ABB Optimization of Engine Performance 2009

ICST Congress
Hamburg
10.Sept.2009
Automatic optimization of diesel engine performance

by loop control of cylinder pressure process
ABB Automation GmbH Dipl.Ing. Wolfgang Krasa
ABB Automation GmbH

September 14, 2009 | Slide 1
Automatic optimization of diesel engine performance
by loop control of cylinder pressure process CONGRESS 2009
Content
Environment 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
Wrtsil solution Loop Control
Integration CBM system
Benefits
Summary
ABB Automation GmbH

September 14, 2009 | Slide 2 Automatic optimization of diesel engine performance
Green house gas emission impact by maritime transportation CONGRESS 2009
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 GmbH

Environmental impact caused by slow speed 2-stroke engines CONGRESS 2009
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.
Total No. Yearly fuel Yearly NOx Yearly

of engines consumption emission CO2 emission
10 680 167.000.000 t 17.000.000 t 500.000.000 t
ABB Automation GmbH

Legislations will force emission reduction CONGRESS 2009
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 Communitys greenhouse
gas emission reduction commitments
up to 2020.
ABB Automation GmbH

Economic background
Fuel costs CONGRESS 2009
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 dont need to bother my vessels fuel costs,
the bill goes anyway on table of the charterer.
ABB Automation GmbH

Economic background
Mapping of the reduction potentials CONGRESS 2009
Optimization of efficiency reduces both emission and fuel costs

Source : IMO MEPC-58
ABB Automation GmbH

Optimization of engine performance
Which information needed to judge diesel motor performance ? CONGRESS 2009
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.
Energy flow
Advanced cylinder pressure process analysis provides key

data to evaluate the fuel efficiency and engine condtions
P
[bar]
start of dP/dA measured
combustion pressure curve
P MAX theoretical
P TDC adiabatic compression curve
exponent
P COMP th expansion pressure
P Alpha2
P Alpha1 start exhaust
gas outlet
MIP
Alpha1 Alpha2 Crank angle
TDC [deg.]
AlphaPmax
ABB Automation GmbH

Today and tomorrow CONGRESS 2009
Today crew has to collect operation data and analyze Tomorrow the optimization of operation performance
the performance. Improving measures has to be will be covered automatically be enhanced engine
chosen and readjustment to be carried out manually. control; the Loop control : collection of operation
Results to be verified by collection and analzye of data, analyze of the performance, decision of
new operation data. improving- measures and readjustment by actuators.
Enhanced engine
control system
Automation Automation
Operation data
Cyl pressure
Performance Performance
Cyl pressure analysis analysis
Control readjust
Verification
Manual
Engine
Readjustment
ABB Automation GmbH

Requirement on supervision and optimization CONGRESS 2009
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
a well Pmax-balanced engine
ABB Automation GmbH

Optimization of engine performance today
Requirement on monitoring the thermodynamic process CONGRESS 2009
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 GmbH

Optimization engine performance today
Advanced
Mechanic cylinder electronic
or portable pressure process
units analysis provides key data to evaluate the not
fuelqualified
efficiency
P max
P comp
P mi
Sensors with membrane principle limited qualified

(piezo, thinfilm or strain gauge technologies)
typical design of combustion The service life expectancy and long term accuracy
pressure sensors with membrane 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
load cell membrane - accuracy check / recalibration needed
ABB Automation GmbH

Cylmate transducer - with pressductor technology fully qualified
Accuracy : better than 0,5 % FS (along whole pressure cycle)

Operation : online & real-time monitoring
Maintenance friendly : no recalibration, no cleaning maintenance
Reliability : MTBF > 10 years
The blow through design The pressure transmission The robust magneto-elastic
solves clogging influences via tube solves the heat measuring principle ensures high
and cleaning maintenance flash influences reliability with long lasting life time
ABB Automation GmbH

