--> Buy True-PDF --> Auto-delivered in 0~10 minutes. GB/T

Transcription

1 Translated English of Chinese Standard: GB/T ICS NATIONAL STANDARD OF THE PEOPLE S REPUBLIC OF CHINA GB J 91 Turbochargers - Part 2: Test methods 涡轮增压器第 2 部分 : 试验方法 Issued on: March 19, 2009 Implemented on: November 1, 2009 Issued by: General Administration of Quality Supervision, Inspection and Quarantine; Standardization Administration Committee. Page 1 of 26

2 Table of Contents Foreword Scope Normative references Terms and definitions Test equipment requirements and measurement General conditions for testing Test items and methods... 7 Appendix A Appendix B Appendix C Page 2 of 26

3 Foreword GB/T " Turbochargers " consists of the following 2 parts: - Part 1: General requirements; - Part 2: Test methods. This Part is the second part of GB/T Appendix A, Appendix B and Appendix C of this Standard are informative. This Part was proposed by China Machinery Industry Federation. This Part shall be under the jurisdiction of National Standardization Technical Committee on Internal Combustion Engine. The drafting organizations of this Part: Shanghai Institute of Internal Combustion Engine and Hunan Tyen Machinery Co., Ltd. Main drafters of this Part: Wang Yidi, Ji Weibin, Deng Maoqiao, Hu Liaoping, Qu Junming, Jiang Lijiao, Chen Yunqing, Ding Zhijian, Xie Yaping, Song Guochan and Li Yueyong. Page 3 of 26

4 Turbochargers - Part 2: Test methods 1 Scope This Part of GB/T specifies the determination of main performance parameters of radial-flow and mixed-flow turbochargers (hereinafter referred to as turbochargers) as well as general method of reliability bench test. This Part is applicable to turbochargers for vehicle, marine, engineering machinery, forestry machinery, power generation and internal combustion engines of other uses (including diesel, gasoline, natural gas engines). This Part is not applicable to axial-flow turbocharger. 2 Normative references The following documents contain provisions which, through reference in this Part of the GB/T 23341, constitute provisions of this Part. For dated references, the subsequent amendments (excluding corrections) or revisions do not apply to this Standard. However, the parties who enter into agreement based on this Standard are encouraged to investigate whether the latest versions of these documents are applicable. For undated reference documents, the latest versions apply to this Standard. GB/T Turbochargers - Part 1: General requirements GB/T Reciprocating internal combustion engines - Measurement of emitted airborne noise - Engineering method and survey method GB/T 2624 (all parts) Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full (GB/T , ISO 5167:2003, IDT) JB/T 6002 Turbochargers - Limit values and measurement methods for cleanliness 3 Terms and definitions The following terms and definitions apply to this Part of GB/T Hot blast test Page 4 of 26

5 The test of which it inputs compressed air of external source that is heated into turbine, and uses thermal expansion of high-temperature gas to drive turbocharger operating. 3.2 Self cycle test The test of which it heats up that compressed air produced by turbocharger operation and inputs into turbine, so as to unitize the thermal expansion of hightemperature gas to drive turbochargers operating. 3.3 Compressor surge flow The phenomenon that - turbocharger speed is constant, when compressor flow decreases to a certain value, compressor outlet pressure and speed shall fluctuate. The corresponding flow rate value shall be called as compressor surge flow. 3.4 Compressor choke flow The phenomenon that - turbocharger speed is constant, as supercharger ratio decreases, compressor flow shall not increase substantially. The corresponding flow rate value shall be called as compressor choke flow. 4 Test equipment requirements and measurement 4.1 Test bench pipeline Test stand pipeline is a circular cross-section with smooth wall. Mutation of pipe cross-sectional area, sharp turns or leak are not allowed. The pipeline gas flow rate shall be less than 0.3 Mach number. The diameter of connecting pipe at entrance connected to compressor or turbine shall be equal. When the entrance of compressor or turbine is non-circular section, it shall be determined by equivalent diameter of equal area. Cone angle of all connecting cone tubes shall be less than Measuring tube shall be close to the compressor or turbine entrance. It shall use equivalent diameter straight tube, of which the length is not less than 5 times the diameter and the cross-sectional area is not less than the corresponding cross-sectional area of turbocharger entrance. When turbocharger has double channel inlet, and turbine inlet pipe is fork tube, its measurement point must not be arranged on the fork tube Heating pipe and measuring pipe shall be wrapped with insulation material, so as to reduce heat impact. 4.2 Speed measurement Page 5 of 26

