TURBOCHARGER

AND
SUPERCHARGER
INTRODUCTION
• The power out put of an engine depends upon the
amount of air inducted per unit time and the degree of
utilization of this air , and the thermal efficiency of the
engine.
Indicated engine Power
IP=P*L*A*n*K/60000 ……………..(1)
Where, IP= indicated power (kW)
P=indicated mean effective pressure(N/m2)
L=length of stroke
A= area of piston
n= no of power stroke, for 2-s engine-N and for 4-s engine N/2, N= rpm
K= No of cylinders
Three possible methods utilized to increase the air consumption
of an engine are as follows:

Increasing the piston displacement: This increases the size

and weight of the engine, and introduces additional cooling
problems.

Running the engine at higher speeds: This results in

increased mechanical friction losses and imposes greater
inertia stresses on engine parts.

Increasing the density of the charge: This allows a greater

mass of the charge to be inducted into the same volume.
 Definition
The most efficient method of increasing the power of an engine is by
supercharging, i.e. increasing the flow of air into the engine to enable more
fuel to be burnt.
• A Supercharger is run by the mechanical drive, powered by engine power .
• A turbocharger uses the otherwise unused energy in the exhaust gases to
drive a turbine directly connected by a co-axial shaft to a rotary compressor
in the air intake system.
 COMPRESSED
AIR

Air inlet

Fig.1 Supercharger
Types

Fig. 2 Turbocharger
Need of turbocharger and super charger

• For ground installations, it is used to produce a gain in the power out

put of the engine.

• For aircraft installations, in addition to produce a gain in the power

out put at sea-level, it also enables the engine to maintain a higher
power out put as altitude is increased.
Components of Turbocharger

The turbocharger has three main components:

• The turbine, which is almost always a radial flow
turbine.
• The compressor, which is almost always a centrifugal
compressor. The compressor increases the mass of
intake air entering the combustion chamber. The
compressor is made up of an impeller, a diffuser and a
volute housing.
• The center housing/hub rotating assembly
Working principle of a turbocharger

• A turbocharger is a small radial fan pump driven by the

energy of the exhaust gases of an engine.
• A turbocharger consists of a turbine and a compressor on
a shared shaft.
• The turbine converts exhaust to rotational force, which is in
turn used to drive the compressor.
• The compressor draws in ambient air and pumps it in to the
intake manifold at increased pressure, resulting in a greater
mass of air entering the cylinders on each intake stroke.
Where the turbocharger is located in the car

FIG. 5
Turbocharged engine with Reservoirs
Additional technologies commonly used in
turbocharger installations
Additional technologies commonly used in
turbocharger installations

• Intercooling
• When the pressure of the engine's intake air is increased, its temperature also
increases. This occurrence can be explained through Gay-Lussac's law, stating
that the pressure of a given amount of gas held at constant volume is directly
proportional to the Kelvin temperature.With more pressure being added to the
engine through the turbocharger, overall temperatures of the engine will also rise.
In addition, heat soak from the hot exhaust gases spinning the turbine will also
heat the intake air. The warmer the intake air, the less dense, and the less oxygen
available for the combustion event, which reduces volumetric efficiency. Not only
does excessive intake-air temperature reduce efficiency, it also leads to engine
knock, or detonation, which is destructive to engines.
• To compensate for the increase in temperature, turbocharger units often make use
of an intercooler between successive stages of boost to cool down the intake air.
A charge air cooler is an air cooler between the boost stage(s) and the appliance
that consumes the boosted air.
Additional technologies commonly used in
turbocharger installations
Additional technologies commonly used in
turbocharger installations

• Top-mount (TMIC) vs. front-mount intercoolers (FMIC)

• There are two areas on which intercoolers are commonly mounted. It can be either mounted
on top, parallel to the engine, or mounted near the lower front of the vehicle. Top-mount
intercoolers setups will result in a decrease in turbo lag, due in part by the location of the
intercooler being much closer to the turbocharger outlet and throttle body. This closer
proximity reduces the time it takes for air to travel through the system, producing power
sooner, compared to that of a front-mount intercooler which has more distance for the air to
travel to reach the outlet and throttle.
• Front-mount intercoolers can have the potential to give better cooling compared to that of a
top-mount. The area in which a top-mounted intercooler is located, is near one of the hottest
areas of a car, right above the engine. This is why most manufacturers include large hood
scoops to help feed air to the intercooler while the car is moving, but while idle, the hood
scoop provides little to no benefit. Even while moving, when the atmospheric temperatures
begin to rise, top-mount intercoolers tend to underperform compared to that of a front-
mount intercooler. With more distance to travel, the air circulated may have more time to
cool and is located away from high temperature locations of the car, front-mount
intercoolers can provide more beneficial cooling compared to that of a top-mount
intercooler
Additional technologies commonly used in
turbocharger installations

