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CIMAC NMA Norge 2014ABB Turbocharging
Thiel Christian 24.09.2014
CIMAC NMA Norge 2014
§ ABB Turbocharging in Norway
§ A200-L for two stroke engines
§ Engine tunings – high pressure tuning method
§ Retrofit and upgrades – 4 stroke
Agenda
© ABB GroupOctober 2, 2014 | Slide 2
CIMAC NMA Norge 2014
§ ABB NO-SE-DK merged 2013
Ø ABB Scandinavia
§ Main station Oslo
§ 39 employees
§ Service engineers
§ Service coordinators
§ Logistics
§ Reconditioning
§ Sales/ New building
ABB Turbocharging in Norway
© ABB Group
October 2, 2014 | Slide 3
ABB servicestations
TromsøOperative end
2014ABB servicestations andsales office
CIMAC NMA Norge 2014
A200-L the dedicatedturbocharger for 2 stroke
engines
A200-L – The next 2-stroke generation
© ABB GroupOctober 2, 2014 | Slide 4
© ABB Group / Turbocharging
CIMAC NMA Norge 2014A200-L – The next 2-stroke generation
© ABB GroupOctober 2, 2014 | Slide 5
© ABB Group / Turbocharging
modified
new
new
new
A200-L
1995 2000 2005 2010 2015
2009New generation
A100-L
2013New generation
A200-L
1999New generation
TPL-B
2011Upgrade
A100-L37
A100-LTPL-B
CIMAC NMA Norge 2014The 6 key effects of A200-L
© ABB GroupOctober 2, 2014 | Slide 6
• UP with pressure ratio
• UP with volume flow
• UP with efficiency
• DOWN with first cost
• DOWN with service cost
• DOWN with fuel consumption
CIMAC NMA Norge 2014The way we made A200-L
© ABB GroupOctober 2, 2014 | Slide 7
A100-L37
A200-L
-8%
-14%
A100-L35 The original 2009
Introduced 2011
Introduced 2013
CIMAC NMA Norge 2014How we made the A200-L
© ABB GroupOctober 2, 2014 | Slide 8
modified
new
new
new
CIMAC NMA Norge 2014Illustrations for constant output
© ABB GroupOctober 2, 2014 | Slide 9
A275-L
Ø -20% product costØ -25% maintenance costs
A180-L35
Same output
CIMAC NMA Norge 2014
§ Continuous high performance from dry-dock to dry-dock
§ One intermediate visual inspection of key components
§ Smart and compact design for easy maintenance
§ Optimized features
§ Integrated lubrication oil tank
§ Integrated bearing design
§ Improved labyrinths for minimum air blow-by and oil blow-by
§ Improved compressor and turbine cleaning devices
A200-L service concept
© ABB GroupOctober 2, 2014 | Slide 10
CIMAC NMA Norge 2014
§ Large number of turbocharger
§ 1’400 A100-L units
§ 400 A200-L units
Ask for A200-L
A200-L referances
© ABB GroupOctober 2, 2014 | Slide 11
CIMAC NMA Norge 2014
Tunings for 2- stroke engines§ New vessels optimized for real operating conditions
§ Slow steaming
§ De-ratating
§ Engine tunigns
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 12
CIMAC NMA Norge 2014
§ Why engine tuning and what’s that?
§ Engine optimizing for lowest fuel consumption at agiven intended load profile of the vessel.
§ Optimized for high-load (90-100%)
§ Optimized for part-load (70-90%)
§ Optimized for low-load (0-70%)
§ Engine adjustments with shims, timing, coolers, etc.,
§ Optimized ABB turbocharger specifications
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 13
CIMAC NMA Norge 2014HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 14
100%95%90%85%80%75%70%65%60%55%50%45%40%High Load Tuning 161,4160,2159,2158,5157,9157,6157,4158,2159,3160,5161,8163,2164,6Part Load HPT 162,9161,7160,7158,7156,9156,1155,2155,2156,3157,5158,8160,2161,6Low Load HPT 162,9161,7160,7159,2157,9157,1154,7153,2154,3155,5156,8158,2159,6
150,0
152,0
154,0
156,0
158,0
160,0
162,0
164,0
166,0SF
OC
[g/k
Wh]
ENGINE LOAD
SFOC
High Load Tuning
Part Load HPT
Low Load HPT
Engine 6G60ME-C9.2MCR (kW) 12 400rpm 92
100%95%90%85%80%75%70%65%60%55%50%45%40%High Load Tuning 161,4160,2159,2158,5157,9157,6157,4158,2159,3160,5161,8163,2164,6Part Load HPT 162,9161,7160,7158,7156,9156,1155,2155,2156,3157,5158,8160,2161,6Low Load HPT 162,9161,7160,7159,2157,9157,1154,7153,2154,3155,5156,8158,2159,6
150,0
152,0
154,0
156,0
158,0
160,0
162,0
164,0
166,0SF
OC
[g/k
Wh]
ENGINE LOAD
SFOC
High Load Tuning
Part Load HPT
Low Load HPT
- 2,2 g/kWh
100%95%90%85%80%75%70%65%60%55%50%45%40%High Load Tuning 161,4160,2159,2158,5157,9157,6157,4158,2159,3160,5161,8163,2164,6Part Load HPT 162,9161,7160,7158,7156,9156,1155,2155,2156,3157,5158,8160,2161,6Low Load HPT 162,9161,7160,7159,2157,9157,1154,7153,2154,3155,5156,8158,2159,6
150,0
152,0
154,0
156,0
158,0
160,0
162,0
164,0
166,0SF
OC
[g/k
Wh]
ENGINE LOAD
SFOC
High Load Tuning
Part Load HPT
Low Load HPT
- 5 g/kWh
CIMAC NMA Norge 2014
§ How to tune an engine for part/low load?
