1|16 The customer magazine of ABB Turbocharging charge! Switzerland
Polishing clear-cut quality ABB quality as a value proposition 14 The never-ending quest for quality perfection Low-speed engine turbocharger and silencer form the complete package 4 ABB’s new compact A160-L completes the A100-L series Continous Product Improvement 16 Benefits all around thanks to interdisciplinary teamwork From the editor
New A100-L series turbocharger Waterway emissions The compact A160-L has key benefits for Senior engineer Wang Shilong discusses new 04 low-speed engines across a range of fuels. 10 standards aimed at cutting emissions in China. charge! 1|16
As our customers continue to see chal- At the same time the 28th CIMAC Con- lenges ahead, providing solutions that gress welcomes to Helsinki experts on help to reduce overall costs remains combustion engine technology for ship central to our business in 2016. We will propulsion, power generation, and rail fulfill this promise through development traction. Our highlight at this event is a of optimized products and customized completely new turbocharger designed turbocharger service solutions. and optimized for marine auxiliary engines. Its robust design provides good Recently, we launched the A160-L turbo- part-load efficiency and allows trouble- charger for small bore, low-speed engines, free operation under HFO conditions. across a range of fuel types. Similar to The user-friendly design enables easy our previous A100-L and A-200-L prod- crew maintenance with standard tools ucts, the new unit is designed for highest for a reduction in Total Cost of Owner- efficiency, reduced fuel consumption, ship. We will be very happy to present and lower emissions. As it can be main- the product to you personally at our tained during engine servicing, opera- Stand and receive your valuable feed- tional costs are reduced and application back on the digital tool designed for its Magdalena Okopska availability is maximized. For more about condition based maintenance. Head of Market Communication the new turbocharger and a silencer that ABB Turbocharging is part of the noise reduction package for We heartily invite our industry partners to the A100-L and A200-L series, turn to visit us either at CIMAC or Posidonia to page 4, or visit our Stand 2.211 at the discuss your operational needs and our Posidonia Exhibition in Athens on June 6 showcased newest products. In the to 10. meantime: Please enjoy this issue of charge!
2 ABB charge! 1|16 Contents
Target: zero defects Marine auxiliary collaboration Keeping ahead means continuously pushing Successful long-term cooperation between 14 quality to the next level. 18 ABB and IHI continues to flourish.
Technology Interview 4 Low-speed engine turbocharger and silencer form the 10 Chinese national standards for inland water shipping complete package emissions ABB’s new A160-L offers series benefits in combination Senior engineer Wang Shilong’s take on his country’s with an innovative noise reduction package efforts to combat waterway emissions 18 Marine auxiliary collaboration Kazuki Dobashi, head of IHI’s marine turbocharger Quality business unit, looks at how IHI and ABB cooperate in 14 ABB quality as a value proposition product development and commercialization Köbi Brem explains some of the processes underway at ABB with the aim of zero defects 16 Continuous Product Improvement News Why CPI, through interdisciplinary teamwork, is an 22 Awards, service agreements excellent tool for tackling product issues Tips for the operator Service 24 Turbine washing on medium-speed engines 7 A helping hand for the little helpers The low-down on turbocharger cleaning and why preven- ABB’s ongoing commitment to developing better tion is better than cure ways of keeping turbochargers on auxiliary engines in prime condition 21 Just-in-time delivery: Polar research icebreaker Recipe Meeting tight delivery schedules is a key ABB strength, 26 Bentos and cherry blossom as this example shows The meaning of and what to eat while enjoying Hanami
ABB charge! 1|16 3 Technology Low-speed engine turbocharger and silencer form the complete package ABB’s new A160-L turbocharger for two-stroke marine engines combines operational flexibility and low fuel consumption, while the industry’s first air outlet silencer offers unique noise abatement qualities.
Text Alexandra Christie, Photography ABB Turbo Systems Ltd
n these challenging times for most 1.7 m × 0.9 m × 1.32 m and weighs only containerships, gas carriers and multi- sectors of the marine industry, ship 1,330 kg, is highly efficient with a pres- purpose vessels of around 15 to 20,000 owners are facing the pressures of sure ratio of up to 5.0. dwt in size. Combining best-in-class effi- I overcapacity, falling levels of demand ABB has designed this latest turbo- ciency with additional market require- and, increasingly, tough new environ- charger for low-speed engines with a typi- ments makes this a very strong addition- mental rules that are coming into force. cal power rating of 3,900 kW to 4,100 kW. al offering to the A100 series.” This is leading to greater demand for It can be employed on diesel engines as High pressure ratios help to reduce technology that helps reduce operating well as the dual-fuel and gas engines which fuel consumption and lower engine costs, while ensuring compliance with are now increasingly popular in a number emission levels, while the exceptionally environmental and emissions regula- of small to medium vessel market sectors. wide compressor maps of the A160-L tions. Joachim Bremer, Head of Product enable optimized performance across Line Low Speed, says: “Our A100-L and different operational situations. Bremer New A100 series turbocharger A200-L turbochargers are designed for says: “Despite the small size of the At Marintec 2015 in Shanghai, ABB highest efficiencies, enabling optimized A160-L turbocharger, the degree of effi- unveiled a new, highly efficient and com- engine tunings to reduce fuel consump- ciency available is still sufficient to meet pact turbocharger for low-speed, two- tion and emissions. Bringing this com- the parameters set by the leading marine stroke marine engines able to deliver value petitive product to the market, we can engine designs. The wide compressor in each of these areas. The latest A160-L now offer these benefits for small bore, maps demonstrated by this design, and unit completes the A100-L series launched low-speed engines across a range of fuel its efficiency in part load operations – a on the market in 2009. The compact types. We anticipate interest for applica- key requirement of many owners and new turbocharger, which measures just tions on small tankers, bulk carriers, operators today – are significant benefits.”
