1|13The customer magazine

of ABB TurbochargingSwitzerlandcharge!

A200-L: Perfect for increasing power density 4The next generation of two-stroke turbochargers with optimized compressor designService Points inside ship repair yards 11ABB Turbocharging China’s step closer to yards and end usersPower for the greenhouse 20Two stage turbocharged gas engines’ reliable energy generation in France

Tried and tested

2 ABB charge! 1|13

From the editor

charge! 1|13

Christian RodunerVice President, Head of Technology and Engineering

On May 13th 2013, the 27th CIMAC WorldCongress on Combustion Engine Tech-nology for Ship Propulsion, Power Gener-ation and Rail Traction opens its doors inShanghai.

This is ample reason to fully dedicate thisissue of charge! to the Congress and itshosting country, China.

The presence of both engine OEMs andend users makes it a prime opportunityfor us as a supplier of engine key compo-nents – turbocharging systems – to show-case our newest products as well asshare our ideas on future solutions intechnical papers and discuss them withour industry partners.

Consequently, we announced the launchof the A100 generation and our conceptfor two stage turbocharging at the 2007Congress in Vienna. Bergen 2010 wascharacterized by the introduction of Power2, our first industrialized two stagesystem. See Roland Berger’s report tofind out how the system is proving itself inthe field (page 20).

At this year’s Congress we will introducethe second generation of Power2 andgive the engine world an update on thecurrent status of VCM development – ourValve Control Management system. Inhonor of the hosting country, China, wewill also present the TPR 56 turbochargerwith VTG, purpose developed for theChinese diesel locomotive market (seepage 15) and, last but not least, theA200-L, our next cornerstone product fortwo-stroke turbocharging (see page 4).

A highlight of every CIMAC Congress isthe traditional ABB Evening, where ABBTurbocharging invites all Congress partici-pants to an unforgettable event, with aprogram that is a well-kept secret untilthe night itself.

I hope you enjoy reading our latest issueof charge! and look forward to meetingyou in Shanghai!

Christian Roduner

Quantum leap A200-LThe next generation of two-stroke turbochargersfeatures significantly increased flow capacity.04 Inside Xinya

ABB Turbocharging China’s new Service Pointinside the ship repair yard.11

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Contents

Technology 4 A200-L: Perfect for increasing power density

The next generation of two-stroke turbochargers withoptimized compressor design

9 What small meansThe customer benefits of the A200-L

10 The A200-L – a quantum leap from constant strivingThe invention story

15 A new railway turbocharger under Siberian conditionsin Northern ChinaVariable Turbine Geometry VTG on the tracks

Service11 Service Points inside ship repair yards

ABB Turbocharging China’s step closer to yards and end users

News19 ABB Turbocharging informs

Applications20 Power for the greenhouse

Two stage turbocharged gas engines’ reliable energy generation in France

Portrait25 With a heavy backpack

Life and work of Roland Schwarz, Head LBU Turbocharging China

Tips for the operator29 The need for high-temperature grease

Improving ABB turbochargers

Recipe30 With best regards to the Fifties

Breton scallops, a traditional French delicacy

Two stage turbocharged gas enginesPositive field inspection results at Serres Vinetin France. 20VTG technology on the tracks

Cold ambient condition qualification tests withstood.15

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Technology

A200-L: Perfect forincreasingpower density Based on the successful A100-L, ABB Turbo Systems has nowlaunched the next generation of two-stroke turbochargers featuring significantly increased flow capacity, but without penaltiesin terms of pressure ratio or efficiency.

Text Dr. Kai Lanzenberger, Photography Michael Reinhard, ABB Turbo Systems Ltd

In 2005 ABB Turbo Systems startedthe development of the A100-L turbo -charger for the two-stroke market.The market introduction in 2009 went

very well and, in the meantime, morethan seven hundred turbochargers havebeen sold. “Enable engine developers toachieve optimum engine performance”was the main product objective with

the A100-L: higher compressor pressureratios and higher turbocharger efficiency.These were essential to fulfill the require-ments of the IMO Tier II marine emis-sions regulations.

However, market requirements areincreasing continuously, the price of oil is rising year by year, and the marketrequires engines with lower fuel con-

sumption and higher power density. ABBTurbo Systems Ltd thus went on todevelop the next generation of turbo -chargers, the A200-L. Based on the suc-cessful A100-L, but significantly better interms of flow capacity, with the A200-L itis possible to use a turbocharger onesize smaller than before, resulting in animportant increase in power density.

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Technology

Optimum in compressor design: The A200-L.

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Technology

Optimized performanceAt the core of the improved perform-

ance is the new compressor stage. Usingstate-of-the-art CFD methods (Fig. 1) itwas possible to take a considerable stepforward in terms of aerodynamic design.But it was not only the most moderndesign tools that brought about this suc-cess. Sophisticated testing methodshelped to find the optimum in compres-sor design. The progress achieved in thefinal design is visible when comparingthe compressor maps of the A200-L and

A100-L (Fig. 2). From these, we see thatit was possible to increase volume flowby up to 30 % and – most importantly –without reducing pressure ratio or effi-ciency. As shown in the specificationillustrated, the area of high efficiency(solid color) is even higher for the A200-L compressor.

Optimized designDesigning a very good compressor is

one of the first steps in the developmentprocess of a turbocharger and certainly

Fig. 2: A275-L compressor map (blue) comparedwith A175-L compressor map (yellow).

Chief designer Matijas Ivankovic and project leader David Ruch investigating the A200-L compressor wheel.

Fig. 1: CFD calculation of the A200-L compressor wheel.

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Sophisticated testingmethods helped to find the optimum incompressor design.

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Technology

also one of the most important. But inorder to achieve a really successful prod-uct, several other elements have to bedesigned to their optimum. In the case ofthe A200-L, project leader David Ruch,his chief designer Matijas Ivankovic, theproject team and the engineers anddesigners of the large turbochargers prod-uct line, developed the complete turbo -charger in parallel with the compressor.

In Figs. 3a and 3b, the new turbo -charger is shown in cross section and asa 3D model. To achieve the highest pos-

sible efficiency, the A200-L turbochargerhas completely new components on thecompressor side: the compressor casing,the wall insert, the diffuser and thesilencer are optimized for the high volumeflow produced by the new compressor.Additionally, the turbine has been up-dated with new, optimized components.For all other parts such as the bearings,bearing casings, turbine inlet and outletcasings, the proven technology of theA100-L platform has been retained.

Fig. 3b: 3D model of the A200-L design.

The compressor casing,the wall insert, the diffuser and the silencerare optimized for the highvolume flow producedby the new compressor.

Fig. 3a: Cross-section of the A200-L – the newly designed parts (as compared with the A100-L) aremarked in colors.

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Technology

Dr. Kai Lanzenberger studiedmechanical engineering at the Univer-sity of Karlsruhe (KIT) and finished hisPhD thesis in fluid mechanics in 1995.After three years at Siemens in thepower plant business he joined ABBin 1998, where he held several leadingpositions in the ABB power plant and turbocharger business. Since 2010 hehas been Head of Product Line LargeTurbochargers, with technical respon-sibility for the large two-stroke turbo -charger types VTR. .4, TPL-B, A100-Land A200-L over their complete lifecycles.

