A100-H 100-H32

Common issues

• Bearing wear (journal and thrust bearings) leading to increased play and vibration.
• Compressor wheel fouling due to intake air contamination, reducing efficiency and causing surging.
• Turbine wheel fouling or erosion from exhaust gas impurities or high temperatures, impacting power output.
• Oil leakage from bearing casing seals (labyrinth or mechanical seals), leading to oil consumption and potential fire hazard.
• Nozzle ring and/or diffuser damage/fouling, affecting gas flow and turbocharger performance.
• Rotor imbalance due to fouling or damage, causing excessive vibration and potential catastrophic failure.
• Surging, often caused by engine load changes, fouling, or incorrect matching, leading to mechanical stress.
• Air filter clogging, restricting intake air flow and causing compressor cavitation or reduced boost.

Inspection checklist

• Check for any oil leaks from the bearing casing, oil lines, and connections.
• Visually inspect the compressor wheel for fouling, foreign object damage (FOD), erosion, or blade cracks (if accessible).
• Check the axial and radial play of the rotor shaft (cold check) against manufacturer's limits.
• Verify the security of all mounting bolts, air/exhaust connections, and oil lines.
• Inspect the condition and cleanliness of the air filter elements.
• Monitor turbocharger RPM, boost pressure, and exhaust gas temperatures for deviations from normal operating parameters.
• Listen for abnormal noises (e.g., rubbing, whistling, grinding) or excessive vibrations.
• Inspect the turbine casing and exhaust gas inlet/outlet for cracks, corrosion, or hot spots.
• Check the functionality of the water washing system (if fitted) and condition of nozzles.

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 (includes journal bearings, thrust bearings, and seals)
• Gasket and O-ring set (for casing opening and reassembly)
• Oil filter elements (if external to turbocharger)
• Air filter elements
• Water washing nozzles (if fitted)
• Nozzle ring (especially if operating with heavy fuels or high exhaust temperatures)

Safety

• Extremely high temperatures of exhaust gas and casing surfaces (up to 600°C), posing severe burn hazards.
• High rotational speeds of the rotor (up to 100,000+ RPM), with risk of catastrophic failure and flying debris in case of imbalance or material fatigue.
• Pressurized air (up to 4-5 bar) and exhaust gas lines, requiring proper sealing and integrity to prevent leaks or ruptures.
• Hot lubricating oil under pressure, presenting burn and slip hazards if leaks occur.
• High noise levels generated during operation, necessitating hearing protection in the vicinity.

Class survey

Class surveyors typically verify the turbocharger's maintenance history, including running hours, service records, and compliance with manufacturer's recommendations. They will conduct an external visual inspection for leaks, cracks, corrosion, and security of mounting. Functionality of safety devices (e.g., overspeed trip, low oil pressure alarm) and performance monitoring (boost pressure, exhaust temperatures, RPM) will be reviewed. Depending on running hours or any noted deficiencies, an internal inspection (e.g., opening for bearing and rotor inspection) may be required, typically aligning with major overhaul intervals or if performance issues are reported. Documentation such as type approval certificates and operating manuals must be readily available.

Estimated lifetime: 16,000 - 24,000 hours (before major overhaul, assuming proper maintenance and operating conditions)