Investment takes facilities beyond ‘workshop’ status to provide high quality repairs
Many service companies specialise in older turbochargers but TurboUSA’s business has shifted its focus more towards newer generations. To facilitate this, the company has invested heavily in the new tooling required for these units and in training for its staff. Although not authorised as an agent for ABB or MAN, TurboUSA now has a team of experienced engineers fully capable of servicing and reconditioning newer generation turbochargers from these manufacturers. These include ABB TPS and TPL series and MAN TCA and TCR series products. The company is authorised by MHI as a service agent, covering all MET turbocharger types.
TurboUSA has a ‘technical centre’ at its Fort Lauderdale, Florida, base, rather than simply a workshop. Its name reflects the company’s major investment in technical equipment including measurement and inspection tools and high-technology repair facilities, setting it apart from a basic overhaul and replacement facility. Combined with extensive staff training, this has made the centre capable of repairing or reconditioning components to a high standard, providing a rapid and lower-cost alternative to fitting new parts.
Repair capabilities include laser metal cladding, shaft hot metal spray recovery and blade repair, with TurboUSA having the only Lloyd's Register-approved thermal spray shaft repair process in the Americas. This provides customers with the assurance of repaired parts being of high quality. Unlike cold repair procedures, where a new layer is applied to the shaft at below 300°C, the TurboUSA process operates at approximately 1,200°C, fully fusing the new sprayed layer to the underlying material. This technology permits machined surfaces, such as keyways and threads, to be treated and allows the shaft to be balanced on new layers without risking damage.
The thermal spray process works well for an entire shaft repair but in cases where only limited sections require attention, laser metal cladding is often the best solution. Using this system a fully-automated laser beam is directed to the damaged section only, reducing the risk of heat damage to adjacent areas. The powder coating material used in the process is driven by inert gas and directed accurately, through a nozzle, onto the surface being laser repaired. The result is a very strong metallurgical bond to the original material. TurboUSA delivers both hot metal spray and laser metal cladding repaired components with a one-year warranty.
To assess returned equipment and ensure repairs are carried out to the highest standards, the technical centre also has comprehensive non-destructive testing equipment. This includes both ultrasonic and ultraviolet crack detection methods. For components such as casings, hydrostatic testing facilities are also available. In all cases, rebuilt or repaired rotors are dynamically balancing before shipment or re-assembly into casings to ensure trouble-free operation.
TurboUSA has made a multi-million dollar investment in spare part stocks to ensure the best levels of customer service. The company has decades of experience in maintaining older turbocharger types but has now expanded its stocks to cover newer products, having seen operators increasingly moving towards the use of new and more efficient turbocharging equipment. As an ISO 9001:2000 certified company, TurboUSA only sources spare parts from world-class manufacturers and, regardless of turbocharger brand, is committed to a policy of one year’s warranty on all parts sold.
TurboUSA offers a one-stop-shop for turbocharger service, whether that is a routine maintenance or overhaul requirement or for emergency repairs. Trained staff are available around the clock to cover these contingencies and can travel to any global location. The company has a strong field service presence in North America, Central and South America and the Caribbean. It also has two Europe-based field service engineers and has a strategic partnership with Rotterdam-based TurboNL to provide further support to European customers.