Turbo Failure Symptoms: 5 Signs You Mustn’t Neglect in Marine Engines

Turbo Failure Symptoms

Turbochargers have become really important for modern ship engines that run on diesel. They make these engines work better and use fuel more effectively when sailing out in the open ocean. However, just like any machine part can get old and worn out, turbochargers in diesel ship engines can also wear down over time. If you can spot the signs that the turbocharger is starting to fail early on, you can stop your engine from getting worse and avoid having to pay a lot for repairs. In this post, we’ll talk about five important signals that show a turbocharger in a marine diesel engine is failing. These are things you should always be careful not to miss.

How Do Turbochargers Function in Marine Diesel Engines?

Before we delve into the symptoms of turbocharger failure, it’s crucial to comprehend their operation.

Ahoy, fellow sea enthusiasts! Ever wondered about the engine powerhouse that propels those mighty marine diesel engines? In this post, we will try to put in our best effort to explain the Turbochargers from their working principles to design operation, and maintenance. Imagine a massive ship gliding through waves with astonishing speed, driven by a remarkable force. That power comes from something called a turbocharger, a really important piece that makes marine diesel engines work better.

From the spinning turbine to the intricate dance of air and fuel, understanding the inner workings of a marine diesel engine’s turbocharger is like peering into the heart of sea propulsion. engines. By the end, you’ll have a clear understanding of the world of turbochargers for marine diesel engines. Prepare yourself as we get into the specifics of Turbo Failure Symptoms

Signs of Turbocharger Failure

1 Unusual Noises

One of the first signs that something might be off with your turbocharger is when you start hearing strange noises. If you pick up on sounds like spinning or grinding, or if there are unfamiliar noises coming from your engine, this could be a signal that the turbocharger is having problems. These sounds might mean that the turbocharger’s bearing is damaged or that some parts inside it are not fitting together properly.

When you’re used to the normal sounds of your engine, anything out of the ordinary can catch your attention. The emergence of these unusual noises is like a red flag, waving to let you know that all might not be well with your turbocharger. Addressing the issue early can prevent further damage to your engine and save you from more complicated and expensive repairs down the line. So, if you’re hearing something odd, don’t ignore it – it might just be your turbocharger trying to tell you something important.

2 Decreased Power Output

If your boat’s diesel engine suddenly feels weaker and doesn’t work as well as it used to, the turbocharger might be the culprit. When the power and performance of your marine engine drop a lot, it could be a sign that the turbocharger is having problems. For example, if your vessel has a hard time speeding up or reaching the speeds it normally can, this could be a hint that something’s not right with the turbocharger.

Think of it like this: the turbocharger is like a boost for your engine, helping it produce more power. If that boost isn’t working properly, your engine won’t be as strong as it should be. So, if you notice that your boat isn’t performing as it should and it’s struggling to go as fast as it usually does, it’s a good idea to check the turbocharger. Investigating what’s going on with the turbocharger can help you figure out what’s causing the drop in power. Fixing the issue sooner rather than later can keep your engine running smoothly and save you from bigger problems later on.

3 Abnormal Exhaust Smoke

If you see a lot of unusual smoke coming out of your boat’s exhaust, especially if it’s really thick and dark, that might mean something’s up with the turbocharger. Sometimes, when the turbocharger isn’t working right, the exhaust smoke can look different from what you’re used to. It could be thicker and darker than normal.

This is kind of like a sign that your engine isn’t feeling well. When the turbocharger isn’t doing its job properly, the exhaust smoke changes because things aren’t burning the way they should.

It’s like when your car isn’t running smoothly, you can see it in the exhaust. If you notice these strange changes in the smoke and you can smell something unusual, it’s a good idea to think about the turbocharger. Getting things sorted out early can help your boat’s engine stay in good shape and prevent bigger issues down the road.

4 Peculiar Odors

If you start smelling something like burning oil, kind of like when your car isn’t doing well, it might be linked to the turbocharger. Sometimes, when the turbocharger isn’t working like it should, you might notice a strange smell in the air. This smell is like a signal that something isn’t right.

Think of it like this: the turbocharger is connected to your engine, and it’s supposed to help your engine work better. But if the turbocharger has a problem, it might let oil escape into places it shouldn’t, like the exhaust system. That’s what can cause this unusual smell.

Just like how you’d notice something burning in your kitchen, you can notice something strange in the air around your boat. If you catch a whiff of this unfamiliar smell and it’s like something’s burning, it could be a sign that your turbocharger isn’t in good shape. Taking a look at it sooner rather than later can help you figure out what’s going on and fix any issues before they get worse. It’s a bit like listening to your boat’s engine when it’s trying to tell you something’s not quite right.

5 Dashboard Warning Lights

The engines in today’s boats have special sensors that keep an eye on different parts, like the turbochargers. If you see lights on the dashboard of your boat, especially the ones about the engine or the exhaust, that’s a sign you should pay attention to right away.

