Usage:
3608 (6MC);
3612 (9RC);
3616 (1PD
Introduction
This special instruction provides the procedure and the tooling needed to wash the turbine (hot) side of turbochargers used on 3600 Series Engines. In order to use this procedure, the engine must be equipped with the later turbocharger water wash lines groups. Refer to Chart 1.
During the normal operation of a Heavy Fuel Oil (HFO) engine, deposits form on the turbine nozzle vanes and turbine wheel blades. The deposits can cause poor efficiency and low performance of the turbochargers. Higher than normal exhaust port temperatures, higher than normal exhaust manifold pressures, and lower than normal air inlet manifold pressures are indications that the turbocharger is not operating at peak efficiency. It is recommended for engines operating on HFO that the turbine side of the turbochargers be water washed every 100 hours of engine operation. More frequent cleaning may be required in severe applications.
This water wash procedure is intended to remove light buildups of deposits. If after completion of this procedure the turbocharger does not return to normal efficiency, indicated by the air inlet manifold pressures and exhaust port temperatures, the turbocharger should be disassembled and a complete mechanical cleaning performed.
The water supply to the wash control module should be clean. Fresh water should be supplied at a minimum of 240 kPa (35 psi) pressure and 21 L/min (5.5 gpm). Salt water should not be used.
Necessary Tooling
Installation
Procedure
Turbocharger Water Wash Lines Group: Water injection valve (1). Nipple (2). Nipple (3). Drain valve (4).
1. Use a copy of the enclosed form to record engine operation data prior to completing the turbo wash.
NOTE: The data should be compared to data recorded at commissioning. If the data is similar, turbocharger cleaning may not be necessary.
2. On 3612 and 3616 Engines, wash one turbocharger at a time.
3. Reduce engine load until the exhaust inlet temperature to the turbocharger is 375 ± 10°C (707 ± 18°F).
4. Operate the engine at this reduced load for five minutes to insure the exhaust inlet temperature to the turbocharger is stable at 375 ± 10°C (707 ± 18°F) before proceeding to Step 5.
5. Install water supply hose assembly (C) between the control module and two nipples (2) on the engine.
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DO NOT OPEN THE TURBOCHARGER WASH VALVES. Opening the valves will allow hot exhaust gas to enter the water lines. This may directly result in damage to the lines and turbocharger wash control box and may cause personal injury to any person standing nearby. To avoid the hot exhaust gas, the turbocharger wash valves should not be opened at this time. |
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6. Install (drain) tube assembly (A) to nipple (3) on the same side of the engine.
7. Insure that (flow control) needle valve (F) in the control module is FULLY CLOSED.
8. Connect the customer-provided water supply to the control module at the nipple. Quick disconnect coupler (B) is provided.
9. Turn on the water supply to the control module. Supply pressure should be more than 240 kPa (35 psi) but less than 1380 kPa (200 psi). Pressure regulating valve (F) in the control module regulates the customer-provided water pressure to 207 kPa (30 psi). This pressure is measured by the pressure gauge (D) in the control module.
NOTE: If the supply pressure does not exceed 240 kPa (35 psi), DO NOT ATTEMPT TO PERFORM A TURBOCHARGER WASHING.
10. Open drain valve (4). Insure that the drain line is clear and open. Exhaust gas should be present.
NOTE: If exhaust gas is not present, then clear the restriction in the line or the drain pipe. Place a suitable container under the drain tube in order to collect the flow of water.
11. Open (flow control) needle valve (F) in the control module one full turn.
12. Slowly turn both water injection valves (1) counterclockwise (CCW) to FULLY OPEN.
13. Adjust (flow control) needle valve (F) in the control module until a flow of 17 L/min (4.5 gpm) registers on flow meter (G). Monitor exhaust port temperatures (taken at the cylinder head) so that they do not exceed 450°C (842°F). If this temperature is exceeded, reduce the water flow until the exhaust port temperature are below 450°C (842°F).
14. Do not permit the exhaust stack temperature to fall below 60°C (140°F). If the temperature falls below 60°C (140°F), close the turbocharger water wash valves. Wait for the temperature on the stack outlet to increase to approximately 250°C (482°F).
15. Continue to wash the turbocharger. Some flow should be observed from the drain line. Collect the flow from the drain tube in a bucket for disposal. A measure for the complete washing time is the clarity of the draining water. Continue the wash for approximately five minutes until the water becomes more clear than the initial drainage of the water
After five minutes turn off BOTH water injection valves to FULLY CLOSED.
16. Insure exhaust inlet temperature to the turbocharger is 375 ± 10°C (707 ± 50°F).
17. Adjust counterclockwise (CCW) the top water injection valve to FULLY OPEN.
18. Monitor the exhaust port temperatures so that they do not exceed 450°C (842°F). If this temperature is exceeded, reduce the water flow until the exhaust port temperatures are below 450°C (842°F).