Testing and qualificationAll ABB turbochargers have to fulfill a

wide range of engineering assessmentsand qualification tests before being intro-duced to the market. The A200-L is, ofcourse, no exception: qualification testsfor the compressor, the turbine and thewhole turbocharger have been per-formed, with some scheduled to becompleted before the first customerdeliveries.

ConclusionOur customers are looking for new

products with high performance, highreliability and high power density. Thenew A200-L will meet these require-ments. Due to its higher performance, itallows engine builders to equip theirengines with a turbocharger one sizesmaller than in the past. Moreover, thissignificantly higher level of power densitycompared to the A100-L was achievedwithout penalizing performance or relia-bility. From our point of view, this is animportant step in the right direction.

First customers have already orderedthe A200-L. Qualification and testing willbe finished shortly and first series unitswill be ready for delivery in April 2013.

The A200-L in the ABB test center.

First customers havealready ordered theA200-L.

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Technology

What small meansA200-L, the next generation turbochargers for low-speed two-stroke engines, is smaller and lighter. The customer benefitsare many.

Text Arie Smits, Photography Michael Reinhard

Since its invention more than 100years ago, the turbochargerhas reduced engine operatingcosts by reducing specific fuel

consumption and lowered capital costsby reducing engine size via a 300 %increase in specific power output. Thenext generation turbocharger A200-L iscontinuing to do exactly the same. Andthere are no negative effects!

The A200-L has a more compactframe, which makes it possible to use asmaller turbocharger on a wide range oftwo-stroke engines. The smaller turbo -charger does the same job as its biggerbrother – the benefits for ship ownersand operators are many. It means, forexample, less vibration and a smallerinstallation space. Extremely high turbo -charging efficiency has a significant effect

on fuel consumption, which is the majorcost factor for the marine industry. Forship owners and operators it also resultsin lower service costs – smaller and lighterturbochargers translate into 25 percentlower costs for spare parts as well aseasier maintenance – plus lower firstcost. Together, these mean lower totalcost of ownership.

Fast step into the marketThe A200-L will allow

engine designers to furtherincrease brake mean effectivepressure (BMEP), the basicmeasure of engine power. Atthe same time it will makeHigh Pressure Tuning (HPT)possible, a feature ABB

launched in 2012. HPT involves using thefull potential of a turbocharger by employ-ing electronic engine valve control. Theresult is the same fuel consumption aswith variable turbine tuning, but withoutthe actual hardware of variable turbinegeometry (VTG), or even an exhaust gasbypass (EGB). No moving parts, no addi-tional first costs, no exchange of a bypasswith its inherent tendency to stick.

With the A200-L, the next generation,ABB has demonstrated how fast an ideacan advance to market introduction. ABBwill launch the full range of A200-L modelswithin one year, at a time of significantmarine industry demand for lower costsand reduced fuel consumption.

Arie Smits was Head of the ABB Turbocharging Rotterdam Service Station before he moved toSwitzerland in 2001. Until October2012 Smits was responsible for theglobal low-speed two-stroke turbo -charger new business. Now he isSenior General Manager Global Turbocharging Projects, active in pur-suing major new-building projects.

Besides the fuel savings, thesaving in service costs aloneamounts to at least 25 percent in many configurations, and insome cases even more.

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Technology

A short story of research

The A200-L – a quantum leap from constant strivingThe A200-L invention told in a three chapter short story.

Text Dr. Volkmar Haueisen, Photography Michael Reinhard

Chapter oneThe A200-L story begins with the unchanging dedication of researchengineers to explore new possibilities.The idea of never being satisfied withthe status achieved, but to strive toexplore the world beyond the presentlimits.

The world of centrifugal compres-sor stages is limited by thermody-namic as well as mechanical bound-aries. In terms of thermodynamics,these are pressure ratio, flow capacityand thermal efficiency. In thermal turbomachinery, we most often haveto face the fact that moving forwardwith one of these three limits meanscompromising one of the others.

“We will challenge this counteract-ing process” was the ambitious tar-get of the compressor team and the starting shot in the A200-L story. Butat that moment the team didn’t knowanything about a story, because theywere starting a basic developmentproject to explore a new world ofphysical parameters not yet connectedto a product. The target was a signifi-cant increase in flow capacity withoutcompromising thermal efficiency. Thefollowing figure illustrates the resultthey achieved, a true quantum leapcompared to the usual steps in adevelopment process.

The black curve, well known fromliterature (Casey-Robinson), shows the characteristic of state-of-the-artdesigns of centrifugal compressorstages. With the abscissa represent-ing the volume flow, we see the con-tinuous decrease in efficiency as flow

capacity rises. The blue mark shows theresult achieved by the research team –high flow capacity while maintaining anextraordinary level of thermal efficiency.Chapter one of the A200-L story wascomplete!

Chapter twoThe A200-L story was immediately con-tinued by the recognition of the potentialof this new world in terms of customerbenefits. The complete compressorstage was designed, thoroughly testedand qualified, ensuring mechanicalintegrity in addition to outstanding per-formance.

Chapter threeWith the final design of the compressorstage, chapter two of the A200-L storywas complete. It was followed by thelast part of the story: integration of thiscompressor stage into new productarchitecture – the A200-L.

As you can see, the quantum leap ofthe A200-L is a short story, based on agiant step in research and development.

Dr. Volkmar Haueisen is GeneralManager, Head of Research & Devel-opment Turbochargers. He gained hisDoctorate at the Darmstadt TechnicalUniversity with a thesis on PeriodicUnsteady Flow in Turbomachines.Volkmar Haueisen started at ABB Turbo Systems Ltd in 1995 as a turbine development engineer and,among other roles, was subsequentlyproject leader for the development ofthe TPL-B turbocharger series andmanager of the medium-speed engineturbo charger product line.

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state of the art

new A200

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Service

Service Points inside ship repair yards: A step closer to customersABB Turbocharging China has launched a strategic initiative thatbuilds on partnerships with local ship repair yards and enablesABB to stay closer to both the yards and end users, supportingthem better and faster.

Text Rachel Chen, Photography ABB Turbocharging China, Xinya

Xinya Shipyard: one of the Top 10 ship repairers in China.

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Service

Currently, there are six ABBTurbocharging Service Sta-tions operating in China. Theyare located along China’s

east and south coast and within the clus-ters of major local ship repair yards. Byproviding fast and professional service,ABB Turbocharging China has cultivateda service brand that is recognized by thelocal yards and maintains a good relation-ship with them.

In order to expand its domestic foot-print and get closer to its customers,ABB Turbocharging China has launchedan initiative calling for the setting up ofService Points inside ship repair yards.This strategic initiative recently cameunder the spotlight when ABB Turbo -charging China and Xinya Shipyard, oneof the Top 10 ship repairers in China, officially signed a partnership agreementfor turbocharger service. The agreementfocuses on ABB Turbocharging implant-ing a Service Point inside the Xinya Ship-yard in Zhoushan Area.

