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.

Calculate parts deviation
Every mm counts

Sign up for more
I would like to know more about proper turbocharger maintenance
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
Blade thickness
Slight deviations in blade thickness, though hardly visible to the naked eye, can lead to complete turbocharger failure.
-
Lower blade thickness at hub...
-
...leads to lower Eigenfrequency
Lower Eigenfreqency can lead to higher failure probabilty
Geometric deviation
iInappropriate 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 at 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
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
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
Geometric deviation
iInappropriate geometry of the turbine 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 turbine wheel can lead to high efficiency loss, translating directly into significantly higher fuel consumption.
Example
A medium sized engine rated at 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
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 1255km/h, the centrifugal force converts 500g to 90 tons, the near maximum take-off weight of a Boeing 737.
- Blade rotating at 1255km/h
90 tons

Take-off weight: 1 Boeing 737’s
ABB turbocharger casings keep this force contained
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 1255km/h, the centrifugal force converts 500g to 90 tons, the near maximum take-off weight of a Boeing 737.
- Blade rotating at 1255km/h
90 tons

Take-off weight: 1 Boeing 737’s
ABB turbocharger casings keep this force contained
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.
+ Click on the hotspots to see the impact of parts deviation on your 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.
+ Click on the hotspots to see the impact of parts deviation on your operations.
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, abrasive particles and high mechanical stress.
+ Click on the hotspots to see the impact of parts deviation on your operations.
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, abrasive particles and high mechanical stress.
+ Click on the hotspots to see the impact of parts deviation on your operations.
Turbine Casing
The turbine and compressor casing of ABB turbochargers are selected and tested 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.
+ Click on the hotspots to see the impact of parts deviation on your operations.
Compressor Casing
The turbine and compressor casing of ABB turbochargers are selected and tested 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.
+ Click on the hotspots to see the impact of parts deviation on your operations.
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.