Turbocharger

The great demand of fuel oil in the maritime industry, turbo chargers reduced the specific fuel
oil consumption of a marine diesel engine because of greater air supply

It is a well-known fact that turbocharger efficiency significantly influences diesel engine

operational performance. For example, a turbocharger efficiency increase of 1% results in the
following improvements (under constant engine power) .Supercharged air pressure increases
by (1%-2%). Fuel consumption decreased (0.4%-0.6%), NOx emission decreases by (5%-8%),
exhaust gas temperature decreases by (2%-4%)

These turbocharger does enables reductions in fuel consumption and CO2 emissions. Some are
high overall efficiency resulting in lower engine fuel consumption.

The purpose of installing turbo chargers in marine diesel engine is to utilize exhaust gases from
the marine engine and to be used to rotate the turbine blades that is in a common shaft with the
compressor turbine that will compressed the atmospheric air and this will result to more
pressurized air, entering the engine’s combustion chamber. This purpose also increases the
efficiency and the power output of our marine diesel engine.

Advantages of installing turbochargers in marine diesel engines are higher plant efficiency, no
separate power source required, power demand low, attempts to cater for overloading
condition, and more efficient than other forms of supercharging.
Fault on turbocharger

Turbocharger is run by exhaust gas which rotate a turbine and at the same time it will rotate
the compressor due to the shaft that makes them connected. This will allow more air enters for
the combustion process. Due to the continuous operation of turbocharger, it will create some
faults and however it is also depends on the maintenance and the method of safe operation. The
faults from turbocharger are:

1. Exhaust gas temperature too high

2. Charge air pressure too low
3. Charge air pressure too high
4. Vibration of turbocharger
5. Noise on running down
6. Constant surging of the turbocharger

Exhaust gas temperature too high

 Fuel injection injects more fuel

 Insufficient air in the combustion chamber for combustion
 Contaminated compressor or turbine of the turbocharger
 Damaged of turbine blade
 Insufficient cooling water through charge air cooler
 Insufficient ventilation around the turbocharger

Charge air pressure too low

 Dirt in the air filter which causing pressure drop

 Leaking in the exhaust gas duct between engine and the turbine
 Labyrinth seal is leaking or damaged
 Turbine blade and compressor impeller damaged
 Exhaust gas back pressure too high

Charge air pressure too high

 Main engine performance is higher than normal

 Fuel injector system is incorrectly adjusted
  Nozzle ring is dirty

Vibration of turbocharger

 The rotor is unbalanced due to heavy contamination of compressor side and turbine
blades and this will give effect when centrifugal force acting in the operation
 Misalignment of bearing

Noise on running down

 Damage on the bearing

 Rotor is rubbing
 Dirt in the turbocharger
 Damages on labyrinth seal

Constant surging of the turbocharger

 Increased flow resistance due to dirt in the charge air cooler

 Exhaust gas pressure increased after the turbine because exhaust gas silencer is dirty
 Defective check valves in a two stroke engine
Proper care and maintenance include;

1. Water cleaning of compressors and turbines to remove dirt and other residual material
from the rotor to ensure proper balance.

2. Regular cleaning and changing of air intake filters to prevent foreign objects entering and
dirt and residue build up on the rotor blades. Furthermore, contamination of air intake filters
results in a higher inlet restriction and may cause turbocharger overspeed or surging.

3. In case of turbocharger separate lubricating system: Regular changing of lubricating oil

(consult manual for approved oil) and cleaning of centrifuges as well as filters.

4. Regular inspection of turbocharger parameters while in operation.

Improper operation and maintenance by the crew.

Improper maintenance and operation by the crew can lead to damage to the turbocharger. The
following is a list of some of the types of causes and events that can lead to more serious
damages.

i) Dirt on compressor and turbine blades – Improperly implemented or neglected washing

routines can let dirt accumulate on both compressor and turbine blades. This will lead to
imbalances in the rotor, and consequentially it can cause bearing damages and even total
breakdown.

ii) Improper lubricating oil – The use of lubricating oils not recommended by the
manufacturer or contaminated oil, can lead to reduced performance and eventual damage to
the bearings.

iii) Improper cleaning and maintenance of filtration rings – The intake air quality can be
affected when air filters are not properly cleaned and/or changed. A clogged filter may lead to
surging. In some cases, it has been observed that the crew, to keep from having to maintain
and clean the filters, have removed the filtration rings.

iv) Turbocharger over-speed – Due to incorrect maintenance or operational activities,

turbochargers are in some cases overspeed. When continuously over-sped by only a few
percent, this quickly damages turbocharger components and reduces their service life. An
over-speed of 30-40% is likely to blow up the turbocharger instantly.
References
1. https://www.academia.edu/18915817/The_Effects_of_Turbocharger_in_Marine_Dies
el_Engines

2. http://www.machineryspaces.com/turbo-failure-prevention.html