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Abbtc Bro1150 Siko
Abbtc Bro1150 Siko
SIKO
The Safety Design Concept
Safety Design Concept SIKO
SIKO is ABB Turbocharging’s Safety Design Concept for
enhancing the reliability and safety of ABB turbochargers and
for making their life cycle costs more predictable.
Centrifugal force
Tip velocity 97 tons / blade
480 m /s ~ 1,750 km / h
W
0 0k
0,0
r1
o we
in ep
rb
Tu
Revolutions
9,900 rpm
Fig. 1: TPL 91-B rotor – some key figures
Over the past decade the output of diesel and gas engines At the same time, expectations regarding the reliability and
has been steadily increased, presenting the turbocharger safe operation of the equipment have grown considerably.
manufacturer with the challenge of continually increasing the Plus there is also demand within the industry for reduced life
compressor pressure ratio. Whereas in the past, turbochargers cycle costs and optimized maintenance of the engines and
could be operated with large design margins, the higher turbochargers. ABB Turbocharging addresses this issue with
performance required today calls for design solutions which its Safety Design Concept “SIKO”.
lie much closer to the physical limits of the turbochargers.
The load factor for the rotating components in particular has SIKO is a calculation tool for determining the speed and
increased dramatically – turbochargers are turning faster temperature limits of turbocharger rotor components for given
and faster. exchange intervals. The program is available for the older
VTR . . 4, VTC . . 4 and RR . . 1 turbocharger families as well as
for today’s TPS, TPL, TPR and A100 series. SIKO is regularly
updated to keep it state-of-the-art and will also be implemented
for coming ABB turbocharger generations.
2
SIKO modules
Type HT
n t Mmax
HZTL 428 765 P2
Mmax 1
n
Bmax
S t Bmax °C
kg
Application according to
the Operation Manual
made in Switzerland
3
SIKO modules
1. Turbocharger operating conditions.
Knowledge of how the rotor components be have in operation ABB designed special data loggers, similar to the “black box”
is a key element of SIKO. The load profile for a turbocharger – in aircraft, in order to measure and collect real world turbo-
load versus time and versus the number of load cycles (Fig. 3) charger operation data over an extended period of time, typi-
– is not the same, for example, for a container vessel and a cally four to six months and in some cases up to one year.
locomotive. Similarly, it is different for a base load power plant This measuring device has allowed ABB to determine load
and a hospital emergency unit. Even within marine applica- profiles for a wide range of engine applications. Over the
tions, the load profiles can be completely different. years, the company has built up a huge database and accu-
mulated a wealth of information and knowledge about the
real world operating conditions of turbochargers used in many
Load Load
different engine applications.
4
SIKO modules
2. Determination of material properties.
Stress amplitude
Increasing temperature
5
SIKO modules
3. Stress and material temperature distribution.
Finite element analyses are carried out to obtain the stress Stress distribution in the rotor components of a turbocharger
and material temperature distribution in the rotor components. varies greatly according to the geometry of the part. Finite
These analyses identify the critical locations and determine element analyses have therefore been carried out for every
the local stress and material temperature as a function of the design of the compressor wheel and turbine. SIKO also takes
turbocharger speed and the suction air and exhaust gas tem- account of the thermal stress caused by temperature distribu-
peratures. tion in the component and, in the case of compressor wheels
with a center bore, even the prestresses induced by spinning
during manufacture.
Damping wire
Blade at damping
wire hole section
Blade
Center of hub
Hub
Fig. 6: Typical critical locations in a TPL compressor wheel Fig. 7: Typical critical locations in a TPL turbine
6
Figs. 6 and 7 show typical critical locations in a compressor
wheel and in a turbine. Figs. 8 and 9 show a finite element
net of a compressor wheel and its stress distribution under
operating conditions.
Fig. 8: Finite element model of a compressor wheel Fig. 9: Stress distribution under operating conditions
7
8
SIKO modules
4. Calculation of speed and temperature limits using the
damage accumulation method.
9
Information on the rating plate
Mmax 1
°C
to the rating plate is a major factor in trouble free turbo- S
n
Bmax t Bmax
charger operation and can prevent costly downtime.
kg
Application according to
the Operation Manual
made in Switzerland
10
SIKO benefits for the customer
11
ABB Turbocharging Service network
www.abb.com/turbocharging