Service Bulletin

VTR..4 Turbochargers
After Sales Service Information
issued by ABB
RL7.2
18.05.99
(Supersedes Bulletin
RL-7.1 of 19.09.97)
2
8
.
7
6
.
0
7
.
4
0

P
r
i
n
t
e
d

i
n

S
w
i
t
z
e
r
l
a
n
d
Technical Information to all Owners / Operators
of Sulzer RL Diesel Engines
Wrtsil NSD Switzerland Ltd PO Box 414 Tel. +41 52 262 49 22
Wrtsil NSD Schweiz AG CH-8401 Winterthur Fax +41 52 212 49 17
Wrtsil 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 2
Large Bore RLType Engines
RL Engines
RL Engines
1 / 2 Service Bulletins RL-7.2
1. INTRODUCTION
You have received through us several After Sales Service Information leaflets issued by ABB
Turbo Systems Ltd, Baden as enclosures to the Service Bulletin RL-7 or 7.1.
We have actually passed on this After Sales Service Information as well as some
Manual-Modifications to the customers of Wrtsil NSD Switzerland Ltd acting as the
emissary only with the aim of directing the news to our customers which have the turbochargers in
question installed on their Sulzer engines.
However, in consultation with ABB we will end this practice with this Service Bulletin as
ABBTurbo Systems Ltd has established a distribution channel through their own Network.
Thus this Service Bulletin RL-7.2 will be the last issue on the captioned subject.
This Service Bulletin should be kept in a separate file in the control room. The respective pages or tables
of the Service Bulletin with modifications to the Operating Manual, Maintenance Manual or Code
Book should be copied and filed in the respective Manual or Book.
2. CONTENTS OF SERVICE INFORMATION
No.
Turbocharger
Type(s)
Series Title
1/95
1)
VTR 454 / 564
VTR 714
Introduction of advanced types of bearings
and centrifuges for VTR..4 turbochargers
3/95
1)
VTR 564
Introduction of an advanced gear oil pump
for VTR 564 turbochargers
1/96
VTR 454 / 564
VTR 714
External protection cover for turbochargers
with one piece Etype compressor wheel
and grey cast iron casings
5/96
1)
VTR 714
New rotor support for VTR 714
turbocharger
1/97
1)
VTR 184...714 Oil discolouration in service
-
1)
VTR 184...714 Lubricating oil list
2/98
VTR 454
VTR 564 / 714
Safety precautions for turbochargers with
two piece compressor wheels
3/98 VTR 184...714 Lubricating oil for turbochargers
4/98
Supersedes
1/98
VTR 454
VTR 564 / 714
Turbocharger speed / Lifetime of the rotor
components / Explanation of rating plate
5/98
VTR 454
VTR 564 / 714
Additional information concerning safety
precautions for turbochargers
6/98 VTR ..4
All series
(except VTR 714)
Introduction of advanced types of
compressorend bearings LA36 for all
types of VTR ..4 turbochargers
1)
Was already contained in Service Bulletin RL-7 or RL-7.1 and is not enclosed again in this
Service Bulletin.
RL Engines
2 / 2 Service Bulletins RL-7.2
This Service Bulletin has been prepared to the best knowledge and ability of its authors. However,
Wrtsil NSD Switzerland Ltd has to rely on the input data furnished by ABB Turbo Systems Ltd.
Wrtsil NSD Switzerland Ltd cannot warrant the correctness of this data. Neither Wrtsil NSD
Switzerland Ltd nor their employees assume any liability under any legal aspect whatsoever in
connection with this Service Bulletin, its contents, or modifications to it or in connection with its use,
including possible negligence.
Further, claims relating to any damage whatsoever or claims of other nature such as e.g. demands for
additional spares supplies, service or others will not be considered.
Changes of any nature to the form and or to the content of this or any other Service Bulletin as published
by Wrtsil NSD Switzerland Ltd, are not permitted.
3. SERVICE BULLETINS PUBLISHED FOR RL-TYPE ENGINES
We have so far published the following Service Bulletins which are valid for RL-Type Engines (RL 56 to RL 90):
RL-1.1 dated 21.09.87 Corrosion in Bore Cooled Cylinder Covers
RL-2 dated 15.09.83 Fuel Nozzles
RL-3.1 dated 21.01.99 Recommendations Concerning Piston Running Performance
RL-4.1 dated 24.01.91 Modification of Cylinder Cover Studs
RL-5 dated 25.01.89 Water Drain from Charge Air Receiver and Charge Air Temperature
RL-6 dated 28.10.94 Oil Supply Monitoring for Geislinger Torsional Vibration Damper
RL-7.2 dated 18.05.99 VTR..4 Turbochargers After Sales Service Information issued by ABB
Should you not be in possession of the above mentioned documentation suitable for your plant, kindly contact your
local Wrtsil NSD representative for your copy.
