Turbocharger Training Russia 2010 Rajesh Sendil

Turbocharger Training Russia 2010 Rajesh Sendil – Area Sales Manager UK, Ireland, Russia and Eastern Europe

Agenda Introduction to Cummins Inc. Cummins Turbo Technologies Overview Products and Technology 2010 Business update Aftermarket Support Examples of Current applications Turbochargers Failure Diagnosis Copy Turbochargers Technology

Introduction to Cummins Inc

Our Vision/Mission: VISION Making people’s lives better by unleashing the Power of Cummins. MISSION Motivating people to act like owners working together. Exceeding customers’ expectations by always being the first to market with the best products. Partnering with our customers to make sure they succeed. Demanding that everything we do leads to a cleaner, healthier, safer environment. Creating wealth for all stakeholders.

The New Cummins: Global presence Less cyclical More diversified Low-cost producer Complementary businesses working together Becoming the first choice of our customers

Tim Solso Chairman and CEO Tom Linebarger President and Chief Operating Officer Jean Blackwell Executive Vice President – Corporate Responsibility and CEO – Cummins Foundation Bruce Carver Chief Information Officer Steve Chapman Group Vice President – China and Russia Jill Cook Chief Human Resource Officer Thad Ewald Vice President – Corporate Strategy and Business Development Ignacio Garcia Chief Manufacturing and Procurement Officer Mark Gerstle Chief Administrative Officer Marya Rose General Counsel and Corporate Secretary Floyd Rutan Executive Director – Cummins Business Services John Wall Chief Technical Officer Pat Ward Chief Financial Officer Cummins Inc

Introduction to Cummins Turbo Technologies

Overview Cummins Turbo Technologies is an autonomous Business Unit of Cummins Inc We are the leading designer and manufacturer of turbochargers for diesel and gas-derivative engines above 2.3 litres We have over 2000 employees globally Headquartered in the UK with global manufacturing facilities in; Brazil, China, Europe, India and USA along with dedicated technical centres in UK and China

Global Customers:

Business Strategy Be the first choice for customers through our market leading dependable technology and innovative air handling solutions To profitably grow the business by delivering the best value turbocharger technology to our customers Focus on customer support excellence to achieve customer loyalty through the reliable supply of turbochargers Harnessing the skills and creativity of our employees to be the benchmark supplier of turbocharger technologies

Products & Technology

The commercial turbocharger market has seen steady growth over the past few years. This is expected to continue into the next decade and beyond Growth is driven by increasingly stringent government emissions legislation worldwide Turbocharging technology is seen as a key tool in enabling engine manufacturers to meet these strict criteria Market Drivers:

To profitably grow the business by delivering the best value turbocharger technology to our customers. Focus on customer support excellence to achieve customer loyalty Reliable supply of turbochargers to all customers Easy to do business with Provide a financial return to ensure future technology investment and growth. Business Strategy:

On-highway, heavy duty emissions legislation by country and date of introduction Emission Regulations

Product Focus Cummins Turbo Technologies has developed advanced turbocharging technologies to enable engine manufacturers to meet strict emissions criteria and engine performance requirements Can offer a portfolio of technology to meet our strategic customers’ target markets: Holset VGT™ with electric actuation Turbo compound System Serial 2 Stage M Squared™

Product Range

Holset HE Range A new technology platform for future emissions engines: Holset VGT with electric & pneumatic actuation options High pressure ratio compressors including Titanium option High durability Advanced control capability Speed & inlet air temperature measurement Fully modulating control valves (DCon) with remote intelligence option (ICon) Low flow turbine stages with wastegate for EGR engines Enhanced MWE for improved compressor map width

Holset Product Features Cast Aluminium: Standard technology Very cost effective and suitable for mid-range turbochargers Not suitable for those with high duty cycles Cast Titanium: Can withstand high temperatures Effective metal to use in heavy duty turbochargers Titanium is a cost premium Cummins Turbo Technologies use a number of different methods and materials to create its impellers. Each give different durability vs cost benefits:

