Turbocharger Retrofits

The benefits of turbocharger retrofits are promoted by manufacturers, arguing that new generation models—with significantly higher overall efficiencies than their predecessors—can underwrite a worthwhile return on investment. Retrofitting older engines with new high efficiency turbochargers can be economically justified when one or more of the following conditions prevail, according to ABB Turbo Systems:

• The engine suffers from high exhaust temperatures; air manifold pressure does not rise to its normal level; and full load can no longer be attained.

• Need to reduce fuel costs and/or exhaust emissions.

• Need to increase engine operating safety for an extended period.

• Engine performance requires optimizing for slow steaming or another new operating profile.

• Unsatisfactory lifetimes are experienced with key turbocharger elements due to erosion or corrosion; older generation turbocharger spares from some manufacturers are difficult to obtain and/or are costly; and a long delivery time is quoted for replacement turbochargers.

The performance benefits from a retrofit (Figure 7.25) are reportedly realized in lower exhaust temperatures (down by around 50-80°C) and a lower fuel consumption (reduced by 3-5 per cent). The uncooled gas casings of new turbochargers also foster a longer lifetime for critical parts subject to wear from erosion and corrosion. Furthermore, ABB

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