15 - Arnet+book TURBOCHARGER

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www.abb.com/turbocharging
Introduction to
ABB Turbo Systems Ltd
October 30, 2001
Daniel Arnet

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H:/!abb/.../ABB_CHTUS011030 / 2 / 26-Okt-01
Program
09.30 Welcome and introduction
to turbocharging
Daniel Arnet
President
10.00 Factory tour in groups Willy Kuhn
VP Production
10.45 Questions & answers all
11.00 Departure

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Turbocharging
n Main purpose:
n increase the specific power output
of the engine
n Further advantage:
n lower specific fuel consumption
n Key performance figures:
n achievable compressor
pressure ratio
c
n turbocharger efficiency
TC
n Customer value:
n 300 % more power
n 10 % lower specific fuel
consumption

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Turbocharging
achievable pressure ratio
C
1
2
3
4
5
3
3.5
4.5
5
5.2
2000 95 90 85 80 75 70 65
peak efficiency
55
60
65
70
75
TC
57%
63%
68%
74.5%
72%
76%
2000 95 90 85 80 75 70 65
Wrtsil 64 engine with ABB TPL80

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ABB

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ABB

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ABB

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ABB

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ABB

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BU Turbocharging
ABB Turbo Systems Ltd BU Network
Baden / Switzerland
Engineering / R&D / Sales
> 70 sales & service stations
Production / Assembly / Service

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Key figures 2000
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Orders received (MUS$) 25 440 368 239
Revenues (MUS$) 22 967 351 233
Employees 160 818 1 614 810

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Total market volume & outlook
Marine
Locomotive
Stationary
0
5
10
15
20
25
30
35
40
45
50
1985 1987 1989 1991 1993 1995 1997 1999 2001 2003 2005
[GW]
2
0
0
0
total market volume 2000 for engines > 500 KW = 40.6 GW

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Market share 2000
ABB
13 %
ABB Licensees
29 %

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Previous turbocharger types
VTC
Produced units 2000:
322
Length 90 - 120 cm
Weight 340 - 720 kg
Turbocharged power
600 - 3 500 kW
RR
1661
Length 50 - 100 cm
Weight 60 - 300 kg
Turbocharged power
500 - 1 800 kW
VTR
644
Length 90 - 350 cm
Weight 280 - 12 500 kg
Turbocharged power
700 - 18 500 kW
produced units: data refers to ABB Turbo Systems Ltd only

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The new ABB turbochargers: TPL and TPS
Produced units 2000: 657
Length: 113 - 380 cm
Weight: 520 - 13 200 kg
Turbocharged power:
1250 - 25 000 kW
Produced units 2000: 1834
Length: 35 - 65 cm
Weight: 80 - 400 kg
Turbocharged power:
500 - 3 000 kW
TPS TPL
produced units: data refers to ABB Turbo Systems Ltd only

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Turbocharger series

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Modular product design
Product type RR VTC NTC VTR TPS TPL
Number of sizes 8 4 3 25 5 7
2
40
18
2
2
10
70
2
10
3
Number of
variantes per
part family

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ABB turbochargers: customized & standardized
Modular concept
n 10 main components
n 159 different main parts
n 242 mio possible combinations
n thereof 3.5 mio make sense
n 52 turbocharger
types/generations/sizes
Mass customization
n available: 182 mio configurations
n in operation:
> 180000 turbochargers
n thereof only in average
5 are identical
IT enabled business
n highly integrated SAP system
including configurator
for order processing
n highly flexible production
n IT enabled service business
2
40
18
2
2
10
70
2
10
3

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Flexible production
40
45
50
55
60
65
70
75
80
85
81 83 85 87 89 91 93 95 97 99
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o
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p
e
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0
2
4
6
8
10
12
14
16
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20
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VTR..4-31/32
RR..1
NTC..4-11
NTC..4-51
VTR..4E
VTR..4P-11/21
VTR..4P-32
NTC..4
VTR..4D-32
TPS 50B,C
VTC..4P
TPS/TPL
TPL..B

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Over 180 000 ABB turbochargers in operation
Locomotives
Stationary
Marine
62%
4%
34%

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Worldwide sales & service network
> 70 sales & service stations in 44 countries

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Standard training courses 2000
Special courses:
Metal spraying / bearing recon-
ditioning / blade welding
Sales and
administration
Advanced training
Elementary course Refresher course
Engine builders
and endusers
33 courses - 118 days - 481 participants

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Spare parts center, Baden/Switzerland
n 24 hours a day
n 365 days a year
n Inventory positions: 9'500
n Availability: 98%

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Availability of spare parts
1992 1993 1994 1995 1996 1997
100%
90%
70%
50%
40%
80%
60%
time
Build-up of spare parts center
Introduction of SAP R/2
Reduction of interfaces
Eliminating functions with no
additional customer value
Improvement of
data management
CHTUS: SAP R/3
SAP R/3
Release 4.5b
1998 1999 2000
BU TC: EDI start
ATURB
@WEB
continuous improvement of processes and IT tools

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n online 24 h, 365 days / year
n for > 70 service stations with > 250 users
n based on SAP and internet / intranet
n complete online information available on:
n 180'000 turbochargers (configuration, status, history)
n 106'000 plants (engine type, builder, application)
n 60'000 customers (customer profile)
n 27'000 spare part positions (spec, weight, price)
spare part identifier right spare part
stock information system availability
n > 50'000 service reports (TC history, field experience)
n service network (service stations, service engineers)
n links to DOC@WEB
Largest turbocharger database in the world
NEW with online order processing based on SAP
DOC@WEB for turbocharger catalogue, outline drawings, manuals,
spare part information & illustrations, working instructions, service & product news

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Two businesses - different but interdependent
popul at i on i n oper at i on
ser vi c e busi ness
new busi ness
pul l ef f ec t / f eedbac k

15 - Arnet+book TURBOCHARGER

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