OLIVER RIEMENSCHNEIDER, ABB TURBO SYSTEMS LTD 8 th AVL Large Engines Techdays
The challenge: increasing complexity April 6, 2018 Slide 2
The challenge: increasing complexity Engine efficiency Conventional vs. advanced technologies April 6, 2018 Slide 3
The challenge: increasing complexity Conventional vs. advanced technologies April 6, 2018 Slide 4
The challenge: increasing complexity Opportunities from digitalization April 6, 2018 Slide 5
Conventional vs. advanced technologies example high-speed engine platform Reference with conventional technologies current (generic) engine platform engine operation range from rated speed to high torque curve diesel for all applications, gas mainly in EPG (constant speed) Potential next generation with advanced technologies increase engine power gas for complete operation range Power Areas of diesel and gas Speed April 6, 2018 Slide 6
Conventional vs. advanced technologies example high-speed engine platform Conventional (currently applied) Advanced Turbocharging single-stage turbocharging p c* up to 5.5 @ h TC up to 65% two-stage conventional* p c* up to 6.5 @ h TC up to 67% Power2 1 st generation p c* up to 8.0 @ h TC up to 73% sequential turbocharging Power2 2 nd generation p c* up to 12 @ h TC > 75% Controls, valve timing waste gate, bypass, throttle valve fixed valve timing Valve Control Management (VCM) step less cycle-to-cycle variation steep closing flanks April 6, 2018 Slide 7 * realized with 1-stage turbochargers
Conventional vs. advanced technologies example high-speed engine platform Conventional «high torque curve» diesel: sequential turbocharging gas: single-stage turbocharging, waste gate, bypass and throttle valve Power Speed April 6, 2018 Slide 8
Conventional vs. advanced technologies example high-speed engine platform Conventional «high torque curve» diesel: sequential turbocharging gas: single-stage turbocharging, waste gate, bypass and throttle valve Conventional «constant speed» diesel: two-stage conventional gas: Power2 1 st generation, waste gate, throttle valve Power Speed April 6, 2018 Slide 9
Conventional vs. advanced technologies example high-speed engine platform Conventional «high torque curve» diesel: sequential turbocharging gas: single-stage turbocharging, waste gate, bypass and throttle valve Conventional «constant speed» diesel: 2-stage conventional gas: Power2 1 st generation, waste gate, throttle valve Power Advanced «high torque curve» and «constant speed» diesel: Power2 2 nd generation + VCM gas: Speed April 6, 2018 Slide 10
Conventional vs. advanced technologies example high-speed engine platform Diesel constant speed up to 6% lower fuel consumption / 25% higher output Fuel consumption v v conventional advanced Power April 6, 2018 Slide 11 Results based on engine cycle simulations
Conventional vs. advanced technologies example high-speed engine platform Diesel constant speed up to 6% lower fuel consumption / 25% higher output Diesel high torque curve app. 5% lower fuel consumption / 25% higher output Fuel consumption v conventional advanced Speed April 6, 2018 Slide 12 Results based on engine cycle simulations
Conventional vs. advanced technologies example high-speed engine platform Diesel constant speed up to 6% lower fuel consumption / 25% higher output Diesel high torque curve app. 5% lower fuel consumption / 25% higher output Gas constant speed up to 4% lower fuel consumption / 15% higher output Fuel consumption v v conventional advanced Power April 6, 2018 Slide 13 Results based on engine cycle simulations
Conventional vs. advanced technologies example high-speed engine platform Diesel constant speed up to 6% lower fuel consumption / 25% higher output Diesel high torque curve app. 5% lower fuel consumption / 25% higher output Gas constant speed up to 4% lower fuel consumption / 15% higher output Gas high torque curve app. 6% lower fuel consumption / 40% higher output Fuel consumption v v conventional advanced Speed April 6, 2018 Slide 14 Results based on engine cycle simulations
The challenge: increasing complexity Conventional vs. advanced technologies April 6, 2018 Slide 15
Conventional vs. advanced technologies gas transient Reference high-speed gas engine lean burn port injection fixed valve timing two-stage turbocharging Conventional control waste gate throttle valve Advanced control Inlet valve closing [ CA] Optimized filling at lower part load with later IVC Full load: earlier IVC to gain engine efficiency & enabling increased cylinder compression ratio Power output [%] ~35% faster load pick-up Valve Control Management (VCM) conventional advanced Time [s] Time [s] April 6, 2018 Slide 16 Results based on engine cycle simulations, load steps based on engine builder manual
Conventional vs. advanced technologies alternating methane numbers and gas composition Reference high-speed gas engine lean burn pre-mix fixed valve timing two-stage turbocharging Conventional control compressor bypass throttle valve Advanced control Valve Control Management (VCM) ΔT knock [K] (distance towards knocking) Derating Acceptance of lower methane numbers without derating Derating Increased knock margin at design point conventional advanced Methane number [-] April 6, 2018 Slide 17 Based SCE test results
Conventional vs. advanced technologies diesel thermomanagement Variation of valve timings to increase temperature for after treatment high-speed diesel engine rated speed 10% of max. torque realization possible with e.g. VCM Fuel consumption 20 g/kwh 50 C Late inlet valve closing Early inlet valve closing Early exhaust valve closing Temperature after turbocharger [ C] April 6, 2018 Slide 18 Results based on engine cycle simulations
The challenge: increasing complexity Opportunities from digitalization April 6, 2018 Slide 19
Opportunities from digitalization exposure-based maintenance (e.g. Digital SiKo) Increasingly varying operating profiles call for Hybrid systems higher loading, less fluctuations DC-grid diesel-electric operation at variable speed change from preventive to exposure-based maintenance Solid line operating time Dashed line cycles Grey based on standard profiles Red actual via monitoring Energy systems with renewables significant more starts and.stops New applications e.g. data centers with fast transient requirements Operational optimization e.g. slow steaming in merchant shipping Extension of TBO* based on actual data (e.g. to next DD**) April 6, 2018 Slide 20 *TBO time between overhauls **DD dry-dock
Opportunities from digitalization advanced sensors and analytics Sense analyze act sensing: noise, vibration, amb. & external temperature power supply: Battery transmission: Bluetooth Cost & installation complexity low Vibration & noise signal translated into: turbocharger speed turbocharger shaft unbalance speed and temperatures translated into utilization of rotating components recommendations (e.g. extend TBO) warning April 6, 2018 Slide 21
Opportunities from digitalization self-service tool (e.g. MXP App) April 6, 2018 Slide 22
Conclusions Advanced technologies Large Operating Range Fuel Flexibility Active Thermo-Management Reduced De-Rating Better Acceleration while allowing standardization in hardware Advanced sensing and analytics in a digitalized environment drive exposure- and condition-based service concepts on- and off-site support and operational simplicity April 6, 2018 Slide 23