§ exhaust gas bypass (EGB)
§ engine control tuning (ECT) for electronic engines only
§ variable turbine geometry (VT)
§ High Pressure Tuning (HPT)
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 15
CIMAC NMA Norge 2014
§ The concept:
§ Increased scavenging airpressure at SMCR (+0.4 –0.5 bar) (two-stroke Millertiming)
§ Results in higherscavenging air pressure atpart and low-load, equal toEGB/VT tuning
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 16
Scavenging airpressure
CIMAC NMA Norge 2014
Similar pressure ratio as with VT tuning
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 17
2,25
2,5
2,75
3
3,25
3,5
3,75
4
4,25
4,5
4,75
40% 50% 60% 70% 80% 90% 100% 110%
Scav
.air
pres
sure
bara
Engine Load
ABB HPT
MDT-L High Load
MDT-L Low load VTΔ Pscav. = + 0.5
Intake Intake
Log V
BD
C
Log p
pC
pmax
Scavenge Pressure
EVO
POEV
C
TDC
Log p
pC
pmax
Scavenge Pressure
EVO
PO
EVC
TDC
BD
C
Log V
Standard Cycle HPT Cycle
ExhaustExhaust
© ABB GroupSeptember 20, 2013 | Slide 5
CIMAC NMA Norge 2014
§ Benefits of HPT:
§ Equal or better SFOC compared to VT or EGB
§ VTG/ EGB not needed§ No investment
§ No maintenance
§ No breakdown
§ Combined with all A200-L§ High charge pressure
§ High volume flow
§ Dual rating possible (part load + low load)
§ Available on MAN electronic engines (ME) and exhaustvalve control
§ 29 engines delivered with HPT
HPT for MAN engines
© ABB GroupOctober 2, 2014 | Slide 19
CIMAC NMA Norge 2014
Upgrades and Retrofit
Upgrades on 4 stroke engines
© ABB GroupOctober 2, 2014 | Slide 20
§ 8 x Wärtsilä 18V46Awith 2 x VTR564-P
§ Upgrade to TPL76-C34 with higherefficiency
§ No changes on the engine
CIMAC NMA Norge 2014Upgrade projects: Power station in Kohinoor, Pakistan
VTR564 TPL76-C
ImprovementFuel consumption - 2.0 %Turbo efficiency + 5.4 %-Pkt.Speed margin + 6.0 %Turbine inlet temperature - 18.0 °C
CIMAC NMA Norge 2014Upgrade projects: Cruise liner Freedom of the Seas
§ First marine application!
§ 6 x Wärtsilä 12V46 with 2 x TPL73-A30
§ Upgrade to newer turbocharger generation compressorstage
§ New recertification issued by DNV
CIMAC NMA Norge 2014Upgrade projects: Cruise liner Freedom of the Seas
CV30à CV32
ImprovementFuel consumption - 3 g/kWh (-1,65%)
Turbo efficiency + 3.5 %-Pkt.Speed margin +7,2 %Turbine inlet temperature -24 °C
Fuel savings > 0,65 MUSD / year
CIMAC NMA Norge 2014Retrofit projects: Power plant of GENOR in Guatemala
§ 4 x Wärtsilä 18V38A-2with 2 x NA457
§ Retrofit from Napier to ABB TPL71-C;introduction of Miller timing
§ Fuel savings of 2% could beguaranteed (actual: 3.5%)
§ Payback time < 1.5 years§ Fuel savings > 1.4 MUSD / year
ImprovementFuel consumption - 3.5%Turbo efficiency (ca. + 3 %)Speed margin + 6 %Turbine inlet temperature - 14 °CNOx reduction - 13 %
NA457 TPL71-C
CIMAC NMA Norge 2014
§ Bergen B32:40L9P with 4’500 kW
§ Equipped with TPL69-A
§ IMO I
§ Upgraded with TPL67-C and new camshaft
§ Miller cycle + IMO II
§ Higher engine efficiency and lower fuel consumption
§ Upgrade in combination with replacement of maincomponents
Updrade: Bergen engines
© ABB GroupOctober 2, 2014 | Slide 25
CIMAC NMA Norge 2014
Questions?
© ABB GroupOctober 2, 2014 | Slide 26