High Efficiency Turbocharger Applications Carl Roemershauser Sales Engineer May 22, 2012

Why the Need for High Efficiency Turbocharger?

Low emission requirements Operational issues at high ambient conditions Larger operating range Horsepower upgrade Obsolete Reliability Issues

Turbocharger Design
Applications Engineering Develop engine air specifications Design upgrade matching (OEM and non-OEM) Ability to design match, test, and guarantee results NPD Engineering Capabilities Aerodynamic & Stress load modeling FEA - Finite element analysis CFD - Computational fluid dynamics CAD - Computer-aided design CAM - Computer-aided mfg. Tools UGS Team center UGS Nx6 ANSYS CD-Adapco

Turbochargers Test & Validation

Closed loop simulate actual on-engine conditions. Two gas fired burners Small Stand Up to 500 gas horsepower Large Stand Up to 2000 gas horsepower Live real time internet test monitoring Engineered quality

Three types of tests available Mechanical Design Point Compressor Map

Engine and Turbocharger Combinations

Cooper ET24, ET18, ET13, CB13, ET11, CB11 Elliott H Model, L Model, G Model, HPO90, BC370 Delaval C17, C13, C10 Clark TCV, TLA, HBA, HRA ABB VTR (Enterprise), VTC and TPS (CAT) Napier NA250 (Low emission package on I-R KVS412s) MAN NA Model (Low emission package on Clark engines)

Currently upgrade components available

Engine and Turbocharger Combinations

Cooper ET24
- Cooper 2 & 4-cycle engines (2,400 12,500 Hp) - One turbo supplies air for ~ 2,400-6,000 hp on a 2-cycle - All 4-cycle LSV engine that use ET24s only require one turbo

Currently upgrade components available

ET18
- Cooper 2 & 4-cycle engines (1,500 7,000 Hp) - One turbo supplies air for ~ 1,500-3,000 hp on a 2-cycle engine - Most 4-cycle LSV engine that use ET18s only require one turbo

ET13
- Cooper GMVH-6 and Superior 825s 12 & 16 cylinder

CB13
- Cooper GMVH-6C, GMV and GMW CleanBurn Conversions - One turbo supplies air for ~ 800-1,500 hp on a 2-cycle engine

ET11 & CB11 - Superior 825s 6 and 8 cylinder

Engine and Turbocharger Combinations

Elliott H-Model (H30, H35, H50, H56, H58)
- Enterprise- Fairbanks Morse (38TDD81/8) - Ingersoll-Rand (410 KVT)- MEP - Superior - Nordberg - Worthington

Currently upgrade components available

L-Model (L20, L40, L60)

- Enterprise - Nordberg - Ingersoll-Rand (412 KVS) - Worthington

G-Model (BCO65 / BCO90)

- Enterprise- Ingersoll-Rand (410 KVR) - Nordberg

HPO90
- Cooper GMW/GMWA-10 w/ HPFi

- Superior 825s 12 and 16 cylinder

- Upgrade of BC370 used on Superior D low emission package

Engine and Turbocharger Combinations

Delaval C17
- Enterprise - Ingersoll-Rand (KVR616) - Worthington (ML & SUTC)

Currently upgrade components available

C13
- Ingersoll-Rand (KVT512) - Worthington - Nordberg

C10
- Nordberg

Success Story One

Unit Description
GMWH -10 Equipped with HPFI HPO-90 turbocharger Non pre chamber 3 gr/bhp-hr permit

Problem Turbocharger reliability Operating issues during high ambient condition

No waste-gate margin Problem maintaining air/fuel set-point Forced to operate with retarded ignition resulting in increased heat rate

Resolution New air specification created Upgrade turbocharger components based on air spec Build and test turbocharger Field installation and testing

Results
Increased air flow rate Maintain waste-gate margin of 19% at all operating conditions at 100 deg ambient Increased reliability

Success Story Two

Clean burn three package for the GMV and W330 engines Emissions
.5 g/bhp-hr NOx .9 g/bhp-hr CO .5 g/bhp-hr VOC .3 g/bhp-hr CH2O

Ambient horsepower up-rate available at 100 deg F Large operating range available
80-100% RPM 70-100% Torque

Lower Heat rate - 6,300 btu/bhp-hr

16W330-C3

New and Improved Turbochargers

Lower Available Energy New Aero Package Design Point Efficiencies Compressor Efficiency = 87% Turbine Efficiency = 83% Overall Adiabatic Efficiency > 70% Surge Margin 30% World Class Efficiency

New Delaval CR-17 Turbocharger & Elliott CRO-90 Turbocharger

New Delaval CR-17 Turbocharger & Elliott CRO-90 Turbocharger Advantages
Low installation cost Increased efficiency Larger operating envelop

Upgrade Experience 2005-present

Turbocharger Model ET11 ET13 CB13 ET18 ET24 H50 BC370H HP090 CRO90 C17 Total # of design codes 2 1 15 42 14 7 12 4 2 10 109

Summary
Proper turbocharger match is essential to maximize engine performance High efficiency Turbochargers are required to meet demands of modern engines Critical steps to success Air specification Turbocharger design Testing before installation