6 orifice flowmeter or end face intake air lemniscate flowmeter. Standard orifice flowmeter is installed on compressor outlet pipeline and end face intake air lemniscate flowmeter is installed on compressor inlet pipeline. Turbine flow measurement shall use gas mass flowmeter or standard orifice flowmeter. Gas mass flowmeter is installed on the intake pipeline in front of combustion chamber. The design, manufacture, installation, use and flow calculation of standard orifice flowmeter shall comply with the provisions of GB/T End face intake air lemniscate flowmeter or other models of flowmeters shall be used only after verification. Meter accuracy: ±0.5% full range. 5 General conditions for testing 5.1 Test program or test specification shall be drawn up for each test of turbochargers. In general, it shall contain test purposes, conditions, operation procedures and requirements, test control, data acquisition and data processing, measuring instruments as well as precision requirements. 5.2 The main test measuring instruments shall be verified and calibrated along with certificate by the authorized metrology department, and they shall be within validity period of test circulation. 5.3 Data measurement shall be conducted only after test parameters are adjusted to the stipulated values and remained stable for 3 min. 5.4 During the test, unless otherwise specified, it shall be controlled by the following parameters: a) Lubricant oil inlet pressure is 0.25 MPa~0.5 MPa, inlet oil temperature is 50 C~90 C, and outlet oil temperature is 120 C. b) Compressor inlet negative pressure is 6 kpa. c) Turbine outlet back pressure is 3 kpa (for back pressure models with high requirements, it shall implement according to special technical conditions). When exhaust ventilation is allowed for test pipeline, turbine outlet negative pressure is usually 1 kpa. However, environmental conditions during all experimental process shall be consistent, so as to prevent measurement error. It must not use exhaust ventilation equipment for turbine performance test, and turbine outlet back pressure is 600 Pa. d) Test speed deviation shall be controlled within ±0.5% of speed range. 6 Test items and methods 6.1 Compressor performance test Page 7 of 26

7 distributed. When compressor is running near surge zone, it shall slowly reduce compressor air flow, so as to measure the surge flow point of compressor Measurement parameters a) Total compressor inlet gas pressure; b) Total compressor inlet gas temperature; c) Compressor flow or gas pressure difference of compressor flowmeter; d) Total compressor outlet gas pressure; e) Total compressor outlet gas temperature; f) Turbocharger speed; g) Atmospheric pressure and ambient temperature in test Data processing Take compressor equivalent flow Gcnp (kg/s) as abscissa, rate of pressurization πc* as ordinates, different equivalent speed ncnp (r/min) and equivalent compressor efficiency η c to draw compressor performance curve, as shown in Figure 1. Make test conclusion according to provisions of technical documents. Compressor performance test data shall be recorded in the format of Appendix A. 6.2 Turbine performance test Test purpose Make comprehensive assessment on aerodynamic performance of the turbine and draw the turbine performance curve as shown in Figure 2. Page 9 of 26

8 d) Turbine outlet gas static pressure; e) Turbine outlet gas static temperature; f) Total compressor inlet gas pressure; g) Total compressor inlet gas temperature; h) Total compressor outlet gas pressure; i) Total compressor outlet gas temperature; j) Turbocharger speed; k) Lubricating oil inlet temperature; l) Lubricating oil outlet temperature; m) Lubricating oil flow; n) Atmospheric pressure and ambient temperature in test Data processing Take turbine similar flow as abscissa, expansion ratio πt, as ordinates, different equivalent turbine similar speed and equivalent turbine efficiency η T to draw turbine performance curve, as shown in Figure 2. Make test conclusion according to provisions of technical documents. Turbine performance test data shall be recorded in the format of Appendix B. 6.3 Turbocharger self cycle performance test Test purpose Examine turbocharger manufacturing and assembly quality, so as to provide evidence for turbocharger s factory leaving Test conditions Factory leaving test shall be conducted on special test bench for turbocharger in the methods of external air source cold blowing, hot blowing and self cycle Test method Self cycle performance test shall be continuously conducted according to the sequence in Table 1, and special turbocharger s shall be conducted according Page 11 of 26

