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G Benvenuto
Dipartimento di Ingegneria Navale e Tecnologie
Marine (DINAV), University of Genova, Italy
U Campora
Dipartimento di Macchine, Sistemi Energetici e
Trasporti (DIMSET), University of Genova, Italy
marine sequential turbocharged diesel engine [2] In previous studies the authors developed and
simulated here. validated a dynamic simulation model [14] for tur-
bocharged diesel engines, to be used as part of a
more general model for the dynamic simulation of
3. Engine Model ship propulsion plants [15± 17]. In the present study
the diesel engine model has been modified with the
The scheme of Fig. 1 shows the sequential turbo-
purpose to describe the new TC system.
charging system and its control valves as considered
Figure 2 shows the overall scheme of the diesel
in the engine model. In this figure, the turbocharger
engine model, including the changes introduced to
named `1st TC’ is always active, while the one named
simulate the sequential TC and its control. The model
`2nd TC’ is disconnected at low engine speed and
is written in SIMULINK (MATLAB toolbox) lan-
load.
guage [14] and is developed in modular form. Each
block of the scheme describes the pertinent engine
component. In the scheme of Fig. 2, only the main
thermodynamic, mechanical and control variables
exchanged between the blocks are reported. The
simulator input variables (Fig. 2) are the mass of
fuel injected in the cylinders (Mf ) and the engine
speed (nE ), while the output variable is the shaft
torque (tE ).
The engine simulation approach is based on the
`filling and emptying’ method. Cylinders and mani-
folds are assumed as a succession of control volumes,
whose temperature and pressure are determined by
means of mass and energy dynamic balance equa-
tions:
dr 1
= (Mi Mo ) (1)
Fig. 1 Sequential turbocharging scheme. dt V
S
A two-zone actual cycle model is used for the chemi- Tref
cal and thermodynamic phenomena simulation in V Cc =VC (6)
Ta
the cylinder, using crank angle as the independent
variable. During the cylinder volume variation, non- and of the corrected rotational speed:
S
adiabatic fluid compression/expansion processes are
Tref
evaluated, while the heat release during combustion nCc =nTC (7)
Ta
in the cylinder is modelled according to the Wiebe
equation [19]:
3.5 Torque equation
C A B D
h h ign Km+1 The engine shaft torque is evaluated, in the cylinder
dxb =1 exp Ka (4) block of Fig. 2, starting from the brake mean effective
Dh
pressure (b.m.e.p.), this last being calculated from
where dxb is the fuel fraction burned during the cal- the equation
culation step (dh). The combustion angle width (D h),
necessary for the Wiebe equation (4), is evaluated (b.m.e.p.)=(i.m.e.p.)+(p.m.e.p.) (f.m.e.p.) (8)
using a simple injector model [20]. Fuel pressures where
before the injector and injection start angle are
changed as functions of engine speed and mass of i.m.e.p.=gross indicated mean effective pressure
fuel injected. p.m.e.p.=pumping mean effective pressure
f.m.e.p.=mechanical friction mean effective
3.2 Intercooler and air receiver pressure
These components are grouped into a single block
This last quantity, expressed as a function of the
(Fig. 2). The air cooling effect is evaluated by
engine speed and of the gross indicated mean effec-
assuming a constant heat exchanger efficiency, while
tive pressure (i.m.e.p.), is evaluated with the
the pressure drop is computed as a function of the
procedure described in reference [22].
inlet pressure and mass flowrate. The fluid mass and
energy accumulation in these volumes are calculated
by means of the dynamic equations (1) and (2).
C A BA BD
kg 1 pTi
TTi =Tcy o 1 1 (5)
kg pcy o
G CA B A B DH
same as those used in reference [14] and described 2kg p 2/k p (kg+1)/kg 1/2
g
above. × pr
kg 1 i i pi pi
(11)
4.1 Turbocharging control valves
In this equation, the control valve parameter V3c
The turbocharging control valves are modelled in
(Fig. 2) simulates the valve throat area variation.
different ways depending on the engine component
Consequently, this coefficient assumes a zero value
modules to which they are connected. Valve equa-
when the valve is closed and a value equal to one
tions are included in the pertinent engine blocks.
when it is open.
