|13 charge! Switzerland - ABB Group...simulation. What is the difference between a retrofit and an upgrade? With a retrofit, you are talking about a like-for-like exchange. So you

2 |13The customer magazine

of ABB TurbochargingSwitzerlandcharge!

Expanding in the Middle East 12Dubai, Bahrain and Iraq with new service facilitiesA step up from retrofits 4Upgrades improve engine performance – Reinier Bakker explains howA launch on the ocean waves 20Sixteen ABB turbochargers on the semi-submersible, self-propelled Odyssey

Powering thrust

2 ABB charge! 2 |13

From the editor

charge! 2 |13

Magdalena OkopskaHead of Market Communication ABB Turbocharging

In fulfilling one of ABB Turbocharging’smission statements, namely that “Wemake a real difference in how our cus-tomers’ engine products perform”, wefocus on what our customers really needand what will add value to their business,while driving innovation forwards.

A look at some recent technologicaldevelopments and how the benefits theyproduce address customers’ needs inthe current market underlines this.

Highly efficient, high-pressure single-stage turbochargers, such as the A200-Land A100-L, enable engine builders tomeet IMO Tier II emissions limits whileconsuming as little fuel as possible. OurValve Control Management (VCM) vari-able valve timing system makes dieselengines more powerful and greener atthe same time, while using technologythat is both reliable and affordable. Thesecond generation of Power2 ensures again in engine efficiency and lowering ofemissions well beyond the potential ofany single-stage system, and it is morerobust and space-efficient, plus easier toservice and overhaul. Last but not least,

to improve the fuel consumption of mod-ern electronically controlled two-strokeengines at low and part load there is HighPressure Tuning (HPT), which was devel-oped for a leading engine designer andlicensor.

You can find out more about all of thesein this issue of charge! Or just visit ourstand at one of the upcoming trade fairs.

At Marintec in Shanghai from December 3until 6, our main focus will be the A200-L,VCM, the new generation of Power2 as well as service offerings such as ourMaintenance Management Agreements(MMA). We heartily invite current as wellas potential customers, business part-ners and other guests to come along andengage in interesting discussions in HallN1 (booth no. J21).

We look forward to seeing you in Shang-hai. In the meantime, please enjoy thecurrent issue of charge!.

The upgrade benefitsThe upgrades system and the difference toretrofits.04 Soon at Drydocks World Dubai

ABB Turbocharging’s planned Service Point forcloser customer proximity.12

ABB charge! 2 |13 3

Contents

Technology 4 A step up from retrofits

Upgrades improve engine performance –Reinier Bakker explains how

6 HPT: High Pressure Tuning for MAN Diesel & Turbo two-stroke enginesReducing fuel consumption

10 A200-L: Well underwayExcellent debut for newly launched A200-L

News11 Awards, updates, openings

Service12 Expanding in the Middle East

Dubai, Bahrain and Iraq with new service facilities14 Supplying electricity in Iraq

ABB Turbocharging equipped plant brings power toSamarra

15 A home in the Middle EastJohn Fyfe, Area Manager Middle East and North East Africa

Applications16 A100 technology in operation

Cogeneration plant at the Mercedes-Benz facility in Rastatt

20 A launch on the ocean waves Sixteen ABB turbochargers on the semi-submersible, self-propelled Odyssey

Tips for the operator24 TPS turbocharger – turbine cleaning in operation

The ten minute washing procedure

Recipe26 Timeless fare from the Middle East

A recommendation from Iraq: Tomato and chickpea soup

Sixteen ABB turbochargers on the OdysseyLaunch operations supported by ABB turbocharging technology. 20Power for a Mercedes-Benz facility

Reliable ABB and MWM technology in the thirdcogeneration plant at Rastatt, Germany.16

4 ABB charge! 2 |13

Interview

A step up from retrofits Upgrades improve engine performance by allowing a more efficient solution with greater tolerance for deviation. Reinier Bakker explains. Interview Victoria Maier, Photography Michael Reinhard

Upgraded power plant in the Dominican Republic.

ABB charge! 2 |13 5

Interview

So let’s start by putting things intocontext. What is an upgrade?

An upgrade is the process of essen-tially redeveloping a turbocharger for anengine so that it will run more efficiently.A turbocharger is an air machine; it pro-vides compressed air to the combustionchamber of an engine. Large enginestoday need to have a turbochargerbecause without one, an engine wouldbe four times as large or would not beable to power the machine in question.So an engine needs a turbocharger, andthe two need to fit together really well. Inorder to do that, to create a turbochargerwith the right specifications, ABB Turbo -charging works together with the enginemanufacturer to achieve the best fit bymeans of a process of matching andsimulation.

What is the difference between aretrofit and an upgrade?

With a retrofit, you are talking about a like-for-like exchange. So you mightexchange an ABB turbocharger foranother brand of turbocharger. But you’relooking to use the ABB turbochargerwith the most identical specification andcharacteristics, so that you can just“drop in” a turbocharger that will fit onthe current solution, the engine, with fewif any modifications. It’s the same solu-tion, but our brand instead of someoneelse’s. That’s a drop-in.

