No.SD.DEV.E 3.

Dt:

03.01.2002

1.The Chief Mechanical Engineer (Rebuilding), Diesel Component Works, Patiala-147003 The Chief Works Manager, 2. Northern Railway 3. Southern Railway 4. Central Railway 5. S.E.Railway 6. Western Railway 7. Eastern Railway Loco Workshop, Charbagh, Lucknow - 226 005. Workshop, Golden Rock, Tiruchirapalli - 620 004. Workshop, Parel, Mumbai. Workshop, Kharagpur. 721 304 Workshop, Ajmer.- 305 001 Workshop, Jamalpur 811 214.

The Chief Motive Power Engineer (Dsl.) 8. Central Railway Mumbai CST-400001 9. Eastern Railway Fairlie Place, Calcutta-700001 10. Northern Railway Baroda House, New Delhi-110001 11. Southern Railway NGO Annexe, Park Town, Chennai-600003 12. South Eastern Railway Garden Reach, Calcutta-700043 13. South Central Railway Rail Nilayam, Secunderabad-500371 14. Western Railway Churchgate, Mumbai-400020. 15. North Eastern Railway Gorakhpur-273001 16. N. F. Railway. Maligaon, Guwahati-781011.

Sub: Stage Balancing Instructions of ABB Turbochargers Ref: This office letter of even number dt. 4.4.2001. Vide this office letter under reference, it had been specified that balancing of ABB turbochargers shall be carried out as per ABB Work Instruction No. 3MYN 940003 and 3MYN 940002. These instructions pertain to pre-balancing checks and balancing of the complete rotor assembly. Under certain circumstances i.e. damages to the rotor assembly or in cases of high initial unbalance, stage balancing of rotor assembly becomes necessary. In such cases it shall be necessary to carry out the balancing of the bladed shaft and the compressor wheel separately. This is known as stage balancing of the turbocharger. M/s ABB is also undertaking a comprehensive training programme for explaining the procedure of stage balancing to the different sheds at their premises in Baroda. Details of the training programme have been issued vide this office letter of even number dt. 12.10.2001. The instructions enclosed explain this procedure giving reference to the relevant ABB work instructions. Please find enclosed herewith a copy of Instruction Bulletin No.MP.IB.ES-01-01-02 for your reference and necessary action please. DA:As above ( Sharad Saxena ) Jt. Director (MP)

Copy to: -The Secretary (Traction), Railway Board, Rail Bhavan, New Delhi-110001.
- The Sr.Div. Mech. Engineer (Dsl.) / Div. Mech. Engineer (Dsl.) , Diesel Loco Shed :-

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Central Rly. Central Rly. Central Rly. Central Rly. Central Rly. Eastern Rly. Eastern Rly. Eastern Rly. Eastern Rly. Eastern Rly. Eastern Rly. Northern Rly. Northern Rly. Northern Rly. Northern Rly. Northeast Frontier Rly. Northeast Frontier Rly. North Eastern Rly. Southern Rly. Southern Rly. Southern Rly. Southern Rly. South Central Rly. South Central Rly. South Central Rly. South Eastern Rly. South Eastern Rly. South Eastern Rly. South Eastern Rly. South Eastern Rly. South Eastern Rly. Western Rly. Western Rly. Western Rly.

Diesel Loco Shed Itarsi - 461 115 Diesel Loco Shed New Katni Jn. - 463 501 Diesel Loco Shed Jhansi - 284 001 Diesel Loco Shed Pune - 411 103 Diesel Loco Shed Kalyan - 421 304 Diesel Loco Shed Andal, Distt. Burdwan - 713 321(WB) Diesel Loco Shed Burdwan, Distt. Burdwan- 713 101 (WB), Diesel Loco Shed Bamangachi ,P.O. Salkia, Howrah 711 106 Diesel Loco Shed Jamalpur, Distt.Munger- 811 214(Bihar), Diesel Loco Shed Patratu, Distt. Hazaribagh - 829 120( Jharkhand) Diesel Loco Shed Mughalsarai, Fdistt. Chandauli- 232 101(UP) Diesel Loco Shed Tughlakabad, New Delhi - 110 044 Diesel Loco Shed Bhagat - ki - kothi , Jodhpur - 342 001 Diesel Loco Shed Alambagh, Lucknow - 226 011 Diesel Loco Shed Ludhiana 141 001 Diesel Loco Shed Malda Town 732 102 Diesel Loco Shed New Gauhati Diesel Loco Shed Gonda 271 002(UP) Diesel Loco Shed Golden Rock, Ponmalai, Tiruchchirapalli - 620 004 Diesel Loco Shed Erode 638 002(TN) Diesel Loco Shed Ernakulam Jn. - 682 011(Kerela) Diesel Loco Shed Krishna Rajapuram , Bangalore - 560 036 Diesel Loco Shed Guntakal, Anantpur (AP) 515801 Diesel Loco Shed Kazipet, Warangal Distt.(AP) 560 003 Diesel Loco Shed Gooty, Anantpur Distt (AP) - 515 402 Diesel Loco Shed Vishakhapatnam, P.O. Kanchrapalam(AP) - 530 008 Diesel Loco Shed Bondamunda, Sundar Nagar, Orissa 770 032 Diesel Loco Shed Kharagpur, Distt. Midnapure(WB) - 721 301 Diesel Loco Shed Raipur, Chhattisgarh-492005 Diesel Loco Shed Bokaro Steel City 827 010 Diesel Loco Shed Angul, Distt.Angul, Orissa. Diesel Loco Shed, Ratlam 413701 (MP) Diesel Loco Shed,Abu Road Sirohi 307 026 Diesel Loco Shed Vatva , Ahmedabad 382 445 (Gujrat) ( Sharad Saxena ) Jt. Director (MP)

