title of presentation - on the mos way · 2015-12-28 · man diesel & turbo man turbocharger...

1< >MAN Diesel & Turbo Sephardim Koblenz Turbocharger Evolution - Athens 22.10.2015MAN Turbocharger

Turbocharger Evolution

Turbocharger Solutions for System Optimization

George Drossos


80 Years Experience in Turbocharging!MAN Turbocharger

MAN Diesel & Turbo Germany

PBS Turbo Czech Republic

MAN Diesel & TurboTurbocharger Plant Changzhou, China

STX HIKorea

Kawasaki Japan

Mitsui Japan


Turbocharger Portfolio

TCATCR

Engine Outputs up to 30.000 kW / Engine

Max press. ratio 5.5

> 6.500 References

TCR

TCA

7 sizes (TCR10 – TCR22)

Suitable for HFO, MDO, GAS

Modular design concept

6 sizes (TCA33 – TCA88)

Over 70 million accumulated operating hours

Suitable for HFO, MDO, GAS

Biggest 4-Stroke TC in the world

> 7.000 References


Operations, Repairs and MaintenanceContribution through…

Maintenance out of

one hand

Optimized

maintenance

schedules

Easy maintenanceOpen maintenance

system

Parts exchange on

condition basis

Wide Service

Network

Training and

Qualification

Well proven

Turbochargers

Reduced costs and

maximum flexibility

http://primeserv.man.eu/hotline-overview



Optimized Maintenance ScheduleIntermediate Inspection for TCA 2-stroke Turbocharger / CUS333

After…

10 years of experience

much more then 5.500 sold units

and millions of operating hours

we cancelled the 12.000 OH bearing

inspection.

Saving you time and money with full

reliability!

(Already standard for TCRxx-2x)

Reduction for manpower by 33%

Dry Dock to Dry Dock


Service ExperienceM/T OCEAN DESTINY 6S50MC

TCA66 29422 OH

Shroud ring reused

Bearings reused

Sealing Covers reused

Labyrinths reused

Also Turbine, Compressor and Nozzle ring reused


Service ExperienceM/T GSW FORWARD 6L35MC Mk6

TCR22 26760 OH

T/S Bearing reused

C/S Bearing replaced

Nozzle ring reused

Also Turbine, Compressor

CBM

lifetime may exceed

the projected values.


Condition-Based MaitenanceAging of Impeller / Thermal Aging

Theoretical average life time of a

compressor wheel is 80.000 OH.

Actual life time is depending on the

operating conditions!

When reaching 80.000 OH, a

compressor wheel has to be

checked.

If material parameters are still good

the CW can be kept on using.The life time evaluation of compressor

wheels is a long term project.


Non-Distructive Measurement MeasureAging of Impeller

p1 p2 p3 p4 p5 p6 p7 p8 p9 p10 p11 p12

Σειρά1 42 42,3 42,3 41,8 41,9 42,1 42,3 41,8 41,9 42,1 42,2 42,2

41,5

41,6

41,7

41,8

41,9

42

42,1

42,2

42,3

42,4

co

nd

ucti

vit

yin

%IA

CS

(f

=60kH

z)

Conductivity (NA57-38237)

P1

P2

P4

P3

P5

P6

P7 P8 P9 P10 P11 P12

The life time evaluation is based on the

relation between electrical conductivity

and material hardness

MV Buxsailor

NA57

>107.000 OH still in

good condition, reused


Open and Easy MaintenanceSuper Bolt

Present design / Variant 4+Compressor wheel exchange

with standard tools

For MDT TCA no special tools needed!

Crew can work on turbocharger without

restrictions!


Piraeus

ShanghaiFort Lauderdale

Busan

Rio de Janeiro

Academy & TC Service Hub

Turbocharger Service Hub

Service Network Worldwide24/7 and Training

Saint-Nazaire

Augsburg

Frederikshavn

Copenhagen

Holeby




Exchange of ideas…

Is the turbocharger influencing the

engine’s performance?


150,0

152,0

154,0

156,0

158,0

160,0

162,0

164,0

166,0

10095908580757065605550454035

SFOC High Load Tuned [g/kWh]

Tuning Methods High, Part and Low Load

Tuning Comparison on basis of CEAS data.

6G50ME-C9.5

SMCR: 6120kW @ 79rpm

ISO conditions

Potential savings up to

5 g/kWh

Potential penalty up to

3 g/kWh

EEDI Measurement

VTAVariable Turbine Area

EGBExhaust Gas Bypass

Standard Tuning

HPTHigh Pressure Tuning

Part

-and L

ow

Load

Hig

h

Load

ECTEngine Control Tuning


150,0

152,0

154,0

156,0

158,0

160,0

162,0

164,0

166,0

10095908580757065605550454035

SFOC High Load Tuned [g/kWh]

SFOC Part Load EGB / HPT [g/kWh]

SFOC Low Load EGB / HPT [g/kWh]

SFOC Part Load VTA[g/kWh]

SFOC Part Load ECT[g/kWh]

SFOC Low Load VTA [g/kWh]

