Information for the Quality and Performance of Rotating Equipment - from the Schenck Balancing & Diagnostic Systems Group
Turbocharger Overhaul With Schenck
Even though turbochargers are designed for an extremely long life cycle, damage still occurs more often due to improper maintenance. Defective turbochargers are usually replaced with new ones, which is not always necessary. With the right knowledge and appropriate equipment, turbochargers can be repaired to like-new condition.
Spare parts including piston rings, journal bearings, thrust collars, spacers and hardware, turbine wheel seals, thrust bearings, and cover gaskets are all key components in turning an old turbo new again. In addition to special tools, cleaning equipment, spare parts and balancing machines are required. Balancing ensures a smooth running turbocharger with the quality and dependability comparable to that of a new turbocharger.
The Overhaul Process
With the number of Turbochargers on the road today increasing, more and more are being repaired. From small passenger turbos to large commercial diesel turbos, the process remains the same.
Complete assemblies are first disassembled and inspected for damaged components.
Next, parts are cleaned with industrial cleaning equipment. After cleaning, the most important step begins: Balancing.
On the Schenck TBcomfort, the Compressor wheel and the Turbine wheel with Shaft are balanced individually at a low speed. Next, they are balanced as a pre-assembled rotor assembly. This process greatly reduces the initial unbalance of the parts, and is the basis for the next step – balancing of the complete core assembly on the Schenck TBsonio.
The pre-balanced core assembly is then finally balanced on the TBsonio at almost full operating speed and under similar operating conditions. After an audit run, the core assembly is ready for an extended long service life.
Why Balance?
A question that most commonly comes to mind when rebuilding Turbochargers is “Why Balance?” Many may think “The parts can just be marked and reassembled at the same spot”. Reassembling a turbocharger without both component and core balancing is a “WARRANTY for failure!!”
Balancing is an essential step in Turbocharger overhaul and in many cases is overlooked. A non-symmetrical rotor from a bent or damaged blade operating at high speeds will result in loss of performance and efficiency. Without proper balancing, the turbo will ultimately have to be rebuilt or replaced shortly after it is put back into service. To provide a long lasting service life of a rebuilt turbo, Schenck has developed the ideal solution: The TBcomfort and the TBsonio.
Balancing with Schenck
The Schenck TBcomfort has the capacity to balance turbocharger components with a weight of up to 35.3 lbs. The machine features permanent calibration so that additional calibration procedures are not required for every single part.
For configuring the instrumentation, only the geometrical data of the components have to be entered into the measuring instrument. The CAB 820 measuring instrumentation, featured on the TBcomfort, can be easily operated by anyone through the intuitive and user-friendly interface.
The TBcomfort features the sensitivity to balance rotors to the tightest tolerances to ensure OEM quality on the finished assembly. For example, when balancing a 10 lb. turbine wheel and shaft, which operates at approximately 200,000 rpm, using ISO 21940-11:2016 quality grade G2.5, we are actually balancing the part down to 0.000009 in. of displacement of the center of gravity (center of mass). That’s 300 times SMALLER than the thickness of a strand of hair!
The Schenck TBsonio balances turbocharger core assemblies at up to 250,000 rpm to simulate real operating conditions. The machine allows the operator to compensate for the elastic behavior of the rotor at high speeds to reduce damaging vibration levels. The highly accurate measuring unit detects the vibration behavior over the entire speed range and calculates the exact location and magnitude for correction.
The CAB 950 measuring instrumentation, featured on the TBsonio, will display the exact unbalance correction in terms of mass and combined with the electronic protractor feature, will show the exact angle where the correction is needed. This removes all the guess-work in balancing the core assembly. The Turbocharger can also be corrected within the machine using a small hand grinder to remove material off of the compressor nut.
The “Combination” Screen on the CAB 950
Not only will the machine balance the turbocharger to a balancing tolerance, i.e. gram-in. or gram- mm, but the TBsonio can also measure to an acceleration tolerance. Typical Turbocharger Core Assemblies are balanced below 1 G (Acceleration) to ensure the vibrations will not become harmful in service. The CAB 950 has the capability to display all of this important information on one screen, showing unbalance, correction amount and angle, and acceleration levels.
A Few Customer Comments
“The TBsonio is an amazing machine. We routinely balance our turbo cores at speeds starting at 50,000 rpm and go up to 108,000 rpm. Yes, that’s one-hundred-and-eight-thousand revolutions per minute!”
“A core balancer and a state of the art component balancer are used in the remanufacturing process of every turbocharger. This assures exact component balance in order to assure optimum turbocharger performance and life.”
“We cannot do without the high process reliability or high measuring accuracy when balancing.”
Schenck Turbocharger Workshop
Schenck Trebel Corporation will be hosting a Turbocharger workshop in 2017, covering topics on Turbocharger overhaul and giving hands-on exposure to the TBsonio and TBcomfort. If you would like to attend the Turbocharger workshop and would like to receive additional information, please contact sales@schenck-usa.com.