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The robust axial turbine of the A160-L “Our A100-L and A200-L Innovative noise reduction package further enables application of the latest In addition to expanding the A100 technologies used for IMO Tier III compli- turbochargers are series, ABB also unveiled the first turbo - ance without compromising fuel economy. designed for highest effi- charger air outlet silencer as part of the The turbocharger is, for example, com- ciencies, enabling opti- noise reduction package for application patible with both low and high pressure on A100-L and A200-L series turbo - selective catalytic reduction (SCR) sys- mized engine tunings to chargers. The air outlet silencer reduces tems, exhaust gas recirculation (EGR) and reduce fuel consumption the effects of noise generated by com- low pressure gas injection technologies. and emissions.” pressed air leaving these turbochargers In response to reduced service costs on low-speed two-stroke engines. With and maximized application availability increases in engine power, turbochargers becoming key priorities across the have higher pressure ratios and specific industry, the A160-L has been designed volume flows. Consequently, the increased to facilitate maintenance and repair time. The A160-L service concept is in energy in the compressed air exiting the activity in line with engine servicing. line with that of our successful A100-L turbocharger can lead to increased noise Significantly, it ensures long intervals and A200-L turbochargers: all key emissions from the surfaces of engine between overhauls, with no need for components have the same service components, despite insulation. maintenance work between dry dock- intervals, time between overhauls and Aiming to reduce noise emissions at ings. “Responding to customer needs in streamlined maintenance requirements, source, the air outlet silencer employs terms of increasing service intervals has reducing downtime to a minimum,” adds the Helmholtz principle, adapted to high been an important focus for us for some Bremer. air flow speeds. Bremer says: “The design
ABB charge! 1|16 5 Technology of this product, which is a first in the ABB’s innovative air industry, ensures that only a minimum of acoustic energy reaches the engine’s air outlet silencer can ducts. It effectively lowers noise radiation reduce air-related noise originating from the turbocharger, reduc- emissions by around ing noise levels not just in the engine room but in other parts of the ship as 5 dB, cutting the level of well.” noise perceived by the IMO SOLAS regulations revised in human ear by half. 2014 have made noise abatement on - board a key requirement. ABB’s innova- tive air outlet silencer can reduce air- related noise emissions by around 5 dB, cutting the level of noise perceived by the human ear by half. It is unique in being the first product available on the market for reducing noise emissions for turbochargers on low-speed marine Commitment to quality. engines. This new package aims to significantly improve conditions for crews, also reduc- dation spaces, resulting in the crew gen- with our commitment to reducing environ- ing the need for investment in additional erally being closer to the sources of noise. mental pollution. Creating a quieter work- insulation of engine rooms, particularly Bremer concludes: “The development ing environment for seafarers demon- on smaller-sized vessels with two-stroke of this noise reduction package with air strates our business commitment to engines. These engine rooms are typically outlet silencer underlines our focus on the occupational health and to supporting proportionately smaller, with shorter safe operation of our turbocharging prod- customers in complying with the revised structure-borne noise paths to other ucts, limiting potential for human error SOLAS regulation aimed at reducing on- parts of the vessel, including accommo- due to noise distraction. It is also in line board noise.”
ABB Turbocharging is meeting the challenges facing the marine industry with new products that combine high efficiency with emissions compliance.
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Turbochargers on auxiliary engines need to be kept in prime condition for highest engine performance. A helping hand for the little helpers ABB is continually developing improved solutions to the problem of turbocharger fouling on auxiliary engines. For severe cases, the company offers an exchange turbocharger program that helps to reduce engine downtime.
Text Markus Rupp, Photography HHI, ABB Turbo Systems Ltd
t is always essential to keep turbo - contribute to premature component wear. On the gas engine side, another article chargers in good condition. A particu- These combustion residues are especially in this edition of charge! (see page 16) lar concern are deposits of combus- prevalent on diesel engines using certain deals with countermeasures to deposits I tion residues on the turbine, nozzle grades of heavy fuel oil (HFO) and when that can arise from the wider range of ring and turbine casings. The result of combustion is incomplete due to poorly gaseous fuels now being burned. As with this so-called “fouling” is reduced turbine adjusted or defective fuel injection equip- the solution to the gas engine issue, efficiency, and hence engine perform- ment. They are also influenced by factors ABB Turbocharging recently undertook a ance, as well an unwelcome increase in such as the exhaust gas temperature, major Continuous Product Improvement exhaust gas temperature, which can also which varies with engine load. (CPI) project in order to find definitive
ABB charge! 1|16 7 Service solutions to problems caused by carbon deposits on the turbine side of A100-M and TPS turbochargers operating on cer- tain engine types. The specific application was high- and medium-speed four-stroke auxiliary engines powering generator sets aboard ships. The engines were operating on HFO and during the course of the CPI, it was revealed that the quality of the combustion of the fuel was central to the problem. “On one hand we only saw these problems on one or two engine makes, pointing towards them being ‘not turbo- charger-related’; on the other hand we had to check if the materials we use in our turbochargers are satisfactory or if they could be a factor contributing to the damage experienced,” notes René Stoverink, Senior Manager Technical Service, based in Baden. “Feedback from our colleagues at ABB Turbocharging Severely fouled turbine. Service Stations included reports of problems with nozzle rings on ABB turbochargers with radial turbines, including accelerated erosion by hard particles in the exhaust gases. On the and injectors are also highly prone to of these “little helpers” contrast with the other hand, severe fouling of nozzle rings contamination. And as with turbocharger fairly constant load on main propulsion was also reported, which could lead to fouling, this can be the start of a down- engines when a ship is at its design oper- turbine seizure and damage due to high ward spiral, where fuel injection becomes ating speed. cycle fatigue (HCF).” less and less effective, leading to even “The wider range of loads generator Although HFO is carefully cleaned in greater problems with two of the major sets are expected to cover, as electrical separators and fine filters to remove solid factors involved: poor combustion and consumers are switched on and off, particles before it is injected into an unburnt fuel.” means prolonged operation at lower engine, combustion residues and abra- In the case of the turbocharger, de- loads, and this can cause severe prob- sive products of combustion readily attach posits restricting the passage of exhaust lems for the engine as a whole and the themselves to turbines and other turbine- gas through the nozzle rings and casings turbocharger in particular, especially when side parts. In addition, they can remain and changing the aerodynamic profile of operating on HFO,” Stoverink explains. suspended in the exhaust gases and the turbine obviously reduce aerodynamic “For example, at lower engine loads, greatly accelerate abrasion of housings, efficiency, while abrasive wear can weaken combustion tends to be cooler and can the vanes of the nozzle ring and the turbine blades and nozzle ring vanes. In be less complete, which compounds blades of the turbine itself. addition, since the deposits on the nozzle existing problems with turbine-side foul- “We should stress that this build-up ring will not be evenly distributed, the ing and wear due to fuel quality.” of carbon deposits due to poor combus- disturbance of the aerodynamic profile All these factors favor the formation of tion of low grade fuels is not restricted will always result in higher excitation of carbon particles and the build-up of to the turbocharger,” Stoverink explains. the turbine blades. In the worst case, if deposits and negate the major targets of “According to the severity of the problem, these increased excitations match one of all engine users: i. e. reliable engine oper- combustion chambers with their valves the natural frequencies of the turbine ation, long times between overhauls blades, a crack can develop under HCF (TBOs), and above all, minimized operat- conditions. ing costs.
