TPS – The performer

© 2004 ABB Turbo Systems Ltd, Baden / Switzerland

ABB Turbocharging
The TPS . . -D / E turbocharger is designed for 4-stroke diesel and TPS . . -D/ E – The performer
gas engines (500 to 3,000 kW per turbocharger).
Product information

ABB Turbo Systems Ltd

CHTUS 2034-0409-5000 E

Bruggerstrasse 71a
CH-5401 Baden / Switzerland
Phone: +41 58 585 40 37
Fax: +41 58 585 51 44
www.abb.com/turbocharging www.abb.com/turbocharging
Performance and reliability Benefits that add up

75 % of a diesel engine’s power relies on one vital component – Simple, rugged and compact – the TPS . . -D / E
the turbocharger. is designed to keep running costs down.

The TPS..-D/E concept provides a robust and Features Benefits

reliable platform for engine applications in the ■ Simplified service concept ■ Easy to service, low lifecycle costs
range of 500 kW to 3,000 kW. In addition to ■ Bearings, rotor and nozzle ring dismantled ■ Service in a confined space possible
improved technical parameters, such as higher from the compressor side; no need to ■ Easy-to-handle subassemblies and parts
efficiency and longer times between overhauls, disconnect the hot gas pipes ■ High availability and reliability,
these turbochargers have new features designed ■ Oil-cooled bearing casing (water-cooled easy to operate
to satisfy stricter environmental requirements. casing for gas engines) ■ Lubrication system easily connected
■ Turbine and compressor cleaning ■ Highest operational safety
A simple, modular design makes the TPS..-D/E (water washing) possible ■ Optimized matching for all applications
easy to maintain and service. Customers benefit ■ Radial bearing bushes with squeeze oil
from low lifecycle costs. damper
■ Oil inlet and outlet at bottom
The ultimate goals of turbocharged-engine TPS..-D/E turbochargers are manufactured ■ Radial compressor and mixed flow turbine,
development are higher power and efficiency – in ABB’s modern turbocharger factory in Baden, with internal plain bearings lubricated by
two areas in which ABB’s TPS turbochargers Switzerland. engine lube oil
make a vital contribution. ABB developed the ■ Wide compressor map
TPS..-D/E series of small turbochargers Reliability ■ Comprehensive qualification test program
for modern high-speed diesel engines, small Comprehensive qualification tests are per- ■ Different turbine and compressor
medium-speed diesel engines and gas engines, formed to ensure the total reliability of ABB trims available
as used in diesel cogeneration power plants, turbochargers.
for auxiliary engines, in gensets and in locomo-
tives, as well as in heavy construction and Pressure ratio and efficiency
mining vehicles. TPS..-D/E turbochargers are outstanding for
their high efficiency and very high pressure
ratios – the two main market requirements.

Ranges of turbocharger efficiency

TC [%]

75
Turbocharger efficiency

70

TPS..-D TPS..-E
65

60

1.5 2.0 2.5 3.0 3.5 4.0 4.5 C [-]

2 Compressor pressure ratio 3

General construction Design features

The TPS . . -D / E turbocharger’s small number of parts Turbine and compressor

keeps lifecycle costs low and speeds up overhauls and
service.

This turbocharger generation is distinguished Turbine Compressor

by its simple, robust and extremely compact The mixed flow turbine with nozzle ring ensures Two different compressor stages are available.
design. Features contributing to this include: the very high efficiency and large volume Together, these cover the complete range of
■ Mixed flow turbine with nozzle ring for flows users expect of turbochargers for 4-stroke required pressure ratios: one stage is designed
constant pressure and pulse applications diesel engines. A key feature of this turbine is for pressure ratios up to 4.25 (TPS..-D), and
■ Two different radial compressor designs its different nozzle ring area per trim for part- the other for pressure ratios up to 4.5 (TPS..-E).
covering the full range of pressure ratio and load and full-load optimization. The TPS..-D/E The turbocharger’s mechanically optimized
volume flow rate requirements turbine concept is suitable for both constant single-piece impeller permits pressure ratios of
■ Single-piece, oil-cooled bearing casing pressure and pulse supercharging. up to 4.5 for a wide range of applications
(water-cooled casing for gas engines) with aluminum alloy as the wheel material. A
■ A new internal plain bearing design with splitter bladed impeller with backswept blades
Turbine efficiency vs. turbine expansion ratio
squeeze film backed profile bore bearings for a TPS 57-D / E is used in each case for highest efficiency
■ Clamp connection flanges for flexible
sT [%] and a wide compressor map. Peak efficiencies
TPS 57 large nozzle ring area

