Measurement of Clearances L and M

LL==KK-- K1
K1

M
M== K2
K2-- KK

See disassembly and

assembly instructions in
your operation manual

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
True Run of Centrifugal Oil Pump

VTR 184 ... 354

See disassembly and

assembly instructions in
your operation manual

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
True Run of Gear Oil Pump

VTR 454 ... 714

See disassembly and
assembly instructions in
your operation manual

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Table of Tolerances L & M
and True Run
The tolerances L and M must be within the values given in the
following table (see your seminar documents): L = K - K1
M = K2 - K
VTR 184 214 254 304 354
L [mm] 0,54 ... 1,28 0,55 ... 1,27 0,56 ... 1,35 0,68 ... 1,50 0,79 ... 1,70
M [mm] 0,20 ... 1,02 0,19 ... 1,21 0,19 ... 1,26 0,20 ... 1,30 0,20 ... 1,37

VTR 184P 214P 254P 304P 354P

L [mm] 0,85 ... 1,60 0,87 ... 1,58 0,96 ... 1,70 1,20 ... 1,95 1,35 ... 2,29
M [mm] 0,50 ... 1,26 0,04 ... 1,05 0,06 ... 1,10 0,05 ... 1,10 0,05 ... 1,17

True run values for nipple and oil slinger

VTR 184 214 254 304 354
B1 0,00 ... 0,04 0,00 ... 0,04 0,00 ... 0,04 0,00 ... 0,05 0,00 ... 0,06 Nipple
B2 0,00 ... 0,03 0,00 ... 0,03 0,00 ... 0,03 0,00 ... 0,03 0,00 ... 0,04 Oil slinger

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Disassembly and Assembly
For a proper overhaul the designated
special tools should be used.

The bearing assembly

has to be pushed home
by the shaft nut and not
with the bearing fixation
bolts!

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Disassembly and Assembly
The shaft nut has to be fixed with a certain tightening angle
according to the instructions in the operating manual.

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Tightening Angles
Box spanner with marked VTR Angle  of the box spanner Dim. of the chord S
tightening angle [o] [ mm ] [ mm ]

- Press on the box spanner 184 35 28 8,5

(90050) and make a mark on the 214 40 35 12
oil slinger (34180) corresponding
254 30 44 11,5
to the radial extension of “0-mark”
304 30 45 11,5
Box spanner without 354 30 52 13,5
marked tightening angle 454 30 60 15,5
564 42 60 21,5
- Use a slide gauge to transfer the
714 45 86 33
length of the chord S, given in the
table, to the box spanner (90050)
and mark it. Press on the box
spanner and make a mark on the
oil slinger (34180), corresponding For VTR 454/564/714 tighten the ring nut on
to the radial extension of the first
mark (right) turbine side with only 2/3 of the angle  .

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Table of Tightening Torques
(see seminar documentation)
For standard bolts with mechanical properties of 8.8 the following tightening
torques are applicable:
Bolt thread M4 M5 M6 M8 M10 M12 M20 M22 M24
Tightening torques [Nm] 3 5 8 20 40 65 315 430 545

For the bolts in the table below the following tightening torques (Nm)
have to be applied:
Pos. Part No. VTR 184 VTR 214 VTR 254 VTR 304 VTR 354 Remarks

1 46002 M12x1,5 M12x1,5 M12x1,5 M12x1,5 M12x1,5

48002 35 35 35 35 35
2 46009 M12x1,5 M12x1,5 M12x1,5 M16x1,5 M16x1,5
48009 35 35 35 50 50
3 74008 M16x1,5 M16x1,5 M16x1,5 M16x1,5 M16x1,5
50 50 50 50 50
4 76036 M16x1,5 M22x1,5 M26x1,5 M30x1,5 M42x2
50 70 90 100 150
5 76021 M6 M8 M8
51025 10 25 25
6 32157
34157 Tightening of the cap nut see sec. 3
7 51048 M10 M10 see

ABB
25 25 VTR..4P

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
Position of Bolts with a Special
Tightening Torque

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 ABB Service Station
field and shop service
 Standard overhaul of turbocharger
 Standard overhaul of rotor
 Reblading of rotor
 Repair of the microblasted impeller/inducer area
(interference fit)
 Metal spraying of bearing journals
 Repair of shaft ends
 Casing testing services - ultrasonic / hydrostatic
 Reconditioning of bearing / pumps
 Reconditioning of turbine blades
 etc.

