Napier295 Instruction Manual

Instruction Manual for

NAPIER 295 TURBOCHARGER

Napier Turbochargers Limited P.O. Box 1, Ruston House, Lincoln. LN5 7FD. Lincolnshire, United Kingdom Telephone: +44 (0)1522 516666 Facsimile: +44 (0)1522 516669 24hr Emergency Telephone: +44 (0)7912 515754 Email: [email protected]

www.napier-turbochargers.com

Publication TB 3207 ( Issue 3 ) January 2000

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Amendment issue register To register the incorporation of an amendment to this Manual, sign against the appropriate Amdt number and insert the date of incorporation. The manual is compiled on a loose leaf system. Due to modification of equipment or changes in technique it is occasionally necessary to amend the manual. The amendments are numbered serially and issued to the engine builder who should ensure that they are distributed to the end user without delay for incorporation into the manual. Full instructions for incorporation and recording are given with each amendment and, because of the importance of keeping the manual up to date, it is recommended that amendments are incorporated without delay in all copies. As occasion demands, Service Bulletins are issued to owners/users. These contain instructions or recommendations either of an urgent or general nature and it is recommended that the instructions are implemented and the bulletin filed with the manual set for subsequent reference.

Amdt

Name

Signature

Date

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Foreword This Operating Manual is provided in support of equipment supplied by Napier Turbochargers Ltd. It is designed to provide information, advice and guidance to the owner/operator on the operation and routine maintenance of the equipment. The equipment supplied is complex which is intended for use only by professionally trained operators. The owner/operator should therefore ensure that all operators are properly trained for the operation and maintenance of the equipment assigned to them. It is essential that this operators manual is read before beginning operation by all persons working with or at the turbocharger. All operators and routine maintenance staff must have ready access to a copy of the Operating Manual. Further copies can be obtained from NAPIER Turbochargers. The instructions set out in this Manual assume that operators have a general understanding of the requirements for safe operation of mechanical and electrical equipment in potentially hazardous environments involving either gas or liquid fuels. These instructions therefore should be interpreted and applied in conjunction with the safety rules and regulations applicable at the site and the particular requirements for operation of other equipment at the site. The final decision for operating the equipment at the site in a safe and responsible manner rests entirely with you as the owner/operator. This involves many factors outside NAPIER’s knowledge and control, and therefore NAPIER is unable to accept (and hereby disclaims) any liability (whether based on breach of contract, warranty or statutory duty, negligence or otherwise) for damage or loss of any kind which may be incurred as a result of applying the information or advice contained in this Manual. No additional representations or warranties by NAPIER regarding the equipment or its use are given or implied by the issue of this Manual. The rights, obligations and liabilities of NAPIER and the owner/operator are strictly limited to those expressly provided in the contract relating to the supply of the equipment. The information set out in this manual has been developed from NAPIER’s standard equipment build specification. Where possible at the time of publication, information has been included in respect of modifications to that equipment which are specific to that contract and for additional equipment manufactured by others. The timing of publication and the ongoing nature of design improvements can mean however, that features of the equipment supplied will be different from those shown in this publication. No liability is accepted by NAPIER for errors, omissions or discrepancies of this nature. Because of variations in equipment build, it is important that owners/operators should only replace components with spare parts which are identical to the origInal or contain modifications approved by NAPIER. When ordering parts always quote the turbocharger serial number and the specification of build. NAPIER accepts no responsibility under its warranty or otherwise for defects, damage or injury which result from the use of repair or replacement parts not approved by NAPIER. This manual must be maintained for the life of the equipment supplied. Updates issued by NAPIER in the form of specific Amendments or more generally published as Service Bulletins will be distributed to the engine builder and they are responsible for the distribution to the end user and should be incorporated without delay for future reference. The data, drawings and other information contained in this manual are confidential proprietary information of NAPIER. They are disclosed in confidence to the owner/operators of the equipment supplied by NAPIER under the contract solely for their use in the operation and maintenance of that equipment. No licence is granted for the manufacture of replacement equipment or components or other purposes. The contents of this manual shall not be copied or disclosed to third parties without written authorisation of NAPIER.

© Copyright Napier Turbochargers Ltd.

2000

Confidential. No part of this publication may be reproduced or copied in any form or manner (including electronic, mechanical, photocopying, recording translating or other information retrieval system) without prior written authority of the copyright owner.

Napier Turbochargers Ltd. P.O. Box 1 Lincoln. LN5 7FD England Tel:+44 (0)1522 516666 Fax:+44 (0)1522 516667 Email:- [email protected]

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Safety Instructions

Safety instructions 1.

Introduction The safety instructions in this manual are given for information and guidance and are provided in the interest of safety of personnel and the installation. NAPIER Turbochargers cannot accept responsibility either for the manner in which they are observed or for any consequence of failure to observe them. Personnel must become thoroughly familiar with the safety instructions and must observe these instructions throughout all procedures. Maximum safety of personnel must be of primary importance, followed closely by protection of equipment from damage. Careful observation of the instructions for safe equipment operation will also result in minimizing hazards to personnel. These instructions in no way override local procedures and regulations when operating and maintaining the installation. Statutory and local requirements, codes of working practices, safety and/or health precautions must be observed.

2.

Correct application This equipment has been designed and constructed so as to be safe and without risks to health ”When properly used for the purpose for which it was designed, and in accordance with the manufacturers recommendations”. This NAPIER turbocharger has been developed exclusively for use on diesel engines to generate the volume of air and the pressure necessary for the operation of the diesel engine. Any other usage shall be regarded as a special application which must be clarified with Napier Turbochargers. NAPIER accepts no liability for other applications. It is important that the equipment should be INSTALLED, OPERATED AND MAINTAINED by, or under the supervision of competent qualified staff. Acceptable standards of engineering practice, recommendations contained in this manual, and any instructions specifically advised by the company, with particular reference to information marked on the equipment, must be employed in these activities. The turbocharger should only be operated and used in a technically perfect condition, for its intended purpose and in compliance with the operation manual. NOTE: You are requested to take such steps as are necessary to ensure that any appropriate information relevant to our products is made available by you, to anyone concerned in the installation, operation and maintenance of the contract supplied equipment. Safety instructions also include procedures to be observed in the event of certain operating malfunctions. To avoid personal injury and damage to equipment, adhere to all caution and warning statements for this product.

3.

Competent personnel A competent person is considered to be one who has the skill, knowledge, practical experience and training to enable them to carry out installation, operating or maintenance tasks on the turbine package. They should also be aware of and understand any local regulations and safety procedures.

4.

Notes, Warnings and Cautions Personnel should be aware and be familiar with the Safety Instructions to be observed when operating or maintaining the turbocharger and equipment before operating or maintaining the equipment. In addition, attention is drawn to conditions which under certain circumstances can be injurious to health and safety, by the insertion of notices in the manual under the headings of ‘‘WARNING”, ‘‘Caution” or ‘‘Note”.

1

NAPIER 295 A WARNING”is given when failure to observe the instruction could result in risk of health and injury to personnel. An example of how this is indicated in the text is shown below: WARNING: FAILURE TO OBSERVE THIS INSTRUCTION COULD RESULT IN RISK OF HEALTH AND INJURY TO PERSONNEL.

A Caution is given where failure to observe the instruction could result in damage to the equipment. An example of how this is indicated in the text is shown below: Caution: Failure to observe this instruction could result in damage to the turbocharger and engine. A Note is used for emphasis or the provision of information of particular importance. To avoid personal injury and damage to equipment, adhere to all caution and warning statements for this product. 5.

Location and content of Warnings, Cautions and Notes Warnings and cautions are located directly above the text to which they relate and are intended to emphasize critical or important information. They tell the reader what he must do to avoid the danger. Any necessary background information follows the initial instruction.

6.

General directives

7.

Directive on safe operation A preliminary walk-round safety inspection of the site should be carried out before beginning any procedures: this inspection should also include any other equipment which may be peculiar to the installation. Any actual or potential hazard must be corrected before proceeding. The equipment is designed to provide safe and reliable operation, when properly used. Close observation of the following directives will aid in the prevention of trouble and will ensure satisfactory operating performance to design standards. The order of listing is not intended to indicate the measure of importance: each item is important to overall safety and satisfactory operation.

8.

Permit to work The Safety Instructions included with this manual meets the obligations of the Health & Safety Regulations regarding the supply and use of machinery and equipment. As our products are supplied world-wide, the importance of observing the Safety Regulations within a particular country is strongly emphasized. It is the responsibility of the user to ensure that all applicable statutory Safety Regulations are observed during the operation of the turbocharger. It is recommended that formal ‘Permit to Work’ procedures and logs are implemented, whereby personnel must adhere to set procedural instructions before undertaking any work on the turbocharger and associated equipment. It is important that work is carried out by competent personnel who should be conversant with the procedures. Personnel should understand and apply these precautions during the various phases of Operation, Inspection and Maintenance. The site safety officer must be consulted for clearance to work and where appropriate a work permit issued before carrying out any tests or maintenance work on the installation.

9.

Operational hazards Health hazard Wear appropriate protective equipment (masks, goggles, gloves etc.) when using cleaning solvents or solutions. Avoid skin contact with solvents or solutions. Should solution enter the eyes, rinse immediately and seek medical attention.

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Napier Turbochargers Ltd.

Safety Instructions

Use all cleaning solvents, fuels, oils and adhesives in a well ventilated area. Avoid inhalation of fumes. Procedural hazards Determine if personnel are working on equipment in the area and whether such work is of a hazardous nature that precludes work on other equipment.

10.

Installation hazards Keep the installation and vicinity clean and unobstructed. Observe all safety instructions listed in the manuals supplied for the engine and ancillary equipment. Exercise caution when climbing access ladders. Check pipelines regularly for corrosion, vibration, fretting and security of clamps, and eliminate any leaks as soon as they are detected.

11.

Maintenance hazards Before disconnecting any pipelines (lubricating oil, water etc.) or dismantling components in situ for maintenance, ensure that the applicable system pressure has been isolated at source, pressure dissipated and the system vented. Ensure that there is no naked flame in the area.

12.

Use of adhesives and jointing compounds Before using adhesives and jointing compounds (particularly in confined spaces), check the manufacturer’s instructions regarding injurious, offensive or inflammable fumes, risk of skin disease etc.

13.

Fluorelastomer synthetic rubber products A fluorelastomer is a synthetic rubber like material containing Fluorine and the most common use found in engineering products is for gaskets, seals, cables, ’O’ ring seals and diaphragms. When used within their designed operating conditions, products manufactured from this material are perfectly safe to use and handle. If, however, due to abnormal circumstances, the material is exposed to a temperature in the region of 400oC and higher, it does not burn, but decomposes. In the event of this situation arising, hydrofluoric acid is produced which is extremely corrosive and if allowed to contact the skin, it can prove almost impossible to remove once contamination occurs. As this constitutes a serious potential safety hazard, it is essential that all personnel who are concerned with the operation and repair of the company products are warned of this risk and are instructed to follow the procedure detailed below. i)

If inspection and dismantling is required on components which have been exposed to excessively high temperatures (e.g. if they have become overheated in operation or have been involved in a fire), carry out a very close examination to determine if there are any seals, gaskets, etc., which have suffered decomposition. Evidence of this will be displayed by the presence of charred particles or a black sticky mass.

ii)

It is of vital importance, if any such indications exist, to ensure that neither the equipment nor the seals are touched with bare hands. PVC gloves must be worn and it is recommended that the eyes be protected. All affected material should be carefully placed in double thickness polythene bags and proper advice obtained on effective disposal. Any equipment contaminated by the decomposed material must be washed with water.

iii)

If skin contamination has occurred, the affected area must be washed with copious quantities of water and then medical attention sought.

The procedures outlined above apply equally if fluorelastomer products are involved in a fire, including production or spare parts storage locations. It should be emphasised that decomposition of parts manufactured from a fluorelastomer will only occur under severe overheat conditions. The designed operating temperatures for this material used in components manufactured by the company is well below 400oC.

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NAPIER 295 Due to the large amount of ancillary equipment supplied, it is not practical to indicate areas where fluorelastomer products are fitted. It is recommended, that should an overheating problem occur, that users err on the side of caution and proceed as outlined above. It should be noted that the company will accept no liability for any failure on the part of turbine users to ensure compliance of personnel with the recommendations and procedures outlined above.

14.

Procedural hazards Place notices in prominent positions, to indicate that personnel are working on the equipment. It is recommended that other personnel are in close proximity. NEVER WORK ALONE. Do not use fingers as guides when installing parts or to check alignment of bolts. Cap all open lines and fittings during maintenance to prevent entry of contaminants into systems. Ensure that all loose items such as nuts, washers and spare wiring are removed from the installation and air intake before starting.

15.

Tooling hazards Improperly maintained tools and support equipment can be dangerous to personnel and can damage turbocharger parts. Maintain tools and equipment in good condition to avoid unanticipated failures. Use tooling only for the purpose for which it was designed, and avoid abuse. Inspect for wear or damage, and initiate appropriate action for immediate approved repair or replacement.

16.

Use of lifting equipment (slings, cranes etc.). Before using any lifting equipment, ensure:

17.

i)

The equipment is the correct type for the task.

ii)

The equipment has valid test certificate and the safe working load is marked on the equipment.

iii)

Shackles, slings are in good condition.

