RRcompressorpressureratioPublicationNo.CH-Z200903E,PrintedinSwitzerland(0301-5000-0),2003ABBTurboSystemsLtd,Baden/SwitzerlandVTRTheClassicABBTurbochargers

TheVTRturbochargerisdesignedfor2-strokelow-speedand4-strokemedium-speedheavydutydieselengines(700to18,500kWperturbocharger).

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VTRTheClassicProductInformation

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3103

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enginepower

ABBTurboSystemsLtdBruggerstrasse71aCH-5401Baden/SwitzerlandPhone:+41585854037Fax:+41585855144

www.abb.com/turbocharging

www.abb.com/turbocharging

VTRTheClassic

Provenreliabilityovertheyears

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toalargeextent,meetcurrentdemandsforsavingsinfueloilconsumption,increasedoutput,unproblematicoperationofshipsatpart-loadandtheuseofheavyfueloil.

Inadditiontowater-cooledgascasings,un-cooledgascasingscanbesuppliedfortheVTR..4rangeofturbochargers.AsaresultoftheintensiveresearchundertakenbyABBinthefieldsofthermodynamicsandaero-dynamics,ABBturbochargersalwaysrepresentaveryhighstandardofpressure-charging,aswidelyrecognized.ThewellestablisheddesignoftheVTRturbocharger,aswellasitsex-tremelyrobustconstruction,offermajoradvan-tagestoboththeenginebuildersandusers.

Inexhaust-gasturbocharging,theenergyin

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IntheVTRturbocharger,exhaustgasfromtheengineflowsthroughthegasinletcasing(1),andexpandsinthenozzlering(2).Itimpartsenergytothebladesoftheturbinerotor(3),andthenpassesviagasoutletcasing(4)andanexhaustpipetotheatmosphere.Theairrequiredbytheengineisdrawnthroughasuc-tionpipeorcombinedfilter-silencer(5)tothecompressor(6).Itthenflowsthroughthediffuser(7)andfinallyleavestheturbochargerviathevoluteofthecompressorcasing(8).

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ABBturbochargershavebeenmanufactured

TheVTRassortmentcomprisesturbochargers

theexhaustgasesfromtheengine(dieselor

since1944inarangeofstandardmodels.Therangeofapplicationoftheseturbochargersongasanddieselenginesextendsfromaratingof700kWtoabout18,500kWperturbocharger.

ThedesignoftheABBturbochargerwithexternalbearingshasproveditsworthmanythousandtimesoverfromthepointofviewofthemainfieldsofapplication,i.e.marine

oftherangeVTR..4.Theenginedesignerisabletocallonsinglestageturbochargerswhich,

gas)isusedtocompresstheairfedtotheengine,resultinginincreasedpoweroutput.

Therotorrunsinspring-mountedrolling-contactbearings,whicharereadilyaccessibleatbothendsoftherotor.Eachbearinghasitsownlubricatingandoilcoolingsystem.

ThecompressorsectionofallVTRturbo-chargersisfittedwithaconnectorsothecompressorcanbecleanedduringoperationbymeansofwaterinjection.

propulsionengines,especiallyatpart-load,stationaryinstallationsforpowergeneration,unitsburningheavyoil,continuousoperationundersevereconditions,useonmedium-speedtwo-andfour-strokeengines.

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Designfeatures

Bearingsandlubrication

NewbearingsupportforVTR454,564,714LA70/TA07hasbeenintroducedtohandlehigherperformanceandvibrations.

ExternalbearingsInmostapplicationsformediumandlargeturbochargers,externalbearingsofferimportant

BearingsandlubricationsystemABBrecommendstheuseofself-lubricatingantifrictionbearings.Thereducedfriction

BearingsupportcompressorsideVTR454

Table1Bearingdesignstandarddesignself-lubricatingonrequest:sleevebearingsantifrictionbearingswithexternallubricationalltypesVTR454,564,714

Table2OilsupplyforcentrifugaloilpumpstandardgearoilpumprollerbearingVTR214,254,304,354VTR454,564

benefits.Theyarereadilyaccessible,whichsimplifiesandspeedsupservicing.Thebear-ingscanberemovedwithoutdismantlingthecompressorwheel,eliminatingthestrenuousphysicaleffortrequired,especiallywithlargeshaftweights.Andtherotorshaftscanberemovedwithoutdismantlingtheairandgaspipes.

Theuseofexternalbearingsresultsinlowerbearingforces,andpermitstheuseofself-lubricatingantifrictionbearings.Sleevebearingswithexternallubrication(enginelubrication)areavailableasanalternativeforlargerturbo-chargertypes(seetable1).

