turbocharger upgrade...naples shipping week, september 2018 turbocharger upgrade the efficiency...
TRANSCRIPT
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NAPLES SHIPPING WEEK, SEPTEMBER 2018
Turbocharger upgradeThe efficiency booster
Alberto Pochiero, Regional Technical Manager, South East Mediterranean Region
—ABB Turbocharging
September 27, 2018 Slide 2
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
—ABB Turbocharging Service
September 27, 2018 Slide 3
Local Business Unit: Italy
59 employees
25 service engineers
Please contact:[email protected]
> 1.450 service jobs per year
Venice
Rijeka
Naples
Malta
Genoa30
11
5
8
5
—Engine operation
September 27, 2018 Slide 4
MEP
End ‘70:
2 stroke engine: 8,5 bar
4 stroke engine: 14 bar
Current days (peak values):
2 stroke engine: 21 bar
4 stroke engine: 30,1 bar
Performance indicator and efficiency development of Diesel engines
0
10
30
60
1900 1920 1940 1960 1980 2020
50
20
40
Year
Engi
ne E
ffic
ienc
y [%
]
2000
MV Preussen & HS Danzig – 1926 - First ABB turbocharged Diesel ships
MV Selandia - 1912 - First oceangoing Diesel ship
MV Petit Pierre – 1903 - First Diesel driven ship
R. Diesel – 1897 - First engine
Source: Technical University Hamburg-Harburg Prof. Dr.-Ing. H. Rulfs
Engine Efficiency
—Reasons to be technology path setters
September 27, 2018 Slide 5
ABB Turbocharging’s journey
—Upgrade Definition
September 27, 2018 Slide 6
+ Modification of Engine
(e.g. Miller timing)
Conventional EfficiencyTurbocharger
High EfficiencyTurbocharger
—Turbocharger Upgrade
September 27, 2018 Slide 7
Improvements 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
Boosting engine performances by replacing:
• Complete Turbocharger or
• Components (e.g. compressor wheels)
ABB offers several upgrade solutions in cooperation with the engine OEM
—Turbocharger Upgrade
September 27, 2018 Slide 8
A recent success story
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
Project Main data
Owner Global worldwide cruise vessels operator
Application Cruise vessel, 3.000 passengers
Engine 4 Stroke, diesel Medium Speed, 6 engines installed
Rating About 10MW; IMO Tier 1 (RINA)
Operation Diesel electric (constant speed)
Current TC TPL77-A30
Upgrade Miller timing conversion, TPL77-A32 for engine part loadoptimization
Project Engine OEM in cooperation with ABB
—Turbocharger Upgrade
September 27, 2018 Slide 9
TPL77-A30 to TPL77-A32
—Upgrade benefits
September 27, 2018 Slide 10
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.
Simulations
1.0 2.0 3.0 4.0 5.0 6.00.70
0.75
0.80
0.85
0.90
Compressor pressure ratio
Com
pres
sore
ffic
ienc
y
TPL77-A32
TPL77-A30
Higher πC
Higher efficiencies
—Upgrade benefits
September 27, 2018 Slide 11
Simulations - Boundary conditions
Ref: TPL77-A30
Matching 1:TPL77-A32
Miller
Matching 2:TPL77-A32
Miller
Engine power [MW] 10 10 10
Turbine Standard Part load optMatching 1
Part load optMatching 2
Compressor wheel TPL-A TPL-C TPL-C
Up-boosting - YES YES
Cam Standard Miller Miller
—Motivation
September 27, 2018 Slide 12
Note:
The Miller Timing
Top dead center
Bottom dead center
Standard intake valve timing
Intake Exhaust
Millerintake valve timing
Intake Exhaust
log p
log VVh - DisplacementVc
pmaxpc
pRec
pTI
pac
pex
1
Volume
Pres
sure
log p
log VVh - DisplacementVc
pmaxpc
pRec
pTI
pac
pex
1
Volume
Pres
sure
log p
log VVh - DisplacementVc
pmaxpc
p’Recp’TI pac
pex
1
1’
Volume
Pres
sure
log p
log VVh - DisplacementVc
pmaxpc
p’Recp’TI pac
pex
1
1’
Volume
Pres
sure
Same amount of airtrapped in the cylinder
Lower temperatures with Miller
—Results
September 27, 2018 Slide 13
Turbine inlet and outlet temperature
50 °C
—Results
September 27, 2018 Slide 14
Specific Fuel Oil Consumption
5 g/kWh
—Pictures at site
September 27, 2018 Slide 15
Nozzle Ring Cartridge Turbine Compressor Wheel
Withdrawn originally installed parts
—Pictures at site
September 27, 2018 Slide 16
Turbine diffuser and Nozzle Ring
Cartridge Cartridge Air Side Compressor Casing with air diffuser
New installed parts
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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 CO2 emissions about 460 ton/year
Summary
September 27, 2018 Slide 17