Beruflich Dokumente
Kultur Dokumente
TURBOCHARGER
SUBMITTED BY:
PROF S.M.GUNADAL
MUMBAI 400019
(2018-2019)
1|Page
ACKNOWLEDGEMENT
It is the incidence of great pleasure in submitting this work,
“Turbocharger ''.
We take this opportunity to express our sincere gratitude to respected guide
Prof. S. M. Gunadal. For his valuable guidance in his undertaking, without which
the work would not have been completed. He has been encouraging us in
eliminating all the errors. The work has been developed as a result of valuable
advices.
We are also grateful for the co-operation and valuable suggestion
rendered by Dr. S. S. Mastud as a head of department.
2|Page
INDEX
1 Abstract 4
2 Introduction 5
3 Objective 5
4 Principle 6
5 History 7
7 Components of turbocharger 11
8 working 11
9 Recent developments or Types 14
of turbocharger
10 Advantages 20
11 Disadvantages 21
12 Application 22
13 Conclusion 23
14 References 24
3|Page
ABSTRACT
If the compressor is driven from the crankshaft of the engine, the system
is called 'mechanically driven supercharging' or often just 'supercharging'. If the
compressor is driven by a turbine, which itself is driven by the exhaust gas from
the cylinders, the system is called 'turbocharging'. The shaft of the turbocharger
links the compressor and turbine, but is not connected to the crankshaft of the
engine. Thus the power developed by the turbine dictates the compressor
operating point, since it must equal that absorbed by the compressor.
Turbocharger has the applications in the Petrol power cars, diesel powered cars,
Motorcycles, trucks, aircraft, marine engines, etc.
4|Page
INTRODUCTION
OBJECTIVE
• The objective is to increase an engine’s volumetric efficiency by increasing
intake density.
• The compressor draws in ambient air and compresses it before it enters into
the intake manifold at increased pressure, that results in a greater mass of
air entering the cylinders on each intake stroke.
• The power needed to spin the centrifugal compressor is derived from the
high pressure and temperature of the engine’s exhaust gases.
• The turbine converts the engine exhaust's potential pressure energy and
kinetic velocity energy into rotational power which in turn is used to drive
the compressor.
5|Page
PRINCIPLE
Darthe Maersk the first ship with turbocharged two stroke engine
in power as well as lower fuel consumption. On the top of this the operating
pressure, combustion wall temperature and the heat load on wall all remained
within acceptable limit.
7|Page
First ships with turbocharged engines 1923 was also the year when vulkan
shipyard built two passenger ships, the pressrun and the hansestadt danzig . Each
ship was powered with two 10 cylinder four stroke engine turbocharged from
1750 to 2500 horsepower. The engine had common exhaust to ensure constant
pressure for all cylinder. The ship was built under Buechi’s supervision. After
their successful test in May 1927 two ship went on to become first ships to be
powered by turbocharged engines.
After that there was no looking back. Turbocharged engine became first
choice for almost everyone Industry, entrepreneur. Fast changing market and
compressor design potential dictated a fast pace for the developmental work
around mid 1990’s. It was concluded that demand of the advanced engines being
built at that time would be best met by two different compressors. So new D and
E compressors were introduced during that time.
This time to time technological developments led to huge opportunities to
work in the field of turbocharger.
8|Page
DIFFERENCES BETWEEN SUPERCHARGERS AND
TURBOCHARGERS
9|Page
A turbocharger uses the exhaust stream for its energy. The exhaust will run
through a turbine that will itself spin the compressor. The turbine spinning can be
as much 15,000 RPM (Rotations Per Minute). To put that in layman’s terms, the
turbocharger is able to have an RPM speed that can be almost 30 times faster than
an ordinary automobile engine. It does take a little while for the turbine to produce
the boost, and can result in the car lunging forward when the turbocharger kicks
into action. The size of the turbocharger can impact power with a smaller one
producing more boost faster. A turbocharger is particularly effective at high
altitudes where other engines experience difficulty. Because the air is less dense
a normal engine gets a smaller amount of air. Turbocharged engines do not suffer
a dramatic reduction in power since the turbocharger is more capable of pumping
thinner air.
