TB/T 3475.8-2020 (TB/T3475.8-2020, TBT 3475.8-2020, TBT3475.8-2020) & related versions
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Components of diesel engine for locomotive and DMU - Part 8: Turbocharger
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TB/T 3475.8-2020
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TBT 3475.8-2020
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TB/T 3475.8-2020: PDF in English (TBT 3475.8-2020)
TB/T 3475.8-2020
RAILWAY INDUSTRY STANDARD
OF THE PEOPLE’S REPUBLIC OF CHINA
ICS 45.060.10
S 42
Replacing TB/T 1383-2011
Components of diesel engine for locomotive and DMU - Part
8: Turbocharger
ISSUED ON: MAY 29, 2020
IMPLEMENTED ON: DECEMBER 01, 2020
Issued by: National Railway Administration
Table of Contents
Foreword ... 3
1 Scope ... 5
2 Normative references ... 5
3 Terms and definitions... 6
4 Technical requirements ... 7
5 Inspection methods ... 9
6 Inspection rules ... 13
7 Marking, packaging, transport, storage ... 16
Appendix A (Normative) Determination method of cleanliness ... 18
Appendix B (Normative) Performance test of turbocharger ... 22
Appendix C (Normative) 100-h test condition of turbocharger ... 30
Components of diesel engine for locomotive and DMU - Part
8: Turbocharger
1 Scope
This Part of TB/T 3475 specifies the terms and definitions, technical requirements,
inspection methods, inspection rules, marking, packaging, transport, storage of the
axial-flow turbocharger, which is used in the diesel engine for locomotive and DMU
(hereinafter referred to as turbocharger).
This Part applies to turbochargers, which is used in the diesel engine for locomotive
and DMU.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB/T 191 Packaging - Pictorial marking for handling of goods (GB/T 191-2008,
ISO 780: 1997, MOD)
GB 253-2008 Kerosene
GB/T 1786 Forging tortillas ultrasonic testing method
GB/T 4118-2008 Trichloromethane for industrial use
GB/T 6402-2008 Steel forgings - Method for ultrasonic testing
GB/T 6519 Ultrasonic inspection of wrought aluminium and magnesium alloy
products
GB/T 13306 Plate
GB/T 21563-2018 Railway applications - Rolling stock equipment - Shock and
vibration tests (IEC 61373:2010, MOD)
HB/Z 60 Radiographic inspection
HB/Z 61 Penetrant inspection
The speed of turbocharger, which is greater than or equal to 110% of the rated speed,
AND at which the turbocharger can safely run continuously for more than 24 hours.
3.7
Maximum gas inlet temperature
The maximum temperature, at which the turbine can work safely for a long time.
4 Technical requirements
4.1 Requirements for working environment
4.1.1 The diesel engine power, which is matched by the turbocharger, under the
following environmental conditions, does not need to be corrected:
a) The altitude is not higher than 1500 m;
b) Atmospheric ambient temperature: -40 °C ~ +40 °C.
4.1.2 When the turbocharger is used in an area above 1500 m above sea level OR the
atmospheric temperature is greater than +40 °C, the influence of atmospheric pressure
and ambient temperature in the area shall be considered.
4.1.3 When it exceeds the scope specified in 4.1.1 and 4.1.2, it shall be determined,
through negotiation between the supplier and the buyer.
4.1.4 The maximum intake vacuum of the turbocharger shall be less than or equal to 4
kPa; the maximum exhaust back pressure of the turbocharger shall be less than or equal
to 3 kPa (except for those with exhaust gas aftertreatment system).
4.2 Basic requirements
4.2.1 The turbocharger shall be manufactured, in accordance with the product drawings
and technical documents, which are approved by the prescribed procedures. It shall
comply with the provisions of this Part.
4.2.2 The main parts of the turbocharger (main shaft, turbine disc, turbine blade, integral
casting turbine, wind guide wheel, compressor impeller) shall be subject to non-
destructive testing; the results shall comply with the provisions of the technical
documents.
4.2.3 The shell, which is equipped with cooling water cavity, shall not leak; repair is
not allowed.
4.2.4 The outlet area or code of the nozzle ring of the turbocharger, AND the area or
code of the inlet throat of the diffuser shall comply with the provisions of the relevant
technical documents. Such information shall be engraved in the designated position
AND recorded in the exit-factory documents.
4.2.5 The assembly clearance of the turbocharger and its main components shall comply
with the provisions of the product drawings or technical documents.
