Maintenance on Turbochargers:

 Regular water washing of compressor and dry cleaning of turbine.

 Regular check of oil level in bearing sump and changing oil after 1000 hrs
 Cleaning of air filter after 1000 hrs or earlier if found dirty.
 The cooling water chamber to be cleaned at every 8000 hrs
 Renewal of bearings after 16000 hrs and gear pumps to be renewed or
reconditioned after 16000 hrs
 During Dry dock, the ME TC is overhauled by shore w/shop, rotor is taken
ashore, cleaned and balancing carried out. Bearings renewed.

COMPRESSOR SIDE WET WASHING : Oil mist and dust drawn from engine
room may get deposited on the compressor surface. Dirt deposits should be
dislodged by injection of water during operation.

This is done at when the engine is at high load (80% load, turbocharger is at a
higher rpm). Wet washing is done once every 24 or 48 hours. Main Engine
turbochargers have a fixed system as shown in sketch above.
1. Open filler of the tank and fill with fresh water. Close vent.
2. Open air supply valve A
3. Open injection valve B and wait for 30 seconds.
4. Close valve A and B and open vent.
5. Check to ensure tank is empty.

On auxiliary engines a syringe like water gun is provided to perform this

procedure. Fill up the gun with water and spray it inside the turbocharger
(normally an injection point is provided to connect the gun).
2. WET WASHING OF TURBINE SIDE

This method is no longer in use because irregular washing causes imbalance

and causes bearing wear damage.
 This is done at a reduced load. Desired rpm of T/C is provided in the
manual. Reduce ME rpm to achieve desired low rpm of the turbocharger.
 Run the engine at this rpm for some time to allow the temperatures to
stabilize. Water washing is then carried out for 20 mins.
 Before washing the turbocharger drain is opened and a hose from fresh
water hydrophore is connected via a reducing valve.
 When water goes into the turbocharger then for the first 5 minutes the water
will evaporate and nothing comes out from the drain. After a few minutes the
turbocharger temperature reduces and then dirty water can be seen coming out
from the drain, carbon is removed by the process of dilution. Normally this
cleaning is done for 20 minutes or until clean water comes from the drain. Close
wash water valve and remove hose.
 The rpm is kept steady for some time to dry off the turbine. Then the rpm of
the engine is gradually increased.
 If washing is not evenly carried out the T/C might start vibrating while rpm
is increased. In such case repeat washing.
3. TURBINE SIDE DRY WASHING

This is also known as Grit washing. Size of grit varies depending upon the maker
of Turbocharger. Grit is made up of Walnut shells, and available in various sizes
(1.5mm-2mm, 2.2mm-2.8mm). Size of grit that is to be used is provided in the
manual by the manufacturer. Quantity of grit to be used is also specified (0.5kg,
1Kg etc). In emergency even rice can be used as dry washing medium.
 While performing grit washing, it is very important to use proper PPE kits
(face shield) as the small particles move at a high velocity and can cause severe
damage to eyes.
 Before starting grit washing, inform bridge to increase RPM (for higher rpm
in turbocharger). The compressed air line is to be drained as due to the moisture
the grit particles could get stuck.

 Close the valve 1 and 2, fill the grit into the chamber. After filling grit, close
the valve 3.Then open valve 2, now the chamber is pressurised. Gradually
open valve 1. Once all the grit is passed, a howling/whistling sound will
come.
 If it is needed to carry out grit washing once again, use the same quantity of
grit and do not reduce or increase the quantity of grit.
 Generally the air line is pressurized at 5-6 bars.
 After the procedure is completed close valve 1 and then 2.
 Surging of Turbocharger

Surging is a phenomenon that affects centrifugal compressor when the mass flow
rate of air falls below a sustainable level for a given pressure ratio.
Surging is a condition whereby an imbalance in demand and supply of air from the
turbocharger causes a rapid deceleration. When this occurs the pressure
downstream of the compressor is relieved to atmosphere backwards through
compressor. This is known as surging and it is accompanied by a loud barking
noise and vibration. The system will now stabilize itself, pressure will be built up
again, and if the condition causing the surge is still present, the cycle will repeat
itself. Depending on the degree of restriction, the frequency can be anything from a
few seconds to a number of minutes. Surging was common on pulse systems in
heavy weather; it is less prevalent in modern constant pressure designs.

The turbocharger must produce the required scavenge pressure. When the
turbocharger cannot maintain pressure and the air flow decreases, the delivered
pressure falls below the scavenge pressure which results in reversal of flow and
surging occurs.(scavenge air flows back to the TC and comes out of the suction
air filter)

If surging occurs engine speed must be reduced, the compressor should be water
washed and air filters cleaned. If this does not solve problems the engine balance
should be checked by taking set of indicator cards.Conditions leading to Surging:
Surging may occur in heavy weather when propeller comes out of water and
governor shuts the fuel almost instantaneously. Other possible reasons of surging
are:

 When governor shuts fuel instantaneously.

 change in engine speed/ load relationship- say due to hull fouling
 cylinder power imbalance
 faulty injectors or timing
 dirty air filter
 dirty air cooler (air side)
 Dirty turbine nozzle ring, clogged gas inlet protection grid.
 deposits on turbine blades or impeller
 damage to blades
 fouled exhaust gas boiler can also lead to surging
How to Prevent Turbocharger Surging?

The following are the ways to prevent turbocharger surging.

 Reduce the engine speed in bad weather conditions.

 Clean air inlet filter, air cooler & scavenge ports, (to provide unrestricted
passage for scavenge air).
 Clean fouled exhaust grids, nozzle ring & exhaust gas economizers (prevent
back pressure of exhaust, do regular soot blow).
 Water-wash the turbine and the compressor side of the turbocharger.
 Proper maintenance and checks should be done on turbocharger periodically.
 A balanced engine. Indicator cards to be taken to assess cylinder and power
distribution of individual units
 Proper matching of the turbocharger to the engine is very important i.e. the
engine operating line should be far enough to the right side of the surge line.

If the mass flow rate for the given pressure ratio drops then the delivery
becomes unstable and surging occurs.