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Customer’s Input

...,so we decided to use only original parts in

vital machine installations. This also because
when non original parts or service stations
are used developments and modifications to
components are missed or installed too late.

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Turbine Blade Welding

zone I
 Alternative
Alternativetotoexchange,
exchange,
High
Highquality
quality- -lower
lower
costs

zone II
costs
 Only
Onlyininapproved
approvedarea
area
 Fully
Fullyininaccordance
accordancewith

zone III
with
the
theinstructions
instructionsset
setby
bythe
the
OEM
OEM
 T/C
T/Cefficiency
efficiencyrestored
restored
good
goodengine
engineperformance
performance

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Turbine Blade Welding

1. damaged blade 2. cleaned & cracktested 3. scored material taken off

4. blade welded 5. blade machined

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Bearing and Gear Oil Pump
Reconditioning

• Complete dismantling and cleaning

• Inspection of all particular areas according
to the headoffice guidelines

• Replacement of parts with dimensions out

of tolerance.
Several parts like naked bearings are
mandatory to change

• Final check after assembly

- Bearings: axial clearance
- Oil pump: test rig

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Bearing Reconditioning
Hertzian Contact
Rel. stress versus rel. depth for
Hertzian contact

Maximum of material stress

rel. stress
is below surface,
damages will start from
there (subsurface cracks)

rel. depth

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Rotor
Components to Recondition
Replacement sealing strips Turbine blade welding
on partition wall (new damping wires required)

Microblasting of impeller/
inducer seats

Replacement sealing
Metal spray on shaft ends & strips on shaft
bearing journals on compressor
and turbine side

+ Rotor balancing
ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Loads on Rotor & Bearings
Un
ba
la nc
Vibrations e TS
r ust BEARING
Th
c
ami
n
Dy rces
Fo
Pulses
Weight

CS
BEARING

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
Rotor Balancing
Unbalance

M
R
U = M x R (gmm)

Example:
Example: Shaft
ShaftVTR354
VTR354 MM==22gg
RR==87
87mm
mm(TS)
(TS)
UU==2g 87mm== 174
2gxx87mm 174gmm
gmm
Admissible
Admissibleresidual
residualunbalance (TS)::
unbalance(TS) 33
33gmm
gmm
ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
Rotor Balancing
Centrifugal Forces

U F
R
2 
F=MxRx

Example:
Example: Shaft
ShaftVTR564
VTR564 MM==10
10gg
RR==130
130mm
mm
nn==15'000
15'000rpm
rpm
FF == 0,01kg
0,01kgxx0,13m (15'000/10)  3'000
0,13mxx(15'000/10)
2
2
3'000 N N
(equivalent to 300 kg)
(equivalent to 300 kg)

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 Procedure of Dynamic Balancing
Rotor with 2-piece Compressor
• Setting of data - according to
Working Instruction tables
• Check admissible deflection of
compressor wheel.
• Measure the unbalance in
planes P1(CE) and P2(TE)
• Compare with the limits of
unbalance: grinding or further
works may be required
• Results to be within admissible
residual unbalance
- as per W.I.
P1 P2

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
SIKO, the Safety Design Concept

Basis:
operating parameters

Result:
* replacement interval of rotating parts
* speed limit for required life

Customer Benefits:
more predictable life cycle cost, increased reliability,
increased availability, maximised safety
reliable turbocharger operation !
ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
ABB Safety Design Concept, SIKO

Riskfactor (-)
Lifetime %
Load vs time Load vs No. of cycles

Example of a load profile Risk of failure

 reliability of turbochargers & life cycle costs more predictable

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
SIKO Test Application
Verification of Temperature Distribution

temperature
gauges

TPL65 impeller

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB
 SIKO, the Safety Design Concept

ABB Turbochargers
Code —H:\Powerpoint\CIAC_4_Operation& Maintenance /1999.09.01 /Hä
ABB