TCA88

Common issues

• Heavy turbine-side fouling, especially during low-load or transient operation, leading to reduced efficiency, increased exhaust back pressure, and potential surging.
• Compressor diffuser and volute contamination (e.g., oil mist, dust), impacting air flow, compressor efficiency, and potentially causing surging.
• Bearing and thrust bearing wear, indicated by increased rotor axial and radial clearances, elevated vibration levels, or abnormal oil analysis results.
• Rotor imbalance after deposit shedding (e.g., carbon deposits from turbine side), causing significant vibration, noise, and accelerated bearing wear.
• Oil leakage from bearing casings, seal rings, or oil supply/drain lines, leading to excessive oil consumption and potential contamination of air/gas streams.
• Exhaust gas leakage from casing joints, expansion bellows, or insulation defects, posing fire hazards, reducing efficiency, and creating hot spots.
• Foreign Object Damage (FOD) to compressor or turbine blades, leading to imbalance, efficiency loss, and potential catastrophic failure.
• Surging, often a symptom of severe fouling, engine combustion issues, or improper operation.

Inspection checklist

• Check rotor axial and radial clearances (free play) using a dial gauge; compare measurements against manufacturer's new and wear limits.
• Visually inspect turbine and compressor blades for fouling, erosion, cracks, bending, or foreign object damage (FOD). Pay close attention to blade tips and roots.
• Inspect compressor diffuser and nozzle ring for fouling, damage, cracks, or excessive wear/deformation.
• Check for oil leaks from bearing housings, oil supply/drain lines, and gas leaks from casing joints, expansion bellows, or insulation.
• Inspect exhaust gas casing and insulation for cracks, hot spots, discoloration, or signs of overheating.
• Verify condition of air filter elements and ensure clean air supply to the compressor. Check for signs of oil ingress.
• Check condition of expansion bellows for cracks, thinning, signs of fatigue, or excessive movement.
• Monitor turbocharger vibration levels (if sensors are fitted) and listen for unusual noises (e.g., rubbing, whistling, knocking) during operation.
• Inspect turbocharger mounting bolts, chocks, and foundations for security, signs of fatigue, or corrosion.

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 shells (radial and thrust bearings) - complete sets.
• Gasket sets and O-rings (especially for casing joints, oil lines, and seal rings).
• Oil filter elements (if applicable for dedicated turbocharger lube oil system).
• Nozzle ring segments (if replaceable and prone to wear/fouling, often kept as a set).
• Locking plates, washers, and specialized fasteners for critical connections.
• Cleaning agents and equipment for compressor and turbine washing (onboard cleaning kits).
• Air filter elements (if applicable for turbocharger intake).

Safety

• High surface temperatures of exhaust gas casing and associated piping (exceeding 200°C) – severe risk of burns and potential fire hazard if insulation is damaged or oil leaks occur.
• High-speed rotating machinery (rotor operating at tens of thousands of RPM) – potential for catastrophic uncontained failure if maintenance is neglected or severe imbalance occurs.
• Pressurized air (up to 5 bar) and hot exhaust gas (up to 400°C) – risk of injury from sudden release or leakage during operation or maintenance.
• Hot lubricating oil – risk of burns during maintenance or from leaks, and potential for oil mist fires.
• High noise levels (often exceeding 100 dB) – requires mandatory hearing protection in the vicinity during operation.

Class survey

Class surveyors typically review the turbocharger's maintenance records, running hours, and previous survey reports. They will conduct a thorough visual inspection for external condition, signs of leaks (oil/gas), and integrity of insulation. Critical checks often include witnessing rotor axial and radial clearance measurements, inspecting bearing condition (if opened for maintenance), and verifying the functionality of safety devices such as the overspeed trip and associated alarms. The overall operational performance, compliance with manufacturer's service recommendations, and the condition of exhaust gas piping and expansion bellows are also assessed.