Holset Product Features Machined from solid (MFS) Aluminium: Casting process can create defects that become weaknesses in the metal The MFS process reduces such defects considerably Cost effective solution over Cast Ti for increasing durability MFS Titanium: Reduces the possibility of defects seen with casting process Process is slow and expensive Suitable for heavy duty turbochargers with high duty cycles Semi Solid Mould (SSM) Aluminium: Process shapes the wheels at high temperatures and cooled to set Fewer defects than casting process A cost effective alternative to using MFS

2010 Business Update

First fit volumes Global Turbocharged Engine Market

A Global Presence

Global Capacity

Turbo Technologies Worldwide Sales & Volume History

Commercial Diesel Market Shares (2009)

Aftermarket Support

Aftermarket & Distribution Network Focused on serving OEM global service networks Specialised service, packaging & logistics Dedicated facilities: USA, China, Europe, India and Brazil 24 hour, 7 day per week coverage Extended opening hours Multi-lingual Staff OEM Remanufacturing Service Independent channel of distributors Local expertise, coverage of old, ex-OE production product, capable of specialised logistics service

Service/Spare Parts Focused on serving OEM global service networks Specialised service, packaging & logistics Dedicated facilities: USA, China, Europe, India and Brazil 24 hour, 7 day per week coverage Extended opening hours Internet Ordering Multi-lingual Staff OEM Remanufacturing Service Independent channel of distributors Local expertise, coverage of old, ex-OE production product, capable of specialised logistics service

UK Operations Aftermarket, UK Technical Centre, UK Technical Centre, UK

Dewas, India India Operations

Palmetto, USA USA Operations Leeds Avenue, USA

China Operations Wuxi, China

Sao Paulo, Brazil Brazil Operations

Amersfoort, The Netherlands Holland Operations

Examples of Current Applications

Peterbilt with Paccar MX engine and Cummins ISX15 – US10 500 series Holset VGT with electric actuation on Paccar MX 400 series Holset VGT with electric actuation on Cummins ISX15

Scania Euro IV Turbo Compound Engine Holset 500 series fixed geometry turbocharger and Holset 700 series power turbine

Volvo New HDEP Engine Platform – Euro IV Holset 500 series fixed geometry

Holset 500 series fixed geometry turbocharger with a Holset 800 series axial power turbine Axial Power Turbine – Euro VI/EPA 10

Ford F250 Pick-up Holset HE221W

Chrysler Dodge Ram 07 – EPA 07 Holset HE351Ve

Iveco Cursor Engines for Stralis – Euro IV Holset HE431V – Cursor 8 Holset HE531V – Cursor 10 Holset HE551V – Cursor 13

Daewoo CNG City Bus – Euro III Holset HX50G

Pisten Bully 400 Holset 400 series wastegate

Griffon Military Hovercraft 4 x Holset 500 series wastegate

Turbochargers Explained

Advantages of Turbochargers In turbochargers the exhaust gas energy which would normally be wasted is used to drive a turbine, which in turn drives a compressor to deliver compressed air to the engine. The advantages of a turbocharged engine are: lower fuel consumption lower emissions better torque characteristics lower weight and smaller engine package lower engine noise

More Power Required 4cyl 4litre 80HP 247 kg Turbocharged 4cyl 4litre 122HP 286 kg 6cyl 6litre 120HP 344 kg Choice is either; Increase the size of engine or fit a turbocharger.

Major Components of a Turbocharger Bearing Housing Compressor Wheel Turbine Housing Turbine Wheel Compressor Cover

How a Turbocharger Works The Turbine End The Compressor End The Oil Supply

How a Turbocharger Works The turbine housing is bolted to the exhaust manifold of the engine. The waste exhaust gasses are used to rotate the turbine wheel which is housed in the turbine casing.Turbine temperatures up to 760 deg C The turbine wheel is connected to a common shaft which in turn rotates a compressor wheel.