A simple, elegant solution?Yes. And you do a retrofit for a whole

host of reasons, some of which havenothing to do with improving perform-

ance. You might do a retrofit to addresssafety issues, for example. But it’salways the same: It’s a like-for-likeexchange. Hypothetically speaking, if itwere to fit mechanically, you could alsothink about installing a more powerfulturbocharger onto an engine at its origi-nal specification, but you would never dothat, because the customer wouldn’treally stand to gain. It wouldn’t be worththe effort and resources. Together withthe engine builder, we took that basicidea one step further and asked our-selves what would happen if we were tomake changes to both the turbochargerand the engine specifications. That’swhen we began talking about upgrades.If you put a new turbocharger on an oldengine, your turbocharger efficiency goes

up, your aerodynamics get better, andthat means that you have to be able tochange things with the engine. Theimproved engine performance is madepossible through improved turbochargerperformance. So with an upgrade, youare not replacing like-for-like. Instead,you are looking for improvement inengine performance. And an upgrademakes it possible to have a more efficientsolution with greater tolerance for devia-tion; there’s also more freedom in termsof what a customer can do with theengine. With a retrofit, you don’t havethat type of freedom. So we have begunto look for these combinations where wecan make changes to both the turbo -charger and the engine to improve per-formance, because then we can reallymake a difference for our customers.

What has the response been fromcustomers so far?

We’ve already had several contracts –quite a lot, really, given that we onlystarted offering the upgrade option in2013. Take Brazil, for example. There is aconversion of something like 15 enginesthere and these power plants supply tothe grid. We are talking about upgrading30 cartridges and one spare cartridge onmultiple plants. So this upgrade is a greatway to meet – or even increase – produc-tivity above and beyond what you’d beable to do in the engine. And for engineproviders who have to show their cus-tomers that their engines will be as pro-ductive as possible, such gains are a realadvantage, especially for companies withcontracts stipulating productivity targets.

An upgrade is the process of essentially redevelop-ing a turbocharger for an engine so that it will runmore efficiently.

The upgrades expert

After his studies in Applied Physics at the Delft University of Technology(NL), Reinier Bakker held managingpositions at DSM R&D and at GEPlastics Europe. He was AccountDirector at Honeywell Turbo Technolo-gies from 2003. Bakker joined ABBTurbocharging in April 2011 as Senior Manager OEM Service Sales inBaden, Switzerland. He has spear-headed the company’s worldwidecommercial promotion of upgradesfrom its inception. Reinier Bakker.

6 ABB charge! 2 |13

Technology

HPT: High Pressure Tuningfor MAN Diesel & Turbotwo-stroke engines

Slow steaming container vessel.

ABB charge! 2 |13 7

Technology

In 2011, ABB Turbocharging introduced a new way of reducingfuel consumption on low-speed diesels. Fast forward 18 monthsand High Pressure Tuning is indispensable for getting the bestout of MAN two-strokes.

Text Klaus Fußstetter, Photography iStockphoto, ABB Turbo Systems Ltd, Michael Reinhard

8 ABB charge! 2 |13

Technology

Owners and operators in aglobal merchant fleet com-prising more than 50,000ships are constantly looking

for ways to improve the profitability ofglobal transportation.

Among their wide range of focuses,reducing fuel costs is an evergreen. Itprovides a major incentive for improvingtheir economic situation, since a vastmajority of total operating costs areattributable to their fuel bills when theirships are at sea. The continuous rise inbunker prices, coupled with the imple-mentation of new emissions control reg-ulations has turned industry attention tofuel efficiency and slow steaming – i. e.operating vessels at reduced speed.

In 2009, ABB Turbocharging launcheda new highly efficient high pressure turbocharger generation – the A100-L. Itopened up operating modes that werenot hitherto fully utilized by enginedesigners. As the next step, and with the

new market requirements of the currentmarket in mind, ABB Turbochargingturned its attention to innovations whichsupport the marine industry’s efforts byemploying the latest turbocharger tech-nologies.

Late in 2011, the innovative conceptof High Pressure Tuning – or HPT – waspresented to leading engine designerand licensor MAN Diesel & Turbo for thefirst time.

Enhancing efficiencyHPT is a way of improving the fuel

consumption of modern electronicallycontrolled two-stroke engines at low andpart load. By increasing scavenging air

pressure (Fig. 1) it results in higher peakfiring pressures in the engine’s cylinders.The laws of physics say that the efficiencyof a diesel engine cycle can be enhancedwith higher cylinder peak pressures. A variable exhaust valve controls theengine’s compression ratio at highengine loads in order to avoid excessivefiring pressures in the cylinder. Toachieve this, under hydraulic control theexhaust gas valve is closed later com-pared to standard operation (Fig. 2). Theengine control system ensures that allengine parameters are well adjusted,according to design requirements. Thestart of injection remains unchanged inorder to achieve the most efficient com-

Log

p

Log V

pmax

pC

EV

OP

OB

DC

Scavenge pressure

TDC

EV

C

Standard cycle

Pistonat sameposition

Air intake

Exhaustvalve

closed

Exhaustvalveopen

Air intake

pmax

pC

EV

O

BD

CPO

Scavenge pressure

HPT cycle

Log VTDC

EV

C

Log

p

Fig. 1: Scavenging air pressure tuning curve.

10 20 30 40 50 60 70 80 90 100 110

Sca

veng

ing

air

pre

ssur

e [b

ar]

Engine load [%]

High Pressure Tuning HPT

High load tuning

VT or EGB tuning

0.5 bar

Fig. 2: Standard versus HPT cycle.

