Radial Turbines and Turbocharger PDF

PEMP
RMD510
Design of Radial Turbines &

Turbochargers
Session delivered by:
Prof Q.
Prof.
Q H.
H Nagpurwala
14
@ M S Ramaiah School of Advanced Studies, Bengaluru
Session Objective
PEMP
RMD510
To discuss the design of radial turbines using a
14
procedure based on optimum specific speed

To understand the basic construction and working
of turbochargers
To discuss the design of radial compressor and
radial turbine modules of a typical turbocharger
PEMP
RMD510
Design of Radial Turbine

(Based on Specific Speed)
14
PEMP
RMD510
Radial Turbine Layout and Expansion Process

Nozzle
blades
At rotor
t iinlet
l t
Expansion process in a
radial turbine
At rotor outlet
14
Design Guidelines
PEMP
RMD510
From Euler turbine equation, specific work is given by:
A significant contribution comes
from the first term. For an axial flow turbine,

where U2 = U1, no contribution to the specific work is obtained from this term.
A positive contribution to the specific work is obtained from the second term
when w3 > w2. In fact, accelerating the relative velocity through the rotor is a most
useful aim of the designer as this is conducive to achieving a low loss flow.
The third term indicates that the absolute velocity
y at rotor inlet should be larger
g
than at rotor outlet so as to increase the work input to the rotor.
14
Design Guidelines
The
Th
PEMP
RMD510
nominall design
d
i defined
is
d fi d by
b
relative flow with zero incidence at rotor inlet, i.e. W2 = Cr2, and
axial absolute flow at rotor exit,, i.e. C3 = Cx3
Thus,
with Cw3 = 0 and Cw2 = U2, the specific work for the nominal design is
Spouting Velocity:
The term spouting velocity, C0 (originating from hydraulic turbine practice) is
ddefined
fi d as that
h velocity
l i which
hi h hhas an associated
i d ki
i energy equall to the
h
kinetic
isentropic enthalpy drop from turbine inlet stagnation pressure p01 to the final
exhaust pressure. When no diffuser is used
or
With complete recovery of the exhaust kinetic energy, and with Cw2 = U2,
At the best efficiency point, generally, 0.68 < U2 / C0 < 0.71.
14
Design Guidelines
The
PEMP
RMD510
blades are aligned along the radii for much of their length.
Absolute
flow angle at rotor inlet = Nozzle outlet angle = ~ 70.
Absolute
Ab l
flow
fl angle
l at exducer
d
exit
i = 0.
0
Inlet relative velocity should be aligned to the blade direction at inlet, which
means that it should be radial. However,
this may lead to high aerodynamic loading at the tip

as the blade tips are open, such high pressure loading can not be maintained
Max. efficiency in radial inflow turbines is achieved when inlet flow angle is
modified by the concept of slip or deviation as applied to radial compressors.
The
Th
recommended
d d slip
li correlation
l ti is
i that
th t given
i
by
b Wiesner
Wi
Cu ,1,ac
cos 1
w
1
0.7
C
Z
u ,1,tl
14
Z = number of blades (incl. splitter blades)
1 = blade angle w.r.t

w r t radial direction
Variation of Slip Factor with Z
PEMP
RMD510
The slip factor for radial bladed rotor varies with the number of blades:
14
Number of radial blades

on rotor pperiphery
p y
Slip factor
Cu,11/u1
9
11
13
15
17
19
0.785
0 813
0.813
0.834
0.850
0.862
0.873
Design Data
Inlet temperature
: 1200 K
Inlet pressure
: 300 000 Pa
PEMP
RMD510
Rotor-outlet stagnation pressure : 110 000 Pa

Hot-gas inlet mass flow
: 0.5 kg/s
Fuel/Air ratio
: 0.02
Number of rotor blades
: 13 (radial)
Nozzle outflow angle
: 70 to radial direction
To find: Rotor diameter

Blade axial width at inlet
Rotational speed
14
Inlet Velocity Triangle
act
c1
C1
PEMP
RMD510
W1
Cr,1
r1
Cu,1
u1
14
10
PEMP
RMD510
Inlet Flow Parameters