Approval on accuracy CONGRESS 2009
Performance test at Wrtsil testbed

Winterthur, Kistler vs. ABB, Dec. 2006
Pmi diff
Comparison measurement in reference

of water cooled sensor with valve
controlled heat flash protection
Conclusion : ABB sensor with magnetoelastic measuring principle prooves highest accuracy
over the whole process cycle in the cylinder over all load stages
ABB Automation GmbH
The monitoring of MIP and SFOC
What is needed for a thermodynamic evaluation of cyl pressure ? CONGRESS 2009
precise cylinder + precise rotation + precise crankshaft = true engine

pressure sensor angle measurement twist error performance data
compensation
wearless pressure sensor flywheel profile scan by real-time crankshaft twist Indicated Engine Power [kW]
Pressductor technology pulsed eddy current sensor computing by mass-elastic MIP [bar]
engine model Pmax [bar]
Pmax [CA]
Pign [bar]
Pign [CA]
Pcomp [bar]
Ptdc [bar]
Pdiff (Pmax-Pcomp) [bar]
dP/d -max [bar/CA]
Pscav [bar]
ABB Automation GmbH

The monitoring of MIP
Approval in the field CONGRESS 2009
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.
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
ward
President's A
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
ABB Automation GmbH
The optimized engine performance
Strong correlation between Pmax and SFOC CONGRESS 2009
The task is to keep Pmax according to the performance curves to operate at best fuel consumption
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
Pmax
SFOC, g/kWh
178,00 177,97
177,50
177,00
176,75
176,50
176,00
175,53
175,50
SFOC
175.00
134 136 138 140 142 Pmax,
144 bar
ABB Automation GmbH

The monitoring of SFOC
Online SFOC Monitoring CONGRESS 2009
Pmax-SFOC test. Performed by KRAL & ABB on a 7S50MC engine
KRAL system measuring

the fuel mass flow at supply CYLMATE Cylmate Controller
and backflow. Operator Station
The fuel signal (kg/h)
connected to Cylmate
CYLMATE
Fuel mass flow Controller
(4 20 mA )
Return
KRAL Volumeter
Supply
Main Engine
ABB Automation GmbH

Online SFOC monitoring CONGRESS 2009
Cylmate system displays online

- indicated and effective power (kW)
- accumulated energy (kWh)
- SFOC (g/kWh)
ABB Automation GmbH

Online SFOC calculation with online fuel mass flow CONGRESS 2009
Result Pmax-SFOC test. Performed by KRAL & ABB on a 7S50MC running at ~75% load
Engine aPign- deg
The fuel injection
7S50MC was changed from about Engine IPOW W
The Indicated7S50MC
Power increased with 0,6MW.
2,5 to 2,0CA by means of FQS - VIT From about 7,7MW to 8,3MW ~5,7% increase
4 10
3.5 9
8
3
7
2.5 6
5
2
4
1.5 3
1 2
1
0.5
0
0 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-
2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02 03 03 03 03 03 03 03 03
14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00: 14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00
Engine Pmax- bar

Pmax increased with about 10bar
7S50MC SFOC SFOCIndicated averag
20 stroke
The SFOC was reduced from 177 to
7S50MC
from 120bar to about130bar about 173g/kWh ~2,2% fuel reduction
160 184
140 182
120 180
100 178
176
80
174
60
172
40
170
20
168
0 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-02- 2007-0
2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02-03 2007-02 03 03 03 03 03 03 03 03
14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00: 14:46:00 14:48:00 14:50:00 14:52:00 14:54:00 14:56:00 14:58:00 15:00:0
ABB Automation GmbH

Engine performance monitoring
Integration of cylinder pressure into superior automation system CONGRESS 2009
ABB Automation GmbH

Ship Performance Online
System concept CONGRESS 2009
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 GmbH

Engine performance monitoring
Integration to online ship performance monitoring CONGRESS 2009
Continous, automatic and reliable information for

onboard crew and ship mangement
ABB Automation GmbH

Ship Performance Online
Automatic fuel efficiency reporting over the fleet CONGRESS 2009
ABB Automation GmbH

