Chapter twelve

Turbo charging and

Supercharging

1
 Introduction
 Turbocharger
 Turbocharger is basically an air pump driven by the exhaust
gas from the engine.
 Location
 On a carburetted engine, the turbocharger may be installed
in two different ways.
 It may be located between the air cleaner and the
carburettor.
 The turbocharger compresses only air and then forces it
through the carburettor.
 In some engines, it is installed between the carburettor
and the intake manifold.
 All the air-fuel mixture from the carburettor is compressed
by the turbocharger.

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 Introduction cont..
 Purpose
 Turbocharger forces an additional amount of air or air-
fuel mixture into the engine cylinder.
 With more air-fuel to burn, the engine produces more
combustion pressure and hence more engine power.
 On many turbocharged engines, power output is
boosted 30% or more (for example, a 100 horsepower
engine could produce 130 horsepower with a
turbocharger).
 With turbocharger a smaller engine which has good fuel
economy can produce high power when needed.

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4
 Turbocharger
 Construction
 The turbocharger consists of the turbine housing, compressor
housing, center housing, turbine wheel, compressor wheel, full
floating bearings, waste gate valve, actuator, etc.

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 Turbocharger cont…
 Turbine & Compressor Wheels
 The turbine wheel and the compressor wheel are mounted on the
same shaft.
 When the engine is running, the exhaust gases flow from the exhaust
manifold to the turbine wheel.
 They strike the blades of the turbine, spinning it up to 100,000 rpm
or higher.
 Since the compressor is on the same shaft, it also spins at high
speed.
 As the compressor spins, it forces the intake air into the engine
cylinders.
 Since the turbine wheel is exposed directly to the exhaust gases, it
becomes extremely hot and since it rotates at high speeds and must
be heat resistant and durable, it is made of an ultra-heat resistant
alloy.

6
 Turbocharger cont…
 Center Housing
 The center housing supports the turbine and compressor wheels
via the shaft.
 Inside the housing, engine oil is circulated through channels that
are provided for this purpose.
 Also, engine coolant is circulated through coolant channels that are
built into the housing.

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 Turbocharger cont…
 Full-Floating Bearings
 Since the turbine and compressor wheels turn at speeds
of up to 100,000 rpm or higher, full floating bearings
are used to ensure the absorption of vibrations from
the shaft and lubrication of the shaft and bearings.
 These bearings are lubricated by the engine oil and
rotate freely between the shaft and the housing to
prevent seizing during high-speed operation.
 Engine oil is prevented from leaking by two ring
seals or by a mechanical seal and a ring seal fitted to
the shaft.

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 Turbocharger cont…
 Waste Gate Valve & Actuator
 The waste gate valve is built into the turbine housing.
 Its purpose is to reduce the boost pressure when this begins to rise
too high.
 When this valve opens, part of the exhaust gas bypasses the
turbine wheel and flow to the exhaust pipe.
 The opening and closing of the waste gate valve is controlled by the
actuator. Basically, it is a spring loaded diaphragm.
 One side of the diaphragm is connected to the boost pressure of the
compressor by means of tube.
 When the boost pressure goes too high, it forces the diaphragm and
opens the waste gate valve.
 Now some of the exhaust gas bypasses the turbine by flowing
through the waste gate valve.
 This prevents increase in turbine speed, thereby limiting
compressor speed.
 This limits the boost pressure
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 Turbocharger cont…
 Intercooler (or) Charge Air Cooler
 Air gets hot when it is compressed.
 This causes the air to expand and become less dense.
 Heated air contains less oxygen to support
combustion.
 To cool the air and increase its density, most
turbocharged engines have a charge air cooler or
intercooler which is either of the air-cooled type or
water-cooled type.
 This is a radiator like heat exchanger that cools the
air after it has been pressurized.
 At the same time, by lowering the temperature of the
air-fuel mixture, knocking is suppressed, giving
improved driveability and fuel economy
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 Supercharger
The method of increasing the air capacity of an
engine is known as supercharging.
The device used to increase the air density is
known as supercharger.
It is a pressure–boosting device which
supplies air (or mixture )at a higher pressure.
Supercharger is merely a blower or a
compressor that provides a denser charge to
the engine.
11
 Supercharger cont…
There are three type of supercharger
1) Centrifugal type
2) Root’s type
3) Vane type