G
Guess S
Stagnation-to-Stagnation
i
S
i polytropic
l
i efficiency
ffi i
= 0.92
0 92
For 13 blades w= = 0.834
T0, 2
T0,1
p0 , 2
p0,1
cp
p ,c
T0,2 = 961.36 K
Then, T 1080.68 K
c p 1194.64 J/kg K
h 0 C p T 0 285,089 J/kg
act
C1
c1
1 W1
Cr,1
h 0 u12 u1 584.7 m/s

Cu,1 487.6 m/s
C1 518.9 m/s
Cr,1 181.1 m/s
W1 206.4 m/s
14
Cu,1
u1
11
Optimum Specific Speed
Distribution of losses along envelope of

maximum total
total-to-static
to static efficiency
(Rohlik 1968)
14
PEMP
RMD510
Typical performance of radial turbine

(Rohlik 1968)
12
Optimum Specific Speed ( contd.)
PEMP
RMD510
Curves for specific speed for radial flow turbine indicate that the max.
efficiency should reach at non-dimensional Ns of 0.6.
N s,op 0.6
2N Vin
60 h
2N d1 Nd1
u1 r1
60 2
60
2 b1
Vin Cr,1 d1 b1 Cr,1 d1

d1
g c h0 u1
34
Cr,1 d1 b1 d1
2
Ns
2 34
14
13
Rotor Inlet Width to Diameter Ratio
PEMP
RMD510
N s2 3 2u13 N s2 3 2 u1
b1
2 2
d1 d1 C r,1 4 C r,1
tan c,1 u1 C r,1
2 12
b1 N s tan c,1
d1
4
Inserting appropriate design inputs,

inputs we get
b1/d1 = 0.072
Bothh b1 andd d1 can be
B
b determined
d
i d by
b calculating
l l i volume
l
flow
fl rate at
rotor inlet.
C1
0.8843
g c RT0 ,1
14
14
Rotor Inlet Mach Number
PEMP
RMD510
Mach number can be determined

from the following relation or
the figure
g
0.8843
1

2
Cp
M
C

2
1
1
R
Cp
g c RT 0
2
1
M 1 0.815
14
15
Calculation of Density
st,1
0 ,1
2
M1
Cp
1
2
R
C p

R
PEMP
RMD510
0.729
The stagnation density at rotor inlet can be assumed equal to that at nozzle
inlet for this preliminary design
0 ,1 p 0 ,1 RT0 ,1 300 10 3 286 .96 120

0 .8712 kg m 3
st,1 0.
0 6353 kg
k m3
14
16
Rotational Speed
PEMP
RMD510
m C r,1 st,1 d1 b1 C r,1 st,1 d12 b1 d 1

0 .5
d
181.11 0 .6353 0 .072
2
1
d 1 138 .6 mm
b1 9 .98 mm
2 N d 1
u1
60 2
60 u1
N
80 560 rpm
d 1
14
17
PEMP
RMD510
Final Design
Having found the basic geometric
parameters of the rotor (and inlet nozzle
vanes), the blade profiles can be generated by
Inlet
Exit
using analytic equations

using
i commercial
i l software,
f
like
lik
BLADEGEN
The
final design has to be arrived at through

iteration between structural integrity
(considering aerodynamic and thermal
loading) and aerodynamic performance.
Finally, the mechanical design should be
carried out, taking due care of the component
manufacturing
g and assemblyy requirements.
q
14
Nozzle
vane
Exducer
18
PEMP
RMD510
Design of Turbocharger
(Based on Specific Speed)
14
19
Schematic of a Turbocharger
14
PEMP
RMD510
20
Turbocharger Components
14
PEMP
RMD510
21
Working of Turbocharger
14
PEMP
RMD510
22
PEMP
RMD510
Turbocharger Design Data