DA:As above

RDSO

MP.IB.ES-01-01-02

INSTRUCTION BULLETIN MP.IB.ES-01-01-02 1.0 2.0 Title :

Stage Balancing of ABB Turbochargers

Scope :
This instruction bulletin explains the procedure for carrying out stage balancing of ABB Turbochargers.

3.0

Introduction / Background :
A large number of ABB Turbocharger failures have been experienced by Indian Railways. Investigations conducted by ABB have revealed that some of the failures are on account of improper balancing of the turbochargers. ABB, India in consultation with their parent company have given the feedback that balancing of the full rotor assembly may not be adequate in all circumstances. In cases of rotor damage or high initial imbalance, it may be necessary to go in for stage balancing. Vide RDSO letter no. SD.Dev.E.3.2 dt. 4.4.2001 it had been specified that balancing of ABB turbochargers shall be carried out as per ABB Work Instruction No. 3MYN 940003 and 3MYN 940002. These instructions pertain to pre-balancing checks and balancing of the complete rotor assembly. However in certain circumstances i.e. damages to the rotor assembly or in cases of high initial unbalance, stage balancing of rotor assembly becomes necessary. In such cases it shall be necessary to carry out the balancing of the bladed shaft and the compressor wheel separately. Only after these individual components are balanced within prescribed limits, should they be assembled and balancing carried out for the complete rotor assembly. This IB explains the circumstances in which complete rotor assembly can be balanced as one unit and when stage balancing has to be done.

4.0
4.1

Technical Content :
Stage Balancing is a term used to describe balancing of the individual components of the rotor assembly before the full rotor is balanced.

Page 1 of 3

RDSO

MP.IB.ES-01-01-02

Following parts are to balanced individually in stage balancing : Compressor wheel Bladed shaft Full rotor assembly 4.2 Methods of Balancing
Stage Balancing using Turbocharger Balancing machines Dynamic 2 plane method In this the vectors of unbalance are indicated on each indicator. The compressor wheel and the complete rotor assembly are to be balanced using the 2 plane method. Static-Moment Method In this the static vector of unbalance will be shown on one indicator and a component of the residual moment of unbalance on the other one. The bladed shaft is meant to balanced using this method. 4.3 Equipment & Accessories : a) Existing balancing machine with hard bearing roller and belt drives. b) Portable grinder with flexible shaft for material removal during balancing. Caution : It may not be possible to use the Static-Moment method of balancing on some analogue balancing machines. These machines therefore have to be upgraded to the digital type. 4.4 Procedure for Balancing The flowchart enclosed in Annexure-I has to be followed for determining the sequence or stages in balancing. Prebalancing checks have to be done as per instruction no. 3MYN 940002 (Annexure-2) Balancing of bladed shaft has to be done as per instruction no. 3MYN 940006 (Annexure-3) The bladed shaft without piston ring is to be balanced using the static couple method. The balancing machine is to be set for separate indications of static and moment unbalances. The static unbalance is to be compensated only on the inner side of the turbine disc. The moment unbalance must be compensated on both sides of the disc. The moment unbalance should be Page 2 of 3

RDSO

MP.IB.ES-01-01-02 compensated first as it is likely to disturb the static unbalance in any case. Balancing of compressor wheel to be done as per instruction no. 3MYN 940005 (Annexure-4) To be done using the 2 plane dynamic balancing method. Balancing of the complete rotor assembly has to be done as per instruction no. 3MYN 940003 (Annexure-5) The complete rotor assembly has to balanced. The measurement of rotor unbalance should be done using the 2 plane dynamic balancing method.