12
13
 Supercharger cont..
Effect of supercharging
 Higher power output
 Greater induction of charge mass
 Better atomization of fuel
 Better mixing of fuel and air
 Better scavenging of product
 Increased detonation tendency in SI engines
 Smooth operation and reduction in diesel knock
tendency

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Chapter thirteen
Two-stroke engine
Scavenge air and exhaust passages
• Scavenging is the process by which the spent
charges or the remnants of it are displaced from
the cylinder by fresh air blown through it.
• Efficient scavenging is necessary for good
combustion and it also assists in cooling of
cylinder & piston.
• It is essential for the scavenging process that the
air entering the cylinder is at a higher pressure
than the gas in the exhaust manifold.
Scavenge air and exhaust passages
• Scavenge air is supplied to the engine cylinder in
a variety of ways.
• In two stroke engines since the cycle is completed
in one revolution there is a very short time
available for purging the cylinder of exhaust gases
and recharging with fresh air supply.
• The gas exchange process takes place while inlet
and exhaust ports are open and piston is close to
the BDC.
Scavenge air and exhaust passages
• Charge air under pressure is admitted from
inlet ports, uncovered by the downward
moving piston, sweeps through the cylinder
and expels the exhaust gases in front of it.
• Though it is the exhaust ports that is un-
covered first by the piston (resulting in blow
down the gases at the end of the expansion
stroke), a certain amount of mixing of charge
air and gases is unavoidable.
Scavenge air and exhaust passages
• This is minimized by admitting a large charge
of air in excess of cylinder volume, the excess
air being expelled along with the last of the
gases.
• Scavenge air is supplied to large diesel engine
cylinders in variety of ways.
• The following methods have used.
Scavenge air and exhaust passages
• Direct driven reciprocating scavenge pumps.
• Positive displacement rotary blowers also
have been used.
• By exhaust gas turbochargers in case of
supercharged engines.
• These may be alone or assisted at low
revolutions by an auxiliary fan or blower.
• This is the usual method in modern engines.
Scavenge air and exhaust passages
Three methods of scavenging
• Loop scavenging
• Cross scavenging
• Uniflow scavenging( valve) & Uniflow
scavenging ( opposed piston)
 LOOP SCAVENGING
• The charge air flows across the piston crown and
rises up the cylinder on the opposite side, and
loop back when it hits the cylinder head and
finally moves down pushing the gases in the
exhaust ports on the same side as the inlet ports.
• The piston crown is concave to assist in deflecting
the gases upwards as it flows across.
• The inlet port is angled in such a manner that air
is given a swirl during scavenging, thus creating
the needed turbulence for good fuel air mixing &
efficient combustion.
 CROSS SCAVENGING
• The charge air is deflected upwards as it hits the
convex rim of the piston crown, rises up on the same
side of the liner, then passes across the cylinder head
to the opposite side and sweeps down to the exhaust
ports on that side.
• The inlet ports are angled upwards to assist the upward
flow of the charge air.
• In both the above cases a long piston skirt prevents the
leakage of the charge air into the exhaust manifold
when the piston is at TDC.
• The scavenge air efficiency is relatively low because of
the complex gas air interchange.
 UNIFLOW
• Air enters the cylinder through the ports around the
full circumference of the liner at the bottom, flows
upwards right through the cylinder and exits through
the exhaust valve on the cylinder head.
• This system offers the highest scavenging efficiency
and the least mixing of the air & gas.
• High temperature gradient between inlet/exhaust
ports & on either side of the piston is avoided.
• Due the absence of the exhaust ports, liner is simple in
construction. Its lubrication is more effective.
Chapter fourteen
Reciprocating
Compressors
 Introduction
The process of increasing the pressure of air
is called compression, and the device used to
carry out this process is called a compressor.
The source of air is the atmosphere.
Depending upon the pressure requirement the
compression takes place in one or several
stages.
When the air is compressed the volume
decrease causing pressure and temperature to
rise.
 USES OF COMPRESSED AIR
Compressed air is used for a variety of purpose
• For automation and control
• For starting of the engine
• For pressurizing the hydrophore system
• For use in pneumatic tools
• For use in painting operations.
• For general cleaning.
• For soot blowing of the boilers.
 Introduction
CONSTRUCTION DETAILS OF RECIPROCATING
COMPRESSOR
CYLINDER BLOCK
PISTON
CONNECTING RODS
CONNECTING ROD AND BEARINGS
Suction and Delivery Valves
 Types of Air Compressors
1. RECIPROCATING
2. ROTARY
 Types of Air Compressors cont…
 Reciprocating air compressors.
 most commonly used for the production of air .
 Above 7 bars the reciprocating m/c with its more
positive sealing is the only correct selection.
 The reciprocating m/cs limitation is the temperature
caused by compression.
 This allows compression ratio to be 7:1 in each
following stage, with inter-cooling between stages.
 Thus air pressure of say 35 bars gauge can be attained
with a two stage machine.
 Types of Air Compressors cont…
Rotary air compressor
The rotary m/c is limited by gas slip past its
seal and a differential of about 7 bars per stage
is about a limit.
Thus a 5 stage m/c will be required for 30 bars
gauge.
.
 Compression In Stages Has The Following Advantages