Auxiliary challenges Findings and solutions As their name implies, marine auxiliary After a typically thorough investiga- engines support the main propulsion tion, employing the most modern meas- engines on ships by powering the gener- uring techniques, the CPI centring on the ator sets which provide on-board electri- problems of turbocharger fouling on aux- cal power. There are usually several high- iliary engines resulted in a series of solu- or medium-speed four-stroke diesels tions. Since the use of various grades of with smaller bore diameters than the HFO will continue for commercial reasons, Heavily fouled nozzle ring. main engines, and the operating profiles and part-load operation of marine gener-
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ommended at the intervals shown on the Auxiliary engines turbocharger rating plate. Again, ABB’s exchange scheme using factory refur- bished turbochargers is a time-saving The adjective auxiliary comes from and electric propulsion, where all alternative to dismantling and servicing the Latin word “auxilia” which in Eng- the ship’s functions rely on generator on site. lish means “help”. Hence, the sets. Vessels like cruise ships and engines which have traditionally sup- small and medium size LNG carriers New nozzle ring coating ported the main propulsion engines are already powered by a series of A further, design-related result of the on ships by powering generator sets generator sets whose electrical out- CPI is the introduction of a new coating are known as “auxiliary engines”. put is shared between propulsion and process for nozzle rings affected by HFO Typically, these are four-stroke, other on-board electrical consumers residues. “The new coated nozzle ring is high- or medium-speed engines in – including the massive “hotel load” a countermeasure against erosion due to bore sizes smaller than the main on cruise ships. And it is forecast that hard carbon particles in exhaust gases,” engines – for example 16, 20 and 32 electric and hybrid drives will take a Stoverink confirms. “The coated nozzle cm are common cylinder diameters greater share of the marine propulsion rings are available as an option on new on auxiliary engines. market, as regulations regarding turbochargers or as a service upgrade
The importance of on-board power vessel efficiency and CO2 emissions on selected specifications of our A100-M generation is growing. The industry tighten. and TPS turbochargers. ABB Turbo- is seeing the start of a trend to hybrid charging service is reporting excellent results on turbochargers fitted with this modification,” he concludes.
ator sets is inevitable, ABB is looking at swapped for the defective unit. This time countermeasures for engines already in saving is important, because mechanical the field as well as modifications which cleaning may reveal badly worn or dam- can be applied both on new turbochargers aged parts which need to be replaced. In and, as far as possible, as upgrades any case, the turbo charger will need during overhauls. rebalancing after cleaning to guarantee safe operation. Bulletins and CIACs To inform engine users about the new Water injection measures, in addition to service bul- For less severe cases turbine cleaning Markus Rupp is Senior Regional letins, ABB Turbocharging has incorpo- during engine operation may be enough Manager End User Sales, supporting ABB Turbocharging’s worldwide net- rated them into a so-called CIAC – Cus- to bring the turbocharger back to a satis- work in the sale of service products, tomer Information ABB Turbocharger. factory condition, and regular repeating service agreements and contract Customers attending this CIAC at one of of the cleaning procedure will ensure that management. He prepares and pres- ABB Turbocharging’s service centers will it stays that way. Two cleaning methods ents customer information on ABB turbochargers to end users and at be informed of the latest news and pro- exist for the turbine components. These conferences, congresses and other cedures to keep the turbochargers in his are wet cleaning by water injection into industry events. He holds a degree care in prime condition. And, importantly, the turbine casings, either for three times in mechanical engineering from the the attendee will be shown how to carry 30 seconds at three minute intervals or, University of Karlsruhe, Germany and joined ABB in 1982. them out. alternatively, for 10 minutes continuously. Tests have clearly shown much better Rectifying, preventing, exchanging cleaning results with the 10 minute The major recommendations from the washing interval, and this finding was marine auxiliary engine CPI project con- published as a recommendation in Ser- cern turbocharger servicing and, espe- vice News 3/2012 (available from ABB cially, preventive maintenance. In severe Turbo Systems). Depending on the com- cases only mechanical cleaning can position of the HFO in use and the quality help, and this involves removing the of combustion, cleaning of the turbines turbocharger from the engine for dis- should be carried out at regular intervals, mantling on the turbine side. In this case as specified in their operating manuals. ABB Turbocharging’s exchange turbo- These operations will certainly avoid charger program helps to reduce engine more severe and expensive mechanical downtime. A unit reconditioned at an interventions and will extend TBOs. At ABB Service Station can be rapidly the same time, regular servicing is rec-
ABB charge! 1|16 9 Interview Chinese national standards for inland water shipping emissions Emissions from vessels on Chinese waterways are a cause of some concern. charge! recently interviewed Wang Shilong, senior engineer in Ji’nan Automotive Engine Testing Center to explore the steps being taken to improve the situation.
Interview Magdalena Okopska, BoZong Hu, Photography iStockphoto, ABB Turbo Systems Ltd
hina is said to be the world’s to reduce emissions in the shipping rules apply to merchant ships navigating largest manufacturing base industry. In July 2014, Shenzhen port or anchoring in the waters of the Pearl and second largest consumer launched a voluntary fuel switching River Delta, Yangtze River Delta and C market, and the country’s scheme that is expected to cost $ 3 mil- Bohai Bay rim. inland waterways play a prominent role in lion in subsidies over three years. In To gain a greater insight, charge! this economic development. In fact, Chi- Hong Kong, it has been mandatory since recently interviewed Wang Shilong, senior na’s river shipping is the world’s largest July 2015 for all berthing ocean-going engineer in Ji’nan Automotive Engine in terms of throughput, carrying 224 mil- vessels to be powered by low-sulfur fuel, Testing Center. Mr. Wang was instrumen-
lion people and 3,790 million tons of with a maximum SO2 content of 0.5 per- tal in devising emission standards for freight annually. However, this water- cent. Government subsidies cover half heavy-duty trucks. He participated in borne traffic contributes significantly to the cost of berthing fees in return for ship China’s 863 science and technology air pollution levels. Severe air pollutants, owners’ cooperation. project on heavy-duty diesel vehicles and such as hydrocarbons (HC), nitrogen From January 2016, tough controls also contributed to the development of
oxides (NOx ), sulfur oxides (SOx ) and on merchant ship emissions aim to reduce key technical standards for pollutant
particulate matter (PM) emitted by river the 2015 level of SO2 by 65 percent in emissions. He is currently on the expert shipping engines pose serious health 2020, according to a document issued team that will formulate the national stan- risks to inhabitants of the river basins. In by the Ministry of Transport. These new dards for inland water shipping emissions.
