PROJECT UPDATES

TURBOCHARGER TPL77-B12 OVERHAULING AT DUNG QUAT SHIPYARD, VIETNAM

Cập nhật: 01-03-2024 03:56:55 | PROJECT UPDATES | Lượt xem: 1831

Bacviet Shiprepair completed ABB TPL77-B12 Turbocharger overhauling & dynamic balancing for MV SIROCCO at Dung Quat Shipyard – 24/7 service in Vietnam.

Bacviet Commercial & Shiptechnical Co., Ltd is a trusted ship repair and marine service provider in Vietnam, offering complete technical solutions for global shipowners, ship management companies, and superintendents.
With more than 15 years of experience, Bacviet has developed a solid reputation for excellence in turbocharger repair, overhauling, and dynamic balancing for both main and auxiliary engines of all vessel types — bulk carriers, oil tankers, container ships, and offshore vessels.

This project showcases the five-year overhauling and dynamic balancing of ABB Turbocharger TPL77-B12 fitted on the main engine of MV SIROCCO, successfully completed by Bacviet’s professional service team at Dung Quat Shipyard, Vietnam.

2. Vessel & Equipment Information

Vessel Name: MV SIROCCO
IMO Number: 9603996
Type: Bulk Carrier
Flag: Panama
Gross Tonnage: 43,974 GT
Deadweight: 82,000 DWT
Length Overall (LOA): 229 m
Beam: 32.26 m
Year Built: 2014
Owner / Management: V.Ship Greece Ltd
Operation Area: South-East Asia trade routes

Image for overhauling Turbocharger ABB TPL77 – B12 at Dung Quat, Vietnam

3. Turbocharger Specification:

Maker: ABB Turbo Systems AG
Type / Model: TPL77-B12
Serial Number: HT 529708
Application: Main Engine Turbocharger

4. Scope of Work

Complete disassembly and overhauling of Main Engine Turbocharger ABB TPL77-B12
Dynamic balancing of rotor assembly at Bacviet workshop (HCM City)
Full inspection, cleaning, measurement, and calibration in accordance with ABB standards
Reassembly, functional testing, and performance verification during sea trial
Documentation: balancing reports, alignment records, and photo documentation submitted to the Owner and Class

5. Step-by-Step Overhauling Procedure

5.1 Preparation and Planning

Before mobilization, Bacviet’s project manager coordinated directly with the Superintendent and Chief Engineer of MV SIROCCO to confirm the scope and tool requirements.
Special ABB toolboxes, measuring instruments, and spare parts were checked and prepared. Safety procedures and risk assessments were reviewed according to Bacviet’s internal HSE policy.

5.2 Boarding and Initial Inspection

Our experienced turbocharger specialists boarded the vessel at Dung Quat Shipyard, equipped with all necessary tools, lifting gear, and calibrated measuring devices.
They conducted visual inspection of the turbocharger exterior, checking for oil leakage, vibration marks, or abnormal clearances. The manufacturer’s technical manual was reviewed to verify clearances and torque specifications.

2. Rotor assembly preparation for dynamic balancing at Bacviet HCM workshop

Image for Dynamic Balancing Turbocharger TPL 77 - B2 in Vietnam

5.3 Dismantling Stage

Removed air inlet filter and silencer assemblies.
Drained lubricating oil from the turbocharger housing.
Marked alignment positions for easy reassembly.
Recorded axial and radial clearances (K, L, M, B1, B2).
Dismantled oil pumps, bearings, turbine wheel, compressor wheel, nozzle ring, and sealing rings with precision lifting tools.
Carefully withdrew the turbine rotor assembly for further inspection.

5.4 Cleaning and Visual Examination

All dismantled parts were cleaned using ultrasonic and solvent cleaning systems.
The internal surfaces of the turbine and compressor casings were descaled to remove carbon and oil residues.
Each part was inspected for erosion, scoring, or pitting. The nozzle ring clearance and bearing journal dimensions were re-measured using micrometers and bore gauges to evaluate wear conditions.

