ABB’s turbine cleaning system: behind the scenes
Extensive simulation and testing have made it possible to design optimal cleaning systems for every single ABB turbocharger series. Meeting both targets – efficient water distribution and minimization of water impact on hot surfaces – is the aim of every ABB cleaning system. The position, angle and water mass flow of each injector are carefully chosen in each case.
The first target (homogeneous water distribution) is the result of development work involving virtual prototyping, in which the injection of water into the exhaust gas stream through the turbine or gas inlet casing is simulated. Numerous possible designs of cleaning nozzles and water injection conditions are simulated on ABB Turbocharging’s high performance computing cluster. Subsequently, a hardware prototype of the system is developed and tested in the laboratories under hot gas conditions. This step not only verifies the virtual prototyping models and methods but is also designed to continuously improve them.
The second target (determination of the impact of water on surfaces) is achieved as a result
of detailed analyses of the water distribution on the surfaces of the casings. This distribution serves as input data for thermomechanical fatigue simulations. The latter allow an assessment of the stress levels in the wetted material, leading to a possible redesign of turbocharger parts.
Finally, every newly developed cleaning system undergoes a strict ABB internal quality approval process and field tests with various customers and installations.