FUNDAMENTALS OF

Turbocharger
Prepared by:
Md. Asifur Rahman Prantik
Assistant Engineer (Technical Service)
RotoTech Bangladesh Limited
Disclaimer:
This document is the exclusive property of RotoTech Bangladesh Ltd. Its contents
shall not be used for other purposes or copied or disclosed without written
authorization of RotoTech Bangladesh Ltd.
Basic Working Principle of Turbocharger:

Fig 1: Turbocharger basic working flow.

Fig 2: Turbocharger work flow in an engine

A turbocharger is a crucial component in modern internal combustion engines,
designed to increase power and efficiency by compressing the intake air before it
enters the combustion chamber. It utilizes the engine’s exhaust gases to drive a
turbine, which in turn powers a compressor, effectively forcing more air into the
engine. This process enables the engine to burn more fuel efficiently, resulting in
higher power output without increasing engine size.

1. How a Turbocharger Intakes Fresh Air & Compresses It

The compressor side of the turbocharger is responsible for drawing in and

compressing fresh ambient air. The process follows these steps:

1. Air Intake:
o The compressor wheel, located in the compressor housing, starts
drawing in fresh air through the air intake system.
o The compressor wheel is aerodynamically designed with blades that
accelerate and pressurize the incoming air.
2. Air Compression:
o As the compressor wheel spins at high speed, it compresses the
incoming air, increasing its pressure and temperature.
o The compressed air is then directed toward the engine intake manifold
for combustion.
3. Why Compression is Important?
o Higher air pressure means more oxygen molecules are available in
the combustion chamber.
o More oxygen allows for better fuel combustion, leading to increased
power output and fuel efficiency.

2. Charge Air Cooler (Intercooler) & Its Function

Since air compression generates heat, the compressed air exiting the compressor is
hot and has lower density. Hotter air is less oxygen-dense, which reduces
combustion efficiency. To solve this issue, the compressed air passes through a
Charge Air Cooler (CAC), also known as an intercooler, which has the following
functions:

1. Cooling the Compressed Air:

o The intercooler acts like a radiator, where compressed air flows
through a series of tubes and cooling fins, while ambient air (or coolant
in water-cooled intercoolers) dissipates the heat.
2. Increasing Air Density:
o As the air cools down, it becomes denser, allowing more oxygen to
enter the engine for combustion.
3. Performance Benefits:
o Cooler, denser air increases power output by improving combustion.
o Reduces engine knocking and improves engine reliability.
o Helps meet emission standards by reducing NOx formation (since
cooler air lowers combustion temperature).

3. How the Turbine Shaft Works Using Exhaust Gases

The turbine side of the turbocharger extracts energy from the engine’s hot exhaust
gases to drive the compressor. This process works as follows:

1. Exhaust Gas Enters the Turbine:

o After combustion, the engine expels hot exhaust gases through the
exhaust manifold into the turbine housing.
o The gases flow through a volute (spiral-shaped passage), increasing
velocity as they reach the turbine wheel.
2. Spinning the Turbine Wheel:
o The high-speed exhaust gases hit the turbine blades, causing the
turbine wheel to spin.
o The turbine is directly connected to the compressor wheel via the
turbine shaft, meaning both wheels spin together.
3. Exhaust Energy Utilization:
o Instead of letting exhaust gases escape as wasted energy, the
turbocharger recovers this energy to drive the compressor.
o This makes turbocharging an efficient way to increase engine
performance without significantly increasing fuel consumption.

5️. Key Performance Parameters of a Turbocharger:

Several performance parameters define the efficiency and effectiveness of a
turbocharger:

Boost Pressure (psi or bar): The amount of pressure generated by the compressor
above atmospheric pressure. More boost means more air is forced into the engine.

Compressor Efficiency (%): How effectively the compressor converts rotational

energy into compressed air. A higher efficiency means less heat generation and
better performance.
Turbine Efficiency (%): How well the turbine converts exhaust energy into
rotational motion to drive the compressor.

Pressure Ratio: The ratio of compressed air pressure to ambient air pressure. A
higher-pressure ratio means more power but also requires better cooling.

Turbo Lag: The delay between pressing the accelerator and the turbo spooling up
to provide full boost. Reduced by using ball bearings or twin-scroll turbos.

Rotational Speed (RPM): Turbochargers can spin over 50,000 to 100,000 RPM,
requiring high-precision bearings for durability.

Exhaust Backpressure: Excessive backpressure can reduce efficiency, so proper

wastegate tuning is necessary.

1. Axial Turbochargers

An axial turbocharger features a turbine and compressor wheel where gases

flow parallel to the shaft axis (along the length of the shaft). The design is similar
to an axial-flow jet engine compressor or turbine.

2. Radial Turbochargers

A radial turbocharger, also known as a centrifugal turbocharger, features a

turbine and compressor wheel where gases flow in radially (perpendicular to the
shaft) and exit axially (along the shaft).
Q. After exhaust gas passing through the turbine of the
turbocharger where did it go?
Through an Exhaust Aftertreatment System (Modern Engines)

Most modern engines use aftertreatment systems to reduce emissions before

releasing exhaust gases into the air. These components include:

🔹 Catalytic Converter (For Gasoline & Some Diesel Engines)

• Converts harmful gases like CO (carbon monoxide), HC (hydrocarbons),

and NOx (nitrogen oxides) into less harmful gases like CO₂ and water
vapor.
• Uses a honeycomb structure coated with precious metals (platinum,
palladium, and rhodium) to trigger chemical reactions.

