See beyond the surface with TurboAid

TurboAid allows you to assess the geometric qualities and clearances your turbocharger parts must meet in order to achieve high efficiency and safe operations.

ABBpictogram-parts-specification

Calculate parts deviation

Every mm counts

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Blade area deviation

Millimeter deviations in blade area can tremendously reduce an applications time between overhaul (TBO).

Deviation in dimension has a knock on effect illustrated below.

  • Reduction in turbine blade area
  • Higher turbocharger speed
    Risk: turbocharger burst
  • Higher bar firing pressure
    Risk: cylinder head piston cracks

This leads to lower turbocharger and engine time between overhauls (TBO)

TBO hours

h

Blade thickness

Slight deviations in blade thickness, though hardly visable to the eye, can lead to complete turbocharger failure.

  • Blde thickness

    Lower blade thickness at hub...

  • Eigenfrequency

    ...leads to lower Eigenfrequency

Turbo fail Lower Eigenfreqency can lead to higher failure probabilty

Geometric deviation

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.

Geometric deviation

Inappropriate geometry of the compressor wheel can lead to high efficiency loss, translating directly into significantly higher fuel consumption.

Example

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

USD
Under centrifugal force

Material strength deviation

Minor material strength deviations can more than halve a turbochargers life time and exchange interval.

  • Material strength deviation leads to...
  • ... drop in running hours

Exchange interval

h
Under centrifugal force

Material strength deviation

Minor material strength deviations can more than halve a turbochargers life time and exchange interval.

  • Material strength deviation leads to...
  • ... drop in running hours

Exchange interval

h

Geometric deviation

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.

Geometric deviation

Inappropriate geometry of the compressor wheel can lead to high efficiency loss, translating directly into significantly higher fuel consumption.

Example

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

USD

Material quality deviation

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.

  • turbo-spinning
  • Blade rotating at 1255km/s
  • tons 90 tons
plane

Take-off weight: 1 Boeing 737’s

ABB turbocharger casings keep this force contained casing-turbine

Material quality deviation

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.

  • turbo-spinning
  • Blade rotating at 1255km/s
  • tons 90 tons
plane

Take-off weight: 1 Boeing 737’s

ABB turbocharger casings keep this force contained casing

Turbine nozzle ring

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.

Impeller blades of compressor wheel

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.

Compressor wheel

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.

Turbine Wheel

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.

Turbine Casing

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.

Compressor Casing

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.

Every millimeter counts

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.