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GENOA SHIPPING WEEK, 29 GIUGNO 2017

Turbocharger upgradeThe efficiency booster

Alberto Pochiero, Regional Technical Manager, South East Mediterranean

—ABB Turbocharging

June 28, 2017 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

June 28, 2017 Slide 3

Local Business Unit: Italy

59 employees

25 service engineers

Please contact:giorgio.rolando@it.abb.com

> 1.450 service jobs per year

Venice

Rijeka

Naples

Malta

Genoa30

11

5

8

5

—Engine operation

June 28, 2017 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

Eng

ine

Effi

cien

cy [

%]

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

June 28, 2017 Slide 5

ABB Turbocharging’s journey

—Upgrade Definition

June 28, 2017 Slide 6

+ Modification of Engine

(e.g. Miller timing)

Conventional EfficiencyTurbocharger

High EfficiencyTurbocharger

—Turbocharger Upgrade

June 28, 2017 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

June 28, 2017 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

June 28, 2017 Slide 9

TPL77-A30 to TPL77-A32

—Upgrade benefits

June 28, 2017 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

0.75

0.90

Compressor pressure ratio

Co

mp

ress

or

effi

cien

cy

TPL77-A32

TPL77-A30

Higher πC

Higher efficiencies

—Upgrade benefits

June 28, 2017 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

June 28, 2017 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

June 28, 2017 Slide 13

Turbine inlet and outlet temperature

50 °C

—Results

June 28, 2017 Slide 14

Specific Fuel Oil Consumption

5 g/kWh

—Pictures at site

June 28, 2017 Slide 15

Nozzle Ring Cartridge Turbine Compressor Wheel

Withdrawn originally installed parts

—Pictures at site

June 28, 2017 Slide 16

Turbine diffuser and Nozzle Ring

Cartridge Cartridge Air Side Compressor Casing with air diffuser

New installed parts

—

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

June 29, 2017 Slide 17