Diesel air supply and exhaust systems

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Flaws

Fortunately, Ford's other independent EGR system was introduced that same year, which was much more advanced. It had an automated system for opening and closing valves under specific engine operating conditions. At low temperatures in the combustion chamber, the valve closed, allowing the motorist to warm up the engine easily. The higher the temperature in the combustion chamber rose, the wider the valve opened, allowing more and more gas to pass through for cooling. However, the lack of feed control remained, which led to the fact that the use of this system was associated with a number of disadvantages.

Chief among them was the fact of loss of power due to the fact that the temperature in the combustion chamber always remained optimal and did not allow voluntarily achieving full power from the engine. However, at that time the system was the ultimate dream and for many years it was this system (of course, with some improvements and updates) that was used on all cars. Moreover, you can still find cars that have a similar exhaust gas recirculation system installed - Niva is one of the clearest examples.

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How it works?

The EGR system functions in a fairly simple way. The fact is that when fuel burns in combustion chambers, nitrogen oxide is formed, which is an incredibly toxic substance. And if it gets into the air along with the exhaust, then the cars will greatly poison the environment. The higher the temperature in the combustion chamber, the more nitrogen oxide is released, so something needs to be done about this process. This is where the EGR system comes into play - it forces some of the nitrogen oxide back into the intake manifold.

The valve is responsible for the supply of exhaust gases, which opens only when the supply is needed, and closes when the gases have already entered the intake manifold in sufficient quantities. From there, the gases, together with the fuel mixture, enter the combustion chamber, where the mixture is, accordingly, burned, and the supplied gases reduce the temperature of its combustion.

As you can see, the system is extremely simple, it functions reliably and constantly, so you don't have to worry about problems that would arise if it weren't installed. The process of operation of this system is clear and the purpose of its existence, in general, is also clear. But it’s still worth taking a closer look at exactly what advantages it provides in order to finally realize how important it is for a car.

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Description

Features
• Exhaust gases from piston internal combustion engines or gas turbines are used as a source of thermal energy without the use of additional regeneration systems • Environmentally friendly refrigerant - water • Low noise and vibration levels • Precise and optimized control using a microprocessor controller with touch display • Maintains optimal performance at partial load • The special design of the main elements allows for unhindered maintenance of the chiller • It is possible to supply a chiller of non-standard dimensions (for specific facility conditions) • It is possible to supply the chiller disassembled

Examples of possible sources of thermal energy

• Gas piston units • Technological process

Open table of all characteristics

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EGR in Russian conditions

In theory, this system is an excellent addition to the car - it brings only benefits and does not portend any trouble at all. And in European conditions, where fuel is of the highest quality and people are willing to pay for everything to function well, this is indeed the case - EGR shows ideal results and one hundred percent satisfaction among car enthusiasts. But what about Russia? Is it really that different?

It turns out that this is more than enough. The fact is that the quality of fuel distributed on the territory of the Russian Federation is significantly lower than in Western countries, so the recirculation system becomes clogged much faster. As a result, this causes the EGR valve to fail much more quickly. This can be corrected at a service station, but the cost of replacing the components of this system is quite high, so many Russian residents refuse to spend extra money on such a system. As a result, they simply jam it, that is, they fix it in one position, preventing its further functioning.

Accordingly, EGR in modern Russian conditions is a relevant system only for those who can afford to purchase high-quality fuel and scheduled expensive repairs of the system. The average Russian either cannot afford this or does not want to do this, so more and more often people prefer to turn off the exhaust gas recirculation system valve, saving themselves from unnecessary problems. And here a very interesting question arises. Are they really saving themselves from problems? Or are they just adding more trouble to themselves?

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What it is?

So what is EGR? It is often called EGR - this abbreviation comes from the English name of the system, but it is very often used by all Russian-speaking car enthusiasts, as it is much more convenient. So what is this mechanism? The exhaust gas recirculation system is responsible for reducing the level of nitrogen oxides in the exhaust gases. This is achieved by returning some of the gases back to the intake manifold. Naturally, at first glance, all this may seem just rather strange and incomprehensible words, but as you read the article, you will begin to understand more and more what exactly this system does, as well as why the car needs it.

