ABB Turbo Systems Ltd., London, April 15 th- 16 th 2015 Turbocharging flexibility to match the operation flexibility challenge

Transcription

1 ABB Turbo Systems Ltd., London, April 15 th- 16 th 2015 Turbocharging flexibility to match the operation flexibility challenge

2 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 2 filename Goals

3 Goals Achieve the lowest operating cost (highest possible engine efficiency) within the given boundaries (reliability and emissions) For diesel fuel (DF) engines to achieve good efficiency also in the back-up mode Achieve gas engine stability Higher power density Enhance transient behaviour May 29, 2015 Slide 3 2-stage USA

4 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 4 filename Goals

5 Power2- The potential of 2-stage turbocharging Impact of turbocharging efficiency Dp over cylinders vs. pressure ratio p c -p T Turbocharging efficiency = 0.65 Turbocharging efficiency = 0.75 Temperature before turbine = 550 C p C Figure 11 Influence of pressure ratio on the May 29, 2015 Slide 5 2-stage USA pressure difference over the cylinders.

6 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 6 filename Goals

7 2-stage turbocharging Miller Timing for 4-stroke engines log p p max log p p max p c p c Pressure Pressure p ex p ex p Rec 1 p Rec 1 p ac p TI 1 p ac p TI Volume Volume V c V h - Displacement log V V c V h - Displacement log V Standard intake valve timing Miller intake valve timing May 29, 2015 Slide 7 2-stage USA

8 Miller vs. Knocking Power Misfiring Lambda

9 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 9 filename Goals

10 VCM: Valve Control Management Valve lift curves May 29, 2015 Slide 10 VCM

11 VCM - Valve Control Management Module principles May 29, 2015 Slide 11 VCM Temperature Sensor

12 VCM Valve Control Management On-engine arrangement May 29, 2015 Slide 12 filename

13 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 13 filename Goals

14 Potential of Power2 on Gas engines 1-stage vs. Power2 & VCM Air cooler turbocharger CMP 1 VOL 3 Air cooler HP turbocharger CMP 1 LP turbocharger CMP 2 VOL 5 CB 3 VOL 3 VOL 3 Intercooler CYL 1 CYL 2 CYL CYL CYL 1 CYL 2 CYL CYL VOL 1 TUR 1 VOL 2 VOL 1 TUR 1 VOL 2 TUR 2 CB 2 Turbine by-pass HP turbocharger HP Turbine by-pass LP turbocharger Air cooler CMP 1 VOL 5 CMP 2 CB 3 VCM Valve Control Management VOL 3 Intercooler CYL 1 CYL 2 CYL CYL May 29, 2015 Slide 14 filename VOL 1 TUR 1 VOL 2 TUR 2 CB 2

15 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 15 filename Goals

16 Boundary conditions Investigated turbocharging systems: 1-stage with WG + TV 1-stage with VTG + TV 2-stage with hpt WG + TV 2-stage with hpt WG + TV 2-stage with hpt WG + TV + VT for 2-stage 2-stage with hpt WG + VT for 2-stage layout point 50% load 2-stage with hpt WG + VT for 2-stage layout point 25% load 2-stage VCM 22 bar bmep 22 bar bmep 22 bar bmep 24 bar bmep 24 bar bmep 24 bar bmep 24 bar bmep WG = wastegate; TV = throttle valve; VT = valve timing ABB Group May 29, 2015 Slide 16

17 Gas exch work (bar) Gas exchange work 2-stage with VCM 2-stage with VVT and WG controlled 1-stage WG controlled 0.1 bar 1 bar BMEP (bar) ABB Group May 29, 2015 Slide 17

18 Waste Gate Rate (-) Wastegate Rate 2-stage with VVT and WG controlled 0.5 (-) 1 bar 1-stage WG controlled 2-stage with VCM BMEP (bar) ABB Group May 29, 2015 Slide 18

19 Engine Efficiency Gains (%) Engine Thermal Efficiency % % stage WG controlled 2-stage with VVT and WG controlled 2-stage with VCM ABB Group

20 Potential of Power2 on Gas engines Engine Controls Engine data 1-stage Power2+EWG Power2 + EWG+VVT Power2+ VCM Valve timing Miller Miller Valve timing Waste gate position gas mode Waste gate position diesel mode Engine control tool Moderate Miller with 2 positions VVT EVO/EVC/IVO/IVC IVC IVC-2 IVC-25 / IVC-10 Exhaust gas waste gate open all loads open full load / close elsewhere HP Turbine by-pass Advanced Miller VCM controlled Gas: IVC-38 / IVC-30 Diesel: IVC-40 / IVC none none VCM May 29, 2015 Slide 20 filename 0 1-stage + WG 2-stage +WG 2-stage +WG + Gas VVT Diesel 2-stage +VCM

21 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 21 filename Goals

22 Engine Power (%) Extended Area Off-shore Extended operation area + 0 g/kwh Genset operating on DE+batteries installation Direct propulsion engine operation g/kwh Genset operating on DE installation g/kwh Genset operating on hybrid installation Engine Speed (%) Pros Cons 1 or 2 stage + WG 1.Conventional equipment 1. Reliability 2. Lowest efficiency at high loads ABB Group May 29, 2015 Slide 22 1 or 2 stage + VCM 1 or 2 stage + VTG 1. Highest efficiency at any load 2. Possibility to optimise diesel and gas operations 1.Enhanced efficiency at part load 1. Cost 1.Lower efficiency at high loads 2.Cost

23 Agenda Power2 Miller Enhanced VCM Extended Field Gas Engine Controls May 29, 2015 Slide 23 filename Goals

24 Conclusions Advanced Miller cycle and advanced controls enables for: Substantial higher efficiency in gas and diesel mode Engine thermal loading control in any operation condition stability in gas mode Higher reliability of the air management system (gas mode) Power2 is VCM offers a necessity for: High power density Increased engine efficiency Reducing engine thermal load Improved emission behaviour flexibility to: adapt engine operation to the operation point adapt engine operation to the fuel Liquid or Gas Different gas qualities Knocking switch from one IVC timing to the next within the next working cycle. an enabler for: Advanced Miller cycle High performance gas engine enhanced engine performance significant fuel consumption reduction further advanced Miller timings with Power2 replacing existing control systems improves engine acceleration May 29, 2015 Slide 24 2-stage USA

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