🔹 Diesel Particulate Filter (DPF) (For Diesel Engines)

• Captures soot (particulate matter) from the exhaust gases and periodically
burns it off through regeneration.

🔹 Selective Catalytic Reduction (SCR) (For Modern Diesel Engines)

• Uses AdBlue (Urea Solution) to convert NOx into nitrogen and water
vapor, reducing emissions.

🔹 Exhaust Gas Recirculation (EGR) (For Emission Reduction)

• Some exhaust gases are recirculated back into the intake to lower
combustion temperatures and reduce NOx formation.
Turbocharger Typical Components and
their basic working principle, Their
Placement, Reason of Placement
Some of the Key Turbocharger Components for both Axial and Radial
Turbochargers are:
28.Air Intake Housing
1.Nozzle Ring
29. Wall Insert
2.Retaining Ring
30. Gas Outlet Flange
3.Turbine Casing
31. Partition Wall.
4.Compressor Casing

5.Labyrinth Sleeve

6.Diffuser

7.Plain Bearing Bush CE (Compressor End) & TE (Turbine End)

8. Heat Shield

9.Partiation Wall

10.Cartridge

11.Piston Ring

12.Auxilary Bearing

13.Thrust Bearing

14. Thrust Ring

15.Thurst Collar

16.Bearing Housing

17.Turbine Shaft/wheel

18.Compressor Wheel/Impeller

19.Damping Wire

20. Cone (axial turbo)

21.Radial Bearing CE and TE

22.Floating Disc

23.Sealing Cover

24.Hood

25.Bearing Flange

26.Bearing Cover

27. Gas Admissible Casing

1. Nozzle Ring
Placement:

• Positioned in the exhaust portion of the turbocharger, adjacent to the turbine wheel.

Reason for Placement:

• Guides the high-velocity exhaust gases to efficiently direct flow onto the turbine blades.
• Converts pressure energy from exhaust gases into kinetic energy to drive the turbine.

Function:

• Accelerates and directs exhaust gases toward the turbine blades at an optimal angle.
• Increases rotational speed of the turbine wheel, boosting turbocharger efficiency.
• Controls turbine inlet conditions, optimizing engine performance.

Failure Effects:

• Broken vanes cause uneven flow, leading to:

o Loss of turbine RPM and power output.
o Increased fuel consumption due to inefficient energy conversion.
• Worn nozzle rings cause inconsistent airflow, leading to turbocharger imbalance.

Fig 1: Nozzle Ring for Radial Turbo (TCR-16) Fig 2: Nozzle Ring for Axial Turbo (Napier 357)

Fig 3: Nozzle Ring for Radial Turbo (TPS52)

2. Diffuser

🔹 Function:

• Converts high-speed, low-pressure air from the compressor wheel into

high-pressure, low-speed air for engine intake.

🔹 Placement:

• Located after the compressor wheel.

🔹 Reason for Placement:

• Optimally designed for pressure recovery, ensuring efficient boost

delivery.

🔹 Failure Effects:

• A damaged diffuser can cause pressure losses, leading to inefficient air

compression and power loss.

Fig 1: Diffuser for Napier NA-357 Fig 2: Diffuser for Radial Turbo TPS-50-B01
3. Turbine Casing:

🔹 Function:

• Houses the turbine wheel and directs high-pressure exhaust gases through
the nozzle ring.

🔹 Placement:

• Encloses the turbine side of the turbocharger.

🔹 Reason for Placement:

• Designed to contain and channel high-temperature exhaust gases safely

and efficiently.

🔹 Failure Effects:

• Cracks or leaks lead to loss of exhaust energy, reducing turbine speed and
boost pressure.

Fig 1: Turbine Casing (TPS-52) Fig 2: Turbine Casing (A140H)

4. Compressor Casing:

🔹 Function:

• Houses the compressor wheel and controls the flow of compressed air into
the engine intake.

🔹 Placement:

• Encloses the compressor side of the turbocharger.

🔹 Reason for Placement:

• Optimized design ensures smooth airflow, minimal pressure losses, and

effective air compression.

🔹 Failure Effects:

• A damaged casing can lead to air leaks, reducing boost pressure and engine
efficiency.

Figure1: Compressor Casing (A140 H) Figure 2: Compressor Casing (TCR-16)

5. Labyrinth Sleeve:

🔹 Function:

• Provides a non-contact seal to minimize oil leakage from the bearing

housing.

🔹 Placement:

• Between the bearing housing and compressor/turbine sides.

🔹 Reason for Placement:

• Prevents oil contamination in the air/exhaust flow while allowing free

rotation of the shaft.

🔹 Failure Effects:

• A worn labyrinth sleeve can cause oil leaks into the intake or turbine,
leading to oil burning, carbon deposits, and reduced efficiency.

Figure: Labyrinth Sleeve of TPS67C32

6. Retaining Ring:

🔹 Function:

• Holds the nozzle ring or other turbo components in position, preventing

unwanted movement due to vibrations or thermal expansion.

🔹 Placement:

• Around the nozzle ring or compressor wheel.