Balancing Machines
For more information about the TBsonio and TBcomfort balancing machines, please visit our web-site.
Guided Path Leads the Way Forward!
The Aviation and Aerospace industry has begun its next Renaissance with a flurry of new technology launches and new product introductions. This Renaissance comes at a time where the work force is experiencing a daunting deficit in qualified technical personnel. The shortage of Aviation Maintenance Technicians and Aviation Maintenance Engineers is well documented and expected to become more severe with each passing year. The makes the job market for those personnel very competitive, which encourages frequent employee turnover. This situation is placing tremendous pressure upon training personnel and available resources to bring new hires up to speed quickly and efficiently. Knowledge and competency in balancing technology has been acutely affected. This issue is now impacting revenue generation in conjunction with new engine introductions at MRO technical operations.
To address this challenge, Schenck introduced a new software extension for its CAB 925 family of instrumentations. Guided Path software provides step-by-step technical instruction customized for a particular rotor configuration with its unique rotor-specific balancing process. A Guided Path process supports on-the-job training that is both repetitively consistent and reproducible from machine operator to machine operator. With each rotor that is balanced, the machine operator receives a reinforced training experience unique to the task at hand.
But the Guided Path software extension can offer much more to MRO Operations.
Schenck’s Guided Path software is a Process Engineer’s electronic work instruction tied to a specific rotor file that guides the machine operator through each step of a specific rotor balancing task.
Photographs, illustrations, other graphic elements, and even complete documents can be incorporated within a Guided Path sequence to help clarify each step of that particular rotor balancing task for the opera tor. Throughout the Guided Path sequence, operators can be required to acknowledge specific tasks have been completed at each checkpoint. Other required inputs can be pre-programmed into the process sequence to ensure:
• Traceability of rotor processing by rotor serial number
• Traceability of tooling used by tooling part number and serial number
• Tooling has been recently inspected and possesses current calibration
• Balancing machine has been recently tested and possesses current calibration
• T ooling Compensation has been performed
• The operator is fully aware of all required process parameters, methods, and documentation requirements.
Guided Path software sequence scan be configured to not permit the operator to proceed until each step of a particular sequence has been completed and the results are determined by the CAB 925 to be acceptable according to pre-programmed process definitions or otherwise signed off by the shift Crew Chief.
Guided Path software serves to ensure uniform process compliance, enhances operator training, and reduces balancing training time and effort.
Equally important, Guided Path can serve as an integral element of quality control systems that are often scrutinized during internal and external audits of overhaul processes.
With so many benefits, Aviation MRO operations will immediately benefit from Guided Path leading the way through complex rotor balancing tasks and associated overhaul processes that otherwise could disrupt efforts to reduce jet engine turn-around times.
***Schenck is pleased to share their trade show schedule for 2017. We look forward to a successful year of displaying our products in today’s leading markets and hope to see you at our booth! For the latest updates on our trade shows, visit our website***.
2017 Schenck Tradeshow Schedule
SHOW DATE/LOCATION
AHR EXPO (AGRAMKOW) January 30 -February 1 Las Vegas Convention Center, Las Vegas, NV
TECMA March 7-10 Expo Bancomer Santa Fe, Mexico City, MX
MRO April 25-27 Orange County Convention Center, Orlando, FL
EASA June 25-27 Tampa Convention Center, Tampa FL
PUMP/TURBO SYMPOSIA September 12-14 George R. Brown Convention Center, Houston, TX
POWER-GEN December 5-7 Las Vegas Convention Center, Las Vegas, NV
Schenck Academy: On-Site Seminars Catered Around YOUR Balancing Equipment
The Schenck Academy is designed as an opportunity to learn about the concepts of balancing, refine skills, and improve the balancing process. These universal theories are applicable to all balancing machines and can be learned by any operator or engineer. The class utilizes an interactive environment where students can discuss their specific problems and experiences. Hands-on sessions reinforce the theory and skills learned in the classroom.
In order to better meet your company’s specific needs and logistic requirements, Schenck Academy offers on-site seminars and workshops throughout North America. These classes also provide the added value of being based around your own facility’s balancing equipment for personalized hands-on demonstrations and training.
Based on your specific needs we can also customize the seminar to exactly meet your requirements. Our seminar staff will work with your team to modify the classroom material in order to expand on areas of interest which are most important to your specific balancing process.
Schenck Academy has had over 1600 attendees over the last five years and over 300 of these attendees also received balancing machine certification.
Specialized Seminars
Schenck Academy offers three levels of balancing instruction:
Level 1: Fundamentals of Balancing – Recommended for any personnel directly related to the balancing process including design engineers. Novices are welcome.
Level 2: Balancing Theory and Applications – Recommended for experienced machine operators, supervisors, process and manufacturing engineers. We highly encouraged that the level 1 course be taken as a prerequisite, as many level 1 topics are reviewed with higher detail.