• Water injection
An alternative to intercooling is injecting water into the intake air to
reduce the temperature. This method has been used in automotive and
aircraft applications.
• Wastegate
• A wastegate regulates the exhaust gas flow that enters the exhaust-side driving
turbine and therefore the air intake into the manifold and the degree of boosting.
It can be controlled by a boost pressure assisted, generally vacuum hose
attachment point diaphragm (for vacuum and positive pressure to return
commonly oil contaminated waste to the emissions system) to force the spring-
loaded diaphragm to stay closed until the overboost point is sensed by the ecu or
a solenoid operated by the engine’s electronic control unit or a boost controller,
but most production vehicles use a single vacuum hose attachment point spring-
loaded diaphragm that can alone be pushed open, thus limiting overboost ability
due to exhaust gas pressure forcing open the wastegate.
 Additional technologies commonly used in
turbocharger installations
• Anti-surge/dump/blow off valves
• Turbocharged engines operating at wide open throttle and high rpm require a large
volume of air to flow between the turbocharger and the inlet of the engine. When the
throttle is closed, compressed air flows to the throttle valve without an exit (i.e., the
air has nowhere to go).
• In this situation, the surge can raise the pressure of the air to a level that can cause
damage. This is because if the pressure rises high enough, a compressor
stall occurs—stored pressurized air decompresses backward across the impeller and
out the inlet. The reverse flow back across the turbocharger makes the turbine shaft
reduce in speed more quickly than it would naturally, possibly damaging the
turbocharger. To prevent this from happening, a valve is fitted between the
turbocharger and inlet, which vents off the excess air pressure. These are known as an
anti-surge, diverter, bypass, turbo-relief valve, blow-off valve (BOV), or dump valve.
It is a pressure relief valve, and is normally operated by the vacuum from the intake
manifold
Additional technologies commonly used in
turbocharger installations

• Anti-surge/dump/blow off valves

• The primary use of this valve is to maintain the spinning of the turbocharger at a
high speed. The air is usually recycled back into the turbocharger inlet (diverter or
bypass valves), but can also be vented to the atmosphere (blow off valve).
Recycling back into the turbocharger inlet is required on an engine that uses a
mass-airflow fuel injection system, because dumping the excessive air overboard
downstream of the mass airflow sensor causes an excessively rich fuel mixture—
because the mass-airflow sensor has already accounted for the extra air that is no
longer being used. Valves that recycle the air also shorten the time needed to re-
spool the turbocharger after sudden engine deceleration, since load on the
turbocharger when the valve is active is much lower than if the air charge vents to
atmosphere.
Additional technologies commonly used in
turbocharger installations

• Anti-surge/dump/blow off valves

Selection process of turbocharger

• The concept of turbocharger is illustrated in Figure 7.

•Compressor air inlet,Point1- p1,

T1
•Compressor air out let, point2-
p2, T2
•Turbine exhaust gas inlet, point
3-p3,T3
•Turbine exhaust gas outlet-
P4, T4

Illustration of the concept of a turbocharger.

 Terms essential for turbocharger selection

Air Consumption and Air-Delivery Ratio:

…………………….(4)
Where
mat = theoretical air consumption rate, kg/h atm &
De = engine displacement, L
Ne = engine speed, rpm
ρa = density of air entering compressor, kg/m3

The air-delivery ratio is the ratio of the measured over the theoretical air
consumption of an engine:

…………………..(5)

where
ev = air-delivery ratio
mat= theoretical air consumption of the engine, kg/h
ma= actual air consumption of the engine, kg/h
 • A turbocharger air delivery ratio.

……………………(5)

•The turbine pressure ratio is defined as , κpt = p3 / p4

……………….(6)
• Pressure ratio across the compressor, κpc, as

………………….(7)

•The temperature ratio across the compressor

……………………..(8)

Where ec = compressor efficiency, decimal.

• The compressor efficiency = ( theoretical temperature rise across the
compressor)/(the actual temperature rise). ec is always less than 1.0.

