Part Sales & Technical Service Team

DOOSAN TC Cut Out System

Rev. 0

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Reducing Fuel oil consumption & Exhaust emissions

TURBOCHARGER CUT OUT SYSTEM

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Contents

1. Why Turbocharger cut out ?

2. Benefits

3. Concept of Turbocharger cut out

4. How to retrofit ?

5. Approval of document after Turbocharger cut out

6. Service Experience

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1. Why Turbocharger cut out ?

1)Purpose of T/C Cut out system

Reduce fuel oil consumption

Reduce exhaust emission

Optimize cargo capacity in fleet

Due to the current economical crisis, it is noticed that some ship-owners, have large

container vessels, are considering operating their vessels with slow speed in order to

reduce main-engine fuel consumption.

To meet this growing demand, turbocharger cut out system has been introduced to

Improve engine performance during low-load operation.

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1. Why Turbocharger cut out ?

Fig.1 shows the relation between power

and speed for a typical modern large post

panamax container vessel.

According to Fig.1 reducing the ship speed

by e.g. 4knots reduces the power requirement

to some 50%.

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Ship speed

knot25242322212019

Relative propulsion power needed

120

%

110

100

90

80

70

60

50

40

18

30

Relative propulsion power needed

25 knots refer to 100%

relative propulsion power

Fig.1 Ship speed

2) Relations between Ship speed and Power

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1. Why Turbocharger cut out ?

3) Technical considerations of ship power reduction !

Operating at low speed in the 30-50% load area can create problems.

Depositing of soot particles in exhaust gas boiler

Build up of soot in turbocharger

Frequently cut in/out of auxiliary blowers

Increased heat load on components

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2. Benefits

1) Benefits of T/C Cut out

Turbocharger cut out will improve scavenge air pressure during low load operation

Improve specific fuel oil consumption

Reduce the heat load on engine components

2) Compare with other methods

Method Advantage Disadvantage

1. Choose a less powerful engine Cheaper initial investment Limits speed for entire ship life

2. Derate a new engine Significant SFOC reduction Typically limits speed for entire ship

life

3. Increase scavenge air

pressure at low load

(Method of TC CUT OUT)

Improve SFOC and reduce heat load on

components in the 30-50% load area

Major modification with regard to

IMO regulations

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2. Benefits

Fig. 2 SFOC versus Engine load

Approx. 5g/kwh reduction of SFOC and 0.33bar increase in scavenge air

pressure at 50% power. (1 T/C cut-out of 4 T/Cs)

Approx. 3g/kwh reduction of SFOC and 0.40bar increase in scavenge air

pressure at 75% power. (1 T/C cut-out of 4 T/Cs)

Engines with four turbochargers and one turbocharger cut-out enables

operation at loads from 20% to 70% MCR :

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2. Benefits

Fig. 2 SFOC versus Engine load

An SFOC reduction of 1 to 3g/kwh in the power range of 25 to 35% can be

expected.

Engines with two turbochargers and one turbocharger cut-out enables

operation at loads from 10% to 35% MCR :

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3. Concept of Turbocharger cut out

swing gate valve

Case of operation :

Possible to operate the TC Cut Out System at

ECR (Engine Control Room) and Local side.

Treatment of rotor shaft :

Remain unchanged

Sealing air line of T/C should be modified

Caution :

It is necessary to supply lub oil for cooling of

journal part of rotor (T-side).

Supplying sealing air from turbocharger in

operation is required. T/C Cut out valve

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3. Concept of Turbocharger cut out

Treatment

of

each flange

Gas inlet Turbine side valve

Air outlet Compressor side valve

Gas outlet No change

LO inlet No change

LO outlet No change

Air vent No change

Sealing air Necessary to be supplied

By T/C modification

Treatment of each flange

Scavenging air receiver

Cooler

Exhaust gas receiver

Cooler Cooler

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4. How to retrofit ?

1) Installation procedure of turbine side valve

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4. How to retrofit ?

1) Installation procedure of turbine side valve (Continue…)

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4. How to retrofit ?

2) Installation procedure of compressor side valve

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4. How to retrofit ?

2) Installation procedure of compressor side valve (Continue…)

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4. How to retrofit ?

2) Installation procedure of compressor side valve (Continue…)

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4. How to retrofit ?

3) Installation of Main Control Panel

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4. How to retrofit ?

4) Installation of local control panel and modify main air valve

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4. How to retrofit ? (MET & ABB TC only)

4) Install and modify T/C sealing air line

Fig. 5 Modify oil labyrinth

Fig. 6 Modify supporter

In case of MHI turbocharger

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5. Approval of document for applying T/C Cut Out System

1) In case of turbocharger cut off, it is considered as a major conversion in

accordance with Reg.13(2)(a) of MARPOL Annex Ⅵ.

2) Therefore the engine shall be carried out NOx emission test to ensure that

it still complies with the NOx emission limits contained in Reg.13 of MARPOL

Annex Ⅵ.

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6. Service Experience

■ Installed swing gate valve - Engine : Doosan MAN-B&W 12K98MC-C (T/C type : MET83MA x 4 sets)

- Test date : 2010.12.20 ( Sea trial )

15.86g/kwh reduction of SFOC at 50% load

* Need to go further for long term measurements

[Normal mode] [T/C Cut Out Mode]

* Yearly operating hours: 7,000 hrs

Reduction 4,085 ton/year

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6. Service Experience

As of JAN 2013

ENG.TYPE

T/C type

Owner

TOTAL

Remark

12K98ME-C MET83 x 4sets CSCL 2 MDT Type

12K98MC-C MET83 x 4sets CSCL 8 MDT Type

10K98MC-C MET83 x 3sets PIL 1 MDT Type

8K90MC-C MET66 x 3sets PIL 8 MDT Type

8K90MC-C TCA77 x 3set PIL 7 MDT Type

8K90MC-C TPL85-B15 x 2set YANG MING 2 MDT Type

8K90MC-C TCA77 x 3set ZIM 1 Doosan Type

TOTAL 29

Reference List of T/C cut out

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