TPS-D

Häufige Probleme

• Fouling of compressor wheel and diffuser, leading to reduced efficiency and surging.
• Oil seal leakage (labyrinth seals), resulting in oil carry-over into exhaust or air side.
• Bearing wear (journal and thrust bearings), indicated by excessive axial/radial play or vibration.
• Turbine blade erosion and/or corrosion, especially with poor fuel quality or high exhaust gas temperatures.
• Cracks in turbine casing or nozzle ring due to thermal stress.
• Exhaust gas leakage from casing joints or flange connections.
• Vibration due to rotor imbalance or bearing deterioration.

Prüfliste

• Check for oil leaks around bearing casing, compressor, and turbine sides.
• Inspect compressor wheel for fouling, foreign object damage (FOD), and blade integrity (visual/borescope).
• Inspect turbine blades and nozzle ring for erosion, cracks, and deposits (visual/borescope if accessible).
• Check axial and radial bearing play (if covers are removed, use dial gauge; otherwise, check for excessive 'rocking' by hand).
• Inspect exhaust gas inlet and outlet flanges for signs of leakage (soot marks).
• Verify cooling water connections for leaks and proper flow.
• Check air filter condition and ensure silencer is clear.
• Monitor turbocharger speed, exhaust gas temperatures (before/after turbine), and boost pressure against engine load.
• Listen for unusual noises (whining, grinding, rubbing) during operation.

Wartungsintervalle

Typische Verschleißgrenzen

Die Bereiche sind für diese Bauklasse typisch. Maßgeblich sind stets die Herstellerunterlagen zur jeweiligen Seriennummer.

Kritische Ersatzteile

• Complete bearing cartridge (journal and thrust bearings)
• Oil seal rings (labyrinth seals)
• Gasket sets for casing, flanges, and connections
• O-rings for cooling water and oil lines
• Compressor wheel nut
• Air filter elements
• Nozzle ring (if operating conditions are harsh or prone to fouling)

Sicherheit

• Hot surfaces: Exhaust gas casing and turbine housing operate at very high temperatures (300-600°C) – severe burn hazard.
• High-speed rotating parts: Rotor operates at speeds up to 50,000-70,000 RPM – extreme injury risk if covers are removed during operation.
• High-pressure exhaust gas: Potential for blow-outs from faulty gaskets or cracked casings.
• Noise levels: High noise output requires hearing protection in the vicinity.
• Risk of component failure: Blade detachment or rotor burst can cause significant damage and injury.

Klassenbesichtigung

Class surveyors typically verify maintenance records (logbooks, service reports, spare parts inventory). They conduct a visual inspection for external leaks (oil, exhaust gas, cooling water), check for excessive vibration, and confirm the general condition and cleanliness of the unit. If the turbocharger has been opened for maintenance, the surveyor will verify the condition of internal components (bearings, rotor, casings) and proper reassembly, often requiring witness of bearing play measurements.

Geschätzte Lebensdauer: 24,000 - 36,000 running hours before major overhaul/refurbishment of core components (rotor, casings), with proper intermediate maintenance.