TCT60
The Everllence TCT60 is an axial‑flow marine turbocharger derived from MAN’s TCT series, intended for medium‑speed diesel engines to boost combustion efficiency and power output.
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Common issues
- Turbine blade fouling (leading to reduced efficiency, increased exhaust gas temperature, and potential imbalance)
- Compressor fouling (leading to reduced air flow, surging, and reduced engine power)
- Bearing distress from oil contamination (causing premature wear, increased clearances, and potential rotor damage)
- Surging under off-design operating conditions (especially at low loads or during rapid load changes)
- Rotor imbalance due to uneven fouling, blade damage, or bearing wear
- Oil leakage from bearing seals (indicating seal wear or high casing pressure)
- Cracks or erosion on turbine nozzle ring or casing components
- Exhaust gas leaks from casing joints or connections
Inspection checklist
- Visual inspection of turbine and compressor wheels for fouling, erosion, foreign object damage (FOD), or cracks (via inspection ports if available)
- Check bearing axial and radial clearances (using dial gauge) against manufacturer's limits
- Monitor turbocharger speed (RPM) and compare against engine load and design parameters
- Verify oil inlet/outlet temperatures and pressures are within specified ranges, checking for signs of contamination
- Inspect turbocharger casing for cracks, exhaust gas leaks, oil leaks, and proper insulation
- Check condition of air filter elements and silencer for cleanliness and damage
- Assess functionality of water wash and dry wash systems, ensuring nozzles are clear and drainage is effective
- Measure exhaust gas temperatures before and after the turbine, and charge air pressure/temperature for deviations from normal operation
- Check for excessive vibration or unusual noises during operation
Service intervals
| Annual Inspection (Class Survey) | As per Class Society requirements, typically involves visual inspection, bearing clearance checks, and review of maintenance records. |
| Bearing Inspection/Replacement | 8,000 - 16,000 running hours, depending on operating conditions and oil quality. |
| Rotor Overhaul (Cleaning, Balancing, Component Replacement) | 16,000 - 24,000 running hours, or as condition dictates (e.g., significant imbalance, blade damage). |
| Water Wash | Daily to weekly, depending on fuel type and engine load profile, to prevent fouling. |
| Dry Wash | As per manufacturer's recommendation, typically less frequent than water wash, for specific types of deposits. |
Typical wear limits
| Bearing Radial Clearance (new) | 0.15mm - 0.25mm |
| Bearing Radial Clearance (wear limit) | 0.30mm - 0.40mm (or +50% of new clearance) |
| Bearing Axial Clearance (new) | 0.08mm - 0.12mm |
| Bearing Axial Clearance (wear limit) | 0.15mm - 0.20mm (or +50% of new clearance) |
| Rotor Imbalance | Max permissible vibration amplitude at bearing housing typically 4-6 mm/s RMS. |
| Turbine/Compressor Blade Tip Clearance | Visual inspection for rubbing marks; any contact is critical and requires investigation. |
| Nozzle Ring Deformation/Cracking | Visual inspection for cracks, significant distortion, or excessive erosion; refer to manufacturer's manual for specific criteria. |
Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.
Critical spares
- Complete bearing set (thrust and journal bearings)
- Oil seals and O-rings for bearing housing
- Gasket sets for casing joints and connections
- Air filter elements
- Nozzle ring segments (if applicable and prone to wear/damage)
- Impeller nut (if applicable for rotor assembly)
- Speed sensor and/or temperature sensors
Safety
- High surface temperatures (exhaust casing, turbine outlet) - severe burn hazard; ensure insulation is intact.
- High-speed rotating components - risk of severe injury during maintenance or if casing integrity is compromised; never open inspection ports while running.
- High pressure charge air and exhaust gas - potential for uncontrolled release if flanges or connections fail; ensure proper tightening and gasket integrity.
- Noise levels - continuous exposure requires hearing protection.
- Oil mist/leakage - fire hazard, slip hazard on engine room floor; ensure proper sealing and ventilation.
Class survey
The class surveyor will typically review the turbocharger's maintenance logbook, including running hours, previous inspections, and any repairs. They will perform a visual inspection for external leaks (oil, exhaust gas), cracks, and corrosion. Bearing axial and radial clearances will be checked and compared against manufacturer's limits. The functionality of safety devices (e.g., overspeed trip, alarm systems) and the condition of the air filter and silencer will be verified. During engine trials, proper operation, charge air pressure, and exhaust gas temperatures may be observed. Availability of critical spare parts onboard is also a key check.
Components & Design
Component data being added…
Technical Data
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Common failures & inspection points
Service & Maintenance
Wartung per Hersteller-Handbuch und Klassifikationsgesellschafts-Anforderungen. Jährliche Inspektion bei Class Survey. Ersatzteile per Herstellerangabe bevorraten.
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