Setting a new industry benchmark, the A200-H turbocharger offers a simple, single stage solution for high performance gas engines, delivering the performance required for lean-burn high-speed gas engines.
A further development of ABB’s A100-H turbocharger, which has been highly successful in meeting the needs of gas engines operating at up to 22 bar bmep, the new A200-H turbocharger will represent a bridge between ABB’s A100-H products and Power2 two-stage systems. The A200-H will offer engine manufacturers a simple and cost-effective solution for engines operating in the 22-24 bmep range.
The A200-H has further pushed the limits to pressure ratios up to 6.5 without compromising efficiencies. The A200-H forecast to achieve above 69 per cent; an improvement of 3 per cent over the existing A100-H generation to ensure engine output and efficiencies can be increased above current single stage limits.
“With the A200-H we are able to offer great value for our customers. As we close the gap between the current A100-H single stage capabilities and ABB’s Power2 by enabling a significant step in engine output development beyond 22bar engine bmep through higher pressure ratio and turbocharger efficiency.
“As well as an increase in engine output, the value A200-H offers in terms of enabling lower operating costs through higher engine efficiency and higher altitude capability without engine derating is unparalleled in the current market.” Gerald Müller, ABB Turbocharging’s General Manager for High-speed Sales commented on the launch of the new product.
Compressor technology is a critical element of turbocharger design and in addition to pressure ratio capabilities, ABB has placed strong focus on compressor map width to ensure good surge margins and enable stable engine operation. Using enhancement technology, an improvement of 70 per cent in map width has been achieved. This has been verified by test stand measurements at defined full load operation points. Aluminum alloy material has been retained for the compressor wheel and the product design is based on a requirement for minimum 40,000 hours life. To ensure this is achieved, ABB is applying its extensive experience in lifting techniques and flexible maintenance principles, combined with the use of digital technologies. The A200-H also has new turbine stage, specifically developed to enable the compressor to be driven to the levels required to achieve 6.5 to 1 pressure ratios. All turbine side components, including the gas inlet, nozzle ring, turbine wheel and diffuser, are designed to meet highest efficiencies and pressure ratios with the necessary component lives being met despite the high rotor speeds required.
With many gas engines now operating in more variable and cyclic applications, there are increased opportunities to move away from more traditional hours-based maintenance regimes to a more technology-based approach, considering all aspects of speed, temperature, stop-start cycles, and ambient fluctuations seen by the turbocharger. The A200-H series will utilize either increased instrumentation and or access to engine information, allowing life assessments and maintenance recommendations to be made based on installation-specific operational data. On-line analysis of this collected data will allow analytical assessment of the shaft and rotor components at every inspection interval, typically at 20,000 running hours for natural gas applications. Where confirmed, the installation will then be warranted as fully capable of operation to the next inspection point. At the 40,000-hour and successive inspection points there will then be the option, subject to condition and analytical assessment, for the extension of rotor lifetime, rather than the more rigid conventional approach of replacement of parts.
Through the assessment of real operation condition of the A200-H there is a significant potential to reduce turbocharger maintenance cost by extending the rotor lifetime and avoiding one rotor exchange event during the engine lifetime.
Safety and integrity are critical features of the new A200-H and all components are designed to operate in arduous conditions of service. In peak shaving applications, for example, fast engine starts are required so advanced analytical tools have been used to optimize thermal and mechanical stresses in all components, including casings. Combined with high numbers of start-stop cycles and high rotor speeds, containment safety against compressor or turbine burst is also a critical aspect and this has always been a top priority for ABB. Design experience, gained with the latest turbocharger types, has been used to identify and eliminate potential weak points at an early development stage. For the A200-H, ABB still plans to carry out containment testing to fully verify the safety of the product.
The A200-H will be offered in three frame sizes; A230-H, A235-H and A240-H. Two rotor sizes will be available for each frame, along with matching components, to allow a wide range of volume flows within each frame. Both rotors use a standard bearing housing arrangement and customers will have the choice of two bearing concepts for the same turbocharger. An ABB patented bearing module design supports robust plain bearings, but a newly developed ball bearing system is also available. This offers increased mechanical efficiency, particularly at part load where power losses are as low as 15 percent of the equivalent plain bearing loss. This reduction enables more rapid turbocharger and engine start times to be achieved. Both bearing types operate with standard engine oil, but oil consumption is reduced significantly if the ball bearing system is adopted. Upgrading to the ball bearing system can be also be carried out with module exchange, with no other changes required.
The A200-H uses the same engine mounting arrangements as A100-H series, but a further configuration option is the availability of mounting either with a hydraulic fastening or a clamping nut system.
ABB Turbocharging (www.abb.com/turbocharging) is at the helm of the global industry in the manufacture and maintenance of turbochargers for 500 kW to 80+ MW diesel and gas engines. Our innovative leading-edge technology enables our customers to increase their performance; producing lower emissions and improving fuel consumption even in the toughest environments. Approximately 200,000 ABB turbochargers are in operation across the globe on ships, power stations, gen-sets, diesel locomotives and large, off-highway vehicles. We have over 100 Service Stations in more than 50 countries globally and a wide service portfolio that guarantees Original Parts and Original Service anytime, anywhere.
ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader with a comprehensive offering for digital industries. With a history of innovation spanning more than 130 years, ABB is today a leader in digital industries with four customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by its common ABB Ability™ digital platform. ABB’s marketleading Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees. www.abb.com