How a Turbocharger Works As more gas passed through the turbine housing, the faster the turbine wheel rotates. As the turbine wheel increases in speed, so does the compressor wheel. This creates a sucking process and pulls air into the compressor cover from the atmosphere (filtered). The faster the wheels spin the, the more air is sucked in.

How a Turbocharger Works As the air is sucked into the compressor cover, it is forced through a diffuser area. This compresses the air and forces it into the engine This process causes the air to increase in temperature, up to 200 degrees C

Typical Turbocharger components Wastegate actuator Wastegated turbine housing Oil inlet Turbine wheel Impeller Wheel Turbine inlet Exhaust Outlet Compressor Housing Bearing Housing

T = 21°C Air Filter T = 25°C Comp T = 180°C After cooler T = 40°C Turb Exhaust Manifold Inlet Manifold T= 690°C T = 550°C Silencer T = 400°C Typical Engine System

Bearing System Journal Bearings fully floating bearings - allows higher clearances, so higher oil flows for cooling oil film thicknesses of 0.008 to 0.015 mm leaded bronze allow high degrees of imbalance Thrust Bearing taper land bearing phosphor bronze or sintered iron thrust loads of 100 - 2000 N (size dependent) typical oil film thickness 0.008 - 0.015mm Has to withstand high temperatures, hot shut down, soot loading in the oil, contaminants, oil additives, dry starts.

A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the turbine – thus limiting turbo speed & boost pressure. Typically the wastegate valve is only opened at high engine speeds & loads (used to prevent turbo speed or boost pressure from exceeding safe levels). Turbocharger Basics – Wastegates

Wastegate Turbocharger

Wastegate Turbocharger Wastegate Mechanism: Actuator-linkage-valve

Wastegate Turbocharger

Wastegate Check Apply 3 bar (300 kPa) air pressure to ensure that the wastegate actuator is not leaking or stuck. Check for air leakage

Turbocharger Failure Analysis

Turbocharger Failure Analysis The purpose of analysing a ‘failed’ turbocharger is to determine the root cause of failure. We also need to determine who is responsible. We need to prevent a reoccurrence - whether it is a Cummins Turbo Technology problem or a customer / end user problem. If the problem is Cummins Turbo Technologies we need to ‘fix’ it. If the problem is the customer’s we need to work with and support them, to ensure it doesn’t happen again.

Customer Reported Faults Leak oil Broken Wheel Low power Noisy Gas leakage Seized Excess bearing wear Broken shaft Smoke

Failure Data Date in Service ( DIS ) Date of failure ( DOF ) Service Life ( Hours,Kms,Mls ) Application ( Truck,Bus,Off road,Genset ) Duty Cycle ( City bus,stand by genset,General freight ) Country in Service Reason for removal from vehicle. ( Need to be specific, not just leak oil or broken ) Turbocharger Serial Number ( Date of manufacture ) Assembly Number Customer Number is applicable Model

Warranty Analysis How can we determine the root cause of the problem?

Customer Responsibility

Disassembly & Inspection Check for compressor end foreign object damage by looking in the intake. AIR INTAKE

Foreign Object Damage Compressor End Damage to the blade tips Cause : Rags,wrenches,nuts,screws,parts from the intake filter.

Disassembly & Inspection Check the turbine intake for signs of solid objects. Note! Except in severe cases the turbine housing needs to be removed (in order to inspect the blade tips). TURBINE INLET

Foreign Body Turbine End

Disassembly & Inspection Check the overall appearance corresponds with the data supplied. (i.e. claim data is 10,000kms, but turbo appears to have been in use for much longer . Check axial and radial clearances. Clearances can be found in the CTT Service Data Sheet (current version can be downloaded from www.Holset.co.uk - Parts & Service section)

Disassembly & Inspection Remove the compressor housing Remove the core assy from the turbine housing Remove the turbine housing and compressor cover and check for any wheel “touches” or “rubs” on the profile.

Disassembly & Inspection Remove the compressor wheel and check for signs of excessive oil on the backface.This could be due to oil carryover past the compressor seal ring. Check condition of the seal ring when removed. The most common cause of oil leakage, is a blocked air intake filter.

