Product information

ABB TurbochargingOriginal spare parts – when spending money is earning money

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ABB Turbocharging original parts Fitting the best to achieve the best.

As a market and technology leader ABB Turbocharging iscommitted to delivering high quality turbochargers for engineswith outputs over 500 kW and servicing those turbochargersto the highest OEM standards.

This commitment takes two complementary forms:– Building the best turbochargers in the business– Assisting customers to maintain those turbochargers in

peak condition and at optimum performance throughouttheir entire life cycle

Shared aims via original partsA machine is as good as the sum of its parts and ABB Turbo -charging is committed to delivering the highest quality parts foryour turbocharger. Combined with a global service networkequipped to rapidly deliver our high quality OEM parts and thehighest levels of OEM workmanship in all turbocharger main-tenance, repair and overhaul operations, ABB TurbochargingService shares the same aims as the end user, i. e. deliveringconsistently optimized levels of:– engine performance – engine reliability – engine safety– engine availability – engine fuel efficiency– engine emissionsand all at economic cost.

OEM parts from the sourceTo achieve these aims ABB Turbocharging undertakes todeliver original spare parts incorporating all the technology,knowledge and experience of turbocharger design and operation available only to the OEM.

They are thus the foundation of the long term efficiency,dependability and economy of ABB turbochargers.

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ABB Turbocharging original parts Designed, manufactured and installed for long life and absolute operational safety.

Painstaking production, accurate geometry and first classmaterials are the cornerstones of the performance of originalABB Turbocharging spare parts.

This means producing service parts on the same high tech-nology machine tools as parts for new turbochargers andaccording to original works drawings which incorporate all the modifications introduced since the turbocharger’s launch.The third part of the ABB original parts quality equation is the chemical composition and physical properties of theirmaterials. All conform to ABB’s own stringent specifications,to ensure low rates of wear for long effective life and highoperational safety.

OEM Service standardsComplementing the quality of ABB Turbocharging spare partsis the quality of the ABB Turbocharging Service organization.It is based on a network of wholly ABB-owned Service Stationswith direct access to all the turbocharger expertise availableat the Service Center in Switzerland and adjacent turbochargerworks.

Global uniformity All ABB Turbocharging Service Stations are equipped to thesame high standards, use the same, frequently updated best practices and employ only service staff trained and qualifiedin-house.

Customer proximity OEM maintenance, overhaul and repair of ABB turbochargersare always readily accessible on a global basis. The ABB Turbocharging Service network consists of over 100 ServiceStations, strategically located at major centers of engine activity.

First class logisticsTo ensure global parts availability, our sophisticated sparesstocking and transport arrangements at our Swiss ServiceCenter underpin a 24 hour order-to-dispatch system whichmakes every spares order a fast-track order.

ATURB product and service documentationBacking the central inventory in Switzerland are stocks heldby the regional Service Stations. Details and locations of all parts are stored in the ATURB spare parts managementsystem. The ATURB database also documents full details of every component fitted to every new ABB turbocharger and tracks the service history of every turbocharger, includingthe spare parts fitted over its complete lifespan.

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Component geometry The shape of efficiency.

Original parts for ABB turbochargers are the embodiment of our company’s skill, expertise and experience. The dimensionalaccuracy of turbocharger parts is critical in attaining thermo -dynamic and aerodynamic efficiency, low rates of wear andoperational safety.

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As the source of the original design, both original spare partsand CPEX original reconditioned parts are made to preciselyoptimised tolerances. Likewise, great attention is paid to thesurface condition of turbine and compressor blades and vanesand all air gas and air path parts to avoid the turbulenceswhich can greatly reduce aerodynamic efficiency. In this way,turbocharging efficiency is optimized over a full range of turbine and compressor operating conditions.

Close matching As well as paying great attention to the dimensions of individualparts, great efforts are made during both new product assemblyand reassembly during maintenance, overhaul and repair, tomatch tolerances. For example, companion parts such as tur-bine and compressor wheels and their casings are carefullychosen to achieve optimum fits and clearances.

