A100-H 100-H37

Common issues

• Bearing wear (journal and thrust bearings), leading to excessive rotor play and potential contact.
• Compressor wheel fouling or erosion, reducing efficiency and potentially causing surging.
• Turbine wheel fouling, erosion, or foreign object damage (FOD) from exhaust gas, leading to imbalance or reduced power.
• Oil leakage from sealing air/oil seals, indicating seal wear or improper pressure differential.
• Rotor imbalance or shaft bending, manifesting as excessive vibration and noise.
• Cracks or deformation in the turbine or compressor casings due to thermal stress or vibration.
• Nozzle ring or diffuser damage/fouling, affecting gas flow and turbocharger performance.
• Surging, often caused by compressor fouling, incorrect engine tuning, or air filter blockage.

Inspection checklist

• Check rotor axial and radial play (cold) against manufacturer's limits to assess bearing condition.
• Visually inspect compressor and turbine wheels for fouling, erosion, rubbing marks, or foreign object damage (FOD).
• Inspect for oil leaks around bearing casings, oil inlet/outlet connections, and air/gas ducts.
• Verify security of all mounting bolts, pipe connections (oil, air, gas), and insulation.
• Check exhaust gas inlet/outlet ducts for signs of cracks, excessive corrosion, or carbon build-up.
• Monitor lubricating oil pressure and temperature at the turbocharger inlet during operation.
• Listen for abnormal noises (whining, rubbing, knocking) and observe vibration levels during operation.
• Inspect air filter condition (if applicable) and ensure compressor intake is clear of obstructions.
• Verify proper functioning of water washing system (if installed) and check drainage lines for blockages.

Service intervals

Typical wear limits

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

Critical spares

• Bearing cartridge set (journal and thrust bearings)
• Oil sealing rings / Labyrinth seals
• Gasket and O-ring set (for overhaul)
• Nozzle ring segments (if applicable and prone to wear)
• Rotor shaft assembly (for catastrophic failure, though less common as a routine spare)
• Compressor wheel (if operating in abrasive environments or prone to surge damage)
• Lubricating oil filter elements (if integral to TC system)

Safety

• High surface temperatures (exhaust gas casing, bearing housing) - severe burn hazard. Always allow cooling before handling.
• High rotational speeds (up to 60,000+ RPM) - catastrophic rotor failure due to imbalance or bearing failure can cause projectile hazards.
• Pressurized hot exhaust gas and charge air - sudden release can cause injury. Ensure system is depressurized before opening.
• Hot lubricating oil under pressure - burn hazard and potential fire risk if leaks occur.
• High noise levels during operation - hearing protection is mandatory in the vicinity of the turbocharger.

Class survey

Class surveyors typically review the turbocharger's maintenance records, including running hours, service history, and spare parts consumption. They will visually inspect for oil leaks, excessive vibration, abnormal noise, and signs of overheating or casing damage. Verification of safety devices (e.g., overspeed trip settings, alarms) and confirmation of proper lubrication oil supply and drainage are also key. Compliance with manufacturer's recommended service intervals and general condition of the unit relative to its age and operating hours will be assessed.

Estimated lifetime: 16,000 - 24,000 hours (before major overhaul, assuming proper maintenance and operating conditions. The unit's total service life with component replacement can extend to 48,000 - 72,000 hours or more).