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”.

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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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 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 dis-
played 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 equip-
ment nor the seals are touched with bare hands. PVC gloves must be worn and it is rec-
ommended 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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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:
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.

17. 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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 Introduction

NAPIER TURBOCHARGER

TYPE NA.295

SPECIFICATION

Type Max. Permissible Pressure Ratio Max. Turbine Weight

Speed ( R.P.M. ) Inlet
Temperature

SEE
NA.295 SEE TURBOCHARGER 4 :1 TURBOCHARGER 510 Kg.
TYPE PLATE FOR TYPE PLATE FOR approx.
DETAILS
DETAILS

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

Example of the Turbocharger nameplate

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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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 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. TELEPHONE: +44 (0)1522 516622

P.O. BOX 1 FAX: +44 (0)1522 516669
LINCOLN LS2 5DJ 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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NOTES

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 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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