4.1.1 2nd TC turbine inlet valve (V1 in Fig. 1) 4.1.4 Exhaust waste-gate valve (V4 in Fig. 1)
For the simulation of this valve, which cuts off the This valve is modelled in a similar way, but in this
mass flowrate to the turbine, a simple scheme is case a supersonic flow equation [23] is also used:
C A B D
adopted: the valve is treated as a flow resistance in
2 (k + 1)/(k 1) 1/2
g g
series with the turbine. A valve control coefficient Mwg =Av a V4c kg pi ri
(V1c in Fig. 2) is interpreted as a flow coefficient and kg +1
is introduced as a factor multiplying the turbine mass (12)
flowrate value: when the valve is open, the value of Obviously, for all of the valves mentioned above,
V1c is one, while it assumes a zero value when the a partial opening may be simulated by assuming, in
valve is closed. this case, for the relative control valve coefficient, an
The control valve parameter V1c comes from the intermediate value between those corresponding to
`TC sequential control’ module (Fig. 2). In order to full open and closed situations.
take into account the valve mechanism inertia, the
passage from the closed to open positions (and vice 4.2 Turbocharging sequential control
versa) is assumed to vary with the time according to In order to switch the 2nd TC in and out of operation,
a very short increase/decrease ramp. The same ramp the valves V1, V2, V3 and V4 are actuated, in the
function was adopted for the control signal variation WaÈrtsilaÈ 18V 26X engine, by a rather complex control
of the other turbocharging sequential control valve system that the simulator reproduces in its main
parameters (V2c , V3c and V4c in Fig. 2). functions, as explained below.
In Fig. 4 the overall engine work area is shown in
4.1.2 2nd TC compressor outlet valve (V2 in Fig. 1) the characteristic map of the delivered power versus
In the compressor model, the pressure ratio and the the engine speed (in this figure and in the following
efficiency are functions also of the mass flowrate, ones the results are presented in dimensionless form,
which is an input variable (MCi in Fig. 2). Then the by referring the quantities to the MCR values). As
outlet compressor cut-off valve (V2 in Fig. 1) is mod- can be seen in Fig. 4, the engine work area is sub-
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divided into two parts: the first one, characterized block are the following: engine speed (nE ), turbo-
by low engine speed and power, where only the 1st charger speed (n1st TC and n2nd TC ) and air receiver
TC is active, and the second one, relative to high pressure (pCo ); the output variables are the valve
speed and power engine work, where also the 2nd control parameters (V1 c , V2c , V3c , V4c ).
TC is connected to the cylinders.
When the engine speed or the receiver pressure
exceeds prefixed values, the control system manages 5. Validation and Results
the opening of the V1 and V2 valves, allowing the
2nd TC switching-in operation. It has to be noted The engine simulation code has been validated by
that, in order to prevent continuous switching in/out comparison with experimental results. A WaÈrtsilaÈ
of turbochargers, when the engine works at `border- 18V 26X diesel engine was instrumented and connec-
line’ between the two areas, the TC switching-in ted to a hydraulic brake giving a cubic power func-
point is different from the switching-out point. In tion satisfying the engine MCR conditions (7200 kW
particular, the TC switching-in point occurs at an at 1000 r/min). In the simulator the dynamics of the
engine speed or load greater than the switching-out engine± brake system is evaluated by means of the
point. In Fig. 4 only the TC switching-in condition is balance torque equation (3).
displayed.
