International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 8, Issue 4, Aug 2018, 109-116
© TJPRC Pvt. Ltd

TURBOCHARGER MATCHING FOR TWO CYLINDER CONSTANT

SPEED DIESEL ENGINE WITH UNEVEN FIRING ORDER

THAMARAIKANNAN. M1, S. JAICHANDRAN2, RUPESH. PL3 & K. LOGESH4

1
Research Scholar, Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala
R & D Institute of Science and Technology, Chennai, Tamil Nadu, India
2
Department of Automobile Engineering, Vel Tech Rangarajan Dr. Sagunthala R & D Institute of
Science and Technology, Chennai, Tamil Nadu, India
3,4
Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R & D Institute of
Science and Technology, Chennai, Tamil Nadu, India
ABSTRACT

The major challenge that is faced by most of the engine manufacturers nowadays is to meet the stringent
emission norms with least modification in the engine design. In achieving the emission norms simplicity of the design has
to be maintained as far as possible by optimizing the available emission control techniques. This project deals with such
optimal technique with reduced cost to meet CPCB II in minimum time with minimum design changes.

Original Article
In this work, Turbocharger matching is done for an uneven firing order Engine that involves the selection of
compressor and turbine based on the airflow requirements to meet the required performance and emission.
The major challenge is to match the turbocharger for uneven firing order engine where the exhaust flow rate will have
pulsation effect. In spite of variations in the exhaust flow, Airflow variation from Turbocharger is kept within 10 kg/h.

KEYWORDS: Turbocharger, Mapping, CPCB II & Uneven Firing

Received: May 30, 2018; Accepted: Jun 18, 2018; Published: Jun 28, 2018; Paper Id.: IJMPERDAUG201812

INTRODUCTION

The significant test that is looked at by the greater part of the engine makers these days is to meet the
stringent emanation standards with minimum change in the engine design. In accomplishing the outflow standards
effortlessness of the plan must be kept up beyond what many would consider possible by enhancing the accessible
discharge control systems. In accomplishing the outflow standards effortlessness of the plan must be kept up
beyond what many would consider possible by improving the accessible emission control procedures.

Turbocharger mapping is a tedious procedure and there is a requirement for an orderly procedure that can
be executed naturally. A engine and test cell control structure that can be utilized to robotize and screen the
estimations by controlling the framework to the coveted working focuses is likewise proposed. In tests, utilized for
developing the compressor speed lines, it is for all intents and purposes difficult to control the turbocharger to the
correct redressed speed that is hypothesized by the speed line.

Turbocharger matching involves the selection of compressor and turbine based on the airflow requirements
to meet the required performance and the emission.

www.tjprc.org SCOPUS Indexed Journal [email protected]

110 Thamaraikannan. M, S. Jaichandran, Rupesh. PL & K. Logesh

The main challenge is to match the turbocharger for uneven firing order engine where the exhaust flow rate will
have which will further affect pulsation effect the air flow to fluctuate. In this project, our aim is to provide the required
with max. Fluctuation of 10kg/hr.

EXPERIMENTAL SETUP

A genuine overwhelming obligation diesel engine, type-h2 with ostensible power 30 kW is utilized as a part of the
test ponder. The exploratory setup incorporates estimating instrumentation used to get the engine execution. The detail of
this engine is a two– barrel, in line, water cooled, of 106 and 110 mm bore and stroke, individually, with the evaluated
yield is 30 KW at 1500 rpm. The engine was joined in revise arrangement with the dynamometer; this helps enduring
running and takes out the vibration. Outer stacking is completed by a Froude water powered dynamometer (type D. P .Y).
A cardan shaft with two general joints and of an outline which counteracts spinning was given to interface the
dynamometer to the engine. The dynamometer is utilized to gauge the engine torque with a mechanical scale.
This dynamometer is guaranteed to be exact to inside ± 0.025% of ostensible rating. All engine liquid temperatures are
checked to utilize K-type thermocouples. The engine has arrangements for differing the fuel infusion timing.
High exactness, high determination, high weight territory up to 6000 psig and Low-run flow meter (FTB500 Series) was
utilized for deciding the fuel utilization of the engine amid tests. Weight drop as per whole stream meter is utilized to
quantify the air conveyed to the engine. This opening plate is fixed before gulf of the compressor with long separation to
guarantee the relentless stream of air. Engine speed (rpm) was estimated by toothed rigging and attractive get mix
introduced on the engine yield shaft. Be that as it may, the turbocharger speed needs to develop unique circuit comprise of
sender and recipient to account the pole pivot. Engine coolant temperature was controlled by warm exchanger tower
framework which was intended to thermostatically set and hold a predefined coolant outlet temperature. A test reassures
contain the dynamometer controls alongside customary gages for showing engine oil weight, engine speed, water weight
too and out the dynamometer, furthermore, the temperatures of delta and outlet water of the engine and the dynamometer,
and fumes gases temperatures. Furthermore, the weight and temperature esteem in the most significant areas along the
admission and fumes framework, and in addition of high recurrence weight information at similar areas are identified.
Likewise, the in barrel high weight sensor (ICP-Model 113B22-up to 350 Pa) is fitted into the engine cylinder to measure
the pressure in the cylinder.