5.0

Agencies for implementation : All diesel sheds, POH shops & DCW.

6.0

Distribution: As per covering letter.

7.0

Annexures. i) ii) iii) iv) v) Annexure 1 : Flow chart Annexure 2 : Instruction No. 3MYN 940002 - Pre-balancing checks Annexure 3 : Instruction No. 3MYN 940006 - Balancing of bladed shaft Annexure 4 : Instruction No. 3MYN 940005 - Balancing of compressor wheel Annexure 5 : Instruction No. 3MYN 940003 - Balancing of complete rotor assembly

Page 3 of 3

ABB Turbocharger India

WORK INSTRUCTUION FLOW CHART FOR BALANCING PROCEDURE

Annexure 1 Application : Indian Railway VTC 304-13

Step 1 Dismantle the compressor wheel and bladed shaft from the Turbosupercharger

Step 2
Carry out pre-balancing checks as per instruction no. 3MYN940002.

yes

Contact ABB

Any deviations?

No

Step 3
Visually check the compressor wheel and bladed shaft for damages.

Step 4
Carry out balancing of bladed shaft as per instruction no.3MYN940006

yes Damages Found?

Is mandrel available? yes

No No

Step 6 Step 5
Carryout balancing of compressor wheel as per instruction no.3MYN940005 Assemble the bladed shaft and compressor wheel without piston rings

Step 7
No Is initial unbalance within limits? Set the rotor for two plane dynamic balancing method. Check for initial unbalance i.e. 2.45 grams on left plane and 2.54 grams on right plane

yes

Step 8
Carry out rotor balancing instruction no.3MYN940003 as per

Step 9
After completion of balancing, mark the different parts of the rotor in straight line with marker. During assembly, ensure the assembly of compressor wheel and bladed shaft to be aligned in the same straight line as marked. Inst. No.3MYN 940007 Page 1 of 1

PRE-BALANCING CHECKS OF ROTOR ASSEMBLY VTC-304-13

Preparation of Rotor assembly before balancing 1. Compressor wheel: 1.1 1.2 1.3 Check visually any damage on the compressor wheel. If found any damage on blade tip dress it. Dressing of the compressor blade tip is allowed up to maximum limit of 3 to 4 mm. If the limit exceed then replace the compressor wheel. Check the dimension X as shown in fig A.

If X is less than allowable value then replace it.

Blade Tip For 3100 hp X = 22 mm For 2600 hp X = 20.6 mm For 2300 hp X = 18.15 mm

Fig. A 2. 2.1 2.2 2.3 Bladed shaft & turbine blades: Check visually any damage on Bladed shaft. Check turbine blades for crack near damping wire holes . Check damping wires at blade/damping wire interface for crack.

Any damage or crack , if found please refer to ABB to get a clearance for further use. Crack detection checks also can be carried out with the use of dye penetration technique. 2.4 Check the bearing seat diameters & width of the piston ring recess w.r.t.the admissible values as indicated in sketch B. If measured values are not with in limits, shaft must be replaced.

Inst. No. 3MYN 940002 Page 1 of 3

PRE-BALANCING CHECKS OF ROTOR ASSEMBLY VTC-304-13

A = 39.98 mm. Min B = 50.98 mm Min. C = 55.8 mm Min. S = 2.85 mm Max.

Fig. B 2.5 Check run out of bladed journal diameters. ( Using between centres.)

Permissible Run out =

2.6

A,B

0.005

Check run out of blade diameters. ( Using between centres.)

Permissible Run out =

0.2

If above conditions are no longer meet then, refer matter with ABB. Note : Clean or flush the center of the bladed shaft to avoid incorrect run out indication. 3. 3.1 Rotor assembly preparation for balancing. Keep the bladed shaft in vertical position (i.e. Turbine end facing downward). Put the compressor wheel on the bladed shaft with slight hand press. & check the value c as per fig C. if c value is not within the limit, check & clean the seating area of the shaft & wheel bush. Refer chapter 5, page 115 of Comprehensive manual. Hold the bladed shaft with wooden block in the vise as indicated in Fig D & assemble the compressor wheel on the bladed shaft as per the assembly procedure using proper\ assembly tools. Refer chapter 5 page 70 of comprehensive manual.

3.2

Check visually the shaft end & compressor wheel collar are in the same plane.

