TPS-E 61-E

Common issues

• Bearing wear (journal and thrust) leading to increased rotor play and vibration.
• Compressor fouling (dirt, oil carry-over) reducing efficiency, increasing surge risk, and causing rotor imbalance.
• Turbine fouling/carbon build-up (poor combustion, low-quality fuel) reducing efficiency and increasing exhaust back pressure.
• Nozzle ring and/or cover ring wear/damage affecting gas flow and turbine efficiency.
• Oil leakage from bearing housing due to worn seal rings or blocked drain lines, posing fire risk and oil consumption.
• Rotor imbalance and excessive vibration, often caused by fouling, bearing wear, or blade damage, leading to accelerated wear.
• Surging, an intermittent flow reversal, typically due to compressor fouling, engine load changes, or incorrect matching.
• Blade damage (compressor or turbine) from foreign object ingestion or fatigue, resulting in imbalance and efficiency loss.

Inspection checklist

• Visually inspect for oil/water leaks around bearing casings, air/gas connections, and exhaust casing.
• Check security of foundation bolts and mounting integrity; look for signs of looseness or fretting.
• Monitor operational parameters: boost pressure, exhaust gas temperatures (in/out), lube oil pressure/temperature, and rotor speed (if sensor fitted).
• Listen for abnormal noises (e.g., rubbing, whistling) and assess vibration levels using a vibration meter if available.
• During planned shutdowns, check rotor axial and radial play against OEM specified limits.
• Inspect compressor wheel for fouling, erosion, or damage; clean as necessary.
• During planned shutdowns, inspect turbine wheel and nozzle ring for fouling, erosion, or damage; clean as necessary.
• Verify the condition of air filter elements to ensure clean air supply to the compressor.
• Inspect the exhaust gas casing for cracks, hot spots, or signs of gas leakage.
• Check the functionality of the overspeed trip mechanism (if testable per OEM guidelines).

Service intervals

Typical intervals for this design class, not the manufacturer’s figures for your model. The manufacturer’s manual is binding.

Typical wear limits

Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.

Critical spares

• Complete set of journal and thrust bearings (including associated O-rings/gaskets).
• Set of seal rings (labyrinth seals) for both compressor and turbine sides.
• Full gasket and O-ring set for reassembly after maintenance.
• Cleaning agents/kits for compressor and turbine washing.
• Air filter elements (if part of the turbocharger's direct intake system).
• Nozzle ring segments (if modular design) or a complete nozzle ring.
• Lube oil filter elements (if the turbocharger has its own dedicated oil filtration system).

Safety

• High surface temperatures (exhaust casing can exceed 400°C) posing severe burn risks; ensure insulation is intact.
• Extremely high rotational speeds (up to 50,000+ RPM) with potential for uncontained failure if rotor is severely imbalanced or damaged.
• High noise levels (often exceeding 100 dB) requiring mandatory hearing protection in the vicinity.
• Pressurized components (air and exhaust gas) present risks during disassembly if not properly depressurized and isolated.
• Hot exhaust gases and potential for fire if oil leaks onto hot surfaces; ensure proper ventilation and fire-fighting readiness.

Class survey

Class surveyors typically check the general condition and cleanliness, absence of excessive oil leaks or corrosion, and security of mounting/foundation bolts. They verify operational parameters (boost pressure, exhaust temperatures, lube oil parameters) against design values, assess vibration levels, and check for the presence and apparent functionality of insulation, guards, and the overspeed trip mechanism. Review of maintenance records for scheduled services, repairs, and component replacements is crucial. Integrity of the exhaust gas casing and effectiveness of insulation to prevent hot spots are also key points.

Estimated lifetime: 24,000 - 36,000 hours before a major factory overhaul or significant component replacement (e.g., new rotor assembly) is typically considered, assuming regular maintenance and proper operation.