CIMAC Congress - Schiff & Hafen

CIMAC Congress - Schiff & Hafen CIMAC Congress - Schiff & Hafen

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CIMAC CONGRESS | BERGEN 2010 highly advanced aero- and thermodynamic design principles applicable to related turbomachinery such as gas turbines and aeroengines. Unlike these applications, however, turbochargers are not always operated with “clean” media. Under harsh conditions turbochargers can ingest oil and dust laden air on the compressor side as well as severely contaminated exhaust gases on the turbine side. Since peak aerodynamic performance is required and the geometries of the compressor and turbine stages are designed with this aim, it is evident that any contamination in the flow duct or on blade profiles will influence aerodynamics and may lead to performance deterioration. Possible consequences for the engine of a drop in turbocharger performance are higher exhaust gas and valve-seat temperatures, while for the turbocharger there is the possibility of increased rotor speed. Each of these consequences can even lead to an undesirable reduction in engine load rating. Additionally, fouling on the turbine side of the turbocharger can cause the blade wear rate exceed acceptable limits. As a result mechanical cleaning, shorter exchange intervals or premature reconditioning may be necessary, with all their economic impacts. Several cleaning procedures are available to counteract the build-up of fouling on turbocharger components and thus keep performance more or less stable. However, under certain boundary conditions, and especially on some four-stroke HFO burning engines, these measures often have only limited effect. As a result, an uncontrolled downward drift in performance is possible over a turbocharger’s operating period. Besides the drop in performance in such circumstances, there is also the disadvantage that today’s cleaning methods are not always well suited to the avoidance of turbine component wear. The present paper outlines available cleaning methods and their integration into the turbocharger design and development process in order to narrow the gap between the performance potential of turbocharger technology and the performance effectively available over standard service intervals. Current methods are described and their efficiency documented, based on field-experience. Further, the paper provides an insight into how wear due to contamination can be significantly reduced and how this can have a substantial economic impact. Finally, parts of the development process are described, showing how procedures can be derived by adopting a systematic approach and how they lead to performance stability in turbochargers operating on HFO. 3D-fluid-structure interaction for an axial turbocharger turbine blade to improve the vibrational safeguard process A. Bornhorn, S. Mayr, T. Winter, MAN Diesel & Turbo SE, Germany The vibrational safeguarding of a turbine rotor blade design is still a great challenge for today’s high performance turbochargers, in particular thereby affected, that the turbocharger has to operate in a very wide rotor speed range without any critical vibrational excitation. According to the state of the art the vibrational safeguarding is an integrated process of numerical simulation and experimental verification. Finite Element calculations establish the basis for experimental determination of dynamic blade load by strain gauge measurement or non intrusive measurement techniques e.g. tip timing. The measured blade loads again are a necessary input for a subsequent numerical calculation of the blades fatigue safety. As this approach is dependent on the availability of prototype hardware results can be obtained in a very late stage of the development process. In order to get decisive references about the excitability of a turbine rotor blade during the development process, a plurality of existing vibrational measurements in their critical modes were recomputed with an unsteady CFD code. The results of the CFD analysis are pointing to aerodynamic effects, which are causative for an excitation. Beside the evaluation and visualisation of the aerodynamic unsteady effects, the time depending pressure distribution on the rotor blade surfaces is the most important result of the CFD computation, as this distribution is impressed as a time depending load on a FE model. Considering, that the damping coefficient is not finally determined, the FE analysis shows tendencies, which are comparable with the measurements. Therefore it will be possible in the future to obtain valuable indications about the vibration behavior of a turbine rotor blade at a very early state of the development process. ST27: A new generation of radial turbine turbochargers for highest pressure ratios R. Drozdowski, K. Buchmann, Kompressorenbau Bannewitz GmbH, Germany The biggest challenge to future developments of medium-size and large diesel engines in marine applications, especially engines using heavy fuel, will be to comply with the tougher environmental regulations of IMO Tier II. A supercharging system offers optimum support for these developments by providing a higher boost pressure and better efficiencies. Since its introduction, KBB’s HPR turbocharger range has been well accepted on the market. KBB will continue to face up to this challenge with the new ST27 range of radial turbine type turbochargers. Based on the successful HPR range, the new ST27 turbochargers reach pressure ratios of up to 5.5 with a high overall efficiency. In order to meet the new demands of engine applications, the ST27 range has been extended by two additional sizes over the HPR range and will be used for gas, diesel and heavy fuel oil engines with a power output from 300 to 4800kW. However, the outline dimensions for the ST3–ST6 are equal to those of the HPR3000 – HPR6000. The ST2 is planned for smaller and the ST7 for higher volume flow rates. The ST27 has already been launched onto the market. The full range will be available by the end of 2010. This paper describes the development of the main ST27 turbocharger features such as bearing and compressor design including temperature measurements in the rotating impeller in preparation for adopting a new air-cooling system. An extensive qualification test program was successfully performed on both the turbocharger test stand and engine test benches. The paper focuses in detail on the development process for the radial turbine wheel. High rotational speeds and high temperatures, but especially blade vibration, make the turbine wheel one of the most critical parts in the turbocharger. In contrast, less time is available for developments. Efficient and fast design and evaluation tools help reduce prototyping and experimental work to a minimum. Knowledge of the occurring peak vibratory stress is essential during the design process. In this regard, a method is presented to estimate the vibratory stress of radial turbine blades by a simple excitation model. The effects of mistuning induced by geometric differences in the blades result in a further uncertainty during the design process. The modeling and analysis of the effects of geometric-based blade mistuning and thus the relevant effect on peak vibratory stress are described in this paper along with the corresponding results of blade vibration measurements. Development of Niigata-NGT3B gas turbine for large standby generator set H. Kojima, S. Tarui, T. Kuribayashi, K. Takahashi, M. Koyama, Niigata Power Systems Co., Ltd., Japan Niigata Power Systems Co., has developed the new gas turbine NGT3B which is installed in a large standby generator set. This gas turbine engine meets a large capacity of important facilities in 62 Ship & Offshore | 2010 | No. 3