DATA ACQUISITION SYSTEM

The signs from the weight transducers, optical sensors and thermocouples, engine speed and wrench edge of pivot
sensors were digitized and recorded in PC with the assistance of Lab View programming for later investigation utilizing an
information procurement card NI display M arrangement multifunction DAQ for USB - 16 Bit, 250 KS/s, up to 80 simple
information. This product is planned, extraordinarily, to incorporate the information from all estimating gadgets and
sensors and present it in PC window. The utilized programming bundle has been created in visual essential to mechanize
the estimating and revealing methods. Estimating the wrench edge hint of the weight inside the engine chamber is for the
most part, a critical target. The program might be utilized for the concurrent estimations up to 8 differential signs.
Likewise, the product is intended to figure another parameter, for example, in-barrel temperature, fuel consumption rate
and warmth discharge rate with the help of the estimating information.

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11
Turbocharger Matching for Two Cylinder Constant 111
Speed Diesel Engine with Uneven Firing Order

Figure 1: Outline of H2 Engine

Table 1: Specification of the Engine

Engine 2cyl. Inline 1.9L TCIC Engine
Bore 106
Stroke 110
Displacement 1.9L
Power rating 30kw@1500rpm
Application 30kvA Genset engine
FIE Mechanical inline pump
Firing order 1-2(0°-540°)
No. of valves/cylinder 2valves

RESULTS AND DISCUSSIONS

Obviously a turbo machine is not preferably suited to work in conjunction with a responding machine,
consequently, the blend diesel engine and turbocharger must be arranged mind. Coordinating of the right turbocharger to a
diesel engine is of incredible significance and is crucial for the fruitful activity of a turbocharged diesel engine.

Three different types of compressors 1570, 1672, 1367 and two turbines KP35 and TR43 were considered for this
study.

Table 2: Compressor Mapping for 1570

Input
Pressure Drop Pressure Drop
Speed Torque Power SFC P4
across Filter T1 °C T3 °C across CAC AFR
rpm Nm kW g/kWh mbar
in mbar mbar
1500 190.0 29.8 240 30 25 600 25 50 26
1500 142.5 22.4 230 22 25 560 20 40 28
1500 95.0 14.9 270 16 25 520 15 25 32
1500 47.5 7.5 295 8 25 490 10 15 40
1500 19.0 3.0 320 2 25 450 10 5 75

The compressor mapping is carried with the input data as shown in table. The values of Airflow, Fuel flow, P1,
P2, T2, T2’were calculated and is plotted in the table. And these values are plotted in the Compressor map as shown in
figure 2. This procedure repeated for the compressors 1672, and1367.

www.tjprc.org SCOPUS Indexed Journal [email protected]

112 Thamaraikannan. M, S. Jaichandran, Rupesh. PL & K. Logesh

Table 3: Compressor Value 1570

1570 Compressor
Compressor
Volume Flow Compressor
Fuel Flow Mass Airflow P1 Efficiency P2 P2' T2 T2" Me
Rate of Air P2/P1 Power
kg/h kg/h bar Initial bar bar K K kg/h
m3/s kW
Assumption
7.2 186.1 0.04559 0.97000 74% 1.9 1.843 1.793 358 379 193.2984 4.21
5.1 144.1 0.03500 0.97800 70% 1.7 1.6626 1.6226 347 368 149.2246 2.80
4.0 128.9 0.03111 0.98400 68% 1.6 1.5744 1.5494 341 361 132.8927 2.27
2.2 88.0 0.02107 0.99200 62% 1.4 1.3888 1.3738 328 347 90.19846 1.19
1.0 71.6 0.01704 0.99800 60% 1.3 1.2974 1.2924 321 337 72.54656 0.77