• The turbine efficiency = ( the actual temperature drop across the

turbine )/(the theoretical temperature drop). The turbine efficiency is
also always less than 1.0.
• The following procedure may be used in selecting a turbocharger for an
engine.
1. Select the desired, achievable power output, Pb; verify that the
chosen power level does not require an excessive pbme. Realistically,
pbme ≤ 1250 kPa is achievable.
2. Calculate mf = Pb × BSFC, using an achievable value for BSFC.
Typically, for a well-designed engine, it is possible to achieve , 0.2 <
BSFC < 0.25 kg/kW h.
3. Calculate ma = mf× (A/F), using the desired A/F ratio of the
turbocharged engine. For a CI engine running on diesel fuel, typically
25 < (A/F) < 32.
4. Select the compressor and the point on the compressor map (see
Figure 8 for an example map) at which the compressor will operate at
rated load and speed of the engine. Equations 3 through 4 can be
reworked into
Performance curve

9
5. Select the turbine and the operating point on the turbine map. The turbine and
compressor must rotate at the same speed, the turbine flow must equal the compressor
flow times , and the turbine must supply enough power to drive the compressor while
overcoming bearing friction.

The mechanical efficiency of the turbocharger

…………………..(9)
 Advantages of supercharger and turbocharger
• The more increase the pressure of the intake air above the local atmospheric pressure
(boost), the more power the engine produces. Automotive superchargers for street use
typically produce a maximum boost pressure between 0.33 to 1.0 bar , providing a
proportionate increase in power.

• Engines burn air and fuel at an ideal (stoichiometric) ratio of about 14.7:1, which means
that if you burn more air, you must also burn more fuel.

• This is particularly useful at high altitudes: thinner air has less oxygen, reducing power
by around 3% per 1,000 feet above sea level, but a supercharger can compensate for that
loss, pressurizing the intake charge to something close to sea level pressure.
Disadvantages of turbocharger and
supercharger
• Cost and complexity
• Detonation
• Parasitic losses
• Turbo lag
Applications of Turbocharger
• Petrol-powered cars
The first turbocharged passenger car was the Oldsmobile Jetfire option on
the 1962–1963 F85/Cutlass, which used a turbocharger mounted to a
215 cu in (3.52 L) all aluminum V8. Also in 1962, Chevrolet introduced a special
run of turbocharged Corvairs, initially called the Monza Spyder (1962–1964)
and later renamed the Corsa (1965–1966), which mounted a turbocharger to
its air cooled flat six cylinder engine. This model popularized the turbocharger
in North America—and set the stage for later turbocharged models from
Porsche on the 1975-up 911/930, Saab on the 1978–1984 Saab 99 Turbo, and
the very popular 1978–1987 Buick Regal/T Type/Grand National. Today,
turbocharging is common on both diesel and gasoline-powered cars.
Turbocharging can increase power output for a given capacity or increase fuel
efficiency by allowing a smaller displacement engine. The 'Engine of the year
2011' is an engine used in a Fiat 500 equipped with an MHI turbocharger. This
engine lost 10% weight, saving up to 30% in fuel consumption while delivering
the same HP (105) as a 1.4 litre engine.
Applications of Turbocharger

• Diesel-powered cars
The first production turbocharger diesel passenger car was the
Garrett-turbochargedMercedes 300SD introduced in 1978.Today, most
automotive diesels are turbocharged, since the use of turbocharging
improved efficiency, driveability and performance of diesel
engines, greatly increasing their popularity. The Audi R10 with a diesel
engine even won the 24 hours race of Le Mans in 2006, 2007 and
2008.
Applications of Turbocharger
Applications of Turbocharger

• Motorcycles
The first example of a turbocharged bike is the 1978 Kawasaki Z1R
TC.Several Japanese companies produced turbocharged high-
performance motorcycles in the early 1980s, such as the CX500 Turbo
from Honda- a transversely mounted, liquid cooled V-Twin also
available in naturally aspirated form. Since then, few turbocharged
motorcycles have been produced. This is partially due to an abundance
of larger displacement, naturally aspirated engines being available that
offer the torque and power benefits of a smaller displacement engine
with turbocharger, but do return more linear power characteristics.
The Dutch manufacturer EVA motorcycles builds a small series of
turbocharged diesel motorcycle with an 800cc smart CDI engine
Applications of Turbocharger

• Trucks
The first turbocharged diesel truck was produced by Schweizer
Maschinenfabrik Saurer (Swiss Machine Works Saurer) in 1938.
 Type of Compressor.

1.Centrifugal 2. Vane type

type

3. Root’s type
FIG.3
•1
•2