Safe exposure to noise Very loud noise causes serious and irreparable hearing damage and studies have shown that continuous exposure to noise levels over 85dB(A) causes hearing damage. NAPIER recommends the use of hearing protection at this level and above. Indicative safe times in high noise surroundings without ear protection are shown below, however international standards and regulations should be referred for definitive figures. It is the responsibility of engine operators to monitor noise levels and advise personnel accordingly about the use of hearing protection.

18.

Pre-start Before starting the turbocharger ensure that no maintenance operation is being conducted, and personnel are clear of the air inlet and exhaust, and that any loose articles, cleaning materials, tools etc. have been removed. Before operating the turbocharger understand the operating procedures and system functions thoroughly. Know and understand all indicators, normal indications and operating limits. Be aware of possible malfunctions by studying the instructions supplied, and be prepared to take appropriate action in the event of any emergency.

19.

During operation Stand clear of all pressure lines and fittings during the start.

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Safety Instructions

Turbine speed and temperature are the best indication of performance. Should an abnormal condition arise take the appropriate action. When carrying out compressor or turbine wash procedures refer to the instruction manual to ensure that limits are not exceeded. Ensure that all drains and vents are kept clear during the wash procedure.

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Introduction

NAPIER TURBOCHARGER TYPE NA.295 SPECIFICATION

Type

Max. Permissible Speed ( R.P.M. )

Pressure Ratio

NA.295

SEE TURBOCHARGER TYPE PLATE FOR DETAILS

4 :1

Max. Turbine Inlet Temperature SEE TURBOCHARGER TYPE PLATE FOR DETAILS

Weight

510 Kg. approx.

NAMEPLATES The turbocharger has the type of plate shown. This plate is mounted on the main casing. The information shown on this name plate is explained overleaf.

295 3EIL 72A 114 K 1000 31,000 650

JH

Example of the Turbocharger nameplate

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NAPIER 295 INFORMATION ON NAMEPLATE TYPE: This indicates the turbocharger type. EXAMPLE NA295

This is the basic type reference for the NAPIER 295 turbocharger.

SERIAL No. The turbocharger identification serial number. EXAMPLE 1000 SPECIFICATION: The turbocharger build reference specification. EXAMPLE ( typical ) 3EIL

72A

114

K Nozzle and rotor blade designation Nozzle Throat area in cm2. First of this design Diffuser throat area in cm2. Compressor capacity ( size & type)

MAX. SPEED: Maximum permissible speed in R.P.M. MAX. TEMPERATURE: Maximum permissible temperature in C ALTERATION RECORD: Alteration numbers 1 to 26 are already entered on the plate. Any alterations affecting turbocharger interchangeability, will be indicated by obliterating the relevant numbers on the plate. SPARE CARTRIDGE ASSEMBLIES A turbocharger serial number followed by the symbol X e.g.( 49X ) indicates an assembly which has been built and supplied as a CARTRIDGE ASSEMBLY only.

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Napier Turbochargers Ltd.

Introduction

Spare parts are supplied to the latest specification applicable to the particular turbocharger. Customers will therefore appreciate ,when checking the part numbers of spare parts supplied against those ordered, that a difference in part numbers does not necessarily indicate that an incorrect part has been supplied. IT IS RECOMMENDED THAT ORDERS FOR SPARE PARTS QUOTE THE SERIAL NUMBER, SPECIFICATION, ITEM CODE NUMBER AS WELL AS THE DESCRIPTION OF EACH PART, AS A SAFEGUARD AGAINST MISUNDERSTANDINGS AND INCORRECT SUPPLY. Enquiries for service and orders for spare parts should be sent to:-NAPIER TURBOCHARGERS Ltd. P.O. BOX 1 LINCOLN LS2 5DJ

TELEPHONE: +44 (0)1522 516622 FAX: +44 (0)1522 516669 E mail: [email protected]

or alternatively, one of our Service Network Centres around the World. Service Network Centre brochures may be obtained by contacting NAPIER TURBOCHARGERS Ltd.

USE GENUINE

NAPIER PARTS MANUFACTURED BY NAPIER Turbochargers

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Contents

INDEX OF CONTENTS

CHAPTER 1

CONSTRUCTION

CHAPTER 2

INSTALLATION

CHAPTER 3

OPERATION

CHAPTER 4

MAINTENANCE AND INSPECTION

CHAPTER 5

DISMANTLING

CHAPTER 6

TABLE OF CLEARANCES

CHAPTER 7

RE--ASSEMBLY

CHAPTER 8

TOOL LIST

CHAPTER 9

SUPPLEMENTARY INFORMATION

CHAPTER 10

SPARES AND TECHNICAL SUPPORT

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Construction

CHAPTER 1. CONSTRUCTION

1.1.

TURBOCHARGER FUNCTIONS

1.2.

CONSTRUCTION

1.2.1

Turbine Outlet Casing

1.2.2

Turbine Inlet Casing

1.2.3

Cartridge Assembly

1.2.4

Compressor Outlet Casing

1.2.5

Rotor Assembly

1.2.6

Main (Centre ) Casing

1.2.7

Bearings

1.2.8

Air Filter Silencer

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Construction

1.1

TURBOCHARGER FUNCTIONS The function of a turbocharger is to use the exhaust gas energy of an internal combustion engine (which would otherwise be wasted )to drive a turbine wheel and hence a compressor. The compressor increases the pressure and density of the charge in the engine cylinder, thereby increasing the power above that of a naturally aspirated engine. Turbocharging has been shown to be the most successful method of reducing cost, weight and space requirement of diesel engine installations, and is recognised as a reliable method of improving their performance, efficiency and fuel consumption.

Exhaust Gas Outlet

Air from Atmosphere

Exhaust Gas Inlet

Air Supply to Engine

Fig. 1

Turbocharger Functions

The NAPIER 295 Turbocharger consists of a single stage axial--flow turbine and centrifugal air compressor connected by a single rotor shaft supported on inboard bearings. The exhaust gas discharged from the engine cylinders enters the turbine inlet casing and is accelerated through a nozzle ring into the turbine blades, where the gas rotates the rotor shaft. The gases then pass through the turbine outlet casing to an exhaust pipe into the atmosphere. The air required by the engine is drawn through an air filter silencer or a compressor inlet casing, and compressed by an impeller and diffuser into the compressor outlet casing. The air is then forced into the engine combustion chamber.

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NAPIER 295 1.2

CONSTRUCTION THE NAPIER 295 turbocharger is an assembly of four casings bolted together, to house a single stage, axial flow, exhaust gas driven turbine and a centrifugal air compressor, which are mounted on a single shaft. The turbocharger is mechanically independent of the engine to which it is applied, but the lubricating and cooling systems may form part of the engine system or be provided from a separate source.

1.2.1

TURBINE OUTLET CASING The water cooled turbine outlet casing , forms the principal structural component to which the other casings are assembled. The turbocharger coolant jacket is incorporated into into the engine cooling system, or connected to an independent water supply depending on site requirements. Coolant jacket passages formed in the casing are sealed by three large cover plates, one of which is designed to function also as the mounting foot of the turbocharger. By attaching the inlet and outlet pipes to selected connection points, correct coolant flow can be provided for every position of the casing. Water deflection unions are fitted to the water inlet of all casings and zinc anti--corrosion plugs are incorporated. The mounting foot for the assembled turbocharger also functions as a water jacket cover plate, permitting a wide choice of alternative positions for the turbine outlet casing.

1.2.2

TURBINE INLET CASING The air or water cooled turbine inlet casing supports the nozzle ring and shroud ring assemblies, with a central gas barrier plate, and is located to the turbine outlet casing.

1.2.3

CARTRIDGE ASSEMBLY A NAPIER design feature which has made servicing simplicity itself, is the CARTRIDGE ASSEMBLY. The assembly comprises of the main casing, compressor casing, rotor assembly and bearings complete, allowing the complete removal of cartridge assembly without disturbing the turbine inlet and outlet casings and water connections. ( see Fig. 1.2 )

1.2.4

COMPRESSOR OUTLET CASING The compressor outlet casing is a cast iron volute also forming the casing for the compressor impeller and the diffuser. Air drawn through the eye of the casing is discharged to the engine through a tangential duct with a flanged connection.

1.2.5

ROTOR ASSEMBLY This consists of a solid steel shaft, one end of which is a shrink fit on the hub of the blisc. NO ATTEMPT SHOULD BE MADE TO SEPARATE THE BLISC FROM THE SHAFT. Seal rings are set into the shaft collar over the wheel hub. On the other end of the shaft is a thrust collar, impeller, lock washer and impeller drive washer. The impeller, lock washer and drive washer are held against a shoulder on the shaft by an end nut. Finally, there are spanner flats at the centre of the blisc, forming the turbine end of the rotor shaft assembly. Each major component of the rotor assembly is dynamically balanced before assembly. After assembly the complete rotor is check balanced.

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Napier Turbochargers Ltd.

Construction

Fig. 2

1.2.6

Removal of the Cartridge Unit

MAIN ( CENTRE ) CASING The main casing assembly consists of a circular casing carrying the diffuser seal plate, impeller labyrinth seal plate and seal ring bush ( oil drain chamber ) on one face, and a seal ring bush ( oil drain chamber ) and encasing cone on the other ( the turbine end ) . A combined thrust/journal bearing is fitted to the compressor end and a bearing bush to the turbine end , both of which support the rotor assembly. Air bled from the compressor casing via the labyrinths on the rear face of the impeller prevents oil loss past the compressor end seal ring or rings. The same supply of air also feeds tubular passages in the centre casing, which in turn pressurise and cool the cone space of the casing. The air then pressurises the turbine end seal rings against the exhaust gas and oil leakages, and also serves to cool the turbine disc.

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NAPIER 295 1.2.7

BEARINGS Hydrodynamic type bearings are fitted at each end of the main ( centre ) casing, the combined thrust/journal bearing is located at the compressor end of the turbocharger. Outboard of each bearing assembly are seal rings and seal ring bush ( forming a part of the main casing assembly ). The bearings are lubricated from the engine oil system or from an independent supply.

1.2.8

AIR FILTER/SILENCER A combined air filter silencer is available for an installation in which the turbocharger is required to draw air from the engine room. The wire mesh filter element consists of two or three segmental panels which are clipped together forming a complete annulus between front and rear casings. Six bolts on the exterior of the silencer fasten the filter silencer assembly to the volute casing periphery. If the air supply is to be ducted to the turbocharger from outside the engine room an aluminium compressor inlet casing can be fitted in place of the air filter silencer.

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Napier Turbochargers Ltd.

Installation

CHAPTER 2. INSTALLATION

2.1

Slinging Arrangement.

2.2

Turbocharger Weights.

2.3

Instrumentation.

2.3.1

Pressure Gauge Connection.

2.3.2

Speed Measurement.

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Installation

2.1

SLINGING ARRANGEMENT

Turbocharger weight 510 Kg. appx.

Cartridge weight 295 Kg. appx.

21

NAPIER 295 2.2

USEFUL TURBOCHARGER WEIGHTS ( APPROXIMATE ) Turbocharger Complete

510Kg.

Turbine Outlet Casing ( complete with mounting foot and covers )

155Kg.

Turbine Inlet Casing ( complete with nozzle and shroud ring assembly ) Single entry air, cooled axial Twin entry air, cooled axial Shroud ring Cartridge Assembly ( comprisied of main casing assembly, rotor assembly and compressor outlet casing )

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50Kg. 55Kg. 10Kg.

295Kg.

Main Casing Assembly ( complete with cone, bearing housings etc. )

75Kg.

Rotor Assembly, complete

23Kg.

Compressor Outlet Casing Single delivery

154Kg.

Air Filter Silencer

27Kg.

Compressor Inlet Casing

25Kg.

Napier Turbochargers Ltd.

Installation

2.3

INSTRUMENTATION

2.3.1

PRESSURE GAUGE CONNECTION A pressure gauge tapping in the outlet of the volute casing, is provided. To eliminate the possibility of damage due to engine vibration, the gauge must be mounted clear of the engine structure. Under no circumstances must a gauge be mounted directly on the turbocharger induction manifold. If it is necessary to adopt some form of attachment to the engine, the gauge should be protected by a suitable flexible mounting. The pressure gauge is outside our scope of supply. Any reputable supplier will satisfy. Connection size is 3/8in. B.S.P.

2.3.2

SPEED MEASUREMENT The turbocharger rotating assembly is arranged to give two pulses during each revolution of the turbocharger shaft. The sensing probe ( perception head ) is threaded and held in place by a captive ‘O‘ ring and locking plate, and positioned on top of the main casing. The electrical connections to the probe are made by, insulated, twin, screened cable, the screen being earthed at the indicator end only and NOT at the probe. A miniature circular connector is fitted to each probe. Socket, “Cannon” KPT.02.E.8.2.S. Plug, “Cannon” KPT.06.F.8.2.P. The connector is suitable for solder type terminations. OPERATING INFORMATION Temperature range, -20o - +150oC. The maximum permissible speed of the turbocharger is recorded on the turbocharger nameplate. PROBE INSTALLATION PROCEDURE Ensure that the locking plate and ”O” ring are positioned correctly on the main body of the probe just below the circular connector. Lightly oil the thread. Assemble the probe in the appropriate housing in the turbocharger main casing, ensuring that the housing bore is clean and free from obstruction and that the body of the probe is clean. Turning clockwise and not using excessive force, screw home the probe until it makes contact with the shaft of the turbocharger. Adjust the probe to shaft air gap by turning the probe one half turn anti--clockwise. The probe is now correctly adjusted and the air gap is 0.8mm.. ( 0.028 ) inch. Lock the probe in position by tightening the locking plate securing screws. Probe removal length 550mm..