HPT is a way of improv-ing the fuel consumptionof modern electronicallycontrolled two-strokeengines at low and partload.

ABB charge! 2 |13 9

Technology

bustion process for the fuel injected. Bythis so called “two-stroke Miller effect”,emissions of oxides of nitrogen (NOx) arereduced at higher engine loads, whichmakes a further reduction in fuel oil con-sumption possible at part loads, whilekeeping the NOx emissions within thelimits of the IMO E3 cycle. Lowering thefuel consumption of an engine means, atthe same time, a reduction in emissionsof the greenhouse gas carbon dioxide(CO2).

HPT tuned engines can be turbo -charged without any additional devices,such as exhaust gas bypass valves(wastegates) or turbochargers with othervariable devices (Fig. 3).

HPT for MANHPT offers engine builders, ship own-

ers and operators financial benefits,thanks to the reduction of extra hard-ware and installation costs, and hencelower initial investment and first costs.The elimination of moving parts andadditional components also removestheir related service costs. Enginestuned with HPT are fuel efficient, fromthe lowest loads right up to higher partload operation, with a fuel saving of 5 gper kWh (Fig. 4), compared to an enginewith standard tuning. The potential fuelsaving on a large container vessel tunedwith HPT could amount to several hun-dred thousand dollars in just one year.

Based on successful engine testing,MAN Diesel & Turbo and ABB decided to make High Pressure Tuning (HPT) avail-able to their customers. Consequently,HPT is now offered on ME and ME-Cengines from the current MAN engineportfolio with bore sizes from 50 cm rightup to the largest 98 cm models.

Late in 2012, ABB Turbochargingintroduced the new A200-L generation,which in combination with HPT enablesthe marine business to further increasethe profitability of global seaborne trans-port. The number of project inquiries for HPT engines with A100-L and A200-Lturbochargers proves that ABB has pre-cisely fulfilled the market’s requirements.

Klaus Fußstetter graduated as amechanical engineer from the Techni-cal University Munich (TUM) andjoined ABB Switzerland in 1993 as asimulation specialist for turbochargingsystems. As senior manager for project and application engineering,he is responsible for ABB’s importantcustomer, MAN Diesel & Turbo.

The potential fuel saving on a large container vessel tuned with HPT could amount to several hundred thousand dollars in just one year.

Fig. 4: Specific fuel oil consumption tuning curve.

10 20 30 40 50 60 70 80 90 100 110

Sp

ecifi

c fu

el o

il co

nsum

ptio

n

Engine load [%]

2.5 g /kWh

High Pressure Tuning HPT

High load tuning

EGB tuning

VT tuning

Fig. 3: Moving parts – VTG.

10 ABB charge! 2 |13

Technology

Arie Smits was Head of the ABB Turbocharging Rotterdam Service Station before he moved toSwitzerland in 2001. Until October2012 Smits was responsible for theglobal low-speed two-stroke turbo -charger new business. Now he isSenior General Manager Global Turbocharging Projects, active in pur-suing major new-building projects.

The A200-L, ABB Turbocharging’snew turbocharger generation forlow-speed engines, has donewell in recent engine tests for an

application in a new container vessel fora German shipping line.

With orders booked for almost allframe sizes, this success reflects anoverwhelming market response to theA200-L generation. As per the originalschedule, all the sizes will be released by2014.

It was around a year ago, during theSMM marine trade show in Hamburg, thatABB Turbocharging officially launchedthese second generation turbochargersfor two-stroke engines: the A200-L is thesuccessor to the very successful A100-L,of which close to a thousand have beensold or specified.

The rapid release of the second generation resulted from a tremendousdevelopment step in turbocharger vol-ume flow. Building on the proven A100-L

comes a massive 30 % rise, allowingsmaller turbochargers to be used overvirtually the complete global two-strokeengine portfolio.

So, while ABB Turbocharging’s con-tinuing focus on ensuring lowest fuelconsumption remains strong, the com-pactness of the new A200-L means notonly less weight has to be installed inless installation space, but also lowerfirst costs – a very important factor forengine builders in the current market.

The compactness of the A200-L turbochargers also translates into a 25 %reduction in spare part prices – anattractive bonus when engine operatorscome to service their turbochargers.And, of course, with features like the wellproven bearing design inherited from theA100-L and the TPL-B generation beforeit, all of the above have been achievedwithout jeopardizing the reliability andefficiency for which ABB Turbochargingproducts are very well known.

A200-L: Well underwayExcellent debut for newly launched A200-L. Engine test resultsare positive and orders are booked for almost all frame sizes.Text Arie Smits, Photography Michael Reinhard

Positive engine tests for the A200-L.

ABB charge! 2 |13 11

News

New facility in Ballò di Mirano.

Service StationopenedVenice. This year ABB Turbochargingopened a new Service Station in Ballò diMirano, Venice, Italy. It replaces theMarghera facility and offers a largerworkspace for improved technical per-formance. The new facility will serve cus-tomers in the maritime sector operatingin the Adriatic Sea and in the power gen-eration industry located in Central andNorthern Italy (particularly in the north-east).

What about IMO Tier III?

Baden. The International MaritimeOrganization (IMO) is considering post-poning IMO Tier III, which is currentlyscheduled to come into effect on 1st

January 2016. Were IMO Tier III to bepostponed, ABB Turbocharging’s plansfor developing and implementing itssolutions would remain unaffected, asthey are not just for IMO Tier III compli-ance. Current technologies would beadapted accordingly.