The source of the power for the supercharger is in a belt connected directly
to the engine. A supercharger will compress air of the atmospheric pressure, and
create the boost by forcing air into the engine. The supercharger can add as much
as 46% more horsepower because the increased air will allow more fuel to be
added to the combustion charge. Like the turbocharger, a supercharger will do
well in high-altitude.
10 | P a g e
COMPONENTS OF TURBOCHARGER
The turbocharger has three main components
1. The turbine, which is almost a radial inflow turbine.
2. The compressor is almost a centrifugal compressor.
3. The centre hub rotating assembly.
1. Capture
Instead of escaping through the exhaust pipe, hot gases produced during
combustion flow to the turbocharger. The cylinders inside an internal combustion
engine fire in sequence (not all at once), so exhaust exits the combustion chamber
in irregular pulses.
Conventional single-scroll turbochargers route those irregular pulses of
exhaust into the turbine in a way that causes them to collide and interfere with
one another, reducing the strength of the flow. In contrast, a twin-scroll
turbocharger gathers exhaust from pairs of cylinders in an alternating sequence.
2. Spin
11 | P a g e
The exhaust strikes the turbine blades, spinning them at up to 150,000 rpm.
The alternating pulses of exhaust help eliminate turbo lag.
3. Vent
Having served their purpose, exhaust gases flow through an outlet to the
catalytic converter, where they are scrubbed of carbon monoxide, nitrous oxides,
and other pollutants before exiting through the tailpipe.
4. Compress
Meanwhile, the turbine powers an air compressor, which gathers cold,
clean air from a vent and compresses it to 30 percent above atmospheric pressure,
or nearly 19 pounds per square inch. Dense, oxygen-rich air flows to the
combustion chamber.
The additional oxygen makes it possible for the engine to burn gasoline
more completely, generating more performance from a smaller engine. As a
result, the Twin Power engine generates 30 percent more power than a non-
turbocharged one of the same sizes.
12 | P a g e
It follows the following process
1. The engine’s air intake sucks in cool air and sends to the compressor.
2. The compressor compresses the incoming air and heats it up. It then
blows out the hot air.
3. The hot air cools down when passing through the heat exchanger and
enters the cylinder’s air intake.
4. The cold air burns inside the combustion chamber at a faster rate because
of carrying more oxygen.
5. Due to the burning of more fuel, the energy output will be bigger faster,
and the engine will be able to send more power to the wheels.
6. Hot waste gasses will leave the chamber and blows past the turbine at
the exhaust outlet.
7. The turbine rotates at a high speed and spins the compressor too as both
are mounted on the same shaft.
8. The exhaust gasses leave the car through the exhaust pipe. They waste
less energy than an engine not having a turbocharger.
13 | P a g e
RECENT DEVELOPMENTS OR TYPES OF
TURBOCHARGER
14 | P a g e
2. PARALLEL TURBO
The parallel turbocharger principle is the most common arrangement on
existing marine two stroke engines. A parallel configuration refers to using two
equally-sized turbochargers which each receive half of the exhaust gases. Some
designs combine the intake charge from each turbocharger into a single intake
manifold, while others use a separate intake manifold for each turbocharger.
The aim of using parallel twin-turbos is to reduce turbo lag by being able
to use smaller turbochargers than if a single turbocharger was used for the engine.
On engines with multiple cylinder banks (e.g. V engines and flat engines) use of
parallel twin-turbos can also simplify the exhaust system.
s used on engines with two or more parallel installed turbochargers to
reduce the fuel consumption at low-load operation. When the engine operates at
low loads, the turbocharger speed is decreased. Thus, the temperature of the air
supplied to the engine is too low, which leads to a less than optimal combustion
process. To increase the speed of the turbocharger, cut-out methods where one or
more turbochargers are cut-out from operation, can be used
MAN Diesel & Turbo, (2018) offer two turbocharger cut-out solutions for
two-stroke low speed engines. The cut-out can be applied by installing blinding
plates on the air outlet, and also on the exhaust gas in- and outlet of the
turbocharger. Installing gate valves on the air outlet and exhaust gas inlet of the
turbocharger is also a mentioned approach. ABB Turbocharging also offers two
types of cut-out methods for their turbochargers, the “fixed cut-out” and the
“flexible cut-out” (Baechi, 2012). In the first method the gas, air, and oil lines are
disconnected, and the bearing and rotating parts are removed. The second
mentioned method involves installing a charger and flexible valves in the gas and
air lines.
