The turbocharger of the group is an important component in the intake and exhaust system. Many faults in the intake and exhaust systems are related to the turbocharger, so how to use the turbocharger well and reduce the occurrence of turbocharger faults should be given sufficient attention. In order to ensure the service life of the turbocharger, lubrication and cooling of the floating bearings of the turbocharger should be ensured in the planning. In this article, a brief explanation is provided on the use and accident repair methods of the turbocharger for diesel generators, hoping to encourage users to play a more correct role in daily maintenance.

Due to the rated working speed of the turbocharger being above 130000 rpm and located at the outlet of the exhaust manifold, the temperature is extremely high (above 800 ℃), and the inlet and exhaust pressures are also high. The working elements of high temperature, high pressure, and high speed require too much lubrication, cooling, and sealing of the turbocharger.

1. After starting the diesel generator, it should idle for 3-5 minutes and not immediately increase the load to ensure good lubrication of the turbocharger. This is because the turbocharger is located at the top of the diesel generator. If the turbocharger starts running at high speed immediately after the diesel generator starts, it will cause the turbocharger to run at high speed without oil supply, resulting in a shortage of oil in the turbocharger and even burning out the entire turbocharger.

2. The idle running time should not be too long, usually not exceeding 10 minutes. If the idle running time is too long, the compressor side will always be in a low-pressure state, which is easy to cause oil leakage at the compressor end.

3. Ensure that the air filter is clean and replace it regularly as required. Poor intake can lead to high negative pressure at the intake of the turbocharger, making it prone to oil leakage.

4. Do not turn off the engine when the diesel generator is running at high speed. It should be idle for 3-5 minutes to lower the speed of the turbocharger and the temperature of the exhaust device, in order to prevent accidents such as poor lubrication and bearing burning. Frequent and inaccurate use can damage the turbocharger.

5. For diesel generators with new turbochargers, left and right engine oil should be added to the oil inlet of the turbocharger before use to prevent the lifespan of the turbocharger from being reduced or accidents caused by poor lubrication.

One of the most common faults in use is oil leakage at both ends or one end of the turbocharger. In theory, the oil that enters the intermediate at normal pressure has become zero oil pressure after passing through the bearing working surface, and only flows back naturally to the oil pan of the diesel generator by gravity. Moreover, under normal working conditions, there is a certain amount of gas pressure at the back of the impeller at both ends of the turbocharger, so the oil will not flow from the low pressure zone to the high pressure zone. The specific purpose of the sealing ring is to seal the gas leakage from the compressor and turbine housing to the intermediate oil chamber, and it only serves the purpose of sealing oil in special circumstances. However, improper use can still cause oil leakage at both ends of the turbocharger under the following conditions.

When a diesel generator is idling for a long time, there will be a certain negative pressure at the back of the turbocharger turbine and impeller, causing the oil in the middle body to leak outward. This is the result of multiple special tests conducted by experts on the test bench. Therefore, it is necessary to prevent the diesel generator from idling for a long time.

If the oil return pipeline of the engine oil is deformed or blocked during use, resulting in poor oil return, high oil pressure in the middle body, and compressor oil flowing along both ends of the rotor axis to squeeze out the sealing ring, causing oil leakage. Therefore, it is necessary to regularly check whether the return oil pipeline is unobstructed to ensure that the oil can flow back to the crankcase normally.

If the exhaust gas pressure in the crankcase exceeds the specified value, it will cause an increase in pressure in the turbocharger return oil pipeline, resulting in poor return oil and causing oil leakage from the sealing ring. Regularly and strictly check the ventilation status of the crankcase and whether the lower smoke exhaust pipeline is unobstructed.

After long-term use of diesel generators, the air filter may become clogged due to excessive dust accumulation, resulting in a high negative pressure in the intake of the compressor. The sealing ring at the back of the impeller may leak oil due to the high negative pressure. Therefore, it is necessary to regularly inspect and maintain the air filter to ensure that it is not clogged or broken down, and to maintain normal gas supply.

Long term failure to change the engine oil results in too many impurities in the oil, which play a role in grinding abrasives and exacerbate damage and thinning of the sealing ring, gradually losing its sealing and oil sealing functions, leading to oil leakage. The so-called impurities refer to the presence of foreign particles larger than 0.02mm in the engine oil, which can randomly flow into the oil film of bearings and shafts, as well as the sealing ring, severely grinding rotating parts and exacerbating their wear and failure.

Floating bearing wear is one of the most common faults that cause oil leakage in turbochargers. After such accidents occur, the clearance between the bearings and the shaft is excessive, the oil film is unstable, the bearing capacity decreases, the vibration of the rotor shaft system intensifies, and the dynamic balance is disrupted. Excessive rotation radius can damage the seals at both ends, and in severe cases, may damage the entire turbocharger. The specific reasons for this malfunction are as follows:

After turbocharging, the thermal and mechanical loads of diesel generators increase significantly, and the working temperature is very high, which leads to an increase in oil temperature, a decrease in viscosity, and a decrease in load-bearing capacity. The speed of the turbocharger is nearly 20 times higher than that of the diesel generator, so the temperature at the turbocharger bearing is much higher than the temperature at the crankshaft of the diesel generator. This requires the engine oil to have a high viscosity, be able to withstand the load of high-speed rotors and high temperatures, and also have good dispersibility, oxidation resistance, and wear resistance.

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