Author Topic: Compound Turbos  (Read 8008 times)

February 10, 2007, 02:51:18 pm

bvanetten

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« on: February 10, 2007, 02:51:18 pm »
There are a bunch of threads on this site that talk about compound setups but no info on how they actually work and the math and formulas behind configuring a set.  I think this would be a great thread and I think a few of you have the knowledge to make it happen. :)

From my very limited understanding, to figure the max useable boost from a compound setup you multiply the pressure ratio of both turbos.  I know there isa heck of alot more to this but for figurings sake here goes.

small turbo making 15lbs boost has a ratio of 2.04
big turbo making 10lbs boost has a ratio of 1.68

(2.04 X 1.68 X 14.7) - 14.7 = 35.67 lbs of boost.

What else is involved?  I'd love to make a compound set that made 35lbs of efficient boost.  

School me.

Reply #1February 10, 2007, 03:01:57 pm

SMOKEYDUB

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« Reply #1 on: February 10, 2007, 03:01:57 pm »
ANDY2 is the only one to the best of my knowledge that is drivvin a twin setup .....Not sure how hes doin it sure looks neat and goes pretty good.
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Reply #2February 10, 2007, 07:45:42 pm

JetPo

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« Reply #2 on: February 10, 2007, 07:45:42 pm »
I would also be interested. But a motor has to be rock solide to be able to run with 35 psi of boost right ???? Because i know a guy that completely closed his wastegate on a k24 (1.6 TD) and it boosted beetween 30 and 35 psi, so why go compound if you can get almost the same boost with only one turbo ????

Thanks for the answers
Alex

Reply #3February 10, 2007, 08:00:51 pm

bvanetten

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« Reply #3 on: February 10, 2007, 08:00:51 pm »
I would think that a k24 or T3 pushing out 30 to 35 lbs would be making a ton of heat.

Reply #4February 10, 2007, 08:23:29 pm

jwspin

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« Reply #4 on: February 10, 2007, 08:23:29 pm »
pressure isnt as important as volume. by using a compound you get the early boost with the little turbo but you also can use a bigger turbo to get the volume and keep egts low.

-jared

Reply #5February 10, 2007, 08:29:29 pm

jtanguay

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« Reply #5 on: February 10, 2007, 08:29:29 pm »
Quote from: "bvanetten"
I would think that a k24 or T3 pushing out 30 to 35 lbs would be making a ton of heat.


correct.  a K24's efficiency range is up to about 22 psi... after that the exhaust pressure is more than the boost pressure.


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Reply #6February 10, 2007, 08:57:31 pm

JetPo

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« Reply #6 on: February 10, 2007, 08:57:31 pm »
So for my 1.9TD, what would be the best turbo for max performance.

Reply #7February 10, 2007, 11:38:24 pm

DVST8R

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« Reply #7 on: February 10, 2007, 11:38:24 pm »
Quote from: "JetPo"
So for my 1.9TD, what would be the best turbo for max performance.


That is way to vauge a question to possibly answer, that and it has been attemped to be answered in at least 11ty billion threads just this week...

Let's keep it on track to compounds, or sequentials as some people would like us to call them... (You know who you are  :P )

As has been covered in a few threads recently, there is a big difference between 35psi from a T3 or kkk24, which both are at max at about 24psi, according to there maps and a GT25R or sequential turbo's running 35psi.

Something else to keep in mind, twins are NOT plug and play you need to tune them. This means you will need at least an EGT gauge and 3 boost gauges. "Low pressure, Manifold pressures, and Drive pressure"

Now to even get a decent start at sizing turbo's you need to get the maps for both the turbo's you intened to run, and then lay them one over the other so that the airflow and pressures are on the same scale, and then you need two that fit well together. I am No engineer, nor do I claim to be an expert at turbo matching, but from my limited knowledge you want to find two maps that make one nice big map without any gaps, and with some overlap but not a tone. (how is that for a vague discription) Once you have seen a couple maps for well designed sequential turbo's it will be easy enough to spot what you need, but there in lies the problem the few people that have that knowledge tend not to share it.   :wink:

I'm hoping that one of our resident engineers will chime in here with a more technical discription of sizing sequential turbos... cough, cough TDIMIESTER, QuickTD...

