Engineering Standard Rolling Stock

ESR 0560 OVERHAUL OF NAPIER NA155 TURBOCHARGER

Version 1.0 Issued June 2010

Owner: Approved by:

Chief Engineer Rolling Stock Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document users sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

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Engineering Standard

RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

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Document control
Revision (RSS 0558) 1.0 (ESR 0558) 1.0 Date August 2007 June 2010 Summary of change Based on TRS 1780 Reformatted and renumbered ESR 0558

Summary of changes from previous version

Summary of change NOTE If the final document is small enough for the Contents and Document control to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the Document control page carries over to a second page separate pages must be used for Contents and Document control Section

Contents
1 Scope..................................................................................................................................................3 2 Disassembly.......................................................................................................................................3 3 Replacement parts ............................................................................................................................6 4 Cleaning .............................................................................................................................................6 5 Inspection and reconditioning procedures ....................................................................................6 6 Assembly............................................................................................................................................6 7 Tolerances..........................................................................................................................................6 8 Final Inspection and testing.............................................................................................................7 9 Performance.......................................................................................................................................7 10 Painting ..............................................................................................................................................7 10.1 Surface preparation...................................................................................................................7 10.2 Painting .....................................................................................................................................7 11 Storage and transportation ..............................................................................................................7 12 Identification ......................................................................................................................................8 13 Reference ...........................................................................................................................................8 13.1 Australian standards .................................................................................................................8 13.2 Other standards ........................................................................................................................8

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RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

ESR 0560

Scope
This instruction provides procedures and qualifications necessary for reconditioning Napier type NA-155Mk.3 turbochargers for use on 48 class locomotives It is to be used in conjunction with the Napier Turbocharger Instruction Manual and provides clarification, amplification and additional requirements where necessary. Bearings, gaskets, O-rings, lockwire, tab washers and lockwashers have been specified for mandatory replacement to provide greater reliability and more cost effective maintenance. Other components are to be replaced on the basis of condition. The overhauled Napier Turbocharger shall be required to operate reliably for a minimum period of five (5) years. Diagram 1 is a cross sectional view of a model NA-155Mk.3 turbocharger.

Disassembly
The turbocharger assembly which incorporates the following items Main casing Rotor assembly Compressor outlet casing Turbine outlet casing Turbine inlet casings Compressor inlet casing shall be disassembled in accordance with Napier Turbocharger Instruction Manual. Diagram 2 gives the cartridge assembly details of a model NA-155Mk.3 turbocharger.

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RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

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Diagram 1 - Model NA-155mk.3 turbocharger cross section

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RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

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Diagram 2 - Cartridge assembly details for Model NA-155Mk.3 turbocharger

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RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

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Replacement parts
All replacement parts must be genuine Napier to the latest revision unless otherwise specified or approved by the Purchaser. It is mandatory to replace the following components: Nut - shaft end Lockwasher, rotor assembly Napier P/N BK.4875 Napier P/N BK.4869

It is also mandatory to replace all gaskets, bearings, nuts, bolts, spring washers, cone washers, tab washers and sealing rings The rotating assembly, is to be replaced on a condition basis, (but has a twelve (12) year service life and must be replaced with a new assembly at the expiration of this period.) All new rotor assemblies are to have the date of installation engraved on the turbine disc. Rotor assemblies are to be balanced in accordance with European Gas Turbines Ltd Napier NA 155 MK3 Turbochargers Balancing and Checking Procedure - SK.No. 14100. Special attention should be paid to the nozzle assembly for cracks and surface defects and the turbine disk lacing wire for fractures and breaks. These items are to be replaced on condition. All other component parts as listed in Napier Part List are to be replaced on the basis of condition as specified in Napier Instruction Manual.

Cleaning
Component parts of the turbocharger assembly are to be cleaned in accordance with Napier Instruction Manual. Extreme care should be exercised when handling rotor parts. Never use a caustic solution, wire brush or scraper on these parts.

Inspection and reconditioning procedures

All reusable parts are to be inspected and maintained in accordance with Napier Instruction Manual.

Assembly
The turbocharger is to be reassembled in accordance with Napier Instruction Manual. The overhaul form provides strip down and build up details for component tracking and maintenance planning. It must be completed and a copy forwarded to the Purchaser. A sample overhaul sheet for the Napier NA-155Mk.3 turbocharger is attached.

Tolerances
During inspection and assembly all specified clearances and tolerances must be maintained.

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RailCorp Engineering Standard Rolling Stock Overhaul of Napier NA155 turbocharger

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Final Inspection and testing

The assembled turbocharger is to be inspected and tested in accordance with the Napier Instruction Manual.

Performance
The overhauled Napier Turbocharger shall be required to operate reliably for a minimum period of five (5) years.

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Painting
On completion of assembly and testing the turbocharger is to be suitable painted. All connections such as flange faces and pipe threads, gauge glass faces and name plates shall not be painted. Additionally the turbine inlet casing is not to be painted.

10.1

Surface preparation
1. Remove all dirt, grease and oil using an appropriate cleaning compound in accordance with AS 1627.1. 2. Power tool clean bare steel areas to Class 2 standard in accordance with AS 1627.2. Feather all paint edges, lightly sand all previously applied paintwork with an appropriate grade of paper, remove sanding debris and spot prime on the same day as tool cleaning.

10.2

Painting
1. Apply one (1) coat of red oxide zinc phosphate alkyd primer to all bare steel areas to a minimum dry film thickness of 38 micrometres (m). Allow an appropriate drying time and overcoat. 2. Apply one (1) coat of full gloss petrol and oil resistant enamel, alpine green, BS 4800 14C 31, to a minimum dry film thickness of 25 m to the spot primed and previously painted surface. Allow an appropriate drying time and overcoat. 3. Repeat Step 2 and allow 24 hours drying time. The primer shall be approved under GPC-C162 and the finish shall be approved under GPC-E-24.

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Storage and transportation

Prior to storing the overhauled turbocharger, it is to be pre lubricated with an acceptable preservative oil such as Shell ENSIS engine oil 30 or Tectyl 823 EM and spin tested for approximately 5 minutes. Clean preservative lubricating oil is to be fed to the turbine bearings through the oil inlet orifice in the turbocharger casing as the spin test is carried out. The turbocharger rotating assembly is spin tested by applying shop air in one side of the gas inlet ports. The overhauled turbocharger is to have all openings and orifices blanked off to prevent the entry of dirt or foreign materials during storage and transportation. Suitable cover plates are to be fitted to the exhaust outlet, compressor inlet and gas inlet casing. Suitable plastic caps or plugs are to be fitted to all water, oil and drain holes. The turbocharger is to be mounted in a suitable wooden stand for transportation purposes. The stand shall provide adequate protection for the turbocharger and must prevent it from tipping over during transportation.

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Identification
The 48 class locomotive can be fitted with a model NA-155Mk.3 Napier turbocharger. The Napier part number for this turbocharger is NA.155. The turbocharger identification plate must clearly indicate the turbocharger serial number and the date of last overhaul (month/year).

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13.1

Reference
Australian standards
AS 1627 BS 4800 Metal finishing Preparation and preheat treatment of surfaces

13.2

Other standards
Instruction Manual for Napier Turbocharger Type NA-155Mk.3. European Gas Turbines Ltd - Balancing and Checking Procedure - SK.No. 14100. GPC-C-162 GPC-E-24 F

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