ABB Turbocharging TPR 61 – The railroad turbocharger

ABB Turbocharging
TPR 61 – The railroad turbocharger
Product information
www.abb.com/turbocharging
Powerful turbochargers for the long haul
75 % of a locomotive diesel engine’s power relies on
one vital component – the turbocharger.
The ultimate goals of turbocharged engine
The TPR design concept provides a robust,
development are higher power and efficiency –
reliable platform for locomotive diesel engines
two areas in which the TPR 61 turbocharger
rated up to 3,300 kW per turbocharger, or
makes a vital contribution. ABB developed the
for newer locomotive engines rated above
powerful TPR 61 especially for modern
4,400 kW – equivalent to 6,000-plus horse-
4-stroke diesel engines used on heavy-duty
power – with twin turbocharger arrangements.
locomotives, with features that meet the
Designed for more power, lower fuel con-
technical, environmental and cost requirements
sumption and compliance with strict emissions
of the traction market well into the next
regulations, the TPR 61 has all the qualities
decade.
required of a modern, dedicated railroad turbocharger.
With the TPR 61, ABB offers railway operators
a turbocharger that combines highest performance and reliability with fuel economy and
environmental compatibility.
2
Purpose-built
The TPR 61 is a dedicated railroad turbocharger,
with special design features for heavy-duty traction
applications.
The TPR 61 takes special account of the typical
A unique, compact construction with single-
conditions in which heavy-duty, long-haul
entry gas inlet and patented integrated foot is
locomotives operate: load variation due to
combined in the TPR 61 with a purpose-built,
acceleration and dynamic braking, high tem-
high-efficiency turbine stage and a single-piece
peratures in tunnels and the effect of altitude
compressor wheel for long times between
operation.
overhauls. Life cycle costs are lower thanks to
the modular, service-friendly design.
Tried and tested
A comprehensive series of qualification tests
ensures the total reliability of ABB turbochargers. The standard 21-point program was
expanded for the TPR 61 by several tests
especially relevant for traction applications,
including tests to prove oil sealing and rotor
stability under extreme conditions.
3
Benefits you can trust
Simple, rugged and compact – the TPR 61 is designed
to keep locomotive running costs low.
Features
Benefits
■
Compact, robust and rigid construction
■
Withstands high mechanical loads
■
Uncooled gas casing
■
No water connections; no corrosion problems
■
Integral axial turbine with blade-tip
■
Minimal tip clearance losses;
winglets; no damping wire
■
Single-piece radial compressor with
high efficiency
■
backswept blades
■
High pressure ratio combined with very
Wide compressor map and increased surge
margin; longer TBO 1
■
high overall efficiency
Allows compliance with strict engine
emission regulations
■
Squeeze oil film damper
■
Increased rotor stability
■
Free-floating axial bearing disc
■
Reduced friction, longer lifetime, inclination
■
Gas outlet casing with integrated foot
■
Compact; 3 optional drainage points
■
Easy removal and replacement of complete
compensation
and drain
■
Unique, patented foot connection
turbocharger, small footprint
1
4
Time Between Overhauls
Design features
Turbine and compressor
Turbine
Compressor
The integral high-efficiency turbine meets all
The compressor features a single-piece, splitter-
the requirements of locomotive operation –
bladed aluminium alloy wheel with backswept
high rotational speeds, very high inlet tempera-
blades for high efficiency and a wide compres-
tures and a very long LCF life. Wide chord
sor map. The solid wheel greatly reduces inter-
blades eliminate the need for damping wire
nal stress, allowing an increase in the maximum
and improve thermodynamic performance.
speed of rotation and in the exchange intervals.
2
Two compressor stages are available:
TPR 61-A10 for a maximum pressure ratio of
4.2 and a high specific flow capacity;
TPR 61-F33 with stabilizer for higher pressure
ratios of up to 4.7 (this version is especially
suitable for altitude operation).
Winglets at the blade tips reduce losses caused
TPR 61 turbocharger efficiency
by tip clearance flow. The axial gas inlet casing
sure turbocharging systems. Highest turbine
stage efficiency is supported by the outlet casing’s large flow-duct cross-sections.
Turbocharger efficiency
has been optimized for use with constant pres-
[%]
70
65
60
TPR 61-A10
TPR 61-F33
VTC 304
2.0
2
Low Cycle Fatigue
2.5
3.0
3.5
4.0
4.5
␲C [-]
Compressor pressure ratio
5
Design features
Bearings
ABB developed the new bearing assembly for
direct lubrication by the engine lube oil system.
The main axial bearing consists of a free-floating thrust disc with profiles on both sides,
rotating at about half the rotor speed. The effect
of this design is to increase the thrust bearing’s
ability to compensate for shaft inclination. Disc
wear is reduced by an extremely hard coating
that offers very high resistance to abrasion
caused by contaminated oil. The non-rotating,
three-lobe radial bearing bushes are centered
in a squeeze oil film damper.
6
Increased bearing lifetime
ABB qualification tests confirm that short-time
TPR plain bearings benefit from experience
high oil temperatures occurring in tunnels have
gained with over 50,000 ABB turbochargers
no detrimental effect on the operation of TPR
with plain bearings in service worldwide.
bearings.
Casings
TPR 61
776
981
263
396
322
320
723
681
361
268
Optimized design
TPR 61 casings are optimized for locomotive
applications. Excellent flow dynamics and
minimized thermal stress are ensured. The
uncooled turbine casing has been designed for
large flow cross-sections after the turbine and
features an integrated foot and drain. The compact, rigid casing offers maximum resistance to
vibration and shock loads while taking full
account of the space restrictions of locomotive
applications.
7
© 2007 ABB Turbo Systems Ltd, Baden / Switzerland
ABB Turbocharging service network
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Status: January 2007
Aberdeen · Agadir · Algeciras · Antwerp · Auckland · Baden · Bangkok · Bergen · Bremerhaven · Brisbane · Buenos Aires · Busan · Cairo · Cape Town
Casablanca · Cebu · Chennai · Chicago · Chittagong · Colombo · Copenhagen · Dakar · Dalian · Delhi · Dortmund · Dubai · Dunkerque · Durban
Falmouth · Faroe Islands · Fukuoka · Genova · Gdansk · Gothenburg · Guangzhou · Guatemala City · Hamburg · Hanoi · Helsinki · Hong Kong · Houston
Istanbul · Izmir · Jakarta · Jeddah · Jiangjin · Kaohsiung · Khartoum · Kobe · Lahore · Las Palmas · Le Havre · Lima · Los Angeles · Lunenburg
Madrid · Malta · Manila · Mannheim · Marseille · Melbourne · Miami · Montreal · Mumbai · New Orleans · New York · Oporto · Oslo · Perth
Piraeus · Qingdao · Reykjavik · Rijeka · Rio de Janeiro · Rotterdam · Sanaa · Saint Nazaire · Santo Domingo · Santos · Seattle · Shanghai · Singapore
ABB Turbo Systems Ltd
Bruggerstrasse 71a
CH-5401 Baden / Switzerland
Phone: +41 58 585 77 77
Fax:
+41 58 585 51 44
www.abb.com/turbocharging
e-mail: turbocharging@ch.abb.com
CHTUS 2060-0701-5000 E
Southampton · St. Petersburg · Surabaya · Sydney · Talcahuano · Telford · Tianjin · Tokyo · Vadodara · Vancouver · Varna · Venice · Vladivostok