Compressor
Turbine
1.0
1.04
Inlet stagnation
g
temperature,
p
,K
300 ((T0,1
0 1)
800 ((T0,4
0 4)
Inlet stagnation pressure, N/m2
1*105 (P0,1)
Find Engine back pressure (P0,4)
Outlet static pressure, N/m2
2* 105(Pst,3)
1.2* 105 (Pst,7)
Air
Combustion
Co
bust o products
p oducts 100%
00%
theoretical air
Cp J/(kg K ) & ( Cp /R )
1010 (3.52)
1172 (4084)
Blade angle
g at periphery
p p y
30 (2)
0 (5)
Specific speed, Ns
0.628
--
dhb,1/ dsh,1
0.60
--
0.82 (p,ts,1-3
0.8
p ts 1 3)
0.82 (p,ts,4-7
0.8
p ts 4 7)
Flow angle at rotor exit, c2 (deg)
60
Flow angle at rotor inlet, c1 (deg)
70
Number of rotor blades,

blades Z
17
13
0.96 (p,tt,1-2)
0.96 (p,tt,5-6)
Mass flow rate, kg/s
Fluid
ud
Polytropic
o y op c efficiency
e c e cy
Polytropic efficiency
14
23
Calculations Planes
14
PEMP
RMD510
24
Wiesners Correlation
PEMP
RMD510
This correlation, defining slip factor, , can be used to calculate

the number of blades, Z, in the radial turbine as well as in the
radial
di l compressor.
cos
Cu,1,ac
1
w
1
0
.
7
C
u
u,
1
,tl
tl
Z
14
25
PEMP
RMD510
Compressor Design Calculations
14
26
Compressor Velocity Triangles
PEMP
RMD510
u2
CCu,2,tl
u,2,tl
Cu,2
Outlet Velocity Triangle
Cr,2 W2
c2=60
60
2=30
30
ush,1
Cx,sh,1
x sh 1
14
h1
w,sh,1 Wsh,1
27
Enthalpy Rise
R
C p
p,c,ts
PEMP
RMD510
T0 ,3 p 0 ,3

T0 ,1 p 0 ,1
p 0 ,3 p st,3 when p,c,ts is used
T0 ,3
2 0 .3484 1.2732
T0 ,1
T 0 ,1 3 0 .2732 300 81.95 K
C pc 1010 J/kgK
Therefore,
and
14
h 0 ,1 3 82722 J/kg
g c h0 ,13 3 4 4879 .9
28
Inlet Volume Flow Rate
PEMP
RMD510
Guess inlet axial velocity

First iteration: 110 m/s
Second iteration: 127.3 m/s (all second iteration values are in parenthesis)
Cx
110
0 .375 0 .434
293 .41
g c RT 0 ,1
For C p R 3 .52 , M 1 0 .32 0 .371

C p R 1
2
0
M
st
Cp
1
2
1.0520 1.0703
14
From slide 15
29
Rotational Speed
PEMP
RMD510
p0 ,1
105
1.1616 kg/m3
0 ,1
R T0 ,1 286.96 300
st,1 1.1042 kg/m3 ( 1.0853 )
m V
st,1 1
V1 0.9056 m 3 /s V1 0.9516
V 0.9214 m /s,
V1 0.9599
60 N s g c h0
N
2 V
30767 rev/min 30500
34
14
30
Compressor Outlet Velocity Diagram
PEMP
RMD510
u2
From Wiesners correlation (slide 25)
CCu,2,tl
u,2,tl
Cu,2
cos 2
Cu,ac
w 1
0.872
0 .7
Cu,tl
Z
Cr,2 W2
c2=60
2=30
For cos 2 cos 30 , Z 17

1
1
Cu,2 tan 2
1
0.676
u2
tan c 2 w
0 .5
g c h0
82772
u2

0.676

d 2 60 u2 /N 219.2 mm
14
0 .5
350.0 m/s
/
31
PEMP
RMD510
Inlet Velocity Diagram

Th procedure
The
d
to
t select
l t minimum
i i
Wsh,1 is
i as follows
f ll
1. Choose a value of d sh,1
2 Calculate u sh,1 N / 60d sh,1