🔹 Reason for Placement:

• Ensures that critical components remain secured under extreme rotational

speeds and high temperatures.

🔹 Failure Effects:

• Loose retaining rings may cause misalignment or dislodging of parts,

leading to vibrations and efficiency loss.

Figure 1: Retaining Ring of TCR-16 Turbocharger

7. Plain Bearing Bush CE & TE:

🔹 Function:

• Supports the turbo shaft, reducing friction between the rotating shaft and
housing.

🔹 Placement:

• At both the compressor end (CE) and turbine end (TE) of the bearing
housing.

🔹 Reason for Placement:

• Ensures smooth rotation of the turbo shaft and prevents excessive radial
movement.

🔹 Failure Effects:

• Worn bearings cause shaft misalignment, excessive vibrations, and

possible turbo seizure.

Figure: Plain Bearing bush/Radial Bearing

8. Heat Shield/Partition Wall:

Function:

• Protects sensitive components from extreme heat generated by exhaust

gases in the turbine section.
• Helps prevent oil coking in the bearing system by reducing heat transfer.

🔹 Placement:

• Between the turbine housing and bearing housing.

🔹 Reason for Placement:

• Prevents oil degradation and maintains optimal bearing temperatures.

Failure Effects:

• Without proper heat shielding, oil degradation and bearing overheating

can occur, reducing turbo life.
• Excessive heat transfer can also weaken surrounding metal structures .

Figure: Heat Shield of TCR-16 Turbo

9.Turbocharger Cartridge:

🔹 Function:

• Houses the shaft, bearings, and seals, acting as the turbo’s core.

🔹 Placement:

• Center of the turbocharger.

🔹 Reason for Placement:

• Provides structural integrity and ease of replacement.

🔹 Failure Effects:

• Cartridge failure results in total turbocharger malfunction.

Figure: Turbocharger Cartridge

10.Turbocharger Piston Ring:

🔹 Function:

• Provides a dynamic seal to prevent oil leakage from the bearing housing.

🔹 Placement:

• Around the shaft ends near the compressor and turbine sides.

🔹 Reason for Placement:

• Prevents oil contamination in the air/exhaust flow.

🔹 Failure Effects:

• Worn piston rings cause oil leakage, leading to blue smoke emissions and
turbo inefficiency.

Figure: Turbocharger Piston Ring

11.Auxilary Bearing:

🔹 Function:

• Provides extra support to the turbo shaft, especially in axial

turbochargers.

🔹 Placement:

• Inside the bearing housing.

🔹 Reason for Placement:

• Helps maintain rotor alignment under high loads.

🔹 Failure Effects:

• Increased shaft vibration and possible imbalance.

Figure: Auxiliary Bearing (AB) for TPS52-D01 Turbocharger.

Figure: AB for TPS 52-F31

12.Thrust Bearing:

🔹 Function:

• Supports axial loads on the turbo shaft caused by air pressure differences
between the compressor and turbine sides.
• Helps maintain shaft position and prevents excessive axial movement.

🔹 Placement:

• Inside the bearing housing, between the shaft and bearing housing walls.

🔹 Reason for Placement:

• Positioned to counteract axial forces from the compressor and turbine

wheels.

🔹 Failure Effects:

• Excessive axial play leads to shaft misalignment, potential contact

between rotating and stationary parts, and compressor/turbine wheel
damage.

Fig: Thrust Bearing TPS52-D01 Fig: Thrust Bearing TPL67C32

13. Thrust Ring:

🔹 Function:

• Works with the thrust bearing to control axial movement of the turbo
shaft.

🔹 Placement:

• Mounted along with the thrust bearing inside the bearing housing.

🔹 Reason for Placement:

• Reinforces the thrust bearing’s function, ensuring minimal axial

displacement.

🔹 Failure Effects:

• If damaged, shaft end-play increases, causing misalignment, imbalance,

and turbo inefficiency.

Fig: Thrust Ring for TCR-16 Fig: Thrust Ring for A140H
14. Thrust Collar:

🔹 Function:

• Transfers axial loads from the turbo shaft to the thrust bearing, allowing
smoother operation.

🔹 Placement:

• Mounted on the turbo shaft, in contact with the thrust bearing.

🔹 Reason for Placement:

• Helps distribute axial forces evenly, reducing wear on the thrust bearing.

🔹 Failure Effects:

• Excessive wear leads to higher axial movement, causing bearing failure

and possible shaft damage.

Fig: Thrust Collar Napier NA-357 Fig: Thrust Collar KBB HPR-4000
15. Bearing Housing:

🔹 Function:

• Houses the turbo shaft, bearings, and lubrication system.

• Facilitates oil circulation for lubrication and cooling.

🔹 Placement:

• Located at the center of the turbocharger, between the turbine and

compressor.

🔹 Reason for Placement:

• Acts as a support structure and provides a passage for lubrication.

🔹 Failure Effects:

• Cracks or oil leakage can lead to bearing failure and turbo malfunction.

Figure: Bearing Housing for Napier-307

16. Bearing Flange:

✅ Function:

• The bearing flange serves as a mounting and securing component for the bearing
housing within the turbocharger assembly.
• It provides structural support, ensuring that the bearing housing remains firmly in
place while accommodating thermal expansion and vibrations.

