NAPIER Turbochargers

SB-295-A-011-01 ADVISORY
SUBJECT: NA295 TURBINE SIDE WATER WASHING
A. TURBOCHARGERS AFFECTED

All NA295 turbocharger with single entry turbine inlet. B. REASONS FOR BULLETIN

Experience has shown that turbocharger system performance in Heavy Fuel Oil (HFO) applications is adversely affected by ineffective cleaning of the turbocharger nozzle and turbine. These components are prone to heavy fouling and consequential loss of efficiency in an HFO environment. Through experimentation and trials using an instrumented turbocharger, a method has been developed which if adhered to, offers effective distribution of injected water and consequently longer intervals between manual stripping and cleaning. C. CHANGES / MODIFICATIONS

No turbocharger parts need to be modified. Potential changes relate to water washing hardware, water supply and method. A new design of water injector has the following part number and is available from Napier Turbochargers Ltd.: SP14216. Napier documents affected Installation Design Manual (IDM) and NA295 Instruction Manual to be updated accordingly.

In the short term, this service bulletin may be added to the current IDM as an update to section 7.3, Hardware and Water Supply.

Siemens Industrial Turbomachinery Ltd 2006

CONFIDENTIAL
This bulletin is the exclusive property of Siemens Industrial Turbomachinery Ltd and is disclosed in confidence to Siemens Industrial Turbomachinery Ltd customers solely for their use in connection with the operation and maintenance of their Siemens Industrial Turbomachinery Ltd turbines. Its contents shall not be used for other purposes or copied or disclosed without written authorisation of Siemens Industrial Turbomachinery Ltd. The information set out in this bulletin is offered by Siemens Industrial Turbomachinery Ltd as part of its ongoing product support services for you as one of its customers. However, the final decision for operating your plant in a safe and responsible manner rests entirely with you. This involves many factors outside our knowledge and control, and therefore Siemens Industrial Turbomachinery Ltd is unable to accept (and hereby disclaims) any liability (whether based on breach of contract, warranty or statutory duty, negligence or otherwise) for damage or loss of any kind which may be incurred as a result of applying this information.

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All correspondence to: Siemens Turbochargers Division P.O. Box 1 Waterside South Lincoln LN5 7FD England Tel: +44 (0) 1522 584000 Fax: +44 (0) 1522 584910 Siemens Industrial Turbomachinery Ltd Registered Office: Ruston House Waterside South Lincoln LN5 7FD England Registered in England No. 4729734

D.

DESCRIPTION

Scope: This bulletin outlines a combination of hardware and procedural requirements that, if implemented, can result in a significant improvement in the maintenance of the cleanliness of turbine side components. The method is highly recommended for HFO installations that currently have fouling problems leading to performance deterioration, or which manually dis-assemble and clean on a frequent basis in order to avoid performance deterioration. The method applies only to installations that have a water drain installed at the turbine outlet casing. The advice contained in this service bulletin does not guarantee successful cleaning. The frequency of cleaning and the cleanliness of the water injectors will be influenced by fuel quality and application, a combination outside the scope of this document which is entirely the responsibility of the operator. The advice contained herein therefore cannot detract from the responsibility of operators to determine, through a superior knowledge of their plant, the most effective cleaning regime. This advisory service bulletin reflects an improved knowledge regarding what measures will result in an improved water distribution around the turbocharger nozzle, provided injectors are kept clean and the prescribed settings are adhered to. NOTE: Experience is being gained constantly about methods of turbocharger cleaning in HFO applications. This bulletin does not represent the scope of understanding of Napiers on the subject, but is a fair reflection of conclusively supported findings. As observations are verified, recommended hardware and procedures may be subject to refinement. Water Wash Hardware Requirements Two injectors may be used, mounted opposite each other. The nearest exhaust flange to the turbine inlet is suitable as indicated in Figure 1. The injectors and associated fittings should be made of a suitable material such as stainless steel type 410S21 (BS970). The recommended water injector detail is shown in Figure 2. For the single entry NA295, these are available from Napier. The water injector part number is SP14216. This produces a flat fan shaped jet of large surface area and low water droplet inertia, capable of mixing efficiently with the exhaust flow. The hemispherical end of the injector should protrude beyond the inner wall of the ducting and into the exhaust flow. The injectors should be oriented so that the fan shaped spray is normal to the exhaust flow, thereby mixing through the largest possible area. Figure 2 also shows the orientation of the injector. A flange is provided which should be used for mounting in a fail safe orientation. Two M8 durehete capscrews are recommended with an appropriate high temperature anti-seize compound (Rocol) and flange sealant. A flow meter capable of displaying 25 litres per minute and a pressure gauge with full scale deflection of 6 bar should be incorporated into the water supply lines. It is advised that a three way valve connected to water and air is used to ensure that when water is not being injected, an air purge is present to keep injector orifices clean.

