Top Banner

of 30

Turbo System 2

Apr 10, 2018

ReportDownload

Documents

  • 8/8/2019 Turbo System 2

    1/30

    Turbo System Optimization

  • 8/8/2019 Turbo System 2

    2/30

    2

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Outline

    1. Turbobygarrett.com Website

    2. Application Information

    3. Turbo Match

    4. System ComponentsAir Filter

    Oil Supply & Drain

    Water LinesCharge Tubing & Charge-Air-Cooler

    BOV

    Wastegate

    5. Common Causes of Oil Leakage6. System Testing/Monitoring

    7. 11-Point Checklist

  • 8/8/2019 Turbo System 2

    3/30

    3

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Turbobygarrett.com Website

    Product information FAQS Tech Tutorials

    - 101 (Basic) Turbo system basics, turbo components, etc.- 102 (Advanced) Wheel trim, housing A/R, manifold types,

    compression ratio with boost, etc.- 103 (Expert) Pressure ratio, mass flow rate, compressor

    map details and formulas required to plot operating pointson a compressor map

    News & Events Distributor Locator

    W e b si t e co n t a in s b o t h g e n e r a l an d t e ch n i ca l in f o r m a t i o n

  • 8/8/2019 Turbo System 2

    4/30

    4

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Application Information

    Understand the intended use of the vehicle;drag, road racing, rally, drifting, street driven,etc.

    Have a target flywheel horsepower in mind

  • 8/8/2019 Turbo System 2

    5/30

    5

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Turbo Match

    Go to www.turbobygarrett.com Click on Turbo Tech Read Turbo Techs 101, 102 and 103.

    Using formulas in Turbo Tech 103, calculate mass flowand pressure ratio (PR) at redline for your specificapplication.

    Plot mass flow and PR on several compressor maps todetermine the best fit.

    For the example in this presentation, the application willbe a 400 flywheel hp street car using pump gas, thereforethe estimated mass flow ~ 40 lbs/min

  • 8/8/2019 Turbo System 2

    6/30

    6

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Air Filter

    Important to appropriately size the air filter for themaximum flow rate of the application

    Target face velocity of 130 ft/min at redline to

    minimize restriction Excessive restriction can cause:

    - Oil leakage from the compressor side piston ring, which

    results in oil loss, a fouled CAC and potentially smoke outof the tailpipe.

    - Increased pressure ratio, which can lead to turbooverspeed.

    - Overspeed will reduce turbo durability and could result inan early turbo failure.

  • 8/8/2019 Turbo System 2

    7/30

    7

    H O N E Y W

    E L L

    H O N E Y W

    E L L - -P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Air Filter

    How do we determine the correct air filter size?

    Example:

    Face Velocity = 130 ft/minMass Flow = 40 lbs/minAir density = 0.076 lbs/ft 3

    Mass Flow (lbs/min) = Volumetric Flow Rate (CFM) x Air Density (lbs/ft3)

    Volumetric Flow Rate (CFM) = Mass Flow (lbs/min)Air Density (lbs/ft 3)

    Volumetric Flow Rate = 526 CFM

    Fo r Tw i n - Tu r b o A p p l i ca t i o n s Di v i d e Th e Fl o w Ra t e B y 2

  • 8/8/2019 Turbo System 2

    8/30

    8

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T A

    R Y

    P R O P R

    I E T A R Y

    Air Filter

    Face Velocity (ft/min) = Volumetric Flow rate (CFM)Area (ft 2)

    Area (ft 2) = Volumetric Flow rate (CFM)Face Velocity (ft/min)

    Area (ft 2) = 526 / 130 = 4.05

    Area (in 2) = 4.05 x 144

    Area = 582 in 2

  • 8/8/2019 Turbo System 2

    9/30

    9

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Air Filter

    How do we determine the correct air filter sizeknowing the calculated area ( 582 in 2)?

