Häufige Probleme
- Compressor fouling (reduced efficiency, surging risk)
- Turbine nozzle ring and blade fouling (reduced power, increased exhaust temperature)
- Bearing wear (excessive radial/axial play, oil leaks, increased vibration)
- Rotor imbalance and vibration (due to fouling, damage, or bearing wear)
- Oil leakage from bearing housings (internal or external)
- Cracks in turbine or compressor casings (especially near exhaust gas inlet/outlet)
- Exhaust gas leaks from turbine casing joints or expansion bellows
- Damage to compressor or turbine blades (impact, erosion, corrosion)
Prüfliste
- Visual inspection of compressor and turbine blades for fouling, erosion, or impact damage (via inspection ports)
- Check bearing radial and axial play (manual check or dial gauge if accessible during overhaul)
- Monitor lubricating oil pressure, temperature, and quality (check for contamination)
- Inspect for oil leaks from bearing housings, oil lines, and casing joints
- Check integrity of turbine and compressor casings for cracks, hot spots, or loose bolts
- Verify exhaust gas temperatures before and after turbine, and boost air pressure (compare to baseline/engine load)
- Inspect air filter condition and ensure proper sealing
- Check operation of compressor wash system and drainage lines (ensure no blockages)
- Listen for abnormal noises or excessive vibration during operation (use vibration monitoring equipment if available)
- Verify proper functioning of overspeed trip mechanism (during planned maintenance, not routine operation)
Wartungsintervalle
| Daily/Watchkeeping | Operational parameter monitoring (boost pressure, temperatures, oil pressure), visual check for leaks/abnormalities |
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| Monthly/Quarterly | Compressor water wash (as per manufacturer's guidelines), air filter inspection/cleaning |
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| Annually (Class Survey) | External inspection, verification of maintenance records, operational performance check. Internal inspection (bearings, rotor) if due or indicated by performance/vibration. |
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| 12,000 - 18,000 Running Hours | Bearing inspection/replacement (thrust and journal bearings) |
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| 24,000 - 36,000 Running Hours | Major overhaul including rotor inspection, cleaning, balancing, and potential replacement of nozzle ring/diffuser components. |
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Typische Verschleißgrenzen
| Bearing Radial Play (Journal Bearings) | New: 0.20 - 0.35 mm; Max Allowable: 0.60 - 0.75 mm |
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| Bearing Axial Play (Thrust Bearing) | New: 0.10 - 0.20 mm; Max Allowable: 0.35 - 0.45 mm |
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| Rotor Blade Tip Clearance | Manufacturer specific, but typically 0.5 - 1.5 mm for compressor, 0.8 - 2.0 mm for turbine. Any contact indicates severe issue. |
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| Rotor Imbalance | Measured in g.mm, specific to rotor size and speed. Exceeding limits requires re-balancing. |
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Die Bereiche sind für diese Bauklasse typisch. Maßgeblich sind stets die Herstellerunterlagen zur jeweiligen Seriennummer.
Kritische Ersatzteile
- Complete bearing cartridge assembly (thrust and journal bearings)
- Gasket and O-ring sets for casing joints and oil lines
- Lubricating oil filters (if separate from engine system)
- Compressor wash nozzles and detergent
- Bolts and nuts for casing joints (especially high-temperature applications)
- Oil seals and labyrinth seals
- Minor repair kit for oil piping/connections
Sicherheit
- Extreme hot surfaces (turbine casing, exhaust gas piping) – risk of severe burns.
- High-speed rotating machinery (rotor) – potential for catastrophic failure if imbalanced or damaged.
- Pressurized air and exhaust gas systems – risk of sudden release if casings or piping fail.
- Lifting heavy components during maintenance – proper lifting gear and procedures are essential.
- Noise levels – high noise during operation requires hearing protection in vicinity.
Klassenbesichtigung
The class surveyor will primarily verify that maintenance and inspection schedules, as per the manufacturer's manual and classification society rules, have been adhered to. This includes reviewing logbooks and maintenance records. They will conduct a thorough external visual inspection for leaks, damage, and proper securing. Operational parameters (boost pressure, exhaust gas temperatures, oil parameters) will be checked against design values and historical trends. If the unit is due for a major overhaul or if performance/vibration issues are noted, the surveyor may require internal inspection of bearings, rotor, and nozzle ring. The functionality of safety devices like the overspeed trip and relevant alarms will also be checked.
Geschätzte Lebensdauer: Bearings typically 12,000 - 24,000 hours before replacement. Major overhaul (including rotor, casings, nozzle ring) typically 36,000 - 48,000 running hours, with some units extending to 60,000 hours with meticulous maintenance and monitoring.