Turbocharging Service Networkupdate

Baden. ABB Turbocharging is adaptingits global Service Network in line withcurrent market needs to better serve itscustomers. With 100+ Service Stationsin 50+ countries, the company’s globalservice network is among the strongestin the industry. As ever, turbochargingservice at ABB offers cutting-edgeexpertise, the benefits and lessonslearned from having a global database,and Original Parts and Original Service. Ifthese changes affect your operationsanywhere, your ABB TurbochargingService Station will contact you in duecourse.

Caterpillar Lafayette.

Bolingbrook. ABB Turbocharging in Bolingbrook, Illinois, an ABB ServiceStation dedicated to re-manufacturingservices for Caterpillar, was awardedSupplier Quality Excellence Process(SQEP) Gold certification by Caterpillarearlier this year. This is the second timethat this Service Station has received aspecial recognition from Caterpillar, hav-ing been awarded the Bronze level in2011.

Caterpillar’s SQEP certification recog-nizes their supplier’s dedication to provid-ing superior quality and is only awardedto those who demonstrate such world-class performance on an ongoing basis.

Second award for ABB TurbochargingBolingbrook (USA)


Service

Expanding in the Middle EastNew Service Points in Dubai, Bahrain and Iraq to meet customers’ growing demands.

Text John Fyfe, Tiziana Ossola Auf der Maur, Photography Drydocks World Dubai, ABB Turbocharging in Dubai

ABB Turbocharging in Dubai iscurrently embarking on expan-sion plans that involve theestablishment of Service Points

within strategic locations around the Arabian Gulf and the Middle East. Theyallow ABB Turbocharging to serve bothlocal and global ship owners withdetailed onsite inspections, repairs androtor balancing of their turbochargers.

During the last year the customers’voice was heeded. ABB Turbocharging

took account of their need for more localservice options. This is driven by twofactors: firstly by the need of shipownersto reduce their operating costs againstthe background of the global economicslowdown; secondly, by the need toenhance communication with the ships’superintendents and support them intheir decision making during technicalinspections.

A new collaborative agreement withDrydocks World in Dubai, a leading player

in ship repair, ship conversion, shipbuilding and offshore fabrication, is in anadvanced stage of finalization. Given thestrategic importance of Drydocks Worldto customers who are also ABB cus-tomers, this initiative provides for theimplant at Drydocks World of the keyequipment required for the overhaul ofturbochargers, thus enabling rapid turn-around times and round-the-clock onsitetechnical support.

Strategically important: Drydocks World Dubai.


Service

The agreement will promote the shar-ing of mutual benefits to enhance thebusiness of both companies, ensure quickturbocharger service to customers in theyard and offer one-stop ABB turbo -charger solutions at Drydocks World.ABB Turbocharging in Dubai will provideinternational factory warranties to allservice jobs done at Drydocks World,including dedicated engineering staffand equipment at a workshop implantedwithin the shipyard facility.

Expanded presence in Bahrain and IraqThe second Service Point will be

located in Bahrain, a major ship repairhub. The Service Point in Bahrain will bedesigned to handle both main engineand generator set turbocharger over-hauls, with key tooling and equipment inplace to ensure faster and more efficientoverhauls.

The third will be a fully-fledged Service Station based in Erbil, Iraq. Due tothe country’s high demand for power, its

number of large to mid-size diesel powerplants is destined to grow. With thatcomes the need for OEM qualified engi-neers and OEM maintenance, repairs,overhauls and, naturally, spare parts. ABBDubai has already established a salesoffice in Iraq and – together with the fullyqualified local engineer – already startedon-site repairs. The Erbil Service Station isscheduled to open in the first quarter of2014.

Approved service quality, here in Dubai … … soon in Bahrain … … and Erbil, Iraq.

ABB Turbocharging Service Station in Dubai.

Iraq’s high demand forpower means that thenumber of large to mid-size diesel power plantswill continue to grow.


Service

Supplying electricity in IraqSince 2008, the ABB Turbocharging equipped diesel power station in Samarra, Iraq, has been making an important contribution to meeting power demand in that historic city.Text Tiziana Ossola Auf der Maur, Photography Corbis, ABB Turbocharging in Dubai

After five years of planning,building, installing and com-missioning, 2009 saw the 350 MW diesel power station

some 120 km north of Baghdad start togenerate electricity. Of the twelve power

plants in Iraq equipped with ABB turbo -chargers, Samarra is the largest. The cityis also historically significant and aUNESCO World Heritage Site. In theaftermath of years of conflict, the powerplant has been able to satisfy at least

part of the demand for electricity in thecity with its population of 348,000. Still,there is a gap between supply anddemand. According to estimates reportedon the Middle East Economic Digest(MEED) website, an average Iraqi house-

Samarra: ABB turbochargers help to supply electricity to its 348,000 inhabitants.


Service

hold received power for only 7.6 hours aday in 2012. The Ministry of Electricity ofIraq (MoE) declared power generation asits top priority, issued an energy masterplan and began placing contracts.

Upgrade for the 36 turbochargersLocal cooperation for the Samarra

power plant with the MoE was handledby engine builder Wärtsilä, who subcon-tracted ABB Turbocharging. The twocompanies worked together to establisha framework, the scope of service onoffer and parts supply for the turbo -chargers.