Inst. No. 3MYN 940002 Page 2 of 3

PRE-BALANCING CHECKS OF ROTOR ASSEMBLY VTC-304-13

C = 4.9 / 7.6 mm

Fig. C

Wooden Block

Fig.D

Now the rotor is ready for Balancing.

Inst. No. 3MYN 940002 Page 3 of 3

BALANCING OF BLADED SHAFT VTC 304-13

Balancing procedure. 1 1.1 Machine / job setting The bladed shaft (without piston rings) is to be balanced regarding the static and moment of unbalance. The balancing machine should show in one plane as static unbalance and other plane should show moment unbalance. Set up the machine as per the setting values mentioned in the table below ( ref table 1) Radius left plane (r1) 74 Radius right plane (r2) 74 Table 1 A 274 B 35 C 95

1.2

1.3 1.4 1.5

The shaft should be placed on pedestals very cautiously. Place the two stoppers at both the ends maintaining a gap with the shaft so that shaft should not touch them while running. It is preferable that the pedestal height should be set such that during rotation of the shaft, shaft should not touch either of the two stoppers. This gives better accuracy to the balancing. Inst. No. 3MYN 940006 Page 1 of 3

BALANCING OF BLADED SHAFT VTC 304-13

1.6 2 2.1 The pedestal height accuracy can be cross checked by confirming that both end stoppers should be free of the force from the shaft. Static / couple balancing On checking the imbalance the static unbalance is to be removed by grinding the material only at the inner side of the turbine disc (position marked as X) at the corresponding unbalance angle. The moment unbalance is to be corrected by grinding the material at positions marked as Y and Z on both sides of the turbine disc. First the material is to be removed at the angle as displayed on screen on position Y and then the material is to be removed at an angle 180 degrees opposite to it at position Z..

2.2

2.3

As shown in the diagram below the limit of f min (after grinding) should be at least 3.0mm

2.4 2.5

Material should not be removed from any other position then marked in the diagram. Allow the shaft to cool upto room temperature after grinding and then check the balance. Generally it takes 15 to 25 minutes. Inst. No. 3MYN 940006 Page 2 of 3

BALANCING OF BLADED SHAFT VTC 304-13

2.6 2.7 Continue the above mentioned steps until balancing conditions as mentioned in Point No.3 are achieved. As a result of unprecise material removal during the grinding process it is possible that slight changes occur in the value of moment of unbalance by compensating the static unbalance and in the static unbalance by compensating the moment of unbalance. Balancing condititons

The admissible values are

Left Plane U bal st grams Gmm 0.42 31

Right Plane U bal m 2.88 213

***

Inst. No. 3MYN 940006 Page 3 of 3

BALANCING OF COMPRESSOR WHEEL VTC-304-13

1 1.1 1.2 1.3

COMPRESSOR WHEEL Check visually any damage on the compressor wheel. If found any damage on blade tip dress it. Dressing of the compressor blade tip is allowed up to maximum limit of 3 to 4 mm. If the limit exceed then replace the compressor wheel. Check the dimension X as shown in fig A.

If X is less than allowable value then replace it.

Blade Tip For 3100 hp X = 22 mm For 2600 hp X = 20.6 mm For 2300 hp X = 18.15 mm

Fig. A 2 Balancing mandrill assembly.

Balancing of Compressor Wheel requires special mandrel assembly as shown in drawings YN 3M SK 310333. The balancing mandrel & belt disc has to be manufactured with the accuracy & material indicated in below drawings. To form the Balancing mandrel assembly fit the belt disc on the mandrel with locktite 0648 as mentioned in drg.no. YN 3M SK 310333. 1. YN 3M SK 3100333 Balancing mandrel assembly. 2. YN 3M SK 310034 - Balancing mandrel. 3. YN 3M SK 410025 Belt disc.

3. Checking of blancing mandrel. Inst. No. 3MYN 940005 Page 1 of 3

BALANCING OF COMPRESSOR WHEEL VTC-304-13

Before balancing the compressor wheel, a unbalance value in the mandrel has to be checked as shown in below data & fig. B.

Fig. B 3.1. A, B : Radial run out < 0.005 mm. 3.2. DV, DT are the spots for material removal on balancing mandrel. Below condition to be achieved in oreder to clear the mandrel for balancing.

U DV

U DT

<

U bal D.

U bal D = 12 gm.mm.

3.3 Clean the coniacal seat surface of the mandrel. Now mandrel is ready for assembly of compressor wheel. 4. Balancing the compressor wheel. 4.1 Do not insert the mandrel in to the compressor wheel with an excessive force. 4.2 check the initial unbalance in the compressoe wheel, if it exceeds then value 200 gm.mm then dismantled & cautiously reassembled. 4.3 The total unbalance is determined as shown in fig. C & below condition.

