189
1 INTRODUCTION
Reliability and safety of a large marine diesel engine
hereafter referred to as Main Engine is dependent on
the reliability of its sub-systems, which include the
fuel oil system, lubricating oil system, cooling water
system, and the turbocharging system [1, 2, 9]. The
turbocharging system forms a vital sub-system that
mainly comprises turbochargers and air coolers,
which form an integral part of turbocharging. This
study investigates some aspects of the turbocharging
process, the malfunction of which can lead to the
failure of the Main Engine [6].
The Kongsberg Engine Room Simulator at the
Australian Maritime College, the University of
Tasmania in Australia is utilised to investigate various
malfunctions of the Turbocharging system, collect
relevant data, and draw useful conclusions.
All large Main Engines propelling huge vessels are
two-stroke turbocharged engines, where the air for
turbocharging is provided by 1 to 4 turbochargers
depending on the engine capacity. The Main Engine
in consideration for the simulation is MAN B&W
5L90MC, with a cylinder bore of 90 cm, piston stroke
of 290 cm comprising of 5 cylinders, 2 air coolers and
2 turbochargers. The maximum continuous rating of
the engine (MCR) is 17400 kW, corresponding. engine
speed is 76 rpm. The mean indicated pressure of each
cylinder is 13.0 bar, scavenge air pressure being 2.1
bar. The turbocharger speed is 8000 rpm. The engine
is attached to a 5 bladed propeller, the propeller pitch
being 1.2. The engine burns fuel DO/ HFO 700 cSt, the
specific fuel consumption168g/kwh Turbocharger’s
Impact of Defective Turbocharging System on the
Safety and Reliability of Large Marine Diesel Engine
M. Anantharaman
1
, R. Islam
1
, A. Sardar
1
, V. Garaniya
1
& F. Khan
2
1
Australian Maritime College, University of Tasmania, Launceston, Australia
2
Memorial University of Newfoundland, St. John’s, NL, Canada
ABSTRACT: Today huge capacity sea-going vessels are propelled by mega high-powered marine diesel
engines, referred to as Main Engine. Turbocharging system is an integral part of large marine diesel engine
plant, contributing to their safety, reliability, and efficiency. Defects in the turbocharging system could result in
higher fuel consumption, erratic running of the Main Engine, and in the worst scenario may result in the
stoppage of the Main Engine at sea. An inefficient turbocharging system may also cause major damage to
turbochargers, resulting in undesirable accidents out at sea. To avoid such undesirable accidents and ensure
smooth operations of the Main Engine, it is required to address this concern. The aim of this research is to study
the turbocharging system for a large Main Engine using a Kongsberg engine simulator. Various malfunction of
the Turbocharging system is considered, relevant data is collected and analysed. Moreover, a Fault Tree
Analysis, (FTA) is considered to identify the top undesirable event which is the failure of the Main Engine.
Based on the results of this study, various steps are suggested to avoid failure of the Main Engine due to the
defective turbocharging system.
http://www.transnav.eu
the International Journal
on Marine Navigation
and Safety of Sea Transportation
Volume 15
Number 1
March 2021
DOI: 10.12716/1001.15.01.19
190
form part of the scavenge sub-system and play a vital
role in the operation of the main engine. Failure of
turbochargers can lead to disastrous consequences
and immobilisation of the Main Engine, [3].
Turbochargers for large Main Engine, would
generally comprise of a single-stage axial-flow turbine
coupled to a single-stage rotary compressor, driven by
a common rotor shaft. The exhaust gases from the
Main Engine drive the turbine which in turn drives
the compressor. The compressor draws air from the
engine room and is compressed to a higher pressure
and temperature which can reach 200 degs C, which is
then directed to the air cooler for cooling, prior to
entering the scavenge manifold, from where the air is
distributed to individual cylinders. A turbocharger on
an engine bed plate is shown in Figure 1.
Figure 1. Turbocharger for a large two stroke engine at test
bed [2].
Figure 2. Main Engine Turbocharging system (Kongsberg
Simulator at AMC), with dirty air filter. The red points
indicated abnormal values.