Figure 2: Compressor Map

Table 4: Compressor Mapping for 1672

Input
Pressure Drop Pressure Drop
Speed Torque Power SFC P4
across Filter T1 °C T3 °C across CAC AFR
rpm Nm kW g/kWh mbar
in mbar mbar
1500 190.0 29.8 240 30 25 600 25 50 26
1500 142.5 22.4 230 22 25 560 20 40 28
1500 95.0 14.9 270 16 25 520 15 25 32
1500 47.5 7.5 295 8 25 490 10 15 40
1500 19.0 3.0 320 2 25 450 10 5 75

Table 5: Compressor Value for 1672

1672 Compressor
Compressor
Volume Flow Compressor
Fuel Flow Mass Airflow P1 Efficiency P2 P2' T2 T2" Me
Rate of Air P2/P1 Power
kg/h kg/h bar Initial bar bar K K kg/h
m3/s kW
Assumption
7.2 186.1 0.04559 0.97000 70% 1.6 1.552 1.502 341 359 193.2984 3.18
5.1 144.1 0.03500 0.97800 68% 1.5 1.467 1.427 335 352 149.2246 2.16
4.0 128.9 0.03111 0.98400 65% 1.4 1.3776 1.3526 328 344 132.8927 1.66
2.2 88.0 0.02107 0.99200 60% 1.2 1.1904 1.1754 314 325 90.19846 0.65
1.0 71.6 0.01704 0.99800 60% 1.2 1.1976 1.1926 314 325 72.54656 0.53

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11
Turbocharger Matching for Two Cylinder Constant 113
Speed Diesel Engine with Uneven Firing Order

Figure 3: Compressor Map

Table 6: Compressor Mapping for 1367

Input
Pressure Drop Pressure Drop
Speed Torque Power SFC P4
across Filter T1 °C T3 °C across CAC AFR
rpm Nm kW g/kWh mbar
in mbar mbar
1500 190.0 29.8 240 30 25 600 25 50 26
1500 142.5 22.4 230 22 25 560 20 40 28
1500 95.0 14.9 270 16 25 520 15 25 32
1500 47.5 7.5 295 8 25 490 10 15 40
1500 19.0 3.0 320 2 25 450 10 5 75

Table 7: Compressor Value 1367

1367 Compressor
Compressor
Volume Flow Compressor
Fuel Flow Mass Airflow P1 Efficiency P2 P2' T2 T2" Me
Rate of Air P2/P1 Power
kg/h kg/h bar Initial bar bar K K kg/h
m3/s kW
Assumption
7.2 186.1 0.04559 0.97000 72% 2.2 2.134 2.084 373 403 193.2984 5.43
5.1 144.1 0.03500 0.97800 74% 1.8 1.7604 1.7204 352 372 149.2246 2.96
4.0 128.9 0.03111 0.98400 72% 1.62 1.59408 1.56908 342 359 132.8927 2.20
2.2 88.0 0.02107 0.99200 68% 1.3 1.2896 1.2746 321 332 90.19846 0.84
1.0 71.6 0.01704 0.99800 64% 1.2 1.1976 1.1926 314 323 72.54656 0.50

Compressor Map

Figure 4: Compressor Map

www.tjprc.org SCOPUS Indexed Journal [email protected]

114 Thamaraikannan. M, S. Jaichandran, Rupesh. PL & K. Logesh

Turbine Mapping

The Turbine Mapping is carried for the 1367(compressor) values as shown in table 7. Considering for KP35
Turbine. work of turbine (WT) is calculated by using the relation Work of compressor (WC) = work of turbine (WT) and is
shown in table 8

Table 8: Turbine Values for KP35

Considering KP35 Turbine

Turbine
EGR % P3/P4 P3 Mp
Efficiency

62% 20% 2.45 2.51 0.63

62% 20% 1.90 1.95 0.61
60% 18% 1.75 1.80 0.58
57% 12% 1.37 1.40 0.49
55% 5% 1.26 1.29 0.42

Figure 5: Turbine Map

Turbine Values TR43

The Turbine Mapping is carried for the 1367(compressor) values as shown in table 7. Considering for KP43
Turbine. work of turbine (WT) is calculated and plotted in table 9

Table 9: Turbine Values TR43

Considering TR43 Turbine

Turbine
EGR % P3/P4 P3 Mp
Efficiency

62% 20% 2.45 2.51 0.63

62% 20% 1.90 1.95 0.61
60% 18% 1.75 1.80 0.58
57% 12% 1.37 1.40 0.49
55% 5% 1.26 1.29 0.42

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11
Turbocharger Matching for Two Cylinder Constant 115
Speed Diesel Engine with Uneven Firing Order

