Вы находитесь на странице: 1из 43

RH..

3
Turbo Systems United Co., Ltd. Turbocharger
Seminar
September 2009

www.turbo.co.jp

TSU Sales Department (GTC) 1 September 2009


RH..3 Turbocharger

Basic design concept and Features


Specification
Operational experiences
(Solutions implemented)

Covers outputs ranging from 280 1800 kW

TSU Sales Department (GTC) 2 September 2009


RH..3 Turbocharger

Basic design concept and Features


Specification
Operational experiences
(Solutions implemented)

Covers outputs ranging from 280 1800 kW

TSU Sales Department (GTC) 3 September 2009


RH..3 Basic Design Concept

Turbine housing Compressor housing Compressor wheel

Turbine wheel

Bearing assembly Diffuser Filter Silencer


L.O. directly from main system

TSU Sales Department (GTC) 4 September 2009


RH..3 Bearing assembly
Radial journal bearings
(Full-floating or Semi-floating)

Thrust bearing

Thrust collar

TSU Sales Department (GTC) 5 September 2009


Features: Compressor Wheel

1-piece compressor, aluminum alloy

Back-swept, splitter bladed design

Compressor wheel turns clockwise

Fixation by nut (left-hand threaded)


Tightening torque;
RH133: 32.4 Nm
RH143 / RH163: 55.9 Nm
RH183: 127.5 Nm

TSU Sales Department (GTC) 6 September 2009


Features: Turbine Wheel

Nickel-based heat resistant super alloy

Mixed flow turbine wheel

TSU Sales Department (GTC) 7 September 2009


Features: Radial Journal Bearing

Two different kinds of radial journal bearing


available in market:

Full-floating

Semi-floating

TSU Sales Department (GTC) 8 September 2009


Features: Radial Journal Bearing

Full-floating:
Sensitive for bearing failures due to unbalance of quickly
contaminated rotor (low-grade fuel operation)
Failure rate reduced due to application of turbine water
cleaning

Full-floating Bearing

TSU Sales Department (GTC) 9 September 2009


Features: Radial Journal Bearing

Semi-floating:
Developed due to high failure rate of
full-floating bearings
Less sensitive for rotor unbalance
Applied on YANMAR Engine only

Semi-floating Bearing

TSU Sales Department (GTC) 10 September 2009


Features: RH..3 T/C Version Y

RH..3 T/C on YANMAR Engine


Conventional model: RH..3
Latest model: RH..3 Version Y

Be sure to specify T/C serial No. to arrange / quote


spare parts in case of YANMAR Engine.

TSU Sales Department (GTC) 11 September 2009


Features: RH..3 T/C Version Y

RH133
Radial Bearing Bearing Housing Compressor Housing Turbine Housing
Full-floating Semi-floating Full-floating Semi-floating Aluminum Cast Iron Gas Outlet Rib Gas Outlet Rib

Bearing Bearing Bearing Bearing Casting small large

RH133
RH133
Version Y

RH143 / RH163 / RH183


Radial Bearing Bearing Housing Compressor Housing Turbine Housing
Full-floating Semi-floating Full-floating Semi-floating Aluminum Cast Iron Gas Outlet Rib Gas Outlet Rib

Bearing Bearing Bearing Bearing Casting small large

RH143 / RH163 / RH183


RH143 / RH163 / RH183
Version Y

TSU Sales Department (GTC) 12 September 2009


Features: Coated Turbine Housing

Low-grade fuel operation caused excessive erosion,


due to hard particles in exhaust gas
Coated turbine housings have been introduced
as countermeasure
Available from 1998.

TSU Sales Department (GTC) 13 September 2009


Features: Coated Turbine Housing

The turbine housing is coated in case the third-digit


number of H is 6.

