ABB Turbocharging

Thiel Christian 24.09.
2014
CIMAC NMA Norge 2014

ABB Turbocharging

Agenda
ABB Group
October 2, 2014
| Slide 2
ABB Turbocharging in Norway
A200-L for two stroke engines
Engine tunings high pressure tuning method
Retrofit and upgrades 4 stroke

ABB Turbocharging in Norway
ABB NO-SE-DK merged 2013
ABB Group
October 2, 2014
| Slide 3
ABB Scandinavia
Main station Oslo

39 employees
Service engineers
Service coordinators
Logistics
Reconditioning
Sales/ New building
ABB service
stations
Troms
Operative end
2014
ABB service
stations and
sales office

A200-L The next 2-stroke generation
A200-L the dedicated

turbocharger for 2 stroke
engines
ABB Group / Turbocharging
ABB Group
October 2, 2014
| Slide 4

A200-L The next 2-stroke generation
1995
1999
2009
2013
New generation
New generation
New generation
TPL-B
A100-L
A200-L
2000
2005
2010
2015
2011
Upgrade
A100-L37
TPL-B
A100-L
A200-L
new
new
new
ABB Group / Turbocharging
ABB Group
October 2, 2014
| Slide 5
modified

The 6 key effects of A200-L
UP with pressure ratio

UP with volume flow
UP with efficiency
DOWN with first cost

DOWN with service cost
DOWN with fuel consumption
ABB Group
October 2, 2014
| Slide 6

The way we made A200-L
A100-L35
The original 2009
A100-L37
-8%
Introduced 2011
A200-L
-14%
Introduced 2013
ABB Group
October 2, 2014
| Slide 7

How we made the A200-L
new
new
new
ABB Group
October 2, 2014
| Slide 8
modified

Illustrations for constant output
Same output
A180-L35
A275-L
-20% product cost

-25% maintenance costs
ABB Group
October 2, 2014
| Slide 9

A200-L service concept
ABB Group
October 2, 2014
| Slide 10
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 referances
Large number of turbocharger
1400
A100-L units
400
A200-L units
Ask for A200-L
ABB Group
October 2, 2014
| Slide 11

HPT for MAN engines
Tunings for 2- stroke engines
ABB Group
October 2, 2014
| Slide 12
New vessels optimized for real operating conditions
Slow steaming
De-ratating
Engine tunigns

HPT for MAN engines
Why engine tuning and whats that?
Engine optimizing for lowest fuel consumption at a

given 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.,
ABB Group
October 2, 2014
| Slide 13
Optimized ABB turbocharger specifications

HPT for MAN engines
166,0
SFOC
Engine
MCR (kW)
rpm
164,0
SFOC [g/kWh]
162,0
6G60ME-C9.2
12 400
92
- 5 g/kWh
- 2,2 g/kWh
160,0
158,0
156,0
High Load Tuning
154,0
Part Load HPT
152,0
Low Load HPT
150,0
High Load Tuning

Part Load HPT
Low Load HPT
40%
164,6
161,6
159,6
45%
163,2
160,2
158,2
50%
161,8
158,8
156,8
55%
160,5
157,5
155,5
60%
159,3
156,3
154,3
65%
158,2
155,2
153,2
70%
157,4
155,2
154,7
75%
157,6
156,1
157,1
ENGINE LOAD
ABB Group
October 2, 2014
| Slide 14
80%
157,9
156,9
157,9
85%
158,5
158,7
159,2
90%
159,2
160,7
160,7
95%
160,2
161,7
161,7
100%
161,4
162,9
162,9

HPT for MAN engines
ABB Group
October 2, 2014
| Slide 15
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
The concept:
Increased scavenging air

pressure at SMCR (+0.4
0.5 bar) (two-stroke Miller
timing)
Results in higher
scavenging air pressure at
part and low-load, equal to
EGB/VT tuning
Scavenging air
pressure
ABB Group
October 2, 2014
| Slide 16

HPT for MAN engines
4,75
4,5
4,25
Scav. air pressure bara
4
3,75
3,5
ABB HPT
MDT-L High Load
Pscav. = + 0.5
3,25
MDT-L Low load VT
3
2,75
2,5
2,25
40%
50%
60%
70%
80%
Engine Load
90%
Similar pressure ratio as with VT tuning

ABB Group
October 2, 2014
| Slide 17
100%
110%
Standard Cycle
HPT Cycle
Exhaust
Exhaust
Log
pC
pC
BDC
PO
PO
EVO
pmax
BDC
p
pmax
EVO
Log
Scavenge Pressure
Intake
ABB Group
September 20, 2013 | Slide 5
Intake
EVC
Log V
TDC
EVC
TDC
Scavenge Pressure
Log V

HPT for MAN engines
Benefits of HPT:
Equal or better SFOC compared to VT or EGB
VTG/ EGB not needed
ABB Group
October 2, 2014
| Slide 19
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 exhaust

valve control
29 engines delivered with HPT

Upgrades on 4 stroke engines
Upgrades and Retrofit
ABB Group
October 2, 2014
| Slide 20

Upgrade projects: Power station in Kohinoor, Pakistan
VTR564
8 x Wrtsil 18V46A
with 2 x VTR564-P
Upgrade to TPL76-C34 with higher
efficiency
No changes on the engine
TPL76-C
Improvement
Fuel consumption
Turbo efficiency
- 2.0 %
+ 5.4 %-Pkt.
Speed margin
+ 6.0 %
Turbine inlet temperature
- 18.0 C

Upgrade projects: Cruise liner Freedom of the Seas
First marine application!
6 x Wrtsil 12V46 with 2 x TPL73-A30
Upgrade to newer turbocharger generation compressor

stage
New recertification issued by DNV

Upgrade projects: Cruise liner Freedom of the Seas
CV30 CV32
Improvement
Fuel consumption
Turbo efficiency
- 3 g/kWh (-1,65%)
+ 3.5 %-Pkt.
Speed margin
+7,2 %
-24 C
Fuel savings > 0,65 MUSD / year

Retrofit projects: Power plant of GENOR in Guatemala
NA457
TPL71-C
4 x Wrtsil 18V38A-2
with 2 x NA457
Retrofit from Napier to ABB TPL71-C;

introduction of Miller timing
Fuel consumption
Fuel savings of 2% could be

guaranteed (actual: 3.5%)
Speed margin
+6%
Payback time < 1.5 years
- 14 C
Fuel savings > 1.4 MUSD / year
NOx reduction
- 13 %
Improvement
Turbo efficiency
- 3.5%
(ca. + 3 %)

Updrade: Bergen engines
ABB Group
October 2, 2014
| Slide 25
Bergen B32:40L9P with 4500 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 main

components
Questions?
ABB Group
October 2, 2014
| Slide 26

ABB Turbocharging

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Thiel Christian 24.09.

CIMAC NMA Norge 2014

CIMAC NMA Norge 2014