Online optimization of tomorrow
Loop Control Engine Auto-tuning CONGRESS 2009
Wrtsil, MAN, ABB, and APM are together running loop control projects since autumn 2007
Pressure sensor electronic

with additional analog signal
interface P/t
ME or RT-flex
Engine control Loop control : Injection
system process and exhaust
valves controlled
individually per cylinder by
means of online cylinder
Loop control signals: pressure monitoring
P(t)
independent &
galvanic isolated
Upgrade for enhanced
thermodynamic evaluation
ABB Automation GmbH
Online optimization of tommorrow
Interface to Loop Control Auto-tuning CONGRESS 2009
Decentralized pressure sensor electronic extended with analog out signal for loop control impementation
Integrated electronic unit Load

Excitat. cell
Signal
Control
condit Sense
CPU
Memory
Power Pressure sensor
D/A &
supply
Interface
Analog out Pt
4 to 20 mA
Bus connector
DC supply
Sync pulse
Field bus
Cylmate Transducer Bus
ABB Automation GmbH

Auto-tuning for MAN engines CONGRESS 2009
Background Original source by
ABB Automation GmbH

Optimization Pmax CONGRESS 2009
Reduction in Fuel oil consumption / CO2 emission Original source by
ABB Automation GmbH

MAN PMI-Online auto tuning CONGRESS 2009
System layout PMI-Online MK2 (under development) Original source by
TCP/IP MOP-S
MOP-B (CoCoS-EDS /
PMI PC)
in p
Arcnet repa TCP/IP
ratio
n
MPC
PMI DAU
Pmax Feedback signals

Cylinder pressures
I/P converters
(MC only)
PMI sensors
Actuators
Control signals
ABB Automation GmbH

System layout PMI-Online MK2 (under development) Original source by
Online cylinder pressure sensors approved & applicable :

ME-ECS
either ABB or KISTLER
ARCNET
MOP
CoCoS-EDS
MOP-B Auto-Tuning
TCP/IP TCP/IP
Kistler
Kistler
PMI Dau PMI-Online Mk2

TCP/IP
ABB
ABB
MOP-S: (CoCoS-EDS / PMI PC)
ABB Automation GmbH

Prototype field test of auto-tuning function Original source by
ABB Automation GmbH

Auto tuning overall benefits Original source by
Fuel oil consumption

Reduction potential: 3 g/kWh
Reduction average: 1 g/kWh
Emission
potential: 2% C02 reduction
Operation cost reduction

Reduced engine maintenance costs,
increased availability/reliability
Simplified operability
Ease workload on crew
Ensures engine is being operated optimally
continuously
ABB Automation GmbH

Loop control for RT-Flex engines
Application target CONGRESS 2009
The CLCPC Funtion
OPTIMISING
PEAK PRESSURES
BALANCING =p
p Firing + 20 ( p p ) 0.01 ( p p ) 0.2 (T
Firing , ISO amb amb , ISO EaT EaT , ISO amb Tamb,ISO ) + 0.1 (Tscav Tscav,ISO )
COMPRESSION PRESSURES
ABB Automation GmbH

Wrtsil Loop Control for RT-Flex CONGRESS 2009
Original source by
System layout (example14RT-Flex engine )
ABB Automation GmbH

Loop Control & enhanced cylinder pressure monitoring CONGRESS 2009
System layout (example14RT-Flex engine )
CANopen system bus WECS-9520
online spare
FCM20 - 10
FCM20 - 14
FCM20 - 13
FCM20 - 12
FCM20 - 11
FCM20 - 7
FCM20 - 8
FCM20 - 9
FCM20 - 5
FCM20 - 6
FCM20 - 1
FCM20 - 2
FCM20 - 3
FCM20 - 4
FCM20
Cylmate
Cylmate Controller
Crank angle
sensor Blower inlet temperature sensor
4X
Scavenge air temperature sensor Cylmate
ABB parts operator
station
Wrtsil parts
ABB Automation GmbH
Loop control & CBM monitoring
Integration to CBM system CONGRESS 2009
ABB Automation GmbH

