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1 Wrtsil 27 September 2007 W50DF06V00BTM04A Rev. 01

06 INTAKE & EXHAUST SYSTEMSWRTSIL W50DFTURBOCHARGER AT FREE END

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06 INTAKE & EXHAUST SYSTEM

Intake and exhaust system arrangement - internal

Fig. name: Principal scheme of internal intake and exhaust system

System components 01 Air filter

02 Compressor

03 Charge air cooler (HT)

04 Charge air cooler (LT)

05 Water mist catcher

06 Cylinders

07 Turbine

Pipe connections

314 Air supply to compressor and turbine cleaningunit

501A Exhaust gas outlet, A-bank

501B Exhaust gas outlet, B-bank

507 Cleaning water to turbine and compressor

607A Condensate water after charge air cooler, A-bank

607B Condensate water after charge air cooler, B-bank

608A Cleaning water to charge air cooler, A-bank

608B Cleaning water to charge air cooler, B-bank

08 Waste gate valve

09 Cleaning devicefor turbocharger

10 Orifice forcondensate wateroutlet

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Intake and Exhaust system on engine

Fig. name: Intake and Exhaust system on engine

System components

01 Turbocharger

02 Charge air cooler


04 Charge air receiver (in engine block)

05 Charge air supply pipe

06 Exhaust manifold

07 Waste gate valve

08 Insulation box

09 Washing device for turbocharger

10 Washing device for charge air cooler

The intake and exhaust system channels delivers thecompressed air to the combustion chamber and carriesthe exhaust gases out from the combustion chamber toexhaust manifold.

The intake and exhaust system can be split up into anintake section including the charge air system and anexhaust section including the exhaust system.

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EF06X0005_01en


Charge air system

System components

01 Filter silencer

02 Radial plain bearing

03 Axial thrust bearing

04 Bearing bush

05 Radial plain bearing 06 Gas outlet casing

07 Gas inlet casing

Fig. name: Principal view of turbocharger

TurbochargerThe turbochargers are driven by the exhaust gases coming fromthe cylinders through the opened exhaust valves. Thecompressor is driven by the turbine. The energy of the exhaustgases are used to compress the intake air of ambient pressure toa higher level. The charged air enlarges the air quantity fed intothe combustion space and thus makes it possible to burn a biggeramount of fuel in the cylinder space.

The combustion air is taken outside of engine to the compressorside of the turbocharger. Passing through the compressor side,the air pressure and density are increasing as well as thetemperature. The hot air is cooled down in the charge air coolers.

08 Nozzle ring

09 Turbine wheel

10 Bearing casing

11 Diffuser

12 Compressor wheel 13 Air outlet casing

01 02 03 04 05 06

07

08

0910

11

12

13

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Charge air system

Fig. name: Basic settings of turbocharging

Basic settings of turbocharging System components

01 Compressor


03 Turbine

04 Waste gate valve

Connections

A Air intake

B Exhaust outlet

Power Plant application

Waste gate: YES

By pass: NO

Marine diesel electric:

Waste gate: YES

By pass: NO

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Charge air system

System components

01 Turbocharger

02 Charge air pipe

03 Air inlet box



06 Bracket and connecting box to engine block

07 Charge air receiver in engine block

08 Waste gate pipe to exhaust outlet

Inlet and charge air flow

A Ambient air

B Air to compressor inlet

C Charge air to inlet box D Charge air to charge air coolers

E Charge air to water mist catchers

F Charge air to charge air receiver

Fig. name: Principal scheme of the charge air system

Exhaust gas flow J Exhaust outlet from cylinder

K Exhaust to TC turbine

L Exhaust outlet to stack

The ambient air is compressed in the TC compressor. The compressedair passes through two 2-stage air coolers. After the coolers the watercondensate is separated from the charged air in the water mistcatchers. The charge air system is in addition equipped with a twonozzles for water washing of the charge air coolers.

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Fig. name: Charge air cooler and water mist catcher

Charge air coolers

Description of charge air coolersThe engine is equipped with two charge air coolers to cooldown the compressed and heated air after the turbochargers.

The charge air coolers are of insert type and mounted in acommon frame.

The charge air temperature is kept at the correct level by theflow of the high temperature and low temperature coolingwater. The cooling water is circulated through the tubes. Thecharge air passes between the fins on the outside of the tubes.Additionally there are two water mist catchers, one for each

cooler, mounted after the coolers in the same frame, whichenables to reduce NOx emission values.

Components and connections



03 Drain pipes for condense water

Components +connections?

Connections

A Air flow

B LT water inlet

C LT water outlet

D HT water inlet

E HT water outlet

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Components +connections?

Charge air supply from receiver to cyl inder head

Components 01 Charge air receiver

02 Cylinder head

03 Air supply pipe

04 Connection flange

05 Clamping ring

06 O-ring

Fig. name: Charge air supply pipe

The charge air flows from the receiver in theengine block to the cylinder heads trough Thecharge air supply pipe and channel in cylinderhead.