Enclosures: ABB-After Sales Service Information 1/96
ABB-After Sales Service Information 2/98
ABB-After Sales Service Information 3/98
ABB-After Sales Service Information 4/98
ABB-After Sales Service Information 5/98
ABB-After Sales Service Information 6/98
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 / 96
VTR 564E32 VTR 564-32 STLK12
VTR 714E32 VTR 714-31 STLK21
VTR 714E33
EXTERNAL PROTECTION COVER FOR TURBOCHAR-
GERS WITH ONE PIECE E-TYPE COMPRESSOR
WHEEL 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 the
compressor wheel due to creep load and/or low cycle fatigue
In such an exceptional case it could be possible, that parts are ejected in radial
direction from the Turbocharger.
For Turbochargers with one piece E-type compressor wheel according to separate
list, 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 be
carried 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 equipped
from the very beginning with gas -and air casings of better material.
In general, the Instructions on safety and hazards (updated version), according
to attached Enclosures 3 and 4, have to be observed.
Remark
Detailed information has
been distributed only to
involved Servicestations,
Engine builders and End-
users.
INTRODUCTION
ACTION
OPERATION MANUAL
ABB - Turbochargers
After Sales Service
Information
ABB
After Sales Service Information 4 / 98 (1 / 98 is cancelled by this document) Date: 98-11-23
ABB Turbo Systems Ltd CH- 5401 Baden, Switzerland Page 1 of 1
VTR354-11/A-11 VTR354-32/A-32 4 / 98
VTR454-11/A-11 VTR454-32/A-32 VTR454E-32
VTR564-11/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 RATING
PLATE
In recent years, advances achieved in engine output, but also requirements from
the 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 wheel
lifetime.
Every turbocharger has a rating plate with information concerning the maximum
allowable speeds and gas inlet temperatures. These operating limits are explained
in 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 replacement
intervals for compressor and turbine are indicated on the rating plate and in the
operation 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 intervals
for your specific operations. We will gladly relay this valuable information to you
without delay.
INTRODUCTION
RATING PLATE
REPLACEMENT
INTERVALS
RECOMMENDATION
(SUPERSEDING 1/98)
ABB - Turbochargers
After Sales Service
Information
ABB
Operating limits:
n
Mmax
, t
Mmax
: Turbocharger - operating limits
at engine overload (110%),
For test trials only, if not
otherwise agreed with the
engine manufacturer.
n
Bmax
, t
Bmax
: Turbocharger - operating limits
in service
n = Turbocharger speed
t = Exhaust gas temperature before turbine
Replacement intervals for turbocharger
components:
Replacement interval for the bearings in 1000h
Replacement interval for the compr. wheel in 1000h
Unless otherwise stated: 100'000h
Replacement interval for the bladed shaft in 1000h
Unless 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 dem
Motorenbauer vereinbart.
n
Bmax
, t
Bmax
: Turbolader - Einsatzgrenzen
im Betrieb
n = Turbolader - Drehzahl
t = Abgastemperatur vor Turbine
Wechselzeiten von Turboladerkom-
ponenten:
Wechselzeit der Lager in 1000h
Wechselzeit des Verdichters in 1000h
Ohne Angaben: 100'000h
Wechselzeit der Turbine in 1000h
Ohne Angaben: 100'000h
Weitere Angaben:
Gewicht des Turboladers in kg
Feld fr die Sonderausfhrungs Bezeichnung
11
Leistungsschild 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 to
Operation Manual
ABB Turbo Systems Ltd
ABB Turbocharger
C
1
s
Q
R
S T U
V
W
Q
R
Q Q
R R
S
T T
U U
V
V
W
S
11
Rating plate Turbocharger
kg
W
Seite / Page 10 ABB Turbocharger VTR..4
Vorbemerkungen Kap. / Chap. 0 Preliminary remarks
10017
ABB Turbo Systems Ltd
- D -
Enclosure 1
Angaben auf dem Leistungsschild
Vorsicht ! Der Turbolader darf nur bis zu den auf dem
Leistungsschild angegebenen Einsatzgrenzen
n
Bmax
, t
Bmax
betrieben werden. Diese sind mit
dem Motorenbauer anwendungsspezifisch
festgelegt.
Einsatzgrenzen n
Mmax
, t
Mmax
sind, wenn nicht
anders vereinbart, nur im Prfstandbetrieb
zulssig.
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 to
the operating limits specified on the rating
plate n
Bmax
, t
Bmax
. These are determined with
the engine manufacturer for the specific
application.
Unless otherwise agreed operating limits
n
Mmax
, t
Mmax
are allowed for test trials only.
The replacement times for the turbocharger
components specified must be observed
without fail!
Turbocharger components whose permis-
sible operating times have expired may not
be used again under any circumstances!