Under its contract, Wärtsilä suppliesMoE with follow-up maintenance workand uses ABB Turbocharging for servicebased on Original Parts. The first over-hauls of the 36 turbochargers were completed in 2012 and 2013 at the ABB Service Station in Dubai. All the 36 turbochargers were upgraded to HPPdesign to reduce wear rates of turbineblades and to maintain their high per-formance. HPP consists of six coatedblades and a new deformation-resistantturbine diffuser. The second round ofoverhauls is scheduled to start in mid2014.

Wärtsilä and ABB joint meetings inBaghdad with the MoE managementhave been taking place for technical dis-cussions, followed-up by visits to theplant for inspections.

A home in the Middle East

For two years Scotsman John Fyfe has been Area Manager Middle East and North East Africaat ABB Turbocharging. For him, settling in Dubai is to return to afamiliar location.

Text Tiziana Ossola Auf der Maur

Photography ABB Turbocharging in Dubai

“For me Dubai is home,” says JohnFyfe who, since January 2012, hasguided the destiny of ABB’s turbo -charger business in the Middle Eastand North East Africa from there.Fyfe knows the Emirate like the backof his hand. Altogether, the 37 yearold has spent fourteen years here.The fascinating vastness of the desert,the mountains and the sea: Dubai isan ideal place for John’s personaldevelopment, both as a family manand a businessman.

Indeed: Fyfe has been in the Middle East longer than in his nativeScotland. He came to Kuwait as theeleven year old son of an ABB man-

ager and as a teenager. After a shortdetour to South Africa, he settled inDubai in 1992.

Many goals in Iraq“I wanted to go for a challenge,”

says Fyfe about his move to Kobe,Japan where, as a 26 year old, hegot his chance to become a servicemanager at ABB Turbocharging’sjoint venture Turbo Systems UnitedCo. Ltd. Five years later, he was pro-moted to General Manager for theWest Japan region, and since 2012the father of four is now in his dreamlocation – back in Dubai.

Part of John’s business activity in the Middle East centers on Iraq,where ABB Turbocharging hasequipped a number of power plants.In a country rebuilding itself afteryears of conflict, providing electricityto the estimated 32 million peoplehas become a primary target for thegovernment. The growing installedcapacity of diesel engined powerplants demands the highest levels ofworkmanship, quality and reliability inthe most challenging of locations.ABB in Dubai must be equal to thistask and ensure the engine’s turbo -chargers continue to perform at thehighest level for the Iraqi people.

Demand for power keeps ongrowing. The installed base has dou-bled in the last four years and thetrend is upwards. Iraq’s recovery andgrowth demands optimum servicefrom a committed on-the-spot ABB Turbocharging presence (seearticle on page 12).

Further expansion projects inDubai, together with developmentplans in Bahrain, have recently beencompeted under Fyfe’s supervision.“But they are accomplishments bythe team as a whole,” Fyfe is eagerto emphasize. “After all, we are talk-ing about a goal we are all commit-ted to: the best possible service,courtesy of close customer proximity.”

John Fyfe, Local Business Unit Manager in Dubai.


Applications

Mercedes-Benz facility in Rastatt.


Applications

A100 technology in operationEfficient and reliable A140-H ABB turbochargers run on the mostpowerful MWM gas engine TCG 2032V16 in Rastatt, Germany.

Text Mirko Lepel, MWM GmbH, Photography Daimler AG, MWM GmbH, ABB Turbo Systems Ltd, Michael Reinhard

The A140-H turbochargers deliv-ered to MWM belong to the firstA100-H machines delivered byABB from series production. In

addition to various mine gas applicationsthis engine is, above all, used in cogen-eration plants all over the world for theefficient production of electrical powerand heat.

For the specific application on gasengines for power generation and com-bined heat and power such as theDaimler AG cogeneration plant, theA100-H offers significant advantagescompared to previous turbocharger generations, including higher pressureratios and higher turbocharger efficiency.This enables the customer to increaseboth nominal engine output and opera-tional flexibility under severe ambient con-ditions such as high temperature andhigh altitude, without the need to deratethe engine.

For the specific application on gas engines, theA100-H offers significant advantages.

Mercedes-Benz in Rastatt: Third cogeneration plant commissioned.


Applications

These benefits are highlighted in the product description of the MWMTCG 2032 engine: – New turbocharger technology increas-

es availability of the genset: improvedoutput under non-ISO conditions.

– High output of up to 4,300 kWe possi-ble through use of A140 high-pressureturbocharger.

– Turbocharger achieves higher pres-sure ratio and enables operation underfull load up to 45 °C air intake temper-ature.

A100: suited for many applicationsA new generation of mixed-flow tur-

bines has been developed for use withthe A100. Powering the new compressorstages, a characteristic of this new tur-bine family is their extensive operatingrange, allowing the high pressure ratiopotential of the new compressor stage tobe utilized over an even wider range ofapplications. The turbine’s design hasbeen optimized in each specific volumeflow range, so that the individual stagesexhibit outstandingly high turbine effi-ciencies. Further development of sealing

technologies has reduced blow-by, sothat flow losses are also lower. In partic-ular, this has allowed a substantialimprovement in turbocharging perform-ance at higher boost pressures.