9 on the provisions of technical documents. Self cycle performance test data shall be recorded in the format of Appendix C. 6.4 Turbocharger 120 h thermal durability circulation examination test Test purpose Make assessment on work reliability of turbocharger, so as to provide evidence for the use of turbochargers mounted internal combustion engine Test conditions a) The test shall be conducted on special bench of which working conditions can be regulated and parameters can be measured. Test bench and conditions shall comply with the provisions of Clause 4 and Clause 5. b) The test shall use external air source heat blow and self cycle Test method a) Turbocharger self cycle performance test shall be conducted according to the sequence in Table 2, and special turbocharger s shall be conducted according to special technical conditions. In calibration parameter operation test, it shall conduct examination and measurement record once every 1 h; conduct measurement record of lubricating oil flow once every 10 h. Conduct measurement record once every 1 h in thermal cycling operation test. No. 1 Table 2 Turbocharg Turbine inlet Operation Test item er speed temperature time Calibration parameter nb h operation test Remark Self cycle working conditions 2 Thermal cycling operation test nmax or 1.1 nmin or h External air source heat blow or self cycle 3 Over speed and over temperature test 1.2 nb TTmax+50 C 5 min working conditions Note 1: nb - Turbocharger rated speed (r/min). Note 2: nmax - Turbocharger highest working speed (r/min). Note 3: nmin - Turbocharger lowest working speed (r/min). Note 4: TTmax - Turbocharger allowable highest turbine inlet temperature ( C). b) Thermal cycling operation test shall be conducted according to the requirements in Figure 3. Page 13 of 26

10 o) Atmospheric pressure and ambient temperature in test Data processing Based on measurement parameters, calculate rate of pressurization, compressor equivalent flow Gcnp, compressor efficiency η c, turbocharger total efficiency η TC and other performance parameters. Draw the monitoring curve of the above parameters and lubricating oil flow operating in 100 h calibration parameters. And dismantle and examine turbocharger, so as to make conclusion, according to product s technical documents. 6.5 Turbocharger over-speed failure test Test purpose Evaluate the safety working factors of turbocharger compressor wheel and turbine, as well as the tolerance degree of turbocharger s compressor housing and turbine housing, so as to provide evidence for turbocharger work safety Test conditions a) The test shall be conducted on special bench of which working conditions can be regulated and parameters can be measured. Test bench and conditions shall comply with the provisions of Clause 4 and Clause 5. Besides, the test bench shall be equipped with safety protection devices. b) The test shall use external air source heat blow Test method a) Compressor wheel and turbine over-speed failure tests shall be respectively conducted. Compressor housing, turbine housing, back plate and equivalent wheel (instead of compressor wheel) shall be processed additionally in advance, according to requirements of design department. And the whole machine shall be inspected as qualified. b) Compressor housing tolerance test shall make the turbocharger operate at 1.1 times highest speed. If the compressor wheel is not broken yet at this time, it shall manually groove or drill on wheel back, so as to make compressor wheel hub broken at this speed. Discrete pieces shall be contained in the housing and outward runaway must not be allowed. c) Turbine housing tolerance test shall make the turbocharger operate at 1.4 times highest speed. If the turbine wheel is not broken yet at this time, it shall be determined as reliable. To make it broken, it shall manually groove or drill on wheel back, so as to make compressor wheel hub broken at this Page 15 of 26

