© ABB Automation GmbHSeptember 14, 2009 | Slide 1
Automatic optimization of diesel engine performance by loop control of cylinder pressure process
ABB Automation GmbH Dipl.Ing. Wolfgang Krasa
ICST Congress Hamburg
10.Sept.2009
© ABB Automation GmbHSeptember 14, 2009 | Slide 2 Automatic optimization of diesel engine performance
CONGRESS 2009
Automatic optimization of diesel engine performance by loop control of cylinder pressure process
ContentEnvironment background
Economy background
Optimization engine performance today
Performance monitoring requirements on 2-stroke engines
Monitoring the combustion performance
SFOC Monitoring
Ship performance Monitoring
Optimization engine performance tomorrow
MAN solution “Auto Tuning”
Wärtsilä solution “ Loop Control”
Integration CBM system
Benefits
Summary
© ABB Automation GmbHSeptember 14, 2009 | Slide 3 Automatic optimization of diesel engine performance
CONGRESS 2009
Environment background Green house gas emission impact by maritime transportation
There are about 110,000 vessels in worlds’ cargo fleet if we count vessels above 100 ton.
Shipping is responsible for transporting 90% of world trade which has doubled in 25 years - vessels are one of the world's most polluting source categories, per unit of fuel consumed.
Studies says that maritime carbon dioxide emissions could rise by as much as 75% in the next 15 to 20 years if world trade continues to grow and no action is taken.
Today annual emissions from shipping are between 600 and 800 million tons of carbon dioxide, which correspond to about 4 to 5% of the global CO2 emission.
© ABB Automation GmbHSeptember 14, 2009 | Slide 4 Automatic optimization of diesel engine performance
CONGRESS 2009
Environment background Environmental impact caused by slow speed 2-stroke engines
Total No. of engines
Yearly fuel consumption
Yearly NOxemission
Yearly CO2 emission
10 680 167.000.000 t 17.000.000 t 500.000.000 t
The world fleet ship propulsion reaches a total power output around 40.000 MW - whereby slow speed 2-stroke application shares 20 % in number of 10.000 machinery units - but with 75 % the major share of total 30.000 MW output.
The number vessels with large slow speed 2-stroke engines are rapidly increasing - there are 3400 vessels in order for delivery up to year 2014.The monitoring and improving of ships fuel economy has a considerable impact of environment : 1,0 % improvement of the specific fuel consumption on the marine diesel engines succeeds in a yearly reduction of 5 million tons CO2.
New technologies are available today to reduce fuel consumption and greenhouse NOx and CO2 gas emissions from vessels. Among these the monitoring and control of the combustion process inside the engine cylinders is a key method to evaluate the economic and ecologic performance marine diesel engines.
A well optimize engine combustion will not only reduce the emission of NOx and CO2 but also carbon particles – and will operate with less wearing and damages.
© ABB Automation GmbHSeptember 14, 2009 | Slide 5 Automatic optimization of diesel engine performance
CONGRESS 2009
Environment background Legislations will force emission reduction
Kyoto protocol and EU is proceeding to incorporate international aviation & maritime transport into the overall greenhouse gas emission reduction program
IMO is working on carta MEPC-58 (Marine Environment Protection Commitee) on emission reduction
The emission issue will become an operating cost factor in the shipping business
„International maritime transport emissions should be incorporated into the EU emissions trading scheme (EU ETS) by 2015 or should otherwise be included in the proposed decision of the European Parliament and of the Council on the effort of Member States to reduce their greenhouse gas emissions to meet the Community’s greenhouse gas emission reduction commitments up to 2020.“
© ABB Automation GmbHSeptember 14, 2009 | Slide 6 Automatic optimization of diesel engine performance
CONGRESS 2009
Economic background Fuel costs
Fuel price will steady increase in long term despite the current drop in the market
Fuel efficiency of ship propulsion is key economic factor in the maritime transport business
Standarized supervision of fuel economy will be request in close future
Annual fuel cost on 12 cylinder large bore engines (96 or 98 bore) = approx. 15 - 20 MUS$ (on average voyage engine load 80% and bunker price level 80 to 100 US$ /barrel)
Bunker fuel price history (since May 2006)
US$ / barrel
A popular statement of ship operators going to move to museum :
„I don‘t need to bother my vessels fuel costs, the bill goes anyway on table of the charterer.“
© ABB Automation GmbHSeptember 14, 2009 | Slide 7 Automatic optimization of diesel engine performance
CONGRESS 2009
Economic background Mapping of the reduction potentials
?