The efficiency, safety, and reliability of the
turbocharger depend on the efficiency of the turbine
and compressor.
To evaluate the efficiency of the turbocharger, it is
essential to evaluate the efficiency of the turbine and
the compressor as given by MAN B&W instructions
for 50-89 MC type engines operation manual [4].
total ocompressor turbine
=
(1)
It is vital that both the compressor side and the
turbine side must be efficient for high turbocharging
efficiency, as seeen in equation (1) above.
2 ASSESSMENT OF MALFUNCTIONS IN THE
TURBOCHARGING SYSTEM
The Kongsberg Simulator is utilised to assess
malfunctions in the turbocharging system. The
compressor and turbine of the turbocharger are the
two vital components that are responsible for the
overall efficiency of the turbocharger, as evident from
Equation1. The compressor is generally referred to as
the airside of the turbocharger, whereas the turbine is
referred to as the exhaust side of the turbocharger.
Any malfunction on the air side or exhaust side leads
to abnormal function of the turbocharger, which will
affect the efficiency hence the reliability of the
turbocharging system, which in turn will adversely
affect the reliability of the Main Engine. Whilst there
are a range of malfunctions that affect the
turbocharging system, this paper would consider two
malfunctions, one each on the air side and exhaust
side and study its impact on the turbocharging system
[10].
2.1 Air filter dirty
Air is drawn from the engine room atmosphere
through air inlet filters. Air inlets are streamlined and
fitted with insulation internally to reduce noise. The
filters can be removed for cleaning. The quality and
quantity of the intake air to the turbocharger depends
to a very large extent on the condition of the air filters.
It is essential that the filters be cleaned at regular
intervals preferably every 500 hours of the engine
running. At the same time, it is necessary that they are
well protected in ports when the Main Engine is on
stop. It is a normal practice to cover the filter casing
with a canvass cover which would prevent intake of
dust in ports, especially on bulk carriers loading coal,
iron ore, or grain. It can thus avoid the intake of the
cargo dust in port. Also, the blower trunk supplying
air to the compressor could be isolated in port.
Having isolated the blower, a notice to that effect
should be clearly displayed at the prominent location
for awareness of the engine room crew, at a local
point and in the ECR (engine control room). Prior to
the departure port, the blower can be put to normal
use and the filter uncovered for Main Engine
operation. Table.1 shows the Main Engine parameters
before and after introducing the malfunction ‘dirty air
filter’.
2.2 Inlet grid dirty
Exhaust gases from the main engine exhaust manifold
enter the turbocharger gas inlet casing via a protective
exhaust grid. The function of the exhaust grid is to
trap the unburnt carbon and coke particles from
entering the turbine. The exhaust grid also traps any
broken piston rings, broken valve components from
entering the turbocharger gas inlet casing which apart
from affecting the balancing of the turbocharger rotor,
will also result in major damage to the turbocharger,
and stoppage of the main engine which may result in
a major accident of the vessel [5]. It is very important
to periodically inspect the exhaust manifold and the
exhaust inlet grid, to ensure that there are no foreign
particles in the form of broken piston rings and
191
similar components. The second malfunction in this
study relates to the turbocharger1 dirty inlet grid.
Table 2 below shows the parameters related to this
malfunction.