11 6.6.1 Test purpose Conduct turbocharger noise test according to requirements of product s technical documents Test conditions a) The test shall be conducted on special bench of which working conditions can be regulated and parameters can be measured. Test bench and conditions shall comply with the provisions of Clause 4 and Clause 5. b) The test shall use self cycle. Do not use silencer during the test. c) Noise testing meter is sound level meter of which the precision is ± 0.5 Db(A) Test method a) Noise measurement shall be conducted according to calibration parameters of turbocharger under self cycle working conditions. b) Noise measurement and data processing shall comply with the provisions of simple method in GB/T c) Measuring position diagram is shown in Figure 4. Take turbocharger axis as measurement level. The height H from turbocharger axis to ground shall be greater than 1 m. The distance from each measuring point to turbine housing is 1 m. The distance from each measuring point to laboratory walls, floor, or other obstacles shall be greater than 1 m. When measuring point coincides with the test pipeline, it shall move measuring point position till it meets requirements. Page 17 of 26

12 e) Atmospheric pressure and ambient temperature in test Data processing Based on measurement parameters, draw turbocharger lubricating oil supply curve shown in Figure Turbine housing flow capacity test Test purpose By comparison with standard turbine housing, test whether the flow capacity of turbine housing meets the design requirements, so as to provide evidence if this model of turbine housing and selected turbocharger matches internal combustion engine or installation of batch production Test conditions a) The test shall be conducted on special bench of which working conditions can be regulated and parameters can be measured. Test bench and conditions shall comply with the provisions of Clause 4 and Clause 5. b) Test bench shall be debugged; instrument and meter shall be accurately verified Test method a) The test shall use external source air cold blowing. b) Select appropriate measuring orifice based on turbine housing flow capacity, and properly install it between pressure tube and fork tube. c) Adjust turbine housing inlet pressure as a constant value. Measure and record the pressure of front orifice as well as the pressure difference between orifice s front and back. d) Test turbine housing for inspection. Conduct the test for standard turbine housing once respectively at the beginning and at the end Measurement parameters a) Turbine housing inlet pressure; b) Front orifice pressure; c) Pressure difference between orifice s front and back; d) Atmospheric pressure and ambient temperature in test. Page 20 of 26

13 6.8.5 Data processing Based on measurement parameters, calculate flow capacity of turbine housing for test and standard turbine housing. Compare flow capacity value of turbine housing for test and standard turbine housing. And make conclusion according to the provisions of product s technical documents. 6.9 Determination of turbocharger cleanliness Conduct according to JB/T Page 21 of 26

14 Appendix A (Informative) Compressor performance test record table r/min Turbocharger model: Atmospheric pressure/kpa: Test personnel: Turbocharger No.: Ambient temperature/ C: Test date: Turbocharger Ambient Atmospheric equivalent temperatu pressure speed re during during test ncnp test Tm kpa T0 C Compressor actual measured flow (or pressure difference of flowmeter) Gc (or ΔH) kg/s (or Pa) Total Total Total Total compress compress compress Rate of Compresso compress or inlet or outlet Compres or outlet pressuriz r equivalent or inlet temperatu temperatu sor pressure ation flow pressure re re efficiency Gcnp ηc Kg/s kpa kpa C C Page 22 of 26

15 Page 24 of 26

16 Appendix C (Informative) Turbocharger self-circulation performance test record table Turbocharger model: Atmospheric pressure/kpa: Test personnel: Turbocharger No.: Ambient temperature/ C: Test date: Turbocharger number Turbocharger equivalent ncnp r/min Ambient Atmospheric temperatu pressure re during during test test Tm kpa T0 C Compressor measured flow (or pressure difference of flowmeter) GC (or ΔH) kg/s (or Pa) Total compress or inlet pressure kpa Total Total Total Total Total Turbine Compres compress compress Turbine compress Turbine Turbine outlet Rate of sor or inlet or outlet inlet Compres Turbocha or outlet inlet outlet static static pressuriz equivalen temperatu temperatu temperat sor rger total pressure pressure pressure temperat ation t flow re re ure efficiency efficiency P2 ure Gcnp kpa kpa kpa C C C T2 C kg/s ηc ηtc Page 25 of 26