Original ServiceWellness for your wallet

Service information

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The ABB Turbocharging Original Service commitment

As a market and technology leader, ABB Turbocharging is committed todelivering high quality turbochargerproducts and services for engines withoutputs over 500 kW.

This commitment takes two comple-mentary forms: – Building the best turbochargers in the

business– Assisting customers to maintain those

turbochargers in peak condition andat optimum performance throughouttheir entire life cycle

Only in this way can ABB Turbochargingenable consistently high levels of engineperformance, fuel efficiency and emis-sions at economic maintenance costs.

Original Service from the source Fulfilling these goals requires us to be asversatile as a Swiss army knife. Startingat the product development stage for allABB turbochargers, long service life andease of maintenance, repair and over-haul share equal priority with perform-ance criteria like efficiency and pressureratio.

Out in the field, the reliability, robustnessand low wear rates designed into everyturbocharger are matched by ABB Turbo -charging’s dedication to ensuring that allthe expertise and experience availableonly to the original equipment manufac-turer, or OEM, are incorporated into:– Original Parts in the highest quality – The highest levels of Original Service

in all maintenance, repair and over-haul work

Global Original ServiceAll ABB Turbocharging Service facilitiesare part of a wholly ABB-owned networkof outlets under the direct control of theSwiss Service Center. They have directaccess to the technology and know-howof the global manufacturing network andare:– Equipped to the same high standards– Use the same, frequently updated

Original Service practices– Employ service staff trained and

qualified in-house at the Swiss Training Center

Customer proximity With over 100 Service Stations, strategi-cally located at major centers of engineactivity, ABB Original Service is at handwherever you are in the world.

First class logisticsOur sophisticated spares stocking andtransport arrangements at our SwissService Center run like a Swiss watch.They underpin a 24 hour order-to-dis-patch system which makes every Original Parts order a fast track order.

ATURB spares tracking Backing the central inventory of OriginalParts in Switzerland are stocks held by the regional Service Stations. Detailsand locations of all Original Parts aresaved in the ATURB Original Parts man-agement system at headquarters inSwitzerland. All ABB TurbochargingService Stations have full access toATURB to facilitate optimum sourcing of spares.

ATURB product documentation The ATURB database also contains fulldetails of every component fitted toevery new ABB turbocharger and tracksthe service history of every turbocharger,including the components renewed overits total lifespan.

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Proactive solutions

Our proactive Original Service solutionscenter on our:– OPAC Operation Performance Package – MMA Maintenance Management

Agreements – AMA Auxiliary Engine Maintenance

Agreements

These offerings provide simplifiedscheduling and monitoring of work andOriginal Parts procurement, while allowing servicing to be coordinated withengine operating schedules.

OPACWith OPAC, engine operators delegatemaintenance, repair and planned over-hauls of turbochargers entirely to theglobal ABB Turbocharging Service net-work. Eligible for OPAC delegated servic-ing are 2- and 4-stroke diesel engines inboth marine and stationary applications.

For a fixed price per operating hour andan agreed number of operating hours – for example 20,000 or 60,000 – ABBTurbocharging Service takes overresponsibility for the reliable, economicoperation of the turbocharger. The benefits are less administrative work for the end user and prompt, wellplanned servicing and preventive main-tenance. All Original Service work is carried out by ABB Turbo charging’shighly qualified technicians using onlyABB Turbocharging Original Parts.

OPAC agreements can also be cus-tomized to specific service requirementsbased on detailed assessment of the turbocharger operating profile.

MMA, AMAMMAs and AMAs target turbochargerend users wanting close support ofservicing rather than complete delega-tion. ABB Turbocharging proactivelyinforms the turbocharger user of anapproaching service event well inadvance and prepares a quotation in the form of standardized, predefinedpackages, including negotiated fixedlabor rates. MMAs and AMAs give theturbocharger end user the benefits of early ordering while allowing ABB Turbocharging to support the manage-ment of the equipment.

