CHARGE AIR SYSTEM & TURBO SUPERCHARGER

P.Kumar LECT(D)

Requirement of Air Charging System

Diesel engine produces Mechanical energy by converting Heat energy derived from burning of fuel inside the cylinder . ie for efficient burning of fuel oil.

FACTORS AFFECTING POWER

Humidity- Water vapour in the air takes the place of oxygen molecules. The molecular weight of water vapor is less than oxygen; as a result moist air is less dense than dry air. Less dense air means decreased performance. Temperature- temperature affects air density which affects performance: T , d ,P Mixture- fuel: air ratio

SUPERCHARGING
 Supercharging is the process of supplying the intake air to the engine cylinder at a pressure greater than the pressure of the surrounding atmosphere .This is done by blower or compressor.  BENEFITS--PRODUCES 50%OR MORE POWER THAN A NATURALLY ASPIRATED FOR THE SAME BORE AND STROKE DIMENSION.THE POWER TO WEIGHT RATIO IS MUCH MORE IN THIS CASE.  CHARGING OF AIR DURING SUCTION STROKE CAUSES BETTER SCAVANGING

BETTER COOLING OF COMPONENTS i.e.piston,liners,cyl.head. DUE TO COOL AIR CHARGED INTO CYLINDER AND SAVE THEM FAILURE DUE TO THERMAL STRESS. BETTER IGNITION DUE TO HIGHER TEMP DEVELOPED BY CYLINDER. BETTER FUEL EFFICIENCY DUE TO COMPLETE COMBUSTION OF FUEL BY ENSURING AVAILABILITY OF MATCHING QUANTITY OF AIR/ O2.

COMPARISON OF SUPERCHARGED AND NATURALLY ASPIRATED AIR STANDARD DUAL-COMBUSTION CYCLES HAVING THE SAME COMPRESSION RATIO

NATURALLY ASPIRATED 3 3 2 2 4 4 SUPERCHARGED

5 51 1 TDC BDC

BOOST AMBIENT

METHOD OF SUPERCHARGING
Different methods of supercharging in diesel engines are adopted. They are reciprocating type air compressor, centrifugal blowers run by the exhaust gas driven turbine. The most efficient & economical methods of supercharging is by centrifugal blowers run by the exhaust gas driven turbine

SPRH GG U CA IN E R

CMESR OP SO R TR SPRH G UB U CA E O E RR ( OETN MH ICLD ESPR AG ( TIZGXASGETDIVAOPESR CNN A E A AYR NU C RE U INEH TA SORE CM SO V IOL C N L IV E H R IL U S R )
POWER INLET MANIFOLD COMPRESSOR CHAIN OR GEAR AMBIENT DRIVE AIR COMPRESSOR INLET MANIFOLD AMBIENT AIR POWER

EXHAUST OUTLET

EXHAUST MANIFOLD

TURBINE

EXHAUST OUTLET

CHARGE AIR/ TURBO SUPERCHARGING SYSTEM

IMPORTANT SCHEDULE ACTIVITIES insp of leakages and tell tale hole checking of A/Cooler: T-20 Changing of Turbo Filter Element: T-60/ 80 Turbo overhauling: M-12, 24, 48 (depending of type of turbo)

WORKING PRINCIPLE OF TURBO SUPERCHARGER

The exhaust gas from all the cylinders accumulate in the common exhaust manifold at the end of which, turbo-supercharger is fitted. The gas under pressure enters the turbo-supercharger and passes through the fixed nozzle ring. Then it is directed on the turbine blades at increased pressure and at the most suitable angle to achieve rotary motion of the turbine at maximum efficiency.

After rotating the turbine, the exhaust gas goes out to the atmosphere through the exhaust chimney. The turbine has a centrifugal blower mounted at the other end of the same shaft and the rotation of the turbine drives the blower at the same speed. The blower connected to the atmosphere through a set of oil bath filters, sucks air from atmosphere.

The air then passes through the diffuser inside the turbo-supercharger, where the velocity is diffused to increase the pressure of air before it is delivered from the turbo-supercharger.. But due to compression heat develops, the density of air decreases. Then it passes through after cooler where cooling water of lower temperature is circulated through the tubes and around the tubes air passes.

The heat in the air is thus transferred to the cooling water and air regains its lost density. From the after cooler air goes to a common inlet manifold connected to each cylinder head. The maximum rotational speed of the turbine is 18000 rpm for the 720A model Turbo supercharger and creates 1.8 kg/cm2 air pressure in air manifold of diesel engine.

