Power2 800-M
The Accelleron Power2 800‑M is a two‑stage turbocharger built for 4‑stroke, medium‑speed marine diesel engines, providing higher boost pressure and improved fuel efficiency.
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Common issues
- Interstage fouling reducing pressure ratio (critical for two-stage efficiency)
- Compressor fouling on high-pressure stage (leading to reduced air flow and surging)
- Bearing distress from oil contamination or insufficient lubrication (axial/radial play increase)
- Control or bypass component sticking where fitted (e.g., wastegate, bypass valves, variable geometry components)
- Turbine side fouling (both LP and HP stages, especially with HFO operation)
- Rotor imbalance due to uneven deposits or minor blade damage (causes vibration, bearing wear)
- Oil leakage from bearing housings or sealing arrangements
- Exhaust gas leakage from turbine casing joints or connections
Inspection checklist
- Visual inspection for oil, water, or exhaust gas leaks from casings, pipes, and connections.
- Check bearing temperatures (local gauges or DCS) for abnormal readings (e.g., >90°C).
- Monitor turbocharger speeds (LP and HP stages via DCS) for consistency and expected values.
- Inspect compressor and turbine wheels (via borescope if possible, or during scheduled opening) for fouling, erosion, or damage.
- Check interstage cooler condition for fouling, external damage, or signs of internal leakage (water in scavenge air).
- Verify proper operation and freedom of movement for all control/bypass valves and actuators.
- Check mounting bolts and support structures for tightness and signs of vibration-induced wear.
- Inspect air filter elements for cleanliness and integrity.
- Listen for abnormal noises (e.g., rubbing, whistling, surging sounds).
Service intervals
| Minor inspection (visual, operational checks) | 500 - 1,000 running hours |
| Compressor wash (wet/dry) | As required, typically 500 - 2,000 running hours |
| Turbine wash (wet) | As required, typically 500 - 2,000 running hours (HFO operation) |
| Bearing inspection and/or replacement (HP & LP stages) | 8,000 - 16,000 running hours |
| Rotor inspection, cleaning, and balancing | 8,000 - 16,000 running hours |
| Interstage cooler cleaning and pressure testing | 4,000 - 8,000 running hours |
| Control valve inspection and overhaul | 4,000 - 8,000 running hours |
| Major overhaul (full disassembly, inspection, NDT, balancing, replacement of wear parts) | 24,000 - 48,000 running hours |
Typical wear limits
| Bearing radial play (new) | 0.15 - 0.30 mm |
| Bearing radial play (max worn) | 0.45 - 0.50 mm |
| Bearing axial play (new) | 0.20 - 0.40 mm |
| Bearing axial play (max worn) | 0.60 - 0.70 mm |
| Rotor shaft runout (max allowable) | 0.03 mm |
| Impeller/Turbine blade tip clearance (new) | 0.8 - 1.5 mm |
| Impeller/Turbine blade tip clearance (max worn) | 2.0 - 2.5 mm (depending on specific design) |
| Nozzle ring deformation (max deviation from true plane) | 1.5 mm |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Complete bearing cartridge sets (for both HP and LP stages)
- Seal rings (labyrinth seals) for both compressor and turbine ends
- Full gasket and O-ring sets for casing openings and connections
- Oil filters (if applicable to TC lubrication system)
- Control valve diaphragms and seal kits
- Nozzle ring segments (especially for HP turbine, if segmented type)
- Mounting bolts and specialized locking washers
Safety
- High surface temperatures (exhaust casing, turbine housing) posing severe burn hazards.
- High-speed rotating components (up to 100,000+ RPM) with potential for catastrophic disintegration if unbalanced or damaged.
- Pressurized air and exhaust gas lines, risk of leakage or rupture.
- High noise levels requiring hearing protection in the vicinity.
- Hot lubricating oil under pressure, risk of spray and fire.
Class survey
Class surveyors will typically review maintenance records, including bearing replacements, rotor inspections, and overhauls. They will check operational parameters (speeds, temperatures, pressures) against manufacturer's specifications. Visual inspection for oil/exhaust gas leaks, security of mounting, and condition of insulation is standard. Verification of safety devices, such as the overspeed trip mechanism and alarm functions, is critical. If opened for maintenance, internal components (bearings, rotor, casings) will be inspected for wear, damage, and cleanliness. Documentation of spare parts inventory for critical components is often requested.
Components & Design
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Service & Maintenance
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