Local responseWhen you need us, our qualified spe-cialists at all our Service Stations aroundthe world work to identical standards to ensure professional repairs at thebest geographically located Service Station. All you do is contact your localABB Service Station, who will arrangeeverything with the Service Station nearest to your turbocharger. Your staff will benefit from working with an identifi-able, familiar contact person in thesame language and same time zone;you can pay in your local currency and do business under your local legalsystem.

Features Benefits

Original Parts direct from the OEM Sure to perform

Original Service direct from the OEM Optimum performance, right first time

Highest availability of specialists Ready access to professional application consulting

OEM technicians highly trained in Original Service Minimized downtime, maximized availability

at over 100 Service Stations around the globe

ATURB product and service database Rapid response based on close knowledge of

your turbocharger /application

Worldwide ABB Turbocharging Service network Direct, local access to ABB Turbocharging

Original technology and know-how

Technical consulting: 24 hour, all-year round service Fast problem solving from the most reliable source

Extensive stocks of Original Parts for all current 24 hour availability of 98% of all Original Parts ABB turbochargers

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First class logistics

Emphasizing ourpromise of 98 %Original Parts avail-ability, the followingcase study illustratesthe smooth workingof ABB spares logistics even whereOriginal Parts arenot currently instock and must bemanufactured.

Dateline Panama/Switzerland, timedifference 7 hours, fast track deliveryof rotor parts to ABB Service StationPanama*– Tuesday, a.m. Panama: customer

accepts ABB offer for repair of two rotors. Parts order placed withSwitzerland Service Center. Deliveryrequired Friday, p.m. Panama.

– Tuesday, 16:30 Switzerland, 09:30Panama: impeller not in stock, can be manufactured immediately.

– Tuesday, 17:00 Switzerland, 10:00Panama: logistics organized.

– Tuesday, 22:00 Switzerland, 15:00Panama: complete consignment col-lected by forwarding agent’s vehicle.

– Wednesday: air freight transportationof consignment from Switzerland toPanama. Arrives p.m. Panama.

– Thursday, a.m. Panama: Import for-malities finalized.

– Thursday, 14:00 Panama: parts reachABB Service Station. Work starts onrotor.

– Thursday, 20:00 Panama: impeller fitted, rotor rebladed, reground, rebal-anced.

– Friday, Panama: rotor delivered tocustomer.

Our sophisticated Original Parts stocking,transport and forwarding arrangementsat our Swiss Service Center underpin a24 hour order-to-dispatch commitment.

Located close to our Swiss turbochargerworks, complete machines, componentsand assemblies not available from ourextensive stocks can be obtained at shortnotice and rapidly prepared for shipment.

*case documented in the ABB Turbocharging Turbo Magazine

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ABB Turbocharging Original PartsThe cornerstone of turbocharger reliability, efficiency and availability.

1, 2, 3 The accuracy of the complex aerodynamic shapes of turbine and impeller blades is crucial to turbocharger efficiency.4, 5, 6 The surface quality of air and gas path parts is vital in preventing aerodynamic losses.7, 8, 9 Before and after. The strength and ductility of turbocharger housings are central to preventing disintegrated rotor parts breaking out

and putting life and property at risk.9 Badly distorted, this original ABB housing nonetheless passed its “containment test”.

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By choosing only ABB TurbochargingOriginal Parts, your turbocharger will berestored as close as possible to its dayone condition. The result is the power,emissions, fuel consumption, availabilityand life cycle costs you expect fromyour engine.

As well as producing parts for serviceon the same high technology machinetools as parts for new turbochargers, andaccording to original works drawings,the composition and properties of theirmaterials must all conform to ABB’s ownstringent specifications. Indeed, many ofthe materials are either patented or weredeveloped specifically for ABB to ensurelow rates of wear for long effective lifeand high operational safety.

Component geometry – the shape ofefficiency As in all turbomachinery, the dimensionalaccuracy of turbocharger components iscritical in attaining thermodynamic andaero-dynamic efficiency.

Consider: inaccurate parts geometry cantranslate directly into increased fuel con-sumption. For example, only the slightestvariance in the clearances between com-pressor and turbine wheels and their

adjacent casings can cause a majordeterioration in your engine’s perform-ance and fuel efficiency. Likewise, stepsat joints and rough surface quality on gasand air path parts can affect aerodynamicefficiency by causing turbulence.

