HPR

Common issues

• Compressor fouling, especially when operating on HFO or with poor air filtration.
• Turbine fouling and erosion, leading to reduced efficiency and increased exhaust back pressure.
• Bearing wear (radial and axial play exceeding limits), causing rotor imbalance and potential contact.
• Oil leakage from bearing seals (compressor and turbine side), indicating seal wear or improper oil drainage.
• Rotor imbalance, often manifested as excessive vibration and noise.
• Exhaust gas leakage from casing joints or flanges, reducing efficiency and posing safety risks.
• Air filter clogging, restricting airflow and leading to compressor surging or reduced boost.
• Damage to compressor or turbine blades (e.g., foreign object damage, erosion).

Inspection checklist

• Visual check for oil leaks around bearing housings, seals, and oil lines.
• Visual check for exhaust gas leaks from turbine casing joints, flanges, and exhaust manifold connections.
• Inspect compressor wheel for fouling, erosion, rubbing marks, and foreign object damage (FOD).
• Inspect turbine wheel and nozzle ring (if accessible) for fouling, erosion, cracks, and rubbing marks.
• Check axial and radial bearing play (rotor shaft movement) against manufacturer's limits.
• Inspect air filter element condition; ensure it's clean and undamaged.
• Monitor turbocharger boost pressure, exhaust gas temperatures (pre/post turbine), and lube oil parameters (pressure, temperature) for deviations from normal operating ranges.
• Check condition of water washing nozzles and ensure proper operation (if fitted and during maintenance).
• Listen for unusual noises or vibrations from the turbocharger during operation.
• Inspect foundation bolts and anti-vibration mounts for security and integrity.

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

• Complete bearing set (thrust and radial bearings)
• Oil sealing rings (compressor and turbine side)
• Gasket and O-ring kit for casing overhaul and oil lines
• Impeller nut and locking washer
• Lube oil filter elements (if separate filter unit)
• Nozzle ring segments (if applicable and prone to wear/fouling)
• Cleaning agents/kits for compressor and turbine washing

Safety

• High surface temperatures of turbine casing and exhaust piping (burn hazard).
• High rotational speed of the rotor (risk of catastrophic failure if bearings fail or imbalance occurs).
• Pressurized exhaust gas and charge air (risk of injury from leaks or during dismantling).
• Hot lubricating oil (burn hazard and fire risk if leaked onto hot surfaces).
• High noise levels during operation (hearing protection required in vicinity).

Class survey

The Class Surveyor will typically verify the general condition of the turbocharger, absence of leaks (oil, exhaust gas), and integrity of mounting. They will review maintenance records, including bearing play measurements, overhaul dates, and spare parts inventory. Performance logs (boost pressure, exhaust temperatures) will be checked for consistent operation. The surveyor will also confirm that the annual inspection requirements as per the manufacturer's manual and classification society rules have been met, and that any reported defects have been rectified.

Estimated lifetime: 16,000 - 24,000 running hours before major overhaul (rotor balancing, bearing and seal replacement). Total component life can be significantly longer with proper maintenance.