🔹 Placement:

The bearing flange is positioned at the junction between the bearing housing and other turbocharger
casings

🔹 Reason for Placement:

• Keeps bearings in place, ensuring stability.

🔹 Failure Effects:

• Misaligned bearings lead to vibrations and excessive wear.

Fig: Bearing Flange of TPS50-B01

Fig: Bearing Flange CE (1st

pic) and TE (2nd pic) of
17. Bearing Cover: TPS-52-D01 Turbocharger
17.Bearing Cover:

Function:

• Protects and contains the bearing system.

🔹 Placement:

• Over the bearing housing.

🔹 Reason for Placement:

• Prevents external contamination.

🔹 Failure Effects:

• Contamination leads to premature bearing failure.

Fig: Bearing Cover of KBB HPR-4000 Fig: Bearing Cover of A135H

Difference Between Bearing Flange, Bearing Housing, and Bearing
Cover in a Turbocharger:
Purpose in
Component Function Placement Failure Effects
Turbocharger

Houses and Centrally Acts as the structural

Failure leads to
supports the located support for bearings,
Bearing improper lubrication,
bearings, provides between allows lubrication oil
Housing overheating, and
lubrication and turbine and to flow through
bearing damage
cooling compressor passages

If loose or damaged,
Keeps bearings firmly
Secures the bearing Attached to the bearings may shift,
Bearing in place, ensuring
assembly within the bearing causing shaft
Flange alignment of rotating
housing housing misalignment and
components
vibration

Damage or improper
Protects the bearing Mounted on or Seals the bearing
sealing can lead to oil
Bearing system from around the system to prevent
leaks and
Cover contamination and bearing dust, debris, or oil
contamination of
prevents oil leakage housing leakage
turbo components

Summary of Differences:

• Bearing Housing: The main body that holds and supports the bearings,
providing oil flow for lubrication and cooling.
• Bearing Flange: A securing component that ensures bearings stay in
position inside the housing.
• Bearing Cover: A protective cover that prevents contaminants from
entering and oil from leaking.
18. Turbine Shaft/Wheel:

🔹 Function:

• Converts exhaust gas energy into rotational energy to drive the

compressor wheel.

🔹 Placement:

• Inside the turbine casing, supported by bearings.

🔹 Reason for Placement:

• Positioned in the exhaust stream to extract maximum energy from hot

gases.

🔹 Failure Effects:

• Shaft imbalance causes vibrations and turbo failure.

• Blade damage reduces energy extraction efficiency.

Fig: Turbine shaft for Napier 357 Fig: Turbine Shaft for A135-H
19. Compressor Wheel/Impeller:

🔹 Function:

• Draws in and compresses ambient air before sending it to the engine

intake.

🔹 Placement:

• Inside the compressor housing, mounted on the turbo shaft.

🔹 Reason for Placement:

• Positioned to maximize air compression efficiency.

🔹 Failure Effects:

• Damaged blades cause uneven airflow, reducing boost pressure and power
output

Fig: Impeller for Napier NA-357 Fig: Compressor wheel for TCR-16
20. Damping Wire/Lacing Wire:

Placement:

• Wrapped around the turbine wheel or turbine shaft, typically located in the hot section
of the turbocharger.
• It is tightly wound within the grooves or recesses of the turbine wheel to absorb
vibrations.

Reason for Placement:

• The turbine shaft experiences high-speed rotation and thermal expansion, leading to
vibration.
• The damping wire helps to reduce resonance and vibrations, ensuring the turbine wheel
remains stable at high speeds.
• It prevents excessive oscillation that could damage the turbine shaft, bearings, or
surrounding components.

Function:

• Acts as a vibration damper to absorb and dissipate harmonic vibrations generated by

the rotating turbine wheel.
• Enhances shaft stability and reduces mechanical stresses, prolonging turbocharger
lifespan.
• Helps maintain efficient energy transfer from exhaust gases to the turbine without
excessive movement.

Failure Effects:

• If the damping wire loosens or breaks, it fails to absorb vibrations, leading to:
o Increased resonance, causing shaft instability and potential fatigue failure.
o Excessive wear on turbine bearings, reducing bearing lifespan.

Figure: Damping Wire

21. Cone:

🔹 Function:

• Guides exhaust gases smoothly into the turbine stage in axial turbochargers.

🔹 Placement:

• Positioned before the turbine blades.

🔹 Reason for Placement:

• Ensures even distribution of exhaust gases, preventing turbulence.

🔹 Failure Effects:

• Uneven flow reduces efficiency and turbine performance.

Figure: Cone for Napier NA-357.

22. Air Intake Housing/Casing:

🔹 Function:

• Directs incoming air into the compressor wheel.

🔹 Placement:

• Before the compressor stage.

🔹 Reason for Placement:

• Ensures smooth airflow for efficient compression.

🔹 Failure Effects:

• Restricted airflow leads to lower boost pressure.

Fig: Air intake casing for TCR-16 PBS turbocharger

23. Floating Disc:

🔹 Function:

• Reduces oil leakage from the bearing housing.

🔹 Placement:

• Between the bearing housing and sealing system.

🔹 Reason for Placement:

• Ensures oil remains in the lubrication system.

🔹 Failure Effects:

• Oil leaks lead to contamination of intake or exhaust systems.

Fig: Floating Disc of TPL67C turbocharger.

