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Technical Brief

A Method for Matching Two-Stage Turbocharger System and Its Influence on Engine Performance

[+] Author and Article Information
Binyang Wu

State Key Laboratory of Engines,
Tianjin University,
Tianjin 300072, China
e-mail: binyang.wu@tju.edu.cn

Zhiqiang Han

School of Automobile and Transportation,
Xihua University,
Chengdu 610035, China
e-mail: 8312862@qq.com

Xiaoyang Yu

State Key Laboratory of Engines,
Tianjin University,
Tianjin 300072, China
e-mail: yxy860701@163.com

Shunkai Zhang

State Key Laboratory of Engines,
Tianjin University,
Tianjin 300072, China,
e-mail: 784047601@qq.com

Xiaokun Nie

State Key Laboratory of Engines,
Tianjin University,
Tianjin 300072, China
e-mail: niexiaokun@tju.edu.cn

Wanhua Su

State Key Laboratory of Engines,
Tianjin University,
Tianjin 300072, China
e-mail: whsu@tju.edu.cn

1Corresponding author.

Contributed by the Turbomachinery Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received April 17, 2017; final manuscript received February 4, 2018; published online February 21, 2019. Assoc. Editor: David L. S. Hung.

J. Eng. Gas Turbines Power 141(5), 054502 (Feb 21, 2019) (8 pages) Paper No: GTP-17-1144; doi: 10.1115/1.4039461 History: Received April 17, 2017; Revised February 04, 2018

Matching of a two-stage turbocharging system is important for high efficiency engines because the turbocharger is the most effective method of exhaust heat recovery. In this study, we propose a method to match a two-stage turbocharging system for high efficiency over the entire range of operational conditions. Air flow is an important parameter because it influences combustion efficiency and heat load performance. First, the thermodynamic parameters of the engine and the turbocharging system are calculated in eight steps for selecting and matching the turbochargers. Then, by designing the intercooler intensity, distribution of pressure ratio, and compressor operational efficiency, it is ensured that the turbochargers not only meet the air flow requirements but also operate with high efficiency. The concept of minimum total drive power of the compressors is introduced at a certain boost pressure. It is found that the distribution of pressure ratio of the high- and low-pressure (LP) turbocharger should be regulated according to the engine speed by varying the rack position of the variable geometry turbocharger (VGT) to obtain the minimum total drive work. It is verified that two-stage turbochargers have high efficiency over the entire range of operational conditions by experimental research. Compared with the original engine torque, low-speed torque is improved by more than 10%, and the engine low fuel consumption area is broadened.

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Figures

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Fig. 1

Two-stage turbocharger configuration

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Fig. 2

Flow chart of process for matching two-stage turbocharger

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Fig. 3

Minimum drive power calculated under ideal operating conditions

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Fig. 4

Effect of intercooler temperature on drive power

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Fig. 7

Drive power distribution under full load condition

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Fig. 8

Torque under full load condition

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Fig. 9

Entire range of operation of the two-stage compressor system: (a) entire range of operation of HP compressor and (b) entire range of operation of LP compressor

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Fig. 5

Effect of efficiency of HP and LP compressors on drive power

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Fig. 6

Full-load operation in the two-stage turbocharger: (a) full-load operation in the HP compressor and (b) full-load operation in the LP compressor

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Fig. 10

Speed/load contour plot depicting BSFC when using two-stage turbocharger

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Fig. 11

Speed/load contour plot depicting percentage improvement in BSFC when using two-stage turbocharger relative to that when using conventional single turbocharger

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