A good place to start for sizing the high pressure turbo is the stock turbo. Now in this case we have a couple to choose from, in bvanetten's case the k24 or T3 is obviously to big, as he is haveing problem's with spooling it all on its own in his application. Here is my very general list for high pressure turbo's and there app's:

T2/K14/k03 - really borderline to small for everything as they will create pretty huge drive pressures, an external wastegate version might do better depending on manifold design.

k14/k24 - hybrid probably the smallest I would consider running ironicly most people when making hybrids like this use the big cold side with the small hot side, but for this it would be the opposite to keep the quick spool, but with liveable drivepressures. This would be my backup recomendation for bvanetten for the highpressure turbo

GT15 - found on early TDI's before the intrduction of VNT turbo's, it spools great and has better flow then the above mentioned turbo's. This would be my recomendation for a street / 4wd application.

K24/T3 - Decent hot street turbo, still a little slow spooling compared to the GT15 and a little less flow, but cheap and availble stock on every car. Too big for 4WD app, but decent for a cheap turbo with good fueling.

T3 .48 hotside - app Merc300TD - good flow and decent spool, on a big fueled street / strip car. Also makes for a good sinlge turbo for someone looking for reduced egt's on a turned up pump.

GT20 - Quicker spooling then the K24/T3's and more flow, best alround street / strip turbo, great single turbo and great for building upon. Only draw back $$$$ both for the turbo and for a new exhaust manifold.

GT22 - Borderline big as a street turbo as a single, and broken crank big as a hp turbo (ie, no one in known history has made enough power to use this in a compound setup)

Well as I said earlier I'm no expert but this is my "guess" on how things work  :roll:

As for the low pressure turbo well that will be another installment... Another time...

But for a quick preview in no perticuler order:

-HX30
-K26
-K24/K26 hybrid
-GT22
-GT25R

A couple more things to keep in mind is that sizing turbo's is a bit of a black art and there are very few people who are experts at doing it. The best way is to find one of them and bribe them well, short of that it is trial and error. A very important thing to remember is that not all turbo's are created equal there are at least 7 variations of GT20's sold by garret, not all will work well on our motor's. That is just Garrett there are a ton of companies that start with a garrett frame and build hybrids out of anygiven turbo. Giving you hundreds of choices of sizes within sizes. Also there are a number of other turbo companies out there that I don't have much for personal experiance with and as such I did not touch on, this is not becuase they are poor turbo's it is just because I don't have any personal experiance with them. Just to name a few: Switzer, Mitsubishi, Catapiller, Holeset, ect...

Well hopefully this sparks a bit of conversation.  :D
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Reply #8February 11, 2007, 08:10:01 am

bvanetten

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« Reply #8 on: February 11, 2007, 08:10:01 am »
DVST8R, great start.  Does this site have a "files" section?  It would be cool to have a place to put turbo maps and all of the extra data related to that map and turbo like the size of the wheels and turbines and housings.

Was my math to determine max boost with a pair of turbos correct?  I realize that equation does not account for maps and heat and whatnot.

Reply #9February 11, 2007, 08:12:55 am

JetPo

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« Reply #9 on: February 11, 2007, 08:12:55 am »
So for my ''STREET'' 1.9 TD, y should use a GT20 but you wrote $$$$, so how much $$$$ does that turbo cost, and can i find it on a company motor ??? Or esle the T3 .43 hotside seems to be good ??? Oh , and by the way, i want to run about 28psi.

Thanks for your help. I hope i am not making you feel like your wasting your time. Im new to this and want to learn  :roll:  So thanks again.

Alex

Reply #10February 11, 2007, 03:31:31 pm

andy2

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« Reply #10 on: February 11, 2007, 03:31:31 pm »
I wish I could comment more on my current setup (k24 hotside/k14 coldside with HX30w however my headgasket only held for the first 10km of my test run.I do believe that my setup will be efficient upto 40+psi anyways as I have used this combo 1 year ago and with it not setup properly it made 37 psi boost with 42psi drive pressure.It also spools very very well espiceally now with 5w40 synthetic which makes it a very good all around combo :wink:.