    Example:

    Pleat Height = 9.00 in.Pleat Depth = 0.55 in.# of Pleats = 60

    Area (in 2) = pleat height x pleat depth x # of pleats x 2

    Area (in 2) = 9.00 x 0.55 x 60 x 2

    Area = 594 in2

    Actual Filter Area ( 594 in 2) > Calculated Area ( 582 in 2)

    Flow 526 ft^3/min

    # of Pleats Pleat Height Pleat Depth Area (in^2) Face Velocity (fpm)50 8.00 0.55 440 17260 9.00 0.55 594 12860 10.00 0.55 660 11560 10.50 0.55 693 109

    - input value

  • 8/8/2019 Turbo System 2

    10/30

    10

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Oil Supply (Journal-bearing Turbo)

    Journal-bearings function similar to rod or crank bearings in anengine - oil pressure is required tokeep components separated.

    Oil restrictor is generally notneeded except for oil-pressureinduced leakage.

    Recommended oil feed is -4AN or hose/tubing with an ID of ~ 0.25. Use an oil filter that meets or

    exceeds the OEM specifications.

    Oi l Re st r i c t o r I s Ge n e r a l l y N o t N e ed e d

  • 8/8/2019 Turbo System 2

    11/30

    11

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Oil Supply (Ball-bearing Turbo)

    Oil restrictor is recommended for optimalperformance.

    Recommended oil pressure is 40 45 psiat maximum engine speed.

    Normally translates to a restrictor with0.040 orifice. Always verify oil pressure entering the

    turbo after the restrictor. OIL LEAKAGE SHOULD NOT OCCUR ON

    A PROPERLY FUNCTIONING SYSTEM IFRESTRICTOR IS NOT USED UNLESS THESYSTEM PRESSURE IS EXCESSIVELYHIGH .

    Recommended oil feed is -3AN or -4ANline or hose/tubing with a similar ID.

    Use an oil filter that meets or exceeds theOEM specifications.

    Oi l Re st r i c t o r I s Re co m m e n d e d

  • 8/8/2019 Turbo System 2

    12/30

    12

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Oil Drain

    Generally -10AN is sufficient but try not to have an IDsmaller than the drain hole in the housing.

    Gravity feed needs to be just that! Oil outlet - direction of gravity +/-35 when installed in

    the vehicle on level ground Turbocharger axis of rotation - parallel to the level

    ground within +/- 15 Avoid:

    - Undulations in the line or extended lengths parallel to theground- Draining into oil pan below oil level- Dead heading into a component behind the oil pan- Area behind the oil pan (windage tray window) where oil

    sling occurs from crankshaft- Scavenge pump should be used if there is not a suitable

    gravity feed option

    Th e L arg e r T h e B et t e r !

  • 8/8/2019 Turbo System 2

    13/30

    13

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Water Lines

    Key design feature for improved durability Eliminates coking by utilizing the Thermal Siphon Effect to

    reduce the Peak Heat Soak Back Temperature at turbine sidepiston after shut-down.

    Avoid undulations in the water lines to maximize the ThermalSiphon Effect

    Hot Water-Out (High)

    Cold Water-In (Low)

    Tilt 20 degrees

    Temperature @ this area

    A lw a y s I n s t a ll Wa t e r L in e s

  • 8/8/2019 Turbo System 2

    14/30

    14

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Water Lines

    Negative degree s:water outlet of center housing is lower than water inlet

    Positive degrees:water outlet of center housing is higher than water inlet

    Se t O r i e n t a t i o n Of Ce n t e r H o u s i n g t o 2 0

  • 8/8/2019 Turbo System 2

    15/30

    15

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Result of No Water Lines

    Bearing retainer meltsand is damaged fromheat soak back

    Bluing on the turbinewheel and turbineside of bearing fromexcessive heat

    D a m a g e To Tu r b o Ca n O cc u r Fr o m W a t e r Li n e s N o t Se t - U p P r o p e r l y

  • 8/8/2019 Turbo System 2

    16/30

    16

    H O N E Y W

    E L L

    H O N E Y W

    E L L - - P R

    O P R I E T

    A R Y

    P R O P R

    I E T A R Y

    Diameter (in) Area (ft^2) Flow Velocity (fps)Flow (CFM) 526. 00

Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.