Optimization of efficiency reduces both emission and fuel costsSource : IMO MEPC-58
© ABB Automation GmbHSeptember 14, 2009 | Slide 8 Automatic optimization of diesel engine performance
CONGRESS 2009
Optimization of engine performance Which information needed to judge diesel motor performance ?
Energy flow
Advanced cylinder pressure process analysis provides key data to evaluate the fuel efficiency and engine condtions
TDCCrank angle [deg.]
P[bar]
P MAX
P COMP th
P TDC
measuredpressure curve
theoretical compression curve
P Alpha2
P Alpha1
Alpha1 Alpha2
AlphaPmax
start ofcombustion
start exhaust gas outlet
expansion pressure
dP/dA
adiabaticexponent
MIP
The converting of the energy inside the engines cylinders is the most essential part of the diesel motor in regard of efficiency and availability
But - today less than 15% of new delivered ships the cylinder pressure process of the propulsion engine is monitored online.
© ABB Automation GmbHSeptember 14, 2009 | Slide 9 Automatic optimization of diesel engine performance
CONGRESS 2009
Optimization of engine performance Today and tomorrow
Automation
Performance analysisCyl pressure
Manual
Engine Readjustment
-
Operation data
Cyl pressure
Performance analysis
Control readjust
Verification
Enhanced engine control system
Automation
Today crew has to collect operation data and analyze the performance. Improving measures has to be chosen and readjustment to be carried out manually. Results to be verified by collection and analzye of new operation data.
Tomorrow the optimization of operation performance will be covered automatically be enhanced engine control; the „Loop control“ : collection of operation data, analyze of the performance, decision of improving measures and readjustment by actuators.
© ABB Automation GmbHSeptember 14, 2009 | Slide 10 Automatic optimization of diesel engine performance
CONGRESS 2009
a well Pmax-balanced engine
Optimization of engine performance Requirement on supervision and optimization
TARGET : Performance optimizing on actual load and ambient condition
Supervising & optimizing of Pmax pressure
Supervising & optimizing of Pmax balancing
Supervising & optimizing of Pcomp balancing
Supervising & optimizing of MIP balancing
© ABB Automation GmbHSeptember 14, 2009 | Slide 11 Automatic optimization of diesel engine performance
CONGRESS 2009
Optimization of engine performance today Requirement on monitoring the thermodynamic process
Advanced cylinder pressure process analysis provides key data to evaluate the fuel efficiency
Qualification requirements :Accuracy : better than 0,5 % FS (along whole pressure cycle)
Operation : online monitoring (for engine control purpose even real-time monitoring)
Maintenance : no recalibration; long interval for maintenance (cleaning)
Reliability : long term continous operation (MTBF > 5 years)
Handling : easy equipment operation for ship crews
© ABB Automation GmbHSeptember 14, 2009 | Slide 12 Automatic optimization of diesel engine performance
CONGRESS 2009
Optimization engine performance today Requirement on monitoring the thermodynamic process
Advanced cylinder pressure process analysis provides key data to evaluate the fuel efficiency
P maxP compP mi
The service life expectancy and long term accuracy reliability of cylinder pressure sensors with membrane design can be effected by :- contamination with combustion residues (heavy fuel)- ageing / wearing of membrane- heat flash- regular cleaning maintenance - accuracy check / recalibration needed
Mechanic or portable electronic units
Sensors with „membrane“ principle
not qualified
limited qualified(piezo, thinfilm or strain gauge technologies)
typical design of combustion pressure sensors with membrane
load cell membrane
© ABB Automation GmbHSeptember 14, 2009 | Slide 13 Automatic optimization of diesel engine performance
CONGRESS 2009
Monitoring the combustion performance Requirement on monitoring the thermodynamic process
Cylmate transducer - with pressductor technology
Accuracy : better than 0,5 % FS (along whole pressure cycle)Operation : online & real-time monitoringMaintenance friendly : no recalibration, no cleaning maintenanceReliability : MTBF > 10 years
fully qualified
The “blow through” design solves clogging influences and cleaning maintenance
The pressure transmission via tube solves the heat flash influences
The robust magneto-elastic measuring principle ensures high reliability with long lasting life time
© ABB Automation GmbHSeptember 14, 2009 | Slide 14 Automatic optimization of diesel engine performance
CONGRESS 2009
Monitoring the combustion performance Approval on accuracy
Comparison measurement in reference of water cooled sensor with valve controlled heat flash protection
Performance test at Wärtsilä testbed Winterthur, Kistler vs. ABB, Dec. 2006
Conclusion : ABB sensor with magnetoelastic measuring principle prooves highest accuracyover the whole process cycle in the cylinder over all load stages
Pmi diff
© ABB Automation GmbHSeptember 14, 2009 | Slide 15 Automatic optimization of diesel engine performance
CONGRESS 2009
The monitoring of MIP and SFOC What is needed for a thermodynamic evaluation of cyl pressure ?