particular, sulfur dioxide (SO2 ), which also causes acid rain, exacerbates respi- ratory difficulties and can lead to prema- ture death. From January 2016, tough controls on merchant The response of the government to mounting public pressure to improve air ship emissions aim to reduce the 2015 level of SO2 quality is the introduction of regulations by 65 percent in 2020.
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Cargo ship on the Huangpu river in Shanghai, China.
ABB charge! 1|16 11 Interview
Mr. Wang, it seems that air pollution is “The public’s increased awareness of shipping being discussed by almost everyone recently. Why is this? pollution and environmental protection has put Air quality in China is deteriorating the government under pressure to take action.” and air pollution affects people’s daily lives in many ways, so it captures more public attention than ever before. We all know the primary causes of air pollution include emissions from thermal power the pollutants are practically the same, pressure to take action. China is moving generation and transportation. Emis- namely HC, NOx, SOx and PM. Therefore, toward a cleaner and more efficient sions from river shipping engines are a the methodologies for emission reduc- economy; green river shipping is integral major contributor to high air pollution tion are essentially the same. to this change. levels. Secondly, emission regulations for A study conducted by the Chinese The Chinese government has imple- heavy-duty trucks have been in force for Research Academy of Environmental Sci- mented rigorous measures against emis- quite some time in China and they con- ences in 2014 stated that river shipping sions by thermal power generation and tinue to get more stringent. Consequently, contributes 13.3 percent of local NOx and automotive engines. Some regulations we have made substantial advances in 17.6 percent of local PM emissions from are already in place for inland waterway solutions for automotive engines and non-road mobile sources in China. transportation emissions for certain the surrounding legalities so they meet The ever-increasing cargo throughput areas, but further opportunities exist to ever-increasing emission restrictions. This of China’s inland shipping routes makes reduce emissions by river vessels. knowledge offers both legislative and the situation even more pressing. The technological reference points for river Yangtze River, with a total cargo load of Your background is in the automobile shipping. two billion tons in 2014, is the busiest industry, what similarities do you see in the world. Annual growth of around between your field of expertise and What is the context of China’s river seven percent since 2009 is a trend that river shipping industry? shipping emission regulations? is expected to continue in the years to First of all, internal combustion The public’s increased awareness of come. Therefore, it is imperative for us to engines, mainly diesel, power both indus- shipping pollution and environmental address river shipping emissions in the tries. Despite different emission levels, protection has put the government under long run.
Wang Shilong, senior engineer in Ji’nan Automotive Engine Testing Center.
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What is the current status of legisla- diesel is another challenge. Ultra-low- Tier II. In stage two, NOx emissions will tion for river shipping emissions? sulfur diesel can significantly cut emis- be reduced by a further 20 percent and This new emissions legislation has sions but is currently too expensive for PM by approximately 40 to 48 percent. already completed the second round of most end users. public feedback bidding and is currently As the new bill only applies to newly What technical solutions could con- in the review process. built engines, actions that can be taken tribute to meeting the new emission to help the fleet in service to meet the targets? What do you find especially positive emission standards is another question A number of technologies are already and where do you see challenges with we have to address. available that can contribute to reducing this legislation? emissions, such as selective catalytic The benefits of legislation that effec- Mr. Wang, you have contributed to the reduction (SCR), scrubbers, liquefied tively reduces air pollution are clear: a development of emission standards, natural gas (LNG), gas engine technol- positive impact on the environment and what are the main points? ogy, miller timing in combination with on the health of inhabitants living along The new emissions legislation applies advanced turbocharging technology, the river shipping routes. However, this to new-build ships’ engines with a single advanced combustion and exhaust gas legislation also presents technical chal- cylinder volume below 30 liters, and a recirculation, and so on. lenges. We must find or develop effective power range above 37 kW. Enactment of technologies that are compatible with the new emissions legislation will take Mr. Wang, on behalf of charge! I’d like existing diesel engines, and affordable place in two stages. In stage one, the to thank you for taking the time to tell for local engine builders and end users of emission standard for NOx is comparable us all about China’s response to river vessels. The availability of low-sulfur to the standards defined by the US EPA inland water shipping emissions.
“The Yangtze River, with a total cargo load of two billion tons in 2014, is the busiest in the world. Annual growth of around seven percent since 2009 is a trend that is expected to continue in the years to come. Therefore, it is imperative for us to address river shipping emissions in the long run.”
Hei longjiang R
iver Irtysh River
Songhua River
Liaohe River
Luan River iang River Tarim River Yaluj Yellow River
Bo Hai
Beijing
Grand Canal – Yellow Sea Hangzhou
ihe River Hua
Jinsha River Yangtze River Nu River Brahmaputra River East China Sea
Lancang River Xijiang River
Pearl River
South China Sea
China’s major rivers.
ABB charge! 1|16 13 Quality
ABB Turbocharging has a zero defects program in place that will push quality to an even higher level. ABB quality as a value proposition “Quality is never an accident; it is always the result of intelligent effort.” The truth of this quote by John Ruskin, English writer and critic, 1819 – 1900, is shared in full by ABB Turbocharging, as this article shows.