4.2.6 After the initial operation test of the turbocharger, there shall be no abnormality.
4.3 Performance requirements
4.3.1 After carrying out the vacuum prestressing overspeed test at room temperature for
the center perforated compressor impeller and turbine disc, the deformation of the inner
hole shall meet the requirements of the technical documents.
4.3.2 The cleanliness of the turbocharger is the total weight of impurities, which are
contained in the lubricating oil passages in and out of each turbocharger AND the
surfaces of the parts in contact with the lubricating oil; the cleanliness limit is 400
mg/set.
4.3.3 The dynamic balance accuracy of the guide wheel, compressor impeller, bladed
shaft, rotor assembly of the turbocharger shall comply with the provisions of the product
drawing.
4.3.4 The oil inlet temperature of the turbocharger is related to the quality of the oil
used by the diesel engine. It shall be adapted to the requirements of the matching diesel
engine.
4.3.5 Performance requirements of the turbocharger's calibration operating point:
a) When the rotational speed is less than 20000 r/min, the rotational speed deviation
shall be controlled within the range of ±100 r/min. When the rotational speed is
greater than or equal to 20000 r/min, the rotational speed deviation shall be
controlled within the range of ±0.5% of the specified value.
b) The pressure ratio deviation shall be controlled within the range of ±1.5% of the
specified value.
c) The air flow deviation shall be controlled within ±2% of the specified value.
d) The total efficiency of the turbocharger shall be greater than or equal to the
specified value; the specified value shall not be lower than 58%.
4.3.6 After the turbocharger is tested at the highest speed, there shall be no damage to
parts or appearance deformation; there shall be no looseness, air leakage, oil leakage or
water leakage at the connection.
4.3.7 When the turbocharger is running under the calibration condition, the ratio -- of
the calibration flow TO the air flow value at the surge point at the equal pressure ratio
5.1.5 Ultrasonic inspection of turbine disc blanks shall be carried out, in accordance
with GB/T 1786.
5.1.6 The X-ray inspection of turbine blade blanks and integrally cast turbine blanks
shall be performed, according to HB/Z 60.
5.2 Vacuum prestressing overspeed test at room temperature
The compressor impeller and turbine disc, which have central perforation, shall be
subjected to the vacuum prestressing overspeed test at room temperature. The
overspeed speed shall be greater than or equal to 110% of the maximum speed; the test
time shall not be less than 3 minutes.
5.3 Cleanliness inspection
Carry out cleanliness inspection, according to Appendix A.
5.4 Rotor dynamic balance inspection
Carry out the rotor dynamic balance inspection, according to the provisions of Chapter
9 in JB/T 9752.3-2014.
5.5 Housing tightness inspection
The housing, which is equipped with cooling water cavity, can be subject to tightness
test by hydraulic or pneumatic pressure. During the tightness inspection by hydraulic
pressure, the hydraulic pressure shall not be lower than 700 kPa; the pressure shall be
maintained for 5 minutes. During the tightness inspection by pneumatic pressure, the
air pressure shall be 1.5 times the working pressure; the pressure shall be maintained
for 15 minutes.
5.6 Initial running test
The turbocharger uses the external air source cold-blowing or self-circulation mode, for
running-in operation; the test speed is 25% ~ 30% of the calibration speed; the duration
shall be greater than or equal to 10 minutes. Check the operation of the turbocharger
and the sealing state of each flange connection. The operation of the turbocharger shall
be normal; there shall be no leakage at the connection.
5.7 Calibration point test
After the cold blowing, the hot air test is carried out. The self-circulation method is
used, to increase the speed of the turbocharger. When the speed reaches the calibration
speed, let it run stably for 10 minutes; record the performance parameters of the
turbocharger. There shall be no abnormal phenomenon during operation.
5.8 Maximum speed test
The turbocharger shall be tested according to the maximum speed; the running time
shall be greater than or equal to 10 min.
5.9 Idling test
When the speed of the turbocharger is 60% of the rated speed, gradually reduce the oil
pressure to the minimum oil pressure; the deviation is ±50 kPa. Cut off the fuel supply,
to carry out the idling test; measure the idling time.
5.10 Compressor characteristic test
5.10.1 The test shall be carried out on the compressor test bench or the turbocharger test
bench, by the external air source; OR the self-circulation method can also be used for
the test. Test various parameters, according to Table B.2 of Appendix B. Calculate the
main performance parameters of the compressor, according to the calculation formula
in B.5. Draw the compressor performance curve, according to Figure B.1 of Appendix
B.