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Operation

CHAPTER 3. OPERATION

3.1

Lubricating Oil.

3.2

Cooling Water Requirements.

3.3

Sealing and Cooling Air.

3.4

Initial Start Inspection.

3.5

Routine Operation.

3.6

Prolonged Shut--down.

3.7

Turbocharger Surge.

3.8

Turbocharger Matching.

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Operation

3.1

LUBRICATION OIL The compressor end thrust bearing and the turbine end bearing inboard of the impeller and turbine wheel respectively, are the only parts of the turbocharger that require lubrication. ( See Fig.3.1. ) Lubricating oil for the rotor bearings may be drawn directly from the filtered side of the engine system or from any other suitable source, provided that correct arrangements are made for filtration. The engine oil filters are to be cleaned in accordance with the Engine Builders Manual. THE FILTER MESH SHOULD NOT EXCEED 25 MICRONS. OIL VISCOSITY GRADE SHOULD BE BETWEEN SAE 20 to SAE 40 OIL CLEANLINESS SHOULD CONFORM TO BS5540 (ISO 4406) LEVEL 19/15 OR BETTER. Oil pressure turbocharger inlet

2.33 -- 3.33 Bar 35 --50 lbs. per sq. in.

Oil flow ( approximate range )

16 -- 25 216 --365

Heat flow rate

45 kW

litres / min. gals. / hr.

according to speed, temperature and pressure with S.A.E. 30 grade. This lubrication system complies with Lloyd’s Register of shipping regulations in that it will operate satisfactorily when tilted permanently at 15 in any direction and at a temporary tilt of 22, such as might be experienced in marine installations. Initial installations must however, be made with the turbocharger shaft horizontal. 3.2

COOLING WATER REQUIREMENTS The jacket cooling water outlet temperature should be maintained above 60C Coolant flow rate

135 litres per min.

Heat flow rate

100 kW

Maximum coolant temperature

92oC or if the system is pressurised T-17oC, where T is equal to the boiling point at pressurisation pressure.

If the cooling water temperature is too low, sulphuric acid corrosion of the exhaust gas passage walls will quicken, resulting in a shorter casing life. If there is an excessive cooling water temperature difference between the outlet and inlet casings, or if the water outlet temperature is too high, scale or salt etc. may deposit in the cooling water passage, clogging or even causing cracking to the casing walls. 3.3

SEALING AND COOLING AIR The seal rings fitted outboard of each bearing are pressurised by air taken from the compressor. Pressurisation of the compressor end seal prevents oil being drawn into the compressor casing and the turbine end seal prevents gas and oil leakage. Close clearances between the rear of the impeller and a labyrinth on the seal plate form an effective seal between the turbine outlet casing and the compressor outlet casings. The seal clearances allow a controlled flow through the main casing to the cone, to cool the inner face of the turbine disc.

27

NAPIER 295 3.4

INITIAL START OF A NEWLY INSTALLED ENGINE, OR NEWLY OVERHAULED ENGINE Checks to be made at the first running of the turbocharger installed on an engine. Before starting the engine: Check that all bolts, holding the turbocharger to the engine mounting faces, are secure. Open the vent cocks or plugs at the highest points of the water system and check that the flow of water is not restricted by air locks. Close the cocks and replace the plugs when air bubbles cease to escape. If the cooling to the turbocharger is independent of the engine system, check that cooling fluid is circulating freely. Start and run the engine up to idling speed. Check and record the oil pressure at the turbocharger inlet. Check all gas, air, and cooling water lines for leakage. After a reasonable period of time, feel the turbine casing and cooling water pipes. The temperature rise should be gradual and evenly distributed. Scald temperature is 70C, so appreciate the coolant temperature during this check. At various engine loads, to serve as a basis for future checks on turbocharger and engine performance, record:-a.

Turbocharger speed

b.

Air delivery pressure

c.

Temperatures before and after the turbine

d.

Temperatures before and after the compressor

e.

Temperatures before and after the charge air cooler

3.5

ROUTINE OPERATION

3.5.1

ROUTINE STARTING Before starting the engine, make the following checks: Check in the log book and by observation if possible, that any maintenance work required has been completed in accordance with the MAINTENANCE AND INSPECTION SCHEDULE given in chapter 4. Proceed as described in 3.4 Initial Start of Engine.

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Napier Turbochargers Ltd.

Operation

3.5.2

RUNNING The turbocharger requires attention only by observation when running. Check the oil and cooling water supply. Record -- the air delivery pressure. --the depression at the compressor inlet. --the rotor speed. --the gas temperature at the turbine inlet. during the watch inspection of the engine. A gradual or sudden deterioration in these figures will indicate the need for internal cleaning or overhaul of the turbocharger, and may also assist in deciding the cause of unsatisfactory engine operation.

3.5.3

STOPPING When shutting down, it is desirable that the turbocharger speed be allowed to stabilise, with the engine idling, before finally stopping. This procedure applies particularly where rapid load shedding occurs. NORMAL STOP

Engine driven pump -- Normally the oil supply will be adequate for the run-down period. Motor driven pump -- It is recommended that a delay of at least 90 seconds is introduced, between engine shut--down and pump shut--down. or A reservoir (run down tank), the capacity of which is sufficient to supply Lube oil for 90 seconds, is included in the turbocharger supply system.

EMERGENCY STOP NOTE:

3.6

As for NORMAL, but subject to prevailing local conditions and legislation.

Should circumstances dictate that the oil supply to the turbocharger be shut--off before it has run--down, then it is recommended that the bearings be inspected before attempting a restart.

PROLONGED SHUT--DOWN The turbocharger should be inhibited at the beginning of any period of disuse which is expected to extend beyond a period of one month. Details of the procedure are given in chapter 4, MAINTENANCE AND INSPECTION, section 4.9.

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NAPIER 295

Oil Air Water

Fig 3.1

30

Lubrication, Air and Coolant systems

Napier Turbochargers Ltd.

Operation

3.7

TURBOCHARGER SURGING Surging is a phenomenon which can occur in all turbocharger systems irrespective of type or make. Surging is defined as the operating point at which the compressor ceases to maintain a steady flow for a given boost pressure, and reversal of the flow takes place. This is usually accompanied by noise in the form of pulsations or panting, sometimes mildly and sometimes noisily with a large amplitude. It is essential that surging during engine operation is avoided. Damage may be caused to the rotating parts with consequent damage to the complete turbocharger. The following may give rise to surge:

3.8

i.

A violent change of engine load or excessive overload.

ii.

An excessive rise of cooling water temperature in the charge air cooler.

iii.

Extreme fouling of the inlet or exhaust manifolds.

iv.

Mismatching of compressor and turbine components in respect of a particular engine.

v.

The turbine nozzles and blades will accumulate carbon deposits from the burnt residue of fuel impurities and lubricating oil additives, resulting in high turbine speeds, high boost pressure and exhaust gas temperature rise. Continued deposits will raise the exhaust gas temperature sufficiently to cause surging.

TURBOCHARGER MATCHING Output of a turbocharger is matched to the engine air demand and exhaust characteristics by the selection of impeller, compressor diffuser, turbine nozzle and turbine blades of the length necessary to drive the impeller at the correct speed with maximum efficiency. Consequently, although the same NAPIER frame size of turbocharger may be fitted to more than one size of engine, the various diffuser and turbine wheel combinations are NOT interchangeable.

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NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Maintenance & Inspection

CHAPTER 4. MAINTENANCE & INSPECTION 4.1

Periodic Maintenance & Inspection Schedule.

4.2

Bearing Replacement.

4.3

Thrust Bearing Wear.

4.4

Rotor Shaft Balance.

4.5

Water Cooled Turbine Casing Wall Thickness Inspection.

4.6

Air Filter Removal and Inspection.

4.7

Anti--Corrosion Plugs.

4.8

Operating Difficulties.

4.9

Protection Against Corrosion ( Inhibiting ).

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NAPIER 295 NOTES

34

Napier Turbochargers Ltd.

Maintenance & Inspection

4.1

PERIODIC MAINTENANCE AND INSPECTION SCHEDULE The table below shows the standard maintenance and inspection periods. Servicing necessity varies with site conditions. It may be that certain operations must be performed more frequently than recommended. Similarly, favourable conditions may result in acceptable extended periods.

TIME

Initial Inspection

After first 100 hrs. of operation.

MAINTENANCE & INSPECTION SCHEDULE

Confirm the circulation of lubricating oil and cooling water, i.e. engine feed supplies. Inspect all gas, air and water pipe connections, ensure they are tight. Inspect security of holding down bolts and casing nuts.

Periodic Inspection.

Every day, this will depend on individual site conditions.

Compressor water wash. ( See Chapter 9 )

Every 250 hrs. This will depend on individual site conditions..

Clean air filter elements.

Every 8,000 --12000 hrs. To coincide with engine manufacturers engine overhaul

Dismantle and clean complete turbocharger.

IMPORTANT: Ensure the turbocharger is fed with clean filtered lube--oil by cleaning the engine oil filters according to the Engine Builders Manual. 4.2

BEARING REPLACEMENT Bearing life varies considerably depending on operating conditions. Providing correct oil grades, oil pressures, and clean oil is supplied, the bearing life of the turbocharger is indefinite. If unfavourable service conditions do prevail the bearing should be inspected every 8,000 hrs.

4.3

THRUST BEARING WEAR Service experience has shown that the major thrust bearing can become worn in service, mainly due as a result of contaminated lubricating oil. In addition, in particular cases, wear has been experienced during initial engine operation when running in compounds have been used. The following notes provide guidance on In general when bearings show any sign of wear they should be changed out, since in most cases, wear precedes failure.

35

NAPIER 295 The anodized surface was introduced to make the bearing more tolerant to contaminants which cause wear. As long as the anodized surface is intact the bearing is suitable for further use. There are some cases when the surface becomes worn and it may not be practical to change the bearings, the following is a guide as to what can be re--used.

4.4

f.

Cocoa staining, a brown discoloration of the anodized surface , is a normal feature and the bearing is acceptable for further use. If however all the pads are affected then it is an indication that the oil temperature may be too hot.

g.

Black marking on the bearing surface is pick--up from the thrust collar and is an indication of lack of lubrication. The bearing is not suitable for further use and an investigation into the oil system is recommended.

h.

In some cases contaminated oil(from running in compounds etc.) will lead to a fine polishing of the pads which wears away the anodized layer. Some such wear is acceptable and the bearing is considered acceptable and the bearing is considered acceptable for a further period of service if less than 1/3rd of the total number of pads are affected (i.e. 4 from 12).

i.

If the pads are scored then this is an indication of particles / debris in the oil system. The bearings are not suitable for further use and the filters should be inspected

ROTOR SHAFT BALANCE CHECK The rotor shaft of the turbocharger is dynamically balanced when new. If any rotating parts have been damaged or major components have been replaced, it is important that the rotor shaft is check balanced. It is recommended that the rotor shaft balance is checked by NAPIER Turbochargers or one of our Approved Servicing Organisations every 32.000 hrs. or every 4 years.

4.5

WATER COOLED TURBINE CASING WALL THICKNESS INSPECTION Turbine casings are subject to corrosion by the oxidation effect of water, and by the sulphuric acid content in exhaust gas. Turbine casing life varies considerably according to site operating conditions, fuels used, water treatment etc,It is advisable to remove the casing water cover plates during each overhaul inspection and thoroughly clean the inner water passages, thereby ensuring free circulation of the cooling water. Use ultrasonic inspection techniques to establish the casing wall thickness during each overhaul inspection, if possible. If the wall thickness is less than 2 mm. it is recommended that a replacement casing be purchased and fitted at the earliest convenience.

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Napier Turbochargers Ltd.

Maintenance & Inspection

4.6

AIR FILTER REMOVAL AND CLEANING At 250 hrs. or when the pressure drop across the air filter reaches 200 m.m. ( 8 ins. ) head of water ( whichever occurs first ) clean the filter elements. The filter elements are of the oil wetted type and can be cleaned by passing air at 300KPa, ( 30 --60 p.s.i. ) through in the reverse direction to normal airflow to the compressor. Eye protection should be worn. Very dirty panels may be washed using a high pressure water--jet, oil and grease may be removed by using Para Chorethylene (Dry Cleaning Chemical) or Industrial Alcohol. The splitters should be cleaned using a hand brush for general dust and debris and Para Chorethylene (Dry Cleaning Chemical) or Industrial Alcohol to remove oil and grease.. Do NOT use solvents. Dust adhesion and dust holding capacity can be improved if the filters are lightly oiled after cleaning.

Fig. 4.1

4.7

Air Filter Cleaning

ANTI CORROSION PLUGS The turbine outlet casing has two cover plates to the cooling water jacket. Attached to the inside of each cover is a zinc anti--corrosion plug. Examine the plugs and descale as necessary during overhaul, and renew if excessively corroded. The wasting by corrosion will be accelerated if sea water is the cooling medium, as opposed to treated fresh water.

37

NAPIER 295

4.8

OPERATING DIFFICULTIES Operating difficulties can be prevented providing the daily turbocharger operating data is measured and regular maintenance and inspection routines adhered to. To assist users in identifying causes of performance deterioration, the following table has been formed:

OPERATING DIFFICULTIES

Engine starts running but the turbocharger does not.