Text Köbi Brem, Photography Michael Reinhard, ABB Turbo Systems Ltd
n the business year ending Decem- faction in terms of the quality and avail- 2016 and beyond, merely maintaining ber 31, 2015, ABB Turbocharging ability of its products and services. this status quo is not an option. achieved a major quality landmark: its In spite of this excellent news, ABB The company has no intention what- I highest ever level of customer satis- Turbocharging has no doubts that for soever of leaning back and patting itself 14 ABB charge! 1|16 Quality on the back. There is still the potential for the customer’s level of satisfaction to be pushing quality to a higher level and the monitored constantly. Towards zero policy must – and will – be zero defects. Excellent progress has already been This is the goal ABB must always be made by ABB Turbocharging towards defects – some striving for, and though it may be difficult its vision of zero defects. Within an over- to achieve, the company must always all response rate of 25 percent, in 2015 processes have it in its sights. 92 percent of ABB Turbocharging’s cus- explained: The devil can lie in the detail: A small tomers were either satisfied or very satis- typing error in the specification of a fied, and the fruits of ABB’s labors could spare parts order, for example, can lead be seen growing in the form of the to the wrong component arriving on site recognition received from customers for for the service task being carried out. performance excellence. In 2015 ABB The additional engine downtime caused Turbocharging received a crop of Gold, can result in huge consequential costs or or even Platinum awards, “A” or “Top 10” CCRP – Customer Complaint losses to the engine operator. When rankings, and satisfaction levels of more Resolution Process even the smallest error or minor defect than 90 percent, according to the cus- n a very effective complaint resolv- can have a huge impact, ABB must use tomer’s chosen method of measuring ing process applied for each all available means to avoid it. This will excellence. single customer complaint mean everybody working harder, but the However, as everyone knows, what is n involves tracking the resolution company is very strong and very deter- excellent today becomes the yardstick of a complaint or problem in a mined. for tomorrow’s quality, and will simply not workflow At the heart of the zero defects policy be good enough the day after tomorrow. n it follows the 8D principle, with an is a wide-reaching, dedicated campaign. Staying on an excellent quality level 8D report as an output This covers a whole bundle of initiatives indefinitely will mean continuing to place n it focuses on root cause analysis which will enable ABB Turbocharging to the highest value on quality and to focus and sustainability, including a provide the best products and services all efforts on the areas that will lead to closed-loop approach on the market and use these to build the next level. n it is implemented by a dedicated strong business relationships with cus- group of specialists, and dis- tomers. And, since quality is strongly cussed in monthly management dependent on the materials and compo- team meetings. nents that are bought, getting even closer to the suppliers will be another vital CPI – Continuous Product element. Improvement Process for ABB Turbocharging’s zero defect pro- technical aspects gram addresses four key areas and uses CQI – Continuous Quality Improve- a range of tools and processes. ABB tar- ment Process for process and gets improvements in leadership, people, handling related issues quality in the value chain and operating n systemic problems are tackled systems, and to attain them a number of and resolved in dedicated projects processes and tools such as Net Pro- n interdisciplinary teams ensure moter Score (NPS), Customer Complaint collaboration through all depart- Resolution Process (CCRP), Continuous ments. Product Improvement Process (CPI) and Continuous Quality Improvement (CQI) Poka-yoke have been implemented. These will play Poka-yoke – a Japanese term that an even stronger role as the zero defect means “mistake-proofing”. A poka- strategy deploys, while other initiatives Starting in 1988 as a young engineer yoke is any mechanism that helps will be kicked-off later this year, such as with a master’s degree in mechanical an equipment operator avoid engineering, Köbi Brem developed and the “Poka Yoke” approach to eliminating (yokeru) mistakes (poka). Its pur- qualified the RR type turbochargers defects in production processes by mak- in the engineering department of ABB pose is to eliminate product defects ing the processes “mistake-proof”. Turbo Systems. Subsequently, over by preventing, correcting, or draw- Of the tools in use, NPS represents a nearly 20 years, he acquired tremen- ing attention to human errors as dous field experience within the tech- key performance indicator (KPI) in the they occur. A simple example is nical service department where he measurement of customer satisfaction. was responsible for troubleshooting making a component asymmetric This is a very important instrument which and resolving customer issues. Today, so that it can only be fitted the right allows ABB to learn from customers Köbi heads the Customer Feedback & way. More complex examples are about their needs. Crucially, the process Management Systems department computer controls to ensure a cor- and has in-depth knowledge of cus- includes a so-called recommend ques- tomer needs as well as a thorough rect part is installed or a series of tion – i.e. would you recommend the understanding of how important it is procedures is carried out in the products and services of ABB Turbo - to perform proper root cause analyses right order (e.g. torqueing bolts). charging to your friend? – and this allows in achieving long-lasting solutions.
ABB charge! 1|16 15 Quality Continuous Product Improvement
Through the interdisciplinary teamwork used in CPI, ABB Turbocharging’s fund of product knowledge becomes available to all company departments.
Text René Stoverink, Photography iStockphoto, ABB Turbo Systems Ltd
s part of its ongoing search for outstanding quality, ABB Turbocharging introduced the A concept of Continuous Prod- uct Improvement (CPI) in 2006. Now the project has gained added relevance as one of the processes used in the quest for zero defects (see page 14). CPI is an excellent tool for tackling product issues in a systemic way. By turning the resolution of problems into interdisciplinary projects, it is ensured that they are not only solved to the customer’s satisfaction, but that the solution adds to ABB Turbocharging’s overall fund of product knowledge and is thus available to all departments. In this way, it will be taken into account during product development and may result in a new feature in a future turbocharger gen- eration.