Rating plate information
n
Mmax
Typ
Type
HT
t
Mmax
n
Bmax
t
Bmax
1
s
[ ]
[C]
Wechselzeit der Lager
Replacement interval for the bearings
Wechselzeit des Verdichters
Repl. interval for the compr. wheel
Wechselzeit der Turbine
Repl. interval for the bladed shaft
Angaben in 1000 h
Descriptions in 1000 h
Ambient air pressure
Air intake temperature
Cooling 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)
t
KWE
= 25 C (298 K)
Note The conditions agreed with the engine
manufacturer apply to the values stated on
the rating plate with regard to operating
limits and replacement times. Otherwise the
conditions according to ISO 3046/1:
[C]
[ ]
1
s
Hinweis Fr die auf dem Leistungsschild angegebe-
nen Werte bezglich Einsatzgrenzen, und
Wechselzeiten 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
After Sales Service Information 5 / 98 (2 / 98 is cancelled by this document) Date: 98-11-23
ABB Turbo Systems Ltd CH- 5401 Baden, Switzerland Page 1 of 1
VTR354-11/A-11 VTR354-32/A-32 5 / 98
VTR454-11/A-11 VTR454-32/A-32
VTR564-11/A-11 VTR564-32/A-32
VTR714-32/A-32
ADDITIONAL INFORMATION CONCERNING SAFETY
PRECAUTIONS 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 strictly
observed.
In rare cases, this could lead to irregular situations, for example a
compressor 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 the
initial 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 and
2) 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, in
fact, 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 and
instructions required to manufacture and install such an external protection
cover. Alternatively, ABB Turbo Systems Ltd. can assist you in purchasing
this additional safety item.
For further assistance, please contact your ABB Service Station.
INTRODUCTION
RECOMMENDATION
(SUPERSEDING 2/98)
ABB
ABB - Turbochargers
After Sales Service
Information
Enclosure 1
3
Hazards and
hazard protection
Hazards may arise during operation of, and work on,
the turbocharger:
- from the turbocharger and its accessories
- from the operating materials used
- from failure to observe safety instructions
- from inadequate maintenance and inspection work.
3.1
Mechanical influences
Physical injury
Warning ! Unconsciousness and injury due to:
crushing, shearing, cutting, winding,
fragmentation
drawing in, knocking, stabbing, rubbing
loss of liquids under high pressure and
high temperature
slipping, tripping, falling
Causes
- sharp edges, pointed parts
- crush, shear and winding areas
- fragmentation of parts
- fracture or rupture of parts due to overload
- elastic elements (e.g. springs), liquids and gases under
pressure or in a vacuum
- slippery, oily work area, obstacles on the floor
3
Gefahrenhinweise
und Gefahrenschutz
Beim Betrieb mit und bei Arbeiten am Turbolader
knnen Gefahren ausgehen:
- vom Turbolader und seinem Zubehr
- von den dabei verwendeten Betriebsmitteln
- vom ungengenden Beachten von Sicherheitshinweisen
- vom ungengenden Ausfhren von Wartungs- und
Prfarbeiten.
3.1
Mechanische Einflsse
Krperschden
Warnung ! Bewusstlosigkeit und Verletzungen
durch:
Quetschen, Scheren, Schneiden, Wickeln,
Zertrmmern
Einziehen, Stossen, Stechen, Reiben
Herausspritzen von Flssigkeiten unter
Hochdruck und hoher Temperatur
Rutschen, Stolpern, Strzen.
Ursachen
- scharfe Kanten, spitze Teile
- Quetsch-, Scher- und Wickelbereiche
- Heraus- / Wegschleudern von Werkteilen
- Bruch oder Bersten von Teilen wegen berbeanspruchung.
- elastische Elemente (Federn), Flssigkeiten und Gase
unter Druck oder im Vakuum
- rutschige, lverschmierte Arbeitsumgebung, Bodenhin-
dernisse.
ABB Turbocharger Seite / Page 7
Sicherheits- und Gefahrenhinweise Kap. / Chap. 1 Instructions on safety and hazards
ABB Turbo Systems Ltd
10002
- B -
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 and
have oil collector basins ready or in position
- Eliminate leaks
- Do not stay neither close nor radially to the
turbocharger while engine is running at > 85% rated
output.
3.2
Operation and
process materials
This includes all substances such as oil, grease, coolant,
detergents and solvents, acids and other hazardous
substances.
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 acids
or 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.
3.2
Werk- und
Arbeitsstoffe
Das sind chemische Substanzen wie le, Fette, Khl-
flssigkeit, Reinigungs- und Lsungsmittel, Suren und
andere 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.
After Sales Service Information 6 / 98 Date: 98-12-16
ABB Turbo Systems Ltd CH- 5401 Baden, Switzerland Page 1 of 1
VTR..4 6 / 98
All series (except VTR 714)
Introduction of advanced types of compressor-end
antifriction bearings LA36 for all types of VTR..4
turbochargers
(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. The
development 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 generation
has performed excellently, proving outstanding reliability. Based on these results,
ABB has decided to discontinue the LA34 and introduce the new bearing generation
as 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 given
operating point. This is due to the improved heat exchange achieved by the new
bearing geometry. A higher lubrication oil temperature causes the oil to age faster,
often accompanied by rapid discoloration of the oil. It is therefore recommended
that a lubrification oil of the latest generation (e.g. synthetic oil) be used with the
new bearings. Any ABB Service Station will gladly provide you with updated
information regarding the most suitable oil types.
previous: LA34 new: LA36
ABB
ABB - Turbochargers
After Sales Service
Information