A wide range of available compressorand turbine specifications makes the A100ideally suited for applications on enginesin the marine, industrial and power gener-ation fields as well as for rail traction andmobile equipment drives. The outstandingthermo-dynamic potential of the A100becomes clear in the case of a full load-optimized turbocharger specification.

1.0 2.0 5.03.0 4.0

Compressor pressure ratio

65

70

75

60

55

50

45

40

�TC

[%]

Turb

ocha

rger

effi

cien

cy

Full load specification

�c [-]

A140

TPS 57-F

Turbocharger efficiency of A140 with full load-optimized specification.

The new turbochargertechnology increasesavailability of the genset:improved output undernon-ISO conditions.

1.51.0 2.0 2.5 3.5 4.0

5%

3.0 �T [-]

Turbine expansion ratio

Turb

ine

effic

ienc

y

A140

TPS 57-F

Turbine efficiencies, A140 and TPS 57-F.

Assembly of an A100 turbocharger.


Applications

The A100 turbocharger represents a striking example of overall low TCO.The long maintenance intervals of TPSturbochargers have been matched bythe A100, even though the demandsmade on its thermodynamic andmechanical performance are higher. Theturbochargers of the new A100 genera-tion will satisfy all demands in respect ofhigh reliability and low maintenanceoperation. As well as long maintenanceand overhauls intervals.

In May 2013 Daimler AG commis-sioned a third cogeneration plant forthe Mercedes-Benz plant in Rastatt,Germany. It consists of a gas fuelledpiston engine (MWM type TCG 2032V16) driving an electrical generator. Itproduces four megawatts of electricityand four megawatts of thermal energy.In addition, an absorption plant wasinstalled capable of producing twomegawatts of cooling capacity. In thewinter months heat recovered from

the gas engine can be used for heat-ing and in the summer months it canbe transformed into cooling – in thisway the heat can be used for produc-tion processes all year round. The effi-ciency of the cogeneration plant totalsover 85 percent, compared to a typi-cal value of 40 percent for a conven-tional power plant. The two existingcogeneration plants each contributetwo megawatts of electricity and twomegawatts of thermal energy.

Cogeneration plant commissioning in May 2013: From left to right: Rolf Busch (project owner), Hans Jürgen Pütsch (mayor of Rastatt) and Peter Wesp (head of plant).

The 140-H turbocharger at Daimler AG

MWM TCG 2032 genset: Its high output of up to 4,300 kWe is possible through use of theA140 high-pressure turbocharger.

Dr. Mirko Lepel has a PhD degree inMechanical Engineering from the Uni-versity of Bochum, Germany in coop-eration with Deutsche Montan Tech-nologie GmbH in Essen. He joinedABB Turbocharging in 2001. He startedas an R&D engineer and projectleader. Today Lepel is Senior ManagerSales and Application Engineering.


Applications

A launchon the oceanwaves

The Odyssey moves to a partially submerged position of 21.5 meters in advance of the start of launch operations to provide a stable launch platform.


Applications

Sixteen ABB turbochargers on eight Ulstein-Bergen enginespower the Odyssey, one of the fastest semi-submersible, self-propelled vessels.Text Francis J. Pelot, Photography Sea Launch, Dave Hutsell

Next April, the Sea LaunchCommander and Odyssey will be positioned along the equator in the Pacific Ocean

preparing for the final launch sequenceof the next payload to meet its orbitalposition in the heavens. Many hours ofpreparation, calculation, education andperspiration will culminate in anothersuccessful launch for the Sea LaunchZenit-3SL system. It will be the 35th suchmission since 1999. These missions canlast as long as 42 days but average 22days for the Commander (assembly andcommand ship) and 29 for the Odyssey(launch platform). Transit time from thehome port in Long Beach, California tothe launch site is eight days for the Com-mander and twelve days for the Odyssey.The program can provide up to six mis-sions a year with one launch per mission.The weight of the payload at launch willbe in the region of 600 tons includingfuel. Typically there are two months ofpreparation involved before occupyingthe Commander, and the payload willarrive approximately four weeks before

departure. The payload is transportedfrom the Commander to the Odysseybefore the vessels’ departure to thelaunch site. Once the vessels havearrived at the launch site the pre-launchprotocol begins. Three hours prior tolaunch, the Odyssey is cleared of all per-sonnel, who are then transferred to theCommander, which will anchor set onDynamic Positioning (DP) 6,000 metersaway before the final launch sequencecommences. Once all support staff havebeen recovered from the Odyssey, launch

control is remotely directed from theCommander with the captains of bothvessels present. The final launchsequence is maintained by the launchdirector. During a launch campaign,meals, transportation, office space, ser-vices and weather reports /warnings fora limited number of staff is part of theSea Launch standard service package.The next campaign will begin preparationin November of this year, with the launchscheduled for April 2014.

Three hours prior to launch, the Odyssey is clearedof all personnel, who are then transferred to theCommander, which will anchor set on Dynamic Positioning (DP) 6,000 meters away before the finallaunch sequence commences.


