TCR16
The Everllence TCR16 is a radial‑type marine turbocharger derived from MAN’s TCR series, intended to increase air pressure for medium- and low‑speed diesel engines on commercial vessels.
Inspector Detail
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Common issues
- Surging caused by fouled air path, unsuitable operating point, or damaged compressor wheel
- Bearing wear (thrust and journal) leading to excessive axial/radial play and potential rotor contact
- Compressor fouling reducing air mass flow and efficiency, increasing exhaust temperature
- Turbine nozzle ring and blade fouling/erosion, leading to reduced turbine efficiency and increased back pressure
- Oil leakage from bearing housing seals, indicating seal wear or excessive crankcase pressure
- Rotor imbalance due to fouling, blade damage, or bearing wear, causing excessive vibration
- Cracked or deformed casings (turbine, compressor, bearing housing) due to thermal stress or impact
- Exhaust gas leakage from turbine casing joints or gas inlet/outlet flanges
Inspection checklist
- Check axial and radial bearing play (cold check, and hot check if possible with vibration analysis)
- Visually inspect compressor wheel for fouling, erosion, foreign object damage (FOD), and blade tip clearance
- Visually inspect turbine wheel and nozzle ring for fouling, erosion, cracks, and foreign object damage (FOD)
- Inspect oil inlet/outlet lines for leaks, correct pressure/flow, and oil quality (via sample)
- Check air filter condition (if fitted) and charge air cooler cleanliness
- Inspect exhaust gas inlet/outlet ducts, insulation, and casing joints for leaks or damage
- Verify functionality of turbocharger washing system (water/granulate) and drainage
- Check security of mounting bolts, vibration dampers, and associated pipework
- Monitor turbocharger speed, boost pressure, and exhaust gas temperatures for deviations from normal operating parameters
Service intervals
| Daily/Weekly | Visual inspection for leaks, abnormal noise/vibration, oil level check |
| Monthly/Quarterly | Air filter check/cleaning, oil sample analysis, water washing (if fitted) |
| 3,000 - 4,000 hours | Bearing inspection (visual, play check), detailed cleaning of compressor/turbine |
| 8,000 - 12,000 hours | Bearing replacement (cartridge), detailed inspection of rotor, nozzle ring, diffuser |
| 16,000 - 24,000 hours | Major overhaul (full disassembly, rotor balancing, replacement of wear parts, NDT checks) |
Typical wear limits
| Axial bearing play | Max. 0.40 - 0.50 mm (new typically 0.15 - 0.30 mm) |
| Radial bearing play | Max. 0.20 - 0.25 mm (new typically 0.05 - 0.15 mm) |
| Compressor/Turbine blade tip clearance | Manufacturer specific, typically 0.3 - 0.6 mm, check for rubbing marks |
| Rotor imbalance | Vibration levels exceeding ISO 10816-3 Zone C (e.g., > 7.1 mm/s RMS for small machines) |
| Blade erosion/damage | Visible cracks, material loss > 10% of blade thickness, or significant leading/trailing edge damage |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Complete bearing cartridge assembly (thrust and journal bearings)
- Gasket and O-ring sets for overhaul
- Oil filters (if external filtration is part of the turbocharger system)
- Compressor air filter elements (if applicable)
- Nozzle ring segments (if replaceable and prone to wear/fouling)
- Speed sensor (magnetic pick-up)
- Sealing rings (labyrinth or piston rings for gas/oil separation)
Safety
- Extreme hot surfaces (turbine casing, exhaust ducts) causing severe burns
- High-speed rotating machinery (rotor) posing severe injury risk during operation or improper handling
- High-pressure charge air and exhaust gas, potential for uncontrolled release if casings or pipes fail
- Noise levels requiring hearing protection in the vicinity during operation
- Oil mist leakage from bearing housing, posing a fire hazard in hot engine rooms
Class survey
Class surveyors typically verify the general condition, cleanliness, and security of the turbocharger mounting. They will check for any visible leaks (oil, exhaust gas, charge air) and the integrity of insulation. Documentation of maintenance, running hours, and previous inspection reports (especially bearing play checks and overhaul records) is crucial. Functionality of safety devices like overspeed trip and associated alarms will be checked. If opened for maintenance, the surveyor may request to witness bearing play measurements and visual inspection of rotor/casings.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Service & Maintenance
Maintenance per manufacturer manual and classification society requirements. Annual inspection at class survey. Stock spare parts per manufacturer specification.
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