This advanced, three-day hands-on training course delivers comprehensive expertise in the complete overhaul and precision rotor balancing of marine turbochargers. Designed to extend beyond standard maintenance protocols, this program immerses mechanical engineers and senior technicians in the end-to-end process, from initial assessment and systematic disassembly to advanced diagnostics, dynamic balancing, and meticulous reassembly. The additional day allows for in-depth exploration of critical areas such as detailed clearance analysis, advanced balancing machine operation, and complex troubleshooting scenarios.
Participants will engage in extensive practical workshops using actual turbocharger components and balancing equipment, reinforcing theoretical knowledge of turbocharger principles, material science, and vibration analysis. Emphasizing rigorous safety standards, precision measurement, and adherence to OEM specifications, this course equips attendees with the expert-level skills required to restore turbocharger performance, ensure operational reliability, and contribute to optimal engine efficiency in demanding marine environments.
COURSE OBJECTIVES
By the end of this course, participants will be able to:
- Explain the fundamental principles, configurations, and critical role of turbochargers in marine engine performance and efficiency.
- Apply comprehensive safety protocols for workshop operations, including the handling of hazardous materials and heavy components during disassembly and assembly.
- Systematically dismantle a turbocharger using correct special tools, following a defined sequence to ensure component integrity and organization.
- Conduct detailed inspections of all major components (rotor, bearings, turbine/compressor housings, seals) and accurately measure, record, and interpret critical radial and axial clearances.
- Perform complete cleaning and functional testing of the lubrication and cooling systems integral to the turbocharger assembly.
- Execute a dynamic rotor balancing procedure, including mounting on a balancing machine, identifying imbalance, calculating corrections, and verifying final balance within specified limits.
- Reassemble the turbocharger with new spare parts (including bearings and seals), performing necessary calibration and final clearance verification to manufacturer’s specifications.
- Complete all required technical documentation, including clearance records, balancing reports, and a final work report compliant with industry standards.
COURSE METHODOLOGY
At Intelliness, our training methodology is built around delivering meaningful learning experiences that translate into real workplace capabilities. Each program is carefully engineered to blend theory with practice, ensuring participants not only understand the concepts but can confidently apply them on the job.
Engaging Learning Environment
Sessions are conducted using real case studies, scenario-based discussions, and collaborative activities that encourage critical thinking and practical problem-solving.
Practical Skill Application
Participants take part in structured hands-on exercises and simulations designed to mirror real operational challenges, enabling them to develop confidence through doing—not just listening.
Smart Learning Tools
Our programs leverage modern digital platforms, including LMS-based modules, interactive content, and online resources that support flexible learning and continuous progress monitoring.
Ongoing Evaluation & Guidance
Regular checkpoints, quizzes, and facilitator feedback help track understanding, close knowledge gaps, and ensure each learner progresses at the right pace.
After-Training Reinforcement
To promote long-term retention, we provide post-training materials, optional follow-up sessions, and access to expert guidance, ensuring learners can continue applying their skills effectively beyond the classroom.
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Module 1: Introduction to Marine Turbocharging Systems-
- Thermodynamic principles of exhaust gas energy recovery and air charging.
- Overview of different turbocharger types and their specific marine applications.
- The impact of turbocharger performance on overall engine efficiency and emissions.
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Module 2: Safety, Documentation & Tool Preparation
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- Comprehensive workshop safety, including handling of hot, heavy, and rotating components.
- Procedures for handling oils, cleaning solvents, and asbestos-containing materials (if applicable).
- How to read and interpret OEM drawings, spare part lists, and technical bulletins.
- Identification, use, and care of special tools (bearing pullers, mounting fixtures, dial gauges).
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Module 3: Hands-On Workshop I – Systematic Dismantling
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- Step-by-step practical disassembly of a turbocharger, focusing on proper sequence.
- Techniques for removing the cartridge assembly, turbine and compressor casings, and bearing housings.
- Proper labeling, cleaning, and storage of components for inspection.
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Module 4: Component Inspection & Clearance Measurement
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- Detailed visual and dimensional inspection of the rotor assembly (shaft, turbine/compressor wheels) for erosion, fouling, and cracks.
- Inspection of bearings (journal/axial), seals, and housing surfaces for wear and damage.
- Hands-on session: Using micrometers and dial indicators to accurately measure and record critical clearances (e.g., rotor float, bearing clearances).
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Module 5: Lubrication & Auxiliary Systems
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- Principles of turbocharger lubrication and cooling.
- Procedures for cleaning and testing oil inlet passages, filters, and drain lines.
- Inspection of water-cooled housings (if applicable) for corrosion and blockage.
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Module 6: Rotor Dynamics & Balancing Workshop
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- Theory of imbalance: static, couple, and dynamic.
- Safety procedures for operating a dynamic balancing machine.
- Hands-on workshop: Mounting a rotor on the balancing machine, conducting a initial run, interpreting vibration data, calculating and applying corrections (drilling/adding material), and verifying final balance.
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Module 7: Hands-On Workshop II – Calibration & Reassembly
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- Pre-assembly checks: verifying cleanliness and preparing new components (bearings, seals, gaskets).
- Step-by-step reassembly of the bearing housing and rotor cartridge.
- Final calibration: setting and verifying critical axial and radial clearances with new bearings installed.
- Installation of turbine and compressor housings with proper alignment and torque sequences.
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Module 8: Installation, Commissioning & Troubleshooting
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- Best practices for turbocharger installation on the engine, including alignment and connection of ducts.
- Commissioning procedures: pre-lubrication, startup monitoring, and performance baseline recording.
- Diagnostic workshop: Analyzing common failure symptoms (high exhaust temp, low charge air pressure, excessive vibration) to identify root causes.
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Module 9: Quality Assurance, Documentation & Final Review
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- Standards for final inspection and performance verification post-overhaul.
- Compiling the overhaul dossier: completed checklists, clearance records, balancing certificate, and parts replaced log.
- Course recap, final assessment, and open forum for specific technical queries.
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