Turbocharger

Surging Balloon surge

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 1 / July 2006
Turbocharger
Surging Balloon surge

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 2 / July 2006
Turbocharger
Surging Balloon surge

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 3 / July 2006
Turbocharger
Surging Balloon surge

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

SURGING !

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CIAC 42 / Ver 2.1 / 4 / July 2006
Turbocharger
Surging Balloon surge

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

SURGING !

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CIAC 42 / Ver 2.1 / 5 / July 2006
Turbocharger
Surging Surging facts

Surging exemplified Surging at high load should be avoided!

Surging facts Excessive loading of the rotating parts during surging can
Surging explained cause damage
Possible causes
The turbocharger speed may increase momentarily by
Countermeasures
about 15% during surging!
Design influences

Aerodynamic noise
There are three main causes of surging:
Flow restriction and fouling in the air/gas system
Malfunctioning of the engine fuel system
Rapid variation in engine load

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CIAC 42 / Ver 2.1 / 6 / July 2006
Turbocharger
Surging Surging facts

Surging exemplified Surging is usually caused by the air or gas flow being
Surging facts restricted in some way:
Surging explained Dirty air filter silencer
Possible causes
Increased backpressure after the turbine
Countermeasures
(dirty exhaust boiler or silencer)
Design influences
Dirty air side of charge air cooler
Aerodynamic noise
High charge air cooler water inlet temperature
Contaminated nozzle ring or turbine
A ship’s hull being dirty, causing the engine to run at
full torque / reduced speed

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Surging occurs in single stage TC installations or in multi
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TC installations, but is more likely to occur in the latter.
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CIAC 42 / Ver 2.1 / 7 / July 2006
Turbocharger
Surging Surging explained – normal conditions

Surging exemplified Pressure

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 8 / July 2006
Turbocharger
Surging Surging explained – normal conditions

Surging exemplified Pressure

Surging facts Operating point

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 9 / July 2006
Turbocharger
Surging Surging explained – normal conditions

Surging exemplified Pressure

Surging facts Operating point

Surging explained

Possible causes Operating line

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 10 / July 2006
Turbocharger
Surging Surging explained – normal conditions

Surging exemplified Pressure Under normal operating

Surging facts Operating point conditions, the turbocharger
Surging explained follows the operating line in
Possible causes Operating line accordance with three criteria:
Countermeasures
pressure ratio
Design influences
air volume flow
Aerodynamic noise

turbocharger speed

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CIAC 42 / Ver 2.1 / 11 / July 2006
Turbocharger
Surging Surging explained – normal conditions

Surging exemplified
High pressure - slow air speed
Surging facts

Surging explained
Low pressure - high air speed

Possible causes

Countermeasures The air flow follows

Design influences the directions
Aerodynamic noise determined by the
diffuser vane.
Diffusion takes place
and speed is
converted into
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pressure.
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CIAC 42 / Ver 2.1 / 12 / July 2006
Turbocharger
Surging Surging explained – flow restriction

Surging exemplified A reduction in air flow

Surging facts changes the velocity
Surging explained angles, causing the
Possible causes boundary layer to
Countermeasures break down.
Design influences The resulting
Aerodynamic noise turbulence reduces
the free air flow area.
No diffusion takes
place, the air speed
remains high, i.e. no
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pressure is produced.
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CIAC 42 / Ver 2.1 / 13 / July 2006
Turbocharger
Surging Surging explained – surging

Surging exemplified
Low pressure - high air speed
Surging facts

Surging explained

Possible causes

Countermeasures Surging takes place

Design influences because the pressure
Aerodynamic noise downstream of the
diffuser is higher than
the diffuser pressure.
The air flow is
reversed.
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CIAC 42 / Ver 2.1 / 14 / July 2006
Turbocharger
Surging Surging explained – overview

Surging exemplified Pressure Normal operation

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 15 / July 2006
Turbocharger
Surging Surging explained – overview

Surging exemplified Pressure Normal operation

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences Boundary layer

Aerodynamic noise breakdown. The
air speed is not
converted into
pressure.

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CIAC 42 / Ver 2.1 / 16 / July 2006
Turbocharger
Surging Surging explained – overview

Surging exemplified Pressure Normal operation

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences Boundary layer

Aerodynamic noise breakdown. The
air speed is not
converted into
pressure.

