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Thesis Submitted by Tomasz Lukasz Duda of the University of Bath Department of Mechanical Engineering August 2017

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Thesis Submitted by Tomasz Lukasz Duda of the University of Bath Department of Mechanical Engineering August 2017 University of Bath PHD Turbocharger performance and surge definition on a steady flow turbocharger test stand Duda, Tomasz Award date: 2017 Awarding institution: University of Bath Link to publication Alternative formats If you require this document in an alternative format, please contact: [email protected] General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal ? Take down policy If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. Download date: 09. Oct. 2021 Turbocharger performance and surge definition on a steady flow turbocharger test stand PhD thesis submitted by Tomasz Lukasz Duda of the University of Bath Department of Mechanical Engineering August 2017 Supervisors: Dr Colin Copeland, Prof. Chris Brace COPYRIGHT Attention is drawn to the fact that copyright of this thesis rests with the author. A copy of this thesis has been supplied on condition that anyone who consults it is understood to recognise that its copyright rests with the author and that they must not copy it or use material from it except as permitted by law or with the consent of the author. If you wish to include copyright material be- longing to others in your thesis, you are advised to check with the copyright owner that they will give consent to the inclusion and public availability online of any of their material in the thesis. If the material is to be copied other than by photocopying or facsimile then the request should be put to the publisher or the author in accordance with the copyright declaration in the volume con- cerned. If, however, a facsimile or photocopy will be included, then it is appropriate to write to the publisher alone for consent. This thesis may be made available for consultation within the University Library and may be photocopied or lent to other libraries for the purposes of consultation with effect from 29.10.17 1 Table of Contents List of Figures ............................................................................................................... 5 List of Tables .............................................................................................................. 13 Acknowledgements ..................................................................................................... 14 Abstract ...................................................................................................................... 15 Abbreviations .............................................................................................................. 17 Nomenclature ............................................................................................................. 18 1. Introduction and fundamentals ................................................................................ 23 1.1 Turbocharging .................................................................................................. 23 1.2 Turbocharger performance ............................................................................... 24 1.3 Compressor performance maps ....................................................................... 24 1.4 Turbine performance maps .............................................................................. 26 1.5 Compressor-turbine matching .......................................................................... 27 1.6 Engine - turbocharger matching ....................................................................... 28 1.7 Exhaust Gas Recirculation ............................................................................... 29 1.7.1 High Pressure Exhaust Gar Recirculation ................................................. 30 1.7.2 Low Pressure Exhaust Gas Recirculation ................................................. 31 2. Thesis objectives .................................................................................................... 33 3. Literature review ..................................................................................................... 34 3.1 Turbocharger test facilities ............................................................................... 34 3.2 Turbocharger performance measurement uncertainty ...................................... 38 3.2.1 Turbocharger performance maps uncertainty analysis based on sensor accuracy and single-sample measurements ...................................................... 39 3.2.2 Heat transfer effects on the turbocharger performance uncertainty ........... 41 3.3 Compressor surge ............................................................................................ 42 3.3.1 Surge definitions ....................................................................................... 42 3.3.2 Surge suppression and performance enhancement methods ................... 43 3.3.3 Compressor surge measurement .............................................................. 54 3.3.4 Compressor surge modelling .................................................................... 55 3.3.5 Surge stabilisation/avoidance ................................................................... 56 3.4 Turbocharger compressor performance with substitute gas ............................. 56 3.4.1 General approach ..................................................................................... 56 3.4.2 LP EGR – an application for compressor operation with substitute gas .... 58 3.4.3 Correction procedures for ratio of specific heats and gas constant ........... 61 2 4. Turbocharger test stand facility development .......................................................... 62 4.1 Turbocharger gas stand modules ..................................................................... 62 4.1.1 Turbine feed module ................................................................................. 62 4.1.2 Compressor module.................................................................................. 63 4.1.3 Lubrication module ................................................................................... 65 4.1.4 Bearing housing/compressor cooling module ............................................ 66 4.2 Turbocharger Maps .......................................................................................... 66 4.2.1 Mapping methodology ............................................................................... 66 4.2.2 Compressor maps .................................................................................... 67 4.2.3 Turbine maps ............................................................................................ 69 4.2.4 Turbomachinery performance measurement ............................................ 71 5. Uncertainty of the turbocharger performance maps ................................................ 72 5.1 Uncertainty of the turbocharger maps with respect to the sensor accuracy ...... 73 5.1.1 Pressure sensors ...................................................................................... 74 5.1.2 Temperature sensors ................................................................................ 76 5.1.3 Flow sensors............................................................................................. 80 5.1.4 Rotational speed sensor ........................................................................... 81 5.1.5 Compressor performance uncertainty ....................................................... 81 5.1.6 Turbine performance uncertainty .............................................................. 92 5.2 Heat transfer related uncertainty of turbocharger maps .................................... 96 5.2.1 Low turbocharger speed data – a comparison between the data obtained experimentally and by map extrapolation ........................................................... 97 5.2.2 3D CHT model of the turbocharger compressor ...................................... 103 5.2.3 Uncertainty of the compressor efficiency based on the heat transfer estimation method ........................................................................................... 110 6. Experimental surge measurement ........................................................................ 115 6.1 Experimental surge measurement methodology in steady-state gas stand conditions – Fox compressor ................................................................................ 115 6.2 Experimental surge measurement methodology in steady-state gas stand conditions – Puma turbocharger compressor. ...................................................... 119 6.3 Experimental surge measurement methodology on-engine conditions ........... 121 6.4 Experimental surge measurement results – Fox turbocharger ........................ 123 6.4.1 Low frequency pressure data analysis .................................................... 124 6.4.2 High frequency pressure data analysis ................................................... 132 6.4.3 Temperature data analysis.....................................................................
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