24. Sealing Cover:

✅ Function:

• The sealing cover acts as a protective barrier to prevent oil leakage from the bearing
housing into the compressor or turbine sides.
• It helps in sealing the bearing chamber, ensuring that lubrication remains confined
within the bearings and does not contaminate other parts of the turbocharger.

✅ Placement:

• Located on both the compressor end (CE) and the turbine end (TE) of the bearing
housing.
• Positioned near the piston rings and labyrinth seals to reinforce the sealing mechanism.

✅ Why is it placed there?

• To prevent oil from escaping into the airflow path (compressor side) or exhaust stream
(turbine side).

✅ Failure Effects:

• If the sealing cover is damaged, cracked, or improperly fitted, oil can leak into the
compressor housing, leading to:
o Oil fouling in the air intake system.
o Blue smoke from the engine due to oil burning.
o Reduced turbocharger efficiency due to oil contamination.

Figure: Sealing Cover for TPL67C turbocharger.

25. Partition Wall:

✅ Function:

• The partition wall acts as a thermal and mechanical barrier inside the turbocharger,
separating the hot turbine side from the cooler compressor side.
• It helps to reduce heat transfer from the turbine side to the bearing housing and
compressor section, protecting sensitive components from excessive heat.

Placement:

• Positioned between the turbine and compressor sections, typically inside or adjacent to
the bearing housing.
• It is mounted between the turbine casing and compressor casing, forming a physical
separation between these sections.

✅ Why is it placed there?

• To prevent excessive heat transfer to the bearing housing, which could cause oil
degradation and bearing failure.
• Ensures that temperature differentials do not cause distortion or misalignment in
turbocharger components.

✅ Failure Effects:

• If the partition wall is cracked, broken, or warped, it can lead to:

o Excessive heat transfer to the bearing housing, causing oil coking and premature
bearing wear.
o Thermal expansion issues, leading to misalignment of rotating parts

Figure: Partition Wall for TPL67C turbocharger

26. Gas Outlet Flange:

✅ Function:

• The gas outlet flange is responsible for directing the exhaust gases out of the
turbocharger after they have passed through the turbine wheel.
• It ensures a smooth transition of the high-velocity exhaust gases into the exhaust piping
or after-treatment system (such as an SCR, DPF, or muffler).
• Helps to reduce backpressure,
• Plays a crucial role in maintaining the aerodynamic flow of exhaust gases,

✅ Placement:

• Located at the exit of the turbine casing, where the exhaust gases leave the
turbocharger and enter the exhaust system.
• Typically bolted or welded to the exhaust pipe or manifold connection, ensuring a
leak-proof junction.

✅ Why is it placed there?

• To provide a secure and sealed connection between the turbocharger and the exhaust
system, preventing leakage of hot gases.

✅ Failure Effects:

• If the gas outlet flange is cracked, loose, or improperly sealed, it can cause:
o Exhaust gas leaks, leading to power loss and reduced turbo efficiency.
o Increased backpressure, Excessive heat near engine components, which could
damage surrounding parts.

Fig: Gas Outlet Flange of TPS50-B01

27. Wall Insert:

✅ Function:

• The wall inserts act as a thermal and protective liner inside the turbine casing or gas
passage sections of the turbocharger.
• It helps to shield the turbine casing from direct exposure to high-temperature exhaust
gases, thereby extending the life of the casing.
• In some designs, it also helps in optimizing exhaust gas flow, ensuring smoother
aerodynamics for improved turbine efficiency.

✅ Placement:

• Typically located inside the turbine casing, acting as a lining for the gas flow path
before it reaches the nozzle ring and turbine wheel.
• It can also be found in specific sections of the exhaust gas routing where heat insulation
is needed.

✅ Why is it placed there?

• To protect the turbine casing from extreme heat and prevent thermal expansion-
related stress.
• Ensures that exhaust gas flow remains efficient, without causing excessive turbulence or
heat loss.

✅ Failure Effects:

o Direct exposure of the turbine casing to hot exhaust gases, causing material
degradation and thermal fatigue.
o Distortion of the turbine casing, Reduced efficiency.

Figure: Wall insert for TPS50-B01

28. Hood:

✅ Function:

• The hood in a turbocharger primarily serves as a protective cover over specific sections
of the turbocharger, usually on the turbine or exhaust side.
• It acts as a heat shield, preventing excessive heat radiation from affecting surrounding
engine components.
• It contributes to noise reduction by dampening sound waves produced by high-velocity exhaust
gases.

✅ Placement:

• Typically found on the turbine side of the turbocharger, covering part of the turbine
casing or exhaust gas discharge section.
• In some designs, it is placed over the gas outlet section, providing additional thermal
shielding and structural support.

✅ Why is it placed there?

• To protect nearby engine components from excessive heat exposure.

• To ensure efficient gas flow and exhaust routing while reducing turbulence.
• To reduce noise levels, especially in larger industrial or marine turbochargers.

✅ Failure Effects:

• If the hood is missing, cracked, or improperly installed, it can cause:

o Increased heat radiation, leading to potential overheating of surrounding engine
components.
o Higher noise levels, as the turbocharger exhaust flow becomes less contained.
o

Fig: Hood of TPL67C34 Turbocharger.

