Asian Marine Engineering Conference 2015 MAN Diesel & Turbo SE Turbocharger. Malte Oltmanns Promotion Manager October 2015

Transcription

1 Asian Marine Engineering Conference 2015 MAN Diesel & Turbo SE Turbocharger Malte Oltmanns Promotion Manager October 2015 MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 1 >

2 Technological and operational BENEFITS and CHALLENGES of turbochargers as a component of marine propulsion system, including technological and design INPUT from leading manufacturers, as well as operational perspectives from top-level shipowners and operators. MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 2 >

3 Introduction Turbocharging Challenges Economical - Technical Challenges Legislational - Technical Challenges Engine Cost Structure for 10 years Fuel Spare Parts Personal Others Invest Reduction of Total Costs of Ownership Emission Limits Changes of Engine Layout Trends MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 3 >

4 Part- and Low Load High Load Tuning Methods High, Part and Low Load Standard Tuning 6G50ME-C9.5 SMCR: 79rpm ISO conditions 166,0 164,0 ECT Engine Control Tuning Potential savings up to 5 g/kwh Potential penalty up to 3 g/kwh 162,0 160,0 158,0 VTA Variable Turbine Area 156,0 154,0 EGB Exhaust Gas Bypass SFOC High Load Tuned [g/kwh] EEDI Measurement ,0 150,0 100 HPT High Pressure Tuning p scav adjustment Tuning Comparison on basis of CEAS data. MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 4 >

5 P scav in bar Change of Market Requirements The scavenging air pressure for modern 2-stroke engines decreases De-rating New engine designs Potential for higher specific volume flows Saving potential for new turbocharger designs with reduced costs for Engine Builder Ship Owner/Operator 5,0 4,0 3, Massflow in kg/s Trend to lower scavenging air pressures p scav [bar] Air amount [kg/kwh] L1 L2 L3 L to to ~+0.15 ~+0.15 ~+0.25 MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 5 >

6 conductivity in %IACS (f=60khz) Scientific Evaluation of Parts Condition Aging of Impeller / Thermal Aging Conductivity (NA ) The life time evaluation of compressor wheels is a long term project. Theoretical and actual lifetime can defer as they are depending on operational conditions. The aging can be evaluated basing on the relation between electrical conductivity and material hardness. 42,4 42,3 42,2 42, ,9 41,8 41,7 41,6 41,5 p1 p2 p3 p4 p5 p6 p7 p8 p9 p10 p11 p12 MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 6 >

7 Future Market Requirements 2-Stage Turbocharging for 4-Stroke Engines Two turbochargers of different size are connected in series with intermediate cooler and charge-air cooler. Reduction of SFOC Reduced exhaust emissions (NO x ) in conjunction with Miller engine cycle Increase of power output Compact design Improved dynamic response Increased charge-air pressure Reduced exhaust emissions MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 7 >

8 Enthalpy TC Efficiency [%] Potential of Two-stage Turbocharging one-stage two-stage with intercooling 5% one-stage two-stage with intercooling p 2 w HPC w HPC p 1 ' w 1-STC q IC w LPC p 1 Compression work saving 2-stage versus 1-stage Entropy Total Pressure Ratio [-] Benefits of 2-stage turbocharging: Reduced SFOC through incerased turbocharging efficiency Higher scavenging air pressures enable downsizing NOx-Reduction with application of Miller - Cycle Optimized flushing MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 8 >

9 Basics of 2-stage Turbocharging Regulation of scavenging air is possible with various regulation strategies: Wastegate (LP / HP), Compressor bypass (LP / HP), VTA (LP / HP). Higher flexibility with different ambient conditions Better scavenging efficiencies through optimized component efficiencies MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 9 >

10 ECOCHARGE First fire 12V35/44G TS HP Stage: LP Stage: 2x TCX17 2x TCR20 >> The Future is Two-Stage! << MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 10 >

11 Special Requirements for HP-stage TCX - Overview turbine side: - optimization for high pressure stage - higher flow capacity at lower pressure ratios - efficiency optimization at lower pressure ratios compressor side: - higher flow capacity at lower pressure ratios - wider compressor map - efficiency optimization at lower pressure ratios optimized casings for containment safety and higher pressure level Compactness in order to minimise additional space (and weight) optimized bearings for increased forces MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 11 >

12 Two-Stage Turbocharging MAN Portfolio of two-stage turbocharged engines MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 12 >

13 Two-Stage Turbocharging MAN Portfolio of two-stage turbocharged engines Well proven TCA88 and TCA77 turbochargers Modular design of LP- and HP turbocharging module and interfaces MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 13 >

14 Tier III Leading to New Developments New products for new demands ETB EGR module consisting of Scrubber Cooler Water mist catcher EGR blower MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 14 >

15 Exhaust Gas Recirculation Blower Challenges Highly corrosive atmosphere Acid water droplets (erosion/corrosion) Machining of stainless steel compressor High speed drive (up to 18,000 rpm) High performance components at competitive costs High mass flow at low pressure ratios Blower efficiency = energy efficiency Compact design MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 15 >

16 MAN Turbochargers Highlights Field Test ETB18 since May 2015 Ship Name: Ship Type: Engine Type: T/C Type: Ship Owner: KEY PACIFICO dwt BC MES 6S60ME-C8.2 Tier III MES TCA55-21 NYK MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 16 >

17 Conclusion The turbocharger is an essential component for engines in general. For conventional application operating costs and reliability are key factors. For new engine designs turbocharger technology is supplying important innovations for meeting new requirements and gives further potential for overall efficiency optimization. MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 17 >

18 Do you have any more Questions? Malte Oltmanns Promotion Manager MAN Diesel & Turbo SE Turbocharger Promotion MDT-AUG / SEVP Stadtbachstr Augsburg, Germany Phone Cell Cell (China) Fax Malte.Oltmanns@man.eu MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 18 >

19 Disclaimer All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions. MAN Diesel & Turbo Malte Oltmanns Asian Marine Engineering Conference 2015 / MDT Turbocharger < 19 >