Connections

A Charge air supply from engine block

B Charge air supply to cylinder head C Gas feed connection

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Water cleaning device for turbocharger

System components

01 Electrical control panel

02 Control valve of water supply 03 Control valve of air supply

04 Ventilation valve

System connections A Shut-off valve of air supply

B Shut-off valve before valve washing unit

C Shut-off valve of input unit

Fig. name: Water cleaning device for turbocharger

Cleaning water pressure increase unit

Function buttons

05 ON/OFF key

06 Selector switch

07 Control switches of cleaning procedures

08 Emergency STOP button

The cleaning pressure increase unit is located outside of theengine. It consists of a water supply unit and of an electricalcontrol panel.

The washing sequences are controlled (operated) by thecontrol unit and are freely programmable with parameters.

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Principal scheme for turbine washing valve unit

System components

CV646 CS valve actuator

CV647 TS valve 1

CV648 TS valve 2

CV645 Air valve actuator

Fig. name: Principal scheme for turbine washing unit

System connections

A Air, pressurized (4 - 8 bar)

W Water from cleaning device

water pressure (5 - 6 bar)

C Compressor cleaning

T Turbine cleaning

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Washing valve unit

Components

01 TS valve 1

02 TS valve 2

03 CS valve

04 Air valve

05 Water inlet

06 Air inlet

07 Water pipe to turbine 1

08 Water pipe to turbine 2

09 Water pipe to compressors

10 TS valve actuator 1

11 TS valve actuator 2

12 CS valve actuator

13 Air valve actuator

14 Non-return valve

Fig. name: Water cleaning device for TC, washing valve unit

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Washing system for turbocharger

Components located on the engine

The turbocharger valve washing unit (one foreach turbocharger) consisting of:

Control valves

Actuator valves and

Pipe system

Fig. name: Washing system for turbocharger

Systems components:

01 Valve unit for water cleaning device

02 Turbocharger

03 Pipe line for compressor washing

04 Pipe line for turbine washing

The washing system equipment mounted on the engineconsists of the washing valve unit and the pipe systemsfor compressor and turbine washing.

The washing procedure is activated and controlled withequipment located outside the engine.

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Cleaning nozzles for charge air system

System components

01 Nozzle with valve and adapter 02 Sealing ring

03 Hose with quick coupling

04 Charge air cooler housing

Fig. name: Cleaning nozzle for charge air system

The charge air system is equipped with a twonozzles for water washing of the charge aircoolers.

The nozzles are mounted in such a position thatthe spraying direction is opposite to the air flow.

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System components

01 Exhaust pipe

02 Exhaust pipe

03 Bracket

04 Bellows

05 Bellows

06 Exhaust pipe

07 Sealing ring 08 Sealing ring

09 Support plate

10 Exhaust pipe

Fig. name: Principal view of exhaust system

11 Turbocharger

12 Support

13 Support arm

14 Support

15 Support

16 Blank flange

17 Waste gate system 18 Bellows

19 Insulation

The exhaust manifold is divided into modules. Each module contains of one exhaust pipe (01)

connected to the cylinder heads with bellows (05) andexhaust pipes (06).

The exhaust pipe modules are provided with flexiblebellows (04) on each end to avoid thermaldeformations.

The bellows are fitted to the pipes with screws andnuts.

Intake & Exhaust manifolds

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Fig. name: Exhaust outlet from cylinder head and charge air and gas supply

Intake & Exhaust manifolds

System components 01 Exhaust pipe insulation

02 Exhaust pipe

03 Exhaust outlet from cylinder

04 Exhaust pipe support

05 Exhaust bellows

06 Gas feed pipe

07 Clamping ring

08 Air inlet pipe to cylinder

09 Gas injection nozzle

10 Cooling water

11 Charge air receiver

12 Cylinder head

13 Cylinder liner

Connections

C Charge air from receiver

E Exhaust gas out

D Gas and air mix into cylinder

G Gas into cylinder head

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Waste gate system

System components

01 Waste gate valve

02 Piping from TC 1turbine inlet

03 Piping from TC 2turbine inlet

04 Bellows

Connections A1 Exhaust gas from TC 1 turbine inlet

A2 Exhaust gas from TC 2 turbine inlet

B Exhaust outlet to stack from TC 2

Fig. name: Principal view of waste gate system

05 Branch pipe to waste gate

valve

06 Pipe to waste gate valve

07 Pipe from waste gate valve

08 Bellows

09 Pipe to stack

10 Exhaust pipe to stack from TC 2

The waste gate system consists of the waste gate unit and anexhaust pipe system with bellows and protection covers. The wastegate unit is mounted near the turbochargers above the charge aircooler housing.

The waste gate valve is working as a regulator and adjusts the air-fuel ratio to the correct value by opening to limit the exhaust gasflow to the turbochargers. The waste gate valve thus reduces thecharge air pressure and firing pressure to suitable level in wholescale of the power output range.