Table 1. Main Engine TCH 1 dirty air filter
_______________________________________________
Main Engine Values during running
Parameters Units Clean Dirty %Change
air air in
filter filter values
_______________________________________________
ME air receiver bar 2.05 2.01 2
pressure
ME exh receiver bar 1.69 1.66 1.8
pressure
ME air receiver degC 46.37 46.08 0.6
temperature
ME exh receiver degC 371.00 377.80 -1.8
temperature
ME TBCH 1 speed rpm 7265.27 7201.51 0.9
ME TBCH 1 air flow ton/h 78.39 74.38 5.1
ME TBCH 1 exh flow ton/h 79.87 77.57 2.9
ME TBCH 1 exh degC 239.82 245.49 -2.4
outlet temperature
ME TBCH 1 air degC 171.22 175.68 -2.6
outlet temperature
ME TBCH 1 air filter mmWC 115.00 140.22 -21.9
pressure drop
ME TBCH 2 speed rpm 7261.49 7210.58 0.7
ME TBCH 2 air flow ton/h 78.12 77.72 0.5
ME TBCH 2 exh flow ton/h 79.71 77.88 2.3
ME TBCH 2 exh degC 239.81 245.45 -2.4
outlet temperature
ME TBCH 2 air degC 171.71 169.67 1.2
outlet temperature
______________________________________________
Table 2. Main Engine TCH 1 exhaust grid dirty
_______________________________________________
Main Engine Values during running
Parameters Units Clean Dirty % Change
grid grid in values
_______________________________________________
ME air receiver bar 2.05 1.78 13.2
pressure
ME exh receiver bar 1.69 1.52 10.1
pressure
ME air receiver degC 46.37 44.21 4.7
temperature
ME exh receiver degC 371.00 486.25 -31
temperature
ME TBCH 1 speed rpm 7265.27 6402.87 11.9
ME TBCH 1 air flow ton/h 78.39 35.68 54.5
ME TBCH 1 exh flow ton/h 79.87 54.55 31.7
ME TBCH 1 exh degC 239.82 360.12 -50.2
outlet temperature
ME TBCH 1 air degC 171.22 231.78 -35.4
outlet temperature
ME TBCH 1 air filter mmWC 115.00 23.83 79.3
pressure drop
ME TBCH 2 speed rpm 7261.49 7061.20 2.8
ME TBCH 2 air flow ton/h 78.12 81.30 -4.1
ME TBCH 2 exh flow ton/h 79.71 66.31 16.8
ME TBCH 2 exh degC 239.81 333.61 -39.1
outlet temperature
ME TBCH 2 air degC 171.71 160.94 6.3
outlet temperature
ME TBCH 2 air filter mmWC 114.21 123.69 -8.3
pressure drop
_______________________________________________
Figure 3. Main Engine Turbocharging system (Kongsberg
Simulator at AMC), inlet grid dirty.
3 ANALYSIS OF SIMULATION
3.1 Dirty air filter
In this engine, the turbocharger 1 air filter dirty
malfunction was activated. The Main engine was run
at full away speed for 10 minutes. It is seen in Table1,
that the air pressure drops across this filter rose by
22%. Apart from the pressure drop across the filter,
there was no noticeable change in the other
parameters of the turbocharging system. The
turbocharger 1& 2, exhaust outlet temperature ME
TBCH 1 rose by 2.4% to a value of 245.49 degs C. The
turbocharger 1 & 2 air outlet temperature showed
some difference. The turbocharger 1 air outlet
temperature showed an increase of 2.6%, whereas the
turbocharger 2 air outlet temperature showed a
reduction of 1.2%. Hence apart from an increase in the
air pressure drop across the filter, there was not much
impact on the main engine operation. It can be seen
from the Neptune log below (Table 3), that even after
49 minutes of running of the Main Engine the
propeller speed remained the same at 74 .0 rpm
However, it is advisable to replace the air filter
elements at the earliest opportunity, which would
prevent further deterioration of the filter element.
Table 3. PC: AMC-FSN83M2 - Neptune Log - 2/03/2021
11:00:48 AM
_______________________________________________
Time Event
_______________________________________________
00:00:00 Z07109 SET=77 % SOUND LEVEL SETPOINT
(AMC-FSN83M2)
00:09:25 DCMES: DO
00:25:09 DCMES: LO
00:43:04 T01601 [46.35 degC]: ME air receiver temp
(AMC-FSN83M2)
00:43:20 M2402 SET=30 % ME TBCH 1 air filter dirty
(AMC-FSN83M2)
00:47:20 N03761 [74.00 rpm]: Propeller speed (AMC-
FSN83M2)
00:47:22 T01613 [245.96 degC]: ME TBCH 1 exh outlet
temp (AMC-FSN83M2)
00:47:49 N03761 [74.00 rpm]: Propeller speed (AMC-
FSN83M2)
00:47:54 N03761 [74.00 rpm]: Propeller speed (AMC-
FSN83M2)
00:49:23 N03761 [74.00 rpm]: Propeller speed (AMC-
FSN83M2)
_______________________________________________
192
3.2 Exhaust inlet dirty grid
On examining Table 2, above, the air receiver pressure
(bar) reduced by 13.2%. The corresponding
percentage reduction in the exhaust receiver pressure
(bar) is 10.1%/. There was a minor reduction in the air
receiver temperature (degC) by 4.7%. On the contrary,
there was a major increase in the temperature of the
exhaust receiver (degC) by 31%.