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CIAC 42 / Ver 2.1 / 17 / July 2006
Turbocharger
Surging Surging explained – overview

Surging exemplified Pressure Normal operation

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences Boundary layer

Aerodynamic noise breakdown. The
air speed is not
converted into
pressure.

Compressor flow
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reversal - SURGING
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CIAC 42 / Ver 2.1 / 18 / July 2006
Turbocharger
Surging Surging explained – overview

Surging exemplified Pressure Normal operation

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences Boundary layer

Aerodynamic noise breakdown. The
air speed is not
converted into
pressure.

Compressor flow
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reversal - SURGING
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Video: surging experienced on turbocharger testbed

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CIAC 42 / Ver 2.1 / 19 / July 2006
Turbocharger
Surging Possible causes

Surging exemplified Fuel oil system:

Surging facts Low circulating or supply pump pressure
Surging explained
Air in fuel oil
Possible causes
Water in fuel oil
Countermeasures

Design influences
Low pre-heating temperature
Aerodynamic noise
Malfunctioning of deaerating valve on top of venting
tank
Turbocharger:
Fouled air filter/silencer
Fouled or damaged compressor side
CIAC home Fouled or damaged turbine side
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CIAC 42 / Ver 2.1 / 20 / July 2006
Turbocharger
Surging Possible causes

Surging exemplified Exhaust system:

Surging facts Exhaust valve not opening correctly
Surging explained
Damaged or blocked protective grating before turbine
Possible causes
Increased backpressure after turbine
Countermeasures

Design influences Scavenge air system:

Aerodynamic noise Fouled charge air cooler, water mist catcher and / or
ducts
Fouled water circulation to charge air cooler
Miscellaneous:
Hunting governor
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Rapid changes in engine load
Too rapid rpm change
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CIAC 42 / Ver 2.1 / 21 / July 2006
Turbocharger
Surging Countermeasures

Surging exemplified Temporary measures:

Surging facts Open relief valve on top of air receiver
Surging explained
Open one exhaust by-pass valve (if installed)
Possible causes
Keep auxiliary blowers longer in service
(surging during running up)
Countermeasures

Design influences

Aerodynamic noise Corrective measures:

Repair / correct the deficient part of the system

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CIAC 42 / Ver 2.1 / 22 / July 2006
Turbocharger
Surging Refer to engine builder’s manual

Surging exemplified

Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 23 / July 2006
Turbocharger
Surging Turbocharging system layout

Surging exemplified One turbocharger

Surging facts with single air
Surging explained receiver
Possible causes inherently stable
Countermeasures against surging
Design influences

Aerodynamic noise

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CIAC 42 / Ver 2.1 / 24 / July 2006
Turbocharger
Surging Turbocharging system layout

Surging exemplified Dual

Surging facts turbochargers with
Surging explained single air receiver
Possible causes inherently
Countermeasures unstable, i.e.
Design influences
the ‘stronger’ TC
Aerodynamic noise
or engine system
deficiencies may
cause the ’weaker’
TC to surge.

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CIAC 42 / Ver 2.1 / 25 / July 2006
Turbocharger
Surging Engine design influence

Surging exemplified
Pressure
Surging facts

Surging explained

Possible causes

Countermeasures

Design influences

Aerodynamic noise Crankshaft angle

Surging is also influenced by air pressure fluctuations.

Fewer cylinders or a smaller air receiver volume create bigger
fluctuations.
CIAC home An appropriate surge margin is important during initial
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matching of the turbocharger.
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CIAC 42 / Ver 2.1 / 26 / July 2006
Turbocharger
Surging Humming noise

Surging exemplified
5 Humming sound:
Surging facts
4,5 Experienced from
Surging explained
time to time, coming
4
Possible causes
from the compressor
Countermeasures
3,5 During low load
Design influences
operation, i.e. with a
Aerodynamic noise 3
low compressor
2,5 pressure ratio

2
Does NOT mean
surging is about to
1,5 begin!
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1 Has no influence on
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engine and TC
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CIAC 42 / Ver 2.1 / 27 / July 2006