TPS-F 61-F

Common issues

• Bearing wear (journal and thrust) leading to excessive axial/radial play and vibration.
• Fouling of compressor impeller and turbine blades, reducing efficiency and potentially causing surging.
• Oil leaks from bearing casings, particularly at the compressor and turbine side seals, indicating seal wear or blocked drain lines.
• Exhaust gas leaks from turbine casing joints, manifold connections, or flexible bellows, posing safety and efficiency concerns.
• Surging during engine load changes or low-load operation, indicating performance issues or control problems.
• Excessive vibration due to rotor imbalance, bearing wear, or foreign object damage (FOD).
• Foreign object damage (FOD) to compressor or turbine blades from upstream components or debris.
• Cracks in turbine casing or exhaust gas inlet/outlet connections due to thermal stress.

Inspection checklist

• Verify turbocharger speed and boost pressure against engine load and design parameters; check for deviations.
• Monitor bearing oil inlet/outlet temperatures and pressures; look for abnormal readings or fluctuations.
• Visually inspect compressor and turbine blades for fouling, erosion, corrosion, or damage through inspection ports (if fitted) or by opening casings.
• Check for any signs of oil leaks from bearing casings, oil supply/drain lines, and exhaust gas leaks from casing joints or expansion bellows.
• Listen for abnormal noises (e.g., rubbing, whistling, grinding) and check for excessive vibration during operation.
• Inspect the condition of the air filter element and silencer for cleanliness and damage.
• Check tightness of all mounting bolts, casing bolts, and pipe connections.
• Measure axial and radial bearing clearances (during engine shutdown) and compare with manufacturer's limits.
• Inspect the condition of the flexible bellows and expansion joints on the exhaust gas side for cracks or signs of leakage.

Service intervals

Typical wear limits

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

Critical spares

• Complete bearing cartridge assembly (journal and thrust bearings)
• Oil seals / Labyrinth seals (compressor and turbine side)
• Gasket sets for casing joints and connections
• O-rings for oil and water connections
• Air filter elements
• Nozzle ring segments (if applicable, or complete nozzle ring)
• Diffuser (if damage is common in specific applications)
• Balancing weights for rotor re-balancing

Safety

• Extremely hot surfaces (turbine casing, exhaust pipes) posing severe burn risks; ensure proper insulation and warning signs.
• High-speed rotating parts (rotor shaft, impeller, turbine wheel) presenting a risk of injury if guards are removed or maintenance is attempted without proper lockout/tagout.
• High pressure air and exhaust gas within the system, requiring careful depressurization before maintenance and awareness of potential uncontrolled releases.
• High noise levels generated by the turbocharger during operation, necessitating hearing protection in the vicinity.
• Potential for sudden component failure (e.g., blade detachment) leading to projectile hazards or casing rupture.

Class survey

Class surveyors typically verify operational parameters (speed, boost pressure, temperatures) against design data and previous records. They inspect for external leaks (oil, exhaust gas), check the general condition of the turbocharger, its mounting, and connections. Review of maintenance records, including bearing replacements, cleaning, and overhaul reports, is crucial. They also confirm the availability of critical spare parts as per class requirements and inspect safety devices such as overspeed trip mechanisms (if fitted) and pressure relief valves on the air side. Any excessive vibration or abnormal noise will be noted.