Boosting Your

Knowledge of
TURBO-
CHARGING
Randy Knuteson Analytical / Air Safety
Turbo Talk Forum
1905 Patent by Dr. Alfred J. Buchi
Historical Perspective:


1910 G.E. begins manufacturing turbos
1915 First turbo diesel engine



1905 Sulzer Bros. designs first turbo




1918 Dr. Sanford
Moss altitude tests a
350 hp turbocharged
engine.

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Historical Perspective:
1920 New altitude record in a LePere
Bi-Plane 33,113 feet!
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Historical Perspective:


1921 John Macready's flight to 40,800' in an
open cockpit Lusac 11, Lepere biplane.
Turbo Talk Forum
Turbo-Supercharged B-36
Six 28-Cylinder Engines
Without Turbos 90
Cylinders per Engine!
ENGINE HORSEPOWER
DEPENDS ON
The amount of fuel and air an engine
burns.

Soactual power is determined by
the MASS of air consumed.

The density of the charge, not the
volume.
Turbo Talk Forum
PRINCIPLES OF
TURBOCHARGING
Sea-level air density = 0.0765 lb. cu. ft.
At 10,000 ft. air density = 0.0565 lb. cu. ft.
100 hp @ sea-level = 73.9 hp @ 10,000 ft.

A Naturally-Aspirated Engine
Turbo Talk Forum
WHY TURBOCHARGE?
Power diminishes with an increase in altitude.

Gain more power and increase engine
efficiency without enlarging the powerplant.

Recapture the heat energy normally wasted
out the exhaust.
GOAL Convert Exhaust Energy into Manifold Pressure
Turbo Talk Forum
A TURBOCHARGER IS AN
AIRPUMP
powered by the
unused heat
energy normally
wasted out the
exhaust.

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Exhaust gas inlet
(T.I.T.) from the
combustion process
Spent
exhaust
gases
overboard
Filtered
ambient
air inlet
Compressor
outlet
Routing of exhaust and compressor
discharge air
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1650 F
As high as
125,000
RPMs!
Turbo Talk Forum
TURBOCHARGING DEFINITIONS
Turbocharging
BOOSTED HP increase (31-45MAP)


Turbo-Normalizing
NORMALIZED Maintains sea-level
performance (29.5 MAP) at altitude.


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TURBOCHARGING
DEFINITIONS
Upper Deck Pressure
From compressor discharge to the throttle
plate.

Manifold Pressure
From the throttle plate to the cylinder
intake port.
Turbo Talk Forum
AME Maintenance Seminar
Sludge build-up in
the wedge can
decrease the oil
pressure feeding
into the bearing
and shaft
TURBO COMPONENTS:
CENTER HOUSING home of:
BEARINGS
For locating the turbine shaft

SEALS (Piston Rings)
Prevents high-pressure gases from
entering the center housing and therefore
the crankcase.
To keep air and exhaust out of the oil.

Turbo Talk Forum
Piston rings keep air and exhaust
pressures out of the center housing
30-60
PSI
TURBO COMPONENTS:
COMPRESSOR STAGE (Cold Side)
Discharge Air
Volute shape
converts velocity
energy into
pressure energy
Turbo Talk Forum
Turbo Talk Forum
Power
increase
Exhaust
volume
increases
Turbo begins
to spin faster
Increased
compressor
discharge
MAP
increases
TURBO RUN-AWAY
COULD EXCEED MAXIMUM
ENGINE OPERATING LIMITS!
Decrease
power
Decreased
exhaust
flow
Turbo slows
down
Compressor
discharge
decreases
MAP
decreases
4 BASIC SYSTEM COMPONENTS
Turbocharger

Controller

Wastegate

Absolute Pressure Relief Valve (PRV)

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Upper Deck
Pressure
Engine Oil from
Wastegaate
Actuator
Aneroid
Bellows
Oil restrictor
Valve
Oil Return to
Engine
Throttle Controlled
Cam
4 BASIC SYSTEM
COMPONENTS
Turbo Talk Forum
4 BASIC COMPONENTS
Wastegate (Exhaust Bypass Valve)






Butterfly
Valve
Drain Port
Oil Inlet
Piston
Oil Outlet to
Controller
Turbo Talk Forum
4 BASIC SYSTEM
COMPONENTS
Absolute Pressure
Relief Valve (PRV)

Escape path for
excess Upper Deck
Air Pressure
Valve Face
Spring and
Bellows Assy
Valve Seat
Turbo Talk Forum
Turbo output
pressures must
be regulated.
Without a control
system, the
turbocharged engine
would Be extremely
unstable.
Why Use an Intercooler?
The compressor wheel spins faster at
altitude producing a hotter charge to
the cylinders.
Decreasing adiabatic efficiency.
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TURBOCHARGERS ARE
SENSITIVE TO:
Insufficient lubrication

Foreign object damage

Extreme temperatures


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INSUFFICIENT
LUBRICATION
RESULTS IN:

Bearing damage that causes an increase in
the orbital motion of the turbine shaft.

Turbine and compressor wheels begin to
contact their respective housings.
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CONTAMINATED
LUBRICATION RESULTS IN:
Damage to bearing(s)
Collateral damage to turbine and
compressor housings
Full floating bearings require 30 PSI
minimum at inlet (3 GPM)

Engine Oil should be changed every 25-35
hours in a turbocharged engine.
Turbo Talk Forum
Lubricating Oil
Recommendations:
Lycoming SI 1014M All turbocharged
engines must be broken-in and operated
with ashless dispersant oil only.