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Condensate and vapor coolers

Condensate coolers are designed for cooling the condensate of heating steam from low-pressure heaters and network water heaters of centralized heating systems connected to state district power plants, thermal power plants and industrial boiler houses. The heat released when cooling the heating steam condensate is used to heat the colder main condensate in the regeneration system of the turbine unit, providing heat savings in the cycle. Condensate coolers can be used to recover heat from condensate from heating steam of steam-water heat exchangers used in various boiler houses and industrial technological systems that use non-aggressive coolants, as well as to recover heat from hot water for chemical water treatment systems of low-power boiler plants.
The exhaust gas condensate cooler is a - water heat exchanger 130 ) identical sections connected in series for both coolants in compliance with the counterflow principle.

Condensate coolers OG-6 and OG-32 are water-to-water heat exchangers of a horizontal type, consisting of one section.

An example of a designation for a condensate cooler when ordering: Exhaust condensate cooler, with a heat exchange surface area of ​​32 m². Condensate cooler OG-32

Exhaust-type condensate cooler (top and side views)

Fitting table

OB type condensate coolers are vertical water-to-water heat exchangers

The main components of the OV-40M and OV-150-3A are: the upper water chamber, the housing and the pipe system. The pipe system of this group of coolers consists of a tube sheet in which the ends of U-shaped steel pipes are flared, and a casing. The latter covers the tube bundle from the outside, which allows minimizing idle leaks of cooled condensate past the tube bundle. The same goals are pursued by a displacer installed in the center of the cooler bundle (between the sections of pipes with the smallest bend), welded in the upper part to the tube sheet.

The OV-140M cooler is a rigid-tube device in which the tube sheets, pipe system, body and water chamber of cooled condensate (on the body) with branch pipes form a single unit. All coolers the OB type use a countercurrent flow pattern for coolants.

An example of a condensate cooler designation when ordering: Exhaust condensate cooler, with a heat exchange surface area of ​​320 m².

Fitting table

OK type condensate coolers are a horizontal shell-and-tube single-casing heat exchanger, the main components of which are the housing, the pipe system, and removable front and rear chambers. The cooler body is made of steel pipe with welded collar flanges. The pipe system consists of two steel tube sheets with straight brass or carbon tubes rolled into them, a free longitudinal partition, transverse partitions with a quarter-circle cutout and a floating head cover with clamping half-rings and a paronite gasket for sealing. The front tube plate is fixed and is attached between the flanges of the housing and the front water chamber, the rear plate is floating. The front and rear water chambers are made of welded pipes, collar flanges and stamped elliptical bottoms.

An example of the designation of a condensate cooler OK when ordering: Condensate cooler OK, with a heat exchange surface area of ​​16 m², for an excess pressure in the pipe system of 1.47 (15 kgf/cm²) MPa, for an excess pressure in the housing of 0.59 (6 kgf/cm² ) MPa

Fitting table

Main technical characteristics of condensate coolers:

Vapor coolers from atmospheric deaerators (OVA), (OVA-M) are designed to condense the maximum amount of steam from the vapor-gas mixture (vapor) removed from the deaerator with heat recovery. Vapor coolers consist of a horizontal cylindrical body and a pipe system located in it. Chemically purified water passes inside the tubes, is heated and then enters the deaeration column. The steam-gas mixture (vapor) enters the annulus, where the steam from it is almost completely condensed. The remaining gases are vented to the atmosphere, and the steam condensate is discharged into the deaerator.

The vapor cooler condenses the maximum amount of steam from the vapor-gas mixture, which is removed from the deaerator with heat recovery.

A surface type vapor cooler consists of a horizontal body and a pipe system located in it (the pipe material is brass or corrosion-resistant steel). To ensure safe operation of deaerators , they are protected from dangerous increases in pressure and water level in the tank using a combined safety device. The device is connected to the deaerator tank through the overflow fitting. The device consists of two hydraulic seals, one of which protects the deaerator from exceeding the permissible pressure, and the other from a dangerous increase in level, combined into a common hydraulic system, and an expansion tank. The expansion tank serves to accumulate the volume of water (when the device is activated) necessary for automatic filling of the device (after eliminating the malfunction of the installation), i.e. makes the device self-priming.

An example of a designation for a vapor cooler when ordering: Vapor cooler OVA, with a heat exchange surface area of ​​24 m².

Vacuum vapor cooler (OVV), (OVV-M) is designed to condense the maximum amount of steam from the vapor-gas mixture removed from the deaerator and utilize the heat of this steam. When the vapor is cooled, a sharp reduction in the volume of the vapor-gas mixture occurs, which is especially important for ensuring the normal operation of air suction devices.