Monday, 14 June Tuesday, 15 June Wednesday, 16 June Thursday, 17 June Japanese metropolitan areas. It is installed in the CNT-3000EA generator set which generates 3000kVA. Furthermore, it is scaled up to 6000kVA by using a twin NGT3B gas turbine. Although the generator set is large, it can be quickly started within 40 seconds defined by the fire defense law in Japan. An additional specification of rapid restarting within 40 seconds after an engine stop increases reliability for a standby generator set. The other features are lightness, a digital control, a remote monitoring system and a low leakage lubricating system. The gas turbine engine is composed of a single shaft, two-stage centrifugal compressor, three-stage axial turbine, a single-can combustor, and a dual-fuel injector. One characteristic is turning-less for rotor cooling after the engine stops. Characteristic positions of rotor bearings realize it. The rated output power is increased from 2207kW to 2648kW by the improvement of NGT3A base model. A thermal efficiency achieves 24.7%. On the other hand, the maximum power is 2800kW, so some margin is given to the rated output power. Durability against the heat cycle by the fast start is tested by repeated engine starts and stops. And rapid restarting tests within 40 seconds are done on the assumption that power grids are returned during the engine stops. Long no load continuous running tests improve reliabilities of early standby to blackout. Over load tests confirm the durability of hot parts. There is no problem for durability of the engine. Any remarkable decrease in performance can be detected in the durability tests. This paper describes the design features of major engine component and a generator set for NGT3B. An engine performance and durability tests results are also shown. June 15th Poster Session Session 1 Exhibition area The design of a new generation mediumspeed research engine O. Kaario, M. Imperato, A. Tilli, K. Lehto, O. Ranta, E. Antila, A. Elonheimo, T. Sarjovaara, M. Nuutinen, M. Larmi, Aalto University School of Science and Technology, Finland, T. Roennskog, S. Pisilae, Componenta Pistons Oy, Finland, J. Tiainen, I Kallio, H. Rinta-Torala, Wärtsilä Finland Oy, Finland Session 2 Improving the combustion process in leanburn natural gas compressor engines R. Evans, R. Brown, A. Mezo, The University of British Columbia, Canada Combustion system design study to maximize thermal efficiency in open chamber stationary natural gas engines L. Tozzi, E. Sotiropoulou, D. Chiera, J. Adair, Woodward , USA D. Montgomery, P. Jensen, B. Hanks, A. Kim, Caterpillar, USA Session 3 Effects of Miller timing on the performance and exhaust emissions of a non-road diesel engine S. Niemi, University of Vaasa and Turku University of Applied Sciences, Finland, P. Nousiainen, P. Lassila, V. Tikkanen, K. Ekman, Turku University of Applied Sciences, Finland Emissions – The way ahead P. Tremuli, A. S. Carter, Ricardo UK Ltd., UK Improvements to transient response times and decreased smoke production in medium speed marine propulsion diesel engines T. Yamada, Y. Okano, K. Hanamoto, S. Shimomura, Daihatsu Diesel MFG.Co., Ltd., Japan NO formation model of a diesel engine based on quantum chemistry S. Zhou, T. Xu, Y. Zhu, Harbin Engineering University, P.R. of China Optimization of combustion system to comply with IMO Tier 2 regulation on medium speed diesel engines K. -D. Kim, W. -H. Yoon, S. -H. Ghal, H. -I. Kim, Hyundai Heavy Industries Co., Ltd., Korea, C.-S. Bae, Korea Advanced Institute of Science and Technology, Korea Session 6 Wärtsilä gas engines – the green power alternative H. Sillanpaeae, U. Astrand, Wärtsilä Finland Oy, Finland Integrated cylinder pressure measurement for gas engine control S. Neumann, M. Bienwald, Imes GmbH, Germany Session 12 Acid and base in engine oil and the correct determination of oil change intervals F. W. Girshick, Infineum USA, L.P., USA No. 3 | 2010 | Ship & Offshore 63