No pain, no gain The painstaking pursuit of precision typical of ABB TurbochargingService engineers and technicians using ABB original partspays dividends in terms of turbocharger performance and efficiency. In terms of engine performance these translatedirectly into: – optimized engine power– minimized fuel consumption– maximized availability

The effects of poorly fitting partsAt the heart of the imperative for accurate geometry is the factthat the efficiency of a turbocharger turbine or compressordecreases in logarithmic progression to the clearances betweenits rotor wheels and adjacent stationary parts like casings, diffusers, etc. Thus, excessive tolerances can quickly result indramatic increases in fuel consumption.

In extreme cases, the turbocharger will be subject to surgeand/or vibration with the risk of accelerated wear. The enginemay be unable to run smoothly or get even close to its ratedoutput.

Further examples from turbochargers in the field where turbo-charger efficiency, safety and smooth operation have beenseverely affected by component geometry deviating from ABB Turbocharging’s rigorous specifications include theseparts: – radial turbine vanes– axial turbine blades– diffusors– nozzle ring vanes

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Certificated high duty materialsThe stuff of safety and longevity.

Like all aspects of the production of ABB turbochargers andtheir original parts, material specifications are fully documentedin tests certificates and type approvals from ClassificationSocieties.

Proprietary specificationsMany materials in ABB turbochargers are either patented ormade to an ABB in-house specification. These define chemicalcomposition, heat treatment, surface quality and requiredmechanical properties. They ensure the right choice of materialcharacteristics to achieve low wear rates and safe turbochargeroperation under conditions like high temperatures and abrasiveresidues in the exhausts of diesels burning heavy fuel oil (HFO).

Operational safetyThe operational safety of the turbocharger is paramount sinceit also affects the reliable operation of the engine and hencethe propulsion of ships and the dependable availability ofelectrical power from diesel power plants. In the extreme, livescan depend on both. As well as tribological characteristics,turbocharger components are chosen for their sheer strengthand ability to resist shock loading.

Facts and figures Consider: the blade tips of a turbocharger can rotate at up toaround 600 meters per second, i. e. around 2100 km/h; thecentrifugal force exerted by a turbine blade on its fixation canbe almost 100 tons, i. e. the weight of a big locomotive; thecentrifugal force of all blades can amount to 3200 tons, i. e.near the maximum take-off weight of ten Jumbo Jets. Partsare also subject to extremely high loads – both mechanicaland thermal – and there is always a risk, however remote, ofexceptional circumstances, such as rotor overspeed or materialfatigue when specified exchange intervals are not observed.

Containment One of the most vital factors for turbocharger parts is thecapability to withstand a worst case scenario where partsrotating at very high speeds lose their integrity, fragment andare hurled with immense force at turbine and compressor casings. ABB Turbocharging goes to great lengths to designits compressor and turbine casings in high grade materialswith the necessary strength to promote absolute safety. Aswell as tensile strength, a major precondition of satisfactoryfragment containment is high ductility in turbine and compres-sor housing materials. ABB is one of the turbocharger manu-facturers that carries out containment qualification tests onthe rotor casings of every new turbocharger type under condi-tions as near to reality as possible. The result is justified confidence in the components’ fitness for purpose and anunrivaled record of operational safety.

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Fitting original parts from ABB Turbocharging is a strong safe-guard of hazard-free turbocharger operation. Aboard ships, inpower plants, on mobile equipment and locomotives.

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Non original spares and repairs – worth the money?Rectifying turbocharger faults arising from non original parts and non-OEM workmanship has become a core competence of ABB Turbocharging Service Stations.

Geometry The efficiency of turbochargers depends on tight tolerancesbetween their moving parts and casings – turbine and com-pressor efficiency de crease logarithmically as clearancesincrease. Similarly, aerodynamic efficiency can be severelyaffected by turbulences from rough, uneven surfaces andsteps at joints between housings and ducts.

Double troubleThe above potentials apply to both the turbine and compressor.Their cumulative effect can lead to increases in fuel consump-tion. Consider: just 1 % lower fuel efficiency on a 10 MWmedium or high speed engine equates to 140 tons of fuelworth USD 70,000 * per year.

