BSME - 92B

MAINTENANCE & REPAIR

July 27, 2023 - THURS
1230 - 1600

1. Submit your research about assembling and disassembling of turbocharger.

Procedure for dis-assembling the turbocharger

1. First remove the filter silencer or compressor inlet casing from position
2. Remove the compressor end cover and measure the critical clearance
3. Remove the suction cover and measure the critical clearance
4. Pull the rotor shaft towards the compressor until the impeller comes in to contact with insert and
determine
5. Thrust the rotor shaft towards the turbine side until the turbine disc and nozzle comes in contact.
6. Remove the lube oil pump assembly after removing the pump locking plate
7. Remove the bearing nut and bearing nut washer
8. Fix the bearing pulling tool in position and slowly tighten it
9. Mark the position of the bearing in position to put it as back as it is while assembling
10. The ball bearing assembly should not be disturbed in any case
11. Now remove the compressor outlet casing with diffuser
12. Remove the impeller nut and impeller washer
13. Remove the impeller and inducer from position

Procedure for assembling the turbocharger

1. Gather the required tools and equipment

2. Clean all components
3. Inspect the components:
4. Assemble the turbine shaft and turbine wheel:
5. Install the compressor wheel
6. Balance the assembly
7. Install the bearing housing and center housing:
8. Install the actuator (if applicable):
9. Fit the compressor housing:
10. Fit the turbine housing:
11. Connect oil and coolant lines
12. Double-check all connections:
13. Perform a pre-installation check:
14. Follow manufacturer guidelines

2. Based on the provided video:

a) How can you measure clearances accurately? What are the tools or equipment needed?

Measuring clearances accurately is essential in various fields, such as engineering, construction,

manufacturing, and maintenance. Clearances refer to the spaces between two objects or
components, and measuring them precisely ensures proper functionality, safety, and
performance. The tools and equipment needed for accurate clearance measurements depend
on the specific application, but here are some common methods and instruments:

1. **Calipers**: Digital or analog calipers are commonly used to measure small clearances
accurately. They have fine measuring tips that can be used to determine the distance between
two surfaces.

2. **Feeler Gauges**: Feeler gauges consist of a set of thin metal blades of different
thicknesses. They are inserted between the surfaces to measure the clearance. The blade that
fits snugly without too much resistance indicates the clearance.
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3. **Go/No-Go Gauges**: These gauges are used to verify whether the clearance falls within an
acceptable range or not. The "Go" end should fit, and the "No-Go" end should not fit if the
clearance is correct.

4. **Micrometer**: Micrometers are used for precise measurements in tight spaces. They
provide accurate readings for small clearances.

5. **Ultrasonic Measurement Devices**: Ultrasonic equipment can be used for non-contact

clearance measurements, especially in situations where direct access is challenging.

6. **Laser Measurement Tools**: Laser-based distance measuring devices are handy for
measuring clearances over longer distances and for non-contact measurements.

7. **Coordinate Measuring Machine (CMM)**: CMMs are advanced measurement tools that
use a probe to measure clearances on complex surfaces with high accuracy.

8. **Optical Comparators**: These instruments project an enlarged image of the clearance

onto a screen for measurement and comparison.

9. **Surface Profilers**: Surface profilers are used to measure clearances and surface
roughness on a microscopic scale, ensuring tight tolerances are met.

10. **Alignment Telescopes**: Used in mechanical applications, alignment telescopes help

measure precise alignments between components.

11. **Crankshaft Deflection Gauges**: These gauges measure the clearance and alignment of
rotating shafts in engines or machinery.

12. **Cable Tension Meters**: In cable-based systems, such as bridges or cranes, cable tension
meters are used to ensure proper clearances and tension levels.

Always ensure that the measuring tools and equipment are properly calibrated and maintained
for accurate results. Different applications may require specific tools, and choosing the right
method for the clearance measurement is crucial to obtaining reliable data.

b) What is the function of flexible joint mounted in main and auxiliary engine? Why is it important
to measure it before & after mounting?