15 | P a g e
3. VARIABLE GEOMETRY TURBO
16 | P a g e
4. TWIN SCROLL TURBO
Twin-scroll or divided turbochargers have two exhaust gas inlets and two
nozzles, a smaller sharper angled one for quick response and a larger less angled
one for peak performance.
In twin-scroll designs, the exhaust manifold physically separates the
channels for cylinders that can interfere with each other, so that the pulsating
exhaust gasses flow through separate spirals (scrolls). With common firing
order 1–3–4–2, two scrolls of unequal length pair cylinders 1 and 4, and 3 and 2.
This lets the engine efficiently use exhaust scavenging techniques, which
decreases exhaust gas temperatures and NOx emissions, improves turbine
efficiency, and reduces turbo lag evident at low engine speeds.
17 | P a g e
• More robust in design versus a VGT, depending on the material
selection.
• Disadvantages:
• Cost and complexity versus using a single turbo or traditional twin-
scroll.
6. HYBRID TURBOCHARGER
18 | P a g e
connected to the turbocharger shaft, located on the compressor side of the shaft.
At high loads it is used to generate electrical power and can replace the auxiliary
blower at low loads by acting as a motor.
In 2008, Mitsubishi Heavy Industries – Machinery & Equipment CO.,
LTD. developed a hybrid turbocharger called MET83MAG together with other
companies, with the purpose of achieving fuel savings and meeting the
environmental regulations. The turbocharger is integrated with a high speed
generator, fitted inside the body of the turbocharger, directly connected to the
rotor shaft of the T/C. The power supply system includes a permanent magnetic
generator that generates a 3-phase alternating current, between 0-400 volts and 0-
167 Hz, depending on the turbocharger speed. To make the electricity useful for
ship application, where the normal power supply is often AC 450 V, 60 Hz, the
system also consists of a converter that reforms the generated AC to DC, with
constant voltage, and is assisted by an insulated gate bipolar transistor that is
suitable for high frequency. The same transistor is also used for the final stage of
the system, an inverter, to get a stable AC 450 V, 60 Hz stand-alone power supply.
When developing this stand-alone power supply system some issues
required investigation and were solved. Due to the fact that the system doesn’t
have a reference waveform when connecting it to the common ship supply, it was
necessary to develop an autonomous control of frequency and voltage. It was also
necessary to develop the supply of reactive power and sustained short-circuit
current. Another problem during the development of the generator was creating
a suitable cooling structure. The final product was tested with verification of the
generator characteristics and turbocharger performance, including load, governor
and temperature characteristics through bench tests. The bench tests were
followed by an engine-matching test where the most suitable engine for the
hybrid turbocharger was decided. Finally, in 2011, the system was installed on an
actual bulk carrying vessel, Shin Koho, shown in, and after successful sea trials
the vessel is still in operation, using the MET83MAG hybrid turbocharger
application. An advantage of the mentioned application is that it can easily be
installed on engines currently in use, due to the few modifications required for
the installation.
19 | P a g e
ADVANTAGES
20 | P a g e
DISADVANTAGES
• Engine Damage
Improperly installed turbocharger systems have an extremely damaging
effect on the engine onto which they are mounted. Turbochargers are rated
according to the amount of air they deliver in pounds per square inch (PSI). Most
cars and trucks work efficiently with additional power and only minor tuning
between five and seven PSI. Levels of eight to 12 PSI often require reinforced
internals such as a heavy-duty valve train and special pistons. Turbochargers
functioning above 12 PSI often require professional engine modification to
prevent serious damage to the engine block and internal components. In some
cases, properly installed and tuned turbocharger systems that are negligently
driven will still fail and permanently destroy the vehicle's engine.
• Excessive Heat
A turbocharger used without an intercooler can create extremely high heat
in the engine compartment of the vehicle. This additional heat can lead to
overheating breakdowns, melting of critical plastic engine components and fires.
Using an intercooler mitigates this problem, but is an expensive addition to the
system. Intercooler systems are not always sold in kit form with the turbocharger.
• Warranty Invalidation
Installing an aftermarket turbocharger on any vehicle still under
manufacturer's warranty can invalidate the vehicle warranty in its entirety.