Since the exhaust grid of ME TBCH 1 was
simulated as dirty, it can be noticed that this had an
impact on the turbochargr1 rpm which reduced by
11.9%, but the reduction in turbocharger 2 rpm was
much less at 2.8%. The exhaust gas flow (ton/h) had
reduced substantially by31.7%, leading to a great
reduction in air flow (ton/h) by 54.5%. The main
engine turbocharger 1 exhaust temperature (egC) rose
by 50.2%, leading to a corresponding increase in air
outlet temperature (deg C) by 35.4%. Another notable
point was the pressure drop across the turbocharger 1
air filter by 79.3%.
It can be seen from Table 4, that the automatic
slowdown of the engine took place 11 minutes after
introducing the faulty condition.
It is essential to periodically check the exhaust
manifold in port, after taking all safety precautions.
Inspect for any broken piston rings, valves, or
excessive carbon accumulation at the turbocharger
inlet grid.
Table 4. PC: AMC-FSN83M2 - Neptune Log - 2/03/2021
12:13:41 PM
_______________________________________________
Time Events
_______________________________________________
00:04:30 Z07109 SET=77 % SOUND LEVEL SETPOINT
(AMC-FSN83M2)
00:05:21 E02005 [16.76 MW]: ME shaft power (to
propeller) (AMC-FSN83M2)
00:05:25 N01620 [7258.65 rpm]: ME TBCH 2 speed
(AMC-FSN83M2)
00:05:46 M2408 SET=70 % ME TBCH 1 inlet grid dirty
(AMC-FSN83M2)
00:07:05 T01614 234.83 HIGH [AG08] ME TBCH 1 air
outlet temp
00:07:09 X07069 SET=1 <0-2> ALARM STATE (AMC-
FSN83M2)
00:07:11 T01614 [234.41 degC]: ME TBCH 1 air outlet
temp (AMC-FSN83M2)
00:07:12 T01614 ACKNOWLEDGE ME TBCH 1 air outlet
temp (AMC-FSN83M2)
00:07:22 V20103 [CLOSED]: ME exh 1 SCR outlet valve
(AMC-FSN83M2)
00:07:27 X01952 1 HIGH [AG03] ME slow down
prewarning
00:07:32 T02100 460.56 HIGH [AG07] ME cyl 2 exh outlet
temp
00:07:33 T02040 457.69 HIGH [AG07] ME cyl 1 exh outlet
temp
00:07:33 T02100 [460.48 degC]: ME cyl 2 exh outlet temp
(AMC-FSN83M2)
00:07:34 T02140 460.44 HIGH [AG07] ME cyl 3 exh outlet
temp
00:07:34 T02100 ACKNOWLEDGE ME cyl 2 exh outlet
temp (AMC-FSN83M2)
00:07:35 T02040 [457.63 degC]: ME cyl 1 exh outlet temp
(AMC-FSN83M2)
00:07:36 T02040 ACKNOWLEDGE ME cyl 1 exh outlet
temp (AMC-FSN83M2)
00:07:37 T02200 459.16 HIGH [AG07] ME cyl 4 exh outlet
temp
00:07:37 T02140 [460.31 degC]: ME cyl 3 exh outlet temp
(AMC-FSN83M2)
00:07:37 T02140 ACKNOWLEDGE ME cyl 3 exh outlet
temp (AMC-FSN83M2)
00:07:38 T02200 [459.10 degC]: ME cyl 4 exh outlet temp
(AMC-FSN83M2)
00:07:38 T02200 ACKNOWLEDGE ME cyl 4 exh outlet
temp (AMC-FSN83M2)