precise cylinder + precise rotation + angle measurementpressure sensor
precise crankshaft twist error compensation
true engine performance data
=
real-time crankshaft twist computing by mass-elastic engine model
flywheel profile scan by pulsed eddy current sensor
wearless pressure sensor Pressductor® technology
Indicated Engine Power [kW]MIP [bar]Pmax [bar]αPmax [°CA]Pign [bar]αPign [°CA]Pcomp [bar]Ptdc [bar]Pdiff (Pmax-Pcomp) [bar]dP/dα -max [bar/°CA]Pscav [bar]
© ABB Automation GmbHSeptember 14, 2009 | Slide 16 Automatic optimization of diesel engine performance
CONGRESS 2009
The monitoring of MIP Approval in the field
Evaluated MIP related to engine power in comparison to MEP performance curve (source of around 7.300.000 stokes per vessel) Winner of the
CIMAC 2004
President's Award
The ABB paper “Stroke-by-stroke measurement of diesel engine performance on board” “ was awarded “On a basis of a practical contribution of the future success of the engine industry”
Field experience proves repeatability and reliability of evaluated engine performance over long term operation - the technology gains recognition and high reputation in the shipping industry.
© ABB Automation GmbHSeptember 14, 2009 | Slide 17 Automatic optimization of diesel engine performance
CONGRESS 2009
The optimized engine performance Strong correlation between Pmax and SFOC
178,00
177,50
177,00
176,50
176,00
175,50
175.00134 136 138 140 142 144
176,75
177,97
175,53
SFOC, g/kWh
Pmax, bar
Example at a 12RTA96 engine
Increase of Pmax effects :
3,5 bar effects about 0,5% fuel savings
7,0 bar effects about 1,0% fuel savings
The task is to keep Pmax according to the performance curves to operate at best fuel consumption
SFOC
Pmax
© ABB Automation GmbHSeptember 14, 2009 | Slide 18 Automatic optimization of diesel engine performance
CONGRESS 2009
The monitoring of SFOC Online SFOC Monitoring
CYLMATE ControllerFuel mass flow
(4 – 20 mA )
Main Engine
Return
SupplyKRAL Volumeter
CYLMATE
Operator Station
Cylmate ControllerKRAL system measuring the fuel mass flow at supply and backflow. The fuel signal (kg/h) connected to Cylmate
Pmax-SFOC test. Performed by KRAL & ABB on a 7S50MC engine
© ABB Automation GmbHSeptember 14, 2009 | Slide 19 Automatic optimization of diesel engine performance
CONGRESS 2009
The monitoring of SFOC Online SFOC monitoring
Cylmate system displays online- indicated and effective power (kW) - accumulated energy (kWh) - SFOC (g/kWh)
© ABB Automation GmbHSeptember 14, 2009 | Slide 20 Automatic optimization of diesel engine performance
CONGRESS 2009
The monitoring of SFOC Online SFOC calculation with online fuel mass flow
7S50MC
0
0.5
1
1.5
2
2.5
3
3.5
4
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Engine aPign-Ø deg The fuel injection was changed from about 2,5° to 2,0°CA by means of FQS - VIT
7S50MC
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40
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100
120
140
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Engine Pmax-Ø bar Pmax increased with about 10bar from 120bar to about130bar
7S50MC
168
170
172
174
176
178
180
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SFOC SFOCIndicated averag20 stroke The SFOC was reduced from 177 to
about 173g/kWh ~2,2% fuel reduction
7S50MC
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Engine IPOW W The Indicated Power increased with 0,6MW. From about 7,7MW to 8,3MW ~5,7% increase
Result Pmax-SFOC test. Performed by KRAL & ABB on a 7S50MC running at ~75% load
© ABB Automation GmbHSeptember 14, 2009 | Slide 21 Automatic optimization of diesel engine performance
CONGRESS 2009
Engine performance monitoring Integration of cylinder pressure into superior automation system