U.= U VV

U VT

Inst. No. 3MYN 940005 Page 2 of 3

BALANCING OF COMPRESSOR WHEEL VTC-304-13

Admissible amterial removal : .m > 1.0 mm. .n < 2.3 mm

Fig C

U bal Gm.mm 50

Ulimit gm.mm 200

r 21
mm 57

r 22
mm 115

b2 mm 148

The compressor wheel is balance when

U < U bal

***

Inst. No. 3MYN 940005 Page 3 of 3

BALANCING OF ROTOR ASSEMBLY VTC 304-13

When Balancing must be done. 1. 2. 3. 4. Mechanical damages to rotating component of rotor. After reblading .(e.g. replacing some of the blades ,damping wire & tablock) After repair on compressor wheel. (e.g. dressing of hit marks.) Minor repairs on the turbine blades.

1.

Balancing machine to be used, Conditions, calibration Only 2-plane balancing machine with belt drive (machine with hard bearing) to be used. The machine must have a minimum measuring accuracy of 0.2 g.mm/kg ( gram-millimeter per kilogram )of rotating mass. The machine should show separately following unbalance. Dynamic unbalance, two vectors of unbalance in two different planes. Balancing machine must be calibrated periodically as instructed by OEM for maintaining correct balancing of rotor.

2.

Balancing procedure.

Ensure satisfactory pre-balancing check as mentioned in instruction no. 3MYN 940002 Place the bearing journals of the rotor (without piston ring) on both pedestal of Balancing machine as shown. See figure A. 2.1 Set the balancing machine & rotor to dimensions indicated in the fig.A & rotate the rotor to required rpm. We recommend to run the balancing machine at speed 900 1500 rpm. Check the unbalance value on compressor side & Turbine side. - If the unbalance is more than 2.45 gms or 282 gm.mm on Compressor side & 2.54 gms or 188 gm.mm on Turbine side, remove the compressor wheel . Reassembled the same on the shaft after rotating compressor wheel by 90from its original position. 2.2 Check the unbalance & repeat above procedure until the unbalance value becomes lessthan 2.45 gms or 282 gm.mm on Compressor side & 2.54 gms or 188 gm.mm on Turbine side.

Inst. No. 3MYN 940003 Page 1 of 4

BALANCING OF ROTOR ASSEMBLY VTC 304-13

60.5

r2=114

r1=74

75.5

346.5

Fig. A Note: Set your balancing machine for radius ( r1) OR diameter ( 2xr1), which ever calls for. Attention is to be given to feed correct radius or diameter ( 2r1) value as required by your machine. 2.3 2.4 2.5 Rotate the rotor to required rpm ( we recommend the range 900 1500 rpm) & Check the unbalance level. Balance the rotor by removing the material on two correction planes of compressor side (r2) & turbine side ( r1). See fig. A. The admissible unbalance should be max. 157 gm-mm ( i.e 0.82 gms on compressor side & 0.85 gms on turbine side.) as shown in below table.

Permissible Residual Unbalance

C.S.

T.S.

Total

Final ( Max) After Balancing

0.69 gms
(78.5 gm.mm)

1.06. gms
(78.5 gm.mm)

1.75 gms
(157 gm.mm)

Inst. No. 3MYN 940003 Page 2 of 4

BALANCING OF ROTOR ASSEMBLY VTC 304-13

3. Mark the position of wheels & the shaft by marker as indicated in fig.B. Note : Match the marking of the bladed shaft & compressor wheel during Turbocharger final assembly. Allowable mismatching of the compressor wheel & Bladed shaft during final assembly ( i.e. by hydraulic pressure) is 10.

Fig. B 4. Material removing plane & its condition Fig.C & Fig D indicates admissible material to be removed & conditions on compressor side & Turbine side correction planes.

Material to be removed from Turbine side correction plane ( r1) after keeping Fmin as indicated below. Fmin = 3.0 mm

Fig. C Note : Use portable hand grinder to remove the material from correction plane.

Inst. No. 3MYN 940003 Page 3 of 4

BALANCING OF ROTOR ASSEMBLY VTC 304-13

Max. Material can be removed from compressor side correction plane ( r2) by depth.

m max. = 2.3 mm

Fig. D Dos & Dont Dos : Do rotor Balancing in dust free environment. Do not rest the rotor on the floor. Instead rest it on the proper designed pallets.

***

Inst. No. 3MYN 940003 Page 4 of 4