This is only one of the Service Pointsthat ABB Turbocharging China plans toopen up in 2013. With its deep under-standing of, and insights into, the dynam-ics of the world’s ship repair business,ABB Turbocharging China foresees a stillgreater role for Chinese ship repair yardsin the global shipping markets of thefuture. Through both Service Stations andService Points ABB is preparing itself toprovide greater coverage for ABB OriginalParts and Original Service to an increas-

ing number of customers who send theirships to China for repair and mainte-nance. These customers can enjoy betteraccess to ABB Original Parts and OriginalService when they dock for repairs atshipyards having a Service Point. Theywill have no more concerns regardingcompromises in terms of service qualitydue to the use of non original parts andservice, or worries about the higher logis-tic costs or risks associated with serviceprovided from outside the repair yard.

China’s ship repair industry

30 percent of the world’s ship repairbusiness takes place in China. Andthe trend is upwards.Today’s global economy and, in par-ticular, the marine industry are facedwith many challenges and uncertain-ties. Overcapacities, low freight ratesand higher fuel bunker costs haveovershadowed recent shipping mar-ket developments on a global scale.It is predicted that the shippingindustry will continue to face toughtimes and cannot expect to rebounduntil 2014. This prolonged recoverytime has forced ship owners to cutrepair and maintenance spendingand to seek the most cost effectivesolutions.

This further enhances the attrac-tion of the low cost centers on theglobal marine maintenance, repairand conversion map, in countriessuch as China, Vietnam, Indonesia

and India. China has been a consistentcompetitor to Singapore since its emergence in ship repair and conversionprojects. Now it is far ahead of Singa-pore in terms of its population of large

and super-large dockyards, which con-tribute to a total docking capacity of over10 million dead weight tons. These infra-structure developments reflect the rapidexpansion of China’s ship repair industry.

Presently, China takes around 30percent of the world’s ship repair busi-ness and is expected to strengthen itsfooting in the near and medium terms,despite the difficult market situation.Increased competition and cost pres-sure, however, will continue to set thetone for the next few years. Local shiprepair yards are forced to embrace costcutting and productivity programs as aresult of reduced revenue per vessel.They are also striving to go beyond thebasic scope of repairs and provide com-petitive offerings to their customers formore complex and demanding projects.

These efforts translate into enhancedcapabilities and services by local yardsand cost competition benefits for ship

One of the Top 10 ship repairers in China: Xinya.

Zhoushan Port’s excellent fairway depths enablevessels of up to 300,000 tons to enter and leavewithout waiting for tides.

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Service

Highly trained serviceengineers ensure that all servicing work is carried out in genuineABB Turbocharging style.

Creating valuesABB Turbocharging Service Points are

set up according to ABB Turbocharging’sglobal standards and equipped with theirown machines, ensuring that ABB Turbo -charging has full control over the workingfacilities. More importantly, highly trainedservice engineers from ABB Turbo -charging Service Stations are stationedat the Service Points to ensure that allservicing work is carried out in genuineABB Turbocharging style – just as cus-tomers expect from any ABB Turbo -

charging service workshop. By integrat-ing Service Stations and Service Pointsinto an expanded local service network,ABB Turbocharging China has reaffirmedits commitment to its global customers.ABB Turbocharging Service Points notonly create value for ship owners, theyalso create value for ship repair yardsand ABB Turbocharging itself.

The global economic slowdown hasposed many challenges and uncertaintieson the ship repair front. Although the Chi-nese ship repair market has continued to

owners. Wang Yu-Hang, Chairman ofthe Ship Repair Sub-committee of China Association of the National Ship-building Industry, revealed that China’stop 20 ship repairers overhauled 3659ships in 2011, with a year-on-yeargrowth rate of 17.4 percent. The num-ber for quarters one to three in 2012was 2606, with a year-on-year growthrate of 5.85 percent. It is generallythought that the total number of vesselsoverhauled in China reached well over5000 when smaller ship repairers aretaken into account.

The Zhoushan AreaThe Zhoushan area is home to around50 ship building and ship repairingenterprises, located on the closely scat-tered islands geographically known asthe Zhoushan Archipelago. These are atthe confluence of China’s coastal ship-ping routes and its inland Golden Water-

way, the Yangtze River. The area alsoenjoys a distinct advantage in having adeepwater coastline, of which almost200 kilometers are deeper than 15 metersand almost 110 kilometers deeper than20 meters. Zhoushan Port boasts 11 portdistricts and 41 deep-water berths forvessels of over 10,000 tons. The excel-lent fairway depths enable vessels of upto 300,000 tons to enter and leave theport without waiting for tides.

According to statistics from the Portand Shipping Administration Bureau of Zhoushan Municipality, the overallcargo throughput in the Zhoushan Areareached 291 million tons in 2012, with a year-on-year increase of 11.69 per-cent. Official statistics also indicate thatfrom 2005 to 2010, an average of 2500vessels were overhauled each year inthe Zhoushan Area, with annual turnoveraccounting for 18 percent of the Chinesenational total.

A large number of the vesselsdocked at the Zhoushan Area forrepair and maintenance enter and sailfrom the neighboring ports of Shang-hai and Ningbo, the No. 1 and No. 6busiest container ports in the world.As Zhoushan Port and Ningbo Portshare the same sea area, fairways andanchorages and complement eachother geographically, they have beenofficially merged into one big port andrenamed as Ningbo-Zhoushan Port,and became the world’s No. 1 port interms of cargo throughput in 2010 and2012. This has a positive influence onthe recent developments of the shiprepair business in the Zhoushan Area.

ABB Turbocharging Service Point workshop.

expand, it was at a lower rate last year aslocal ship repair yards face increased localand global competition. They try to attractand retain customers with enhanced ser-vice capabilities and guaranteed servicequality. ABB Turbo charging Service Pointson their premises offer them a convenientsource for the OEM standard service pre-ferred by many customers around theworld. ABB Turbo charging China is thusreinforcing its support of local ship repairyards in a difficult market situation. Inreturn, ABB Turbocharging becomes bet-ter positioned to capture growth opportu-nities within China’s future oriented shiprepair market and to exploit the full poten-tial of turbocharger service business theyards create.

ABB Turbocharging Service Pointsalso provide field demonstrations of ABBOriginal Parts and Service which will helpChinese ship repair yards and ship ownersto better understand ABB Turbo charging’sservice value propositions, includingoperating safety and product quality.

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Service

Xinya’s fast growthAs the Chinese ship repair industry is

constantly growing and transforming,ABB Turbocharging China has been prudent with the selection of partnersamong local ship repair yards. It is fullyaware that the setup of an ABB ServicePoint on a partner’s premises is a solidcommitment based on shared valuesand mutual trust, and should lead to along lasting partnership that is beneficialand profitable for both parties.

Xinya Shipyard is one of the local shiprepair yards which has convinced ABBTurbocharging China of its capacity to bea strong partner. As the largest privatelyowned ship repair yard in China, Xinyaexperienced fast growth in the pastdecade and has ranked among the Top10 players in the Chinese ship repairmarket since 2008. More than 200 shipsare overhauled each year at Xinya’s repairfacilities.

In the past years, ABB TurbochargingChina’s Shanghai Service Station hashelped Xinya to satisfy many customersand demonstrated to Xinya its servicecompetence and commitment by strictlyimplementing ABB Turbocharging globalstandards. The cooperation on servicecontracts has been smooth, as both par-ties attach the same degree of impor-tance to safety and quality, sharing great

commitment to customer satisfaction.Such shared values and trust laid thefoundations for the joint decision todevelop the collaboration to the next level.