Turbocharger experiences surging during operating.

PROBABLE CAUSE

REMEDIAL MEASURES

Foreign matter / debris caught between the turbine blade tips and the shroud ring. Blade tips rubbing the shroud ring.

Provide cleaning and eliminate the cause for the ingress of the foreign matter.

Bearing disorder.

Inspect and replace with new bearings.

Fouling of turbine nozzle, blades.

Cleaning of the turbine side of turbocharger as required.

Engine cylinder unbalance.

Refer to Engine Builders Instruction Manual.

NOTE; Rapid changes of engine load, particularly during shut--down can cause turbocharger surging. ( See 3.7 Turbocharger Surging )

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Napier Turbochargers Ltd.

Maintenance & Inspection

Exhaust gas temperature higher than normal.

Fouling or damage to turbine nozzle or turbine blades.

Cleaning the turbine side of the turbocharger or component replacement.

Lack of air, e.g. dirty air filter.

Clean as required.

Exhaust back pressure too high.

Investigate cause.

Charge air cooler dirty, cooling water temperature too high.

Clean and adjust as Makers Instruction Manual.

Engine fault in fuel injection system. NOTE. Refer to Engine Builders Instruction Manual for other remedial measures.

Charge air ( boost ) pressure lower than normal.

Pressure gauge faulty or connection to it leaking.

Rectify.

Gas leakage at engine exhaust manifold

See Engine Builders Instruction Manual.

Dirty air filter, causing pressure drop.

Clean as required.

Dirty turbocharger.

Cleaning of complete turbocharger required.

Turbine blades or nozzle ring damage.

Inspect and replace as necessary.

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NAPIER 295

Charge air pressure ( boost) higher than normal.

Turbocharger vibration.

Pressure gauge reading incorrectly.

Rectify.

Nozzle ring clogged with carbon deposits.

Clean as required.

Engine overload, engine output higher than expected.

Consult Engine Builders Instruction manual.

Fault in engine fuel injection system.

Consult Engine Builders Instruction Manual.

Severe unbalance of rotor due to dirt or damaged turbine blading.

Rebalance the rotor assembly

Bent rotor shaft.

Inspect and replace as necessary.

Defective bearings.

Inspect and replace as necessary

Incorrectly assembled bearings.

Inspect and replace as necessary.

A simple system of washing the compressor components while the engine is running, is available, to help maintain peak performance between overhaul periods. Provision for fitting such equipment is made on all Turbochargers. The system consists of an injection pipe located on the Air Intake Duct, with a discharge orifice located to spray the eye of the impeller, which may be injected by a syringe or pressurised system. For full compressor cleaning instructions see Chapter 9. Additional copies of these instructions are available on request.

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Napier Turbochargers Ltd.

Maintenance & Inspection

4.9

PROTECTION AGAINST CORROSION The bearing surfaces, oil passages, thrust faces etc, in all Turbochargers leaving the NAPIER factory are inhibited with SHELL ENSIS 158. It is recommended that Turbochargers, at the beginning of any subsequent period of idleness likely to be more than one months duration, should be similarly inhibited. Inhibiting should be repeated at four monthly intervals if the turbocharger continues to be inoperative. Turbochargers fitted to engines which are to be shut down for long periods, or Turbochargers to be held as spares, must receive preparation for long term storage. More extensive treatment and instructions for this work can be obtained on request. INHIBITING AN INSTALLED TURBOCHARGER Disconnect the lubricating oil supply from the top of the main casing. Remove the lubricating oil drain flange and pipe. Introduce inhibiting oil (e.g. Shell ENSIS 158) for a short period through the open connection at the top of the main casing, to the turbocharger rotor shaft bearings. At the same time rotate the shaft by hand whilst draining off excess inhibiting oil. Spray or brush the turbocharger internal surfaces with inhibiting oil. Refit the drain flange and pipework previously removed, or blank off the drain. Seal all the turbocharger vents and open connections with fabric tape. GENERAL ANTI--CORROSION TREATMENT In addition to inhibiting, the following precautions are taken, prior to despatch from the NAPIER factory, to prevent damage to Turbochargers during transit and short term storage:-Each unit is finished in high quality paint. External steel and all bright parts are coated with acid free mineral grease. Blanks are fitted to all machined facings and outlets, etc. Spare parts and tools are treated similarly with preservative and grease resistant packing. Rubber joints and sleeves are ‘french chalk’ dusted and wrapped in grease resistant paper. All other joints are dry packed. The turbocharger unit is bolted to a wooden base, the formers of which prevent movement within the packing case, if supplied. The packing case, if supplied, is lined with waterproof material for overseas shipment.

41

NAPIER 295 NOTES

42

Napier Turbochargers Ltd.

Dismantling

CHAPTER 5. DISMANTLING 5.1

Preparation for Dismantling.

5.2

Safety of Personnel.

5.3

Dismantling Operation.

5.4

Care After Dismantling.

5.4.1

Component Cleaning.

5.4.2

Component Inspection.

43

NAPIER 295 NOTES

44

Napier Turbochargers Ltd.

Dismantling

5.1

PREPARATION FOR DISMANTLING This chapter contains the information necessary to completely dismantle the turbocharger. Included are the instructions for a strip inspection considered to be within the scope of a customer without special facilities. It is assumed that strip inspection and overhaul will be linked with engine overhaul periods advised by the engine builder. At the same time that the turbocharger is overhauled, the air filter and the engine lubricating oil filters should be serviced. Complete overhaul, including detailed viewing, crack detection and pressure testing can be undertaken by NAPIER Turbochargers The facilities of our technical organisation and the services of our engineers are available at all times to assist in the investigation of any matter connected with Turbochargers. A kit of tools is supplied with each turbocharger. Individual tools referred to in the following instructions have been given item numbers from a complete list given in Chapter 8. Although it may be possible to remove some of the components using tools other than those specified, the correct, designed tools will avoid damage to the components, surrounding parts and personnel. The spanners and tommy bars are supplied of such a length that the resulting torques do not exceed those considered safe for the components to which they are applied. Before the start of any dismantling work, mark the vertical centre--line at the top of all casing flanges and joints to be certain that all components are returned to their correct relative positions. The identity marks must not damage the flanges etc., but should be sufficient to remain in evidence after cleaning. Drain the oil and cooling water systems. Disconnect the oil and cooling systems. Disconnect the air and exhaust pipes and trunking. Disconnect the charge air cooler. Disconnect and protect all fitted instrumentation. Ensure all connections are blanked off until re--assembly. Adjustment shims, thrust washers, and the rotor assembly components are to be carefully handled. Renewal can involve delay and replacement costs. Damage can alter the working clearances or affect the dynamic balance of the rotor assembly. The fine dynamic balance of the rotor assembly is to be maintained and protected by noting or establishing ”M” marks on:-------

5.2

the shaft end. the impeller drive washer. the shaft end nut lockwasher the thrust collar. the impeller.

SAFETY OF PERSONNEL Operators should, before removing any section, be certain that the mounting bolts to the engine are secure. The change of the centre of gravity must be appreciated when casings are removed from the turbocharger. The reduction in the stability of the assembly when the turbine inlet casing, for example, is removed creates a safety hazard.

45

NAPIER 295 If the whole unit is to be taken down from the engine for servicing, adequate holding provision must be made at the working surface.

Fig. 5.1

5.3

A Typical Form of Stand which may be made to Support the Cartridge ( not supplied by NAPIER ).

DISMANTLING OPERATIONS (refer to front pullout diagram) Disconnect the compressor washing pipework and speed measurement connector at the turbocharger. Remove the side entry compressor inlet casing, if fitted, from the compressor outlet casing, alternatively:-Remove the air filter / silencer, if fitted, from the compressor outlet casing. First remove the filter panel which is in two or three segments, each fastened with two toggle clips. Sling the remainder of the assembly in such a way that the risk of unexpected release from the compressor outlet casing is avoided. Remove the nuts and washers which hold the compressor casing to the main casing, having prepared to sling or man--handle it ( with two operators ). Take off the compressor casing with extra care so that the impeller is not damaged during removal. Jacking bolts may have to be used to remove the compressor outlet casing.

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Napier Turbochargers Ltd.

Dismantling

Fig. 5.2

Example of Slinging the Compressor Outlet Casing

To remove the diffuser, unlock the countersunk ”long loc” securing screw at the rear of the compressor outlet casing. DISMANTLING TOOL: 1032 Transfer the lifting brackets to the main casing compressor end flange. The 3/4” B.S.P. oil inlet tapping will already have been plugged, UNDER NO CIRCUMSTANCES MUST IT BE USED AS A LIFTING EYEBOLT SOCKET.

Fig. 5.3

Removal of Cartridge Assembly.

The cartridge now comprising the main casing and the rotor shaft complete, is to be removed from the engine for further dismantling. Since the turbine blades and the impeller will become exposed to the risk of damage, it is recommended to retain the cartridge in a horizontal position on a prepared stand or in a controlled sling from the service crane. ( See Fig. 5.3 ).

47

NAPIER 295 Remove the nuts and washers which secure the main casing to the turbine outlet casing. M8 x 40 m.m. long jacking screws provided may be used to free the flange. Withdraw the cartridge without tilt or droop to protect the turbine blades. Rest in a stand if available, ( See section 5.2 Safety of Personnel ) or on a suitable work surface. Release speed measuring probe ( if fitted ) as follows. Check whether the main casing is fitted with a speed measuring head. If fitted, loosen the screws on the locking plate and turn the speed probe at least five complete revolutions in an anti--clockwise direction. This action will avoid damaging the speed probe perception head when withdrawing the rotor shaft later. Prepare to remove the rotor assembly parts from the cartridge. RETAIN THE SHAFT HORIZONTALLY. Establish an ”M” mark on the end of the shaft, for re--assembly purposes. Release the lock washer from the shaft nut, DO NOT DAMAGE OR DISTORT IT. Remove the rotor shaft nut. DISMANTLING TOOL: 1011 Remove the lock washer and impeller drive washer. The drive washer may require a gentle tap to aid removal. Withdraw the impeller ( assembly ) using the removal tool if necessary. Maintain the rotor shaft horizontal. ( See Fig.5.4 ) NOTE:

This assembly comprises of impeller, sleeve and seal ring carrier. Under no circumstances must this assembly be separated. The compressor end seal ring or rings may be removed as required for inspection or cleaning. 1002

1003

1004

1005

1008

1025

Fig. 5.4

48

Removal of Impeller.

1.

Lock the jacking screw onto the threaded end of the rotor shaft.

2.

Screw the impeller adaptor onto the nose of the impeller sleeve.

3.

Bring the assembly of the body, nut and handle up to the impeller adaptor.

4.

Fit the two M8 setscrews to the assembly.

5.

With the tommy bar fitted into the end of the jacking screw , rotate the nut anti--clockwise thereby pulling the impeller assembly away from the rotor shaft.

Napier Turbochargers Ltd.

Dismantling

DISMANTLING TOOLS: 1002, 1003, 1004, 1005, 1007, 1008, 1018 & 1025. Unlock and remove the six setscrews and tab washers that hold the compressor end seal ring bush to the main casing. Withdraw the seal ring bush using three extraction screws if necessary, together with joint washer, or shim if it is a positive stop arrangement. DISMANTLING TOOLS: 1023, 1027. Remove the compressor end bearing, support plate and impeller adjustment washer as follows. Remove the four ”long loc” setscrews which hold the bearing, bearing support plate and impeller adjustment shim to the main casing. Use extractor screws to remove the bearing and shim, if necessary. DISMANTLING TOOLS: 1023, 1027. Remove the impeller adjustment shim from the compressor end bearing. 1004

1005 1009

1006

1023

1003

1002

1025 1013

Fig. 5.5

Removal of Thrust Collar.

Remove the thrust collar from the shaft as follows. 1.

Position the guide sleeve over the shaft and secure to the compressor bearing flange using the two M8 x 25 m.m. long setscrews provided.

2.

Lock the jacking screw onto the threaded end of the rotor shaft.

3.

Secure the body extension tube of the removal tool into the internal thread of the thrust collar which faces the compressor end of the turbocharger.

4.

Screw the adaptor into the body extension tube.

5.

Bring the assembly of the body, nut and handle up to the adaptor.

6.

Fit the two M8 x 35mm setscrews to complete the assembly of the tool.

7.

With the tommy bar fitted into the end of the jacking screw, rotate the nut anti--clockwise thereby pulling the thrust collar away from the rotor shaft.

8.

Once the thrust collar is free, carefully remove the rotor shaft from the main casing as shown in Fig. 5.6

49

NAPIER 295

Fig. 5.6

9.

Removing Rotor Shaft.

The turbine end seal rings are now exposed and may be removed as required for inspection or cleaning. TAKE CARE TO PROTECT THE TURBINE BLADES. DO NOT REST THE TURBINE WHEEL ON THE BLADE TIPS AFTER REMOVAL. DISMANTLING TOOLS: 1002, 1003, 1004, 1005, 1006, 1007, 1009, 1013, 1018, 1023, 1025.