Flexible joints, also known as flexible couplings, are used in various machinery, including main
and auxiliary engines, to connect two shafts that are misaligned or not directly in line with each
other. The function of flexible joints in main and auxiliary engines is to transmit torque from
one shaft to another while accommodating angular, axial, or radial misalignments between
them. This helps to reduce stress on the connected components and prevent damage to the
machinery.

Here's why measuring the flexible joint is important both before and after mounting:

1. **Before Mounting**: Prior to mounting the flexible joint, it is essential to measure its
dimensions and specifications accurately. This is crucial because it ensures that the chosen
flexible joint is suitable for the specific misalignment requirements of the engine. Each engine
may have unique alignment issues, and selecting the right flexible joint with proper
measurements is vital to ensure its effectiveness and longevity.

2. **After Mounting**: Once the flexible joint is mounted between the two shafts, it is crucial
to measure it again. This is done to verify that the joint has been installed correctly and is
operating as expected. Measuring the flexible joint after mounting helps ensure that it has been
aligned properly and that there are no issues with its installation. Misalignment, improper
torque transmission, or faulty installation can lead to premature wear and failure of the joint or
other engine components.

In summary, the function of a flexible joint in main and auxiliary engines is to transmit torque
while accommodating misalignments between shafts. Measuring the flexible joint before
mounting ensures the correct selection for the engine's requirements, while measuring it again
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after mounting ensures proper installation and operation, reducing the risk of potential failures
and optimizing the engine's performance and reliability.

c) In the video, end gap of turbine seal ring should face upwards. Explain why.

Turbine seal rings are critical components used in various types of turbines, including steam
turbines and gas turbines. These seal rings are designed to create a sealing barrier between
different sections of the turbine, such as between the high-pressure and low-pressure stages or
between the turbine stages and the casing. The orientation of the seal ring is essential for
ensuring proper turbine operation and efficiency. In most cases, the turbine seal ring should
face upwards, and here's why:

1. **Preventing Leakage**: The primary purpose of turbine seal rings is to prevent or minimize
the leakage of steam or gas between different sections of the turbine. When the seal ring faces
upwards, it is in a better position to counteract the effects of gravity. This orientation helps the
seal ring maintain better contact with the adjacent components, minimizing the likelihood of
steam or gas leaking through the seal.

2. **Gravity-Assisted Contact**: By facing upwards, the turbine seal ring benefits from gravity,
which helps to ensure that it remains in contact with the adjacent surfaces. This is particularly
important during startup and shutdown phases when the turbine may experience thermal
expansion and contraction. Gravity assists in maintaining a more consistent and reliable seal
throughout these temperature variations.

3. **Lubrication and Cooling**: Some turbines use lubrication and cooling mechanisms that
rely on gravity to distribute lubricants or coolants. When the seal ring is oriented upwards, it is
more likely to receive the necessary lubrication and cooling fluid efficiently, which helps in
reducing friction and maintaining the seal's integrity.

4. **Avoiding Debris Accumulation**: Turbine environments can be harsh, with the possibility
of debris, dust, and other contaminants present. When the seal ring faces upwards, it is less
likely to accumulate debris and contaminants, reducing the risk of damage to the sealing
surfaces.

5. **Reducing Wear**: Correct orientation can help reduce wear on the seal ring itself and the
mating surfaces. Improved contact and reduced friction resulting from the upward-facing
position contribute to a longer service life for the seal ring and improved overall turbine
efficiency.

It's important to note that the specific design and installation guidelines may vary depending on
the type and manufacturer of the turbine. Following the manufacturer's recommendations and
industry best practices is crucial to ensure proper installation and operation of the turbine seal
ring. Incorrect installation can lead to sealing issues, increased leakage, reduced efficiency, and
potential damage to the turbine system.