Monday, 14 June<br />

Tuesday, 15 June<br />

Wednesday, 16 June<br />

Thursday, 17 June<br />

Japanese metropolitan areas. It is installed in the CNT-3000EA<br />

generator set which generates 3000kVA. Furthermore, it is scaled up<br />

to 6000kVA by using a twin NGT3B gas turbine. Although the<br />

generator set is large, it can be quickly started within 40 seconds<br />

defined by the fire defense law in Japan. An additional specification<br />

of rapid restarting within 40 seconds after an engine stop increases<br />

reliability for a standby generator set. The other features are lightness,<br />

a digital control, a remote monitoring system and a low leakage<br />

lubricating system. The gas turbine engine is composed of a single<br />

shaft, two-stage centrifugal compressor, three-stage axial turbine, a<br />

single-can combustor, and a dual-fuel injector. One characteristic is<br />

turning-less for rotor cooling after the engine stops. Characteristic<br />

positions of rotor bearings realize it. The rated output power is<br />

increased from 2207kW to 2648kW by the improvement of NGT3A<br />

base model. A thermal efficiency achieves 24.7%. On the other<br />

hand, the maximum power is 2800kW, so some margin is given to<br />

the rated output power. Durability against the heat cycle by the fast<br />

start is tested by repeated engine starts and stops. And rapid restarting<br />

tests within 40 seconds are done on the assumption that power<br />

grids are returned during the engine stops. Long no load continuous<br />

running tests improve reliabilities of early standby to blackout. Over<br />

load tests confirm the durability of hot parts. There is no problem<br />

for durability of the engine. Any remarkable decrease in performance<br />

can be detected in the durability tests.<br />

This paper describes the design features of major engine component<br />

and a generator set for NGT3B. An engine performance and<br />

durability tests results are also shown.<br />

June 15th<br />

Poster Session<br />

Session 1<br />

Exhibition area<br />

The design of a new generation mediumspeed<br />

research engine<br />

O. Kaario, M. Imperato, A. Tilli, K. Lehto, O. Ranta, E.<br />

Antila, A. Elonheimo, T. Sarjovaara, M. Nuutinen, M.<br />

Larmi, Aalto University School of Science and<br />

Technology, Finland,<br />

T. Roennskog, S. Pisilae, Componenta Pistons Oy,<br />

Finland,<br />

J. Tiainen, I Kallio, H. Rinta-Torala, Wärtsilä Finland<br />

Oy, Finland<br />

Session 2<br />

Improving the combustion process in leanburn<br />

natural gas compressor engines<br />

R. Evans, R. Brown, A. Mezo, The University of<br />

British Columbia, Canada<br />

Combustion system design study to<br />

maximize thermal efficiency in open<br />

chamber stationary natural gas engines<br />

L. Tozzi, E. Sotiropoulou, D. Chiera, J. Adair,<br />

Woodward , USA<br />

D. Montgomery, P. Jensen, B. Hanks, A. Kim,<br />

Caterpillar, USA<br />

Session 3<br />

Effects of Miller timing on the performance<br />

and exhaust emissions of a non-road diesel<br />

engine<br />

S. Niemi, University of Vaasa and Turku University<br />

of Applied Sciences, Finland,<br />

P. Nousiainen, P. Lassila, V. Tikkanen, K. Ekman,<br />

Turku University of Applied Sciences, Finland<br />

Emissions – The way ahead<br />

P. Tremuli, A. S. Carter, Ricardo UK Ltd., UK<br />

Improvements to transient response times<br />

and decreased smoke production in<br />

medium speed marine propulsion diesel<br />

engines<br />

T. Yamada, Y. Okano, K. Hanamoto, S. Shimomura,<br />

Daihatsu Diesel MFG.Co., Ltd., Japan<br />

NO formation model of a diesel engine<br />

based on quantum chemistry<br />

S. Zhou, T. Xu, Y. Zhu, Harbin Engineering University,<br />

P.R. of China<br />

Optimization of combustion system to<br />

comply with IMO Tier 2 regulation on<br />

medium speed diesel engines<br />

K. -D. Kim, W. -H. Yoon, S. -H. Ghal, H. -I. Kim,<br />

Hyundai Heavy Industries Co., Ltd., Korea,<br />

C.-S. Bae, Korea Advanced Institute of Science and<br />

Technology, Korea<br />

Session 6<br />

Wärtsilä gas engines – the green power<br />

alternative<br />

H. Sillanpaeae, U. Astrand, Wärtsilä Finland Oy,<br />

Finland<br />

Integrated cylinder pressure measurement<br />

for gas engine control<br />

S. Neumann, M. Bienwald, Imes GmbH, Germany<br />

Session 12<br />

Acid and base in engine oil and the correct<br />

determination of oil change intervals<br />

F. W. Girshick, Infineum USA, L.P., USA<br />

No. 3 | 2010 | Ship & Offshore<br />

63

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