Considering that Xinya is more than350 km away from the ABB TurbochargingShanghai Service Station, including a tripon a ferry, this means a one-way trip of atleast 5 hours for ABB service engineers.Thus, it is clear that the setup of an ABBTurbocharging Service Point inside XinyaShipyard will offer many benefits.

Commenting on the new partnershipbetween ABB and Xinya at the signingceremony of the partnership agreement,Wu Zhixiang, Vice-Chairman of XinyaCompany noted, “this partnership is anew beginning and a new challenge forboth parties. We expect that with theactive engagement and joint efforts ofboth parties, this strategic partnership willfurther enhance the brand influence andcore competitiveness of ABB and Xinya,making a solid contribution to the industrialand economic development of Zhoushan.”

Roland Schwarz, LBU Manager atABB Turbocharging China, expressedthe same expectation when he was pres-ent at Xinya Shipyard on January 8th,2013 to sign the partnership agreementwith Zhou Yaguo, Chairman of XinyaCompany. He also emphasized theimportance of being closer to customersin order to support them faster withimproved logistics. The signing of theagreement was followed by a firm hand-shake, signifying united efforts towards acommon aim with a sustainable future.

More than 200 ships are overhauled each year in theXinya repair yard.

Convinced ABB Turbocharging China of its capacity to be a strong partner: Xinya Shipyard.

Signing of the agreement: Roland Schwarz andZhou Yaguo.

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Technology

A new railway turbocharger under Siberian conditions in Northern ChinaPutting ABB’s Variable Turbine Geometry technology on the tracks.Text Pierre Jacoby, Photography CSR Qishuyan Locomotive Co., ABB Turbo Systems Ltd, Michael Reinhard

“Smart Loong” locomotive in North China for cold conditions qualification test.

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Technology

VTG enriches the rail turbocharginglandscape

Variable Turbine Geometry technologyfor the TPS and TPL turbocharger plat-forms has been in commercial use formore than 15 years and there are morethan 1100 units in the field. This VTGtechnology has now been transferred tothe TPR turbocharger platform. VTGenables greater operational flexibility onengines by constructing the nozzle ringwith adjustable vanes, whose pitch canbe controlled by levers actuated by a slotring. By turning the ring, the nozzle vanesare moving around the rotation axis asthey are both linked through the adjust-ing lever. It produces a synchronizedmovement of all vanes, adjusting the flowarea of the turbine stage. This modulatesthe pressure of the exhaust gases reach-ing the turbine and hence the energy the turbine stage provides to the compres-sor stage. It allows close control of thelevel of boost pressure the turbochargerdelivers, thus influencing the amount ofair that flows into the cylinders (Fig. 1).

The success story of BBC/ABBturbochargers on locomotivesstarted in the 1930’s. Since thefirst ABB turbocharged diesel

engine in a rail traction application, re -quirements from the rail transport sectorhave been constantly re-defined. Turbo -charging systems for locomotive engineshave meanwhile become ever moreimportant as a means of enhancing oper-ational reliability and fuel economy. Overthe last decade, the search for environ-

mentally friendly solutions has alsobecome a major focus for railways.Hence, these latest rail turbochargingdevelopments incorporate these techni-cal specifics.

ABB Turbocharging’s solution for railapplications

When TPR 61 – the larger frame sizein ABB’s turbocharger platform specifi-cally for rail applications – was launchedfor commercial operation in the early2000s, a full set of design features fortraction operation was also introduced inorder to meet the operational, economicand regulatory requirements of the loco-motive market. Compactness, robust-ness and rugged construction have beencombined with outstanding thermo-dynamic performance and efficiency,complemented by features designed toensure reliable turbocharger operationover extended times between overhaul.

Building on a proven record in com-mercial rail applications – more than1850 units are in operation on long-haulapplications in India, where some turbo -chargers have logged more than 50,000operating hours – a second frame sizewas released in 2011 for commercialoperation, the TPR 56. The TPR portfoliois thus structured around the TPR 56 andTPR 61 frame sizes and targets medium-speed engines primarily designed for railtraction applications. The corresponding

VTx350 BBC turbocharger on ALCO 8 cylinder; engine rating: 900 hp at 700 rpm.

Fig. 1: VTG module principle.

engines are typically rated at 4500 and6000 horsepower and equipped with twounits of TPR 56 or TPR 61 turbochargers,respectively.

In recent years, new features havebeen introduced to tackle the everincreasing requirements of engine buildersin terms of higher power output andemissions control – namely a high-pressure compressor stage with air recir-culation and a Variable Turbine Geometry(VTG) module to allow more flexibility ofthe turbocharging system as a whole.

The VTG technology hasnow been transferred to the TPR turbochargerplatform.

Gas outlet casingSupport ringRotation axisSlot ringAdjusting leverGas inlet casingNozzle vaneTurbine shaft

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Technology

In fact, from a closed to an open VTGposition, the effective area of the turbinestage can be changed by 50 percent. Thisin turn provides corresponding turbo -charging adjustment possibilities, withthe following benefits:– Reduced fuel consumption (from 2 to

5 percent, depending on VTG integra-tion possibilities).

– Lower engine thermal load (~ 80 °Clower turbine inlet temperature); in -crease in reliability and durability.

– Extended range of locomotive opera-tion.

– Increased locomotive load dynamics;reduced smoke emissions.

– Alleviation of the effects of high ambi-ent temperatures and high altitude onengine operation.

– New trade-off possibilities for enginepower optimization, specifically forcomplying with the latest emissionregulations.

TPR 56-F33 VTG turbochargers on ABB Turbo Systems’ final assembly bench.

The VTG feature is currently availablefor the TPR 56 frame size and also inte-grates a control system that permits theoperation of two VTG turbochargers inparallel – a typical configuration for veeconfiguration engines – while preventingboost pressure from exceeding a presetvalue.

As with all new turbocharger designs,VTG versions first undergo a full matrix of extensive qualification tests on the

Intake air temperatures varying from – 40 °C to+ 50 °C in the open air and altitude differences of over 2500 meters are simply seen as normal.

turbocharger test bed. Among otheraspects, efficiency measurements, ther-mal and load cycle endurance tests andlow and high cycle fatigue (LCF/HCF)qualifications are preconditions prior tomoving on to engine testing. All theseturbocharger qualification tests havenow been completed within ABB TurboSystems’ facilities, leading to the fullrelease of the TPR 56 VTG for commer-cial operation.

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Technology

VTG turbocharging technology on theengine test bed

To achieve the reliability standard thatthe rail industry is demanding, new powerpacks for locomotives (i. e. the engineand generator which power the tractionmotors of diesel electric locomotives)need to withstand all types of operatingconditions encountered in commercialservice. This is the main goal qualificationtests are designed to meet. In the caseof the TPR 56 VTG, the qualification pro-cess is ongoing on an R12V280ZJ engine,being structured across two main blocks,namely the engine test bed and field trials on the locomotives themselves.