Turbine efficiency (total to static)

TPS 57 small nozzle ring area
housing orientation and easy disassembly, 90 of more than 84 % can be achieved.
even after long periods of operation
85
■ Proven turbine containment, provided by
80
internal and external burst protection rings
■ Oil inlet and exit located at bottom 75

1.5 2.0 2.5 3.0 3.5 T [-]

Turbine expansion ratio

Example of compressor map for TPS 57-D

C [-]
5.0 n/n = 1.06
o

Volume flow range of TPS turbochargers 4.5 n/n = 1.00

o

TPS 48

TPS 52

TPS 57

TPS 61
4.0

Compressor pressure ratio

C [-] n/n = 0.90
o
3.5

.81
4.5

Compressor pressure ratio

3.0

.79
.82
E-version

.76
n/n = 0.80

.78 0
.8
o

2
.7
4
.7
4.0 2.5

0
.7
D-version

5
.6
n/n = 0.70
o

3.5 2.0

3.0 1.5 n/n = 0.60

at full load
o

n/n = 0.50
o

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 V [m3/s] 1.0 1.5 2.0 2.5 3.0 V [m3/s]

Intake volume flow Intake volume flow

4 5
Design features

Bearings and casings

Stability and compactness

ABB turbocharger
40,000 ABB turbochargers with plain bearings
qualification tests
in operation around the world provided the
experience base for the TPS plain bearing
■ Resonance endurance

technology. TPS plain bearings are designed ■ Low cycle fatigue

for 34 µm mesh filtration and direct lubrication ■ Temperature cycle
by the engine lube oil system. Shaft stability at ■ Hot shutdown
Burst turbine wheel;
the casing is undamaged. all speeds has been ensured by positioning the ■ Oil leakage
axial thrust bearing between the radial bearings
■ Compressor containment
– a feature that also contributes to the compact
■ Turbine containment
rotor design. The radial bearing bushes run on
■ Blade vibration
a squeeze oil damper. This high-tech bearing
technology guarantees long-term safety and ■ Thrust bearing

reliability for the TPS..-D/E turbocharger under ■ Prototype qualification

all working conditions. ■ etc.

G H
E F
Radial shaft motion vs. turbocharger
Burst protection devices Optimized design
speed measured with TPS 57-E The rapid increase in the brake mean effective TPS..-D/E casings have been optimized for
[%]
Low unbalance pressure of diesel and gas engines in recent applications on 4-stroke engines. Excellent K
High unbalance L
% of total bearing clearance

80 years has led to considerably higher power fluid dynamics, minimized thermal stress and

60
densities for the turbocharger rotors. Burst tests total containment are all ensured. Additional

Shaft motion limit for ABB turbochargers

have shown that even in the worst case of, features include integrated connections for the
40
e.g., a fire in the exhaust system (which can waste gate, for temperature and pressure mea-
J A
20 cause the compressor or turbine wheel to surement, for turbine and compressor washing
Type A J A+J E F G H K L Weight kg*
burst) all parts remain within the turbocharger and for speed measurement. TPS 48 184 184 368 112 106 163 195 155 134 110
100 200 300 400 500 600 [s-1] TPS 52 221 214 435 132 128 188 225 185 160 160
casings. There is no danger to personnel. Total TPS 57 271 258 529 161 157 230 270 226 196 260
TPS 61 323 305 628 192 187 274 321 269 233 450
Turbocharger speed containment has been ensured by including
* weight without options
an inner and outer burst protection ring in the
turbine casing.

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