TSU Sales Department (GTC) 14 September 2009


Features: Spare Parts Kit
Spare Parts Kit
Kit 1
Service Kit 1 Cleaning kit
- Seal Ring
- Snap Ring (Circlip)
- O Ring

Service Kit 2 Bearing exchange kit


- Radial Journal Bearing Kit 2
- Thrust Bearing
- Thrust Collar
- Distance Piece
- Sealing Bush

TSU Sales Department (GTC) 15 September 2009


RH..3 Turbocharger

Basic design concept and Features


Specification
Operational experiences
(Solutions implemented)

Covers outputs ranging from 280 1800 kW

TSU Sales Department (GTC) 16 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 17 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 18 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 19 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 20 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 21 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 22 September 2009


Specification of RH..3 T/C

TSU Sales Department (GTC) 23 September 2009


RH..3 Turbocharger

Basic design concept and Features


Specification
Operational experiences
(Solutions implemented)

Covers outputs ranging from 280 1800 kW

TSU Sales Department (GTC) 24 September 2009


Operational experiences

Dirt on Turbine
Eroded

Eroded
Corroded Shaft

TSU Sales Department (GTC) 25 September 2009


Operational experiences: Summary

Based on extensive field experiences

( > 10000 units of RH..3 T/C in operation)

following improvements have been introduced:


Service News
Spare parts kit (Service Kit 1 & Kit 2)
Optional semi-floating bearings
Optional turbine cleaning (during operation)
Increased spare parts availability
Worldwide support (RH..3 WWS)

TSU Sales Department (GTC) 26 September 2009


Operational issues

General:
Operation manual instruction not followed
Usage of low-grade fuel

Overhaul by ship crews:


Incorrect cleaning of rotor
Insufficient cleaning of turbine housing
Incorrect assembly of turbocharger
No after-cooling

TSU Sales Department (GTC) 27 September 2009


RH..3 Periodical
maintenance & inspection

Inspection points Inspection interval [rhs]

400 1200 2400 4800

Check fixing bolts

Check rotating condition of rotor

Check rotor clearance

Disassembling, cleaning,
inspection and bearing change

TSU Sales Department (GTC) 28 September 2009


Usage of low grade fuel

Low-grade fuel operation caused excessive erosion,


due to hard particles in exhaust gas
Coated turbine housings have been introduced
as countermeasure
Available from 1998.

TSU Sales Department (GTC) 29 September 2009


Usage of low grade fuel

The turbine housing is coated in case the third-digit


number of H is 6.

TSU Sales Department (GTC) 30 September 2009


Usage of low grade fuel

Without water cleaning


~ 2000 rhs

With water cleaning


~ 4800 rhs

Cleaning interval ~250 rhs

TSU Sales Department (GTC) 31 September 2009


Usage of low grade fuel
Without water cleaning

With water cleaning

~ 2000 rhs

~ 4800 rhs

TSU Sales Department (GTC) 32 September 2009


Usage of low grade fuel

Water Cleaning Device of Turbine during operation


DAIHATSU Engine
Cleaning device is equipped on new engine as standard.

YANMAR Engine
Cleaning device is equipped on new engine as option.

If required, please ask to the customer


to consult with Engine Builder.
( Not available in IHI / TSU )
TSU Sales Department (GTC) 33 September 2009
OVERHAUL - Dismantling
DO NOT FORGET THAT SHAFT END HEXAGON NUT
IS LEFT-HAND THREADED.