Disassembly & Inspection Remove the shaft & wheel,check for any heat discolouration and any wear on the shaft.

Disassembly & Inspection Remove the circlip Remove the oil seal plate Remove the O-ring seal Check for damage to the O-ring seal

Disassembly & Inspection Remove the oil slinger from the oil seal plate. Check for wear or score marks in the bore. Remove the seal ring

Disassembly & Inspection Remove the thrust bearing and thrust collar,check for blockage of the oil feed holes ( a common cause of thrust failure ). Check for heat discolouration and scoring marks of both the bearing and collar. If excessive radial clearance was found it is likely that the journal bearings will also be damaged.

Silicone Applied to Oil Inlet Gasket Do not use silicone

Foreign Body Blocking the Oil Supply to the Thrust Bearing Silicone blocking oil to the thrust bearing

Blocked Thrust Bearing Foreign object blocking the oil feed to the thrust system Cause : Silicone from the oil feed pipe fitting. Cleanliness during service intervals,filters and oil.

Disassembly & Inspection Remove the compressor-end outer circlip and remove the journal bearing. Look for scoring marks on both the outside (OD) and inside (ID) diameters, this can be caused by oil contamination ( dirt ) in the oil. Remove the turbine-end bearing. This bearing will normally be a much darker colour than the compressor bearing (due to higher operating temperature).

Oil Dirt Ingress Cause : Service intervals overdue Cleanliness during service Poor quality oil Poor quality filters

Oil Dirt Ingress Shaft wear from oil dirt ingress

Oil Contamination New bearing Contaminated bearing Check the colour of the bearing, a natural darkening with age is acceptable. A duller,powdery surface is an indication of engine coolant in the oil - the same appearance will normally also be found on the thrust bearing.

Oil Delay Bronze particles on the shaft Causes :Restricted oil feed pipes. Low oil level in the sump Blocked oil filter Long periods on Non – use Lack of priming

Oil Starvation Cause : Oil pump failure Broken oil feed pipe No oil in engine.

Hot Shutdown - Overheating Cause: Hot shutdown of the engine, poor quality lub. oil, infrequent service intervals, check for heavy carbon deposit in the bearing housing.

Hot Shutdown Oil Drain Blocked oil drain cavity Oil Leakage

Hot Shutdown - Overheating

Time (secs) 0 360 60 120 180 240 300 140 180 220 260 300 340 Bearing Temperature oC Hot Shut Down from Peak Torque 3 min Idle 2 min Idle 1 min Idle Temp Limit of CD Oil Failure Diagnosis: Hot Shutdown

Oil Leakage External - Common Causes : Loose / Damaged oil inlet and oil drain fittings. If fitting a new gasket and tightening the fittings does not stop the leak,then look for a damaged oil line or leaking centre housing. Internal Compressor & Turbine - Common Causes : Restriction in the turbo oil drain will ‘force’ oil past the split ring seals at both the turbine and compressor ends. Oil leakage at both ends simultaneously is a good indicator that this may be the problem Engine blow by pressure - which can be due to the engine crankcase vent being blocked by damage,plugging or icing.

Oil Leakage Restriction

Oil Leakage - Compressor An inlet ‘depression’(vacuum) greater than 25 in water will ‘pull’ oil past the compressor end split ring seal. THIS WILL NOT DAMAGE THE TURBO UNLESS THE THRUST BEARING FAILS. Typical cause is a blocked air intake filter or collapsed intake pipe.