00:07:39 T02240 [457.05 degC]: ME cyl 5 exh outlet temp
(AMC-FSN83M2)
00:07:41 T02240 456.96 HIGH [AG07] ME cyl 5 exh outlet
temp
00:07:41 T02240 [456.96 degC]: ME cyl 5 exh outlet temp
(AMC-FSN83M2)
00:07:41 T02240 ACKNOWLEDGE ME cyl 5 exh outlet
temp (AMC-FSN83M2)
00:07:44 X07069 SET=1 <0-2> ALARM STATE (AMC-
FSN83M2)
00:07:49 DCMES: SHAF
00:07:52 T01601 [44.21 degC]: ME air receiver temp
(AMC-FSN83M2)
00:07:55 N03761 [74.07 rpm]: Propeller speed (AMC-
FSN83M2)
00:08:01 N03761 [74.06 rpm]: Propeller speed (AMC-
FSN83M2)
00:08:03 T02106 206.48 HIGH [AG04] ME cyl 2 liner temp
(mean)
00:08:11 T02105 262.24 HIGH [AG04] ME cyl 2 cover
temp (mean)
00:08:17 T02145 262.72 HIGH [AG04] ME cyl 3 cover
temp (mean)
00:08:19 T02205 262.04 HIGH [AG04] ME cyl 4 cover
temp (mean)
00:08:25 T02045 260.27 HIGH [AG04] ME cyl 1 cover
temp (mean)
00:08:33 T02146 203.24 HIGH [AG04] ME cyl 3 liner temp
(mean)
00:08:33 T02245 261.25 HIGH [AG04] ME cyl 5 cover
temp (mean)
00:08:39 T02206 203.03 HIGH [AG04] ME cyl 4 liner temp
(mean)
00:08:57 T02046 202.70 HIGH [AG04] ME cyl 1 liner temp
(mean)
00:09:05 T02246 202.76 HIGH [AG04] ME cyl 5 liner temp
(mean)
00:09:25 DCMES: DO
00:11:04 X02445 2 HIGH [AG03] Autochief : Slow down
00:11:12 N01610 [6925.85 rpm]: ME TBCH 1 speed
(AMC-FSN83M2)
00:11:12 N01610 [6925.85 rpm]: ME TBCH 1 speed
(AMC-FSN83M2)
00:11:12 N01610 [6925.85 rpm]: ME TBCH 1 speed
(AMC-FSN83M2)
00:11:12 T01601 [43.27 degC]: ME air receiver temp
(AMC-FSN83M2)
00:11:12 N01610 [6925.85 rpm]: ME TBCH 1 speed
(AMC-FSN83M2)
00:11:12 X07069 SET=1 <0-2> ALARM STATE (AMC-
FSN83M2)
_______________________________________________
4 RELIABILITY ANALYSIS OF THE
TURBOCHARGING SYSTEM
This can be represented by means of a Fault Tree as
shown in Figure 4.
193
Figure 4. Fault Tree for failure of a Main Engine.
The above condition can be expressed by a
reliability block diagram (RBD) [15].
The reliability of the Main Engine may be
expressed by the following simple relationship [8].
Figure 5. RBD for a Main Engine.
where,
RME = Reliability of Main Engine,
RFO = Reliability of fuel oil system,
RLO = Reliability of lubricating oil system,
RCW = Reliability of the cooling water system and
RTC = Reliability of the Turbocharging system.
If any of the system shown in the RBD for the Main
Engine fails, then it would result in the failure of the
Main Engine [12].
The Reliability of the Main Engine can also be
represented as
4
1
1, 2, 3 & 4
ME i
i
FO LO CW TC
RR
R R R R
=
=
= = = =
The fault tree for the Main Engine Turbocharging
system is shown in Figure 6.