TCM M87-12 Rev 1 Straight Mineral Oil
(MIL-L-6082) may be used not to exceed
25 hours or 6 months of operation.
Turbo Talk Forum
VERIFY TURBO CONDITION
Does the shaft spin freely?



Turbo Talk Forum
VERIFY TURBO CONDITION
Wheels should not contact housing.




Turbo Talk Forum
VERIFY TURBO CONDITION
Use a light source to
carefully examine the
condition of the leading
edges of the Turbine
Wheel blades.
Check inducer
blades for
damage
Turbo Talk Forum
FOREIGN OBJECT DAMAGE
Bolts, valves, and rocks will break
pieces from the blades or machine
them down.
Abrasive matter (sand, dirt) will wear
away the underside of the blades.
Soft material (shop rags) will bend the
compressor blades backwards.
Turbo Talk Forum
Avoiding Turbo Oil Leaks
Drain ports must point
down. (not more than
35 degrees from vertical
centerline)
Drain line should slope
entire length (no sink
traps).
Check hoses for internal
de-lamination.
No sludge at outlet
From coking of
bearing housing.
Restriction or faulty
check valve(s)
Turbo Talk Forum
TROUBLESHOOTING
LOW/FLUCTUATING MAP:
Restriction in Duct Between Air Cleaner
and Intake Manifold.

Restriction in Engine Exhaust /Intake
Manifold

PRV Opens Prematurely (At Too Low a
Pressure)

Turbo Talk Forum
TROUBLESHOOTING
LOW/FLUCTUATING MAP:
T/C Output Low/Sluggish

Engine Oil Pressure Low

Controller/Wastgate Dirty or Sticking

Controller Cover Gasket Leak
Leaking
Cover
Gasket
No Split-Lock
Washers
Turbo Talk Forum
CONTROLLER MALFUNCTIONS
Dirt / Debris in Poppet Valve

Worn Poppet Seat Assembly

Case / Gasket Leakage
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Wastegate Malfunctions
Sticking /
Frozen Butterfly
valve

Caused by:
Lead and E.G.
deposits build-up
on pivot bushings
Cure:
Mouse Milk
Turbo Talk Forum
Testing the Wastegate Assy.
Turbo Talk Forum
How NOT to Check the Condition
of the Pressure Relief Valve
DONT TEST THE ABSOLUTE PRESSURE
RELIEF VALVE ON THE ENGINE!
WARNING: Never advance the throttle boosting
manifold pressure beyond red-line to determine if
the absolute pressure relief valve is functioning.
This is an emergency controller.
Turbo Talk Forum
Overspeed/Overshoot/Overboost
Overspeed
Overshoot
Operating an engine above its rated speed
or RPM.
Automatic controls cant respond quickly
enough to the inertia of the turbocharger
speed as it increases when the throttle is
rapidly advanced.
Turbo Talk Forum
Overspeed/Overshoot/Overboost
Overshoot
Lycoming says:
If overshoot does not exceed 2 inches and 3
seconds duration, it may be disregarded.
Turbo Talk Forum
Overspeed/Overshoot/Overboost
Overspeed
Overshoot
Overboost
Occurs when the manifold pressure
exceeds the limits at which the engine was
tested and FAA certified.
Turbo Talk Forum
OVERBOOST CAUSED BY:
Rapid throttle movement
Exhaust By-Pass Valve fails to open.
Sticking Wastegate
Air in the oil feed to the controller
PRV (pop-off valve) fails to open at
predetermined crack point.
Turbo Talk Forum
UNACCEPTABLE OVERBOOST
TCM SB67-12

OVERSHOOT / OVERBOOST

3-6 INCHES Check System,
Adjust or Replace Malfunctioning
Components.


Turbo Talk Forum
UNACCEPTABLE OVERBOOST
LYCOMING MSB-369J



Not exceeding 5 inches Hg. or 10
seconds Normal 50 hour inspection
required.



Not exceeding 10 inches Hg. Complete
engine disassembly and inspection.
Over 10 inches Hg. Complete engine
Overhaul and crankshaft replacement.
Turbo Talk Forum
ACCEPTABLE OVERBOOST
LYCOMING MSB-369J



Momentary - not exceeding 3 inches Hg.
for 5 seconds
Log Book entry required.

Maximum manifold pressure reached.
Duration of overboost
Cylinder head temperature
Ambient air temperature
Pressure altitude

Turbo Talk Forum
ACCEPTABLE OVERBOOST
LYCOMING MSB-369J



Visual inspection of compressor and
turbine wheels
Manually check for excessive movement of
turbine shaft in the journal bearings.


Turbo Talk Forum
Radial Bearing
Check
Axial End Play
Bearing Check
CHECKING BEARING CLEARANCES
0.003-0.007
0.004-0.009
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Maintenance of Turbo System
Preflight Visual Inspection
Check for security of turbo mountings and
connections.
Inspect for evidence of oil leakage, air
leakage, or exhaust leakage.
Turbo Talk Forum
Maintenance of Turbo System

Inspect the hoses and tubing of the air
intake system.
Check for leakage due to cracks, damaged
gaskets, loose clamps or connections.
Restrictions due to kinks, collapsed hoses,
or dented tubing.
Inspect for exhaust leakage.


50 and 100 hour inspections:
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Maintenance of Turbo System
50 and 100 hour inspections:
Inspect the torque on
all V-band clamps


Turbo Talk Forum
Maintenance of Turbo System

Check oil feed and return lines.
Unusual noises or vibration.
Observe the engine exhaust.
FOD damage to wheels or evidence of
contact with housings.


50 and 100 hour inspections:
Turbo Talk Forum
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