Turbocharger

11/03/2013

TURBOCHARGER TRAINING

Turbocharger

Components and their function ?

Why do we use one ?

How does a TC works ?

Compressor and Turbine Map

Wastegate turbocharger

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Power And Torque

130 550

120 525

110 500

100 475
Power (kW)

90 450

Torque Nm
80 425

70 400

60 375

50 350
Power
40 Torque 325

30 300
1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine Speed (rpm)

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BSFC and Volumetric EFF

230 90

225
85
220
SFC (g/kW-h)

Vol Eff %
215 80

210
BSFC
75
Vol Eff
205

200 70
1000 1200 1400 1600 1800 2000 2200 2400 2600
Engine Speed (rpm)

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Four Cornerstones Of Turbo charging

The evolution of turbocharger has been fundamental to the development of
diesel engines in terms of
• Power
• fuel economy
• emissions.
The scientific and technical environment of the 19th and early 20th century was
the catalyst for turbocharged diesel engine development.
• The invention : In 1903 by Alfred Buchi
• Non-dimensional analysis : Lord Rayleigh in 1912
• The 2nd law of thermodynamics and entropy
• Aerodynamic and engine turbocharger gas exchange processes

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What Is A Turbocharger ?

An exhaust gas driven turbine, connected to, and driving a radial compressor, to
supercharge the engine.

exhaust gas energy drives a (radial) turbine wheel

the flow of gas to the turbine wheel is controlled by the volute passage of
the turbine housing

the turbine is mechanically connected to a radial compressor

the impeller draws air from the atmosphere, and adds kinetic energy to it

this kinetic energy is converted to pressure in the compressor volute and
diffuser sections

the shaft connecting the turbine and compressor wheels runs in bearings
held in a central housing, which is supplied with oil for lubrication and
cooling.

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Cut Section Of Turbocharger

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Impeller Profile/Trim
t
Shroud profile Example : A77J68GM
for lower trim
D = 77mm, d = 0.68*D mm
J stands for Tip to Inducer ratio
code 0.5
d’
A1 = Pi*D*t
d
D
A2 = Pi*d*d/4
A1/A2 = Tip to Inducer ratio
d/D = Squareness

Shroud Smaller trim : A77J65GM

Profile
D = 77mm, d’ = 0.65*77 mm
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Why do we use turbocharger ?
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 Why Do We Use One ?

• Adding extra air means Comp

extra fuel can be injected into Air Out Atm.
the engine, and thus achieve Air In
better combustion.

• Increased engine power

output (in the region of 50%
increase)
• Improved fuel consumptionExhaust
(improved pressure balance Gas out
across the engine)
• Improved emissions
Exhaust
• altitude compensation Gas In

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WGT- waste gate turbo

VGT- variable geometry turbine
VGC- variable geometry compressor
eTurbo- electronically controlled turbo

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Naturally Aspirated Engine

Air Exhaust

100kW output

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Supercharged Engine
Compressor
50kW Requires
crankshaft
power to drive
compressor

Air Exhaust
Higher density
air allows more
fuel to be burnt
= more power !
250kW – 50kW
= 200kW output

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Turbocharged Engine
Compressor Turbine Turbine recovers
energy from the hot
exhaust gas that would
otherwise be lost.
Improves thermal
efficiency.

Air Exhaust
The inlet manifold can
often be higher pressure
than the exhaust
manifold, thus increasing
power output through
pumping work.

250kW output

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 6.9litre 206kW

Comp
Turb ρ = 1.1kg/m³
P = barom P = -50mbar
T = 400°
400°C T = 25°
25°C

Silencer Air Filter

11/03/2013 Presenters: Hitesh Chaudhari & P = barom 16

Madhu Reddy, Organized by T = 21°
21°C
Experts Hub for Anjuman College
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Compressor Map Representation

3.8 78
72%
3.6 70%
68%
3.4 66%
74%74% 64%
3.2 72
Speed Parameter 62%
Pressure Ratio

3.0 [rev/sec/sqrt(K)] Isentropic

72% Efficiency
2.8 66
2.6 60%
58%
70%
68%
2.4 61

2.2
54 76%
2.0
1.8
45
1.6
1.4 34
1.2
1.0
0 25 50 75 100 125 150 175 200
Flow Parameter [kg/s * sqrt(K)/MPa]
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Major Regions Of A Compressor Map

Excess
mild flutter to wildly fluctuating Rotor
boost and
“barking” from the compressor Speed
Pressure Ratio