29. Gas Admissible Casing:

✅ Function:

• The Gas Admissible Casing is a key component of the turbocharger that directs the
incoming exhaust gases towards the nozzle ring and turbine wheel.
• It serves as a housing that ensures the exhaust gases are delivered in a controlled and
efficient manner, maximizing the energy transfer to the turbine.
• In some turbochargers, it also functions as a pressure chamber, ensuring even
distribution of exhaust gases before they reach the turbine.

✅ Placement:

• Located on the turbine side of the turbocharger, forming part of the exhaust gas inlet
system.
• It surrounds the nozzle ring and is directly connected to the turbine casing, ensuring a
smooth transition of exhaust gases.

✅ Why is it placed there?

• To control and direct exhaust gas flow, ensuring optimal turbine speed and
performance.
• To contain and withstand high temperatures and pressures, as it handles exhaust
gases directly from the engine.

✅ Failure Effects:

• If the Gas Admissible Casing is cracked, eroded, or improperly sealed, it can cause:
o Leakage of exhaust gases, leading to reduced turbine efficiency and power loss.
o Increased backpressure, negatively affecting engine performance.
o Overheating of surrounding components, since hot gases may escape in
unintended directions.

Fig: Gas admissible casing of TCR-16 turbocharger

30. Spacer:

✅ Function:

• The spacer in a turbocharger is a metal ring or cylindrical component used to

maintain proper axial clearance between rotating and stationary parts.
• It helps in positioning bearings, thrust collars, and other components within the
bearing housing.
• Reduces unwanted movement and prevents metal-to-metal contact between critical
turbo components.

✅ Placement:

• Typically found inside the bearing housing, positioned between the thrust bearing,
thrust collar, or radial bearings.
• Some spacers are also placed between the turbine and compressor wheels to maintain
correct rotor alignment.

✅ Why is it placed there?

• To ensure correct spacing and prevent misalignment of internal components.

• To reduce excessive play that could cause imbalance, wear, or damage.
• To maintain oil flow channels, ensuring proper lubrication between moving parts.

✅ Failure Effects:

• If the spacer is missing, deformed, or worn out, it can cause:

o Misalignment of the rotor assembly, leading to bearing failure or increased
vibration.
o Improper axial clearance, which could result in bearing wear or shaft damage.

Fig: Spacer of KBB4000 turbocharger.

Different types of Engines used in IPP
(Independent Power Plants) and
Different types of Turbochargers and
their series.
Famous Engine Brands which are typically used in Bangladesh with their
specialization, origin and most common series:

Serial Engine Brand Country of Specialization Popular Models

No Origin in Bangladesh

1 Wärtsilä Finland Medium & Wärtsilä 32,

large power Wärtsilä 34DF,
plants, marine Wärtsilä 46,
engines Wärtsilä 50DF
2 MAN Energy Germany Power plants, MAN 18V48/60,
Solutions marine MAN 12V32/40,
propulsion MAN 9L28/32H
3 Caterpillar USA Power CAT 3516, CAT
(CAT) generation, C175, CAT
industrial G3512, CAT 3616
engines
4 Rolls-Royce UK/Norway Large power Bergen B32:40,
(Bergen plants, marine Bergen C25:33,
Engines) engines Bergen KV-G4
5 MWM Engine Germany Natural gas MWM TCG 3016,
(Motoren- power plants, MWM TCG 2020,
Werke biogas plants, MWM TCG 2032,
Mannheim) and combined MWM TCG 3042
heat & power
(CHP)
systems.
6 Jenbacher Austria Gas power Jenbacher J320,
plants, Jenbacher J420,
combined Jenbacher J620
heat and
power (CHP)
7 Perkins UK Industrial Perkins 4016,
generators, Perkins 2506,
small power Perkins 2806
plants
Different types of Turbochargers and
their series.
1.ABB (Now Accelleron)
Comprehensive Accelleron Turbocharger Series Table
Engine
Series Models Engine Type Application Key Features
Speed

- High air delivery

efficiency for better fuel
consumption.
TPL65-B, TPL69-B, Medium-speed 500 – Large power plants,
TPL-B - Optimized for
TPL71-B, TPL73-B, 4-stroke 1,200 Marine propulsion,
Series continuous operation.
TPL76-B, TPL77-B engines RPM Industrial
- Supports high-pressure
ratios for power
generation.

- Built for low-speed and

highly durable engines.
TPL65-C, TPL69-C,
TPL-C Low-speed 2- 100 – 400 Large marine engines, - Designed for large-
TPL71-C, TPL73-C,
Series stroke engines RPM Diesel power plants scale power generation.
TPL76-C, TPL77-C
- Capable of handling
high thermal loads.

- Compact &
lightweight design.
TPS44-D, TPS48-D, High-speed 1,200 – Power generation,
TPS-D - Improved radial
TPS52-D, TPS57-D, diesel & gas 2,200 Locomotives, Marine
Series turbine efficiency.
TPS61-D engines RPM auxiliary engines
- Suitable for high-speed
diesel/gas engines.

- Enhanced compressor
efficiency for better
TPS44-E, TPS48-E, High-speed 1,200 – Locomotives, Small performance.
TPS-E
TPS52-E, TPS57-E, diesel & gas 2,200 marine vessels, Industrial - Upgraded bearings for
Series
TPS61-E engines RPM generators longer lifespan.
- Optimized for fuel-
efficient operation.

