VED-BORD4

Turbocharger Maintenance

Regular turbocharger maintenance is essential for the overall performance of the engine, the fuel consumption and compliance with the emission regulations, e.g. IMO MARPOL Annex VI. Apart from reducing the risk of costly major breakdowns, regular maintenance is required to prevent too large degradation of the overall turbocharger efficiency and to maintain the surge margin.

At our well-equipped workshop in Copenhagen and through our global network we cater for every need for turbocharger maintenance. We can offer service and reconditioning of most turbocharger brands – as well as retrofits. We can supply most spare parts at short notice, as well as offer an exchange system.

We are authorized by a number of turbocharger manufacturers to carry out turbocharger maintenance. Our Service Engineers and Workshop Technicians have received a wide range of type specific turbocharger training by the manufacturers.

We are specialized in repairing and reconditioning turbocharger cartridges. We have a comprehensive stock of required parts and can offer a wide range of complete cartridges on exchange basis. The cartridges are dismantled and thoroughly cleaned and inspected. Parts are reconditioned where possible and the cartridge is reassembled in accordance with the specified tolerances.

 

We offer turbocharger maintenance, utilizing the following techniques:


  • Dynamic & static balancing
  • Steam cleaning
  • Ultrasonic inspection
  • Glass bead blasting
  • Micro blasting
  • Hydrostatic testing
  • Metal spraying
  • Wet blasting
  • Blade weld repair
  • TIG welding
  • Ultraviolet crack inspection
Turbine-fritskrabet

Turbocharger Authorizations

We hold a number of turbocharger authorizations by some of the world’s leading turbocharger manufacturers. Recognizing our competencies, capabilities and quality commitment, a number of manufacturers have chosen us to be part of their authorized service network. Being part of global service networks allows us to assist our clients wherever in the world they require assistance.

Striving to offer the best service, technical solutions and spare parts to our clients, we work closely together with the turbocharger manufacturers. The turbocharger authorizations allow us to offer genuine parts and gives us access to technical data, training, etc. This allows us to obtain the high quality level that we aim for – our staff being trained in a variety of turbocharger types and staying abreast of developments. Quality is furthermore ensured by regular audits, carried out by the companies that have chosen to issue the turbocharger authorizations.  Hence, the turbocharger authorizations are the clints’ assurance that we stay up to date with regards to developments and service requirements.

Being close to our broad range of clients also ensures that we are well aware of the operational requirements. Thus we are able to identify and implement the best solutions – ensuring the correct technical solutions, with the minimum disruption to the commercial operation of our clients’ assets.

 

We presently hold turbocharger authorizations from the following companies:


  • Mitsubishi Heavy Industries Co. Ltd. (Japan)
  • Napier Turbochargers Ltd. (UK)
  • KBB – Kompressorenbau Bannewitz GmbH (Germany)
turbocharger service

Turbocharger Service

Our trained and experienced turbocharger Service Engineers are available for worldwide turbocharger service  – all year round – whether for turbocharger servicing during scheduled repair periods, e.g. during dry dockings, or for normal maintenance and in case of breakdowns during operation.

To reduce costs and save time, our Service Engineers will normally bring a turbocharger service kit based on our experience, in order to have the turbocharger operational again in the shortest possible time – reducing the risk of having to wait for necessary turbocharger spare parts. To further reduce costs, manpower for turbocharger service can in many cases be arranged through our global network of trusted partners.

If a major overhaul is scheduled, we recommend our Turbocharger Exchange System. This concept ensures that all required parts are not only available for the Service Engineers, but also that the turbocharger rotor is already balanced and that all parts are verified fit for use until the next scheduled major overhaul. Not only being cost effective, the Turbocharger Exchange System also removes a lot of uncertainties from the turbocharger service process – uncertainties that would else only be resolved once the turbocharger is dismantled. Furthermore, it makes the turbocharger service independent of any specialized equipment, e.g. a local workshop with a turbocharger balancing machine. The Turbocharger Exchange System thus minimizes the time required for turbocharger service, reduces uncertainties with regard to spare part requirements and enables the overhaul to be performed anywhere in the world – ensuring the best quality every time.

In case of sudden turbocharger breakdowns, we know that time is of the essence in order to get the engine back into service. Being experienced in dealing with such repairs, we can quickly evaluate the best solution – both technically and economically. Working closely with the owners and manufacturers, we act decisively and through our network we can normally quickly obtain the required correct parts.

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Turbocharger Balancing

In case of high-speed rotating components, turbocharger balancing is of the essence – both for the sake of safety and time between overhauls. We employ state of the art equipment – not only for the balancing of turbocharger rotors, but for balancing of high-speed rotating components for a wide variety of applications.

We balance all components separately and correct for static unbalance. In order to check the balance after assembly, the complete unit will finally be checked for dynamic unbalance.

