Automatic optimization of diesel engine performance - · PDF fileAutomatic optimization of diesel engine performance ... Automatic optimization of diesel engine performance. ... 46:00

© 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


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.


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.


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.“


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.“


CONGRESS 2009

Economic background Mapping of the reduction potentials

?

Optimization of efficiency reduces both emission and fuel costsSource : IMO MEPC-58


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.


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.


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


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


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


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


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


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]


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.


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


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


CONGRESS 2009

The monitoring of SFOC Online SFOC monitoring

Cylmate system displays online- indicated and effective power (kW) - accumulated energy (kWh) - SFOC (g/kWh)


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

2007-02-0314:46:00

2007-02-0314:48:00

2007-02-0314:50:00

2007-02-0314:52:00

2007-02-0314:54:00

2007-02-0314:56:00

2007-02-0314:58:00

2007-0215:00:

Engine aPign-Ø deg The fuel injection was changed from about 2,5° to 2,0°CA by means of FQS - VIT

7S50MC

0

20

40

60

80

100

120

140

160

2007-02-0314:46:00

2007-02-0314:48:00

2007-02-0314:50:00

2007-02-0314:52:00

2007-02-0314:54:00

2007-02-0314:56:00

2007-02-0314:58:00

2007-0215:00:

Engine Pmax-Ø bar Pmax increased with about 10bar from 120bar to about130bar

7S50MC

168

170

172

174

176

178

180

182

184

2007-02-03

14:46:00

2007-02-03

14:48:00

2007-02-03

14:50:00

2007-02-03

14:52:00

2007-02-03

14:54:00

2007-02-03

14:56:00

2007-02-03

14:58:00

2007-003

15:00:0

SFOC SFOCIndicated averag20 stroke The SFOC was reduced from 177 to

about 173g/kWh ~2,2% fuel reduction

7S50MC

0123456789

10

2007-02-03

14:46:00

2007-02-03

14:48:00

2007-02-03

14:50:00

2007-02-03

14:52:00

2007-02-03

14:54:00

2007-02-03

14:56:00

2007-02-03

14:58:00

2007-03

15:00

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


CONGRESS 2009

Engine performance monitoring Integration of cylinder pressure into superior automation system


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


CONGRESS 2009

Engine performance monitoring Integration to online ship performance monitoring

Continous, automatic and reliable information for

onboard crew and ship mangement


CONGRESS 2009

Ship Performance Online Automatic fuel efficiency reporting over the fleet


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


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


CONGRESS 2009

Online optimization of tomorrow Auto-tuning for MAN engines

Original source byBackground


CONGRESS 2009

Online optimization of tomorrow Optimization Pmax

Reduction in Fuel oil consumption / CO2 emission Original source by


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


CONGRESS 2009


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


CONGRESS 2009

Prototype field test of auto-tuning function Original source by



CONGRESS 2009

Auto tuning overall benefits Original source by


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


CONGRESS 2009

Loop control for RT-Flex engines Application target

BALANCINGCOMPRESSION PRESSURES

OPTIMISINGPEAK PRESSURES

The CLCPC Funtion

( ) ( ) ( ) ( )ISOscavscavISOambambISOEaTEaTISOambambISOFiringFiring TTTTpppppp ,,,,, 1.02.001.020 −⋅+−⋅−−⋅−−⋅+=

http://upload.wikimedia.org/wikibooks/sv/7/7e/Justitias-v%C3%A5gsk%C3%A5l,-bild-av-.gif


CONGRESS 2009 Original source by

Online optimization of tomorrow Wärtsilä Loop Control for RT-Flex

System layout (example14RT-Flex engine )


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


CONGRESS 2009

Loop control & CBM monitoringIntegration to CBM system


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


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


CONGRESS 2009

SummaryThe presented solutions shallcontribute to a significant step

to achieve „greener“ ships, optimize operation costsand provide better safety


CONGRESS 2009

Documents

Automatic optimization of diesel engine performance - · PDF fileAutomatic optimization of diesel engine performance ... Automatic optimization of diesel engine performance. ... 46:00