On the engine test bed, there are fourdistinct steps – matching and perform-ances tests, type approval tests, emis-sions tests and finally the delivery test –all of which are prerequisites for therelease of an engine power pack to beinstalled on a locomotive for field qualifi-cation. The objectives of the latter is tooperate under all the different conditionsa locomotive will see during its commer-cial lifespan and to ensure safe andproper functioning of the whole system.Typically, the testing is gradual in itsseverity and lasts for at least a year, soas to undergo seasonal impacts. Amongthese, the ring railway test for start-stop,braking and other transient modes are

absolutely critical for safe operationbefore going out onto open track. Thewidely changeable ambient conditions along haul locomotive will have to with-stand while pulling goods from oneextremity to the other in a country suchas China is vast: intake air temperaturesvarying from – 40 °C to + 50 °C in theopen air and altitude differences of over2500 meters are simply seen as normal.Going through tunnels and crossingdeserts entail further conditions that willhave to be endured.

The “VTG Locomotive” on trackThe “Smart Loong” locomotive

employing the R12V280ZJ diesel powerpack with its TPR 56 VTG turbochargingsystem is currently in the field qualifica-tion process. It is produced by China’sCSR Locomotive Co. and has alreadyfulfilled many of the prescribed criteria.The cold ambient condition qualificationtest took place last January, overnight ina North China province to ensure thelowest possible ambient temperatures;at minus 40 °C this is clearly a “Siberian”climate!

Under these conditions, compressorsurge stability is an operational parame-ter which is challenged to the utmost.Likewise, tight control over deliveredboost pressure is critical to ensure the

engine’s mechanical integrity. With aVTG turbocharging system installed,both aspects were subject to closescrutiny and their respective stabilitydemonstrated.

Having withstood the cold conditionoperation test, the locomotive is nowmoving onwards to other extreme condi-tions: desert environments, tropical cli-mates and tunnel conditions are nowdefinitely priorities in the test schedule.

From the VTx350 installed on ALCOengines to the TPR 56 VTG on theR12V280ZJ, a span of 80 years of devel-opment has passed. And while it is still all about diesel engines, about per-formance, about reliability, durability andsafety in operation, the requirements andstandards to be met have been re-written several times. Although only atthe dawn of its commercial operation,the R12V280ZJ power pack with itsTPR 56 VTG turbocharging system isalready a new benchmark for heavy dutydiesel locomotives, as it lays down newmilestones for performance, reliabilityand operational flexibility along the rail-way industry development track.

Newly developed R12V280ZJ engine with TPR 56-F33 VTG turbocharging system; the engine rating is3530 kW at 1000 rpm under nominal conditions.

Pierre Jacoby has an M.Sc. inMechanical Engineering from the vonKarman Institute for Fluid Dynamics in Brussels and an MBA from the University of Chicago. Starting hiscareer in 1994 at ABB Poland insteam turbine testing, he moved in1995 to gas turbine development at ABB Kraftwerke AG in Mannheim.In 1996, he relocated to Baden andworked in turbocharger applicationengineering. As Head of ApplicationEngineering in China from 2005 to2010 he was responsible for all domes-tic four-stroke engine projects. Since2010 he is General Manager of theNew Business department responsi-ble for rail projects worldwide.

ABB charge! 1|13 19

News

Baden. ABB Turbocharging has beennamed a Bronze Level SQEP supplier forCaterpillar Motoren Kiel GmbH & Co. KG.SQEP, or Supplier Quality ExcellenceProcess, is Caterpillar’s system for ensur-ing the high quality of its suppliers andconfers upon a company preferred sup-plier status. Obtaining SQEP status forequipment as complicated and variedas a turbocharger constitutes a majorachievement, because strict requirementsmust be met in several categories, in -

cluding product quality, process manage-ment, manufacturing, logistics, deliveryand customer service, to name just afew. Only Caterpillar’s most trusted sup-pliers are bestowed with this honor. “We are very proud of this achievement,because we really try to cater to everycustomer’s needs, and this award reflectsCaterpillar’s great faith in what we do,” said Oliver Riemenschneider, GroupSenior Vice President and Head of ABBTurbocharging.

ABB Turbocharging named SQEP supplier in Caterpillar Kiel

Optimized longstanding processes in Cape Town.

Caterpillar Kiel.

Cape Town. ABB Turbocharging SouthAfrica has moved its operation to newpremises. With about fifteen peopleincluding service engineers, the team isexpanding its electrical department(medium- and low-voltage), so a decisionwas made to build new operations fromscratch. Careful consideration was given to the optimization of longstandingprocesses and planning for the future.

To begin with, the new building has more storage capacity and office space.The warehouse is now also set up toincrease efficiency by stationing eachservice work area in the correct chrono-logical order, allowing workers to coordi-nate their tasks better and minimize the distances the turbochargers have tobe transported from one station to thenext.

A new home for ABB TurbochargingSouth Africa

Upgrades save customers fuel byone to three percent

Baden. Only a few months after its offi-cial launch, ABB Turbocharging’s newupgrade service is being extremely wellreceived by customers. Within less thana year, customers have placed four majorcontracts worldwide. The many differentimprovements make it easy to see whycustomers are so convinced. An upgradeallows customers to use less fuel,increase turbocharger efficiency, widenspeed margin, and vastly reduce thermalwear and tear. “With the upgrade, cus-tomers can also benefit from their olderengines and turbochargers by reducingtheir total cost of ownership. Our cus-tomers are saving anywhere from one tothree percent. Payback times for anupgrade are less than three years, andthat makes this a very viable investment,particularly in this challenging market,”said Reinier Bakker, Manager OEM Service Sales, who has spearheaded theupgrade effort at ABB Turbocharging.

For more information, visitwww.abb.com/turbocharging

20 ABB charge! 1|13

Applications

Power for thegreenhouse

Serres Vinet in Machecoul, Loire-Atlantique region, France.

ABB charge! 1|13 21

Applications

At Serres Vinet in France, Jenbacher two stage turbochargedgas engines generate hot water and electricity – flexibly, and reliably. The inspection after two years verified the fault free functionality of Power2.

Text Roland Berger, Photography Corbis, Roland Berger, GE Jenbacher GmbH & CO OG, Michael Reinhard

22 ABB charge! 1|13

Applications

Since the beginning of 2010,two of GE’s flexible, high out-put, high efficiency JenbacherJ624 gas engines with Power2

two stage turbocharging have been running at the French Serres Vinet mar-ket garden in Machecoul, in the Loire-Atlantique region. These two lean-burn,spark-ignited gas engines with two stage turbocharging were the first oftheir kind in France. They are the heart oftwo cogeneration (CHP) plants poweringSerres Vinet’s original greenhouses plusa 17 hectare expansion, also added in2010. They generate all the hot waterand electricity required for the marketgarden’s extensive tomato, cucumberand lettuce greenhouse cultivation.

The gas engines give Serres Vinet theflexibility to switch among priorities forelectrical energy, thermal energy and achoice of fuel sources as economics dic-tate.

“The efficiency, flexibility and reliabilityof these two stage turbocharged gasengines since being commissioned inJanuary 2010 has been outstanding,” saysGilles Marquerat, director of the powerproduction department at GE’s customerForclum involved in the engineering of theplants. Because the performance of the installation has been so impressive,Forclum has purchased two more new624 gas engines with Power2 two stageturbocharging for another French grower’sgreenhouse.

Serres Vinet: A total of 30 hectares, corresponding to 42 soccer fields.

One of the Jenbacher J624 gas engines at the Serres Vinet CHP plant.

The efficiency, flexibilityand reliability of the two stage turbochargedgas engines since beingcommissioned in January2010 has been out-standing.

