Test results on an engine show 2% efficiency gain, “raising industry standards”
Exceeding an industry efficiency benchmark and launching digital solutions that enhance performance and deliver cost savings reflects a commitment by ABB Turbocharging to consistently deliver value for customers, the company told Worldwide Turbocharger Guide.
Based on the MAN Diesel & Turbo efficiency benchmark, ABB Turbocharging said it had raised industry standards for low-speed turbocharging efficiency with an additional 2% increase, measured on a low-speed test bed engine at a Hyundai facility in South Korea. The efficiency of three of the latest generation ABB A180-L turbochargers was measured, fitted to a MAN-designed 8G95ME-C9.5 engine. Hyundai had manufactured the turbochargers under licence and measurements were recorded using the latest wireless technology equipment to ensure highest data accuracy.
This 2% efficiency increase figure now offers the potential for annual fuel savings of up to US$35,000 per vessel for operators, depending on fuel price and load profile, ABB predicted. Announcing the achievement, ABB Turbocharging senior general manager, Product Group Low Speed, Arie Smits, described that measurement on an actual engine as “confirmation of our promise and commitment to continue to push for highest efficiencies and value for our customers.”
ABB A100-L series single-stage turbocharger products are specifically designed for low-speed two stroke engine applications. With high efficiencies and pressure ratios, they also feature wide compressor maps for maximum operational flexibility. The smallest A100-L product starts the series, from a capacity of below 10 m3/s with the largest A190-L capable of exceeding 50m3/s. The new efficiency record was set at well over 75% load and at higher charge pressures, with compressor pressure ratios of up to 5.0:1.
Complementing the 100-L range, ABB Turbocharging has introduced its latest A200-L products. Sharing many common features, this newest generation of turbochargers for low-speed engines includes an advanced design compressor that delivers 30% more volume flow for its size and a significantly improved power-to-weight ratio. A further advantage, ABB said, is that costs of some spare parts are proportionally reduced, with potential savings of up to 25% for operators.
ABB’s engineers have developed the A200-L to meet the requirements of the latest generations of low-speed two-stroke engines, operating on both diesel and gas fuels. They have been able to provide the same high pressure ratios and efficiency levels but within a smaller and lighter envelope that requires reduced installation space on engines.
To further enhance efficiencies, A100-L and A200-L turbocharger operation can be combined with ABB’s high-pressure tuning (HPT) technology. HPT is suitable for electronically controlled two-stroke engines, fitted with high-pressure turbochargers when operating at lower loads. A more regular practice might be to include exhaust gas bypass or variable turbine geometry systems, ABB noted, saying that HPT reduces the need for these features and delivers improvements by delaying the closure of the exhaust valves, compared with conventional timing. Scavenging air pressure is increased, resulting in higher peak firing pressures and greater efficiencies, with a simple and reliable tuning and turbocharging arrangement.
In a further development, ABB has now launched its Flexible Integrated Turbocharging System for Two-Stroke Engines (FiTS2). This provides marine operators with the flexibility for vessels to run at high loads without cost penalties while still enabling fuel savings at part- and low-load, with rapid return to full engine output levels when required.
The sequential turbocharging system enables fuel savings of up to 6 g/kWh (3-5%) compared with fuel consumption levels typically achievable with conventional turbocharging systems on low-speed diesel engines, ABB reported. Depending on the price of fuel and the load profile to be met by the engine, fuel savings over 10 years can amount to US$0.5M for a VLCC and well over US$1M for a container vessel, the company predicted.
In addition to the A100-L and A200-L products, which are available for engine powers of up to 30,000 kW per turbocharger, ABB Turbocharging offers TPL-B and VTR series products for low-speed two-stroke applications. The TPL-B is available in five frame sizes covering engine outputs from 3,000 kW to 28,000 kW per turbocharger. The design is described as simple and modular and the products can deliver pressure ratios of up to 4.5:1.
Part count is minimised to enable easy maintenance and low lifecycle costs. VTR products, which are also suitable for four stroke medium speed heavy-duty diesel engines, are available in a power range from 700-18,500 kW per turbocharger.
For medium speed engines, the ABB Turbocharging portfolio includes A100-M products for marine and stationary applications, with power output from 500-6,000 kW per turbocharger. Pressure ratios can be as high as 5.8:1 and turbocharging efficiencies can exceed 60%. The products feature exceptionally wide compressor maps, the company said.
For diesel and gas engines in the power range of 2,500 kW to 12,500 kW, TPL-A and TPC-C products are available. These turbochargers are of rugged construction and are designed for long service with low running costs. TPS and VTC products are available for lower power engines, typically of up to 3,000 kW per turbocharger. The MXP turbocharger, ABB’s first dedicated turbocharger designed specifically for small-bore medium-speed marine auxiliary diesel engines of up to 2MW power output, is included in the portfolio.
For demanding medium speed applications, ABB offers the Power2 two-stage turbocharging system. It is the most potent power booster for four-stroke engines, as well as being the most compact two-stage turbocharging system of its kind. High pressure ratios up to 12:1 and turbocharging efficiency boost engine power density and save 10 g/kWh of fuel, for six-figure savings in annual fuel costs, ABB said. NOx emissions are also reduced by up to 60% and an optimised layout results in a 20% smaller footprint and an extractable cartridge reduces overhaul time by 30%, it said.
ABB Turbocharging also offers products for high speed engines, including the A100-H, which is suitable for duties including marine power generation in the power range of 500-6,000 kW. For duties up to 3,300 kW, TPS-D/E and TPS-F turbochargers are available.
Digital solutions ‘can save time and money’
ABB Turbocharging launched its first digital solutions for enhanced performance, operational flexibility and lower operating costs for marine customers at the Marintec China exhibition in December 2017. Fleet operators can save time and money with ABB’s Tekomar Xpert, the company said, which incorporates engine performance analytical software that evaluates deviations and quantifies potential fuel oil savings for any two-stroke diesel main engines on marine vessels. Advanced diagnostics, combined with intelligence, allow ship operators to immediately focus on optimising operations, rather than initially spending many hours on its analysis.
ABB Turbo Systems acquired Tekomar Group in 2017 and has since upgraded Tekomar Xpert to its 2.0 version. The new software version enhances efficiencies, especially for fleet managers, with connectivity as a key benefit, the company said, as the software integrates with almost any onboard platform. The software also provides a platform on which engine licensors and builders can work in cooperation.
ABB Ability is ABB’s unified, cross-industry digital offering with devices, systems, solutions and services, and is a platform which assists customers to increase productivity and lower costs. Looking ahead, ABB plans to integrate Xpert further into ABB Ability, which it said will enable ship management companies to understand more about vessel operations and achieve better business performance from their fleets.
ABB Turbocharging has also extended its ‘Sicherheitskonzept’ (‘Safety Concept', or ‘SIKO’) to create ABB Ability Digital SIKO. This provides “a paradigm shift towards predictive maintenance”, ABB said, by following a data-driven assessment approach that considers the real conditions under which the turbocharger rotor is operating. Digital SIKO offers operators and owners a unique level of reliability and lifecycle cost management, the company advised, saying that, like the traditional SIKO – which is still available and valid – “Digital SIKO ensures the reliability and safety of ABB turbochargers.”