Main Components Of TSC

Gas Inlet Casing : It is made of CH20 stainless steel
which is highly heat resistant. The function of this casing is to take hot gases from the exhaust manifold & pass them through the nozzle ring.

Turbine Casing : It is made of alloy CI or fabricated.

It is fitted in between inlet & intermediate casing. This casing is water cooled.

Intermediate Casing : It is made of alloy CI or

fabricated like turbine casing. It is placed between turbine & intermediate casing. This casing is also water cooled. It separates exhaust & air side.

 Blower Housing Assembly : Air enters

through the blower inlet axially & discharge radially the vane diffuser. The vane diffuser is a aluminum casting.

Rotor Assembly : It contains rotor shaft, rotor

blade, inducer etc. It is dynamically balanced component, as it has a very high rotational speed.

COMPARISON BETWEEN AIR COMPRESSOR & CENTRIFUGAL BLOWERS

Sl No. 01. 02. 03. Air Compressor Large Size Requires More Power Does Not Maintain Proper Air Fuel Ratio Less Efficient Centrifugal Blowers Small Size Requires Less Power Maintains Proper Air Fuel Ratio

04.

More Efficient

TURBO RUN DOWN TEST

This test is done to check the performance of turbo supercharger. Procedure for Turbo Run Down Test The engine is started at 8th notch for some time and then at 4th notch ensuring water temperature should be 60C. Engine is then shut down through the over speed trip mechanism.

 When the rotation of the crank shaft stops, the free running time of the turbine is watched through the chimney exhaust gas/torch light and recorded by a stop watch. The minimum tine allowed for free running is 90 sec and maximum 180 sec. If time is less than 90 sec, bearing of turbo supercharger is jammed. Fail the loco. If time is more than 180 sec, turbine is moving freely. Check towards compressor side.

TYPE OF TURBO SUPERCHARGERS

SL NO. TYPE OF TSC RPM TRD THROTTLE POSITION FOR TRD CHECKING 4TH FITTED IN LOCOMOTIVE OVH DONE AFTER

ABB

28000

40-85 SEC

WDM2,WDG3A,

18 MONTHS

NAPIER

28000

40-85 SEC

4TH

WDM2,WDG3A,

03 YEARS

GE

28000-30000

90-120 SEC

4TH

WDM3A,WDG3A,

06 YEARS

HYSPANO SUIZA

27000

90-180 SEC

4TH

WDM3A,WDG3A

06 YEARS

720 A

18000

90-120 SEC

4TH

WDM2

06 MONTHS

COMPARISON OF DIFFERENT MODELS OF TSC

Time Period 1960-90 1990-95 High Efficiency 1995-2000 2001 Technology Conventional wise classification of TSC Turbo models used by RDSO Overall Efficiency Exhaust gas temp Frequency of Maintenance ALCO 720A Twin Discharge New Generation

Napier NA-295 ABB VTC304 62% 156 580 2-3 Years

GE 7S 1716

HS5800 NGT ABB TPR61 70% 151 500 3-6 Years

50%

64% 154 500 6 Years

SFC gm/BHP/Hr 168 600 Degree C 6 months

HIGH EFFICIENCY TSC (SINGLE DISCHARGE)

NAPIER ABB VTC304

TWIN DISCHARGE TURBOCHARGER

ABB VTC-304 TD GE 7S 1716

NEW GENERATION TURBOCHARGERS

ABB TPR61 HS5800 NGT

SALIENT FEATURES
EFFICIENCIES
TURBINE COMPRESSOR 87.2% 81.5%

TEMP. FOR WHICH CRITICAL COMPONENTS ARE DESIGNED

COMPRESSOR STAGE--AIR TEMP UPTO 190.6OC TURBINE STAGE ----GAS TEMP. UPTO 593.3OC ON INLET SIDE ----GAS TEMP. UPTO 482.2OC ON OUTLET SIDE

CAUSES OF LOW BOOSTER AIR PRESSURE/LOW HAULING POWER

LOW F/OIL PRESSURE. FIP OR NOZZLE DEFECTIVE. GOVERNOR MALFUNCTIONING. TSC DEFECTIVE. WHEEL SLIP OCCURING. DEFECTS IN EXITATION SYSTEM. DEFECTIVE AFTER COOLER. BOOSTER AIR LEAKAGE FROM AIR ELBOW JOINTS. EXHAUST GAS LEAKAGE FROM MANIFOLD(BELLOWS CONNECTOR CRACK).