2.
2
2
3. Calculate Aa d sh,
1 / 4 1 0.6
4 Calculate m RT0 ,1 /Aa p0 ,1

4.
2
m RT0 /g
/ c
M
M
1
5. from the relation
AP0
Cp
R
1
1
2
calculate M1
Cp
R
6. Calculate pst,1 /p0 ,1 pst,1 C x,1 Wsh,1
Cp
1
R
This pprocedure is given

g
in tabular form in Slide 33,, in which the second iteration
values are given in brackets. The optimum value of dsh,1 is found to be 120 mm.
14
32
PEMP
RMD510
Calculation of Optimum Shroud Parameter

dsh,1 (mm)
100
125
120
ush,1(m/s)
= 1610.97 dsh,1
(= 1575.22 dsh,1)
161.10
(157.22)
201.37
(199.64)
193.32
(191.65)
Aa (m2 ) 0.5027dsh2 ,1 103
5 026
5.026
7 854
7.854
7 2389
7.2389
0.5838
0.3736
0.4053
0.61
0.34
0.37
0.836
0.944
0.934
204 93
204.93
116 06
116.06
127 31
127.31
260.7
(258.5)
232.4
(230.9)
231.5
(230.1)
m RT0 ,1 /A p0 ,1
M1
st, 1 / 0 ,1
C x,1 ( m/s )
0 .86088
Aa st,1 / 0 ,1
Wsh,1 Cx2,1 ush2 ,1

14
33
Impeller-Diffuser Interface
PEMP
RMD510
The minimum value of Wsh,1 is found to be 230.1 m/s.

Hence, the de Haller velocity ratio, W2 / Wsh,1= 0.83.
This should not lead to diffusion induced separation.
Impeller-Outlet and diffuser-inlet width, b2:
C2 u 2 sin c,2 274.1 m/s

T0 ,2 381.95 K
C2
g c RT0 ,2 0.8281
M 2 0.740
st,2
0.771
0 ,2
14
34
Inducer Hub-Tip Ratio
PEMP
RMD510
Find
Fi d the
th rotor-outlet
t
tl t stagnation
t
ti pressure using
i the
th rotor
t efficiency
ffi i
C
p
R

p,c,tt,1 2
p0 ,2 T0 ,2
p0 ,1 T0 ,1
5
2
Therefore,, p0 ,2 2.262 10 N/m
0 ,2 2.0635 kg/m 3
3
.
st,
1
5909
kg/m
g
st 2
C r,2 C 2 cos 60 137 .1 m/s
b2 m d 2 st,2C r,2 6.69 mm

Inducer hub diameter can be determined from hub-tip ratio
d hb,
hb 1
0.60 d hb,1 0.60 120 72 mm
d sh,1
14
35
Radial Diffuser Stability
PEMP
RMD510
C2 d 2 2 st,2
Re,2
st,2
for mean Tst,2 320 K
2.020 10 5 Ns/m 2
Re,2 2.44 106
b2 r2 0.061
From the Stability limits in Jansens curves
b 2 / r2
0.125
0 08
0.08
0.061
14
(r3 / r2)mx
4.0
29
2.9
2.0 (by interpolation)
80 percent of 2.0 is 1.6

d3 =11.6
6 x 219
219.22 = 350 mm
36
Radial Diffuser Stability ( contd.)
PEMP
RMD510
Stable operating range of vaneless diffusers (Jansen, 1964)

14
37
PEMP
RMD510
Turbine Design Calculations
14
38

Turbine Rotor Diameter:
h0 ,e
The turbine has
slightly increased
mass flow,
flow because
of fuel addition, and
must supply windage
and
d bearing
b i power in
i
addition to
compressor power.
PEMP
RMD510
2
u
1
02
.
5 Cu,5
82772 J/kg
g c u5
1.04
cos 5
Cu,5
1
Z e0 .7
Cu,u 5 ,tltl
Cu,5 ,tl u5 and 5 0 ; Z e 13
C u,5 ,ac
0 .834
u5
1.02 82772 .4
u
*
1.04 0 .834
u 5 312 .0 m/s
/ d 5 198 .1 mm
2
5
14
39
PEMP
RMD510
Turbine Pressure Ratio:

m e h 0 ,e 1.02 m c h 0 ,c
T 0 ,e
1010
1
.
02
1
.
0
81 .953 69 .27 K
1.04
1172
p 0 ,in T0 ,in

p 0 ,,ex T0 ,,ex
p 0 ,ex
C p

R
800
730 .73
p st,ex
p,e,ts
C p

R
p,e,ts
1.570
p 0 ,in 1.570 1.2 10 5 1.884 10 5 N/m

14
40
PEMP
RMD510
N l Outlet
Nozzle
O l Velocity:
Vl i
The following parameters have been calculated:
Blade speed = 312.0 m/s ; Work coefficient, = 0.834 ; Nozzle angle = 70
Cu,1 u1
tan 70
Cr,1 Cr,1
Cr,1 0.834
0.3035
u1
tan 70
Cr,1 94.70 m/s
Cr,5
cos 70
C5 276.89 m/s
C5
C5
276.89
0.5779
g c RT0
286.96*800
with C p R 4 .084 M 0 .513