It is well known [3] that for a correct TC connection 5.1 Steady state results
procedure, the turbine switching valve (V1 in Fig. 1) In Table 1, a comparison between the simulation
must be open well before the compressor switching output and test data at MCR engine conditions is
valve (V2 in Fig. 1). For the present application a time reported. Mismatches turn out to be less than 2.4 per
lag of 3 s is assumed. This time lag is not necessary cent. The engine performance map of Fig. 4 shows
at TC shut-down. experimental and calculated lines of constant specific
In addition to the above-mentioned operations, in fuel consumption. It can be seen that the calculated
order to ensure an efficient and safe engine manage- curves (solid lines) are in good agreement with the
ment, the turbocharging control system also manages experimental ones (dash-dot lines).
the air bypass and exhaust waste-gate valves (V3 and
V4 respectively in Fig. 1). In particular, the V3 valve 5.2 Transients results
partial opening controls the air receiver pressure, A dynamic model validation has been obtained by
while the V4 valve is used to avoid the turbocharger testing two different engine load variations. The first
overspeed. transient is caused by an increasing ramp of engine
In the model, the above-mentioned control criteria fuel mass flow, with consequent engine power and
are simulated in the TC sequential control block of speed variation from about 22 per cent MCR to full
Fig. 2. As can be seen, the input variables of this load for the power and from 60 to 100 per cent MCR
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Table 1 Comparison between experimental and simulation results at MCR engine conditions.
for the speed. The acceleration transient line is than that reported in the engine map of Fig. 4. This
reported on the engine map in Fig. 4. difference is justified because the engine used for the
Figure 5 shows a comparison between experimen- transient experimental tests is characterizd by a dif-
tal and calculated turbine and compressor switching ferent setting of the turbocharger sequential control,
valve positions (respectively V1 and V2 in Fig. 1) as compared to the standard one shown in Fig. 4.
during the transient. In this figure, a zero coefficient As regards the 1st TC speed variation, the results
value means that the valve is closed, while a unit reported in Fig. 7 show good agreement between the
value corresponds to a fully open valve. From the experimental and calculated values, especially in the
comparison, the calculated and experimental data final part of the acceleration transient. A greater but
appear to be in very good agreement. limited difference can be noticed in the first part of
Figure 6 shows the engine speed variation during the transient and near the switching point.
the acceleration; in this case there is also very good The 2nd TC speed simulation (Fig. 8) shows good
agreement between the experimental and calculated agreement with the experimental values. There is a
results. From the presented results it may be limited overestimation of the speed only during the
observed that, during the transient, the 2nd TC
switching-in point occurs at a greater engine speed
TC switching-in phase. The air receiver pressure pre- pressor map during the considered acceleration
diction during the acceleration transient (Fig. 9) is in transient. The figure points out the good dynamic
good agreement with the experimental data with the performance of the 1st TC during the 2nd TC
exception of the switching-in phase, where the calcu- switching-in phase.
lation does not account for the observed pressure The second engine load variation, which has been
drop. considered for the dynamic model validation, is due
A greater difference between calculated and exper- to a decreasing ramp of engine fuel mass flow, with
imental values is found as far as the exhaust gas consequent engine load and speed decrease from full
receiver pressure is concerned (Fig. 10). In this case, load to about 22 per cent MCR for the power and
in fact, a difference between experimental and calcu- from 100 to 60 per cent MCR for the speed. The decel-
lated results already appears before the 2nd TC eration line is very similar to the acceleration line
switching-in point (see Fig. 5), while a better agree- reported on the engine map in Fig. 4, but it is obvi-
ment is reached in the final part of the acceleration ously routed the opposite way.
transient. Figure 12 shows a comparison between the exper-
Fig. 11 shows the working line on the 1st TC com- imental and calculated turbine and compressor
switching valve positions (respectively V1 and V2 in
Fig. 1) during the transient. As already stated, for the
2nd TC disconnection, the switching valve phase dif-
ference is not necessary. In Fig. 12 the position of the
switching valves V1 and V2 is thus reported by
means of a unique curve, which gives good agree-
ment between the experimental and calculated
values. For the engine speed prediction during the
transient (Fig. 13) good agreement with the exper-
imental data is also obtained.
Fig. 9 Acceleration transient, air receiver pressure. Turbocharger speed variations are reported in
Figs 14 and 15. Both figures show good agreement
between the experimental and calculated values.
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