I noticed you said your aiming for 35 psi with a compound setup so
building an engine that can handle 30+ psi "efficienty" and lots of fuel is the only other issue.You need a better intake manifold,stronger rods,bigger precups(to burn the extra fuel+lower CR) then you need to O-ring/fire ring the head and block and use a copper HG.I'm burning well over double the stock fueling and only 29 psi boost my EGT's are now not too far out of control and when I get my engine back together I'll run 35 psi and it may be enough to safely keep the egt's under control.

The only reason for using compounds is to be able to make lots of hp and have good spool up.If your aiming for less than 150 hp 30 psi max then I would reccomend using a single turbo!Over 150 hp be prepared for lots of engine issues :cry:.

Reply #11February 11, 2007, 04:10:54 pm

DVST8R

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« Reply #11 on: February 11, 2007, 04:10:54 pm »
Quote from: "JetPo"
So for my ''STREET'' 1.9 TD, y should use a GT20 but you wrote $$$$, so how much $$$$ does that turbo cost, and can i find it on a company motor ??? Or esle the T3 .43 hotside seems to be good ??? Oh , and by the way, i want to run about 28psi.

Thanks for your help. I hope i am not making you feel like your wasting your time. Im new to this and want to learn  :roll:  So thanks again.

Alex


Start a new thread. I will answer the questions there.
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Reply #12February 11, 2007, 04:18:22 pm

DVST8R

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« Reply #12 on: February 11, 2007, 04:18:22 pm »
Quote from: "andy2"
I wish I could comment more on my current setup (k24 hotside/k14 coldside with HX30w however my headgasket only held for the first 10km of my test run.I do believe that my setup will be efficient upto 40+psi anyways as I have used this combo 1 year ago and with it not setup properly it made 37 psi boost with 42psi drive pressure.It also spools very very well espiceally now with 5w40 synthetic which makes it a very good all around combo :wink:.

I noticed you said your aiming for 35 psi with a compound setup so
building an engine that can handle 30+ psi "efficienty" and lots of fuel is the only other issue.You need a better intake manifold,stronger rods,bigger precups(to burn the extra fuel+lower CR) then you need to O-ring/fire ring the head and block and use a copper HG.I'm burning well over double the stock fueling and only 29 psi boost my EGT's are now not too far out of control and when I get my engine back together I'll run 35 psi and it may be enough to safely keep the egt's under control.

The only reason for using compounds is to be able to make lots of hp and have good spool up.If your aiming for less than 150 hp 30 psi max then I would reccomend using a single turbo!Over 150 hp be prepared for lots of engine issues :cry:.


For everyone reading this, the only two vw idi motor's I know of that have made over 150hp, are Andy's and Malone's. There are lots of rumours of big power motors across the pond but I have never seen dyno sheets or time slips to prove this. Not saying it isn't possible just saying I haven't seen the proof.

So those two are definatly your guides, I know that Dave @ PP had a big hand in the build of Malone's motor, and QuickTD had a hand in at least the turbo setup of Andy's motor, and BOTH run GILES pumps.  :wink:
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Reply #13February 11, 2007, 06:49:44 pm

bvanetten

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« Reply #13 on: February 11, 2007, 06:49:44 pm »
I'm going to cut and paste your questions in my other thread about my rig and comment there.  I'm REALLY REALLY interested in what you have to say but would like to keep this thread about turbo engineering and compounds in paticular.

I googled up some info that seems to be pertinant.

http://www.mrcontrols.com/primers/sizing.htm
It refers to a specific motor but the math and steps apply to us all.

Pressure ratio
Motor CFM naturally aspraited at different rpm ranges
CFM potential of turbo at different PE's
VE or Volumetric efficiency
Intercooler efficiency
HEat generated
Density ratio

Whooo!  Lots of stuff to digest.  And this is probably just the tip of the iceberg.  A list of required info that one needs to have to start the process of picking turbos is probably the next step.  MAybe after I let this all soak in.

Reply #14February 11, 2007, 09:17:17 pm

bvanetten

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« Reply #14 on: February 11, 2007, 09:17:17 pm »
Any of you guys ever checked out this site/calculator?

http://not2fast.wryday.com/turbo/glossary/turbo_calc.shtml

The smallest T3 map you can play with is a T3-40 which is a bit bigger that what we run I think.  Even still you have to rev the hell out of the motor to be anywhere near the sweet spot.  I wish they had maps for our otehr turbos.