Remove the ”long loc” screw which secures the diffuser packing ring to the main casing. Remove the packing ring. DISMANTLING TOOL: 1032 Unlock and remove the six setscrews and tabwashers that secure the labyrinth seal plate to the main casing. Withdraw together with the labyrinth seal plate adjusting shim, using three extraction screws if necessary. DISMANTLING TOOLS: 1024, 1027. Unlock and slacken the six bolts that secure the seal plate at the compressor end and also the outer cone at the turbine end. Do not remove the bolts at this stage. Position the main casing so that the outer cone may be released. ( See Fig. 5.7 )

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Napier Turbochargers Ltd.

Dismantling

Careful and systematic tapping on the heads of the bolts will remove a carbon seized cone. Partly slacken the six bolts.

Wooden frame to support the assembly above the bench.

TAKE CARE. Ensure the frame is adequate and secure before commencing. Fig. 5.7

Removal of Outer Cone

Using wooden blocks to support the main casing flange so that the cone is clear of the working surface, the cone may be freed by systematic tapping of the bolt heads. The bolts will require further slackening as the cone becomes free. Remove the bolts and lift the casing away from the cone and joint washer. DISMANTLING TOOL: 1029. Remove the seal plate from the main casing if required. Remove the six setscrews and tab washers which hold the seal ring bush to the turbine end of the main casing. Remove the seal ring bush and gasket. DISMANTLING TOOL: 1027. Remove the turbine end bearing as follows. Unlock and remove the four setscrews which hold the bearing and the bearing flange support to the main casing. DISMANTLING TOOLS: 10. Prepare to remove the turbine inlet casing. Sling the casing as indicated in Fig 5.8. Remove the casing nuts, spring washers and plain washers from the studs securing the inlet casing to the turbine exhaust casing. It may be necessary to separate the joint faces with jacking screws. Holes tapped M12 are provide in the inlet casing flange. Application of the jacking screws must be gradual and uniform. Guide out the casing horizontally until the nozzle and shroud ring assembly is clear of the turbine outlet casing, maintain stability of the removal by restraint applied at the gas inlet flange. Remove the inlet casing joint. DISMANTLING TOOL: 1017, 1024,1027.

51

NAPIER 295

Fig. 5.8

Removal of Turbine Inlet Casing.

Unlock the tab washers and remove the six setscrews from the shroud and turbine inlet casing flanges,and remove the shroud ring from it’s spigot. DISMANTLING TOOL: 1015 Remove the six caphead screws and disc--lock washers which hold the nozzle ring to the turbine inlet casing. DISMANTLING TOOL: 1034. Note and mark the position of the cooling connections and cover plates and then remove the turbine outlet casing from the engine if necessary. Remove the twelve M12 x 30 long setscrews and tab washers from the mounting foot. Remove the mounting foot , joint and dowels. DISMANTLING TOOL: 1029. 5.4

CARE AFTER DISMANTLING

5.4.1

COMPONENT CLEANING With the exception of the coolant system, turbocharger components must be cleaned with unleaded motor fuel or washed in a chlorinated hydrocarbon degreasing plant. if neither of these cleaning agents is available the parts may be washed in paraffin ( kerosine ). Surfaces subject to exhaust gas heat must be restored to a sufficiently dry state to ensure against fire. CAUTION:

Flammable mixtures. Keep away from naked lights and operate only in a well ventilated area.

The nozzle ring and turbine blades may require boiling in water to remove stubborn deposits resulting from using low grade fuel or arising from additives in the engine cylinder lubricant.

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Napier Turbochargers Ltd.

Dismantling

COTTON WASTE MUST NOT BE USED FOR CLEANING TURBOCHARGER COMPONENTS. Coolant jacket passages can be cleaned with a weak solution of hot water and soda, employing a brush suitable for metal. Propriety cleaning agents recommended by the engine builder may also be used. After cleaning, drain off the solution and flush the passages with hot fresh water. KEEP SODA SOLUTIONS AWAY FROM ALUMINIUM COMPONENTS If conditions exist which cause higher than average turbocharger coolant inlet temperature or if the cooling water contains sediments, the coolant jacket passages will require more frequent cleaning. On all such occasions, assess the deflector plates attached to the cover plates for renewal. Inspect the zinc plugs and descale or renew. If sea water is the cooling medium, the plugs will be consumed more quickly. As already stated, it is important to ensure that adjustment shims, thrust washers, rotor assembly components, etc., receive particularly careful handling as renewal could involve re--work and expense. Bearing sleeves and thrust washers waiting re--assembly must be kept in a bath of clean lubricating oil, precautions being taken AT ALL TIMES to protect them from dirt, dust and moisture. 5.4.2

COMPONENT INSPECTION After cleaning, all components should be inspected for serviceability. Examine all of the dismantled components for:-Excessive wear, corrosion or structural damage. The security of fittings, studs, bolts and location dowels. The condition of threads on the rotor shaft, in the lubricating oil tappings, in extraction holes etc. The condition of bearings and thrust faces. Confirm that the oil, air, drain holes and all passages are free from fouling or positive obstruction. Damaged joints, ”O” rings etc., to be replaced. All tab washers to be and unserviceable spring washers to be replaced. AIR/FILTER SILENCER Examine for damage, corrosion of the casing and fittings, condition and security of the lining, and the condition of the filter panel media. Paraffin must not come into contact with the lining, use only ”WHITE SPIRIT”. Clean and repaint exterior areas and frames as necessary. ALTERNATIVE SIDE ENTRY CASING Inspect for damage, corrosion etc. and repaint. BEARING SURFACES Examine the bearing bores for wear and the thrust faces for scoring. Check both seal ring bushes for scuffing in the bore. Every precaution must be taken AT ALL TIMES to protect bearing surfaces from dirt, grit and moisture. Refer to Chapter 4 for bearing wear limits. Bearings awaiting reassembly should be kept in a bath of clean lubricating oil, keep new parts in their protective packing until required.

53

NAPIER 295 TURBINE ( or BLISC ) The repair of individual blades is not possible. Both ends of the lacing wire are bent inwards midway between adjacent blades, any damage requires investigation and replacement. Dynamic balance must be maintained.

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Napier Turbochargers Ltd.

Clearances

CHAPTER 6. TABLE OF CLEARANCES 6.1

Table of Clearances.

6.2

Torque Settings.

55

NAPIER 295 NOTES

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Napier Turbochargers Ltd.

Clearances

6.1

TABLE OF CLEARANCES COMPRESSOR END BEARING THRUST CLEARANCE TURBINE WHEEL / CONE CLEARANCE

IMPELLER CLEARANCE

IMPELLER / LABYRINTH CLEARANCE

Turbine wheel/cone clearance Turbine wheel/cone clearance (295 WD only) Impeller axial clearance (295) Impeller axial clearance (295IR,A720,A520,295WD Impeller/ Labyrinth clearance Compressor end bearing thrust clearance

2.47 5.00 0.69 0.61 0.15 0.16

-------

4.36 mm 3.60 mm 0.81mm 0.81mm 0.25mm 0.24mm

( 0.097 -- 0.172 ) inch ( 0.197 -- 0.142 ) inch ( 0.027 -- 0.032 ) inch (0.024 -- 0.032 ) inch ( 0.006 -- 0.010 ) inch ( 0.006 -- 0.009 ) inch

Clearances measured with shaft pushed towards the compressor end. See chapter 7, REASSEMBLY, for procedure.

57

NAPIER 295 6.2

TORQUE SETTINGS The following tightening torques are provided for general guidance:

58

Shaft End Nut

102Nm

(75lbf.ft )

Seal Plate / Cone Bolts

85Nm

(62.7lbf.ft )

Labyrinth Seal Plate Screws

25Nm

(18.4lbf.ft )

Seal Ring Bush T/E Setscrews

25Nm

(18.4lbf.ft )

Seal Ring Bush C/E Setscrews

25Nm

(18.4lbf.ft )

Shroud Setscrews

25Nm

(18.4lbf.ft)

Nozzle Cap Screws

40Nm

(29.5lbft )

C/E Bearing Setscrews

25Nm

(18.4lbf.ft)

T/E Bearing Setscrews

25Nm

(18.4lbf.ft )

Napier Turbochargers Ltd.

Re-Assembly

CHAPTER 7. RE--ASSEMBLY 7.1

Preparation for Re--assembly.

7.2

Re--assembly Operations.

7.3

Clearance Measuring Procedure.

59

NAPIER 295 NOTES

60

Napier Turbochargers Ltd.

Re-Assembly

7.1

PREPARATION FOR RE--ASSEMBLY During re--assembly of the turbocharger, clearances must be checked. It should not be necessary to alter clearances following an overhaul, during which no component parts of the turbocharger were replaced . However, if a particular clearance is found to be incorrect, the adjustment shims should not be altered until all components have been checked for cleanliness, that they are undamaged and correctly assembled. All tab washers must be renewed during re--assembly, and unserviceable spring washers and disc--lock washers replaced. Care must be taken when tightening nuts, screws etc., particularly when fasteners are located in light alloy casings. Torque settings are provided for general guidance. Check that all components are clean, un--damaged and free from burrs. CASING POSITIONS If the marks made at the top of the casings during dismantling have been erased, the original position of each casing must be ascertained and the casings re--marked. Similarly, if a casing is to be re--assembled in a new position, it should be re--marked in accordance with instructions given in Chapter 2. ROTOR ASSEMBLY To enable the original dynamic balance to be retained, components not aligned by other means are marked with a letter ”M”. These MUST be aligned during re--assembly with the letter ”M” etched on the rotor shaft. Bores and diameters of components such as bearing housings and sleeves are manufactured to close tolerances, and the normal practice of applying clean lubricating oil to these surfaces before assembly should be followed.

7.2

RE--ASSEMBLY OPERATIONS ( Refer to front pullout diagram ) NOTE:

Disc--lock washers are assembled in pairs and must have the cam faces together for correct fitment.

Cams on mating surface

Seizing ridges on outer surface

Prepare the turbine outlet casing for replacement on the engine. Re--fit the mounting foot, cover plates, joints, dowels, setscrews and tab washers. Sling the casing and replace it on the engine. RE--ASSEMBLY TOOL: 1017

61

NAPIER 295 Prepare the turbine inlet casing for re--assembly. Re--fit the nozzle and clamp ring to its correct position noting the position of the off--set hole, use the 6 capscrews and disc--lock washers Torque setting 50 Nm. 37.5 lb.ft. Use high temperature anti--seize compound on the capscrew threads. Refit the shroud ring with the six setscrews, twelve tab washers and six nuts. Torque setting 15Nm. Re--fit the turbine inlet casing joint washer. Sling the casing and return it to its original position, relative to the engine exhaust manifolds, on the turbine outlet casing. Fit the nuts and spring washers to the studs in the turbine outlet casing and secure. RE--ASSEMBLY TOOL: 1029. NOTE:

All oil and air passages should be blown through with high pressure air and inspected to ensure that no foreign objects are present before re--assembly of the main casing commences.

Fit the” O” ring to the turbine end bearing, lightly oil the bearing and fit to the main casing. With the bearing fully located, replace the bearing support plate and secure with the 4 long--loc setscrews and torque load to 29Nm ( 21lbf.ft ) RE--ASSEMBLY TOOL: 1027. Ensure that the air holes are clear and that there is no damage to the bore of the seal ring bush. Replace the turbine end seal ring bush and gasket. Coat the setscrew threads with Loctite Pipe Sealant, fit the six setscrews and lock the tab washers. Torque setting 29Nm (21lbf.ft ). RE--ASSEMBLY TOOL: 1027. Coat the compressor side of the main casing with a thin film of Loctite Silicone Sealant. Fit the seal plate to the recess in the main casing, the air holes will automatically align with those in the main casing. Prepare to re--fit the outer cone. Seal plate Thin film of silicone sealant

Cone

Fig. 7.1

62

Re- assembly of Cone.

Napier Turbochargers Ltd.

Re-Assembly

For safety and convenience, place the cone on an even and firm surface with the broad face uppermost. Position the joint washer on the cone. Carefully offer the main casing to the cone, ensuring the whole assembly remains stable. Replace and locate the six bolts and disc--lock washers, ensuring the joint washer has not moved,thereby preventing the bolts from engaging with the tapped holes in the cone. Tighten the bolts and torque load to 102Nm ( 75lbf.ft ). The seal plate and cone are now secure. RE--ASSEMBLY TOOL: 1029. Again, to avoid the risk of damage to the turbine blades and compressor impeller, it is advisable to place the main casing on a prepared stand or in a sling from the service crane. The bearing centre line will be retained horizontally. Ensure that there is no damage to the turbine blades or shaft. Replace the seal rings to the turbine end of the shaft, with the gaps being positioned 180 degrees apart and lightly lubricate the seal rings and shaft. The rotor shaft is now to be re--fitted. CAUTION:

The turbine blades are very sharp and can cause damage to the hands. When handling the turbine use gloves or some suitable alternative.

Guide the rotor shaft through the turbine end of the main casing assembly, keeping both horizontal. As the disc and blades approach the end of the outer cone, raise that end of the shaft slightly, taking care not to damage the seal rings. Locate the seal rings into the seal ring bush. Gently push the shaft towards the compressor end until firmly located.

1005 1009 1004

1023 1006

1003

1002

1025

1013

Fig. 7.2

Re- assembly of Thrust collar

Refit the thrust collar onto the shaft, after applying Rocol anti--scuffing paste to the shaft, as follows:--

63

NAPIER 295 1.

Position the guide sleeve over the rotor shaft and secure to compressor bearing flange using the two M8 x 25 mm long setscrews provided.

