increase in oil temperature at the givenoperating point. This is due to the improved heat exchange achieved by the newbearing geometry. A higher lubrication oil temperature causes the oil to age faster,often accompanied by rapid discoloration of the oil. It is therefore recommendedthat a lubrification oil of the latest generation (e.g. synthetic oil) be used with thenew bearings. Any ABB Service Station will gladly provide you with updatedinformation regarding the most suitable oil types.

previous: LA34 new: LA36

ABB ABB - TurbochargersAfter Sales ServiceInformation

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