Anyimbalanceoftherotorshaftcausedbycontaminationorforeignparticlesisabsorbedbydampingspringassembliesinthebearings.Inthiscontext,thelowerbearingforcesasso-ciatedwithexternalbearingsareadistinctadvantage.

ofthistypeofbearingsprovidesahighermechanicalefficiency,andofferssignificantadvantageswhenstartinguptheengineandduringmanuvring.Afurtherbenefitistheabilityofthistypeofbearingtowith-standshort-termoilfailure.

Oilcentrifugesintheclosedlubricationsystemoftheantifrictionbearingseparateoutanydirtparticles,andensureconstantlubricationwithpurelubricatingoil,eveninaninclinedposi-tion.Theturbineoilusedhasapositiveeffectonservicelife.

Theoilpumpsmentionedintable2areused.Sleevebearingswithexternallubrication:Althoughsleevebearingswithexternallubrica-tionareavailable(seetable1),thesenormallyinvolveconsiderablyhighercosts,particularlyforlargechargers.Separateoilfilteringsystemsandastandbytankforemergencylubricationmustbeprovided.

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Designfeatures

Casingsandcooling

GasinletcasingAlargeselectionofcasingvariantsisavailable,withdifferentnumbersandarrangementsofgasinlets.Thisallowsconsiderableflexibilityinthematchingofthechargertovariouschargingsystems,enginetypes(veeorin-line),andnumbersofcylinders.Uncooledcasingsareavailableasanalternativetothewater-cooledcasingonVTR..4turbochargers.Theyareused

GasandaircasingsThegasinlet,gasoutletandcompressor

incaseswhereheatrecoveryisessential.

Sectionthroughwater-cooledVTRturbochargerSectionthroughuncooledVTRturbocharger

casingsaresplitverticallyandboltedtogether.Thethreecasingsandthesupportscanbeturnedwithrespecttooneanotherinincrementsof15or30degrees,togivetheenginedesignerthemaximumfreedominthemountingofthechargertotheengine.

Table3Uncooled/cooledgascasingsTypeuncooledcooledVTR214

ConceptoftheuncooledVTRturbochargerThegasinletductsofthisdesignareentirelyuncooledandarenotincontactwithcoolingwateratanypoint.Thegreatestpossibleamountofheatisthereforemadeavailableforfurtherutilization.

Intheinterestoffunctionalreliability,thebearinghousingontheturbineendiscooledwithsmallamountofwaterandthetempera-

AirintakeTheairtobecompressedisdrawninthrougheitherairsuctionbranchesorfiltersilencer.

Anintegralpartofeverysilencerisafilterwhichinterceptscoarsedirtparticlesfromtheintakeair,andcounteractscompressorcontam-ination.Thefiltercanbecleanedduringopera-tionwithouthavingtodismantlethesilencer.

VTR254VTR304VTR354

tureofthelubricatingoilistherebykeptlow.

Thecompressornoiseisreducedinline

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VTR454VTR564VTR714

Variantsofgasinletcasings

Thesimultaneouscoolingofthejacketofthegasoutletcasingmakesitpossibleforthetem-peratureoftheentiresurfaceofthecasingtobekeptwithinthelimitsstipulatedbytheclas-sificationsocietiesforpreventionoffireandprotectionagainstaccidentalcontact.

withinternationalregulationsbymeansoffelt-covered,shapedplates.

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VTR214PVTR254PVTR304PVTR454PVTR454VTR454DVTR564PVTR564VTR564DVTR354PVTR304compressorpressureratioatMCRVTR354VTR714VTR714DVTR214VTR254Designfeatures

Powerrange

AiroutletcasingGasoutletcasing

Gasinletcasing

Turbineandcompressor

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VTRturbochargersarefittedwithsingle-stage4.5axialturbinesandradialcompressors.The

combinationofvariousturbinebladeheightswithalargenumberofguidevanevariants(nozzlerings),aswellasdifferentcompressorwheelwidthsandavarietyofcorrespondingdiffusers,affordsoptimummatchingof

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enginesandturbochargeroperating

151020

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Airfilter-silencer

RemovaloftherotorshaftWithVTRturbochargersthereisnoneedtodisconnectanyair,gasorwaterpipesincaseswheretherotorshaft,thenozzleringsordiffusershavetoberemoved.

characteristics.

AirinletcasingDiffuser

intakevolumeflow

ThetableshowsthecapacityrangesofthevariousVTRturbochargers,andcanbeusedasaninitialselectionguidetoidentifytheoptimumchargersizeforaparticularengine.