- Designed for large two-

stroke engines.
A140-L, A155-L, Ultra-low- Large marine propulsion, - High-pressure ratios
A100-L 80 – 250
A160-L, A165-L, speed 2-stroke Bulk carriers, Container improve engine
Series RPM
A170-L engines ships efficiency.
- Meets IMO emissions
regulations.
2.MAN TURBOCHARGERS
Comprehensive MAN Turbocharger Models Table

Engine
Turbocharger
Models Engine Type Speed Application
Series
(RPM)
Marine propulsion,
TCA66, TCA77, TCA88, TCA99, Medium-speed 500 – 1,200
TCA Series Industrial, Power
TCA106 4-stroke RPM
plants

TCR12, TCR14, TCR16, TCR18,

Large marine
TCR22, TCR26, TCR28, TCR32, Low-speed 2- 100 – 400
TCR Series engines, Diesel
TCR36, TCR77, TCR88, TCR99, stroke RPM
power plants
TCR106

NR18, NR22, NR28, NR32, NR36, Medium-speed 500 – 1,500 Power plants,
NR Series
NR40 4-stroke RPM Marine, Industrial

Medium-speed 500 – 1,500 Marine, Industrial,

NA Series NA22, NA28, NA32, NA36
4-stroke RPM Power generation

NR18-R, NR22-R, NR28-R, NR32-R, Medium-speed 500 – 1,500 Power plants,

NR-R Series
NR36-R 4-stroke RPM Marine, Industrial

Heavy-duty
1,000 – Industrial, Power
HTC Series HTC22, HTC28, HTC32 Industrial
2,500 RPM generation, Marine
engines

Medium-speed 500 – 1,500 Marine, Industrial,

NA-R Series NA22-R, NA28-R, NA32-R
4-stroke RPM Power generation
3.NAPIER TURBOCHARGERS
Napier Turbochargers offers a diverse range of turbocharger series and models designed for
various industrial applications, including marine, power generation, oil and gas, and rail sectors.
Below is an overview of their primary series and corresponding models:

NTR Series

• NTR: This series encompasses small industrial turbochargers suitable for applications
requiring compact and efficient solutions.

7 Series

• NA297: Supports engine outputs up to 3.5 MW.

• NA307: Supports engine outputs up to 4.5 MW.
• NA357: Supports engine outputs up to 6.5 MW.
• NA397: Supports engine outputs up to 9 MW.
• NA457: Supports engine outputs up to 10 MW.

The 7 Series is known for its high efficiency and broad operating range, making it versatile for
various industrial applications.

NT1 Series

• NT1-10A: Designed for engine power outputs up to 4 MW.

• NT1-12A: Designed for engine power outputs up to 5.5 MW.
• NT1-14A: Designed for engine power outputs up to 9 MW.

The NT1 Series offers high-pressure ratios up to 6:1, enhancing engine performance and
efficiency.

NT2 Series (Two-Stage)

• NT2-26: Specific details are limited, but this model is part of Napier's two-stage
turbocharger lineup.
• NT2-28: Specific details are limited, but this model is part of Napier's two-stage
turbocharger lineup.

The NT2 Series is engineered for applications requiring advanced two-stage turbocharging
solutions.
5 Series

• HP201: Supports various industrial applications.

• HP202: Supports various industrial applications.
• HP203: Supports various industrial applications.
• HP204: Supports various industrial applications.
• HP210: Supports various industrial applications.

The 5 Series is recognized for improved fuel consumption, reduced engine emissions, and
extended service life.

8 Series

• NA298: Features high efficiency and pressure ratio capabilities.

• NA358: Features high efficiency and pressure ratio capabilities.

The 8 Series incorporates the latest bearing technology and gas path components, ensuring
optimal performance.

MS Series

• MS100: Supports various industrial applications.

• MS200: Supports various industrial applications.
• MS300: Supports various industrial applications.
• MS400: Supports various industrial applications.
• MS500: Supports various industrial applications.

The MS Series includes models like MS100 and MS200, catering to specific industrial needs.
4.KBB TURBOCHARGERS
KBB Turbochargers offers a diverse range of turbocharger series and models designed for
various applications, including marine propulsion, power generation, and rail transport. Below is
an overview of their primary series and corresponding models:

ST27-EP Series

• Models: ST3, ST4, ST5, ST6, ST7

• Engine Output Range: 500 to 6,000 kW
• Pressure Ratio: Up to 6:1
• Features: Designed for medium-speed and high-speed diesel, gas, and dual-fuel engines.
Equipped with oil supply through the turbo support, compressor and turbine washing
devices, speed measurement, and jet assist cartridges.

K2B Series

• Engine Output Range: 1,500 to 6,000 kW

• Pressure Ratio: Up to 10:1
• Features: Includes water-cooled bearing housing, compressor washing device, speed
measurement, and jet assist.

HPR Series

• Models: HPR3000, HPR4000, HPR5000, HPR6000

• Engine Output Range: 500 to 3,000 kW
• Pressure Ratio: Up to 5:1
• Features: Single-stage turbines suitable for medium-speed engines. Equipped with oil
supply through the turbo support, compressor and turbine washing devices, speed
measurement, and jet assist cartridges.