2.

Lock the jacking screw onto the threaded end of the rotor shaft.

3.

Secure the body extension tube of the assembly tool into the threaded portion of the thrust collar. Locate assembly onto the rotor shaft, aligning the ”M” marks.

4.

Screw the adaptor into the body extension tube.

5.

Bring the assembly of the body, nut and handle up to the adaptor.

6.

Fit the two M8 x 35mm setscrews to complete the assembly of the tool.

7.

With the tommy bar fitted into the end of the jacking screw, rotate the jacking nut clockwise thereby pushing the thrust collar onto the rotor shaft.

8.

Remove the assembly tool and guide sleeve in preparation for re--fitting the compressor end bearing. RE--ASSEMBLY TOOLS: 1002, 1003, 1004, 1005, 1006, 1007, 1009,1013, 1018, 1023, 1025.

NOTE:

The thrust collar may be heated to 80 degrees above ambient temperature prior to fitting, but steps 1--8 above must still be carried out to ensure that the collar is fully seated. Leave the tooling in place until the collar has cooled otherwise it can move off it’s seat and reduce the thrust clearance.

CAUTION:

Use heat resistant gloves when handling the thrust collar if it has been heated.

Re--fit the impeller adjustment shim behind the flange of the compressor end bearing. Assemble into bore of the main casing, and together with the bearing flange support, secure with the four ”long loc” setscrews. Torque load to 29Nm ( 21lbf.ft ) RE--ASSEMBLY TOOL: 1027. NOTE RE CLEARANCE CHECKS Re--assembly operations 13 to 20 incorporate actions which allow the measurement of:-1.

COMPRESSOR END BEARING THRUST CLEARANCE.

2.

IMPELLER VANE AND LABYRINTH CLEARANCE.

3.

TURBINE WHEEL TO CONE CLEARANCE.

Clearances can be measured with a suitable dial gauge indicator, depth gauge / micrometer, or feeler gauge. If new component parts have been fitted, the clearances may need to be re--set to ensure i.

The turbocharger operates efficiently.

ii.

The turbocharger has been correctly re--assembled.

Instructions for adjustment of clearances are included at appropriate positions in the text. Prepare to replace the impeller assembly after replacing the seal ring in the groove provided. Smear the rotor shaft with ”Rocol” anti--scuffing paste and replace the impeller by hand, ensuring

64

Napier Turbochargers Ltd.

Re-Assembly

that the impeller abuts against the shoulder on the rotor shaft. If the impeller is tight on the rotor shaft then use the tool which was previously used during dismantling. Fit the drive washer and shaft end nut. RE--ASSEMBLY TOOLS: 1002, 1003, 1004, 1005, 1007, 1008, 1018, 1025.

Fig. 7.3

Re- assembly of Impeller

Check the BEARING THRUST CLEARANCE between the compressor end bearing and the thrust face, by using a dial indicator or or depth gauge to measure the axial movement of the shaft. See Fig.7.4

0,16 / 0,24 m.m. .006 / .009 ins.



Compressor end bearing thrust clearance.

IMPELLER ASSEMBLY

 ROTOR SHAFT

Fig. 7.4

THRUST COLLAR

Compressor End Bearing Thrust Clearance

Prepare to measure the impeller clearances as follows:-1.

Remove the impeller from the rotor shaft and impeller adjustment shim from behind the compressor end bearing flange previously fitted in Ops. 13 and 15. Re--fit the bearing but do not torque load. The impeller adjustment shim will be re--assembled later.

2.

Replace the labyrinth seal plate and adjustment shim. Fit the six setscrews and the tab washers. Torque setting 29 Nm ( 21lbf.ft )

3.

Replace the diffuser packing ring to the main casing and secure in position with the countersunk ”long loc” screw.

4.

Return the impeller to the rotor shaft but at this stage , DO NOT FIT the impeller drive washer, lock washer, or the rotor shaft end nut.

65

NAPIER 295 5.

Replace the diffuser carefully into its recess on the compressor outlet casing. Secure with the countersunk ”long loc” screw. Replace the compressor outlet casing in the correct position on the main casing spigot. Return four of the plain washers, nuts and secure. Space at 90 intervals.

Check the IMPELLER TOTAL FLOAT as follows:-1.

Pull the impeller, so as the impeller vanes lightly rub against the compressor outlet casing. Place a parallel bar across the open inlet of the casing. See Fig. 7.5.

Parallel bar

Measure the distance from the face of the inlet to the outer face of the impeller hub. This is DIMENSION A.

Dim’n A PULL Dim’n B PUSH

 ROTOR SHAFT

Fig. 7.5

2.

THRUST COLLAR

Confirming Impeller Total Float

Push the impeller towards the turbine end, so that the impeller back face lightly rubs against the labyrinth seal plate. Measure the distance from the face of the inlet, as before, to the outer face of the hub. This is DIMENSION B. The TOTAL IMPELLER FLOAT = Dimension B -- Dimension A Record the result of this calculation for checking the impeller / labyrinth clearance later.

66

Napier Turbochargers Ltd.

Re-Assembly

NOTE:

Note that the total impeller float may be measured directly by a suitably mounted indicator dial gauge, if preferred.

Prepare to measure the impeller vane and labyrinth clearance as follows, 1.

Remove the compressor inlet casing complete with diffuser, and impeller using the extractor tool if necessary. Remove the compressor end bearing.

2.

Re--fit the impeller adjustment shim behind the flange of the compressor end bearing. Assemble into bore of the main casing, and together with the bearing flange support, secure with the four ”long loc” setscrews.

3.

Return the impeller to the rotor shaft but at this stage , DO NOT FIT the impeller drive washer, lock washer, or the rotor shaft end nut.

4.

Replace the compressor outlet casing in the correct position on the main casing spigot. Return four of the plain washers, nuts and secure. Space at 90 intervals.

Check the IMPELLER VANE and LABYRINTH CLEARANCE as follows:-1.

Pull the impeller, so that the vanes rub lightly against the compressor outlet casing. Place a parallel bar across the inlet of the compressor casing. See Fig. 7.6, Measure the distance from the face of the inlet to the outer face of the impeller hub, as before. This is DIMENSION C.

2.

Replace and partly tighten the shaft end nut to ensure abutment of the impeller assembly to the shaft.

3.

PULL and HOLD the ROTOR SHAFT TOWARDS the COMPRESSOR END.

4.

Measure the distance from the face of the inlet to the outer face of the impeller hub, as before. This is DIMENSION D.

5.

The IMPELLER VANE CLEARANCE = Dimension D -- Dimension C and must be between the following values. 0,61 / 0,81 m.m. ( .024” / .032” )

6.

If the correct impeller clearance is not achieved, modifications must be made to the impeller clearance adjustment washer as follows. A new shim, thicker by the appropriate amount, must be fitted if the clearance obtained is greater than that specified above. An appropriate amount of metal must be machined from the existing shim if the clearance obtained is less than that specified. It is essential to maintain a flatness and parallel tolerance of 0,013 m.m. ( .0005 ins. ) on the shim.

7.

Remove the compressor inlet casing complete with diffuser, and impeller using the extractor tool if necessary.

8.

Refit the compressor end seal ring bush and shim to the main casing recess. Fit the six setscrews and lock the tab washers. Torque setting 29Nm.

NOTE:

This shim is set on the initial build and does not require adjustment unless the impeller or seal ring bush has been replaced. The procedure for this measurement follows later in the text.

NOTE:

Both faces of the shim are coated with a thin coating of silicone sealant and the setscrew threads are coated with pipe sealant.

67

NAPIER 295 9.

Smear the rotor shaft with Rocol anti scuffing paste and return the impeller to the rotor shaft, fit the impeller drive washer, lock washer or shaft end nut. Ensure that the seal ring is properly engaged in the bore of the seal ring bush.

10. ALIGN THE M MARKS ON THE ROTOR SHAFT AND IMPELLER ASSEMBLY. 11. Apply a continuous bead of Loctite Superflex R.T.V.2 Silicone sealant to the spigot of the main casing that locates the compressor casing. Replace the compressor outlet casing, complete with diffuser, in the correct position on the spigot of the main casing. Return the plain and spring washers, nuts and secure.

Impeller clearance 0,61 / 0,81 m.m. .024 / .032 ins.

Parallel bar

Impeller clearance adjustment shim.

Dim’n C PULL

Impeller vanes



Dim’n D

 ROTOR SHAFT

THRUST COLLAR

Shaft end nut to be fitted and tightened before checking dimension D only.

Fig. 7.6

Confirming Impeller Vane / Labyrinth Clearance

12. When these clearance checks are complete, remove the shaft end nut. 13. Replace the impeller drive washer, lock washer and shaft end nut ensuring that M marks on the rotor shaft, impeller assembly, and impeller drive washer are aligned. 14. Replace the shaft end nut. Lock the rotor using the spanner flats on the turbine wheel and fully tighten the nut. Indent the shroud washer at two diametrically opposite points. Torque setting 102 Nm. Check the IMPELLER / LABYRINTH CLEARANCE as follows:-1.

68

This clearance is calculated from measurements made in the previous operations ( 16 ) & ( 18 ) and is the impeller vane clearance subtracted from the total impeller float.

Napier Turbochargers Ltd.

Re-Assembly

IMPELLER LABYRINTH CLEARANCE = ( B -- A ) -- ( D -- C ) The value should lie between 0,28 / 0,33 m.m. ( .011 / .013 ins. ) with the shaft pushed towards the compressor end. This setting ensures a minimum impeller labyrinth clearance of 0,05 m.m. ( .002 ins )with the shaft pushed towards the turbine end. 2.

This clearance between the back of the impeller and the labyrinth seal plate, i.e. IMPELLER LABYRINTH CLEARANCE, is adjusted by the thickness of the laminated ( peelable shim ) behind the labyrinth seal plate. Each peelable lamination is 0,05 m.m. ( .002 inch ) thick.

Check the TURBINE WHEEL / CONE CLEARANCE as follows:--

Outer cone



WD ONLY

2.47 / 4.36 m.m. ( .197 / .142 )ins. 3.60 / 5.00 m.m. ( .097 / .172 )ins. Turbine wheel



PULL

Fig. 7.7

1.

Turbine Wheel / Cone Axial Clearance

With the rotor shaft pulled towards the compressor end, use a feeler gauge to confirm the clearance between the land on the outer cone and the turbine blisc. The value should lie between 3,25 / 3,90 m.m. ( .128 / .154 ins ). This clearance is NOT adjustable and if the above values are not obtained, check for incorrect assembly.

69

NAPIER 295 With the clearance checks complete, the cartridge consisting of the main casing and the compressor outlet casing can now be re--assembled to the turbine outlet casing taking care to keep the rotor shaft horizontal and the turbine wheel concentric with the bore of the shroud ring which is fitted inside the turbine outlet casing. Position the lifting brackets, one on each side of the main casing / volute flange for this operation. Replace the nuts and washers. RE--ASSEMBLY TOOL: 1017 Adjust the speed measuring probe clockwise, not using excessive force, until contact is made between the perception head and the rotor shaft. To set the air gap between the rotor shaft and perception head, turn the probe one half turn anti--clockwise. The probe is now correctly adjusted and the air gap will be approximately 0.7mm ( 0.028 ” ). Lock the probe in position by tightening the locking plate securing screws. RE--ASSEMBLY TOOL: 1014 Refit the air filter silencer to the compressor outlet casing and when secure replace the three filter panel segments. Re--fit the compressor inlet casing, if fitted instead of an air filter silencer. Re--connect the compressor washing pipework and the speed measurement connector to the turbocharger. Re--connect the turbine washing pipework if fitted. Remove the temporary protective plugs from the lubricating oil inlet and the flange cover from the oil drain immediately before re--connecting to the oil supply. Calculate the positive stop arrangement shim size as follows:-1. Place the seal ring bush on a surface plate, measure from the top flange to the surface plate. This is dimension “A”

2. Fit the seal ring bush without the shim to the main casing, ensure that it fits flush. Measure from the top of the seal ring bush to the minor thrust face of the bearing. This is dimension “B”

70

Seal Ring Bush A

B

Seal Ring Bush

Compressor End Bearing

Shim “Z”

Main Casing

Napier Turbochargers Ltd.

Re-Assembly

3. To calculate “R” Subtract dimension “B” from Dimension “A”.

S 4. To obtain dimension “S” measure the seal ring carrier as shown.

Ring Carrier Impeller

5.

Measure the width of the seal ring. This is dimension “D”.

6. Fit the seal ring into the seal ring bush and measure from the top of the seal ring bush to the top of the seal ring. This is dimension “F”.

7.

To obtain “T”. “T” = “A”--(”D”+”F”)

8.

To obtain “V”. “V” = (“R”+”S”) -- (”T” + “C”) (“C” is thrust bearing clearance)

9.

The figure which was obtained in 8 is the thickness of the shim required to give the correct setting for the positive stop arrangement.

END OF SEQUENCE.

71

NAPIER 295 NOTES

72

Napier Turbochargers Ltd.

Tool List

CHAPTER 8. TOOL LIST 8.1

Care of Tool Kit.

8.2

List of Tools.

73

NAPIER 295 NOTES

74

Napier Turbochargers Ltd.

