Engineering Standard

Rolling Stock

Engineering Standard
ESR 0560

OVERHAUL OF NAPIER NA155

TURBOCHARGER

Version 1.0
Issued June 2010

Owner: Chief Engineer Rolling Stock

Approved Stephen White, Authorised Michael Uhlig,
by: Technical Specialist Rolling by: Manager,
Stock Performance Standards, Rolling Stock Access Integrity
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
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RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
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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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RailCorp Engineering Standard — Rolling Stock
Overhaul of Napier NA155 turbocharger ESR 0560

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

Summary of changes from previous version

Summary of change Section
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’

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

1 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.

2 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 ESR 0560

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

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Overhaul of Napier NA155 turbocharger ESR 0560

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 ESR 0560

3 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 Napier P/N BK.4875

• Lockwasher, rotor assembly 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.

4 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.

5 Inspection and reconditioning procedures

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

6 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.

7 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 ESR 0560

8 Final Inspection and testing

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

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

10 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 (μm). 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 μm 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.

11 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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RailCorp Engineering Standard — Rolling Stock
Overhaul of Napier NA155 turbocharger ESR 0560

12 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).

13 Reference

13.1 Australian standards

AS 1627 Metal finishing – Preparation and preheat treatment of surfaces

BS 4800

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 F

GPC-E-24

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