Level 3: Advanced Balancing Theory and Applications – This course expands in detail on various topics which are discussed in previous courses. This class is recommended for operators and engineers who deal with a wide variety of applications, including flexible rotors and high speed balancing.
Industry specific seminars are also offered. These seminars provide a unique opportunity to explore the key aspects of balancing within a certain industry.
Our most popular classes include:
Fundamentals of Jet Engine Balancing – Students are taught about types of unbalance, and how to balance for each situation. It is recommended for operators and novices with a focus in the jet engine industry.
Advanced Jet Engine Balancing - Recommended for process engineers who wish to formulate a full balancing process for your facility.
Pump & Impeller Balancing – Recommended for operators and engineers in facilities which primarily balance pump impellers. Level 1 Topics from the Fundamentals of Balancing are covered, with emphasis on API Standards, and single/multi-stage pump balancing. Novices are welcome.
Vibration Analysis & Field Balancing – This program provides attendees with the skills for vibration analysis and eliminating unbalance in operation field conditions. It is recommended for maintenance supervisors and field technicians. Novices are welcome.
Balancing Certification:
We offer machine certification for operators who utilize balancing machines, and would like to demonstrate a level of machine proficiency which is held to a Schenck standard. At the conclusion of a particular level course, the attendees are tested on the theory and machine operation prior to receiving their balancing Certificate.
The operator exam is divided up into a written portion, and a hands-on portion. The written portion will test balancing terminology, practices and theory. The hands-on portion will ensure the student can perform rotor verification, setup a machine properly and operate the instrumentation.
What our attendees are saying....
“Great mix of hands-on/classroom learning” ~On-site FOB
”For me, I was able to connect the dots, in things I have previously learned” ~BT&A
“Learned how to use new software in our machine” ~On-site BT&A
For a complete listing of our 2017 Schenck Academy schedule visit our website here.
2017 Schenck Academy Seminars & Workshops
Registration Link
DATE SEMINARS LOCATION
March
March 3 Balancing Workshop III Greenville, SC
March 7 - 9 Fundamentals of Balancing Deer Park, NY
March 9 Certification Level I Exam Deer Park, NY
March 10 Balancing Workshop II Chicago, IL
March 17 Balancing Workshop VI Houston, TX
March 24 Balancing Workshop I Santa Ana, CA
April
April 11-13 Fundamentals of Balancing Houston, TX
April 13 Certification Level I Exam Houston, TX
April 14 Balancing Workshop III Chicago, IL
April 18 - 20 Fundamentals of Balancing Santa Ana, CA
April 20 Certification Level I Exam Santa Ana, CA
April 18 - 20 Pump And Impeller Balancing Houston, TX
April 21 Balancing Workshop IV Greenville, SC
May
May 12 Balancing Workshop I Houston, TX
May 16 - 18 Fundamentals of Balancing Greenville, SC
May 18 Certification Level I Exam Greenville, SC
May 19 Balancing Workshop II Santa Ana, CA
June
June 6 - 8 Fundamentals of Jet Engine Balancing Deer Park, NY
June 13 - 15 Fundamentals of Balancing Chicago, IL
June 15 Certification Level I Exam Chicago, IL
June 16 Balancing Workshop II Houston, TX
July July 11 - 13 Balancing Theory & Applications Deer Park, NY
July 13 Certification Level I & II Exam Deer Park, NY
July 14 Balancing Workshop VI Greenville, SC
July 18 - 20 Fundamentals of Balancing Southfield, MI
July 20 Certification Level I Exam Southfield, MI
July 21 Balancing Workshop III Santa Ana, CA
August
August 8- 10 Fundamentals of Balancing Deer Park, NY
August 10 Certification Level I Exam Deer Park, NY
August 18 Balancing Workshop IV Chicago, IL
August 22 -24 Advanced Jet Engine Balancing Deer Park, NY
September
September 1 Balancing Workshop IV Santa Ana, CA
September 5 - 7 Fundamentals of Balancing Mexico City, MX
September 7 Certification Level I Exam Mexico City, MX
September 15 Balancing Workshop III Houston, TX
October
October 17 - 19 Fundamentals of Balancing Greenville, SC
October 19 Certification Level I Exam Greenville, SC
October 20 Balancing Workshop VI Chicago, IL
November
November 7 - 9 Fundamentals of Balancing Santa Ana, CA
November 9 Certification Level I Exam Santa Ana, CA
November 7 - 9 Advanced Balancing Theory & Applications Deer Park, NY
November 9 Certification Level III Exam Deer Park, NY
November 10 Balancing Workshop I Greenville, SC
Schenck Trebel Corporation
535 Acorn St.
Deer Park NY 11729
Phone: 631-242-4010
url: http://www.schenck-usa.com
Contact:
Tarek El-Sawaf
Director, Business Development