5.5 Non-Destructive Testing (NDT)

Critical rotating components such as the turbine rotor and compressor wheel underwent dye-penetrant testing (DPT) to identify surface cracks.
Only components passing inspection criteria per ABB tolerance limits were approved for re-installation.

5.6 Dynamic Balancing

The rotor assembly was packed in a specially fabricated wooden box and transferred to Bacviet’s certified dynamic balancing workshop in Ho Chi Minh City.
Dynamic balancing was performed on high-precision Schenck balancing machines.

Balancing standard: ISO 1940 Grade G 2.5
Final residual unbalance: within 2 gmm/kg
Balancing and alignment certificates were issued and attached to the project documentation.

5.7 Reassembly On Board

After receiving the balanced rotor, the team reassembled the turbocharger following ABB procedures:

Replaced new bearing shells and oil seals.
Checked and adjusted axial/radial clearances again (K, L, M, B1, B2).
Applied proper torque to all housing bolts.
Conducted lubrication system flushing to ensure oil cleanliness before operation.

5.8 Functional Testing & Sea Trial

Upon reassembly, the turbocharger was run during engine test at idle and full load.
Parameters such as vibration, oil pressure, exhaust gas temperature, and rotational speed were recorded.
The system showed stable vibration and temperature within ABB limits, confirming the successful overhauling and balancing.

4. Final inspecting of ABB TPL77-B12 before installing on board of vessel at Dung Quat, Vietnam

6. Work Duration & Location

Work Period: 24 – 29 February 2024
Location: Dung Quat Shipyard, Vietnam

The entire process — from dismantling to testing — was completed within five working days, ensuring minimal vessel downtime and smooth class approval.

7. Technical Highlights

Advanced dynamic balancing equipment calibrated per ISO 1940 G 2.5 standard
Precise measurement and tolerance control with digital micrometers (±0.001 mm)
Dye-penetrant inspection for surface integrity verification
Vibration measurement under load using portable analyzer
Comprehensive documentation including before/after measurement sheets, balancing charts, and photographs

8. Quality Control & Reporting

Every step of the operation followed Bacviet’s Quality Assurance and Safety Management System.
A full set of documents was submitted upon completion:

Turbocharger dismantling & inspection report
Dynamic balancing certificate
Clearances and measurement records
Photo log before / during / after overhauling
Final test and performance report

All documents were reviewed and signed by both Bacviet’s project engineer and the vessel’s Chief Engineer, ensuring full traceability and class compliance.

Technicians measuring axial clearance of turbocharger bearing housing

9. Bacviet’s Turbocharger Service Capability

Bacviet Shiprepair provides comprehensive services for all turbocharger makers and models:
ABB, MAN NA / NR, MET, KBB, IHI, Napier, and PBS.
Our facilities in Hai Phong and Ho Chi Minh City are fully equipped with dynamic balancing machines, hydraulic test benches, ultrasonic cleaning systems, and machining tools, enabling rapid turnaround for both onboard and workshop repairs.

Available Services:

Main engine & auxiliary engine turbocharger overhauling
Dynamic balancing for all rotor sizes
Supply of genuine / OEM spare parts
Bearing housing reconditioning and nozzle ring renewal
On-site troubleshooting and vibration analysis
24/7 emergency attendance at ports and anchorages

10. Service Coverage in Vietnam

Our field service teams are available at all major Vietnamese ports and anchorages:

Northern Vietnam: Hai Phong, Cai Lan, Hon Gai, Cam Pha
Central Vietnam: Nghi Son, Vung Ang, Son Duong, Da Nang, Dung Quat, Quy Nhon
Southern Vietnam: Nha Trang, Cam Ranh, Cai Mep, Phu My, Vung Tau

No matter where your vessel calls, Bacviet ensures prompt mobilization and class-approved service within the shortest possible time.

11. Client Assurance

Bacviet Shiprepair always commits to:

Meeting every customer requirement efficiently and reasonably
Maintaining the highest quality standards for all delivered services
Completing all jobs on schedule, minimizing vessel idle time
Offering competitive pricing and transparent cost control
Providing clear communication and documentation for shipowners and superintendents