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Figure 1

Water Injection Position

Figure 2

Water Injection Geometry

Water Wash Procedure Take a record of performance parameters. Turbocharger speed, exhaust temperatures and boost pressure are critical. Allow temperatures to stabilise after setting the engine load to 25%. The turbine inlet temperature should not be allowed to exceed 450C before washing. For all single entry NA295 applications, this load will result in approximately the same exhaust mass flow, which means that the procedure is relevant for all engines which use the single entry NA295. Open the turbine outlet casing water drain. This will prevent a pool of water accumulating in the turbine outlet casing. It is not essential to observe the cleanliness of any water emerging from the drain, since it is possible that the water running from the drain is black after running back down the exhaust stack. Inject water for a period of one minute, or longer if there is sufficient margin from exhaust temperature alarms (exhaust temperatures may rise during washing, due to choking of
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the nozzle). Provided the correct injector geometry is used (see below), water pressure drop across the injector will not be a critical determinant of water distribution, although a differential pressure of at least 2 bar should be ensured. Flow rate is an indicator of injector cleanliness and for clean injectors should be about 19 litres per minute for a pressure drop of 2 bar. Turn the water supply off. Allow temperatures to re-stabilise before injecting again. This may take up to 5 minutes. Repeat up to five times, depending on the site specific requirements as determined by the operator in acknowledgement of the fuel quality and operating regime. Check that water flow from the drain has ceased before closing the water drain valve. Return the engine load back to the required operational setting and allow it to run for at least 15 minutes to allow all components to dry completely. Take a record of performance parameters, for comparison with the record before washing. The frequency of cleaning is determined through a combination of the loading, the quality of the fuel and the effectiveness of cleaning. This should be determined by the operator, with once a week being a reasonable starting point. E. IMPLIMENTATION

This bulletin is graded advisory. The method is known to frequently result in improvements to operational efficiency, through reduced fouling to the turbocharger nozzle and an increase in the intervals between manual stripping and cleaning. Engine load, injector design, water pressure drop across the injector and injector orifice cleanliness are the four most critical elements to the successful implementation of this advisory service bulletin. For components other than the water injectors, it is considered the responsibility of the engine manufacturer to include appropriate changes for new and existing installations. It is advised that those operating engines which burn heavy fuel oil be encouraged to adopt the detail outlined in this bulletin. The water injectors may be provided by Napier Turbochargers Ltd. F. SUPPLEMENTARY INFORMATION

Summary of Changes to Superseded Water Washing Methods The traditional method of water washing was been detailed in two documents, with the hardware and water delivery requirements included in the IDM, and the method described in the Instruction Manual. This service bulletin outlines a procedure which supersedes previous understanding and related documents. The main changes are outlined below. The next issue of the IDM and Instruction Manual IDM Section 7.3 (Hardware and Water Supply): Water injector geometry has changed from a round exit hole facing either downstream or normal to the flow and there is now some flexibility on the number of injectors used, with two or three both resulting in good water distribution. The water flow and pressure drop across the injector have also been more accurately determined for a given engine load. Instruction Manual, Section 9 (Method): Engine load is now the determinant for good water distribution, not exhaust temperatures, although the first time the new procedure is used, the level of safety with respect to exhaust system temperature alarms, should be
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accurately determined. Injectors mounted on the turbine inlet flange are known to be capable of providing a good water distribution. Importantly, drains are no longer used as a gauge for determining the effectiveness of washing and the water is not injected for a period of between 15 and 20 minutes. It should be injected more frequently and for a reduced time period, reflecting the necessity for safety margin with respect to exhaust valve temperatures at a load of 25%.

Date of Issue:

22nd June 2001

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