Applications

One system – three segmentsThe program originated in the early

1990s after the dissolution of the USSR.RSC Energia (Russia) looked to utilizetheir wealth of space expertise, in asso-ciation with Boeing, Kvaerner, Yuzhmashand Yuzhnoye, which is a partnership ofcompanies from the United States, Nor-way, Russia and the Ukraine respectively.The Sea Launch AG headquarters islocated in Bern, Switzerland and isresponsible for the contracting and man-agement of all launch services. SeaLaunch is one of the industry leadersbecause of the innovation, service, com-petition and diversity of supply they havedelivered to the world’s satellite opera-tors. Sea Launch AG provides high qual-ity facilities and services in support ofcustomer spacecraft operations basedon the Zenit-3SL launch system. Thissystem consists of three components:the rocket segment, the marine segment

and the home port segment. The rocketsegment consists of the launch vehicle,ground support equipment and groundcontrol systems. The marine segment comprises the Sea Launch Commanderand the launch platform Odyssey andsupport staff. The home port segmentprovides a stable base of logistical sup-port for both vessels as well as a state of

the art payload processing facility. Thecustomers include well known brandssuch as Dish Network, Direct TV, XMSatellite Radio and Lockheed Martin.The missions are not considered suc-cessful until the customer can take con-trol of the satellite, usually one hour afterlift-off.

The azimuth/bow thruster positioning system stabilizes the Odyssey to a point with less drift than a human maintaining a standing position.

The missions are not considered successful until the customer can take control of the satellite, usuallyone hour after lift-off.


Applications

A brief historyThe two vessels first arrived at their

home port in Long Beach, California in1998. The launch platform Odyssey wasbuilt in 1983 and was previously a NorthSea oil drilling platform named the Ocean Odyssey. It was then refurbishedby Kvaerner Rosenberg Shipyard in Stavanger, Norway and then transferredin 1997 to Vyborg Shipyard outside St. Petersburg, Russia where it wasmodified to its current design. At over27,400 tons displacement and a sub-merged draft displacement of 50,600 tonsat 70 feet, the Odyssey is one of thelargest semi-submersible, self propelledvessels on the seas. The Odyssey is builton two large pontoons which have threeballast pumps each that allow theOdyssey to partially submerge prior tothe start of launch operations, plus and adynamic positioning system that uses acombination of azimuth and bow thrusters

with the main propulsion system to holdthe platform on station at the launch site.

When asked about the relationshipwith ABB over the years, Jan Bakke, Senior Superintendent /CSO who hasbeen with Sea Launch since the Com-mander and Odyssey arrived at theirhome port in 1998, shares somethoughts. “We find that the key to thesuccess of our launch campaigns is toensure that the safety and training of thepersonnel and the maintenance of theequipment is never compromised. TheABB turbochargers fit right in with thatphilosophy. We have seen, based on theirperformance history, that the ABB turbo-chargers are reliable and that is whatcounts. It speaks to the quality of the ABBequipment. We have had a relationshipwith the ABB Service Station in Carson,California from the very beginning andhave not been disappointed with the ser-vice or the performance of the equipment.”

The technology

The Odyssey is powered by eightUlstein Bergen KVG12TC engines, rated 2,300 kW at 720 rpm. The airrequirements are supplied by sixteenABB VTR 214-11 turbochargers, in arare but effective combination. Theload profile for these engines isunique, falling somewhere betweenthat of a cruise ship and a tug boat.

The Commander, the Assembly and Command Ship (ACS) is powered by two Wärtsilä 8L46B ME

diesels equipped with ABB VTR 454-D32 turbochargers and four UlsteinBergen KRG8/ TC auxiliary engineswith VTR 254-11 turbochargers. Thevessel has a displacement of morethan 34,000 tons and a range of18,000 nautical miles. The Com-mander is equipped to accommodateup to 240 crew and customersincluding 20 FAA (Federal AviationAdministration) members.

Francis J. Pelot has a Bachelor’sDegree in Psychology from the Uni-versity of the Pacific, California. Hehas eighteen years of experience inthe metallurgical sector with manage-ment positions in operations and pro-duction at small to mid-size fabrica-tion and manufacturing facilities. Pelot joined ABB Turbocharging in2008 as a Business Administrator andwas promoted to Account ManagerEUS in 2010.

137 m

65.3 m

137 m

65.3 m

Launch pad

Launch vehicle inlaunch position

Launch vehicle intransit position

Rocket hangar

Launch deck132.9 � 67.1 m


Tips for the operator

Turbochargers operated on HFOare exposed to fouling anddeposits originating from theengine’s exhaust gases. The

extent of the turbine side foulingdepends on various factors, such as fuelquality, the engine operating point orcombustion quality. Fouling reduces theturbocharger’s efficiency and results in

both higher exhaust gas temperaturesand increased fuel consumption. Regularturbine cleaning also helps to keepengine performance up to design power.

Two turbine cleaning methodsThe ABB Turbocharging water washing

system allows turbine cleaning whileoperating at reduced load. Two methods

are in use. A procedure with a shortwater injection time (3 � 30 seconds) ispermissible on any turbocharger turbinecasing. The long water injection proce-dure (ten minute wash) was first intro-duced with the latest turbine casings,which feature an additional gasketbetween the turbine casing and the bearing casing (TH22, TH32 and TH42).

The ABB Turbocharging water washing system allows turbine cleaning while operating at reduced load.

TPS turbocharger – turbinecleaning in operationA ten minute turbine washing procedure for TPS turbochargersoperating in HFO applications.