For these reasons, accurate componentgeometry and excellent surface condi-tion is paramount in the production ofboth new Original Parts and our CPEXguaranteed reconditioned parts. More-over, during a repair or overhaul, ourservice engineers take great care to getthe best match of tolerances betweenturbine and compressor wheels and thecasings they run in.

Material specifications – the stuff oflongevity, durability and safetyThe chemical composition, heat treat-ment and surface condition of all ABBturbocharger materials are closely con-trolled to ensure that each part performsto your satisfaction over its assignedSIKO lifetime. For components like tur-bines, compressor impellers, shafts and casings, the materials of these vitalrotating and gas and air path parts are chosen to withstand extreme heatand abrasive particles as well as thehighest mechanical stresses.

Containment In the case of compressor and turbinehousings, this includes the selection andtesting of materials with the strengthand ductility to withstand intense shockloading.

In the worst-case “containment” sce-nario, this involves making certain thatcasings hit by fragments of compressorimpellers and turbine wheels and bladesdistort but do not break. In this way,fragments remain within the turbochargerstructure and are prevented from flyingunder great force into the engine orengine room where they can endangerproperty and human life and limb.

Facts and figuresTo get an idea of the forces at play in aturbocharger: the blade tips of the rotorcan turn at up to around 600 meters persecond, i. e. almost 2100 km/h; thecentrifugal force exerted by a turbineblade on its fixation can be almost 100tons per blade, i. e. the weight of a loco-motive; the centrifugal force of all bladescan amount to 3200 tons, which isaround the maximum take-off weight often jumbo jets.

The high quality of ABB Turbocharging Original Parts is thebedrock of their performance. They incorporate all the technology, knowledge and experience of turbocharger design and operation available only to the OEM.

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Non original parts and non original service – worth the money?Rectifying turbocharger faults arising from non original parts and non original service has become a core competence at ABB Turbocharging Service Stations.

Geometry The efficiency of turbochargers dependson tight tolerances between their movingparts and casings. Turbocharger rotor tohousing clearances are precisely calcu-lated to maximize efficiency. They are in the region of 0.66 millimeter – thethickness of about 5 human hairs. None-theless, in a logarithmic progression, anincrease of only 0.1 millimeter wouldmean the loss of over 1 % turbochargerefficiency. Similarly, aerodynamic effi-ciency can be severely affected by tur-bulences caused by rough internal sur-faces and steps at joints.

Double trouble These potentials apply to both the turbineand compressor. Their cumulative effectcan lead to an appreciable deteriorationin fuel consumption. A leading enginebuilder has indicated that a 1 % reductionin turbocharger efficiency translates intoover 1⁄3 gram per kilowatt hour (g /kWh)higher specific fuel consumption. Hence,a medium-sized low-speed engine rated50 MW with a turbocharger 2 % below

its design efficiency will use more than200 tons of extra fuel in a 6000 houroperating year. This equates to 100,000US dollars at a fuel price of 500 USD per ton.

Engine operation ABB Turbocharging has documentedcases where the use of non original partsprevented steady-state turbochargeroperation (surging) or meant steady-stateoperation was only achievable at reducedengine power and fuel efficiency. Thisled to: – Enforced slow steaming and slippage

in vessel schedule – Financial penalties in baseload electri-

cal power generation applications – Reduced transient engine response – Excessive vibration leading to

accelerated wear and reduced safety

SafetyThe failure of turbocharger casings tocontain rotor fragments could lead toconsequential losses, including personalinjuries. Turbocharger failure leading to

complete loss of engine power couldleave a vessel “dead-in-the-water” onthe high seas or a town without electri-cal power.

Operating economics Rectifying problems due to non originalparts and non original service 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 higheremissions of greenhouse gases.Increased harmful emissions – especiallyNOx and visible particulates – can lead to: – Loss of incentives, e.g. Norway – Prohibition from port entry– Fines– Unpleasant environment for cruise or

ferry passengers

* 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 non original gas and airpath components can affect turbocharger performance.