5.10.2 The speed and flow division methods are as follows:
a) Carry out division according to the iso-speed line: The minimum starting speed
shall not be higher than 40% of the calibrated speed; then make an iso-speed line
every 1000 r/min ~ 3000 r/min, until the maximum speed. There shall be no less
than 6 iso-speed lines;
b) Carry out division according to flow measuring points: Starting from the surge
point, divide by flow on each iso-speed line; there shall be not less than 5
measuring points.
5.11 Turbine characteristic test
The external air source method can be used on the turbocharger test bench or combined
with the performance test of the compressor. The compressor can be used as a
dynamometer, to measure various parameters of the compressor and turbine ends. Test
various parameters, according to Table B.2 of Appendix B. Calculate the main
performance parameters of the turbine, according to the calculation formula in B.5.
Draw the turbine performance curve, according to Figure B.2 of Appendix B.
5.12 Lubricating oil seal test
Use external air source for blowing; the test speed is 3000 r/min (the inlet oil
temperature is 55 °C ± 5 °C; the oil pressure is the upper limit of the design value). Shut
down after running for 10 minutes. Check whether there are oil traces on the compressor
end and the turbine end.
5.13 100-h test
6.3.2 Inspection sequence: Initial running test, calibration operating point test,
maximum speed test, idling test, lubricating oil seal test.
6.3.3 The exit-factory inspection can be carried out again, in the following cases:
a) If a certain inspection item is found to be unqualified during the inspection, after
debugging or repairing;
b) If the parts are found to have defects such as cracks and serious scratches during
the inspection, after the damaged parts are replaced.
6.4 Type inspection
6.4.1 Scope of inspection
If it falls under any of the following circumstances, type inspection shall be carried out:
a) When the new product is finished of trial production;
b) When the trial production of the products, after trans-plant production, is
completed;
c) When there are major changes in product structure, process or materials, that affect
performance and safety;
d) When the continuous production is more than 5 years (or the production volume
is 1000 sets);
e) When production resumes, after 2 years of shutdown.
6.4.2 Inspection procedure
6.4.2.1 The following inspection record documents shall be provided, for the
turbocharger subject to type inspection:
a) Rotor's dynamic balance inspection record;
b) Inspection and inspection records of the main shaft, turbine disc, turbine blade or
integrally cast turbine, air guide wheel, compressor impeller;
c) Inspection records of the rotor's axial movement, the clearance between the air
guide wheel and the compressor impeller and the casing, the clearance between
the turbine blade and the insert;
d) Inspection report on material chemical composition and mechanical properties of
main shaft, turbine disc, turbine blade or integrally cast turbine, air guide wheel,
compressor impeller;
e) Inspection records of the dimensions of the main shaft, turbine disc, turbine blade
or integrally cast turbine, air guide wheel, compressor impeller;
f) Process inspection record of turbocharger;
g) Exit-factory inspection records of turbocharger.
6.4.2.2 Inspection sequence: Initial operation test, compressor characteristic test,
turbine characteristic test, calibration operating point test, 100 h test, structural
verification test, calibration operating point test (verification), dismantling inspection,
vibration test, dismantling inspection.
6.4.3 Sampling
During the type inspection, a turbocharger that has passed the exit-factory inspection
shall be randomly selected. The turbocharger for vibration test may not be the same as
the turbocharger for other items of type inspection.
6.4.4 Judgment rules
6.4.4.1 During the type inspection, the number of test suspensions, due to non-
turbocharger failure (air leakage, oil leakage or water leakage), shall not exceed one;
the suspension time shall not exceed 60 min. At the same time, the test time of the
turbocharger shall be extended, according to the suspension time accordingly. If the
suspension time exceeds 60 minutes, the type inspection will be deemed invalid.
6.4.4.2 In the process of type inspection, if one of the following situations occurs, the
product is judged to be unqualified:
a) The performance index of the calibration operating point does not meet the
requirements of the specified index;
b) During the 100-h test and the structural verification test, the main components are
damaged, so that the test cannot be continued;
c) During the test, there is oil, gas, water leakage, which cannot be recovered after
treatment;
d) During the dismantling inspection, it is found that the main parts have cracks or
serious abrasions, OR there are oil stains on the outside of the oil seal disc.