The waste gate system is controlled by WECS. When engine isrunning with gas mode the waste gate system operates as active

and with diesel mode mainly as passive when the is valve closed.

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Waste gate valve

System components

01 Butterfly valve

02 Actuator (pneumatic power cylinder)

03 Positioner 04 Cooling extension

05 Positioner pilot valve

06 Lever

07 Cam

08 Adjusting screw

09 Adjusting screw

Fig. name: Waste gate valve

The waste gate valve unit is situated in a pipeline betweenexhaust inlet to TC and exhaust outlet to stack. The valve iscontrolled electronically and operated pneumatically.

The waste gate control system gets compressed air from theinstrument air system.

Connections A Control air from the system

B Connections to and from the actuator

C Control air from I/P converter

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System components

01 Insulation for charge air pipe 1

02 Insulation for charge air pipe 2 03 Insulation for air inlet to coolers

Fig. name: Insulation for charge air supply pipes and inlet to cooler

The Insulations for the charge air supply lines andthe charge air cooler consists of insulation piping,sealing covers and plate frames insulated withsuper wool. The super wool insulations are coveredwith glass fibre cloths.

Insulations for charge air supply l ines and cooler

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Insulation for exhaust manifold

System components

01 Insulation, upper segment

02 Insulation, upper end segment

03 Insulation, side segment

04 Insulation, side segment

05 Insulation, end segment

06 Frame

07 Frame

08 Fixing band

09 Tensioning bar 10 Cotter pin

11 Locking latch

Fig. name: Insulation for exhaust manifold

The Insulation for the exhaust manifold consists of insulationsegment spit up in parts that can easily be dismantled formaintenance of the exhaust manifold.

The insulation segments are supported by frames. Theinsulation sections are fixed to each others with fixing bands.

The fixing bands are joint together with tensioning bars. Theupper and side segments are kept together with lockinglatches.

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Fig. name: Insulation between exhaust manifold and charge air receiver

Insulation between exhaust manifold and charge air receiver

System components

01 Insulation, bottom segment



04 Connection piece

05 Connection piece

06 Connection piece

The insulation between charge air receiver and exhaustmanifold consist of insulating bottom segment. Thebottom segments are kept in place with connectionpieces. The amount and type of the insulation segmentand the connection pieces is depends on the engineconfiguration.

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Fig. name: Insulation for exhaust inlet to turbocharger

Insulation for exhaust inlet to turbocharger

System components

01 Exhaust pipe insulation, upper part, left

02 Exhaust pipe insulation, upper part, right

03 Exhaust pipe insulation, lower part, left

04 Exhaust pipe insulation, lower part, right

The insulation cover between the exhaustmanifold insulation box and the turbochargersconsists of four insulation parts. These partsare mounted in place with screws.

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Fig. name: Insulation for turbocharger

Insulation for turbocharger

System components

01 Insulation for exhaust inlet to turbine 02 Insulation for turbine

03 Insulation for compressor

All parts of the turbochargers are covered withinsulation boxes.

The figure shows the turbocharger in B-bank

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Fig. name: Insulation panels for turbochargers

Insulation panels for exhaust inlet to turbochargers

System components 01 Insulation panel

02 Insulation panel

The hot exhaust inlet side of the turbochargersare in addition to the insulation covers alsoprotected with insulation panels.

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Insulation between cylinder head and insulation box

Fig. name: Insulation between cylinder head and insulation box

The insulation between the cylinder head and themain insulation box for the exhaust manifoldconsists of a steel plate cover insulated with superwool insulation which is covered with glass fibrecloths. The insulation covers the flange of theexhaust bend.

System components

01 Insulation for exhaust bend

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Fig. name: Insulation for waste gate valve

Insulation for waste gate system

System components

01 Insulation

02 End piece

03 End plate

04 End piece

05 Tensioning bar

06 Spring cotter

07 Clamping band

The insulation box assembly for the waste gatesystem consists of one insulation box and threeend plates sections. These sections areattached to each others with tension bar lockinglatches. The tensioning bars are secured withspring cotters. The insulation covers the wastegate valve and the exhaust pipe betweenconnection pipe branch from exhaust manifoldand outlet to stack.

Waste gate valve

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Fig. name: Insulation for waste gate piping

System components

01 Insulation, TC1 outlet to stack

02 Insulation, TC2 outlet to stack

03 Insulation, Bellows, waste gate connection

04 Insulation, Exhaust pipe support

05 Insulation, Bellows DN150

06 Insulation, Bellows

07 Tensioning bar

08 Spring cotter

The insulation for the waste gate pipe systemconsists of insulation boxes as shown in the figure.

These insulation boxes are split up into sections foreasy dismantling for maintenance work. The boxsections are attached to each others with tension barlocking latches. The tensioning bars are secured withspring cotters.

The insulated parts covers the branch pipe fromturbochargers to waste gate valve and the bellows on

the exhaust pipe between the waste gate valve andthe connection to the outlet to stack.

Insulation for waste gate system

Waste gate piping

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