TCP

Common issues

• Compressor fouling leading to reduced efficiency and surge
• Turbine-end fouling from exhaust gas, causing back pressure and power loss
• Bearing wear (journal and thrust) due to inadequate lubrication, contamination, or high loads
• Seal leakage (oil and gas) leading to oil consumption, contamination, and performance issues
• Rotor imbalance causing excessive vibration and potential damage to bearings/shaft
• Casing cracks, particularly in the hot exhaust gas sections, due to thermal stress
• Exhaust gas leaks from flanges or expansion joints, posing fire and safety risks
• Foreign object damage (FOD) to compressor or turbine blades

Inspection checklist

• Check for oil leaks from bearing casings and air/gas leaks from flanges/expansion joints.
• Inspect compressor and turbine blades for fouling, erosion, cracks, and foreign object damage (FOD). Use a borescope if necessary.
• Listen for unusual noises (whining, grinding) and check for excessive vibration during operation.
• Verify lubricating oil pressure and temperature are within manufacturer's specified limits.
• Inspect air filter elements for cleanliness and integrity; replace or clean as required.
• Check cooling water flow and temperature (if applicable) to bearing casing.
• Monitor boost pressure and exhaust gas temperatures (before and after turbine) for deviations from normal operating parameters.
• Inspect casing for cracks, corrosion, loose fastenings, and signs of overheating.

Service intervals

Typical intervals for this design class, not the manufacturer’s figures for your model. The manufacturer’s manual is binding.

Typical wear limits

Ranges are typical for this design class. Always confirm against the manufacturer documentation for your serial number.

Critical spares

• Bearing cartridges (journal and thrust bearings)
• Seal rings / Labyrinth seals (compressor and turbine side)
• Gasket sets and O-rings for overhaul
• Air filter elements
• Lubricating oil pump (if external, or repair kit for internal)
• Compressor/turbine cleaning nozzles (if water wash system)
• Rotor shaft assembly (for emergency replacement, though usually repaired)

Safety

• Hot surfaces: Exhaust gas casing and turbine outlet can reach extreme temperatures, posing severe burn risks. Ensure insulation is intact.
• High-speed rotating parts: The rotor operates at very high RPMs. Risk of rotor burst if severely imbalanced or damaged, leading to catastrophic failure and projectile hazards.
• High-pressure exhaust gas and boost air: Leaks can cause noise hazards, fire risks (if oil-contaminated), and potential injury.
• Noise levels: Turbochargers generate significant noise; hearing protection is mandatory in the vicinity.
• Fire risk: Oil leaks onto hot surfaces (exhaust casing) can ignite, leading to engine room fires.

Class survey

Class surveyors typically check the external condition for leaks, cracks, and security of mounting. They verify maintenance records, running hours, and performance logs (boost pressure, exhaust temperatures). 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 confirm the functionality of safety devices like overspeed trips and alarm systems, and ensure compliance with SOLAS/MARPOL regulations regarding emissions and safety.

Estimated lifetime: 24,000 - 48,000 running hours for a scheduled major overhaul, with proper maintenance the main casing and rotor can last significantly longer (100,000+ hours) through multiple overhauls.