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Network standards

Global uniformity To ensure a uniform, rapid response tothe needs of turbocharger end usersand consistent standards of workman-ship, all ABB Turbocharging Service Stations: – Are equipped to the same high tech-

nical standards – Use the same, frequently updated

turbocharger servicing practices

The human element Having Original Parts and the best OEMequipment is only part of the equation.The benefits of OEM know-how thatderive from ABB Turbocharging OriginalParts apply equally to the high level ofworkmanship our service engineers andtechnicians put into Original Servicefrom ABB Turbocharging.

ABB Turbocharging ensures the highestquality in a finished Original Serviceusing Original Parts via the continuousqualification of our service engineers.

Siting our Training Center next to ourmain producing works in Switzerlandensures ready access to the latest turbocharger technology and the imme-diate transfer of works know-how.

Right first timeA very tangible benefit of using OriginalParts with our official warranty, fitted byABB Turbocharging’s OEM qualifiedtechnicians during Original Servicework, is the extremely high probabilitythat maintenance, repairs and overhaulswill be right at the first time of asking.

Minimized downtime This ensures minimal downtime, whilethe quality of OEM components andworkmanship result in maximized longterm turbocharger efficiency and reliabil-ity, translating into dependable opera-tion between scheduled overhauls.

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Customer proximity

Where engines are built, used andmaintained Typical ABB Turbocharging sites includemajor seagoing and inland waterwayports; centers of shipbuilding; areas ofoil and gas exploration and production;clusters of diesel and gas engined power and cogeneration plants; mineralrich regions with open cast mining;major locomotive builders and rail main-tenance depots; and, naturally, centersof engine building.

Direct access to Original Service and OEM technology As well as being readily accessible geo-graphically, the fact that all ABB Turbo -charging Service facilities are whollyABB-owned and under the direct controlof the Swiss Service Center means that service customers have directaccess to all the product know-how andapplication experience of a market and technology leading OEM of turbo -chargers for large 2- and 4-stroke

diesel and gas engines. This is a majoraspect of our “OEM Advantage”.

Our missionWe see it as our mission to make avail-able to end users of ABB turbochargersthe full benefit of our unique fund ofexpertise in turbocharger manufacturingand service.

In the past five years ABB Turbocharging has invested heavily in its network of wholly owned turbocharger Service Stations. The current count is over 100 Service Stations, strategicallylocated at major centers of large engine activity.

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SIKO Safety Design Concept

Original Parts and SIKO The ideal counterpart to ABB OriginalParts, the SIKO Safety Design Concept is ABB Turbo charging’s central tool forestablishing maximum running timeparameters for vital turbocharger com-ponents. It involves the definition of the optimum number of running hoursfor a given component before its re -placement. It results in the assignmentof an effective lifetime for that com -ponent as the basis for the planning ofturbocharger inspection, maintenanceand overhaul.

In combination with original ABB new orreconditioned CPEX parts, SIKO allowsyou to restore your turbocharger topeak performance and safety at everyABB Turbocharging Original Serviceevent, whether maintenance repair oroverhaul.

A firm basis SIKO effective lifetimes are based on apowerful combination of extensive turbo-charger testing, wide operating experi-ence and precise statistical and fatigueanalysis. Operating experience includesdedicated turbocharger and componenttrials and tests at the ABB TurbochargingTechnical Center in Switzerland as wellas on engines on test stands at leadingengine builders and under commercialoperation in the field.

The major statistical input derives fromour comprehensive ATURB turbocharg-ing documentation database. ATURBtracks the operating and complete ser-vice histories of all the 190,000 pluspopulation of ABB turbochargers in useworldwide. Crucially, it also tracks theircomponents, including the condition ofused parts on replacement.

SIKO and Original Parts from ABB Turbocharging are your best route to:– High engine power – High fuel economy– High reliability – High availability – High operational safety

Your turbocharger is a bundle of energy. With the SIKO SafetyDesign Concept, ABB Turbocharging has a potent tool for proactively managing and controlling this source of power.

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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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