14
41
PEMP
RMD510
C p R 1
0
M
1.137
1
st 2 C p R 1
1.884 10 5
0 .8207 kg/m 3 st,5 0 .7215 kg/m 3
0 ,5
286 .96 800
2
The mass flow rate is 1.04 kg/s

Hence, the volume flow rate is 1.441 m3/s,
and the enthalpy drop is 81180 J/kg.
Vin
2 N
Specific speed, N s
60 g c h 0 3 4
14
2 30500
1441
0.797
0 797
3 4
60
81180
42
Velocity Function vs Mach Number for Perfect Gases
14
PEMP
RMD510
43
Exit Width to Diameter Ratio
PEMP
RMD510
The optimum specific speed for radial-inflow turbine is about 0.65. The
specific speed of this turbine is high. We might expect that there might be a
problem arriving at an exducer in which the outlet diameter reduce.
Turbine inlet blade width to diameter ratio is calculated using the relation
b1 N s2 tan c1 3 2 N s2 tan c1 1 2

4
4
d1
b5 N s2 tan c 5 1 2
d5
4
0.797
tan 70 0.834
0.1269
4
1 7.9
14
44
Optimum Specific Speed
Distribution of losses along envelope of

maximum total
total-to-static
to static efficiency
(Rohlik 1968)
14
PEMP
RMD510
Typical performance of radial turbine

(Rohlik 1968)
45
PEMP
RMD510
Outlet Static Density:
The outlet static pressure is specified together with the stagnation

temperature
temperature.
The Mach number here is low, and it will be sufficiently accurate to

guess the static temperature.
pst,6 1.2 105 N/m 2

T0 ,6 730.73 K
Tst,6 725 K
guess
1.2 105
st,6
0.577 kg/m 3
286.96 725
st,5 st,6 1.257
14
46
PEMP
RMD510
Results
The results of the calculations, made for an exducer hub-shroud ratio

of 0.3, are tabulated below:
---
0.8
0.9
1.0
---
0.935
0.881
0.836
---
1.15
1.208
1.314
w,sh,6 tan1 d sh,6 d5 Cx,6 Cr,5
Degrees
75.44
72.77
70.05
w,hb,6 tan
t 1 dsh,6 d5 Cx,6 C5
Degrees
49 12
49.12
44 06
44.06
39 51
39.51
Whb,,6 W5
14
47
Diameter Ratio
PEMP
RMD510
The diameter ratio and the relative flow acceleration are both
marginal at 0.8 velocity ratio. Both are satisfactory at a velocity ratio
of 0.9.
We select
d sh,6
0.881
d5
The flow angles give a guide to the exducer blade angles.

The exducer angles should be set to somewhat higher values to
allow for flow deviation.
An approximate estimate of this deviation would be 33 at the

shroud and 5 at the hub.
14
48
Turbine Hub and Tip Dimensions
PEMP
RMD510
d sh,6 0.881*198.1
174.5 mm
2
34
d hb , 6
N s1
2
1 1
d sh , 6
0.8343 4 0.797
0.712
0.3035
2 1.0.506944 0.702
d hb,6 0.702 174.5 122.49 mm
b5
0.1269
d5
b5 0.1269 198.1 25.138 mm
14
49
Data for Modeling the Compressor
PEMP
RMD510

At Shroud
At Hub
uhb,1
Cx,hb,1
Whb,1
ush,1 =191.65 m/s
uhb,1 = 114.98 m/s
Cx,sh,1 = 127.3
127 3 m/s
Cx,hb,1 = 127.3 m/s
Wsh,1= 230.1
Whb,1 = 171.53
w,sh,1 = 56.4
14
w,hb,1
w,hb,1 = 42.1
50
Data for Modeling the Compressor

