ABB Turbocharger Repairs VTR..4 Turbine Blades
ABB Turbocharger Co. has extended its turbine blade remanufacturing program to include welding repairs of damaged VTR..4 series turbocharger turbine blades to original design specifications. The new technique was developed jointly with ABB Turbo Systems Ltd., Switzerland, and the service is performed by ABS-certified welders at the company's 13,000-sq.-ft. repair facility in New Jersey.
The remanufacturing of welding VTR..4 series turbine blades joins that of VTR..0 and 1 series blades, which has been performed by ABB Turbocharger Co. since 1985. Turbine blade remanufacturing must follow the latest ABB proprietary, factory-approved procedures.
"Two years were spent in the development and testing stages to assure that ABB Turbocharger's quality standards were satisfied, since welding ofVTR. .4 series blades requires a distinctly different technique," said Mark Rothmann, president. An earlier procedure developed by ABB included remanufacturing VTR..0 and 1 series turbocharger blades of forged steel alloy, subjected to pressures up to three bar during operation. VTR..4 series turbocharger blades are cast steel alloy, according to Mr. Rothmann, and are subjected to even greater operating pressures. VTR..4 series turbine blades provide extra durability, but they are harder and more brittle compared to earlier designed blades. As a result, changes in weld material and tungsten inert gas (TIG) welding procedures were developed. Damaged and worn blades received for remanufacturing are cleaned and inspected for cracks and excessive wear, against ABB proprietary guidelines. Cracked and excessively worn or damaged blades are replaced by new ones. Repairable blades are TIG welded at low amperage, under an inert gas bath to guarantee a pure weld. All turbine blade welding is performed in a totally enclosed, environmentally-controlled "clean room." The weight is checked and marked on each blade, and a final check for cracks is performed before identification stamping. In keeping with the company's ISO 9002 Certification, "the utmost in quality, procedural documentation and service records are always maintained to guarantee customer satisfaction," said Mr. Rothmann.
Remanufactured turbine blades are covered by ABB Turbocharger's warranty. "The normal time to remanufacture a set of turbine blades for a main propulsion turbocharger is one week; however, the actual time can be substantially reduced if a customer's schedule is tight," said Joseph Kersulic, shop service manager. ABB Turbo Turbocharger is increasing its stock of complete sets of remanufactured turbine blades, which are available on an exchange basis, to further assist customers in an emergency. The turbine blade exchange program allows the company to completely overhaul a turbocharger rotor— including cleaning, blade replacement, shaft seals and balancing— in as little as 48 hours, said Mr. Kersulic. For more information on ABB Turbocharger,