1. Further development of two-stage turbocharging systems for large engines

2. Content Development of the second generation Power2 Case studies
Medium-speed engine
High-speed engine
Conclusions
© ABB Group
September 20, 2018

3. Requirements and main design targets
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Pressure ratio up to 12
System efficiency over 75%
Low emissions, low fuel consumption
Low thermal load
Large compressor map width
High flexibility for various engine concepts
High specific volume flow rates
Compact design
High natural frequencies, high reliability and optimal mounting on engines
Designed for service
Downtimes comparable to single- stage turbochargers
© ABB Group
September 20, 2018

4. Power2 800-M design features
Extractable cartridge concept
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
The big plus of the new extractable cartridge concept
No disconnection of any gas or air flange connections required
No disconnection of oil piping required
No removal of any insulation parts required
All service work can be done from the “cold” side
Less dependency on cranes
© ABB Group
September 20, 2018

5. Power2 800-M design features
Compactness
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Very compact designs for high- and low-pressure turbochargers
Optimum in axial length; limited by flange dimensions only
Air and gas casings CFD optimized
Air inlet Air outlet Gas outlet Gas inlet
Power2 800-M LP
© ABB Group
September 20, 2018

6. Compressor development
Power2 800-M
Compressor development
2012 LP -
compressor
2010 -
2013 HP
compressor
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Limitation by inlet Mach number
Limitation by blade length
© ABB Group
September 20, 2018

7. Power2 800-M Compressor stages
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
High pressure compressor stage
for pressure ratio up to 12
Single-stage turbocharging
A100-M axial
Two-stage turbocharging
Power2 800-M low-pressure compressor stage
High pressure compressor stage
for pressure ratio up to 10
© ABB Group
September 20, 2018

8. Power2 800-M Turbine stages Design target low pressure turbine
High efficiency at similar range of specific flow areas compared to single- stage turbines
Design target high pressure turbine
Very large range of specific flow areas at similar performance compared to single-stage turbines
Two-stage turbocharging
Power2 800-M
High pressure turbine
Two-stage turbocharging
Power2 800-M
Low pressure turbine
Single-stage turbocharging
Single-stage turbocharging
© ABB Group
September 20, 2018

9. Overall system performance
Power2 800-M
Overall system performance
Overall performance comparison of A100-M and Power M system
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
TIC= 55°C
TIC= 70°C
TIC= 55°C
TIC= 70°C
Two-stage turbocharging
Power2 800-M
Pressure ratio up to 12
Two-stage turbocharging
Power2 800-M
Pressure ratio up to 9
Single-stage turbocharging
A100-M axial
TIC = Intercooler temperature
© ABB Group
September 20, 2018

10. Cases definition BMEP = 25 bar Case A – single stage, no Miller
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Case A – single stage, no Miller
Case B – single stage, maximum Miller
Case C – 2-stage, same Miller as case B
Case D – 2-stage, optimum Miller and variable valve timing
© ABB Group
September 20, 2018

11. Turbocharging system dimensions
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
2-stage size decrease
1-stage size increase
© ABB Group
September 20, 2018

12. The part load problem Basics
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
High pressure and high efficiency lead generally to a stronger pressure reduction at part load
This is due to the combined effects of efficiency and turbine area. These effects are described by the part load parameter:
© ABB Group
September 20, 2018

13. FPP operation VVT VVT VVT
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
VVT
VVT
VVT
© ABB Group
September 20, 2018

14. Variable speed operation
with variable valve timing
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
lC at BMEP = 10 bar is considered representative for the possibility to run an operating line
© ABB Group
September 20, 2018

15. Load change 0-100% at constant speed
Transient operation
Load change 0-100% at constant speed
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Case D with variable valve timing can achieve the load change much faster than in the reference case
© ABB Group
September 20, 2018

16. Influence of pressure split
Transient operation
Influence of pressure split
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Increasing the pressure ratio of the HP stage gives a slower load change
© ABB Group
September 20, 2018

17. Load acceptance 0-100% in 2 steps
Transient operation
Load acceptance 0-100% in 2 steps
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
© ABB Group
September 20, 2018

18. Case studies Evaluation Case A B C D Compactness   
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Case A B C D
Compactness 
 
Engine efficiency 
 
  
Part load
Transient performance
Nox emissions
Potential for power increase
2-stage turbocharging is only attractive when a large step in pressure ratio is achieved in connection with variable Miller timing
© ABB Group
September 20, 2018

19. Conclusions
Power2 800-M HP
Power2 800-M system is based on a completely new extractable cartridge concept
Focus on minimal service downtime supported by a new service tool concept
Focus on compact and reliable design
Two turbines and two compressors newly designed
Every component optimized for a two-stage system without compromise
High performance level and flexibility is achieved
Two case studies have shown that a consistent pressure ratio increase is necessary to exploit the full potential of the new turbocharging system
Development of the second generation Power2 Case studies Medium-speed diesel engine High-speed diesel engine Conclusions
Power2 800-M LP
© ABB Group
September 20, 2018