Figure 6: Compressor Map

Figure 7: Best Compressor Match 1367

Figure 8: Best Turbine Match KP35

CONCLUSIONS
Compressor Mapping
Along the three given maps, we have selected the compressor map1367 which has required choke and surge line.
The other two maps were rejected due to the surging and choking.

www.tjprc.org SCOPUS Indexed Journal [email protected]

116 Thamaraikannan. M, S. Jaichandran, Rupesh. PL & K. Logesh

Turbine Mapping

In turbine, we took two types of turbine maps (i.e. KP35 & TR43) for each compressor in all possible
combination. Finally, we came through plotting that KP35 is matching with compressor 1367. The other compressor isn’t
matching with the turbine maps. We successfully concluded our project by matching the compressor 1367 to the turbine
KP35.

REFERENCES

1. Shingne, P., Assanis, D., Babajimopoulos, A., Keller, P. et al., "Turbocharger Matching for a 4-Cylinder Gasoline HCCI
Engine Using a 1D Engine Simulation," SAE Technical Paper 2010-01-2143, 2010, https://doi.org/10.4271/2010-01-2143.

2. Leufven, O. and Eriksson, L., "Engine Test Bench Turbo Mapping," SAE Technical Paper 2010-01-1232, 2010,
https://doi.org/10.4271/2010-01-1232.

3. Tyagi, N., gupta, S., Bhardwaj, P., Gayen, H. et al., "Optimization of GENSET Engine for CPCB- II Norms using Cost
Effective Techniques," SAE Technical Paper 2013-01-2838, 2013, https://doi.org/10.4271/2013-01-2838.

4. Wang, Y. and Gangopadhyay, A., "Exhaust Backpressure Estimation for an Internal Combustion Engine with a Variable
Geometry Turbo Charger," SAE Technical Paper 2009-01-0732, 2009, https://doi.org/10.4271/2009-01-0732.

5. Stoffels, H., Quiring, S., and Pingen, B., "Analysis of Transient Operation of Turbo Charged Engines," SAE Int. J. Engines
3(2):438-447, 2010, https://doi.org/10.4271/2010-32-0005.

6. Kapoor, P., Costall, A., Sakellaridis, N., Hooijer, J. et al., "Adaptive Turbo Matching: Radial Turbine Design Optimization
through 1D Engine Simulations with Meanline Model in-the-Loop," SAE Technical Paper 2018-01-0974, 2018,
https://doi.org/10.4271/2018-01-0974.

7. Mutta, S., Sathiya Narayanan, M., Gupta, P., Nandhakumar, K. et al., "Thermodynamic Study of Turbocharger Matching and
Combustion Optimization for Better Low End Torque and High Speed Power," SAE Technical Paper 2016-28-0015, 2016,
https://doi.org/10.4271/2016-28-0015.

8. Brynych, P., Macek, J., Tribotte, P., De Paola, G. et al., "System Optimization for a 2-Stroke Diesel Engine with a Turbo
Super Configuration Supporting Fuel Economy Improvement of Next Generation Engines," SAE Technical Paper 2014-32-
0011, 2014, https://doi.org/10.4271/2014-32-0011.

9. Brockbank, C., "Application of a Variable Drive to Supercharger & Turbo Compounder Applications," SAE Technical Paper
2009-01-1465, 2009, https://doi.org/10.4271/2009-01-1465.

10. Watel, E., Pagot, A., Pacaud, P., and Schmitt, J., "Matching and Evaluating Methods for Euro 6 and Efficient Two-stage
Turbocharging Diesel Engine," SAE Technical Paper 2010-01-1229, 2010, https://doi.org/10.4271/2010-01-1229.

11. Ismail, M., Costall, A., Martinez-Botas, R., and Rajoo, S., "Turbocharger Matching Method for Reducing Residual
Concentration in a Turbocharged Gasoline Engine," SAE Technical Paper 2015-01-1278, 2015, https://doi.org/10.4271/2015-
01-1278.

12. Shamsderakhshan, M. and Kharazmi, S., "Turbocharger Matching and Assessments of Turbocharger Effect on a Diesel
Engine based on One-Dimensional Simulation," SAE Technical Paper 2014-01-2557, 2014, https://doi.org/10.4271/2014-01-
2557.

13. Zinner, C., Stelzl, R., Schmidt, S., Leiber, S. et al., "Experimental Verification and Drivability Investigations of a Turbo
Charged 2-Cylinder Motorcycle Engine," SAE Technical Paper 2014-32-0112, 2014, https://doi.org/10.4271/2014-32-0112.

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11