METxxSD

Common issues

• Bearing wear (journal and thrust) leading to increased rotor play and vibration.
• Compressor fouling due to dirty intake air or oil mist, reducing efficiency and air flow.
• Turbine fouling/erosion from poor fuel combustion, high exhaust gas temperatures, or abrasive particles.
• Oil leakage from bearing housing seals, indicating seal wear or blocked drain lines.
• Cracks or deformation in turbine/compressor casings due to thermal stress or excessive vibration.
• Exhaust gas leakage from casing joints or bellows, reducing efficiency and posing safety risks.
• Imbalance of rotor assembly due to blade damage or uneven fouling, causing excessive vibration and bearing stress.
• Failure of speed sensor or other monitoring instrumentation due to vibration or contamination.

Inspection checklist

• Check for any signs of oil leakage around the bearing housing, oil inlet/outlet pipes, and casing joints.
• Inspect exhaust gas inlet/outlet bellows and casing joints for gas leaks (soot marks) and structural integrity.
• Visually inspect the compressor and turbine wheels (if accessible through inspection ports or after opening) for fouling, erosion, or damage to blades.
• Check rotor axial and radial play (after engine shutdown and cooling, if safe and accessible) against manufacturer's limits.
• Monitor turbocharger operational parameters (RPM, exhaust gas temperature before/after turbine, charge air pressure/temperature) for deviations from normal.
• Listen for unusual noises (whistling, grinding, rubbing) during operation, indicating bearing wear or rotor contact.
• Inspect the condition of the air filter elements and ensure the compressor intake is clean and unobstructed.
• Verify the functionality of the water washing system (if fitted) and check nozzles for blockage.

Service intervals

Typical wear limits

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

Critical spares

• Journal Bearings (complete set)
• Thrust Bearings (complete set)
• Sealing Rings (gas and oil side)
• Gasket Set (for overhaul, including casing joints and oil/gas connections)
• Impeller Nut
• Speed Sensor
• Oil Pump (if external type)
• Air Filter Elements (if applicable to turbocharger intake)

Safety

• High surface temperatures of casings and exhaust gas piping, posing burn hazards.
• Extremely high rotational speeds of the rotor, requiring strict adherence to lockout/tagout procedures before any maintenance.
• Potential for hot oil spray or oil mist leakage, creating a fire hazard in the engine room.
• High noise levels during operation, necessitating hearing protection.
• Stored energy in the rotating assembly; ensure rotor has completely stopped before opening any part of the casing.

Class survey

Class surveyors typically review the turbocharger's maintenance logbook, verify adherence to manufacturer's service intervals, and check for valid DNV TA certificate (TAM0000153). During annual surveys, an external visual inspection for leaks, damage, and general condition is performed. For intermediate or special surveys, depending on the engine running hours and condition, the surveyor may require opening of the turbocharger for bearing inspection, rotor clearance checks, and assessment of compressor/turbine wheel condition. Availability of critical spare parts onboard is also checked.

Estimated lifetime: 80,000 - 120,000 hours (for main casings and rotor shaft with regular major overhauls and component replacements)