The efficiency booster

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Frederica Avis Gilmore
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1 GENOA SHIPPING WEEK, 29 GIUGNO 2017 Turbocharger upgrade The efficiency booster Alberto Pochiero, Regional Technical Manager, South East Mediterranean

ABB Turbocharging 112 years of customer care A global leader in the manufacture and maintenance of turbochargers for 500 kw to 80+ MW diesel and gas engines Leading-edge technology and innovation

2 ABB Turbocharging 112 years of customer care A global leader in the manufacture and maintenance of turbochargers for 500 kw to 80+ MW diesel and gas engines Leading-edge technology and innovation enables our customers to perform better and produce fewer emissions, even in the toughest terrains Approximately 200,000 ABB turbochargers in operation globally on ships, power stations, gen-sets, diesel locomotives and large off-highway vehicles Over 100 Service Stations in 50+ countries and a wide service portfolio providing tailored solutions with Original Parts and Original Service anytime, anywhere June 28, 2017 Slide 2

ABB Turbocharging Service Local Business Unit: Italy 59 employees Genoa 30 Venice 11 25 service engineers Rijeka

3 ABB Turbocharging Service Local Business Unit: Italy 59 employees Genoa 30 Venice service engineers Rijeka 5 > service jobs per year Please contact: giorgio.rolando@it.abb.com Naples 8 Malta 5 June 28, 2017 Slide 3

4 Engine operation Performance indicator and efficiency development of Diesel engines MEP End 70: 2 stroke engine: 8,5 bar 4 stroke engine: 14 bar Engine Efficiency Current days (peak values): 2 stroke engine: 21 bar 4 stroke engine: 30,1 bar Engine Efficiency [%] MV Preussen & HS Danzig First ABB turbocharged Diesel ships MV Selandia First oceangoing Diesel ship MV Petit Pierre First Diesel driven ship R. Diesel First engine Year Source: Technical University Hamburg- Harburg Prof. Dr.-Ing. H. Rulfs June 28, 2017 Slide 4

5 Reasons to be technology path setters ABB Turbocharging s journey June 28, 2017 Slide 5

6 Upgrade Definition Conventional Efficiency Turbocharger High Efficiency Turbocharger + Modification of Engine (e.g. Miller timing) June 28, 2017 Slide 6

7 Turbocharger Upgrade ABB offers several upgrade solutions in cooperation with the engine OEM Improvements Boosting engine performances by replacing: Complete Turbocharger or Components (e.g. compressor wheels) Benefits Reduced fuel consumption Wider speed margin Significant reduction of thermal wear and tear lower operation cost operation flexibility reduced maintenance cost longer components lifetime lower emissions environmental improvement June 28, 2017 Slide 7

Turbocharger Upgrade A recent success story Project Main data Upgrade idea: Due energy efficiency solutions previously implemented on board the vessel, during port stay less electrical power is need

8 Turbocharger Upgrade A recent success story Project Main data Upgrade idea: Due energy efficiency solutions previously implemented on board the vessel, during port stay less electrical power is need (engine only runs at part load) First pilot engine upgraded end year 2016 Owner Application Engine Rating Operation Current TC Upgrade Project Global worldwide cruise vessels operator Cruise vessel, passengers 4 Stroke, diesel Medium Speed, 6 engines installed About 10MW; IMO Tier 1 (RINA) Diesel electric (constant speed) TPL77-A30 Miller timing conversion, TPL77-A32 for engine part load optimization Engine OEM in cooperation with ABB June 28, 2017 Slide 8

9 Turbocharger Upgrade TPL77-A30 to TPL77-A32 June 28, 2017 Slide 9

series. 0.90 Compressor efficiency 0.75 0.80 0.

10 Upgrade benefits Simulations Upgrade of the compressor stage CV20 to CV32 The CV32 compressor stage of the TPL-C generation is implemented and adapted to the TPL-A series Compressor efficiency TPL77-A32 TPL77-A30 Higher efficiencies Higher π C Compressor pressure ratio June 28, 2017 Slide 10

Upgrade benefits Simulations - Boundary conditions Ref: TPL77-A30 Matching 1: TPL77-A32 Miller Matching 2: TPL77-A32 Miller Engine power [MW] 10 10 10 Turbine

11 Upgrade benefits Simulations - Boundary conditions Ref: TPL77-A30 Matching 1: TPL77-A32 Miller Matching 2: TPL77-A32 Miller Engine power [MW] Turbine Standard Part load opt Matching 1 Part load opt Matching 2 Compressor wheel TPL-A TPL-C TPL-C Up-boosting - YES YES Cam Standard Miller Miller June 28, 2017 Slide 11

12 Motivation The Miller Timing Intake Exhaust Intake Exhaust Note: Same amount of air trapped in the cylinder log p Top dead center p max log p p max Lower temperatures with Miller Pressure p c Pressure p c p ex p ex p Rec 1 p Rec 1 p ac p TI 1 p ac p TI V c Volume V h - Displacement Bottom dead center log V V c Volume V h - Displacement log V Standard intake valve timing Miller intake valve timing June 28, 2017 Slide 12

13 Results Turbine inlet and outlet temperature 50 C June 28, 2017 Slide 13

14 Results Specific Fuel Oil Consumption 5 g/kwh June 28, 2017 Slide 14

15 Pictures at site Withdrawn originally installed parts Nozzle Ring Cartridge Turbine Compressor Wheel June 28, 2017 Slide 15

16 Pictures at site New installed parts Turbine diffuser and Nozzle Ring Cartridge Cartridge Air Side Compressor Casing with air diffuser June 28, 2017 Slide 16

17 Summary Turbocharger upgrade to A32 in combination with engine upgrade to Miller successfully tested A32 enables Miller timing and turbocharger with higher efficiency Miller timing enables fuel savings while keeping NOx emissions below IMO limit Customer benefits Significantly reduced fuel oil consumption at part load >5g/kWh Simple on board re-certification of IMO Tier 1 engine Reduced exhaust gas temperature at turbocharger inlet ~50 C «Green Image» Reduced NOx emissions >1g/kWh Reduced CO 2 emissions about 460 ton/year June 29, 2017 Slide 17

C. Christen, D. Brand, CIMAC 2013 Simulation-based study on turbocharging dual-fuel engines Paper no. 187

C. Christen, D. Brand, CIMAC 2013 Simulation-based study on turbocharging dual-fuel engines Paper no. 187 Dual-fuel engines As a solution for IMO Tier III GAS MODE Low NO x emission NO x Level < IMO Tier