SFOC Low Load ECT [g/kWh]

Tuning Methods High, Part and Low Load

VTAVariable Turbine Area

EGBExhaust Gas Bypass

Standard Tuning

HPTHigh Pressure Tuning

Part

-and L

ow

Load

Hig

h

Load

ECTEngine Control Tuning

6G50ME-C9.5

SMCR: 6120kW @ 79rpm

ISO conditions


Application Example37,000 dwt Chemical Tanker

General T/C Requirements:

Scavenging Air-Pressure: 3.60 bar

Scavenging Air Mass Flow: 12.9 kg/s

Turbine Inlet Temperature: 377 °C

Exhaust Receiver Pressure: 3.50 bar


Excourse dot 5 EnginesConsequences on Turbocharger

L1:

• Scavenge air pressure: -0.2 bar

• Air amount: +0.1 kg/kWh

Speed derating (L3):

• Scavenge air pressure: -0.2 bar

• Air amount: ~+0.15 kg/kWh

MEP derating (L2):

• Scav air pressure: -0.48 to -0.6 bar compared

to L1


MEP + Speed derating (L4):

• Scav air pressure: -0.48 to -0.6 bar compared

to L1


Trend to lower Scavenge

Air Pressures!

L1

L2

L3

L4

From L1-L3 line to L2-L4 line

reduction of scavenging air

pressure


New Opportunities Entering New Markets & Applications


Challenges for Ship Industry and Power Generation

More stringent emission limits for SOX, NOX, PM, CO2 (IMO Tier I – III, ECAs, EEDI, WB II)

Reduction of operational costs and invest

NOx Limits – Exemplary Cost Structure (10 years)


Future Market Requirements2-Stage Turbocharging for 4-Stroke Engines

Two turbochargers of different size are

connected in series with intermediate cooler

and charge-air cooler.

Reduction of SFOC

Reduced exhaust emissions (NOx) in

conjunction with Miller engine cycle

Increase of power output

Compact design

Improved dynamic response

Increased charge-air pressure

Reduced exhaust emissions


Potential of Two-stage Turbocharging

Benefits of 2-stage turbocharging:

Reduced SFOC through incerased turbocharging efficiency

Higher scavenging air pressures enable downsizing

NOx-Reduction with application of Miller - Cycle

Optimized flushing


Regulation of scavenging air is possible with various regulation strategies:

Wastegate (LP / HP), Compressor bypass (LP / HP), VTA (LP / HP).

Higher flexibility with different ambient conditions

Better scavenging efficiencies through optimized component efficiencies

Basics of 2-stage Turbocharging


ECOCHARGEFirst fire 12V35/44G TS

HP Stage: 2x TCX17

LP Stage: 2x TCR20

>> The Future is Two-Stage! <<


TCX Overview

compressor side:

- higher flow capacity at

lower pressure ratios

- wider compressor map

- efficiency optimization

at lower pressure ratios

optimized bearings for increased forces

turbine side:

- optimization for high

pressure stage

- higher flow capacity at

lower pressure ratios

- efficiency optimization

at lower pressure ratios

optimized casings for containment

safety and higher pressure level

Compactness in order to minimise

additional space (and weight)


Two-Stage TurbochargingMAN Portfolio of two-stage turbocharged engines


Two-Stage TurbochargingMAN Portfolio of two-stage turbocharged engines

Well proven TCA88 and TCA77

turbochargers

Modular design of LP- and HP

turbocharging module and interfaces


Tier III Leading to New DevelopmentsNew products for new demands

ETB

EGR module consisting of

Scrubber

Cooler

Water mist catcher

EGR blower


ETB – Electrical Turbo BlowerMAN Diesel & Turbo’s exhaust gas recirculation blower

MAN compressor competence in combination with

high-speed e-motor

High efficient compressor wheel optimised for low

pressure ratios

Variable speed operation

Design to cost


Exhaust Gas Recirculation BlowerChallenges

Highly corrosive atmosphere

Acid water droplets (erosion/corrosion)

Machining of stainless steel compressor

High speed drive (up to 18,000 rpm)

High performance components at competitive

costs

High mass flow at low pressure ratios

Blower efficiency = energy efficiency

Compact design


MAN TurbochargersHighlights

Field Test ETB18 since May 2015

Ship Name: KEY PACIFICO

Ship Type: 82.000 dwt BC

Engine Type: MES 6S60ME-C8.2 Tier III

T/C Type: MES TCA55-21

Ship Owner: NYK


Conclusion

Combination of new high performance components with proven design

concepts

Robust and cost effective solutions

From one single source: Engine, Blower, Control System, Turbocharger

Proven designs with extensive references

Wide service network


George Drossos

Head of Marine New Sales and Promotion

MAN Diesel & Turbo Hellas Ltd

89, Akti Miaouli Str. Piraeus, 185 38, Greece

Phone +30 210 4587 915

Cell +30 6932 631409

Fax +30 210 4587 928-9

[email protected]

Do you have any more Questions?

mailto:[email protected]

title of presentation - on the mos way · 2015-12-28 · man diesel & turbo man turbocharger...

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