Compressor End Oil Leakage

Oil Leakage

Blow By Recirculation Future legislation may prohibit all uncontrolled engine emissions, including crankcase blow-by gases. CCV systems filter the crankcase emissions from engine piston rings valve stem leakage turbocharger seal leakage air compressor leakage These are generally routed to the turbocharger compressor inlet

Compressor fouling due to CCV system Oil deposit build up can be significant over a period of time

Impeller LCF - Defects Duty cycle Defect presence raises local stresses and initiates fatigue Defects have variety of sizes and appearances There are three common failure locations - back face, suction side exducer blade root and the bore (highest stresses) Back Face

Impeller LCF - Defects Blade Root - Inclusion Blade root - Linear/oxide blow

Impeller LCF - Defects Bore Bore inclusion Bore cavity Cause of failure could also be due to overspeed

Machined From Solid Impeller MFS Overview

x1 - Base Material Fatigue Properties x2 - Material selection and processing Base materials properties improved in MFS impellers due to increased alloy content and fine grain structure from forging process Inherently low level of oxides in wrought alloy used to make MFS impellers Fine grain structure in MFS leads to improved fatigue life

MFS Impeller

x1 - Base Material Fatigue Properties x2 - Material selection and processing Fine grain structure in MFS leads to improved fatigue life Cast microstructure Forged microstructure

Defect (casting process) related failures not experienced in MFS impellers Oxide casting defect

Balance - Related Failures Balance failures due to a manufacturing problem (hence Holset Responsibility) usually occur in very early life. (i.e. most within 500 km). If a balance failure occurs in late life - it is normally caused by wheel foreign-object damage, turbo overspeed or tampering) Balance failure causes: Parts misaligned Rotor parts replaced without check-balancing Incorrect parts used.

Closed crankcase ventilation system Engine Compressor inlet Intercooler Exhaust Crankcase blowby gases Filter system

Copy Turbochargers

Copy Turbos Introduction: Copies are flooding the market from China &Brazil. Many varieties Hosel, Hovte, Hobest and Honesty! They look good (to the untrained eye) Cheap: Approx. 1/2 price of original Holset Turbo

Copy Turbos Back to Back Engine tests: Three copies tested Results follow findings of wastegate settings Low boost and air flow Generally lower total efficiency, by up to 10% This would result in loss of power, higher fuel consumption and higher emissions.

Copy Turbos Holset Vs Copy 1

VIDEO

Copy MAN Turbo Copy turbo – See nut, machining and the shape of the struts. HOLSET genuine turbo

Copy MAN Turbo Copy Turbo – No washers on the screws,machining,flat on the wastegate rod. PS – ignore the shape of the bracket. Genuine Genuine

Copy MAN Turbo Copy turbo – Hose clip and hole in the capsule Holset

Impeller Locknut Copy Genuine

Oil Seal Plate Retaining Ring Copy Genuine Difference Machined

Compressor Housing Retaining Ring Copy Genuine Machined Difference

Turbine Housing Screws Copy Genuine

Installing a Turbocharger

Fitting a Replacement Turbocharger Each HOLSET turbocharger is designed to match a specific engine specification (power, speed, charge cooling etc). The turbocharger dataplate information includes: Assy Number Serial Number Customer Number It is important that the Assy Number shown is the correct number for that engine, per the engine manufacturers specifications. DO NOT REMOVE THE DATA PLATE

Fitting a Replacement Turbocharger It is important that the engine intake / exhaust systems are checked for debris. It is recommended that the air intake filter is changed using only OEM genuine parts

Fitting a Replacement Turbocharger Check that the oil inlet and drain flanges are clean and free from obstruction. Replace the gaskets

Fitting a Replacement Turbocharger Replace the oil and filter using only OEM recommended parts and specified oil grade & classification.

Fitting a Replacement Turbocharger Ensure the engine manifold mounting flange and studs are in good condition and are not warped or bent. Check for any cracks. Check the oil intake line is free from dirt or carbon, if in any doubt - replace the line and fittings with new ones. Mount the turbocharger on the manifold and check that the turbine inlet gaskets fits correctly.

Fitting a Replacement Turbocharger The orientation of the bearing housing or compressor housing may require changing, to align correctly with the air, oil and water connections. Make sure all fasteners are tightened to the specified torque when the orientation is set. Take care not to damage any ‘O’ rings when changing the orientation of the compressor housing as this could cause air leakage. See Holset Service Manual for the recommended torque settings

Fitting a Replacement Turbocharger Connect the oil drain line and then fill the turbocharger oil feed hole with clean engine oil. Slowly rotate the rotor by hand.