19. Do not permit the exhaust stack temperature to fall below 60°C (140°F). If the temperature falls below 60°C (140°F), close the turbocharger water wash valves. Wait for the temperature on the stack outlet to increase to approximately 250°C (482°F).
20. Continue to wash the turbocharger. Some flow should be observed from the drain line. Collect the flow from the drain line in a bucket for disposal. A measure for the complete washing time is the clarity of the draining water. Continue the wash for approximately five minutes until the water is clear.
After five minutes turn off the TOP water injection valve to FULLY CLOSED.
21. Insure the exhaust inlet temperature to the turbocharger is 375°C (707°F).
22. Adjust the bottom water injection valve to FULLY OPEN.
23. Monitor the exhaust port temperatures so that they do not exceed 450°C (842°F). If this temperature is exceeded, reduce the water flow until the exhaust port temperatures are below 450°C (842°F).
24. Do not permit the exhaust stack temperature to fall below 60°C (140°F). If the temperature falls below 60°C (140°F), close the turbocharger water wash valves. Wait for the temperature on the stack outlet to increase to approximately 250°C (482°F).
25. Continue to wash the turbocharger. Some flow should be observed from the drain line. Collect the flow from the drain tube in a bucket for disposal. A measure for the complete washing time is the clarity of the draining water. Continue the wash for approximately five minutes until the water is clear.
After five minutes turn off the BOTTOM water injection valve to FULLY CLOSED.
26. Turn off the water supply and disconnect the water supply from the control module.
27. Close (flow control) needle valve (F) in the control module.
28. Close drain valve (4).
29. Remove hose assembly (C) between the control module and nipples (2).
30. Remove (drain) tube assembly (A).
31. Open both turbocharger wash valves on the exhaust manifold for five seconds in order to allow exhaust gases to force out water from the valves. This will prevent the build-up of deposits in the valves.
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THE WATER THAT IS DRAINING IS VERY HOT! If the hot water contacts anyone, personal injury will result. Stand to the side of the valve when opening the valve in order to avoid contact with the hot water. |
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32. For 3612 and 3616 engines, repeat the procedure on the other side of the engine.
33. Operate the engine at the reduced load for five to ten minutes before increasing the engine load or stopping the engine.
34. Operate the engine at the same load as before the turbocharger water wash procedure. Record the engine operation data and compare it to data recorded prior to the procedure. This data should also be compared to data recorded at commissioning.
NOTE: If there has not been a reduction to the exhaust port temperature, a decrease in exhaust manifold pressure, and an increase in inlet manifold pressure, disassembly of the turbocharger and mechanical cleaning may be necessary.
Troubleshooting
When water flow of 17 L/min (4.5 gpm) cannot be achieved:
1. Close the water injection valves and the flow control valve in the control box.
2. Check the reading of the pressure gauge in the control box.
- * If the pressure reading is below 207 ± 14 kPa (30 ± 2 psi):
Check that the water supply of the customer will deliver a minimum of 17 L/min (4.5 gpm) at 241 kPa (35 psi).
Check that the strainer in the regulator of the control box is clean and free of debris.
Reset the pressure regulator to 207 kPa (30 psi).
- * If the pressure reading is greater than 207 ± 14 kPa (30 ± 2 psi):
Insure that the water injection valves on the engine are in the FULLY OPEN position.
Check that the hose between the control box and the engine is clean and free of debris.
Check that the fittings and hose connecting the water injection valves are clean and free of debris.
Check that the orifices of the water injection valves are clean and free of debris. To clean, remove the gland nut and use a 5 mm drill to remove any foreign matter. Use care to prevent damaging the valve seats.
When there is a lack of discharge from the drain tube:
1. Insure that the exhaust gas temperature at the turbocharger inlet does not exceed 375°C (707°F).
2. Check the inlet water flow to make sure it is correct.
3. Make sure that the drain valve is FULLY OPEN.
4. Check the drain tube to make sure it is free of debris.
When the exhaust port temperatures exceed 450°C (842°F):
1. Insure that the exhaust gas temperatures to the turbocharger inlet do not exceed 375°C (707°F);
NOTE: Reducing the inlet water flow will increase the turbocharger speed, which will increase the volume of the inlet manifold air, which will reduce the exhaust port temperatures. Minimum recommended water flow is 12 L/min (3 gpm).
When the turbocharger surges:
NOTE: Reducing the inlet water flow will increase the turbocharger speed which will eliminate turbocharger surge. Minimum recommended water flow is 12 L/min (3 gpm).
1. Complete the turbocharger wash at the reduced flow rate.
2. Operate the engine for one hour at its usual speed and load.
3. Repeat the turbocharger wash procedure using the standard water flow rate of 17 L/min (4.5 gpm).