Tool List

8.1

CARE OF TOOL KITS A set of tools is normally ordered and supplied with the turbocharger. It comprises of all the tools listed in section 8.2. It is suggested that all tools for servicing the turbocharger and in particular the multi--purpose assembly and removal tool, should be thoroughly cleaned after use. The tools, in particular their screw threads, should be treated with a soft preservative ( such as DEF.2231 ) and returned to their storage area. NOTE:

All customer connecting flanges and other turbocharger threads are drilled and tapped to I.S.O. Metric Coarse Thread Series

LIST OF TOOLS

ITEM NO.

TOOL DESCRIPTION

TOOL SHAPE

PART NO

NO. OFF

1002

Jacking Screw

BJ.6141

1

1003

Nut, Jacking Screw

BJ.6602

2

1004

Handle

BJ.6626

1

1005

Screw Jack Body

BJ.6611

1

75

NAPIER 295

ITEM NO.

76

TOOL DESCRIPTION

TOOL SHAPE

PART NO.

NO. OFF

1006

Body Extension Tube

BJ.6504

1

1007

Tommy Bar (Jacking tool )

BF.98J.015

1

1008

Adaptor -- Impeller

BJ.6219

1

1009

Adaptor Plate

BJ.6104

1

1010

Rotor Locking Tool

BJ 6195

1

1011

Impeller Nut Spanner

BJ 6850

1

Napier Turbochargers Ltd.

Tool List

ITEM NO.

TOOL DESCRIPTION

TOOL SHAPE

PART NO.

NO. OF

1012

Guide Pin

ND 11074

2

1013

Guide Sleeve -- Thrust Collar

BJ.6214

1

1014

Combination Wrench ( Speed probe ) 10 mm

399 981 210

1

1015

Combination Wrench ( Oil drain ) 13 mm

399 981 213

1

1016

Combination Wrench 17 mm

399 981 217

1

1017

Combination Wrench 19 mm

399 981 219

1

1018

Combination Wrench (Jacking screw nut ) 30 mm

399 981 230

1

1019

Eye Bolt

383 711012

1

77

NAPIER 295

ITEM NO.

78

TOOL DESCRIPTION

TOOL SHAPE

PART NO.

NO. OFF

1022

Jacking Screw M12 x 40 mm long

117 312040

3

1023

Jacking Screw ( C.E. bush ) & Guide Sleeve M8 x 25 mm long

117 308 025

5

1024

Jacking Screw ( Main csg. ) M8 x 40 mm long

117 308 040

4

1025

Jacking Tool Handle Screw M8 x 35m.m. long

117 308 035

4

1026

Tool Box

T.B.A.

1

1027

Socket ( 13 mm )

399 982 213

1

1028

Socket ( 17 mm )

399 982 217

1

1029

Socket ( 19 mm )

399 982 219

1

1032

Hex Drive Socket ( 4 mm )

Fam4A/P72SO

1

1033

Hex Drive Socket ( 6 mm )

Fam6A/P72SO

1

1034

Hex Drive Socket ( 8 mm )

Fam8A/P72SO

1

Napier Turbochargers Ltd.

Supplementary Information

CHAPTER 9. SUPPLEMENTARY INFORMATION 9.1

Compressor In--Service Cleaning

9.2

Turbine In--service Cleaning

9.3

Emergency Operation

79

NAPIER 295 NOTES

80

Napier Turbochargers Ltd.

Supplementary Information

9.1

TURBOCHARGER IN--SERVICE CLEANING When air intake filters are fitted to a turbocharger, particulate matter entering with the ingested air slowly accumulates on the working surfaces of the compressor. The rate at which the surface contamination takes place depends on the working environment of the engine but is exaggerated if oil vapour is present in the air stream. In order to maintain the optimum performance from the turbocharger during the periods between overhauls, the compressor and turbine wheels can be washed. It is important that the instructions for washing are followed closely, as incorrect methods could cause severe damage to the turbocharger. It is also important to follow guidelines on the frequency of washing, as too long a period between washes may allow a heavier build up of hardened deposits which will be difficult to remove by water injection, thus necessitating a strip down of the turbocharger. Partial removal of heavy deposits may lead to rotor imbalance and consequential catastrophic failure.

9.1.1

COMPRESSOR WASHING There are 2 methods of compressor washing which can be used, pneumatic or syringe. Pneumatic is the normal method, for ease of operation and consistent results. Compressor washing should be carried out using warm fresh water only.

TURBOCHARGER

2ND TURBOCHARGER (IF FITTED)

3 WAY VALVE TEE PORT COCK

ACTUATING BUTTON

SYRINGE

PNEUMATIC DISPENSING VESSEL Fig. 9.1

AIR MANIFOLD

Typical Installation of Equipment for Compressor Washing

81

NAPIER 295 9.1.2

INSTALLATION Where pneumatic injection is used a fluid dispensing vessel of fixed volume is required. This is generally mounted on the engine adjacent to the turbocharger, and is pressurised from the turbocharger compressor outlet or from the engine charge air manifold.

9.1.3

FREQUENCY OF WASHING The frequency of washing the compressor during operation depends on the environmental conditions in which the engine is operating, the engine duty and the frequency of filter maintenance. Typically, once a week gives satisfactory results for a reduced duty “normal” environment. If more than one turbocharger is fitted to an engine, then both turbochargers should be cleaned. However, they should be cleaned one after the other, not at the same time.

9.1.4

CLEANING FLUID Optimum results will be obtained by using warm fresh water only, no additives should be used.

9.1.5

CLEANING OPERATION Before commencing the wash procedure record the turbocharger air delivery pressure and the turbine inlet temperature, these can be used to assess the efficiency of the wash. With the engine operating at about 75% load, the container filled with 0.75 litres of warm water is pressurised and injected into the compressor wheel over a period of 30 seconds. Do not exceed the recommended rate of injection as damage to the engine may occur. Record the turbocharger air delivery pressure and the turbine inlet temperature and compare these with the readings taken before the wash to assess the effectiveness of the wash. If it is thought that the compressor has heavy fouling then it may be necessary to repeat the washing procedure.

82

Napier Turbochargers Ltd.

Supplementary Information

9.2

TURBINE IN--SERVICE CLEANING During engine operation the turbine nozzle vanes and rotor blades become coated with deposits. The rate of build--up will be more severe if lower grades of fuel are employed. From NAPIER’s long experience with many types of fuel, it has been found that the best method of turbine cleaning during engine operation is by means of water washing. Injection of water just upstream of the turbine wheel in the form of spray allows water droplets to impinge upon the nozzle and turbine blades. The droplets remove the deposits by a combination of scouring and dissolving actions. A thin coating of deposits on the nozzle and rotor blades has a negligible effect on the turbine performance but if deposits become excessive the turbocharger performance can alter significantly. Coatings which are deposited unevenly will effect the dynamic balance of the rotor assembly. In--service cleaning of turbocharger turbine, if carried out as part of a routine schedule, assists in maintaining optimum turbine performance between turbocharger overhauls. Operators should realise however , that whilst this cleaning operation is very useful, it an adjunct to and not a substitute for the periodic overhaul of the turbocharger as stipulated in this manual. Turbochargers fitted with this facility have fluid injectors fitted at convenient positions on the turbine inlet casing. Cleaning fluid pressure can be observed at the pressure gauge and the flow is controlled by a shut off valve.

Turbine Inlet Casing

Orifice

Enlarged view of Injector Nozzle Shut Off Valve

Pressure Gauge Cleaning Fluid Injectors

Fig. 9.2

9.2.1

Typical Arrangement of Turbine Washing Equipment.

FREQUENCY OF WASHING The optimum period between cleaning operations will vary from installation to installation and from one fuel type to another, and may also depend on the type of lubricant used. Under “normal” operating conditions, engines running on medium quality residual fuel have found that periods of 200--250 running hours between cleaning to be satisfactory. However, this may be varied to suit other maintenance, or to correspond to a time when engine load is reduced to meet operating demands.

83

NAPIER 295 9.2.2

CLEANING FLUID Optimum results will be obtained by using de--mineralised water, but hot fresh domestic water is acceptable, no additives should be used. Turbochargers running on gas engines may require a cleaning solvent, but this should never be injected.

9.2.3

ENGINE OPERATION DURING TURBINE CLEANING It is generally accepted that water washing procedure is most effective when carried out at 10% to 15% of full engine output. However, the significant parameter is the gas temperature at turbine entry and this should not be higher than 450 C if cleaning is to be effective and damage to the turbine is to be avoided. TYPE OF TURBINE ENTRY

9.2.4

NOZZLE SIZE and NUMBER

1 ENTRY

3mm x 3

2 ENTRY

3mm x 2

3 ENTRY

3mm x 3

4 ENTRY

3mm x 4

FLOW RATE L/Min @ 200KPA

FLOW RATE L/Min @ 300KPA

10.8

15.2

CLEANING PROCEDURE Record the boost pressure, turbine entry temperature and turbocharger speed for latter use when assessing the efficiency of cleaning and any subsequent deterioration in performance. Reduce the engine output so that the turbine entry temperature is approx. 450C. Operate the engine at this condition for about 15 minutes to allow stabilisation of thermal conditions. Open drains and check that these are not blocked with deposits, by means of a short probe. Connect the water supply to the washing pipe array, open the supply valve and inject for a period of 15 -- 20 minutes. The drains should be kept under constant observation to ensure that the system is not being flooded. This cannot happen unless excessive water pressures are being used, or if the drains become blocked by large pieces of displaced carbon. Water flow from the drains should be approximately 20--30% of injection flow. CAUTION:

Failure to do this may result in serious damage to the turbocharger and engine.

CAUTION:

Be aware that the scalding temperature of hot water is 70C.

Cleaning can be considered complete when clean water is seen to issue from the drains. On completion of the washing operation, disconnect the water supply to prevent the possibility of any unscheduled leakage. CAUTION:

Failure to do this may result in serious damage to the turbocharger and engine.

Ensure that the drain points are clear from sludge or other deposits before closing them. Resume normal engine operation at higher power and, as soon as possible, repeat the readings taken under heading 1. for comparative purposes.

84

Napier Turbochargers Ltd.

Supplementary Information

9.3

EMERGENCY OPERATION If a defect occurs which prevents further operation of the turbocharger, the engine may still be run for a short period provided that the rotor assembly is removed and the exposed centre casing apertures are blanked off, as shown in Fig. 9.3. Coolant flow to the turbine casings must be continued during this emergency running. The turbocharger is then required to be stripped for complete inspection and cleaning , at the earliest opportunity. If a longer period of emergency operation is necessary, the turbocharger can be by--passed by arranging a suitable connection between the the exhaust pipes on the engine and the exhaust uptake pipe from the turbocharger exhaust casing. For guidance the following blanking plate details are given in Fig 9.3.

Fig. 9.3

Arrangement of Blanking Plates

85

NAPIER 295 NOTES

86

Napier Turbochargers Ltd.

Spares and Service Facilities

CHAPTER 10. SPARES AND SERVICE FACILITIES 10.1

Spare Parts List.

10.2

User Training Courses.

10.3

User Publications.

10.4

Factory Overhauls.

10.5

User Service Support.

10.5.1

Technical Support.

10.5.2

Approved Servicing Organisation.

87

NAPIER 295 NOTES

88

Napier Turbochargers Ltd.

Spare Parts List for:

NAPIER 295 TURBOCHARGER

Section

Title

Item Numbers commencing at

10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8

Consumable Items Main Casing Rotor Assembly Compressor Outlet Casing Turbine Outlet Casing Turbine Inlet Casing Air Filter Silencer Optional Items

100 200 300 400 500 600 700 800

NAPIER Turbochargers Ltd. Ruston House PO Box 1 Waterside South Lincoln LN5 7FD England

Tel.: +44 (0) 1522 516666 Fax: +44 (0) 1522 516669 24hr Emergency Telephone: +44 (0) 7912 515754

Publication TB 3207 ( Issue 4 ) January 2000

89

NAPIER 295 NOTES

90

Napier Turbochargers Ltd.

Spares and Service Facilities

CONSUMABLE ITEMS

ITEM CODE NO.

DESCRIPTION

141 145 146 147 148 149 150 151 152 153 154

BOLT M 12 x 120 M 12 x 45 PLUG 2’’ BSP 1’’ BSP 1/2’’ BSP M 12 1’’ BSP NUT M8 M 10 M 10 M 12 M 12 (THIN) DRIVE SCREW No 7 x 5/16’’ No 6 x 1/2’’ SETSCREW M 6 x 12 M 6 x 16 M 8 x 12 M 8 x 16 M 8 x 20 M 8 x 35 M 8 x 40 M 10 x 35 M 10 x 40 M 12 x 30 M 8 x 20 CAPSCREW

155 156

M 8 x 30 5/8’’ U.N.C. x 1/4’’

111 112 115 116 117 118 119 120 121 122 123 124 130 131

PART NO.

QUANTITY

111 312 120

6 6

05 31 10 05 31 06 01 25 20 336 105 212 SL 1605/8

1 14 8 3 10

211 117 008 211 117 010 211 114 010 211 114 012 211 124 012

6 16 8 12 2

010407 010409

2 8

117 306 012 117 306 016 117 308 012 117 308 016 117 308 020 117 308 035 117 308 040 117 310 035 117 310 040 117 312 030 119 608 020

8 2 4 6 4 6 12 16 12 36 6

117 708 030 50 70 18

6 12

91

NAPIER 295

ITEM CODE NO.

