TurboAid allows you to assess the geometric qualities and clearances your turbocharger parts must meet in order to achieve high efficiency and safe operations.
Every mm counts
I would like to know more about proper turbocharger maintenance
Millimeter deviations in blade area can tremendously reduce an applications time between overhaul (TBO).
Deviation in dimension has a knock on effect illustrated below.
This leads to lower turbocharger and engine time between overhauls (TBO)
Slight deviations in blade thickness, though hardly visable to the eye, can lead to complete turbocharger failure.
Lower blade thickness at hub...
...leads to lower Eigenfrequency
Lower Eigenfreqency can lead to higher failure probabilty
Inappropriate geometry of the compressor wheel can lead to high efficiency loss, translating directly into significantly higher fuel consumption. Click on the i for details.
Inappropriate geometry of the compressor wheel can lead to high efficiency loss, translating directly into significantly higher fuel consumption.
A medium sized engine rated 50MW with a turbocharger operating at 0.5% below its design efficiency will use more than 50 tons of additional fuel in a 6000 hour operating year.
This equates to 15000 USD at a fuel price of ca. 300 USD per mt (metric tonne).
Calculate potential impact on fuel consumption
Minor material strength deviations can more than halve a turbochargers life time and exchange interval.
Material deviations of the turbine casing can lead to non-containment of rotor fragments within the casing, leading to complete engine damage and personal injury in severe cases.
The weight of the turbine blade is 500g. At a rotating speed of 125km/s, the centrifugal force converts 500g to 90 tons, the near maximum take-off weight of a Boeing 737.
Take-off weight: 1 Boeing 737’s
ABB turbocharger casings keep this force contained
Minimal deviations of the turbine nozzle ring vanes can reduce the time between overhaul by more than 50% and tremendously impact turbocharger efficiency, safety and smooth operations.
Minimal geometric deviations of the impeller blades cause blade vibrations that will significantly reduce the application's time between overhaul (TBO) and can lead to the complete failure of a turbocharger.
The materials of vital rotating parts as well as gas and air path parts, such as the compressor wheel are chosen to withstand extreme heat and abrasive particles and highest mechanical stress.
The materials of vital rotating parts as well as gas and air path parts, such as the turbine wheel are chosen to withstand extreme heat and abrasive particles and highest mechanical stress.
The turbine and compressor casing of ABB turbochargers are selected and test to withstand intense shock loading. This way, fragments are contained within the casing of the turbocharger and prevented from flying out into the engine under great centriful force.
The dimensional accuracy and material strength of turbocharger components are critical for achieving thermodynamic and aerodynamic efficiency. Inaccurate parts geometry and sub-standard material quality can lead to increased fuel consumption, shorter time between overhaul (TBO) and therefore more downtimes. Your operation safety can be jeopardized severely as well.
+ Click on the hotspots to see the impact of parts deviation on your operations.