© ABB Automation GmbHSeptember 14, 2009 | Slide 22 Automatic optimization of diesel engine performance
CONGRESS 2009
Ship Performance Online System concept
Integrated logging of nautical data and engine performance
Automatic 24 hours noon report generator
E-mail client to management office
Local ship data archiv and central fleet data archiv
© ABB Automation GmbHSeptember 14, 2009 | Slide 23 Automatic optimization of diesel engine performance
CONGRESS 2009
Engine performance monitoring Integration to online ship performance monitoring
Continous, automatic and reliable information for
onboard crew and ship mangement
© ABB Automation GmbHSeptember 14, 2009 | Slide 24 Automatic optimization of diesel engine performance
CONGRESS 2009
Ship Performance Online Automatic fuel efficiency reporting over the fleet
© ABB Automation GmbHSeptember 14, 2009 | Slide 25 Automatic optimization of diesel engine performance
CONGRESS 2009
Online optimization of tomorrow Loop Control – Engine Auto-tuning
Wärtsilä, MAN, ABB, and APM are together running loop control projects since autumn 2007
Loop control signals:
independent & galvanic isolated
P(t)
Pressure sensor electronic with additional analog signal interface P/t
Upgrade for enhanced thermodynamic evaluation
ME or RT-flex Engine control
systemLoop control : Injection process and exhaust valves controlled individually per cylinder by means of online cylinder pressure monitoring
© ABB Automation GmbHSeptember 14, 2009 | Slide 26 Automatic optimization of diesel engine performance
CONGRESS 2009
Online optimization of tommorrow Interface to Loop Control –Auto-tuning
DC supply
Sync pulse
Field bus
Cylmate Transducer Bus
Sense
Pressure sensor
Bus connector
CPU
Signalcondit
Excitat.Control
Powersupply
Integrated electronic unit Loadcell
Memory&
InterfaceD/A
Analog out Pt 4 to 20 mA
Decentralized pressure sensor electronic extended with analog out signal for loop control impementation
© ABB Automation GmbHSeptember 14, 2009 | Slide 27 Automatic optimization of diesel engine performance
CONGRESS 2009
Online optimization of tomorrow Auto-tuning for MAN engines
Original source byBackground
© ABB Automation GmbHSeptember 14, 2009 | Slide 28 Automatic optimization of diesel engine performance
CONGRESS 2009
Online optimization of tomorrow Optimization Pmax
Reduction in Fuel oil consumption / CO2 emission Original source by
© ABB Automation GmbHSeptember 14, 2009 | Slide 29 Automatic optimization of diesel engine performance
CONGRESS 2009
Original source bySystem layout PMI-Online MK2 (under development)
Online optimization of tomorrow MAN PMI-Online auto tuning
MOP-S (CoCoS-EDS / PMI PC)
MOP-B
PMI DAUMPC
Control signals
Pmax Feedback signals Cylinder pressuresI/P converters
(MC only)
PMI sensorsActuators
TCP/IP
Arcnet TCP/IPin preparation
© ABB Automation GmbHSeptember 14, 2009 | Slide 30 Automatic optimization of diesel engine performance
CONGRESS 2009
Online optimization of tomorrow MAN PMI-Online auto tuning
System layout PMI-Online MK2 (under development)
Online cylinder pressure sensors approved & applicable : either ABB or KISTLER
Original source by
KistlerKistler
PMI-Online Mk2
CoCoS-EDSMOPAuto-Tuning
PMI DauTCP/IP
TCP/IPTCP/IP
ME-ECS
ARCNET
ABBABB
MOP-S: (CoCoS-EDS / PMI PC)
MOP-B
© ABB Automation GmbHSeptember 14, 2009 | Slide 31 Automatic optimization of diesel engine performance
CONGRESS 2009
Prototype field test of auto-tuning function Original source by
Online optimization of tomorrow MAN PMI-Online auto tuning
© ABB Automation GmbHSeptember 14, 2009 | Slide 32 Automatic optimization of diesel engine performance
CONGRESS 2009
Auto tuning overall benefits Original source by
Online optimization of tomorrow MAN PMI-Online auto tuning