Engine operationThe use of non original parts can prevent steady state turbo-charger operation (surging) or mean it is only achievable at reduced engine power and fuel efficiency. This leads to:Enforced slow steaming and– Slippage in vessel schedule– Reduction in onboard electrical power– Reduced transient responseExcessive vibration leading to:– Accelerated wear and reduced safety

SafetyThe failure of turbocharger casings to contain rotor fragmentscould lead to consequential losses, including severe personalinjuries. Turbocharger failure leading to complete loss of enginepower could leave a vessel “dead-in-the-water” on the highseas or a town without electrical power.

Operating economics OEM rectification of non OEM maintenance, overhauls andrepairs leads to: – Duplication of repair costs– Delayed departure /extra harbor dues

as high as USD 15,000** per day– Possible cost of additional sea trials– Possible cost of new turbocharger

Environmental impactHigher fuel consumption leads to higher emissions of green-house gases. Increased harmful emissions can lead to: – Loss of incentives, e.g. Norway – Prohibition from port entry– Unpleasant environment for cruise or ferry passengers

* assumes SFC 200 g/kWh, 7000 running hours, fuel 500 USD per ton.

** 70,000 GT container ship overstaying 5 day fee period, Hamburg.

Deviation from ABB specification Effect on performance

efficiency stability vibration safe operation interval containment

Turbine and compressor geometry • • • • •Turbine and compressor material quality • • • • •Turbine and compressor surface quality • • • •Casing geometry • • •Casing material quality •Casing surface quality • •Rotor hub geometry • • • • •Shroud thickness • •Shroud gap • • •

The table shows major areas where inaccurate machining, out-of-specification materials and poor surface finish on gas and air path parts canaffect turbocharger performance.

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White knightsFast track damage limitation.

ABB is often called in to correct turbochargers where the poordimensional tolerances of non original parts have prevented anoverhauled or repaired turbocharger from functioning properly.Almost every ABB Turbocharging Service Station has its ownparticular story of a “white knight” emergency call out. Typically,an ABB Service Station rapidly diagnosed problems due tonon original parts, quickly obtained original ABB replacements,fitted them and returned the turbocharger to full working order in the shortest possible downtimes.

Dateline SingaporeThe ABB Turbocharger Service Station in Singapore wascalled in to diagnose problems with a repaired turbochargeraboard a bulk carrier. The rotor, nozzle ring, cover ring and diffuser had been replaced with non original parts, but oncompletion of the repair the turbocharger was subject to serious “surging”. This put the rotor bearings at serious risk of failure as well as preventing the engine from reaching itsdesign output and design fuel consumption. As a result, theship’s departure from Singapore was delayed for 5 days, incurring unnecessary harbor fees.

After dismantling the turbocharger, the ABB Service engineersestablished out-of-tolerance dimensions on the replacementparts. Among other things, the rotor shaft was not machinedin accordance with ABB specifications. Following exchange ofthese parts for original ABB Service parts, the engine immedi-ately ran normally, without surging, during a 10 hour sea trialand its performance was back to rated output.

Dateline South Coast UKAn engine user purchased a second hand nozzle ring for hisolder turbocharger on the “gray market”. While an originalABB part, after basic cleaning the nozzle ring had been markedwith the wrong part designation. After only a few hours thevessel reported performance problems and asked ABB Turbo-charging to investigate. Measurements established the nozzlering to be a different version to the designation shown on thespecification.

ABB supplied and fitted the correct size of nozzle ring – unfor-tunately incurring duplicated parts and labor costs for theowner – as well as engine downtime and a considerable delayin the vessel’s schedule.

Dateline Florida USA During a standard overhaul on a TPL 77-A30 turbocharger,radial bearing bushes showed signs of severe wear on all 3 segments after just a short time in operation.

Close investigation revealed non original bearing bushes with serious deviations in geometry from the original ABBspecification. The bushes were replaced with original ABBTurbocharging parts and gave excellent service with low wear.

Damage limitation: the non OEM bearing parts were detectedbefore they could fail and cause damage to the shaft or acomplete breakdown of the turbocharger with the vessel atsea.

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Rogues gallery Non original parts have caused turbocharger end users untoldproblems and expense. Duplicated purchases, duplicatedefforts, vessel downtime, additional harbor fees and unnecessarysea trials to name but a few.

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ABB Turbocharging Service network

ABB Turbo Systems LtdBruggerstrasse 71 aCH-5401 Baden/SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144E-mail: turbocharging@ch.abb.com

www.abb.com/turbocharging

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