Turbochargers are considered off road racing equipment and most vehicle are not
designed to use them. Your warranty will be invalidated and you will have to pay
for repairs out of pocket if the damage to the vehicle is caused by the
turbocharger.
• Insurance
Vehicles with turbochargers are much more expensive to insure than
vehicles without turbochargers installed. The difference is much more significant
for teen drivers who possess turbocharged vehicles, at times as much as doubling
the standard insurance premium
21 | P a g e
APPLICATION
Turbocharging has become a recognized means of increasing the power
output of gasoline and diesel passenger car and commercial engines. The
application of turbochargers involves the consideration of many factors in the
engine and vehicle systems. The optimization of these systems requires wide
knowledge and experience in turbomachinery, engine design, performance
analysis, emissions, and reliability.
• Petrol-powered cars
• Diesel-powered cars
• Motorcycles
• Trucks
• Aircraft
• Marine and land-based diesel turbochargers
22 | P a g e
CONCLUSION
The aim of the study was the turbocharger technologies applied on two-
stroke diesel engines as well as four-stroke engine. The intention was to present
the objective and principle of working of the turbocharger. The history of the
evaluation of the turbocharger. A brief concepts of the supercharger and the
turbocharger. The difference between them. The study was done on the
advancements in the turbocharger. The advantages and disadvantages of
advances and give an overview of which technologies would be of interest for
future development. The results are shortly summarized of all the advancements
of the turbocharger. The hybrid turbocharger is seemingly a solution for slow
steaming operations and can be used to generate electric power at high load,
which makes it of interest for further development. Also the advantages ,
disadvantages and the applications of the turbocharging.
For future research within the topic, creating a simulation model of the
different turbocharging technologies are applied and tested in order to get a more
accurate comparison. Another suggestion is involving the manufacturers, for better
cooperation regarding specific technologies.
23 | P a g e
REFERENCES
• A PROJECT REPORT OF SUMMER INTERNSHIP AT INDIAN INSTITUTE OF
TECHNOOGY, GUWAHATI - “Analytical study of a Turbocharging Device” by
Tanmay Jyoti Deka.
• A report on “Turbocharger” by Mitsubishi heavy industries.
• Review on Recent Advances for Marine Turbocharger Technologies For Two-stroke
Diesel Engines Bachelor’s thesis in the Marine Engineering Programme Naomi
Andersson Erika Kisbenedek
• Anantharaman, M., Garaniya, V., Khan, F., & Lewarn, B. (2015). Marine Engines and
their Impact on the Economy, Technical Efficiency and Environment. Journal of The
Japan Institute of Marine Engineering, 50(3), 360–367.
https://doi.org/10.5988/jime.50.360
• Andersson, K., Brynolf, S., Lindgren, F. J., Granhag, L., Svensson, E., & Wilewska-
Bien, M. (2016). Shipping and the Environment Improving Environmental
Performance in Marine Transportation. (K. Andersson, S. Brynolf, F. J. Lindgren, &
M. Wilewska-Bien, Eds.). SpringerNature. https://doi.org/10.1007/978-3-662-49045-7
• Baechi, R. (2012). Slow steaming and turbocharger cut-out. Retrieved May 6, 2018,
from
https://library.e.abb.com/public/91721604fb81367048257d660030dc37/ABBTC_CH
AR GE_2012_02_TFO.pdf
• Feneley, A. J., Pesiridis, A., & Andwari, A. M. (2017). Variable Geometry
Turbocharger Technologies for Exhaust Energy Recovery and Boosting-A Review.
Renewable and Sustainable Energy Reviews, 71, 959–975.
https://doi.org/10.1016/J.RSER.2016.12.125
• MAN Diesel & Turbo. (2018). Turbocharger Cut-Out-System. Retrieved May 6, 2018,
from https://primeserv.mandieselturbo.com/service-
solutions/productssolutions/upgrades/primeserv-green/turbocharger-cut-out-system
• https://drivetribe.com/p/turbocharger-components-working
YP7yEQmiTx23PEJh3ajASw?iid=BzQZbW9aSougNeYBo_tevA
• https://en.wikipedia.org/wiki/Turbocharger
24 | P a g e