CPI in action In the recent past, ABB Turbo- charging’s service department reported several cases where turbochargers on gas engines seized after shutdown of the engine. This became evident when the operator tried to restart the engine some 10 to 15 minutes after a short shutdown, and wasn’t able to do so because the rotor did not rotate freely. Even though the rotor would free itself up after about one to two hours, the phenomenon was absolutely unacceptable for the engine operator, since it limited his ability to earn revenue. To get to the bottom of the problem an interdisciplinary team was put together in line with the principles of the CPI process. The first step was to collect all available information and to find the root Deposits on the turbocharger turbine vary according to the engine fuel (e.g. biogas). cause of this problem. From within the
16 ABB charge! 1|16 Quality
proposals for the business process which Contamination on the gas outlet flange caused the problem. In this example, the lesson learned included a recom- mendation to consider the fuel types when determining turbocharger rotor clearances during the design process, because deposits on the turbine vary according to whether the engine will burn diesel, HFO, gas or even biogas. In the case of gas engine applications, the composition of special gases like bio- gases, synthetic gases, well-head gases or associated petroleum gases can differ greatly from the composition of pipeline quality natural gas. The nature of the deposits on the turbine in question was undoubtedly related to the type of biogas in use. When such a problem has been company’s own resources it was possi- the coolant temperature decreases. In experienced and solved, it becomes an ble to confirm that this phenomenon of the case at hand, the preference was for integral part of the CPI process: the find- sticking turbocharger rotors occurred pre-lubrication of the turbine shaft over a ings are extracted in full and the lessons exclusively on TPS turbochargers and period of 10 to 15 minutes if turbine are learnt, everything being thoroughly was encountered in four different plants sticking is experienced during re-start of documented and, in this case, added to where gas engines are fueled with bio- an engine after such a short shutdown. the list of aspects to be considered dur- gas. An in-depth root cause analysis on The engine and turbocharger will still be ing turbocharger development. In this site and in the lab revealed that several close to their operating temperatures way sustainability is ensured. influences were at work. and the pre-lubrication will cool the shaft One was contamination on the turbine far enough to allow it to contract and side of the turbocharger caused by create a suitable clearance between the deposits of calcium phosphate. These turbine and any deposits on the housing. were capable of rapid growth and could The second measure involved chang- quickly reduce the clearance between ing the exhaust gas outlet flange for one the turbine blades and the turbine hous- in a material with different physical prop- ing (gas outlet flange). ABB Turbochargers erties. By installing a gas outlet flange are made to very tight tolerances in order made of a material with a different thermal to ensure high turbocharging efficiency – expansion rate, it could be ensured that efficiency reduces exponentially as the this part of the turbine housing would gap between turbines and compressor also expand less after engine shutdown wheels and their adjacent housings and help to maintain a positive clearance increase. What was happening was between the turbine and the housing. caused by the heat which is always The next phase of the CPI centers transferred after shutdown from the hot on implementation of the solution. While turbine into the shaft, and which can no in many cases a product improvement is longer be cooled by lubricating oil when introduced into series production for new the rotor is stationary. This leads to the turbochargers, in this case it was decided turbocharger shaft expanding in length, to introduce the new housing (gas outlet and in these cases it was pressing the flange) as an option. The background turbine against the deposits on the hous- to this decision is that the root cause ing. Result: the rotor became stuck. analysis indicated – and field experience Having established the causes of the confirmed – that only a small proportion sticking rotors, in the next two phases of of turbochargers with radial turbines René Stoverink is Senior Manager the CPI process possible solution con- operating on biogas are affected by this Technical Service, handling claims management and technical/breakdown cepts were worked out, the most prom- problem. investigations, project management ising solution was selected and a of interdisciplinary teams, technical detailed solution developed and quali- One step beyond support for end users and operators fied. Two countermeasures were worked Problem solved? Yes, but while at this and supporting the ABB Turbocharging worldwide network with customer out. The first is reminiscent of a measure point the operator’s problem is usually seminars. He holds a Bachelor’s taken on passenger cars with turbo-diesel solved, the CPI process goes a step fur- Degree in mechanical engineering engines. To prevent damage to water- ther before the project is closed. The last from the FHO Fachhochschule cooled turbochargers on cars, the cool- phase comprises a process reflection, Ostschweiz, Rapperswil, and joined ABB in 1988. ing fan runs after engine shutdown until including identification and improvement
ABB charge! 1|16 17 Interview
Marine auxiliary collaboration ABB have had a license agreement with the Japanese corporation IHI since 1958. In 1998, a joint venture between the two companies was founded to promote and sell IHI- and ABB-designed turbocharger products to the Japanese market. In this interview, Kazuki Dobashi, head of IHI’s marine turbocharger business unit and one of IHI’s key decision makers, tells charge! readers more.
Interview Magdalena Okopska, Photography IHI, ABB Turbo Systems Ltd
Dobashi-san please tell our readers IHI is very familiar with the requirements about your responsibilities at IHI? Cooperation between of domestic engine builders and impor- I am currently head of the marine tant Japanese ship owners. turbocharger business unit in IHI. IHI is a IHI and ABB IHI began to consider ways to develop Japanese corporation with businesses a new product. Around this time, ABB involved in the manufacture of products n 1958: IHI becomes a licensee of approached IHI to explore the possibility for many industries. I am also on the BBC/ABB-designed turbochargers of a collaboration for the development of Board of Directors of Turbo System United n 1998: foundation of Turbo a dedicated turbocharger for the marine (TSU), an ABB and IHI joint venture we Systems United Co. Ltd. in auxiliary market. IHI and ABB have a his- set up in 1998. TSU is responsible for the Japan – an ABB and IHI joint tory of successful long-term collabora- sale of IHI and ABB turbochargers in venture to promote and sell IHI- tions, with TSU since 1998 and, prior to Japan. TSU is fully integrated into the and ABB-designed turbocharger that, a license cooperation between ABB Turbocharging network. products on the Japanese market BBC/ABB and IHI since 1958. This was n Since 2014: cooperation between in fact the very first license agreement How did the opportunity for a joint IHI and ABB in the development BBC had had with a Japanese company. project between IHI and ABB arise? and commercialization of a A new product would mean TSU could As global leaders in the design and dedicated marine auxiliary supply a competitive product to its main production of small-bore, medium-speed turbocharger market, so we decided to combine our engines, Japanese engine builders have n 2016: launch of the joint IHI and different technological expertise to work a significant influence on the marine aux- ABB marine auxiliary product on this new project. iliary market. As a Japanese company,
18 ABB charge! 1|16 Interview
Kazuki Dobashi, head of IHI’s marine turbocharger business unit.
Dobashi-san, in your role as Director Looking back on your experience of Teamwork was very good during this of TSU, it is your target to ensure the this product development collabora- project, although some misunderstand- successful promotion and sale of this tion by the joint project team, were ings did arise due to the different lan- marine auxiliary turbocharger for the there any challenging situations? guages, different perceptions and work- Japanese market. Can you tell us a bit There are, of course, cultural differ- ing style. What was remarkable was that more about the product? ences between Europeans and Japanese, everyone listened respectfully to each All will be revealed at the CIMAC especially in their approaches to corpo- other, discussed topics thoroughly and event in June, so I don’t want to give rate culture and how to make a business reached a consensus beneficial to all away too much here! However, I can tell decision. However, we all shared a com- involved. you that the new dedicated marine auxil- mon objective: to develop a new product iary product line will have three frame that meets customer needs and to gen- Do you have a particular philosophy sizes and will be easy for crews to main- erate benefits for ABB and IHI, as well as that guides your personal success tain. It will also feature part-load opti- grow TSU as our common sales channel and that aided the success of this mization and have a very competitive life in Japan. I think, on the whole, the chal- project? cycle cost. lenge of the cultural differences was My motto is always to give more than I turned into a very positive thing from receive and strive to add value in excess which both parties benefited. of the value of other inputs presented. The value of the contribution from Roland Schwarz (Head Hub ABB Turbocharging “We all shared a common objective: to develop Japan and Head of Product Group Marine a new product that meets customer needs.” Auxiliary) during negotiation and product
ABB charge! 1|16 19 Interview
nately, the last year has been very busy and I was only able to attend two com- petitions. But I did manage to win two medals – silver and bronze!