M Series

• Models: M40, M50, M60, M70

• Engine Output Range: 900 to 8,000 kW
• Pressure Ratio: Up to 4:1
• Features: Designed with axial turbine stages and water-cooled bearing housings.
Includes compressor washing devices and speed measurement.

R Series

• Models: R2-2, R3-2, R3-3, R4-2, R4-3, R5-3

• Features: Specific details are limited, but this series is recognized for its application in
various industrial sectors.
HSR Series

• Models: HSR4, HSR6

• Features: Specific details are limited, but this series is known for its high-performance
capabilities.

LPR Series

• Models: LPR5
• Features: Specific details are limited, but this series is tailored for specialized
applications.
5.Garrett TURBOCHARGERS
Garrett Motion offers a comprehensive range of turbochargers designed to enhance engine
performance across various applications. Below is an overview of their primary series and
corresponding models:

G-Series

The G-Series turbochargers are engineered for high-performance applications, featuring

advanced aerodynamics and dual ceramic ball bearing cartridges. They support a wide range of
engine displacements and horsepower outputs.

• G25-550: Supports 1.4L to 3.0L engines, delivering up to 550 horsepower.

• G25-660: Supports 1.4L to 3.0L engines, delivering up to 660 horsepower.
• G30-770: Supports 2.0L to 5.0L engines, delivering up to 770 horsepower.
• G30-900: Supports 2.0L to 5.0L engines, delivering up to 900 horsepower.
• G35-1050: Supports 2.5L to 6.0L engines, delivering up to 1,050 horsepower.
• G35-1150: Supports 2.5L to 6.0L engines, delivering up to 1,150 horsepower.
• G40-1150: Supports 2.0L to 6.0L engines, delivering up to 1,150 horsepower.
• G42-1200: Supports 2.0L to 7.0L engines, delivering up to 1,200 horsepower.
• G42-1450: Supports 2.0L to 7.0L engines, delivering up to 1,450 horsepower.
• G45-1500: Supports 3.0L to 8.0L engines, delivering up to 1,500 horsepower.
• G57-1800: Supports 5.0L to 12.0L engines, delivering up to 1,800 horsepower.
• G57-3000: Supports 5.0L to 12.0L engines, delivering up to 3,000 horsepower.

GTX Gen II Series

The GTX Gen II Series represents the latest evolution in the GTX lineup, featuring state-of-the-
art aerodynamics and improved compressor wheel designs for enhanced performance.

• GTX2860R Gen II: Ideal for 1.4L to 2.5L engines, supporting up to 475 horsepower.
• GTX2867R Gen II: Suitable for 1.4L to 2.5L engines, supporting up to 500 horsepower.
• GTX3071R Gen II: Designed for 2.0L to 3.0L engines, supporting up to 650
horsepower.
• GTX3076R Gen II: Supports 2.0L to 3.0L engines, delivering up to 700 horsepower.
• GTX3582R Gen II: Suitable for 2.5L to 4.0L engines, supporting up to 850 horsepower.
• GTX3584RS Gen II: Designed for 2.5L to 4.5L engines, supporting up to 1,000
horsepower.

GT Series

The GT Series turbochargers are known for their reliability and performance, commonly used in
both OEM and aftermarket applications.

• GT2052: Supports 1.4L to 2.0L engines, delivering 140 to 230 horsepower.

• GT2554R: Ideal for 1.4L to 2.2L engines, supporting 170 to 270 horsepower.
• GT2860R: Suitable for 1.8L to 3.0L engines, supporting 250 to 475 horsepower.
• GT3071R: Designed for 2.0L to 3.0L engines, supporting 300 to 500 horsepower.
• GT3582R: Supports 2.0L to 4.0L engines, delivering 400 to 700 horsepower.

GTW Series

The GTW Series offers a balance between performance and affordability, featuring updated
compressor wheel designs.

• GTW3476: Supports 2.0L to 4.5L engines, delivering up to 750 horsepower.

• GTW3884: Suitable for 3.0L to 5.5L engines, supporting up to 950 horsepower.
• GTW3884R: Designed for 3.0L to 5.5L engines, supporting up to 1,000 horsepower.

GBC Series

The GBC Series is tailored for enthusiasts seeking cost-effective turbocharging solutions without
compromising on performance.

• GBC14-200: Ideal for 0.4L to 1.2L engines, supporting up to 200 horsepower.

• GBC17-250: Suitable for 0.6L to 1.5L engines, supporting up to 250 horsepower.
• GBC20-300: Designed for 1.0L to 2.0L engines, supporting up to 300 horsepower.
• GBC22-350: Supports 1.4L to 2.5L engines, delivering up to 350 horsepower.
• GBC25-450: Ideal for 1.8L to 3.0L engines, supporting up to 450 horsepower.
SOME ABBREVIATION
Accelleron:
1. TPS - TPS stands for "Turbocharger Power Small."
TPS-D(D for diesel Series)
TPS-E (E for Enhanced means for advance)

2.TPL - TPL stands for "Turbocharger Power Large.

TPL-B (B for Baseline or Basic means old versions)
TPL-C (C for Compact or Competitive Series A newer,
more advanced version of the TPL turbocharger series.)

3.A100-E Series
The "A100" denotes Accelleron's high-efficiency radial-
flow turbocharger series. The "E" stands for Enhanced,
signifying improvements over previous models.
MAN:
NAPIER TURBOCHARGERS: