1|14The customer magazine

of ABB TurbochargingSwitzerlandcharge!

Safety and reliability is the focus 18 Joachim Bremer on responsibility in the offshore sectorPrecision technology for the oil and gas offshore industry 14Light well interventions with ABB turbocharged vessel Island WellserverPower2 leading the way in two-stage turbocharging 4Second-generation technology with new benefits

Going offshore

2 ABB charge! 1|14

From the editor

charge! 1|14

Magdalena OkopskaHead of Market Communication ABB Turbocharging

2013 was a tough year for many of ourcustomers and for us. Nevertheless, wewere able to provide our customers withsome 10,000 turbocharging solutions. Asthe market situation is going to stay chal-lenging in 2014, our strategy is first andforemost to provide those solutions thatrespond directly to our customers’ needs.Topics we shall focus on will include fuelefficiency, reliability and 24 /7 support,wherever our customers need it.

This issue of charge! looks at, amongother topics, service upgrades with a fastpayback for end users by significantlyreducing fuel consumption and allowingimmediate and long-term lower mainte-nance costs. And you can read aboutanother key technology contributing tolower fuel consumption in the report onour two-stage turbocharging solution,Power2 800-M. This is the second gen-eration of Power2, which was success-fully introduced in 2010 and solves thedilemma posed by demand for a reduc-tion in both NOx emissions and fuel con-sumption. Power2 800-M offers a portfolio

with four sizes covering the entire powerrange of large medium speed engines.

ABB Turbocharging is also a reliablepartner of the oil and gas industry, wheresafety and security play a huge role.Joachim Bremer – head of ABB Turbo -charging in Scandinavia – talks about hisexperience and the company’s commit-ment to the high standards of thisdemanding sector in the interview start-ing on page 18.

For more information about ABB Turbo -charging products and the industries we serve, please visit our websitewww.abb.com/turbocharging which, Ihave the pleasure to announce, offers anupdated content in a new, lighter andfresher layout starting this spring.

It would also give us great pleasure tomeet you personally at the PosidoniaExhibition taking place in Athens on June2 – 6. We look forward to seeing youthere at Stand 2.211. In the meantime,please enjoy this issue of charge!

Second-generation Power2Two-stage turbocharging for increased enginepower density.04 Strongly expanding segment

Joachim Bremer on the importance of the oil andgas offshore industry for ABB Turbocharging.18

ABB charge! 1|14 3

Contents

Technology 4 Power2 leading the way in two-stage turbocharging

Two-stage turbocharging for the entire power range oflarge medium-speed engines

8 Up-to-speed in half the time with VCMSignificant fuel savings possible with intelligent valve train system

9 Maximizing safety for ABB turbochargersContainment reliably avoids rotor parts ejection

12 Variable Turbine Geometry (VTG) breakthrough in rail tractionChina’s TPR order for “Smart Loong” locomotive

News13 Services, Openings, Awards

Applications14 Precision technology from top to bottom

Light well interventions with ABB turbocharged IslandWellserver

26 First choice for maritime trainingABB turbochargers for new training ship of Dalian Maritime University in China

Interview18 Safety and reliability is the focus

Interview with Joachim Bremer, head of ABB Turbocharging’s Center of Excellence Oil & Gas Offshore

Service22 Offshore in Brazil

Servicing the growing oil and gas offshore industry in Brazil

Tips for the operator28 Developing to benefit the customer

Upgrades for significant turbocharger improvements

Recipe30 Harmony in the shape of a cake

Airy and creamy: The Norwegian classic dessert Bløtkake

Working offshore in BrazilHighest professional standards are demandedin the oil and gas offshore industry.22 Training on ABB turbochargers

A new training ship for the Dalian Maritime University in China will have A165 turbochargers.26

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Technology

Power2 leading theway in two-stageturbochargingSecond-generation Power2® can be used for the entire powerrange of large medium-speed engines.

Text Dr. Thomas Behr, Photography Michael Reinhard, ABB Turbo Systems Ltd

Power2.

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Technology

In 2013 ABB Turbocharging began pre-senting to customers Power2 800-M,the second generation of its two-stageturbocharging system Power2. Offer-

ing considerable improvements in engineefficiency and reductions in emissions thatgo far beyond any single-stage system,even exceeding the high expectations,Power2 in its second generation repre-sents the next step in two-stage turbo -charging for large medium-speed engines.A portfolio with four different frame sizes isplanned for second-generation Power2,two more than for the first-generationPower2 that has been on the marketsince 2010.

Two-stage turbocharging is a keytechnology that facilitates a reduction inboth fuel consumption and emissionswhile helping to increase engine powerdensity. With pressures of up to 12 barand turbocharging efficiencies over 75 %,second-generation Power2 leverages thefull potential of extreme Miller cycles tominimize NOx reduction and fuel con-sumption.

Optimum performancePower2’s high efficiency comes as a

result of its sophisticated design, whichwas always planned as a dedicated two-stage turbocharging solution. Its com-pressor and turbine stages make a spe-cial contribution in this regard.

Two-stage turbocharging implies spe-cific requirements having to be met by thethermodynamic components that differfrom those of single-stage systems. Pres-sure ratios of compressors and turbines inlow- and high-pressure turbochargers oftwo-stage systems are generally differentto those of components in single-stageturbochargers. Fig. 1 shows this differ-ence by comparing the compressor mapsof a single-stage design and the Power2low-pressure stage design for the sameimpeller wheel diameter. With respect toflow areas, differences in fluid densityresulting from specific temperatures andpressures in the high- and low-pressurestages need to be considered. In addi-tion, performance maps of compressorsand turbines need to be matched per-

fectly in order to allow unrestricted engineoperation over the entire load range.

The high-pressure turbocharger fea-tures two compressor stage variants,which are specified according to thedesired overall pressure ratio. The com-pressor stage known from the first gen-eration yields optimum performance forapplications with pressure ratios up to�C = 10. For pressure ratios up to �C = 12, an entirely new high-pressurecompressor stage design has beendeveloped. Both stages have been opti-mized, focusing on the compressor mapwidth and efficiency at their specificoperating range. Performance maps ofboth stages are presented in Fig. 2. Bothstages operate at an efficiency level ofup to 84% at design pressure ratio.

Axial turbines will be used for both thelow- and the high-pressure stage. Theturbine stage designs take into accountthe diverging needs of the high- and low-pressure sides. These result fromdifferent temperature levels and flow arearequirements.

Fig. 1: Compressor performance maps of a single-stage turbocharger (A100-M) and Power2 800-Mlow-pressure turbocharger at equal impeller wheeldiameter.

0.0 0.2 0.4 0.6 0.8

Com

pre

ssor

pre

ssur

e ra

tio (n

orm

aliz

ed)

���ref [-]

1.2

1.0

0.8

0.6

0.4

0.2

Volume flow (normalized)

V/Vref [-]

Single-stage turbocharger

Power2 800-M low-pressure turbocharger

Fig. 2: Compressor performance maps of thePower2 800-M high-pressure turbocharger.

0.0 0.2 0.4 0.6 0.8 1.0

���ref [-]

1.2

1.0

0.8

0.6

0.4

0.2

High-pressure design �C,Sys ≤ 10

High-pressure design �C,Sys ≤ 12

Com

pre

ssor

pre

ssur

e ra

tio (n

orm

aliz

ed)

Volume flow (normalized)

V/Vref [-]

Two-stage turbochargingis a key technology that facilitates a reductionin both fuel consumptionand emissions whilehelping to increaseengine power density.

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Technology

For the second genera-tion turbochargers theproven cartridge concepthas been enhanced inorder to further reduceservice time.

Fig. 3: Turbine efficiency vs. specific effectiveflow area of a single-stage turbocharger and Power2 800-M high-pressure turbocharger.

0.4 0.5 0.6 0.7 0.8 0.9 1.0 [-]

Turb

ine

effic

ienc

y

[%]

86

84

82

80

78

76

Specific effective flow area (normalized)

Single-stage turbocharger

Power2 800-M high-pressure turbocharger

Fig. 4: Turbine efficiency vs. specific effectiveflow area of a single-stage turbocharger andPower2 800-M low-pressure turbocharger.

0.2 0.3 0.4 0.5 0.6 0.7 [-]

Turb

ine

effic

ienc

y

[%]

88

86

84

82

80

78

Specific effective flow area (normalized)

Single-stage turbocharger

Power2 800-M low-pressure turbocharger

The axial turbine design for the high-pressure turbocharger combines theadvantages of high specific volume flow(Fig. 3), excellent efficiency even at partload and good acceleration behavior dueto low mass moment of inertia.

The requirements for the low-pres-sure turbine stage also differ significantlyfrom those for single-stage turbines. Therequired range of specific volume flowsin the case of the low-pressure turbine is shifted toward a lower level than for single-stage turbines (Fig. 4). Conse-

Service friendliness for optimal economic performance.

quently, this lower requirement has beenexploited in the design of the new low-pressure turbine stage to gain higherstage efficiency.

In addition to the compressor and turbine design, the design frameworkaround these components needs to beconsidered to achieve optimum systemperformance. Therefore, the design of theflow channels and subsystems has beenoptimized specifically during developmentof the new turbochargers.

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Technology

Dr. Thomas Behr received his degreein mechanical engineering from the Dresden University of Technologyin Germany in 2002. In 2007 he completed his PhD thesis on turbo-machinery aerodynamics at the Turbomachinery Laboratory of theSwiss Federal Institute of Technologyin Zurich (ETH). He subsequentlyjoined ABB Turbo Systems Ltd inBaden, Switzerland, as a turbo-charger development engineer and is currently Project Manager for thedevelopment of the second-generationPower2.

Fig. 5: Power2 800-M high-pressure turbocharger with extractable cartridge.

Focus on minimal service downtimeEngine availability is a key factor for

achieving optimal economic perform-ance. Consequently, the time requiredfor service work needs to be reduced to a minimum. In the case of two-stageturbocharging, this aspect becomeseven more important as there are double the number of turbochargers tobe serviced. During development of thenew turbocharger generation, servicefriendliness has been considered fromthe very beginning. The designated goalwas to reduce service time of the com-plete two-stage system to below the reference value of current single-stageturbochargers.

For the second generation turbo -chargers the proven cartridge concepthas been enhanced in order to furtherreduce service time. The idea behind theextractable cartridge is a turbochargerwhich has an outer shell, consisting ofcompressor casing and gas casings, anda cartridge group which contains theentire interior of the turbocharger. Inorder to exchange the cartridge duringservice, only the air inlet casing togetherwith the insert wall of the compressorneeds to be removed. All other interfacesto the engine, such as oil connections,air outlet flange connection, gas inlet andgas outlet flange connections, remainuntouched. Furthermore, there is noneed to remove the insulation of the

turbocharger anymore, since only theflange connection of the air inlet needs tobe accessed during service (Fig. 5).

ConclusionDemand for highly efficient engines

with high power density and low operat-ing costs that comply with today’s emis-sion requirements is driving the develop-ment of new turbocharging solutions.Second-generation Power2 representsan optimized technology enabling enginedesigns that fulfill all these requirementsat once. The entire system has beendesigned and optimized for the specificneeds of two-stage turbocharging. Withpressure ratios of up to 12 and turbo-charging efficiencies beyond 75%, Power2enables full exploitation of the advan-tages of two-stage turbocharging. Easeof service has been especially consid-ered in the design. With the newextractable cartridge, service downtimehas been minimized, which increasesengine availability. The Power2 800-Mseries provides a two-stage turbocharg-ing solution for the entire range of largemedium-speed engines.

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Technology

Up-to-speed in half the time with VCMSignificant fuel savings made possible byABB’s intelligent valve train system

ABB offers engine builders a turbocharg-ing solution that enables gas and dieselengines to go from idling to full load inhalf the time it usually takes, thereby significantly reducing fuel consumptionand greenhouse gas emissions.

Fuel accounts for more than two-thirds of the operating costs of gas anddiesel engines. This and the increasinglystringent emissions regulations for themaritime, power generation and otherindustries make engine efficiency thenumber one priority for engine buildersand end users alike.

One of the tools that engine buildersare using to reduce fuel consumptionand greenhouse gas emissions is ValveControl Management (VCM®), ABB’svariable valve train system.

VCM can typically increase gas engineefficiency by more than one percentagepoint, and that means fuel savings ofmore than two percent. For a 10,000 kilo-watt gas engine, this translates into about$ 200,000 in fuel savings annually. For apower plant with ten such engines ormore, the savings are significant.

Optimized at all timesVCM is an intelligent valve train sys-

tem that works adaptively to provide anengine with the optimal amount of air fordifferent speeds, loads and operatingconditions. This enables, among otherthings, the turbocharger to take theengine from idling to full load in no morethan half the time it usually takes.

As a result, a turbocharged engineequipped with VCM operates with opti-mal air supply and maximum efficiency at all times. It reduces engine fuel con-sumption, greenhouse gas emissions andthe engine’s thermal load. VCM in combi-nation with ABB’s two-stage turbocharg-ing solution, Power2, enables customersto further reduce emissions and saveeven more on fuel.

VCM is particularly effective for high-performance engines in which largeoperating ranges or rapid load responsesare required such as tugboats, ice-breakers, pump drives, compressor drivesand power generators.

Integrating a VCM in the cylinder headhas the following benefits:– The cylinder head remains virtually un -

touched except for limited machiningoperations.

– The original mounting and assemblyprocess is retained.

– Existing parts, including the mechani-cal bridge, rocker arm and rockershaft, are reused.

Aside from the new VCM unit, the onlycomponents that are modified are theshortened push rod, the cam profile andthe rocker cover with its gaskets.

The VCM unit can be designed sothat a minimum of modifications and newparts are needed even when space islimited. Thanks to this design, it wouldalso be possible to use the VCM unit witha diesel version of this engine.Example of VCM on a pre-mix gas engine.

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Technology

Maximizing safety for ABB turbochargersContainment ensures that even in the unlikely event of a turbocharger rotor bursting, the ejection of rotor parts can be reliably avoided.Text Markus Kahi, Photography Michael Reinhard, ABB Turbo Systems Ltd

In a technical context, the term “con-tainment” is most commonly asso-ciated with the building enclosingnuclear reactors. This enclosure is

designed to ensure that no radiation willescape from the reactor in an emer-gency, whether its cause originatesinside or outside the reactor.

Of course, a turbocharger can neverbe compared with a nuclear reactor interms of its potential to endanger life orproperty. Nevertheless, as with any fastrotating machine, the risk of a turbo -charger rotor bursting does exist andhas to be taken seriously. Turbochargersare operated at very high rotating

speeds, with centrifugal forces that produce very high loads. As a result, high kinetic energy is stored in the rotorcomponents and a burst can lead toconsiderable damage being caused tothe rest of the turbocharger, nearbyequipment and – in the worst case – persons close by.

A190-L turbine with a maximum operational speed of 11,280 rpm. At that speed a centrifugal load of 109 tons acts on a single blade. The kinetic energyof the bladed shaft is equivalent to a 20 tons truck traveling at 100 km/h.

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Technology

Compressor side of an A100-L turbocharger after successfully passing a containment test.

ABB Turbocharging’s recognition ofthe importance of turbocharger contain-ment safety goes back more than thirtyyears and the company is committed toensuring that, in the unlikely event of arotor bursting, the ejection of compo-nents is avoided as reliably as possible.

History of containment safety andqualification methods

First containment tests with ABB turbochargers were carried out with theVTC. .4 and RR. .1 in the 1980s, longbefore the classification societies or otherregulatory authorities required any verifi-cation of containment safety. A wholeprogram of containment tests followed inthe 1990s with the VTR. .4 turbochargers.Through these tests, ABB Turbocharginggained an insight into the basic causesand types of rotor bursts and learnt howto apply this experience to future designand manufacturing for containment safety.The engineers were getting to grips withthe complexity of the different mecha-nisms taking place during a burst inci-dent on both the turbine and the com-pressor side.

Building on the know-how obtainedfrom these tests, upgrades, for examplechanging the casing materials from gray

cast iron to nodular cast iron and intro-ducing special protection measures onthe turbine side, were implemented in the1990s for the VTR. .4 turbochargers. Infact, since that time, ABB Turbocharginghas used nodular cast iron exclusively forall relevant turbocharger casings.

At the same time, a systematic quali-fication test program that included con-tainment safety as one of the importantqualification criteria was established forevery new turbocharger series. Contain-ment safety became an integral part ofthe product development process. AllABB turbochargers introduced since then,such as the TPS, TPL, TPR and A100®

series, have been developed, tested andverified for containment safety.

ABB Turbocharging has not stoppedthere. The development of new and im -proved design and qualification methodsrelating to containment continues. Anexample is the introduction of a dedicatedand highly reliable method to initialize thebursting of the compressor wheel at a desired rotating speed. The picturebelow shows the compressor end of anA100-L turbocharger which has success-fully passed the containment test.

The experience and know-howobtained from structured testing and eval-

Since the 1990s ABB Turbocharging uses nodular cast ironexclusively for all the relevant turbochargercasings.

uation are complemented at ABB Turbo -charging by software tools that simulateburst incidents. These computer simula-tion tools provide indispensable supportduring the design process as they enablecontainment safety to be considered at avery early development stage. Often,with their help, the final experimentalqualification test can be passed suc-cessfully today with just one single verifi-cation run. An example of such a con-tainment simulation during the designphase of a new turbocharger type isshown in the picture on page 11.

Today, it can be stated that, together,the containment related design processand qualification tests ensure an optimallevel of safety for ABB turbochargers.

SIKO – Minimizing the risk of a burstin the first place

While the possibility of a rotor burst-ing can never be ruled out altogether,measures are of course taken to reducethis risk to a minimal level. To this end,ABB Turbocharging has developed asophisticated safety design conceptknown as SIKO. Development of thisconcept also started in the early 1980sand the field experience since acquiredhas provided the basis for its continuous

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Technology

ABB Turbocharging’s SIKO concept specifies speedlimits, temperature limits and replacement intervals ofrotor components for different application conditions.

In 2011 Markus Kahi was appointedSenior General Manager with respon-sibility for product development andall turbocharger development productlines. Before that he was generalmanager of the product line mediumsize turbochargers (2010) and two-stroke turbochargers (2004). He joinedABB Turbocharging in 1994. Kahi has a master’s degree in mechanicalengineering from the Swiss FederalInstitute of Technology Zurich (ETH).

improvement. With the SIKO concept,speed limits, temperature limits andreplacement intervals of rotor compo-nents are specified for different applica-tion conditions. The combination of SIKOconcept and the containment designconcept form a strong overall turbo -charger safety package.

And it is a safety package that is wellproven, with field experience from cur-rently about 200,000 ABB turbochargersof different generations in operationtoday. By tracking and analyzing failurecases it has been possible to confirm thehighest levels of product safety for ABBturbochargers.

How operators can contribute to safetyAs already mentioned, innovations and

action taken since the 1980s have continued to increase the safety of ABBturbochargers, and this has been con-firmed by the positive field experiencegained from the large ABB turbochargerpopulation.

However, for our turbochargers to stayfit for purpose they must be operatedwithin the defined design limits and withparts fulfilling ABB Turbocharging’s designstandards. Therefore, owners and opera-tors can also contribute to operationalsafety over these products’ life cycle byfollowing the instructions and precau-tions found in the operating manuals andby using only ABB Original Parts andOriginal Service for all repairs and over-hauls.

Further information on the importance of containmentin the oil and gas offshore industry can be found byturning to page 18.

Example of a containment simulation study on the compressor side. Left hand images show the analysis of deformations and stresses.

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Technology

VTG breakthrough in rail tractionTPR order for “Smart Loong” locomotives

A batch order has been received fromChina to equip the first production seriesof the “Smart Loong” locomotive withTPR turbochargers. Roll-out of the loco-motives is scheduled for the second halfof 2014. The TPR turbocharger, featuringenhanced flexibility with VTG technology,will also be tested in Russia on a new medium-speed traction engine. Testmaterial is being prepared and engineperformance testing is scheduled towardmid 2014. First requests to test VTGtechnology have also been received fromIndia.

With the order from China, the roll-outof ABB Turbocharging’s Variable TurbineGeometry (VTG) on the TPR turbochargerplatform into the railway market has defi-nitely taken off. Engine testing in Chinahas successfully proven the benefits ofthe VTG technology, i. e. fuel savings andlower thermal engine load as well asimprovements in load acceptance andsmoke emissions during the accelerationphase. Moreover, operational advantageswere shown during 2013’s locomotivetesting, e.g. how the VTG technologycompensated for extreme ambient tem-

perature conditions and also enabled the engine to develop full power up to analtitude of 2,500 meters.

VTG technology provides this marketwith the potential to utilize the full capa-bility of single-stage high-pressure turbo-charging during future engine develop-ment steps. ABB Turbocharging is readyto support this development of new rail-way power packs in order to maximizebenefits for engine builders and opera-tors alike.

TPR turbocharger with Variable Turbine Geometry (VTG).

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News

Fully equipped: The new Namibian Service Station in Walvis Bay.

New Service Station in Namibia

Walvis Bay. ABB Turbocharging openeda new Service Station in Walvis Bay,Namibia, in fall 2013. The market for shiprepair is growing on the West AfricanCoast as a result of new oil and gas busi-ness in Angola, and the new facility willaccommodate this increasing need. TheService Station’s full range of equipment,

including a balancing machine, meets allcustomer needs. The new premises havebeen placed near the Elgin, Brown &Hamer’s dry dock, one of the busiest inthe region, where competent repair ofsupply and support vessels is in greatdemand.

Worldwide Service NetworkadaptationsNetwork. ABB Turbocharging adaptedits network. Two full-size ABB Turbo -charging Service Stations were openedin Barranquilla, Columbia and Dhaka,Bangladesh. Seven Service SupportPoints were opened: in Walvis Bay,Namibia; Mombasa, Kenya; and Mauri-tius and Batam, Indonesia.

Service Support Points were openedinside the Dubai Drydocks (see charge!2|13) and in two Chinese shipyards.

LBU numbersadjustedScandinavia, Iberia and North America.The LBUs Norway, Denmark and Sweden were brought together to formLBU Scandinavia on 1 January 2014.Spain and Portugal have been combinedto form LBU Iberia. Head of LBU Iberia is Marta Sanchez. LBU North Americacomprises the United States and Canada.Chuck Noddin continues to head up LBUNorth America, formed in 2013.

SQEP gold certification for ABB TurbochargingBaden. Following its Bronze Level Awardin 2013, ABB Turbocharging was named aGold Level SQEP supplier for CaterpillarMotoren Kiel GmbH & Co. KG. SQEP, orSupplier Quality Excellence Process, isCaterpillar’s system for ensuring the highquality of its suppliers and confers upona company preferred supplier status.

Caterpillar’s SQEP certification recog-nizes their supplier’s dedication to pro-viding superior quality and is only awardedto those who demonstrate such world-class performance on an ongoing basis.Each year, suppliers are evaluated withincreasingly strict criteria for distinguish-ing outstanding supplier quality perform-ance, exceptional service, capacity plan-ning, and delivery performance.

Achieving SQEP status for equipmentas complicated and varied as a turbo -charger constitutes a major achievement,because it must meet strict requirementsin several categories, including productquality, process management, manufac-turing, logistics, delivery and customerservice, to name just a few.

Original Services

OPAC Customize. With ABB’s Operation Performance Package (OPAC), youget a fully customizable, fully dele-gable OEM service package, paid bythe actual number of turbochargerrunning hours. Designed with and forthe customers, the OPAC is a moreflexible, cost-effective approach toturbocharger servicing, made to meetyour exact needs everywhere, everytime, with Original Parts and OriginalService.

You can go with OPAC BASE, whichoffers the fundamentals of goodservice and lets you upgrade at anytime. Or you can build on that solidfoundation with OPAC PREMIUM andprepare for unforeseeable incidentswell in advance.

MMAOptimize. A Maintenance Manage-ment Agreement (MMA) is a serviceagreement for maintaining your ABBturbocharging solutions in your fleet.It optimizes your maintenance man-agement and reduces your workload.You get an annual budget plan,advance service recommendations,discounts on new Original Parts, anda single point of contact who willwork with you in your language andon your time.

If you’re looking for a full-service sup-port system that gives you a proactiverole and full transparency, then anMMA is right for you. 150 of our cus-tomers are already convinced. Theyhave chosen to cover some 7,000 turbochargers under an ABB MMA,and that’s not just because you cansave 20% on Original Parts.

For more information:http://www.abb.com/product/us/9AAC125887.aspx

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Applications

Precision technology from top tobottomWhen an offshore oil well in the North Sea needs repairing or stimulating, the ABB turbocharged Island Wellserver from Norwegian company Island Offshore can help. “Depth no obstacle”, down to 1,500 meters.

Text Tiziana Ossola Auf der Maur, Photography Island Offshore, ABB Turbo Systems Ltd

First a few figures: worldwidethere are 5,000 offshore wells inproduction and this number isfirmly set to go up. According to

ABB calculations, in 2010 oil and gas off-shore met 18% of global total energydemand. It will rise to 21% by 2020. Inthe past few years, oil and gas produc-tion shifted more and more toward deepwater – 300 to 500 meters – and ultra-deep-water – 1,500 to 3,650 meters.This is challenging in the extreme. Atsuch depths – unattainable for humans –water pressure is several hundred timeshigher than air pressure on the earth’ssurface. It is dark and cold.

Island Wellserver. Width: 25 m.

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Applications

The need to develop and then tomaintain offshore wells has grown inrecent years. It requires materials thatcan withstand the extreme ambient con-ditions at these depths. And then there isthe actual process of boring holes intothe well that has to be mastered techno-logically. Just as in microsurgery on ahuman body, this prescribes maximumprecision and maximum safety. All thesemethods used had to be developed fromscratch and have been rigorously triedand tested over the past 20 to 30 years.This evolution was rapid.

ABB turbocharged dynamically positioned Island Wellserver performing light well intervention services.

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Applications

Island Wellserver: Replacing drilling rigsOne specialist company in the oil and

gas offshore sector is Island Offshorebased in Norway. It was founded in 2004and having grown constantly since thennow boasts a fleet of 27 high technologyservice vessels, with a further six projectseither at the planning or building stage(status May 2014). A subsidiary of IslandOffshore is Island Offshore Subsea,whose activities cover, among others,light well intervention (LWI). The aim ofLWI is to increase oil recovery from awell. Island Offshore Subsea developssolutions to achieve this goal. One of theLWI ships is the MOU Island Wellserver.Based on good, long term experience,Island Offshore relies on Rolls-Royceengines for its power plants, and in turn,Rolls-Royce chooses turbochargers fromABB for the vessel’s four main engines.

Since it slid down the slipway in 2008,Island Wellserver has never been out ofwork. The reason: during the life of an oilor gas well, a number of planned orunplanned interventions may be required,including processes such as diagnostics,stimulation, surveillance, manipulation ofequipment and repair of mechanical fail-ures. Also, the age of the subsea wells isincreasing, resulting in the need for lightwell interventions to maintain the wells’condition and optimize oil recovery.

Traditionally, many well operationshave been carried out from drilling rigs.LWI operations performed from dynami-cally positioned vessels like the IslandWellserver have become more attractivein recent years, because they can achieveresults faster and with less preparation.

During the life of an oil or gas well, a number ofplanned or unplannedinterventions may berequired.

Launching the Remotely Operated Vehicle (ROV) over the side of the Island Wellserver by means of alaunch and recovery system (LARS).

ABB charge! 1|14 17

Applications

A ship like the Island Wellserver can sailrelatively quickly from the harbor to thewell and for certain operations needs noadditional anchor handling and supplyvessels. Positioned near the well, withina few days the Island Wellserver can exe-cute trenching, plugging and abandoning(P&A) of suspended subsea wells, toname but a few examples of underseaprocesses. In central and northern partsof the North Sea multiple XMT installa-tions – both horizontal and vertical –have been performed. An XMT or, “Xmastree”, controls the flow of oil or gas out ofthe well. In some cases a tree injects gasor water from another well into a non-producing well to stimulate oil production.

Inspector on the ocean floorTo replace hands and eyes on the

seabed, offshore operations employ so-called Remotely Operated Vehicles(ROVs), which are launched and retrievedfrom the ship. In fact, the Island Wellserverhas available the most advanced versionof an ROV: Heavy Work Class Vehicles(WROVs) are dependable inspectorseven in ultra deep water applications andare literally capable of using their“hands”. Measuring, fault detection, tooltransport or replacement and valve oper-ations are part of the WROV’s repertoire.

This highly specialized underwatertechnology conforms to quality normsabove the surface, too. The IslandWellserver has the class notation “DNVcomfort class”, which includes a set ofcriteria such as noise, vibration andindoor climate. For the 50 to 70 expertsper vessels involved in tasks in the North

Sea, value was placed on comfort inwell-equipped eating and leisure areas,etc. Still more, the ship was not onlyclassified by DNV, but also received thehighest comfort class ratings for some ofits fixtures and fittings. In terms of noiseand vibration levels, the Wellserver fulfilsthe same requirements as a cruise ship.

Island Offshore’s visit to ABB Turbo -charging: Common understanding

Some time ago, Alf Ove Sævik andKarsten Ola Klungsøyr, Island Offshore’sShip Managers, paid a visit to ABB Turbo-charging in Baden, where Sales ManagerScandinavia Truls-Magnus Lindseth andRegional Manager Thomas Knüsel re -ceived their Norwegian guests. They wereable to experience turbocharger produc-tion in Klingnau, which both Sævik undKlungsøyr found very impressive.

Island Offshore is well acquaintedwith ABB Turbocharging as a servicepartner in Norway – a cooperation whichhas run smoothly for years. “For us it’simportant to have short response timeand to fix problems quickly and reliably,”Sævik notes. “ABB Turbocharging hasproven to be a very good supplier.”

“With our Service Stations we areclose to our customers and close to their needs,” says Sales Manager Truls-Magnus Lindseth, who works in Oslo. Insaying this, he makes it clear that cus-tomers can also be regarded as col-leagues. “Above all, we have the com-mon goal of keeping the turbochargers intop condition; there is a common under-standing of the products and we com-municate well together,” he confirms.

Island Wellserver in figures

Deadweight 9,200 tons Cargo deck area (main) 1,050 m2

Max speed 14 knots Generator power 13,440 kW Length overall 116 mBreadth molded 25 m Depth to main deck 11.2 m Design draught 7.7 m Draught max 8.7 m Dynamic positioning DP-3

The Island Wellservercan sail relatively quicklyto the well and for certain operations needsno additional anchorhandling and supply vessels.

Thomas Knüsel (ABB Turbo Systems Ltd, Baden, Switzerland), Alf Ove Sævik and Karsten OlaKlungsøyr (Island Offshore), Truls-Magnus Lindseth (ABB Turbocharging in Scandinavia).

Year of delivery: 2008.

18 ABB charge! 1|14

Interview

Head of ABB Turbocharging’s Center of Excellence Oil & Gas Offshore, Joachim Bremer.

ABB charge! 1|14 19

Interview

Safety and reliability is the focusThe oil and gas offshore industry will continue to grow. Joachim Bremer, head of ABB Turbocharging’s Center of Excellence Oil & Gas Offshore and head of ABB Turbochargingin Scandinavia, understands what that means for business.Interview Tiziana Ossola Auf der Maur, Photography ABB Turbocharging in Scandinavia

What is the importance of the oil andgas offshore business to ABB Turbo -charging?

Oil and gas offshore is a stronglyexpanding segment within the marinemarket, driven by the world’s constantthirst for energy from depleting finiteresources. Currently, about 10 % of ourinstalled turbocharger population is run-ning on offshore vessels. However, thecurrent ship newbuilding order bookshows that about a third of recentlyordered vessels will be employed in the

oil and gas offshore segment, anddemand remains strong. Thus, the seg-ment’s importance will likewise continueto grow in terms of turbocharger newbusiness as well as service.

Tell us about ABB Turbocharging’soffering in oil and gas offshore?

The oil and gas offshore industry is aclose partnership of the marine sectorwith the petroleum industry, with a veryhigh focus on reliability, safety and riskminimization. This is a perfect match with

We do all we can in thevery early stages ofdesign to ensure that theturbocharger can beoperated safely at alltimes.

20 ABB charge! 1|14

Interview

ABB Turbocharging’s strengths and phi-losophy. Consider our long establishedand proven features, like containment(see page 9) and the safety design con-cept (SIKO). With these we do all we canin the very early stages of design toensure that the turbocharger can beoperated safely at all times and so that –in the worst case – no consequentialdamage arises. Or look at our unique,dense service network with dedicatedturbocharging professionals at literallyevery appropriate location in the world.All this supports our customers inachieving reliable, safe and efficient dailyoperation, so that they can focus on theirown businesses and serve their clientsas well as possible.

In addition, we also offer service tai-lored to customer’s needs. Being able toperform turbocharger service rapidly atvery short notice is vital for oil and gas

customers, who place the highest priorityon the availability of their ships. Underour “Swing Unit Concept”, customers getan exchange turbocharger and can goback to sea straightaway. While they areaway, their turbochargers are serviced.

Where is ABB Turbocharging repre-sented in the worldwide oil and gasindustry?

We are continuously optimizing ourglobal Service Station Network and now,for example, we are covering the coastaround Africa quite well. Additionally, weare planning to open soon a new ServiceStation in Tromsø in northern Norway, tobe close to our customers in that devel-oping region. Our extensive worldwidenetwork of more than 100 Service Sta-tions is absolutely fit-for-purpose for theglobal oil and gas offshore industry, be itin Brazil, the Gulf of Mexico, North Sea,Africa, South East Asia or Australia.

How is the oil and gas offshore busi-ness developing?

The new wells being discovered andbrought on stream these days are all inmore and more remote areas, in deeperand deeper waters and ever further fromthe nearest coastline. In these locationsthe industry works with floating produc-tion platforms instead of fixed installa-

Oil and gas customers place the highest priority on the availability of their ships. Being able to perform turbocharger service rapidly at very shortnotice is vital.

Service Station in Bergen, Norway.

Inside the Bergen Service Station: Engineer Giuseppe Manzo (left) with Joachim Bremer.

ABB charge! 1|14 21

Interview

Under our “Swing Unit Concept”, customers get anexchange turbocharger and can go back to seastraightaway. Meanwhile their turbochargers areserviced.

A good place to be

Joachim Bremer is head of ABB Turbocharging in Scandinavia. He hasbeen living in Oslo, Norway for twoyears. A mechanical engineer, he waspreviously General Manager BusinessDevelopment & Cooperations at HeadOffice in Baden.

The move to Norway was no prob-lem for Bremer. Norway offers a highquality of life. Bremer appreciates anumber of advantages that Norwayhas over Switzerland: “It’s wonderfulto go out fishing in a boat with friendson the Oslo fjord on a summerevening. Cod, sea trout, floundre andmackerel. The fjords are teeming withfish of different kinds.”

Norway is generally a great placeto live and work. “The people are veryopen, friendly and the work climate issimilar to Switzerland. What is specialhere in Norway is the high emphasison a good work-life balance, familyand gender equality.”

Bremer is head of ABB Turbo -charging in Scandinavia and ispresently establishing the new Centerof Excellence Oil & Gas Offshore. It is

Moved from Switzerland to Norway: Joachim Bremer, here in Bergen.

located at ABB Turbocharging in Nor-way due to the global leadership theNorwegian oil and gas industry clustersenjoy in terms of both the technology

used and their market status. He isinvolved with existing circumstancesand the future development of theindustry worldwide.

tions. This dictates a dedicated hightechnology infrastructure with a multi-plicity of ships with different functions.First you need ships for seismic explo-ration, then for drilling and finally thecomplete fleet required for floating pro-duction with storage and offloading.Then, supply vessels are needed to sup-port the facilities with the transport ofmaterials, crews, accommodation onsite, anchor handling etc.

And in Norway in particular?In the past few years new oil and gas

fields have been discovered in NorthernNorway, including the area up toward theBarents Sea. The business is moving further north. Whole towns and regions,like Tromsø, which were previously rathersleepy, are now starting to boom.

Keyword Arctic: How does activity indeep sea areas measure up in termsof safety and environmental protec-tion?

That is an important subject. Thewhole sector is under an obligation to actresponsibly. Indeed, to a great extent thisawareness exists. Both with the fieldoperators and the large oil companies,as well as with the shipping companiesthat provide the infrastructure and sus-tain day-to-day operations. All are doingtheir utmost to minimize risks. Quiterightly, standards for safety, quality, riskmanagement and environmental protec-tion here are as high as anywhere in theworld. Mishaps are in no-one’s interest.

22 ABB charge! 1|14

Service

Offshore in Brazil

The platform support vessel (PSV) CBO Arpoador, seen here off Copacabana, is designed for the flexible transportation of bulk and general cargo toBrazilian installations offshore. It was delivered in 2013.

ABB charge! 1|14 23

Service

ABB Turbocharging offers a range of products and services to the growing oil and gas offshore industry. High standards ofsafety are paramount in this sector.Text Francisco Lopes and Fabricia Morais, Photography CBO

24 ABB charge! 1|14

Service

The Brazilian oil and gas industryis going through a time of greatchange. The country, whichalready previously had a robust

infrastructure for exploration and pro-duction activities offshore, and led globalproduction of hydrocarbons in deep andultra-deep waters, significantly expandedits growth opportunities in 2007 withimportant oil discoveries in what is calledthe “pre-salt layer”.

“Pre-salt”, a geological term, is acluster structure lying below the salt lay-er that was formed later. The pre-salt islocated off the Brazilian coast, extendingfor 800 km. In certain coastal areas, thelayer can be as much as 2,000 metersthick. The distance between the surfaceof the sea and the oil reservoirs can beas much as 7,000 meters.

Petrobras, a Brazilian state companyresponsible for the oil and gas industry inBrazil, has formulated the ambitious goalof reaching the country’s new reservesand increasing its oil production by2020, especially in deep pre-salt layerwaters. This challenging project is havinga strong impact on the whole value chain of this particular business, such asexploration, underwater construction, oil

recovery, ship construction, platform sup-port, as well as on after-sales services.

Well-trained for Campos bay’s platformsABB Turbocharging is present in Brazil

with Service Stations in Santos, Rio deJaneiro and Manaus. In 2005, the RioService Station was inaugurated to serveBrazil’s oil and gas offshore market,strategically located to operate on Campos Bay’s main platforms, located300 km from the coast, and to serveBrazil’s largest ship repair and construc-tion yards. ABB Turbocharging’s expertsalso carry out offshore services all alongthe coast of Brazil, such as repair ormaintenance work on oil platforms andall kinds of supply vessel.

For this, ABB Turbocharging has setup a well-trained team of professionalsand qualified maintenance engineers,conversant with Petrobras’ high stan-dard of safety rules for offshore work.Periodically, every engineer has to com-plete a number of training programs,such as preparation for rescue and evac-uation out of helicopters and platforms,as well as health and safety techniquesand procedures. Annual health checks aremandatory. Marc Paredes, LBU-ManagerABB Turbocharging in Brazil, explains:“People working in potential hazardousoffshore environments require a stronghealth and a proactive safety culture.These qualities are highly requested,monitored closely and very strictly by oil

Since ABB integrated CBO’s turbocharger fleet into its maintenance programs, there have been nomore breakdowns.

Santos Rio de Janeiro

Manaus

A healthy, well trainedand safely acting profes-sional is also an efficientand well performing pro-fessional.

ABB Turbocharging Service Stations in Brazil.

ABB charge! 1|14 25

Service

and gas offshore companies. Every effortis made to prevent accidents that couldinjure people or damage the environmentand equipment. Safety, high quality andreliability are going hand in hand: Ahealthy, well trained and safely actingprofessional is also an efficient and well performing professional.” To illus-trate safety aspects offshore, Paredesgives a picture: “Offshore vessels oper-ate next to platforms. An engine failure ora turbocharger breakdown can causeproblems with the propulsion. Should thevessel no longer be maneuverable, itcould hit the platform and cause seriousdamage. Maximal safety minimizes allkind of risks.”

Fulfilling high expectationsAs said, safety, quality and reliability

go hand in hand. Quick response timesand locally available inventories help toavoid operational problems on site and

equipment downtime. Many oil and gasoffshore companies carry out audits inorder to guarantee the service company’squality standards and compliance withPetrobras’ high expectations. CompanhiaBrasileira de Offshore (CBO) is a maritimecompany specialized in the petroleumplatform support sector and is based in Rio de Janeiro. The CBO quality standards determine the choice of busi-ness partnerships. CBO selected ABBTurbocharging as the preferred partnerfor turbocharging, delegating the mainte-nance, repair and overhaul of turbo -charging equipment to ABB. With suc-cess, since ABB integrated CBO’s turbocharger fleet into its preventive andpredictive maintenance programs, theequipment has not caused any problemswhatsoever. There have been no morebreakdowns.

For Paulo Conte, Operations andMaintenance Director at CBO, these are

the aspects that make all the difference:the guarantee that comes with purchas-ing high quality products with immediateavailability, service quality from systemimplementation to maintenance of theentire turbocharger fleet and the avail-ability of round-the-clock service withrapid response times. Currently, thecompany is committed to modernizingits fleet in order to adapt to the morecomplex operations in the oil and gas off-shore business. In just the last half year,the CBO vessel fleet equipped with ABBturbochargers increased from 20 to 23.

As Marc Paredes emphasizes, “ABBTurbocharging has many years of experi-ence working with oil and gas offshorebusinesses in Brazil. We are committedto delivering quality in both our productsand services. But that’s not all. ABB Turbocharging is one hundred percentresponsible for safety. That goes for everyprofessional in every operation.”

The overall engagement is recognizedand acknowledged. Only a few weeks agoCBO demonstrated its complete satisfac-tion by certifying ABB’s compliance withcentral aspects that every business activ-ity in the oil and gas offshore demands:“Security, environment and health”.

In just the last half year, the CBO vessel fleetequipped with ABB turbochargers increased from 20 to 23.

CBO Flamengo, delivered in 2012. Ship type: Platform supply vessel (PSV).

26 ABB charge! 1|14

Applications

First choice for maritime trainingThe Dalian Maritime University in China is acquiring a freighteras a training ship for master marine engineers, prospective maritime instructors and superintendents. It chooses turbo -chargers from ABB. “We are fired up about this project,” saysMarkus Kohling, the ABB Turbocharging manager responsible.

Text Tiziana Ossola Auf der Maur, Photography DMU

The pleasure was mutual. Highranking representatives of theDalian Maritime University (DMU)recently welcomed ABB Turbo -

charging Vice President Axel Kettmann,Senior Global Project Manager MarkusKohling und Sales Manager Andy-Cong

Chen to Dalian, to prepare a plannedcooperation between the two partnersand to confirm their common interests.

This year DMU ordered a 30,000 dwtmulti-purpose heavy-lift vessel with11,000 kW of engine power and all thatthat involves. It is ocean-going and can

11,000 kW of engine power with A165 turbochargers from ABB: Visualization of the planned training ship.

do everything a conventional merchantvessel can do. It is suitable for the trans-port of dry bulk cargo like grain, salt,sugar, metals and mineral ores, but alsocommercial vehicles and yachts.

The owners are going for the highestquality: The components are all state-of-

ABB charge! 1|14 27

Applications

the-art and the suppliers hand-picked.ABB Turbocharging is the preferred busi-ness partner for turbochargers on themain engine, a Wärtsilä 6RT-flex58T-Dtwo-stroke diesel. Two type A165-L34turbochargers are due to be delivered at the beginning of 2015 for the two-stroke engine from ABB Turbocharging’sChinese joint venture ABB Jiangjin TurboSystems Co., Ltd.

For the bestA 200 meter freighter with the latest

marine technology and providing realworking conditions instead of simulatorsand lecture theatres: Which place of further education can offer its studentsthis? With around 20,000 students DMU,on the East China Sea, is one of thelargest specialist marine universities inChina. It is a maritime institution underthe Ministry of Transport of the People’sRepublic of China. Its tradition as anacademy for education and training inthe area of shipbuilding and shippinggoes back to the 1920s. And in all thattime, the DMU has always enjoyed a highnational and international reputation as acenter of excellence.

That this university should be endowedwith such a considerable investment isindicative of the importance that Chinaattaches to its maritime industries. Thecountry needs well educated personneland consequently the availability of a

high quality educational system. Anyonewho has been chosen to complete several weeks of training on the shipbelongs to the best. These are the master students who will later becometeachers and instructors at the DMU, as well as the future superintendents ofthe Chinese marine industry. The coursesencompass traffic engineering, naviga-tion and mechanical engineering. Thevessel will also be equipped for scientificresearch in these subjects.

Trained by ABBA further education project of these

dimensions is unique on both a nationaland international scale. “The projectcaptured our imagination from the start,”says ABB Turbocharging Senior GlobalProject Manager Markus Kohling suc-cinctly. “The fact that the DMU authori-ties, who are themselves engineeringexperts, selected our products has a historical background. We are recog-nized as world leaders in engine turbo -charging, with a vast fund of knowledgeand experience,” Kohling stresses. From2015, the elite of the DMU will grow upwith turbocharging technology fromABB. “This is an honor and a privilege.”Because what one learns as a studentleaves its mark, as every mechanicalengineer knows from personal expe-rience.

The academic resources that theDMU can boast, so close to industrialreality with its whole value chain, issomething Kohling could only havedreamt of as a student. The graduate of atechnical university recalls: “I only saw fullyequipped test stands like that used forthe students at the DMU after my studieswhen I started my first job – as a matterof fact at ABB Turbo Systems Ltd.” Forhis diploma thesis on theoretical aero-dynamics, Kohling had to buy himself a20 MB hard disk computer from his ownpocket, and in those days they cost farmore, MB for MB, than they do today.

In the course of the delivery of the turbochargers, ABB Turbocharging willinstruct the DMU lecturers so that theyare capable of giving tuition aboard ship.It was also discussed whether expertsfrom ABB Turbocharging should lectureon turbocharging as guest tutors. “ABBTurbocharging is open to proposals,”says Kohling. “There are certainly manyof us who would like to swap an officejob for a job in a lecture theatre on atraining ship for a day or two.”

The training ship in figures

Deadweight 30,000 tonsLength, overall 199.80 m Beam molded 27.80 m Depth molded 15.50 m Design draft molded 10.30 m Crew 31 persons Cadets 8 persons Teachers and instructors 6 persons Students /engineers / 90 persons superintendents

From left: Professor Zhang Chunlai (Project Manager DMU), Andy-Cong Chen (ABB Turbocharging inChina), Markus Kohling and Axel Kettmann (ABB Turbo Systems Ltd, Baden, Switzerland), ProfessorZhang Cunyou (Project Manager DMU).

The owners go for the highest quality: the components are allstate-of-the-art, the suppliers hand-picked.

28 ABB charge! 1|14

Tips for the operator

Engine operators around theworld have seen their operatingcosts increase significantly overthe past decade, and mainly

due to the escalating price of fuel. Hence,operators are always looking for ways tomeet these new challenges. As a conse-quence of this market trend and to sup-port its customers, ABB has developeddifferent turbocharger upgrade pack-ages providing added value for our cus-tomers by reducing the operating costs.

How does it work?As a technology leader, ABB Turbo -

charging is continuously developing newcomponents and technologies to furtherimprove the capabilities of its turbo -charging systems.

The implementation of these develop-ments into existing turbocharger plat-forms running in the field is an attractiveoption from which customers can benefit.The available solutions are as versatile asour customers’ expectations.

As an example, application engineersat ABB have run computer simulations to evaluate the use of a new, high effi-ciency compressor stage in existing turbochargers, this having turned out tobe the most promising option. The simu-lation revealed a potential fuel saving of about 1%. After the design and manu-facture of the parts to be modified, thesewere installed during regular maintenanceof the turbocharger in order to carry outa field test. The proximate measurementseven slightly exceeded the expectedreduction in fuel consumption.

Taking into consideration that theannual fuel costs for large diesel enginescan easily reach tens of millions of dol-lars, a saving of 1% reflects a significantamount of money.

As a secondary effect, the exhaustgas temperature level dropped about40 °C after the installation of the new,high efficiency compressor stage, also inline with the computer simulations. Thiswill have a positive impact on the lifetimeof all components affected by the hotexhaust gases and further contribute toa reduction in the operating costs.

The above mentioned upgrade is justone example of a range of solutions ABB can provide. To reach the optimum

in a given situation a tailor-made solutionis essential, and only a technology leaderlike ABB Turbocharging can provide it.The following optimizations give an ideahow an upgrade could have a positiveeffect on your operation. – Reduction in fuel consumption.– Longer time between overhauls (TBO).– Increased efficiency stability.– Reduced thermal loading of compo-

nents.– Resolution of operational restrictions.– Competiveness of installation main-

tained.– Spare part availability.– Emissions (e.g. NOx ) reduction.

Developing to benefit the customer Upgrades: Tailor made solutions significantly improve a turbocharger’s capabilities. Fuel saving is just one positive effect.

Text Axel Martin, Photography Michael Reinhard

TPL-A turbocharger with components for a compressor stage upgrade highlighted.

ABB charge! 1|14 29

Tips for the operator

The best upgrade solution needs tobe determined case by case. Duringmeetings with the customer, ABB Turbo -charging collects the information relevantfor selecting the most promising solutionfor an individual installation.

In all cases, the engine and turbo -charger need to fit together well. In manycases, to achieve the maximum opera-tional benefits it is essential to cross the borders of the turbocharger and toinvolve the engine builder as the special-ist for the complete system.

Upgrade levelsWhen talking about upgrades, ABB

Turbocharging differentiates between dif-ferent execution levels:– Exchange single turbocharger compo-

nents.– Exchange the complete turbocharger

by a similar or technically optimizedversion.

– Replace with a completely new turbo -charger (identical outline dimensions).

– Replace with a completely new turbo -charger (different outline dimensions).

The easiest way is to exchange singlecomponents of an existing turbocharger.Usually, these modifications can be doneduring a normal overhaul of the turbo -charger without additional engine down-time.

Alternatively, an existing turbochargercan be replaced by a new unit featuringdifferent properties such as higher effi-ciency compressor stages or turbinestage, or components with special coat-ings. If the outer dimensions and connect-ing positions are similar the adaptation iseasy; otherwise new adapter parts areneeded to connect the new turbocharger.

Considering the costs, pay-back timesof three years or less are realistic, and if such upgrades are conducted at thetime of an exchange of the rotating com-ponents, the additional upgrade costsare minor.

Axel Martin graduated as a mechani-cal engineer at the University ofApplied Sciences in Konstanz, Ger-many. 2005 he completed his studiesin Konstanz with a master’s degree inmechanical engineering and interna-tional sales management. Axel Martinjoined the engineering department ofABB Turbocharging in 2003. Today heis Team Manager Technical Service.

Turbocharger inlet temperature, impact ofupgrades.

50 60 70 80 90 100

[° C]

600

580

560

540

520

500

480

460

[%]

Turb

ocha

rger

inle

t te

mp

erat

ure

Engine load

Today’s setup

Upgrade number 1

Upgrade number 2

Specific fuel oil consumption, impact ofupgrades.

50 60 70 80 90 100

Sp

ecifi

c fu

el o

il co

nsum

ptio

n

Engine load

Today’s setup

Upgrade number 1

Upgrade number 2

[%]

2 g/kWh

Please get in touch!

Is there any Tip for the Operator youwould like to see covered on thispage? If there is a particular difficultyyou have faced lately and managedto solve, please share your fieldexperience with other operators.Contact us and tell us about yourturbocharger technical concerns atcharge@ch.abb.com.

30 ABB charge! 1|14

Recipe

The western world knows manyclassic desserts based onberries, cream and vanilla. Theyare tastes which ideally com-

plement each other. In Norway, this com-bination is the perfect basis for the muchloved Bløtkake, meaning “soft or wetcake”. On Norway Constitution Day Syttende Mai (May 17) as well as onbirthdays or at weddings, the airy, creamycake forms a culinary backdrop in theshape of a gateau. In our suggestedrecipe, it consists of layers of spongecake separated by a light vanilla filling,with the cake, in this case, wrapped in

whipped cream. The fresh berries areused as a decorative topping and are areal eye-catcher.

Norway is not only rich in mineralresources; it also has a fantastic berryseason. Nature’s bounty includes straw-berries, raspberries and blueberries. Spe-cial mention should be given to Norway’smuch loved cloudberries, which we rec-ommend picking yourself from bushesgrowing wild.

If you prefer to carry your basket to the supermarket instead, no problem:Bløtkake can be made to your personaltaste. You simply use the berries you pre-

fer and that are available. Those who livein Europe or North America have the goodfortune of being able to obtain native vari-eties in the coming weeks and months.

Strawberries foreverBerries are always a treat. You would

hardly believe it, fine and delicate as theyare, but berries truly explode with nutri-ents. In 100 grams of strawberries thereis enough vitamin C, potassium, magne-sium und calcium for one person for awhole day. Folic acid and iron also makethem healthy eating for expectant mothers.They are even said to be an aphrodisiac.

Harmony in the shape of a cakeBerries harmonize wonderfully with cream and vanilla. The Norwegians have enshrined this idea in a classic dessert:Bløtkake. This is the international feel-good-recipe No. 8, to be first eaten with the eyes.

Text Tiziana Ossola Auf der Maur, Photography Roger Hardy /Samfoto

ABB charge! 1|14 31

Acknowledgments

Published byABB Turbo Systems Ltd

AddressP.O. BoxCH-5401 Baden/SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144www.abb.com/turbocharginge-mail: charge@ch.abb.com

EditorTiziana Ossola Auf der Maur

PhotosMichael ReinhardiStockphotoABB Turbo Systems LtdCBOABB Turbocharging in ScandinaviaIsland OffshoreDMURoger Hardy /Samfoto

Cover photo: Corbis

PrinterDietschi Print & Design AG, Olten /Switzerland

Layout, typography, electronic publishingDomino Style & Type AG, Gebenstorf /Switzerland

Reprints require the publisher’s written consent.

© 2014 ABB Turbo Systems Ltd, Baden /SwitzerlandAll rights reserved

NorwegianBløtkake

Ingredients1 vanilla sponge cake, sliced

horizontally (one or more times)4 eggs, at room temperature 225 g sugar 140 g plain flour*1 tsp. baking powder*1 tsp. vanilla extract250 g cream, whipped500 g raspberries and blueberries

(or berries to your personaltaste), washed

(*Or 140 g self-raising flour)

Preparation1. Preheat the oven to 175 °C. 2. Line the bottom of a 23 cm

round spring-form pan withbaking paper and smear withbutter.

3. Beat the eggs in a large bowlwith an electric mixer untilfrothy. Raise the speed onyour mixer to high, and addthe sugar gradually, beatinguntil thick and lemon-colored.

4. Using a separate bowl, stirtogether the flour and bakingpowder. Reduce the speed ofthe mixer to low and slowlyadd the flour to the whippedeggs, mixing until just blended.Finally, blend in the vanilla.

5. Pour the mix into the preparedpan, spreading it out to theedges and bake for 25 – 30minutes, until lightly golden.Check if cooked through witha toothpick – the center of thecake should bounce backwhen touched. Remove thecake from the pan and cool ona wire rack before slicing it.

6. Decorate the top with thewhipped cream using an icingbag.

7. Add the berries as shown inthe picture or to your own pattern.

Valve Control Management. Go from idling to fullload twice as fast.

Want to know what it takes? Valve Control Management (VCM®) is intelligent turbocharging that responds adaptively to change valve timing so that your enginealways has the ideal air-to-fuel ratio. And since VCM increases engine efficiency by optimizing engine configuration for every type of load, it can take an engine fromidling to full load twice as fast as it normally takes – in some cases even more quickly. The resulting lower thermal load and exhaust gas temperature will also makeyour equipment more reliable and durable and reduce pollution at the same time. www.abb.com/turbocharging