Regarding the new marine auxiliary product: what are your expectations for the near future? The next steps include the product release before the end of 2016 and a successful product launch to gain mar- ket share. IHI would like to maintain the collaboration with ABB for the develop- ment of next-generation products.
Finally, could you please tell our readers something about your educa- tion and career? MaX project team members Ken Nakano, Susumu Aruga, Kazuki Dobashi and Keisuke Matsumoto. In 1991, I graduated with a degree in mechanical engineering from the Univer- sity of Yamanashi, Japan. My career with development on this project was sub- tomers, their expectations and product IHI began that year as an application and stantial. I aspired to add value in excess requirements. I believe all engineers think design engineer in marine turbochargers, of the input from Roland as we have dif- in a similar way; nationality is meaning- designed by ABB and IHI. ferent backgrounds and experience. less. But, in my opinion, there is a differ- When TSU was established in 1998, I This carries over too to the relation- ence between European engineers and joined as an application engineer for ship between ABB and IHI, which was Japanese engineers. European engineers two- and four-stroke engines, selling the previously one of licensor and licensee. tend to have a high-tech focus while first TPL and TPS to the Japanese market. Now, we are building a new relationship Japanese engineers place more empha- In 2001, I became manager of a test bed between two companies and my contri- sis on robustness, standardization and with IHI Compressor and Machinery Co., bution to this is my “giving more than I cost minimization. A combination of these Ltd. (ICM), in Tatsuno. ICM managed the receive by commitment and creating approaches is advantageous for both testing and evaluation of newly devel- value” factor. parties. oped turbochargers and newly localized TPL and TPS. ICM is a subsidiary of IHI What do you think Swiss engineers You clearly had a lot of work during that manufactures marine turbochargers can learn from the Japanese engi- the project. What do you do to unwind designed by IHI and ABB in Japan. neers and vice versa? and relax? I became manager of the marine turbo- If Swiss engineers learned more I enjoy spending time in the company charger engineering department of ICM about Japanese culture from us, it would of my friends, but my passion is rally car in 2002, with responsibility for localiza- help them understand Japanese cus- racing with my Honda S2000. Unfortu- tion and product care of licensed turbo - chargers. In 2011, I was appointed head of the marine turbocharger business unit in IHI and general manager of the marine Dedicated turbocharger for marine auxiliary turbocharger engineering department in ICM, Tatsuno. engines: Benefits at a glance I joined the Board of Directors of TSU in 2014.
n Optimized design, specifically to Dobashi-san, on behalf of ABB and fulfill marine auxiliary requirements. charge! I’d like to thank you for taking n User-friendly design for easy self- the time to tell us all about the marine maintenance. auxiliary collaboration. n Interactive and intuitive digital self- service support guide for condi- tion-based maintenance (CBM). n Designed for part-load efficiency. n Robust design for trouble-free operation under HFO conditions. n Reduced Total Cost of Ownership (TCO).
20 ABB charge! 1|16 Service
Xue Long, the flagship vessel of the Polar Research Institute of China.
Just-in-time delivery Polar research icebreaker
The entire ABB Turbocharging supply Built in 1993, Xue Long was retrofit- ship supplies call in Australia during chain was put to the test at the end of ted with a new main engine in 2013, in a November. The turbocharger was initially 2015 following a request for delivery of a project that also saw installation of two expected to be assembled, produced complete ABB TPL 73-B11 unit on board ABB TPL 73-B11 turbochargers. In Octo- and transported to Australia by Novem- Chinese icebreaker Xue Long. ber 2015 the customer requested a third ber 23. However, the customer asked for The Polar Research Institute of China unit as a spare to support smooth oper- it to arrive earlier, on November 15. Even is the country’s central polar information ations and maximize uptime. including six days of flight time, the resource and its flagship vessel Xue Long The successful response and delivery turbocharger was delivered on time, is a floating laboratory, fully equipped for were made possible by teams across actually arriving in Australia on Novem- 128 researchers and dedicated to under- production, delivery and installation, ber 14, and enabling the Xue Long to taking expeditions in unforgiving Arctic meeting the tight scheduling require- depart on time for the Antarctic. and Antarctic waters. ments to coincide with a refueling and
ABB charge! 1|16 21 News Supplier quality recognized
Awards. Customer feedback remains essential to the development of better turbocharging products, technologies and services. Efforts continued in 2015 to meet the supplier requirements and high standards set by customers, resulting in recognition through supplier awards. The long-time relationship with GE Jenbacher earned “A” level for quality and “B” level for total supply excellence. The success of another strong relation- ship was demonstrated for the third con- secutive year by the Supplier Quality Excellence Process (SQEP) award from Caterpillar USA, at the highest level, platinum, for ABB Inc. BU Turbocharging in Bollingbrook, USA. Caterpillar USA also recognized ABB Turbo Systems Ltd operations in Klingnau and Baden, Dredger Shanti Sagar XVI at Adani Ports and Economic Zone Ltd, Gujurat, India. Switzerland, with a gold award which fol- lows bronze in 2014. ABB Turbo Systems Ltd in addition received a gold level SQEP award from Caterpillar Kiel (MaK), also for the third consecutive year. Customers seek to optimize asset performance through service agreements
Service. Adani Ports & Special Economic Agreement (MMA) was seen as the most Zone Ltd (APSEZ) in Gujurat, India, has appropriate fit to ensure reliability and opted to bring the management and exe- availability of the turbochargers. As with cution of service and maintenance for 65 the full ABB Turbocharging service port- turbochargers under a service agreement. folio, the service agreement ultimately APSEZ operates across a large net- aims to reduce the total cost of turbo - work of ports with the Special Economic charger operations and the administra- Zone of Mundra, India’s largest private tion workload of maintenance manage- port operator. Responsible for a total ment. Essential for many customers, the Karl-Jakob Brem, General Manager, cargo throughput of over 120 million MMA still allows flexibility to define the Customer Feedback & Management Sys- tonnes per year, it operates harbor ves- scope of the service and products to be tems, ABB Turbocharging commented, sels and locomotives equipped with a covered. “These awards reflect the improvements wide variety of ABB turbochargers, in - With over 15,000 ABB turbochargers we have made to add value for cus- cluding TPR, TPS, and VTC, VTR and RR. now covered under the MMA, it is fully tomers and we aim to replicate this into Such agreements have been proven established across the large engine 2016 and beyond. The awards are a to provide service and maintenance sup- market in the marine, rail, power and min- motivation for the people who have port more closely aligned with customers’ ing sectors. As outsourced maintenance achieved the im provements and we will specific needs. For APSEZ, consistency becomes the norm across the industry, continue to seek and analyze all feed- of port services and inland logistics was working closely with customers to further back, drawing on our successes to live a driver for this contract: “With a pres- tailor service offerings for their specific up to our market leading reputation ence across eight locations, perform- current and future needs will continue to across the industry.” ance of the assets deployed to support be a focus for ABB Turbocharging. activities is critical in the logistics chain.” The customer valued the cooperation Designed for operators who want with ABB: “We have had excellent sup- close support in servicing their turbo - port from ABB to date and we are look- chargers, rather than complete delega- ing forward to a successful partnership tion, the Maintenance Management over the course of the contract.”