Figure 6. Fault Tree for Turbocharging system
Figure 7. Reliability Block diagram (RBD) for a Main Engine
Turbocharging system
4
1
1
2
3
4
* * * *
*
*
*
E
TC i
iE
E
E i A B C D E
iA
G
E i F G
iF
I
E i H I
iH
K
E i J K
iJ
RR
R R R R R R R
R R R R
R R R R
R R R R
=
=
=
=
=
=
==
==
==
==
It can be seen from the reliability block diagram in
Figure. 1, that the reliability of the turbocharging
system is dependent on the reliability of air cooler E1,
turbocharger compressor E2, turbocharger turbine E3,
and turbocharger shaft E4. E1, E2, E3 and E4 are in
series. Hence the failure of any one of the components
will result in the failure of the turbocharging system,
which in turn will result in the failure of the main
engine. Using the above method, the reliability of the
turbocharging system R_TC may be computed.
Details of this method will be taken up in further
work on this topic.
The manufacturers of the main engine and
turbochargers specify the time intervals for
overhauling and maintenance of various components
of the main engine and turbochargers. One of the
important factors essential to compute the reliability
of any system component is the time between failures,
[13, 14]. The time between overhauls may be taken as
a useful guide to computing reliability [7].
Some sample values of overhaul intervals for the
turbocharger given by a leading manufacturer are
shown below [11].
Table 5. Turbocharger Maintenance schedule
_______________________________________________
Activity Cleaning interval in hours
_______________________________________________
Clean turbine – dry clean 250
Clean turbine – wet clean 250
Clean air filter 250
Clean and check compressor 12000
casing insert and compressor wheel
Major overhaul 24000 – 30000
_______________________________________________
5 CONCLUSIONS
A turbocharging system is an integral part of a large
Main Engine. The main components of which being
the turbocharger and the air cooler. The turbocharger
utilises the energy contained in the exhaust gases, of
the Main engine to compress the air, temperature of
which may rise to 200 dges C, required for
combustion of the fuel in the Main engine cylinder.
The compressed air is cooled in an air cooler before
194
being sent to the engine cylinder, the air outlet
temperature at the cooler outlet cooled down to 40
degs C. The turbocharger must run at its optimum
efficiency to ensure efficient operation of the Main
engine. The Kongsberg engine simulator at AMC was
utilised to study the impact of the defective
turbocharging system on the safety of the Mai Engine.
This was done by running the engine at its normal
speed of 74 RPM, under loaded condition. For the
present study, two malfunctions of the turbocharging
system were introduced to look at its effect on the
operation of the Main Engine. These included one
each on the air side and exhaust side of the
turbocharger. The first malfunction introduced was a
dirty air filter. It was seen that this malfunction did
not hamper, the operation of the engine to a great
degree. There was no drop in the RPM of the Main
engine, only a marginal rise in the pressure drop
across the filter and the temperature of exhaust gas
after the turbocharger. The second malfunction
involved a dirty exhaust inlet grid to the turbocharger.
This condition had a major impact on the exhaust gas
cylinder outlet temperature which rose by about 50%.
This also led to an increase in the cylinder liner and
cylinder cover temperature to its alarming levels.
After 11 minutes of running the Main Engine slowed
down automatically, as per the safety provision
provided by the engine manufacturer. Hence it is
important to avoid this condition by carrying out the
Planned Maintenance and periodic inspection of the
exhaust manifold and ensure that the inlet grid is
always clean and free from any coke deposits. Also,
the turbocharging system must be reliable. With the
help of a Fault Tree analysis and developing a
Reliability Block Diagram, an equation was
established, using which the Reliability of the
Turbocharging, hence the reliability of the Main
engine may be computed.
6 FUTURE WORK
Malfunctions of turbocharger compressor failure,
turbine failure, failure of rotor bearings, and failure of
air cooler to be considered to see its impact on the
Main Engine operation. The study can be employed to
other sub-systems of the main engine to establish a
safe and reliable Main Engine at sea.
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