The compression ratio at each stage is lower and so

the final temperature is lower. This reduces
problem with lubrication.
The machine is smaller and better balanced.
Water can be drained off at each stage.
Compression better approaches the ideal
isothermal.
It is important that the compressor clearance
volume is kept small as possible
Compression In Stages Has The Following Advantages

To improve volumetric efficiency, as the air

trapped in this space must expand to below
suction pressure before new air can enter.
A clearance is required in order to prevent the
piston striking the cylinder cover when starting
or stopping off load.
This clearance volume is referred to as the
` Bump clearance.`
Schematic diagram two stage air compressor
 2 stage in line compressor
Most modern diesel engines use starting air at
a pressure of about 26-28 bar.
To achieve this a two stage type compressor
would be adequate.
These compressors are generally of the
reciprocating type.
 2 stage in line compressor
This type of compressor has two pistons of
different diameters mounted in line.
After each stage there is a cooler to cool the
compressed air, with provision for drainage.
At each stage safety valve is provided on the
air side and bursting disc on the water side.
Cooling of jacket is done with fresh water and
inter and after coolers with sea water.
 Two stage compressor pressures and
temperatures
Delivery Air
Temperature
Pressure Before the coolers After the coolers
First Stage 4 bar 130 deg. C 35 deg.C
Second stage 26 bar 130 deg. C 35 deg.C
 Air Vessel Mountings
Mountings generally provided are as shown in the
figure below.
Air Vessel
 Removal of Moisture
When air is compressed, water vapor in the air
is also compressed.
The moisture may be held in suspension in
vapor form because of the heat developed.
When the air flows from the compressor, it
begins to cool and the vapor condenses.
This condensation should be removed since
moisture can shorten component life, create
rust, clog air lines.
 Removal of Moisture cont..
 To remove condensed water and contaminants, a filter-
separator is used.
 A filter-separator or “filter” separates solid particles and
water by centrifugal action and then filters additional
impurities out of the airstream by the filter element.
 Operation of an air line filter is simple - air entering the
filter passes through louvers which direct the air into a
swirling pattern.
 Centrifugal force throws the liquid droplets and
particulate matter outward to the inside of the filter
bowl.
 Removal of Moisture cont..
Automatic Drain Traps
 Traps need to be inspected periodically to ensure
that they are not stuck in either the open or closed
position.
 Maintenance is performed properly, on schedule.
 An automatic drain trap stuck in the open position
will leak compressed air; a drain trap stuck in the
closed position will cause condensate to backup
and be carried with the compressed air.
 Removal of Moisture cont..
 The extent to which water vapour is removed
depends upon the final requirement of the air.
 If the requirement is for control system where air
without moisture is needed, the temperature of the
air is lowered below its dew point.
There are basically three types of compressed air
dryers:
(i)Desiccant,
(ii)Chemical
(iii) Refrigerant.