It’s kind of like your boat’s way of talking to you. The sensors notice when something isn’t going as it should with the turbochargers or other important stuff. Then they send a signal, and that signal makes a light turn on in your dashboard. This light is like a signal to let you know that something needs your attention.

Just like how a light in your house shows you where something is happening, these dashboard lights show you that something might not be quite right in your boat’s engine. It’s a good idea to listen to what the lights are saying and check things out. When you notice these warning lights, especially the ones about the engine or exhaust, it’s best to take action quickly. This can help you figure out what’s going on and get things fixed before they become bigger problems.

Common Causes of Turbocharger Failure

In my 45 years of experience in the marine industry and captive diesel power plants, I have come across the following problems.

1. Bearing failures,
2. Damage to the compressor wheel
3. Abnormal erosion on Nozzle rings
4. Surging in Turbocharger
5. Overspeeding of Turbocharger
6. Low discharge air pressure.

Bearing failures

Bearing failures during the operation can cause damage to the Turbo rotor, compressor wheel, Turbine blades, and damage to the turbocharger casing. 

The Reasons Behind Turbocharger Bearing Failure

• Neglecting the bearing change schedule; – In one factory, there was a catastrophic failure in the Turbocharger. During the inspection observed that the customer did not change bearings as per schedule. Bearings were not available. The maintenance Engineer didn’t procure the bearings before the maintenance. The poor planning of the maintenance engineer has caused the heavy expenses to bring the Turbocharger back in service.
• Poor lubrication;- Using an inferior grade of oil for the bearing lubrication has been one of the reasons for failure in the Turbocharger with splash type bearing lubrication. In the Turbocharger with the pressure lubrication system, dirt in the oil was the reason. Dirt and carbon particles passing across the filters have clogged the oil holes. Blocking of the oil holes will make the Turbocharger starve with oil. The prolonged oil change schedules are the leading cause of such failures. In one case,
  
  I have observed the excessive blow-by from the cylinders has been polluting and causing the contamination of the engine lubricating oil. In one case, I have watched the oil diluted with the fuel. Dilution has been the cause for the reduction in oil viscosity. The less viscous oil at working temperature would cause the boundary lubrication of the bearings and, in the continuous operation, will cause the oil starvation.

Overspeeding of Turbocharger

In engines with improper combustion of fuel, the after-burning will cause the high exhaust temperature. High exhaust temperature will be the cause of high turbocharger speed. If the exhaust temperatures are unnoticed, it will result in overspeeding of the Turbocharger.

Overheating of Turbocharger. In the Turbocharger with water cooling, the clogged water passages cause the overheating of the turbochargers. Overheating will cause the cracking of the turbocharger casing manufactured with the casting process. The external leak will not be dangerous as compared to the internal leaks. Internal leaks will cause the water to ingress in the lubricating oil.

Damage to the compressor wheel

From what I’ve seen, I’ve come across a lot of broken compressor wheels. The cause behind these damaged compressor wheels is.

1. Sometimes, when the air around is dusty or if something foreign gets into the engine, it can hit the spinning blades of the compressor wheel. This usually happens because the wheel is spinning really fast. Most times, it’s this foreign stuff getting in that breaks the compressor wheel.
2. A lot of turbochargers have broken because the way they’re put together isn’t good. The clamps that hold the casing can break, and when they do, the cone that holds things together can break too. When that happens, the compressor wheel starts rubbing against the casing and that’s why it gets damaged. This kind of damage can happen suddenly.
3. I’ve also seen times when turbochargers fail really badly right after they’ve been worked on. This usually happens because something called the “K clearance” wasn’t set up correctly. When this K clearance isn’t right, it can cause big problems like this kind of failure.

Abnormal erosion on Nozzle rings

1. Premature failure of nozzle rings has been due to the engines running with high sulfur fuel. High sulfur fuel causes erosion on the Nozzle ring blades. An increase in the exit area of blades has proved to be the reason for the decrease in engine efficiency.
2. Improper combustion is also one of the most influential factors in accumulating carbon deposits on the nozzle ring blades. The clogging of the blades will cause the surging in the Turbocharger. The clogged nozzle ring blades also cause an increase in high exhaust temperature.
3. Valve burning and traveling off the burnt valve material with the exhaust were also reasons for the nozzle ring damage. 

Surging in Turbocharger

The turbocharger can start acting strangely, like speeding up and slowing down suddenly. This can happen because the timing when the exhaust valve opens is not right, and there’s also a problem with the valve lid getting burned. Another reason can be that the exhaust pipe where the gases go out gets blocked.

To fix this, you should make sure the exhaust pipe is the right size and shape, without too many twists and turns. Also, check if there’s anything blocking the exhaust pipe or the part that captures extra heat.

Conclusion

If you hear weird sounds, feel less power, see strange smoke, or smell odd scents, it might mean the turbocharger is not okay. Also, if the lights on the dashboard turn on, it’s like a signal to investigate. Fixing these problems early can stop them from getting worse and costing more. So, pay attention to your boat’s signs and watch over the turbocharger to keep everything working well.

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