We have the latest equipment for balancing components in two planes, from the smallest size up to a length of 3,000 mm and a diameter of 1,200 mm, with three balancing machines available to cater for every need:

  • SCHENCK H20/H40 BUTL with CAB 920
  • SCHENCK H10BU with CAB 610
  • SCHENCK HEC121 with CAB590

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Turbocharger Reconditioning

Being an expensive piece of equipment, turbocharger reconditioning is a cost-effective alternative to renewing partly or completely. In addition, the advances in engine development, in order to meet emission requirements and reduce fuel consumption, have prompted development of new turbocharger types with higher pressure ratios and efficiency. This has caused earlier turbocharger types to be discontinued by the manufacturers, in some cases making it difficult to readily obtain new parts for such types still in service.

In order to meet the above-mentioned challenges, we offer turbocharger reconditioning of most types. At a fraction of the cost of new components, this allows the clients to maintain their turbochargers in good condition throughout the full service life. Apart from being cost effective, and for older turbocharger types often the only viable alternative to retrofitting a newer type, reconditioning is also less of a drain on the natural resources and thus being more sustainable than just replacing with new components.

Turbocharger reconditioning

Turbocharger Reconditioning Services Include:


  • Turbocharger Shafts
  • Blades and Nozzle Rings
  • Turbocharger Balancing

Reconditioning of Turbocharger Shafts


We offer repair and reconditioning of all rotating shafts by hot and cold metal spraying. All shaft journals, threaded areas, pump spigots and seal areas can be repaired by metal spraying and then machine to the original specification. Unlike a cold repair process, metal spraying allows a shaft to be restored to its original dimensions and strength.The metal spraying procedure employed by us is approved by Lloyd’s Register.

 

Reconditioning of Blades and Nozzle Rings


When reconditioning turbochargers, the key competence is the ability to rebuild turbine blades, compressor wheels and nozzle rings. We do this by a specialized procedure, approved by Classification Societies, carried out by highly qualified technicians.

The turbine blades are dismantled, cleaned ultrasonically and accurately measured. A non-destructive inspection by ultra-violet light is performed to detect possible fractures. Fractured blades are replaced with new ones.

Our turbine blade welding is based on a procedure developed through extensive research by metallurgists. The method used is TIG (Tungsten Inert Gas) welding – a technique using a non-fusing electrode at low amperage, shielded by an inert gas.

The welding is carried out under strictly controlled conditions. Only a small zone may be exposed to heating, and the operation must be carried out in a closed welding chamber, free from dirt particles and air turbulence, as any draught would disperse the shielding gas and result in poor welding quality.

After welding the turbine blade is machined and ground back into its specified shape, inspected for cracks using both ultra-violet light and dye penetrant inspection and the weight is verified.

In order to achieve the correct weight distribution, a computer calculates the sequence in which the blades should be mounted on the rotor in preparation for the balancing.

Similar processes are employed to recondition nozzle rings and compressor wheels.

 

Turbocharger Balancing


In case of high-speed rotating components, turbocharger balancing is of the essence – both for the sake of safety and time between overhauls. We employ state of the art equipment – not only for the balancing of turbocharger rotors, but for balancing of high-speed rotating components for a wide variety of applications.

We balance all components separately and correct for static unbalance. In order to check the balance after assembly, the complete unit will finally be checked for dynamic unbalance.

We have the latest equipment for balancing components in two planes, from the smallest size up to a length of 3,000 mm and a diameter of 1,200 mm, with three balancing machines available to cater for every need:

  • SCHENCK H20/H40 BUTL with CAB 920
  • SCHENCK H10BU with CAB 610
  • SCHENCK HEC121 with CAB590

 

 

 

Turbocharger Exchange System

Turbocharger Exchange System

In cooperation with our clients, we have developed a Turbocharger Exchange System. This concept is based on supplying all parts required for an overhaul – consumables as well as relevant major components – packed in a suitable box. The concept allows for a full turbocharger overhaul in the shortest possible time, as the box contains everything that is conceivably needed – including a balanced rotor, nozzle ring and shroud ring. The advantage is that down time is reduced and nasty surprises are avoided – the complete overhaul being carried out on site, with no requirement for local workshop facilities, e.g. for balancing of the rotor.

The concept only requires the client to pay for the parts actually used, as unused parts are to be returned together with the replaced parts. Hence the client avoids the hassle or extra costs associated with ordering of too few or too many parts. The replaced parts are being reconditioned upon their return and included in subsequent Turbocharger Exchange System boxes. This concept is especially suited for clients operating series of vessels, with identical engine and turbocharger configurations, where the Turbocharger Exchange System will enable a structured overhaul schedule – independent of turbocharger workshop availability in the trading area of the individual vessel.

The concept is equally suitable for engines in service, where down time can result in costly off-service, or for scheduled overhauls, where the lead time for condemned components may exceed the time available during e.g. a dry docking.

Turbocharger Repair

 

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