Recent Projects

Turbo Solutions Engineering has recently completed several ground-breaking projects including the hydrodynamic and structural design of a kinetic energy hydro turbine, an advanced refrigeration compressor design, and several industrial turbocharger redesigns.  We have the personnel and skills to offer small-scale design audits as well as entire design and development programs.  A few of our recent programs are illustrated below.

 

Turbocharger Rerate Designs for Large Stationary Engines
Designed new internal components for two different models of legacy engine turbochargers.  The goal was to substantially increase turbocharger mass flow, efficiency and pressure ratio, and then fit the newly designed components into the existing casings.  Turbo Solutions reverse-engineered the existing machinery and then redesigned new impellers, diffusers, and nozzles.  The scope of work included all aerodynamic and structural design and analysis, rotordynamic analyses, solid modeling and manufacturing drawings, and test data reduction and analysis.

 

Hydrokinetic Turbine Design
Designed a hydrokinetic water turbine for power generation.  This turbine is intended for green energy production and a part-scale prototype design is currently scheduled for laboratory testing.

 

Turbocharger Compressor Design
Designed a high-performance automotive turbocharger.  The project scope included meanline and 3D design and analysis, CFD analysis, structural analysis, and solid modeling.  The client fabricated and tested the compressor, and verified that the design met all performance goals.

 

Rankine Cycle Analysis and Turbine Design
Performed a Rankine cycle analysis of a waste heat recovery turbine and associated system, which noted a shortfall in the predicted power output.  The system conditions were revised to match the client's requirements, after which Turbo Solutions designed the radial inflow turbine and waste heat power recovery system.  The scope of work included aerodynamic and structural design and solid modeling.

 

Multi-Stage Refrigeration Compressor Design
Designed a 2-stage R134a compressor, including aerodynamic and structural design and solid modeling of the impellers, diffusers and volutes. 

 

Fuel Cell Blower Design
Designed a 2-stage blower for a fuel cell application.  Scope of work included aerodynamic design and analysis, CFD, solid modeling, and structural analysis.

 

Steam Turbine Design Audit
A client's newly commissioned steam turbine-generator was not capable of producing rated power output.  Turbo Solutions was hired to evaluate the aerodynamic design and identify reasons for performance shortfall, and to recommend remedial redesign details and approach.  The analysis uncovered problems related to excessive nozzle admission losses and poor rotor performance, and various solutions to the problems were presented to the client.

 

LOx/Methane Turbopump Design
Designed turbopumps for a 60,000 lbf rocket engine, including the aerodynamic and hydrodynamic design and the solid modeling.

 

Water Pump Analysis and Redesign
Completed meanline and viscous CFD analyses of an existing water pump and compared them to test data.  The pump was not meeting head, flow, or shutoff expectations.  Both analyses showed specific deficiencies in the hydrodynamic design.  Turbo Solutions collaborated with the customer to redesign the pump to improve performance.

 

Owner’s Engineering for Safe Water Network
Safe Water Network is a not-for-profit organization established to develop, optimize, and validate viable water purification solutions that provide safe water to neglected populations – a critical global issue impacting more than 1 billion people.  Turbo Solutions was hired to provide recommendations and third-party engineering evaluations of various emerging technologies related to water purification systems, to determine which should be funded by the client.

 

 

 

 

 

 

 

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Exploded View of Rerated Turbocharger


Exploded View of Kinetic Energy Hydro Turbine Generator


Solid Model of Turbocharger Volute Design


2-Stage Refrigeration Compressor Design


Solid Model of Fuel Cell Blower Design


3D Viscous CFD Analysis of Water Pump

  
       

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