161 162 163 164 165 170 171 172 173 174 175 184 185 186 187 188 189 190 191 192 193 194A 195 196 196A 197 198 198A 199 199A 194 172A

92

DESCRIPTION STUD M 12 x 35 M 10 x 25 M 10 x 30 M 10 x 30 M 12 x 35 WASHER TAB M8 M 12 M8 5/16’’ 1/2’’ 5/8’’ WASHER JOINT 3/8’’ BSP 1/2’’ BSP 3/4’’ BSP 1’’ BSP 1’’ BSP 2’’ BSP WASHER SPRING M6 M8 M 10 M 12 M12 WASHER PLAIN M 10 M 12 M 12 SCREW CAP M 10 x 30 M 10 x 35 ADAPTOR 3/8’’ to 1/8’’ BSP STUD COUPLING 3/8’’ OD -- 3/8’’ BSP 3/8’’ OD DISC--LOCK WASHERS M12 M10

PART NO.

QUANTITY

191 312 035 191 310 025 192 310 030 193 710 030

36 8 24 16 16

237 112 008 237 112 012 237 115 008 02 48 03 02 48 05 02 48 06

18 12 24 6 3 12

01 26 52 01 26 53 01 26 54 01 26 55 01 26 35 01 26 39

1 11 1 17 10 1

233 211 006 233 211 008 233 211 010 233 211 012 233 121 012

12 10 36 6 6

231 111 010 231 111 012 231 121 012

12 12 3

151 110 030 151 510 035

6 12

01 98 51

1

03 94 09

1 1

EJ0902/12 EJ0902/10

6 Pairs 6 Pairs

Napier Turbochargers Ltd.

Spares and Service Facilities

93

94

MAIN CASING

202

225

206 or 111

170 149

194

209

218

210 205

217

221

145 190

198A 186

148 191

212 211 or 234

147 170

199 184

222 223

219

230

190 226 227

145

201

224

220

207 204 208

213

130

214 231

215

229 228

115 189

216

150 170

203

141 190

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

MAIN CASING ASSEMBLY

ITEM NO.

200

DESCRIPTION

PART NO. QUANTITY

201 202

MAIN CASING ASSEMBLY comprising the following parts listed in this section MAIN CASING PACKING RING

BJ 2006 or

1 1 1

203

CONE

BJ 2001 BJ 2206 or

1

204

JOINT CONE

BJ 2205 BJ 2207 or

1

205

SEAL PLATE

BJ 2210 BJ2623 or

1

206 207

BOLTS for item 204 & 205 SEAL RING BUSH -- TURBINE END

BJ2629 BJ2650 BJ2305 or

6 1

208 209 210 211 212 213 214 215

JOINT for item 207 LABYRINTH SEAL PLATE PEELABLE SHIM for item 209 SEAL RING BUSH -- COMPRESSOR END JOINT WASHER for item 211 ( non positive stop) NAME PLATE BEARING -- TURBINE END BEARING FLANGE SUPPORT -- TE

ND85381 BJ2309 BJ2624 BJ2641 BJ2304 BJ2310 BS 06J179 BJ2560 BJ2626 or

1 1 1 1 1 1 1 1

216 217

SCREW for item 214 BEARING COMPRESSOR END

BJ2625 BJ2514 BJ2550A

4 1

218

SCREW for item 217

BJ2628

4

95

NAPIER 295

ITEM NO.

DESCRIPTION

PART NO. QUANTITY

219

Bearing Flange Support -- CE

BS 95J451

1

220

Speed Probe Assembly

BS 06J151--1

1

221

Back Up Plate for item 220

or BS 06J151--5 BF06J186

1

222

Oil Drain Blanking Plate

ND85120

1

223

Joint for item 222

BL2469

1

224

Lifting Bracket

ND85193

2

225 226

Screw for Packing Ring Speed Measuring Blanking Plate

or BS96J002 BL3919 BF06J152

1 2

227

Joint for item 226

BK2403

2

228

Breather Blanking Plate

BS06J153

2

229

Joint for item 228

BJ2407

2

230*

Impeller Adjustment Shim

BJ2627

1

* If this shim is renewed, the clearance controlled by it must be checked and adjusted.

96

Napier Turbochargers Ltd.

Spares and Service Facilities

97

98

306

ROTOR ASSEMBLY

305

307

303

309

304

302

308

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

ROTOR ASSEMBLY

ITEM NO.

*301

DESCRIPTION

QUANTITY 1

*302

Rotor Assembly. Dynamically balanced and comprising of parts listed in this section. Shaft, Disc and Blades

*303

Impeller

1

304 305 306 307 308 309

Thrust Collar Nut Shaft End Lock Washer Impeller Drive Washer Seal Ring, Turbine End Seal Ring, Compressor End

1 BJ4890 BJ4872 BJ4873 BJ4903 EJ2632 ND65324

1 1 1 1 2 2

*These items have basic Part Numbers and prefixes to indicate variants to suit the particular application. It is therefore, ESSENTIAL to quote the turbocharger serial number and specification when ordering spares.

99

100

COMPRESSOR OUTLET CASING

401

401

196A

118

405

161 193 403 or 123 165 196

402

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

COMPRESSOR OUTLET CASING

ITEM NO.

401

DESCRIPTION

PART NO.

QUANTITY

Order by titlle

1

402 403

Compressor Outlet Casing Assembly, comprising single or twin delivery, all studs, nuts and washers Screw -- Diffuser Diffuser

BL3918 Order by title

1 1

405

Plug

BA 0976

2

101

102

123 & 124

161 193

TURBINE OUTLET CASING

504

503

Compressor end

508

153 or 152

171 or 192

506

501

505

116 or 119

187 or 188

195

192

509 163

188

121 192 164

122 502

131

507

153 193 or or 151, 162 192 & 122

506

Turbine end

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

TURBINE OUTLET CASING

ITEM NO.

DESCRIPTION

PART NO.

QUANTITY

BJ1040 or BJ1002

1

501

Turbine Outlet Casing Assembly, comprising the following parts listed in this section and all studs, nuts and washers Turbine Outlet Casing

1

502

Cover Plate Assembly

503

Plug Anti--Corrosion

504

Foot

505 506

Dowel for item 504 Joint for items 503 & 504

507 508

Name Plate Stud for Anti--Corrosion Plug

509

Water Connection Adaptor

BJ1040 or BX95J468 BJ1050 or BJ1325 ND85221 or ND10984 AND85516 or BJ1323 ND85170 BL1045 or BL07J056 BS07J048 ND85220 or BJ1857 BK8111

510 511

The following items are not illustrated Turbine Outlet Adaptor Joint for item 508

500

BJ7188 BJ1855 or BJ1854

2 2 1 2 3 1 2 2 4 1 1

103

104

TURBINE INLET CASING

154

172A

602

120

604

172 or 191 (Spring washer)

603

601

172

155

600

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

TURBINE INLET CASING

ITEM NO.

600

601 602 603 604 605 606 607 608 160 192 121

DESCRIPTION

Alternative Turbine Inlet Casings 1 Entry A/C Axial 1 Entry A/C Axial (Offset) 4 Entry A/C Axial (15_ Position) 4 Entry A/C Axial (30_ Position) 2 Entry A/C Axial (15_ Position) 2 Entry A/C Axial (30_ Position) 1+2 Entry A/C Axial (15_ Position) 1+2 Entry A/C Axial (30_ Position) Joint between Turbine Inlet & Turbine Outlet Casings Clamp Ring Nozzle Assembly Shroud Ring The following items are not illustrated Adaptor T.I./T.O. Casing used with BJ0303 Joint for item 605 Adaptor T.I./T.O. Casing used with BJ0306 Joint item for 607 Stud for items 605 & 607 Spring Washer for items 605 & 607 Nut for item 605

PART NO.

BJ0131 BJ0132 BJ0411 BJ0400 BJ0241 BJ0242 BJ0303 BJ0306 BJ1077 or ND85280 BJ0888 Order by Title Order by Title BJ0822 BJ0828 BJ0823 BJ0823

QUANTITY

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 12 12

105

106

175

156

743

197

COMPRESSOR AIR FILTER/SILENCER

744

747

741

742

745

746

174

123

NAPIER 295

Napier Turbochargers Ltd.

Spares and Service Facilities

COMPRESSOR AIR FILTER / SILENCER

ITEM NO.

DESCRIPTION

PART NO.

QUANTITY

740

Air Filter Assembly comprising the following parts listed in this section and all nuts bolts and washers Filter Panel Assembly comprising three sections Front Casing Fabrication Rear Casing Fabrication Adaptor Plate SpacerTube Stud Retaining Plate

BJ5035

1

BM03J031--1 BJ5033 BJ5016 BJ5706 Bj5026--02 BS03J034--1 BJ5512

1 1 1 1 3 3 1

741 742 743 744 745 746 747

107

NAPIER 295

112 196 194A

800 ( Assembly ) 802

803 184

199A

108

COMPRESSOR INLET CASING

801

Napier Turbochargers Ltd.

Spares and Service Facilities

COMPRESSOR INLET CASING

ITEM NO.

DESCRIPTION

800

Compressor Inlet Casing Assembly

801 802 803

Inlet Casing Water Wash Pipe 3/8 inch Male Stud Coupling

112 184 194A 196 199A

M12 x 45 U/HD Bolt Washer Spring Washer Washer 3/8 inch Female Stud Coupling

PART NO.

QUANTITY

BJ5128 BJ5127 BJ5122 BJ5121

1

BL5839 BL5839 or BF03J069 111 312 045 231 111 012 233 121 012 012652 039509

1 1 1 1 6 1 6 6 1

109

NAPIER 295 TURBINE WATER WASH EQUIPMENT

971

975

185

966 967

970

965

969 977

978 & 963 187 962 961 976 959

968

972

110

973

974 960

187

958

TURBINE WATER WASHING EQUIPMENT

964

Napier Turbochargers Ltd.

Spares and Service Facilities

TURBINE WATER WASH EQUIPMENT

ITEM NO.

950 958 959 960 961 962 963 964 965 966 967 968 969 970 971 972 973 974 975 976 977 978

DESCRIPTION

Turbine Water Washing Equipment comprising of the following Quick Release Coupling Pipe Adaptor Valve Pipe Assembly None Return Valve Union Pipe 28mm dia Elbow Adaptor Cross Orifice Union Injector Elbow Pressure Gauge Gauge Adaptor Elbow Pipe 15mm dia Bracket Progressive Ring Progressive Ring

PART NO.

QUANTITY

DT21442

1

DT22237/4 DT22237/4 DT22237/1 DT22242 DT22237/2 DT22237/8 DT21443 DT22237/9 DT22237/10 DT22237/11 DT22236 DT22237/12 DT21445 DT22237/13 DT22237/3 DT22237/14 DT22237/15 DT21444 DT22237/6 DT22237/17 DT22237/18

1 1 1 1 1 1 1 1 3 1 3 3 3 2 1 1 1 2 1 3 1

111

NAPIER 295 9.4

USER TRAINING COURSES The Company has an Instruction School at its Lincoln works which provides couses for customers technicians on the operation, maintenance and overhaul of turbochargers.The courses are essentially practical with supporting lectures. User training courses may also be run at customer sites in both the U.K. and overseas. These may be an economical alternative to a Lincoln based course, and allow you to provide more training places for your technicians. Full details will be supplied on request.

Fig. 10.1

The Lincoln Training Centre Workshop

Within the Training Centre specifically established to train user and operator technicians, there are facilities for technical and practical training. The basic theory of turbocharging a diesel engine, the design features of each of the different NAPIER types and the essential operating criteria are discussed. The workshop is equipped with a turbocharger of each type manufactured and practical training includes instruction in the proper use of tools, methods of inspecting component parts and dealing with component changes introduced through technical improvement . The correct method of ordering spare parts is also discussed. Trainees may also see the manufacture and test facilities of Napier turbochargers and the strict Quality Control procedures under which they are produced. The completion of the course is marked by the presentation of the NAPIER CERTIFICATE OF COMPETENCE

112

Napier Turbochargers Ltd.

Spares and Service Facilities

These training certificates are security coded against copying, remain the property of the sponsoring company and list the delegates name and the types of turbocharger on which training was received. 9.5

USER PUBLICATIONS A copy of this instruction manual, complete with spare parts list, is supplied with each turbocharger. Additional copies of manuals and wall charts may be purchased.

9.6

FACTORY OVERHAUL At Lincoln we have established, as an important part of our User Support Servicies, special facilities for the overhaul of used turbochargers. The same procedures apply to the rebuilding of these units as to new production units. Dynamic balancing of rotating assemblies, crack detection of component parts, ultrasonic and pressure checking of casings, sophisticated equipment for the cleaning and descaling of the returned unit ,are all available to the overhaul facility. A turbocharger overhauled in this facility carries a six--month guarantee. Customers are advised of recommendations for reconditioning or renewal of parts, together with a complete inspection report on all components.

9.7

USER SUPPORT SERVICES

9.7.1

TECHNICAL SUPPORT Qualified engineers attend the commissioning of new installations and are experienced in the operation, installation and maintenence of turbochargers. They are available to leave at short notice whenever and wherever their servicies are required.

9.7.2

APPROVED SERVICE ORGANISATIONS Our Approved Servicing Organisations are available at any time to provide technical advice, spare parts and service assistance, worldwide. Contact can be made to any of the following addresses.

113

NAPIER 295 NOTES

114

Napier Turbochargers Ltd.