HOW TO PULL OUT COMPRESSOR WHEEL


FROM TURBINE SHAFT
(1) Please pull out Compressor Wheel (CW) from Turbine Shaft swinging CW on the shaft.
Do not try to pull out CW from the shaft by means of hammering the shaft end.
If CW can not be swung and pulled out, please heat CW evenly as the following way.
(2) Do not heat CW more than max. 100 degrees centigrade.
And propane gas (LP gas) should be used to heat up CW.
Do not use acetylene gas which make CW overheated locally with strong flame.
Acetylene gas is not suitable to heat up CW evenly for pulling it out, and also it can cause CW material
(aluminum alloy) weakened due to local overheating.
(3) Please rotate Turbine Shaft slowly (approx. 10 to 20 rpm) at turbine side by hand, and heat up hub section
(root of the blades) of CW evenly.
Please take care of burner flame not to heat up the shaft end to avoid thermal expansion of Turbine Shaft.
(4) If CW is still not pulled out, it should be naturally-cooled until it becomes to ambient temperature.
After an adequate cooling down period, please repeat the above way again.
(5) In case CW is still not pulled out after the above way is repeated three times, please place the Center Section
(Rotor with Bearings in Bearing Housing) vertically (compressor side down) after the said adequate cooling
down period, and soak the CW section only into fresh water (Hot water is preferable.) for 4 to 6 hours to
remove the dirt in between CW and Turbine Shaft. (Not required any chemicals in water. )
Please pay attention to adjust water level NOT to soak whole the Center Section or Bearings into water.
(6) After an adequate cooling down period, please repeat the above way, Section (1) ... (4).

TSU Sales Department (GTC) 34 September 2009


OVERHAUL - Cleaning

Turbine Shaft (Turbine Wheel)

Please protect the shaft section

properly with grease !

Otherwise the shaft can be corroded

TSU Sales Department (GTC) 35 September 2009


OVERHAUL - Cleaning

Center Section is installed although Turbine Housing


is not sufficient to be cleaned.

Tip clearance between Turbine Wheel and shroud part


of Turbine Housing is too small.
Turbine wheel touches to shroud part of the housing
with hard carbonized deposit.
Excessive load on Bearings with Rotor vibration
High risk for breakdown
TSU Sales Department (GTC) 36 September 2009
OVERHAUL - Cleaning

Turbine Housing
Cylinder Gauge

1. Remove the carbonized deposit on Shroud part.

Check with Cylinder Gauge after cleaning, if available.

2. Do not hit Gas scroll using hammer, needle gun, etc.

to avoid coating layer peeled off.

TSU Sales Department (GTC) 37 September 2009


OVERHAUL - Assembling

Turbine Shaft bent due to over-tightening of


Shaft End Hexagon Nut. Use proper torque wrench !
DO NOT FORGET THAT
SHAFT END HEXAGON NUT
IS LEFT-HAND THREADED.

Tightening torque;
RH133: 32.4 Nm
RH143 / RH163: 55.9 Nm Left-hand threaded
RH183: 127.5 Nm
Incorrect fitting of Thrust Bearing
Pay attention to its position for guide pin.
IF NOT, LUB. OIL CHANNEL IS BLOCKED
AND BEARING FAILS IN A SHORT TIME.
TSU Sales Department (GTC) 38 September 2009
OVERHAUL - Measurement

Axial Clearance / Radial Clearance

Axial Clearance Radial Clearance


Design Allowable Limit Design Allowable Limit
RH133 0.06 0.12 Max. 0.12 0.37 0.57 Max. 0.67
RH143 / RH163 0.06 0.12 Max. 0.12 0.45 0.60 Max. 0.80
RH183 0.08 0.15 Max. 0.15 0.45 0.60 Max. 0.80

TSU Sales Department (GTC) 39 September 2009


OVERHAUL - Measurement

Radial Tip Clearance R


measured by a couple of
thickness gauge (feeler gauge)

R1 + R3, R2 + R4
Design
RH133 0.75 x 2 = 1.50
RH143 / RH163 0.70 x 2 = 1.40
RH183 0.90 x 2 = 1.80

TSU Sales Department (GTC) 40 September 2009


OVERHAUL - Measurement

Seal Ring Groove of Turbine Shaft

Ring groove measured by a couple of thickness gauge (feeler gauge)

Incorrect ! Correct Measurement of


Seal Ring Groove
RH133 < 2.36 mm
RH143 / RH163 < 1.87 mm
RH183 < 3.37 mm

TSU Sales Department (GTC) 41 September 2009


No after-cooling

Carbonized deposit by coking encourages


wear-down of seal ring groove !

TSU Sales Department (GTC) 42 September 2009


TSU Your turbocharger partner http://www.turbo.co.jp

TSU Sales Department (GTC) 43 September 2009