ABB charge! 1|13 23

Applications

The field inspectionIn July 2012, after two and a half

years and thousands of operating hourswithout unplanned downtime, the twostage turbocharging modules of the twonew J624 engines at Serres Vinet wereinspected by the local ABB TurbochargingService Station in St. Nazaire. In atten-dance during the service work, engineersfrom ABB Turbo Systems Ltd found all thecomponents, including all wearing parts(e.g. bearings), of both Power2 340-Hturbocharging systems to be fully opera-tional. “Reliable continuation of operationof the Power2 340-H turbocharging sys-tems would have been possible without

any limitations,” noted Antje Hertel, ABB Turbo Systems Product DevelopmentEngineer and project leader of the twostage development project.

With these positive inspection results,the Power2 two stage turbocharging hasverified the level of reliability and faultfree functionality that customers havecome to expect from the products ofABB Turbocharging.

Power2 enlarges the product portfolioof ABB Turbocharging to cover new twostage turbocharged engines due to belaunched in the near future, while alsounderlining the Company’s technologicalleadership in advanced turbocharging.

Cogeneration (CHP): How it works

Schematic of a CHP plant with CO2 fertilization.

From left to right: Yvon Guillemot, ABB Service Station Manager, St. Nazaire (F); Samuel Serreau, ABB Service Engineer, St. Nazaire (F); Roland Berger, ABB Sales and Application Engineer, Baden (CH); Laëtitia Lelièvre, ABB Service Coordinator Northern France, St. Nazaire (F); Antje Hertel, ABB Product Development Engineer, Baden (CH); Patrick Aberle, ABB Product Construction Engineer, Baden (CH).

The engineers from ABB Turbo Systems Ltdfound all the compo-nents of both Power2340-H turbochargingsystems to be fully oper-ational.

Fuel gasUrea tank

Catalytic converter

Heat exchanger

Buffer

Blower

Exhaust gas

Lighting

CO2

Heat consumer(Greenhouse)

Electricalenergy

24 ABB charge! 1|13

Applications

Close cooperation

In 2007, GE introduced the world’sfirst 24 cylinder gas engine for com-mercial operation, also equipped withthe latest turbocharger technologyfrom ABB Turbo Systems Ltd, namelythe single stage A100-H.

In June 2010, with the new J624,GE introduced its next generation ofgas engines, featuring Power2 340-H,ABB Turbo Systems’ advanced twostage turbocharger technology. Mainlydue to the new two stage turbochargertechnology, this 24 cylinder engine sig-nificantly extended the limits of gasengine performance and substantiallyincreased the engine’s benefits to theend user:– Turbocharging efficiency > 73 %;

electrical engine efficiency raised to46.5 %.

– Full engine output and efficiencyeven at high ambient temperaturesand high altitudes.

– 10 % higher power output (power density).

– Up to 90 % total efficiency for CHP applications.

ABB Technology within GE’s Jenbacher gas engines has con-tributed to improved performance.GE’s gas engine manufacturing arm,GE Jenbacher GmbH & CO OG, hasover 50 years of experience in thedevelopment and manufacturing ofgas engines for all types of gaseousfuels. Over its history of gas engineinnovation, the GE Jenbacher devel-opment program has continually driven up the output and efficiency ofall engine versions, reaching newrecords.

For decades ABB Turbo Systems Ltdhas maintained close cooperation withGE in the development of new products.The 20 cylinder version of the type 6engine, introduced in 1998, was thesmallest package in the 3 MW outputrange to use ABB turbocharger tech-nology. Since then, engine perform-ance has continuously improved onthe Jenbacher type 6 family, which iscapable of providing its maximum ratedoutput and efficiency over a widerange of ambient conditions.

Roland Berger is Senior Manager in Sales and Application Engineering.After his studies at the University of Stuttgart, he joined ABB TurboSystems Ltd in 2001. He is special-ized in turbocharging of four-strokegas engines and is responsible for thetechnical support of GE Jenbacherwithin the High-Speed Segment. As aresult, he managed the layout, testingand validation of the Power2 340-Hturbocharging system currentlyapplied on the Jenbacher two stageturbocharged J624 engine.

The combined heat and power (CHP)greenhouse enables flexible power gen-eration and the supply of electrical powerto the local electricity supply grid. Inaddition, the thermal energy producedby the engines during power generationcan be transferred to the greenhouseduring cooler periods, or retained in ther-mal storage tanks for use at other timesof the day. Apart from electricity andheat, it is also possible to use the carbondioxide (CO2) from the exhaust gas to

fertilize the plants. After cleaning in spe-cial catalytic converters (SCR and oxida-tion), the exhaust gases are cooled in aheat exchanger to around 50 °C and thenfed to the greenhouse for carbon dioxide(CO2) enrichment. “GE has installed morethan 800 gas engine CHP units globally,representing approximately two gigawattsof power generation capacity, plus CO2

fertilization systems”, says Scott Nolen,product line management leader PowerGeneration at GE Gas Engines.

Jenbacher J624 with two stage turbocharging unit Power2 340-H.

ABB charge! 1|13 25

Portrait

With a heavybackpackRoland Schwarz, Head LBU Turbocharging China, lives with his partner in Chongqing. And that means familiar territory. A portrait of a seasoned traveler.

Text Tiziana Ossola Auf der Maur, Photography Corbis, Anthea Tan, ABB Turbocharging China

The powerhouse driving Western China: Chongqing.

26 ABB charge! 1|13

Portrait

More are being planned. Schwarz relateshow the handy sized Jiangbei airport hasbeen upgraded for international trafficover the past 10 years. The townscape,and with it a whole way of life is changing:“There is always a little sadness whenyou see how the old Chongqing, which I was privileged to see 10 years ago, is disappearing. But I also see how the local population, including our own ABB employees, is benefiting from thechanges in society. Overall prosperityhas increased. Opportunities in educationare now much better”. ABB Turbochargingplayed – and still plays – its part in offer-ing China’s school leavers chances forpersonal development. Schwarz noteswith some satisfaction that among Uni-versity graduates, ABB is still high on theemployer wishlist.

Looking to the futureRoland Schwarz points to his large

rucksack. “My mobile office!” With sixService Stations between Dalian andHong Kong, his area of responsibilitystretches around 2000 kilometers North

The weekend ritual takes awhole half day. First it’s decidedwhat’s on the menu. Then theyset off, if possible on foot, to

get the ingredients. In a year and a half,Roland Schwarz and his partner SimoneJampen have experienced all sorts: aswell as Chinese cabbage and lotus roots ahost of unknown vegetables, a butcher’sdepartment in a supermarket with livechickens and ducks, the market witheverything meaty, from snails via chicken’sfeet to pigs’ heads.

Both of these Swiss citizens lovemangoes. In China they taste likenowhere else. They are just as familiar –and cool – with the fact that they can’tfind everything they know from theirnative Swiss cuisine. So if they choose arecipe from the Swiss cook books theytook with them, they have to be flexible.“We just see what ingredients we can getour hands on,” is their simple rule. Find-ing cheese and natural yoghourt is diffi-cult. And it helps to roll up your sleeves.They both bake their own bread. And asa precaution, a pressure cooker was intheir luggage when they left for China inDecember 2011.

