ABB Turbocharging has developed a new digital application to identify the potential operational risks of replacing turbocharger parts with non-original components. The app uses data from turbocharger failure scenario simulations to calculate the impact of parts from manufacturers that do not fit ABB turbocharger specifications. It is presented to the marine industry for the first time at SMM 2016.
The new app addresses a widely acknowledged and persistent issue in the industry, where use of parts supplied by third parties can compromise or even harm marine equipment. The app offers solid numerical and graphical guidance on the consequences over time of using “copycat” parts, supporting research commissioned by ABB Turbocharging that original parts best ensure continued performance.
Showing a 3-D animated image of a latest generation turbocharger for medium speed engines, the app focuses specifically on six components: turbine nozzle ring; impeller blades of the compressor wheel; the compressor casing; compressor wheel; turbine wheel; and turbine casing. The sliding scales for each of these allows users to quantify the potential consequences of even the slightest adjustment to material quality or geometric dimensions. The variation of each parameter is reflected as a potential impact for turbocharger operation, for example its ability to withstand extreme heat, abrasive particles, or shock loading. It also shows the impact on turbocharger efficiency, and the implications of turbocharger failure. Users can see the direct effect their decisions have on time between overhauls (TBO), fuel consumption, and even on safety by operating outside tolerances specified by ABB.
Earlier this year, results of a study by Forrester Consulting for ABB Turbocharging showed that around 87% of maintenance and repair specialists using capital intensive equipment primarily choose OEM suppliers for spare parts procurement. Commonly cited advantages included better spare parts availability, improved reliability, lower downtime and better service responsiveness. Around 70% also indicated that reducing unscheduled incidents leading to downtime was one of their top priorities for 2016.
“The calculation capability of this new app allows customers to see for themselves the potential impact to turbocharger performance and reliability of using parts other than those supplied by ABB,” says Remo Kissling, General Manager Service Spare Parts ABB Turbocharging. “Supporting our customers in better management of their maintenance is very important, and this app offers an objective means of simulating and calculating the impact of even the slightest deviation in material quality and dimensions from the ABB Turbocharging Original Parts standard.”
Volkmar Haueisen, Head of R&D, ABB Turbocharging said that the data used are based on customer experience and draw on real incidents, with the simulations developed in-house. “This app takes into account realistic scenarios, but also real cases: it is a practical tool which allows engineers in our customers’ organizations to see why ABB Turbocharging recommends using original parts for its equipment.”
The app will be available for customers to download from the start of October, and will be available for use through web browsers as well as iOS and Android mobile devices.