The vapor cooler is a shell-and-tube heat exchanger , consisting of a horizontal housing in which a pipe system is located (the tube sheet is attached to the housing by welding to avoid air suction). Chemically purified water moves inside the tubes (part of the source water flow), which is then sent to the deaerator. To ensure the required vapor flow at all deaerator loads, the water flow to the vapor cooler must correspond to the rated capacity. The condensate from the vapor cooler is returned through a separate pipeline through a hydraulic seal to the deaerator (on the overflow plate) or drained into drainage tanks; for this purpose, the cooler is tilted towards the condensate drainage side.

An example of a cooler designation when ordering: Vacuum vapor cooler HVAC, with a heat exchange surface area of ​​16 m².

HVAC vapor cooler

Fitting table

Main characteristics of HVAC type vapor coolers:

Main characteristics of OVV-M type vapor coolers:

Vapor cooler OVA-M

Fitting table

Main technical characteristics of OVA type vapor coolers:

Main technical characteristics of OVA-M type vapor coolers:

Vapor coolers for atmospheric deaerators are manufactured in accordance with the requirements of PB10-115-96 “Rules for the design and safe operation of pressure vessels” and OST 26-291-94 “Welded steel vessels and apparatus. General technical conditions”.

Vacuum vapor cooler (OVV), (OVV-M) is designed to condense the maximum amount of steam from the vapor-gas mixture removed from the deaerator and utilize the heat of this steam. When the vapor is cooled, a sharp reduction in the volume of the vapor-gas mixture occurs, which is especially important for ensuring the normal operation of air suction devices.

The vapor cooler is a shell-and-tube heat exchanger , consisting of a horizontal housing in which a pipe system is located (the tube sheet is attached to the housing by welding to avoid air suction). Chemically purified water moves inside the tubes (part of the source water flow), which is then sent to the deaerator. To ensure the required vapor flow at all deaerator loads, the water flow to the vapor cooler must correspond to the rated capacity. The condensate from the vapor cooler is returned through a separate pipeline through a hydraulic seal to the deaerator (on the overflow plate) or drained into drainage tanks; for this purpose, the cooler is tilted towards the condensate drainage side.

An example of a cooler designation when ordering: Vacuum vapor cooler HVAC, with a heat exchange surface area of ​​16 m².

HVAC vapor cooler

Fitting table

Main characteristics of HVAC type vapor coolers:

Main characteristics of OVV-M type vapor coolers:

Breakdowns

If we are talking about malfunctions of the exhaust gas recirculation system, then it is worth taking a closer look at them. What could they be and what consequences could they ultimately lead to? There are a large number of different options for minor malfunctions, an impressive part of which is associated precisely with the fact that the recirculation system becomes clogged very quickly. This happens while using the car, so it is simply impossible to avoid this effect.

If you study the documentation for this system, you can find out that on average it is designed for full operation for 70-100 kilometers. After this, you must contact specialists for scheduled replacement of spare parts. And, as you already learned earlier, this replacement costs a lot of money, so many people try to avoid it by all means. Especially in Russia, since due to the low quality of fuel in the country, the service life of such a system is reduced to approximately fifty thousand kilometers. As a result, if you do not carry out scheduled repairs, you may experience certain breakdowns and malfunctions.

One of the most common problems is valve leakage due to prolonged use. As a result, it happens that gases begin to flow in abnormal quantities, and additional air also enters the intake manifold, which negatively affects how the exhaust gas recirculation system functions. Malfunctions result in not the most pleasant consequences.

• Firstly, due to the uncontrolled flow of gases and the presence of excess oxygen in the fuel mixture, it becomes depleted. What does it mean? That instead of reducing fuel costs, they increase, since the fuel mixture turns out to be less efficient, and the engine has to admit even more fuel.
• Secondly, this can lead to the opposite effect - to excessive enrichment of the fuel mixture, since the pressure in the intake manifold will increase significantly.

Depending on the type of system, you may experience one effect or the other, and there is also the possibility that they will occur alternately. For example, at idle the mixture will become excessively rich, and when switching between modes it will become sharply lean. It’s not even worth telling how harmful this is for the engine and what excessive fuel consumption it leads to. What to do if a malfunction occurs?