Back at the flat there follows anextended aperitif, communal slicing andfrying. They talk, they exchange newsand views: Roland and Simone haveobserved their cooking ritual ever sincethey became a couple. In Chongqing,too, as far as Roland’s schedule allows.

Roland Schwarz took over in January2012 as Head of ABB TurbochargingChina. In this way he is continuing hiscareer in a place he knows well. As earlyas 2003 he was making regular businesstrips to Chongqing and from the end of2005 to the beginning of 2009 he livedthere. As principal Financial Controller,the native of Canton Thurgau was in atthe ground floor on the planning andbuilding of the Local Business Unit Turbocharging with both a production andservice organization in China. He knowsnot only the history of this organization infine detail, but also its employees andthe Chinese authorities. He returned toChongqing as General Manager andsubsequently, at 42, took over the man-agement of ABB Turbocharging China, arecently updated manufacturing works forturbochargers with sales of more than100 million U.S. Dollars and around 500employees throughout China. And he wastasked with addressing a tough marketsituation. For Schwarz this was, all at

once, a vote of confidence in him, a chal-lenge and a personal temptation. Hispartner Simone – likewise open for a lifeabroad – decided to accompany him (seeinterview on page 28). To experience thisproject together is a great enrichment theysay in unison. This put the seal on thedecision to take the three year assignment.

Big plans The couple lives in a flat in the City of

Chongqing, the key driving force inWestern China. Things are happeninghere. Schwarz: “It is incredible how this town has changed in the past tenyears, especially the infrastructure.” TheChongqing Planning Exhibition Hall, whichSchwarz and Jampen like to visit fromtime to time, includes an 892 square meterscale model of the future Chongqing cityproper. The urbanization plans of theGovernment can be experienced live onthe streets. For example, the develop-ment of the transport system in a conur-bation of 32 million people, including the expansion of the Chongqing Metro,which presently comprises four lines.

Roland Schwarz took over the management of ABB Turbocharging China in 2012.

ABB charge! 1|13 27

Portrait

to South. In addition there are cus-tomers, suppliers and authorities all overChina. But geography alone does notentirely explain the mobile office. “To meeveryday life means precisely that I haveno everyday life.” It consists of meetingsand negotiations plus everything un -planned and unpredictable. That’s allpart and parcel of his job. As such, it’s tohave a sense of pragmatism and thenecessary composure, says Schwarzwith a laugh. These qualities, Schwarzgoes on to say, are generally helpfulabroad, where differences of languageand mentality are simply a fact of life.

The economic situation in China ismore acute than when he took over hisjob, above all in the marine sector. Thedownturn due to overcapacity in com-mercial vessels and at shipyards posesexacting challenges for Schwarz and hiswhole management team. “More thanever it is important to understand cus-tomers’ needs and to create value forthem,” Schwarz declares. ABB Turbo -charging is very successful in accompa-nying those customers that wish, for

example, to broaden their portfolios inorder to enter new markets. “We activelysupport our customers in the area ofapplication engineering and tests withour local experts. Because we see thisas a chance for both us and our cus-tomers to come out of the current marketsituation stronger.”

In addition, the market in China ischaracterized by parallel worlds of olderand newer technologies. Both interna-tional and, increasingly in recent years,local suppliers are trying to secure theirmarket shares in both the large engineand turbocharger businesses. “Today,China is one of the most complex mar-kets”, says Schwarz. In spite of growingcompetition, ABB Turbocharging remainsthe market leader in China. But it isimperative to be on your toes: “Morethan ever we need the right offerings inChina. On the other hand we have to ful-fill the quality and service expectations ofour globally active customers.”

This year the LBU Turbocharging Chinahad to adapt its production capacity.Forecasts for 2014 are showing a

slight improvement. Nonetheless, RolandSchwarz is cautious. “On the other handwe are confident that, thanks to our cus-tomer proximity, we can exploit servicebusiness opportunities.” At this pointSchwarz emphasizes how impressed heis with the way his colleagues stayfocused on the future at this difficulttime. “They are always positive and givetheir best. They remain eager to learnand want to develop themselves. Iadmire that!”

Meet Roland Schwarzat the CIMAC Congress

The 27th CIMAC Congress takes placefrom May 13th to 16th, 2013, at theShanghai Exhibition Center in Shang-hai, China. ABB Turbocharging willhave a stand there. Roland Schwarz,his team and colleagues from ABBTurbocharging invite you to the tradi-tional ABB Evening in Shanghai onTuesday, 14th May 2013 at 6.30 p.m.

ABB Jiangjin Turbo Systems Co., Ltd.

We actively support ourcustomers in the area ofapplication engineeringand tests with our localexperts.

28 ABB charge! 1|13

Portrait

Chinese lessons in a taxiInterview Tiziana Ossola Auf der Maur, Photography Anthea Tan

Simone Jampen is the partner ofRoland Schwarz. They live togetherin Chongqing. Jampen is a lawyer.She gave up her job in the Legal &Compliance Department at the UBSat the end of 2011.

What attracted you personally toChina?Simone Jampen: I already had a con-nection to China via Roland’s earlierstay in Chongqing. During that time I visited China several times andtogether we traveled a lot. But themain point was that I saw it as a greatopportunity to share a life experiencewith my partner.

How hard was it to give up yourlife in Switzerland? It wasn’t easy to leave friends andfamily behind. I had a stimulating joband enjoyed going to work. But I wasable to give a clear yes to this moveand found it exciting to undertakesomething new.

How does a normal day in Chongqing look?In the morning I have four hours Chinese language tuition. In the after-noons I do my homework. Then I goshopping or read our many books aboutChina. I also go walking a lot in thetown. I like to do that. It’s a good andfascinating way to learn about life there.You constantly discover new things, newaromas, new sounds, new corners ofthe City.

Do you enjoy learning Chinese?I have a basic interest in languages. I findChinese especially fascinating because it is so different to European languages.It is often said that Chinese cannot belearnt. My experience to date: Chinesecan be learnt. In the last year and a half I have made real progress. Although Isoon reach my limits in everyday life I stillseek conversations. A ten minute taxiride is as instructive as week of Chineseat school (laughs).

What kind of town is Chongqing to you?In contrast to Shanghai, Peking – andof course Hong Kong – Chongqing issimply more Chinese. But without thecyclists because it’s so hilly. The nat-ural situation is appealing. The Citylies between the rivers Yangtze undJialing and is actually very green. Atthe same time it has a lot of traffic anda lot of emissions. What characterizesChongqing is its abundant contrasts.There is a Louis Vuitton shop with themost expensive handbags and on the pavement a man will walk by witha traditional bamboo pole over hisshoulder, carrying a heavy load.

What do you like most? The Chinese are great pragmatists.There is a solution for everything. Youmay think yourself that somethingwon’t work. But the Chinese alwaysfind a way.

What is your relation to ABB Turbocharging?I feel I belong to it. From time to timeI do things with the partners of otherABB employees over here fromSwitzerland. Last year there werethree other ladies here. In the mean-time I also know a number ofRoland’s colleagues in Jiangjin. Ienjoy it when visitors come fromBaden. They all take an interest inme, too.

Are there things in China that youwould no longer want to go with-out? Yes, their cuisine and way of eating.We have long adopted it as our own.You order four or five dishes, putthem in center of the table and every-one tries everything. And the fooditself. There is an incredible variety ofincredibly good things to eat.