Fuel oil consumptionReduction potential: 3 g/kWhReduction average: 1 g/kWh
Emissionpotential: 2% C02 reduction
Operation cost reductionReduced engine maintenance costs, increased availability/reliability
Simplified operabilityEase workload on crewEnsures engine is being operated optimally – continuously
© ABB Automation GmbHSeptember 14, 2009 | Slide 33 Automatic optimization of diesel engine performance
CONGRESS 2009
Loop control for RT-Flex engines Application target
BALANCINGCOMPRESSION PRESSURES
OPTIMISINGPEAK PRESSURES
The CLCPC Funtion
( ) ( ) ( ) ( )ISOscavscavISOambambISOEaTEaTISOambambISOFiringFiring TTTTpppppp ,,,,, 1.02.001.020 −⋅+−⋅−−⋅−−⋅+=
© ABB Automation GmbHSeptember 14, 2009 | Slide 34 Automatic optimization of diesel engine performance
CONGRESS 2009 Original source by
Online optimization of tomorrow Wärtsilä Loop Control for RT-Flex
System layout (example14RT-Flex engine )
© ABB Automation GmbHSeptember 14, 2009 | Slide 35 Automatic optimization of diesel engine performance
CONGRESS 2009
4 X
ABB parts
Wärtsilä parts
Cylmate Crank angle sensor Blower inlet temperature sensor
Scavenge air temperature sensor
Blower inlet temperature sensor
Scavenge air temperature sensor Cylmate operator
station
Cylmate Controller
CANopen system bus
FCM
20 -
1
FCM
20 -
2
FCM
20 -
3
FCM
20 -
4
FCM
20 -
5
FCM
20 -
6
FCM
20 -
7
FCM
20 -
8
FCM
20 -
9
FCM
20 -
10
FCM
20 -
11
FCM
20 -
12
FCM
20 -
13
FCM
20 -
14
FCM
20 –
onlin
e sp
are
WECS-9520
System layout (example14RT-Flex engine )
Online optimization of tomorrow Loop Control & enhanced cylinder pressure monitoring
© ABB Automation GmbHSeptember 14, 2009 | Slide 36 Automatic optimization of diesel engine performance
CONGRESS 2009
Loop control & CBM monitoringIntegration to CBM system
© ABB Automation GmbHSeptember 14, 2009 | Slide 37 Automatic optimization of diesel engine performance
CONGRESS 2009
Loop control / Auto tuning on conventional camshaft engine
The benefit of auto tuning motivates to adapt also on camshaft engines,
development are under progress at the engine makers accordingly.
The basic level application will control the engine VIT automatically.
The full level solution shall specificly control cylinders injection pumps.
Operation
Engine size
Poor conditions Average Within norm limits
Large 3 –5 months 5–8 months 8 –12 months
Medium 6 –12 months 12 –18 months 18 –30 months
Small 18 –30 months 30 –48 months 48 –72 months
Beside engine size and operation the pay back time depends on fuel price
Investment and payback
© ABB Automation GmbHSeptember 14, 2009 | Slide 38 Automatic optimization of diesel engine performance
CONGRESS 2009
SummarizeCombined benefit
Fuel consumption reduction potential SFOC 1- 3 %
Emission reduction (CO2 reduction potential 2 %)
Increased availability/reliability
Simplify work load for crew
Monitoring of the fuel effiency
Supervison of the load balance
Recogntion of engine wear and faults
Reduction engine maintenance costs
Support of technical shipmangement
Engine performance is continouslysupervised for best operation condition
Enhanced engine control& monitoring
Engine is continously adjustedto best operation condition
Performance monitoring& condition analysis
Optimized operation and costIncreased safetyState of the art tools for crewand shipmangement
Performance analyze
Engine control
© ABB Automation GmbHSeptember 14, 2009 | Slide 39 Automatic optimization of diesel engine performance
CONGRESS 2009
SummaryThe presented solutions shallcontribute to a significant step
to achieve „greener“ ships, optimize operation costsand provide better safety
© ABB Automation GmbHSeptember 14, 2009 | Slide 40 Automatic optimization of diesel engine performance
CONGRESS 2009