What Causes Turbo Failure: 5 Worst Key Reasons Unveiled

“What Causes Turbo Failure” – Turbochargers are like special machines that enhance marine diesel engines, but they can face issues. Commonly, fine particles, mostly carbon from combustion, can erode parts when their concentration gets too high.

This makes the gap between parts bigger, and it also blocks important holes where oil goes. Over time, this makes it so that the oil can’t do its job of keeping everything working smoothly This deterioration is often accompanied by a sharp surge in noise levels and the seepage of oil past the turbine end seal, resulting in oil being burned. In boats and ships with marine diesel engines, this problem gets even more serious. You can easily spot it when you see smoke coming out of the exhaust. In this article, we will talk about why turbos break and how you can make sure it doesn’t happen

Understanding Turbochargers

Before we talk about why turbochargers can fail, let’s understand how they work in simple terms. Turbochargers are made up of two important parts: the turbine and the compressor. The turbine is like a little fan, and it’s spun by the exhaust gases that come out of the engine. On the other side, the compressor does something like squishing the air before it goes into the engine.

When the compressor compresses the air, it makes it denser, which means there’s more air going into the engine’s combustion process. More air means better combustion, and that gives the engine more power. It’s a bit like when you blow up a balloon really hard, it has a lot of energy inside, and that’s what the engine needs to go faster.

So, turbochargers help engines be more powerful and efficient. But, they can have problems too, and that’s what we’ll talk about in this article—why they sometimes don’t work and how to stop that from happening.

Signs of Turbocharger Failure

 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.

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.

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.

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.

What Causes Turbo 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 of 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.

FAQ on What Causes Turbo Failure

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.