Roland Schwarz and Simone Jampen in Chongqing.

Hydraulic tools ensure that bolt tension staysconstant and can be reproduced.

ABB charge! 1|13 29

Tips for the operator

The need for high-temperature greaseImproving our turbochargers down to the last detail.

Text Holger Markow, Photography Michael Reinhard

grease can create unwanted frictionbetween the mechanical components ofthe turbocharger. And using the wrongtype of grease can stretch out and weaken bolts, making them less stableand safe and even causing them tobreak.

The screws and bolts that hold a turbocharger together are set to a partic-ular tension before the machine is putinto operation. Deploying the right typeof grease – and specifically right type of high-temperature grease – is morecritical than ever because today’s state-of-the-art turbochargers, such as ourA200-L generation, need to be tensionedmore precisely than ever.

Once the turbocharger is in operation,the high temperatures cause the variouscomponents in the turbocharger to ex -pand. However, since these parts aremade of different materials, how muchthey expand can differ considerably, andthe screws and bolts holding the turbo -charger together are also affected.

Clearly, the bolts and screws in a turbocharger must be tensioned very dif-ferently prior to operation based on theirfunction in the turbocharger. A welldefined grease thus needs to be used toensure the right tension at this criticalstage. Hydraulic tools are increasinglybeing used to tighten and loosen suchbolts and screws because these toolsensure that this tension stays constantand is replicable.

In service and maintenance, using thewrong type of grease can also jeopardizethe process of loosening the nuts andbolts safely when it is being taken apart,particularly in remote areas. High-tem-perature grease creates a layer that sep-arates the parts from one another so that

they can move and be disassembledeffectively. Without it, parts may seize orbe much more difficult to take apart. Inthe worst case, it may even causescrews and bolts to break right away andwithout warning when an engineer triesto loosen them. Such complications canbe very frustrating to everyone, especiallyin the field.

In order to solve these problemsproactively, ABB Turbocharging usesonly high-temperature grease on all itsturbochargers. Furthermore, we use onlyone type of high-temperature greaseworldwide to make our operations safer,simpler, and more effective from start tofinish, i. e. from assembly to maintenanceand service. Finally, the heavy-metal freeformula of the high-temperature greasethat we use means less pollution in theenvironment.

Holger Markow is a Manager TechnicalService at ABB Turbocharging. Hismain areas of responsibility includeclaims management, breakdowninvestigation, technical support forend users, operators, and service stations. He is an environmental engineer and has worked for thecompany since 1996.

Turbochargers become very hotwhen they are in operation, so high-temperature grease isneeded to ensure that the bolts

and screws connecting the turbochargercasings remain secure and lubricated. Atthe high temperatures at which a turbo -charger operates – e.g. 800 °C – normalmachinery grease would simply burnaway within a few hours of operation.High-temperature grease will stay on theturbocharger essentially forever becauseit has a different chemical compoundthan normal machinery grease.

Our goal is to ensure that everyprocess is safe, so absolutely every vari-able in each process has to be accountedfor and monitored. Using the wrong

30 ABB charge! 1|13

Recipe

With best regards to the FiftiesIt was said to have been fabulous. But what there was to eat at the very first CIMAC Congress remains speculative. What we do know is what was “en vogue” in Paris in the 1950s. Here comes international recipe No 6.

Text Tiziana Ossola Auf der Maur, Photography Corbis

Excellent catering and plenty ofspace to park cars on theChamps-Elysées.* Thus goesan eyewitness account of the

very first CIMAC Congress, held in 1951in Paris. What has not been handeddown is what the delegates were pre-sented on their plates. The CIMAC Central Secretariat in Frankfurt am Main,Germany, has no information about thecatering arrangements in its archives.

We can only speculate, but we do sowith the assistance of “Savarin”, one of the legendary gastronomic authors inthe Paris of the Fifties. Under his realname, Robert J. Courtine, he was dis-dained as a wartime collaborator, butafter rehabilitation enjoyed a forty yearcareer at “Le Monde” newspaper as afood columnist. He knew what a delicacywas in the gourmet’s paradise: scallops,or “Coquilles Saint-Jacques” to givethem their more poetic French name.“They undoubtedly belong to our finestmussels”, notes Savarin in his classiccookbook “Real French Cooking”.

The scallops came principally fromNormandy and Brittany and were onlyavailable from October to May at the lat-est. In Paris, far away from the fishinggrounds, they were surely much soughtafter, and it is entirely possible thatCoquilles Saint-Jacques were the culi-nary visiting card of CIMAC cateringback then.

Our recipe is a traditional Breton dish,delicate but also rich – catching themood of Europe’s post-war recovery.

Breton Scallops (a starter for 4 people)8 scallops, shelled1 onion1 shallot100 g breadcrumbs100 g butter1 glass dry white wine1⁄2 bunch parsley50 g Parmesan or Sbrinz cheeseSalt Pepper

Preparation1. Pre-heat the oven to 200 °C.2. Finely dice the onion, shallot, parsley

and, if desired, garlic.3. Coarsely grate the cheese.4. Lightly salt and pepper the scallops. 5. Melt half the butter in a frying pan

and lightly braise the onion and theshallot.

6. Raise the temperature, add the scal-lops and brown them on both sidesfor 1½ minutes.

7. Quench with the white wine.8. Add the parsley and allow to simmer

until the sauce is somewhat reduced.9. Transfer the scallops with the liquid

into a small baking dish. 10. Sprinkle over the scallops the grated

cheese, the breadcrumbs and finallythe remainder of the butter in littlewedges.

11. Cook for 10 – 15 minutes in the pre-heated oven until golden brown.

And now – enjoy!

* “The First Fifty Years: CIMAC 1951 – 2001” byGeorge C. Fleischhack and Paul R. Russak.

ABB charge! 1|13 31

Acknowledgments

Published byABB Turbo Systems Ltd

AddressP.O. BoxCH-5401 Baden/SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144www.abb.com/turbocharginge-mail: charge@ch.abb.com

EditorTiziana Ossola Auf der Maur

PhotosMichael ReinhardABB Turbo Systems LtdABB Turbocharging ChinaXinyaCSR Qishuyan Locomotive Co.Caterpillar Motoren GmbH & Co. KG 2013CorbisRoland BergerGE Jenbacher GmbH & CO OGAnthea Tan

Cover photo: Corbis

PrinterDietschi AG Druck & Medien, Olten /Switzerland

Layout, typography, electronic publishingDomino Style & Type AG, Gebenstorf /Switzerland

Reprints require the publisher’s written consent.

© 2013 ABB Turbo Systems Ltd, Baden /SwitzerlandAll rights reserved

I always prefer to restore than to repair. I preferOriginal Parts and Original Service.

Fuel is the overwhelming element in the life cycle costs of an engine. Only a 1%increase in fuel consumption can cost as much as 60,000 dollars on a 10 MW engineoperating 6000 hours per year. With their geometrical precision, the excellent strengthand surface quality of their high grade materials, Original Parts fitted during OriginalService from ABB Turbocharging are designed to restore the efficiency, pressure ratioand dependability of your ABB turbocharger. For your engine this means optimized fuel efficiency, availability, reliability and emissions. www.abb.com/turbocharging