Tips for the operator Developing to benefit the …...Fuel saving is just one positive effect. Text...

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28 ABB charge! 1|14 Tips for the operator E ngine operators around the world have seen their operating costs increase significantly over the past decade, and mainly due to the escalating price of fuel. Hence, operators are always looking for ways to meet these new challenges. As a conse- quence of this market trend and to sup- port its customers, ABB has developed different 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 new components and technologies to further improve the capabilities of its turbo- charging systems. The implementation of these develop- ments into existing turbocharger plat- forms running in the field is an attractive option from which customers can benefit. The available solutions are as versatile as our customers’ expectations. As an example, application engineers at ABB have run computer simulations to evaluate the use of a new, high effi- ciency compressor stage in existing turbochargers, this having turned out to be 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, these were installed during regular maintenance of the turbocharger in order to carry out a field test. The proximate measurements even slightly exceeded the expected reduction in fuel consumption. Taking into consideration that the annual fuel costs for large diesel engines can easily reach tens of millions of dol- lars, a saving of 1% reflects a significant amount of money. As a secondary effect, the exhaust gas temperature level dropped about 40 °C after the installation of the new, high efficiency compressor stage, also in line with the computer simulations. This will have a positive impact on the lifetime of all components affected by the hot exhaust gases and further contribute to a reduction in the operating costs. The above mentioned upgrade is just one example of a range of solutions ABB can provide. To reach the optimum in a given situation a tailor-made solution is essential, and only a technology leader like ABB Turbocharging can provide it. The following optimizations give an idea how an upgrade could have a positive effect 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. NO x ) 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.

Transcript of Tips for the operator Developing to benefit the …...Fuel saving is just one positive effect. Text...

Page 1: Tips for the operator Developing to benefit the …...Fuel saving is just one positive effect. Text Axel Martin, Photography Michael Reinhard TPL-A turbocharger with components for

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.

Page 2: Tips for the operator Developing to benefit the …...Fuel saving is just one positive effect. Text Axel Martin, Photography Michael Reinhard TPL-A turbocharger with components for

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.

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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 [email protected].