Text Fabian Wittmer, Photography Michael Reinhard


Tips for the operator

Field experience and tests haveshown improved cleaning results withthe ten minute washing procedure.Especially good results were obtainedwhen washing with the engine idling.

RecommendationIn cases where operators experience

inadequate results when cleaning withshort water injection, ABB Turbochargingrecommends changing to the ten minuteprocedure, regardless of the casing type.

On turbochargers without the addi-tional gasket, long water injection maylead to minor water leakage between thebearing casing and the turbine casing.This is due to unequal thermal expansionduring the long water injection proce-dure. The water leakage represents norisk to the turbocharger and it is up tothe operator to judge whether a potentialtemporary leakage is permissible from anoperational point of view.

Regardless of the chosen washingprocedure, the exhaust gas temperaturelimits described in the operation manual

must be maintained carefully. Failure toprecisely observe the washing proce-dures may drastically shorten the servicelife of the components.

The detailed washing procedures aredescribed in the operation manual. Forquestions concerning washing, or toobtain the latest operation manual,please contact your local ABB ServiceStation. Fabian Wittmer was awarded an

M.Sc. in engineering science in 2007from the ETH Zürich. He has beenManager Technical Service at ABBTurbocharging since 2008. Hisresponsibilities comprise technicalsupport for engine builders, end usersand ABB Service Stations as well as claims management and technicalinvestigations.

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].

Washing procedure

The three phases of the ten minutes washing procedure: Cool-down, cleaning, drying.

Eng

ine

load

Time

min 10 min

Cool-down

10 min

Cleaning

min 10 min

Drying


Recipe

Timeless fare from theMiddle EastTomato and chickpea soup is the tasty recommendation of ABB Turbocharging Sales Manager Zaid Alzubadi. “It is on themenu daily at my house,” says the Iraqi. International recipe No 7.

Text Tiziana Ossola Auf der Maur, Photography iStockphoto

Chickpeas have an historic sig-nificance in the Middle East.The first examples of thedomesticated variety were

found in Tell el-Kerkh, Syria, and weredated to the tenth millennium BC. Laterthere were ancient finds in Turkey andthe West Bank. Greece and Italy haveknown of chick peas since at least theBronze Age.

Merchants from the Orient or Euro-pean Conquerors: they all did their bit tospread the small bean. Chickpeas aretoday enjoyed on every continent, and inmany places belong to the population’sstaple foods. According to the FAO, Indiaand Australia are the two top producers.

The chickpea is versatile. Many cul-tures have their own specialities: whetherhummus, the Lebanon’s savory purée, a spicy stew in India or “pasta e ceci”(pasta and chickpeas) in Italy – cold orwarm, hot, spicy or mild.

There has to be something specialabout a bean that has spread throughthe continents and established itself overthe millennia. In modern language itsounds like this: Like other beans, chick-peas have slow burning complex carbo-hydrates and cholesterol-lowering fiber.It is rich in proteins, vitamin B complexand iron. It boosts the immune system, isgood for the digestion and wonderful forvegetarians.

Tomato and chickpea soup (Hasa tamata ma' hummus)(Serves four)

Ingredients1 can (ca. 200 g) of chickpeas (or

garbanzo beans), drained andrinsed in water. If you prefer touse dried chickpeas, soakthem overnight in ample waterand throw away the liquid.Then simmer them for 1 to 2hours without salt but withsome rosemary twigs.

A little olive oil1 small onion 1 small shallot3 cloves garlic15 g fresh cilantroA few fresh mint and parsley leaves1⁄2 tsp. ground cumin1⁄4 tsp. ground allspice1 large pinch cayenne pepper

4 dl tomato juice4 dl water50 g rice, rinsed

Salt and pepper

Preparation1. Finely chop the onion, the shallot and

the herbs, crush the garlic cloves. 2. Heat the olive oil in a pan and braise

the onion and the shallot.3. Add the garlic, cilantro, cumin, all-

spice and cayenne pepper and sautéa few minutes over a moderate heat.

4. Stir in the remaining ingredients –except the mint and the parsley –and bring to the boil.

5. Reduce the temperature and simmerat moderate heat until the rice iscooked (approx. 15 to 20 minutes).

6. Add salt and pepper to taste. 7. Add the fresh mint and parsley to

taste.


Acknowledgments

Published byABB Turbo Systems Ltd

AddressP.O. BoxCH-5401 Baden/SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144www.abb.com/turbocharginge-mail: [email protected]

EditorTiziana Ossola Auf der Maur

PhotosMichael ReinhardiStockphotoABB Turbo Systems LtdDrydocks World DubaiABB Turbocharging in DubaiCorbisDaimler AGMWM GmbHDave HutsellSea Launch

Cover photo: Corbis

PrinterDietschi Print & Design AG, Olten /Switzerland

Layout, typography, electronic publishingDomino Style & Type AG, Gebenstorf /Switzerland

Reprints require the publisher’s written consent.

© 2013 ABB Turbo Systems Ltd, Baden /SwitzerlandAll rights reserved

Confidence is good, checking is better. I checkfor Original Parts and Original Service.

Original Parts installed during Original Service from ABB Turbocharging incorporatethe experience, know-how and precision only available to a market and technologyleading turbocharger OEM. The geometrical accuracy, high strength and surface quality of the high grade materials used in Original Parts translate immediately intooptimized fuel consumption, reliability, availability and operational safety for yourengine. www.abb.com/turbocharging

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