Outlet Velocity Triangle
PEMP
RMD510
=350 m/s
=271
271.3
3 m/s
=236.6 m/s
C2=274.1 m/s
=137.1 m/s
158.08 m/s
137.1
78.7
14
51
Data for Modeling Turbine
PEMP
RMD510
act
C5=276.89 m/s
c1=70
w5=28.68
Cr,5=94.7
W5=107.95 m/s
260.19
U5 =312.0 m/s
14
52
Modeling Using CFX
PEMP
RMD510
Creating a Blade:
Radial Impeller Configuration
14
Initial Angle/Thickness Dialog
53
Geometric Model - Compressor
PEMP
RMD510
Input Parameters:
Blade
Fluid Domain
14
Dsh = 14 mm
Dhb = 8.5 mm
D2 = 25 mm
D3 = 30 mm
2 = 30
Z = 10
54
Geometric Model - Compressor

Blade
Fluid Domain
14
PEMP
RMD510
Input Parameters:
Dsh = 21 mm
Dhb = 5.25 mm
D5 = 30 mm
c5 = 70
Z=9
55
3-D CAD Models
PEMP
RMD510
Compressor
Turbine
14
56
Session Summary
PEMP
RMD510
A procedure for design of radial turbines based on optimum

specific
ifi speedd is
i discussed.
di
d
Salient constructional features and working principle of a

turbocharger are presented.
presented
The design of radial machines is explained through step by step

design of compressor and radial turbine modules of a typical
turbocharger
14
57

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PEMP

Design of Radial Turbines &

@ M S Ramaiah School of Advanced Studies, Bengaluru

To discuss the design of radial turbines using a

procedure based on optimum specific speed

@ M S Ramaiah School of Advanced Studies, Bengaluru

Design of Radial Turbine

@ M S Ramaiah School of Advanced Studies, Bengaluru

Radial Turbine Layout and Expansion Process

@ M S Ramaiah School of Advanced Studies, Bengaluru

From Euler turbine equation, specific work is given by:

A significant contribution comes

from the first term. For an axial flow turbine,

@ M S Ramaiah School of Advanced Studies, Bengaluru

@ M S Ramaiah School of Advanced Studies, Bengaluru

flow angle at rotor inlet = Nozzle outlet angle = ~ 70.

this may lead to high aerodynamic loading at the tip

Z = number of blades (incl. splitter blades)

1 = blade angle w.r.t

@ M S Ramaiah School of Advanced Studies, Bengaluru

Variation of Slip Factor with Z

Number of radial blades

@ M S Ramaiah School of Advanced Studies, Bengaluru

Rotor-outlet stagnation pressure : 110 000 Pa

Number of rotor blades

Nozzle outflow angle

To find: Rotor diameter

@ M S Ramaiah School of Advanced Studies, Bengaluru

Inlet Velocity Triangle

@ M S Ramaiah School of Advanced Studies, Bengaluru

Inlet Flow Parameters

h 0 u12 u1 584.7 m/s

Optimum Specific Speed

Distribution of losses along envelope of

Typical performance of radial turbine

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Optimum Specific Speed ( contd.)

Vin Cr,1 d1 b1 Cr,1 d1

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Rotor Inlet Width to Diameter Ratio

Inserting appropriate design inputs,

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Rotor Inlet Mach Number

Mach number can be determined

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0 ,1 p 0 ,1 RT0 ,1 300 10 3 286 .96 120

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m C r,1 st,1 d1 b1 C r,1 st,1 d12 b1 d 1

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using analytic equations

final design has to be arrived at through

@ M S Ramaiah School of Advanced Studies, Bengaluru

@ M S Ramaiah School of Advanced Studies, Bengaluru

@ M S Ramaiah School of Advanced Studies, Bengaluru

@ M S Ramaiah School of Advanced Studies, Bengaluru

@ M S Ramaiah School of Advanced Studies, Bengaluru

Turbocharger Design Data

Inlet stagnation pressure, N/m2

Find Engine back pressure (P0,4)

Outlet static pressure, N/m2

1.2* 105 (Pst,7)

Flow angle at rotor exit, c2 (deg)

Flow angle at rotor inlet, c1 (deg)