TCR12
The Everllence TCR12 is a radial‑type marine turbocharger designed for medium‑speed diesel engines, delivering high pressure ratios in a compact package.
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Common issues
- Compressor fouling (reduced efficiency, surge risk)
- Turbine fouling (reduced power, high exhaust back pressure)
- Bearing distress (journal and thrust bearings - indicated by high vibration, oil leaks, abnormal noise, high bearing temperature)
- Rotor imbalance (leading to excessive vibration, bearing wear, potential rotor contact with casing)
- Oil leakage (from bearing housing seals, oil supply/drain lines)
- Surge (unstable operation, often due to fouling or engine issues)
- Cracks in casings (especially turbine casing due to thermal stress)
- Air filter blockage (restricting intake, reducing boost pressure)
Inspection checklist
- Visual inspection of compressor wheel for fouling, erosion, or damage (e.g., bent blades, foreign object damage).
- Visual inspection of turbine wheel for fouling, erosion, cracks, or damage (e.g., burnt blades, foreign object damage).
- Check axial and radial play of the rotor shaft (using a dial gauge) against manufacturer's limits to assess bearing wear.
- Inspect bearing housing for oil leaks, ensuring oil supply and drain lines are clear and secure.
- Check condition of air filter elements and intake silencer for cleanliness and integrity.
- Inspect turbine and compressor casings for cracks, corrosion, and secure mounting.
- Verify proper functioning of compressor wash system (if fitted) and drainage.
- Monitor turbocharger performance parameters: boost pressure, exhaust gas temperatures (in/out), turbocharger RPM, and vibration levels. Look for deviations from baseline or trends.
- Check security of all fasteners, especially mounting bolts and casing clamps.
Service intervals
| Daily/Weekly | Performance monitoring (boost pressure, exhaust temp, RPM, vibration), visual check for leaks/abnormal noise. |
| 500-1000 Running Hours | Compressor water wash (if fitted and required by operating conditions). |
| 2000-4000 Running Hours | Inspection of compressor side, cleaning if necessary. Check bearing play. |
| 8000-12000 Running Hours | Major inspection of bearings (journal and thrust), seals, and rotor assembly. Replacement of bearings and seals as per manufacturer's recommendations. Cleaning of turbine and compressor sides. Check for rotor imbalance. |
| 24000-36000 Running Hours | Major overhaul (complete disassembly, NDT of critical components, replacement of wear parts, dynamic balancing of rotor assembly). |
Typical wear limits
| Bearing Radial Clearance (Journal) | Typically 0.05 - 0.15 mm (new). Replace if exceeding 0.25 - 0.30 mm or manufacturer's specific limit. |
| Bearing Axial Clearance (Thrust) | Typically 0.10 - 0.25 mm (new). Replace if exceeding 0.35 - 0.45 mm or manufacturer's specific limit. |
| Rotor Run-out (at specific points) | Max. permissible 0.02 - 0.05 mm. Exceeding this indicates imbalance or bent shaft. |
| Blade Tip Clearance (Compressor/Turbine) | Critical and model-specific, typically 0.3 - 0.6 mm. Any contact or significant reduction indicates severe issue. |
| Casing Cracks/Deformation | Any visible cracks, especially in the turbine casing, or significant deformation are unacceptable and require repair/replacement. |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Complete bearing cartridge assembly (journal and thrust bearings)
- Oil seals and O-rings for bearing housing
- Gasket sets for turbine and compressor casings
- Air filter elements
- Compressor wash nozzles (if applicable)
- Mounting bolts and nuts (high-temperature resistant)
Safety
- High-speed rotating machinery: Risk of rotor disintegration if overspeed or severe imbalance occurs. Always follow safe operating procedures and ensure overspeed trip is functional.
- High temperatures: Exhaust gas and turbine casing surfaces can reach extreme temperatures (>500°C), posing severe burn hazards. Ensure insulation is intact.
- High pressures: Boost air and exhaust gas are under pressure. Ensure all connections are secure to prevent blow-outs.
- Noise: Turbochargers generate significant noise levels; hearing protection is mandatory in the vicinity.
- Hot oil/oil mist: Potential for fire if oil leaks onto hot surfaces.
Class survey
Class surveyors will typically review maintenance records, verify compliance with manufacturer's service bulletins, and conduct a visual inspection of the turbocharger's external condition (leaks, damage, security of mounting). During special surveys (e.g., 5-year), an internal inspection of the compressor and turbine sides may be required, often involving opening the casings. They will also check the functionality of safety devices (e.g., overspeed trip) and confirm the availability of critical spare parts onboard. Performance data trends are also often reviewed.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Service & Maintenance
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