Beforetheturbochargercanbepreciselyspecified,therewillofcoursebeotherfactorssuchastheturbineblades,guidevanesandcompressorwheelvariantstobeconsidered.Thisisanareawhereonlyclosecollaborationwithtrainedandexperiencedturbocharger

Therotorshaftcanbewithdrawninfoureasysteps.Afterdismountingthefilter-silencerorthesuctionbranchattheairintake,thebear-ingsareremoved.Thentheairinletcasingandtheheatinsulatingpartitionwallaredis-connectedfromthegascasingandtherotorassemblycanthenbewithdrawn.

InducerImpeller

PartitionwallNozzlering

specialistsofABBTurboSystemsLtdwillensuretheoptimumsuperchargingsolution.

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Turbinewheel

VTR..4-11ABA+BCA+CDEDE+/2kg*Waterl/sOill/minVSTS214403613101667010736493316563502.400.900.60254479722120179712767683947785703.101.251.05304558870142896015189204689288204.102.001.4835463910131652112617651095556110417005.402.201.6645480512702075141622211374700138732507.504.353.625641014158425981767278117128701726650011.308.807.53714122520313256224434692190110922041250016.3018.0015.60VTR..4-32ABA+BCA+CDEDE+/2kg*Oill/minVSTS454D-3279712662063141222091464700143235404.353.62564D-32101015812591177527851802870177167008.807.53714D-32126120263287223935002280110922491300018.0015.60MaindimensionsMajorbenefits

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Fortheenginemanufacturer

Closecollaborationwiththeworld-widedieselengineindustrygivesABBatremendouswealthofexperienceinevery

Fortheengineuser

VTRturbochargersgivehighreliability,andaredesignedforthelifeoftheengine.

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aspectofsupercharging.

Precisemanufacturingtolerancesenable

sparepartstobeinstalledwithouttheneed

AcontinuingprogramofdevelopmentandtestingworkensuresthatABBturbochargersarealwaysintheforefrontoftechnology.

Acomprehensiveandconfidentialcon-sultancyserviceisavailable,rightfromthe

forre-machining.

Externalbearingsareeasytomaintain.Therotorshaftcanberemovedwithoutdis-mantlingthegasmanifolds,orpullingofthecompressorwheels.

*notincludingwater(withwateraddapprox.5%)VS=bearingcompressorsideTS=bearingturbineside

earlieststagesofnewprojects.

Lowfrictionlossesoftheexternalantifriction

ThemodularconceptoftheVTRturbo-charger,withvariouscasingconfigurations,

bearingsaffordoptimumoperatingper-formanceofenginesinpart-loadoperation.

*notincludingwater(withwateraddapprox.5%)VS=bearingcompressorsideTS=bearingturbineside

turbineblades/nozzleringsandcompressor

wheels/diffusers,ensurestheoptimum

Connectorsonthecompressorsideallow

Theprincipalspacerequirementsandattach-mentconfigurationsontheenginecanbedeter-minedfromtheoveralldimensionsshowninthetable.DetaileddimensionaldatashouldbetakenfromthedrawingsABBTurboSystemsLtdprovideforeachsizeofturbocharger.

becauseoftheirbetterresistancetoageing.Ifsyntheticoilsareused,thelifetimecanbeincreasedupto3000hours(dependingonturbochargersizeandapplication).Viscosityrangesvaryaccordingtooperatingconditions,andprecisedetailsaregivenintheoperating

matchwithalltypesanddesignsofengines.

AnintegratedlubricationsystemoftheVTRturbochargerseliminatestheneedforaseparatelubricationsystem,withitspipingfilters,oiltanksandsafetyfeatures

watercleaningduringoperation.

Anexperiencedtechnicalteamisavailabletooffersupportinallaspectsofoperation.

Aworld-widenetworkofservicestations

Alsoindicatedaretheoilflowsrequiredon

instructions.

Withtheirexternal,antifrictionbearings,

offers24-hourserviceavailability.

thecompressorandturbinesectionsforself-lubricationoftheantifrictionbearings.

Themaximumrequiredcoolingwaterflowsgiveninthedataarebasedonagastempera-tureattheturbineinletof600degreesC,

theVTRturbochargerscanmakeamajorcontributiontoimprovedpoweroutputandefficiency.

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Theoilmustbechangedafter5001000hoursofoperation,dependingontheoilqualityinuseandtheworkcycle.Turbineoilsarepre-ferredtoengineoils(particularlyengineoilswithadditivesforheavyfueloiloperation),

andacoolingwatertemperatureattheinletof65degreesCforbothgascasings.Theex-haustgastemperatureassociatedwith2-strokeengineswouldnormallycallforwaterflowsofabouthalfthesefigures.

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