7 Marking, packaging, transport, storage
7.1 Marking
Each turbocharger shall be provided with a sign. The type and size of the sign shall
comply with the provisions of GB/T 13306. Its contents shall at least include:
A.1.2.4 Clean containers, such as cups, plates, pots, buckets with lids.
A.1.2.5 Magnets, magnifying glasses, tweezers (flat ends without teeth).
A.1.3 Filter elements
A special white microporous filter membrane, which has a size of 5 µm and a diameter
of 50 mm.
A.1.4 Cleaning solution
Use kerosene in compliance with GB 253-2008 or chloroform specified in GB/T 4118-
2008.
A.2 Sampling
A.2.1 Randomly select the cleaned parts and carry out the sampling work, for
cleanliness determination. The sampling can be carried out, on the production site.
A.2.2 The cleaning solution, which is used for sampling, shall be pre-filtered; the
containers and tools shall be clean.
A.2.3 The sampling method shall use the following two:
a) Sampling by rinsing method: It is suitable for oil channel sampling. It should carry
out repeated rinsing, along the actual working flow of the oil or fuel; use a
container, such as a funnel, to collect the cleaning fluid with impurities, after
flushing.
b) Sampling by scrubbing: It is applicable to other parts, except oil passages. Center
the finished product into the bucket, so that it does not touch the sides of the
bucket. Use the cleaning solution to flush the outer surface and inner holes of the
part, whilst using the nylon brush to repeatedly scrub it.
A.2.4 When sampling, the cleaning solution with impurities shall be prevented from
splashing out of the container.
A.2.5 At the end of sampling, collect all the cleaning solutions with impurities
separately; mark them, including the sampling date, part number, sampling location.
A.3 Preparations for determination
A.3.1 The cleanliness measurement shall be carried out, in a dedicated cleanliness
testing room. The room shall be clean (the amount of dust falling within 24 hours is not
more than 60 mg/m2); it is well ventilated and has reliable safety facilities.
A.3.2 Operators shall wear clean clothes, hats, shoes; wash hands before operation.
A.3.3 All measuring instruments and work surfaces shall be clean.
A.3.4 The sampling container shall be cleaned, to ensure that there is no dust and debris.
A.3.5 The cleaning solution, which is used for testing, shall be filtered through a 5 µm
membrane.
A.3.6 The constant weight treatment of the filter element is as follows:
a) Use tweezers, to put the filter membrane into the weighing bottle with the cap
open. Place the cap together with the bottle cap in an electric heating constant
temperature oven, that has been heated to 90 °C ± 5 °C, for 10 min ~ 15 min;
b) Close the weighing bottle cap. Take it out and put it in a desiccator for 10 minutes,
to cool down to room temperature;
c) Weigh on an analytical balance. Record the weight of the filter membrane;
d) Repeat the whole process, until the weighing difference between the two drying
operations, is not more than 0.4 mg;
e) The average value of the two weighing is the constant weight value of the filter
membrane.
A.3.7 Weigh the constant weight G1 of 5 µm clean filter membranes, according to the
method in A.3.6.
A.4 Determination method
A.4.1 Filtration of impurities
Filter the cleaning solution with impurities, which is collected in the process of A.2, as
follows:
a) Use tweezers, to take the clean filter membrane that has been weighed in A.3.7
out of the weighing bottle. Wet it in the filtered cleaning solution. Then place it
tightly on the glass sand core of the M50 type glass sand core filter device. Use a
metal clip, to clamp the butt of the sand core. Place it on the suction filter bottle
(see Figure A.1). Connect the vacuum pump;
b) Pour the cleaning solution with impurities into the funnel, for vacuum filtration;
c) After the suction filtration of all the dirty liquid is completed, use the cleaning
solution to rinse the inner wall of the funnel and the filter membrane several times,
to ensure that all impurities are filtered;
d) After the cleaning solution evaporates, use tweezers, to put the filter membrane
with impurities into the original weighing bottle, to prepare for weighing.
......
| Standard ID | TB/T 3475.8-2020 (TB/T3475.8-2020) | | Description (Translated English) | (Diesel engine parts for locomotives and EMUs. Part 8: Superchargers) | | Sector / Industry | Railway & Train Industry Standard (Recommended) | | Word Count Estimation | 20,223 | | Date of Issue | 2020-05-29 | | Date of Implementation | 2020-12-01 | | Older Standard (superseded by this standard) | TB/T 1383-2011 | | Regulation (derived from) | State Railway Regulations (2020) No. 20 |
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