Surge

rapid drop of compressor

efficiency

Heart
Choke

1.0
0
Flow Parameter [kg/s * sqrt(K)/MPa]

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Turbine Map Representation
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The peak
74.8% ,
efficiency is 74% 74%
76 74% 72.6%
74%
71.3%
72 Taking the 1.6
68 expansion
Efficiency

64 ratio as an
example 1.6 3.5 1.6
60 1.8 1.8
56 2.2 3.5 Turbine Maps And
2.6 2.2 3.0
52 3.0
2.6
Swallowing Capacity Curves
48
0 20 40 60 80 100

3.0
2.6
54 3.5
m?T/p Corp. (kg/sec.?K/MPa)

2.2
52 Swallowing Capacity Curve
51.4 51.2
51 50 4.0

50.2 1.8
48

Expansion Ratio
46 3.0
47 1.6 3.5
44 3.0
Represented by
42 2.2 2.6 this point on the
2.0
43.8 1.8
swallowing
40and NOT
the APPROVED
1.6
capacity curve
flow will be
43.8 M√T/P
Flow Parameter

38 1.0
0 20 40 60 80 100 30 35 40 45 50 55
Flow Parameter(M?T/P)
N/?T (rps/?K)

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Speed Parameter
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 Effect of parameters on Compressor and Turbine

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Turbocharger Matching

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Turbocharger selection & matching for up gradation of existing engine 11/03/2013

i. Calculation of Engine operating line in Compressor map

Step-1: Collection of inputs according to Lowest full load speed, Maximum torque
speed and Rated speed conditions.

Engine speed Power Fuel flow A/F with Vol. eff. Manifold EGR
[rpm] [kW] [kg/h] EGR [%] [%]
2400 29.8272 6.9 25 85 12
1600 27.1429 6.0 23 87 10
1000 14.9136 3.4 21 82 5

Step-2: Calculate Reference Intake manifold pressure intake manifold pressure [K]

P2= Reference intake manifold Pressure [bar]

T2= Reference intake manifold Temperature [K]
P1= Atmospheric Pressure [bar]
T1= Atmospheric Temperature [K]

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Step-3: Calculate Reference Air flow rate [kg/s]

mair= Reference Air flow rate [kg/s]

P2= Reference Intake manifold Pressure [bar]
ηv= Vol. efficiency related to intake manifold conditions [-]
Vd = Volumetric displacement [l]
n=Engine speed [rpm]
R= Gas constant [j/kg K]
T2= Reference intake manifold Temperature [K]
nc=Number of Cycles, 1 for two strokes and 2 for four strokes

Step-4: Calculate Target Air flow rate [kg/s]

mair= Target Air flow rate [kg/s]

AFR= Air Fuel Ratio [-]
BMEP= Brake Mean Effective Pressure [bar]
Vd = Volumetric displacement [l]
n=Engine speed [rpm]

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Step-5: Match Target Air flow rate with Reference Air flow rate

Match Target Air flow rate with Reference Air flow rate by varying intake manifold Temperature.

Step-6: Calculate intake manifold Pressure [bar]

Step-7: Calculate boost pressure ratio [-]

Πc=Boost pressure ratio [-]

P2= Calculated intake manifold Pressure [bar]
T2= Reference intake manifold Temperature [K]
P1= Atmospheric Pressure [bar]
T1= Atmospheric Temperature [K]

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Contd….

Step-8: Plot engine operating line in the compressor map

i.If the compressor is too small, the rated speed operating point is beyond the speed limit of the compressor or in the
choked flow region

ii.If the compressor is too large, low and/or mid speed operating points are located left of the surge line

iii.If the correct compressor is selected, the entire engine operating line is located within the map

Corrected mass
Corrected mass
flow Target Air Target Air Boost
Target Air flow rate flow [g/s]
Speed [kg/s.√K/Mpa] flow rate flow rate pressure
[kg/h] With Ref
Without Ref [kg/s] [m3/s] ratio [-]
Conditions
Conditions

1000 165.93 8.07 46.76 0.04609 0.03951 1.71

1600 284.27 13.93 80.69 0.07896 0.06769 1.97
2400 438.55 21.78 126.15 0.12182 0.10442 1.99

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Compressor
Too small,
Rated speed
point beyond
Choking of
compressor !

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Compressor
too large,
Lowest full load
and max torque
speed left of
compressor
surge line !

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Correct
compressor
size !
Good surge
and choke
margin !

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Thank You