Fitting a Replacement Turbocharger Connect the oil inlet line and the remaining external fittings to the turbocharger. Pull out the fuel stop and crank over the engine using the starter motor, until normal operating engine oil pressure is developed. Check for any oil leaks from the connections.

Fitting a Replacement Turbocharger Start the engine and idle,checking that all air,gas and oil connections are tight and free from leakage. Tighten any fastenings as required. Use soapy water to help detect air and gas leaks.

Technology

Holset VGT® Overview

Turbocharger Basics – Fixed Geometry Turbochargers consist of an exhaust-gas driven turbine connected to and driving a radial compressor, providing a boosted air supply to the engine. At a given engine speed, turbo speed (hence boost pressure) can be changed ONLY by changing fuel-rate. - i.e. at a fixed fuelling rate, boost pressure is also fixed. Turbine Stage Compressor Stage Bearing System

A wastegate mechanism functions, by allowing some of the exhaust gas to bypass the turbine – thus limiting turbo speed & boost pressure. Typically the wastegate valve is only opened at high engine speeds & loads (used to prevent turbo speed or boost pressure from exceeding safe levels). Turbocharger Basics – Wastegates

Turbocharger Basics

VGT - Electronic Control Strategy 1 Wastegate Valve Open

VGT - Electronic Control Strategy 1

Holset VGTTM – Performance benefit

By continuously varying the turbine housing’s critical area the exhaust gas can now vary the speed of the turbo, boost pressure and exhaust manifold pressure – independent of engine speed and load. Various ways of achieving Variable Geometry (VG) Variable Geometry (VG) - Basics

Swing Vane – non Holset Variable Geometry (VG) Turbine wheel is surrounded by a ring of nozzle guide vanes. Flow area varied by changing the angle of these vanes in unison.

Holset VGTTM - One Piece Sliding Nozzle

Holset VGTTM - One Piece Sliding Nozzle Fewer moving parts Nozzle carried and moved by 2 rods Fewer potential wear sites

VGT a

Holset VGTTM - One Piece Sliding Nozzle Nozzle ring fully closed Min. turbine volute exit area Max. exhaust manifold pressure Max. shaft speed Max. turbo boost Nozzle ring in mid position Reducing turbine volute exit area Increasing exhaust manifold pressure Increasing shaft speed Increasing turbo boost Nozzle ring fully open Max. turbine volute exit area Min. exhaust manifold pressure Min. shaft speed Min. turbo boost

VGT System - Pneumatic Actuation

Actuator development for VGTTM 2002 Electric Type 1 1998 Pneumatic 2007 Electric Type 2

1 2007 Type 2 SMART electric actuation

2007 Type 2 SMART electric actuation

VGT System - Electronic Actuation

No external moving parts – direct fit on bearing housing On-board microprocessor – relieves load on engine ECU Position request from engine ECU via CAN network Sends status message back to engine ECU: Actual position v target position Internal temperature Motor effort 2007 Type 2 SMART electric actuation

An on-board thermistor monitors temperature. Current limiting is applied if the internal temperature exceeds a safe limit. Motor-effort is monitored, and a de-rate applied under limiting conditions. Has integral event log: 250 error codes – retrievable through OBD connection – or via Holset hardware and software 2007 Type 2 SMART electric actuation

Aspect Actuator “T” Cable Std USB cable Interface Box Holset SOFTWARE Interface Box Aspect System: Interface Hardware & Software 2007 Type 2 SMART electric actuation

2007 Type 2 SMART electric actuation Diagnosis We can see the number of hours run and life history e.g what temperature and load – and for how long

Variable Geometry benefits include: Modulate EGR flow-rate Reduce emissions Higher engine power density Increase engine ‘usable’ speed range Increase low speed torque Improve transient response & ‘driveability’ Enhance engine braking Turbocharger Basics – Variable Geometry

Any Questions? Thank You