Loop control / Auto tuning on conventional camshaft engine
CONGRESS 2009
Investment and payback
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.
Beside engine size and operation the pay back time depends on fuel price
Operation Poor conditions Average Within norm limits
Engine size
Large 3 5 months 58 months 8 12 months
Medium 6 12 months 12 18 months 18 30 months
Small 18 30 months 30 48 months 48 72 months
ABB Automation GmbH

Summarize
Combined benefit CONGRESS 2009
Optimized operation and cost
Increased safety
State of the art tools for crew
and shipmangement
Engine performance is continously Engine is continously adjusted
supervised for best operation condition to best operation condition
Monitoring of the fuel effiency
Supervison of the load balance Fuel consumption reduction potential SFOC 1- 3 %
Recogntion of engine wear and faults Emission reduction (CO2 reduction potential 2 %)
Reduction engine maintenance costs Increased availability/reliability
Support of technical shipmangement Simplify work load for crew
Performance Engine
analyze control
Performance monitoring Enhanced engine control

& condition analysis & monitoring
ABB Automation GmbH

Summary
The presented solutions shall CONGRESS 2009
contribute to a significant step

to achieve greener ships,
optimize operation costs
and provide better safety
ABB Automation GmbH

CONGRESS 2009
ABB Automation GmbH


ABB Optimization of Engine Performance 2009

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ABB Optimization of Engine Performance 2009

Uploaded by

Copyright:

Available Formats

ICST Congress

Automatic optimization of diesel engine performance

ABB Automation GmbH Dipl.Ing. Wolfgang Krasa

ABB Automation GmbH

ABB Automation GmbH

ABB Automation GmbH

New technologies are available today to reduce fuel consumption and

Total No. Yearly fuel Yearly NOx Yearly

ABB Automation GmbH

Kyoto protocol and EU is proceeding to incorporate international aviation & maritime

International maritime transport

ABB Automation GmbH

Bunker fuel price history (since May 2006)

A popular statement of ship operators going to

ABB Automation GmbH

Optimization of efficiency reduces both emission and fuel costs

ABB Automation GmbH

Advanced cylinder pressure process analysis provides key

ABB Automation GmbH

ABB Automation GmbH

TARGET : Performance optimizing on actual load and ambient condition

Supervising & optimizing of Pmax pressure

a well Pmax-balanced engine

ABB Automation GmbH

ABB Automation GmbH

Sensors with membrane principle limited qualified

ABB Automation GmbH

Cylmate transducer - with pressductor technology fully qualified

Accuracy : better than 0,5 % FS (along whole pressure cycle)

ABB Automation GmbH

Performance test at Wrtsil testbed

Comparison measurement in reference

precise cylinder + precise rotation + precise crankshaft = true engine

ABB Automation GmbH

Field experience proves repeatability and reliability of evaluated

Evaluated MIP related to engine power in comparison to MEP performance curve

The ABB paper Stroke-by-stroke

Example at a 12RTA96 engine

3,5 bar effects about 0,5% fuel savings

ABB Automation GmbH

Pmax-SFOC test. Performed by KRAL & ABB on a 7S50MC engine

KRAL system measuring

ABB Automation GmbH

Cylmate system displays online

ABB Automation GmbH

Engine Pmax- bar

ABB Automation GmbH

ABB Automation GmbH

Integrated logging of nautical

ABB Automation GmbH

Continous, automatic and reliable information for

ABB Automation GmbH

ABB Automation GmbH

Pressure sensor electronic

Integrated electronic unit Load

ABB Automation GmbH

Background Original source by

ABB Automation GmbH

Reduction in Fuel oil consumption / CO2 emission Original source by

ABB Automation GmbH

System layout PMI-Online MK2 (under development) Original source by

Pmax Feedback signals

ABB Automation GmbH