22 ABB charge! 1|16 News Flexible service with fixed rates
Service. The model of servicing industrial products is changing, and the move towards outsourced service is a clear trend in the turbocharger market. Influ- enced by this, the focus for ABB Turbo - charging service is now firmly on bringing more flexibility to the servicing of turbo- chargers, and to more comprehensively meeting customer needs, resulting in the extension of our portfolio of service agreement packages. Already in place are the full service agreements: the Operation Performance Package as well as the agreement for customers who want more flexibility with less delegation, the Maintenance Man- agement Agreement. Customers across Engine room of a power plant owned by West African cement manufacturer SOCOCIM. the large engine industry make it clear that requirements for maintenance and service are varying, and these offerings for service management of products ment. One example comes from a power combined with a consultative approach for customers, freeing up resources to plant application in West Africa, where enable customizable solutions for ABB focus on other important aspects of their the focus was on reducing engine down- turbocharger service. business. Working in partnership with time, improving planning and bringing The latest addition is the Fixed Rate customers to support them with plan- benefits to budgeting and cost manage- Service Agreement, with flexibility in the ning, management and execution of ser - ment. The Plant Manager told us, “This scope of service and spare parts required vice ultimately aims to maximize uptime contract has had a very positive impact combined with the option of payment and reduce unexpected maintenance on operations and maintenance costs. by fixed installments. As with our other costs. We have increased engine availability with service agreements, the value is in Customers are already seeing the value very good performances while reducing ABB Turbocharging taking responsibility of the new Fixed Rate Service Agree- costs.”
Vadodara plant wins 2015 star recognition from CII
Award. At its first attempt, the ABB The 3,410 m² Vadodara plant, which chargers for the locomotives of Indian turbocharger plant run by ABB India Lim- has been operational since 1991, is the Railways and serves as a sourcing hub ited in Vadodara, India, has won the headquarters of ABB Turbocharging’s within ABB Turbocharging’s global supply prestigious Emerging Leader award for activities in India. It produces turbo - network. Excellence in Operation Management, organized by the Confederation of Indian Industry (CII). The accolade was conferred in the Power and Automation segment at a cer- emony during the CII’s 23rd National Quality Summit, held on 18 November 2015 in Bangalore and attended by the Chief Minister of Karnataka state. “Par- ticipation was initiated by the OPEX team and winning this award the very first time we registered for this national event is a great motivator to improve further and reach even higher quality levels,” says Keyur Patel, Marketing Communication Manager for the LBU Turbocharging at ABB India Limited, based at the Maneja works in Vadodara, Indian State. The turbocharger assembly area at ABB India’s Vadodara plant.
ABB charge! 1|16 23 Tips for the operator Turbine washing on medium-speed engines
Building on the report in this issue of charge! describing countermeasures to turbine fouling, this article looks at the best way to prevent the problem arising in the first place.
Text René Stoverink, Photography ABB Turbo Systems Ltd
hile the CPI project (see The alternatives are, of course, much page 7) specifically ad- Schematic of the more expensive. Whether the turbo- dressed A100-M and TPS turbocharger turbine charger needs repair or mechanical W turbochargers on engines cleaning, it will have to be removed from burning certain grades of heavy fuel oil washing set-up the engine and dismantled. And even if (HFO), and which are likely to be operated downtime is minimized by the use of at low and part load for extended periods, refurbished exchange turbochargers, 01 02 03 its findings are equally valid for engines higher expenditure is inevitable. operating on HFO in land-based power generation applications. In baseload Wet, wet, wet power generation applications on land, On turbochargers for the type of four- part load running should be far less stroke, high- and medium-speed engines prevalent, but combating fouling is just involved in the CPI project, ABB Turbo- as essential. charging specifies wet cleaning of the After ensuring the correct precondi- turbine-side components at defined Prevention is better than cure – and tions for turbine washing, as shown intervals. cheaper in Table 2, and that the water supply This involves injection of water into The central lesson learnt and a major (01) is reliable: the turbine according to a prescribed solution proposed for auxiliary engines n Open the stop valve (02) and set procedure. The principle at work is that operating on HFO has universal validity: the water volume flow VW with a the dirt layer on the turbine components flowmeter (03). is removed by the kinetic energy exerted n Close the stop valve (02) after 10 by the water droplets. Washing is exe- Regular washing of turbines is the minutes. cuted using devices supplied by the best way to prevent fouling and n Wait for 10 minutes; do not engine builder and manufactured in possible turbocharger damage due change the engine load during accordance with ABB Turbocharging’s to deposits on nozzle rings and this stabilization phase. recommendations. turbines. During the CPI project two turbine washing procedures were tried. One
24 ABB charge! 1|16 Tips for the operator
Cool, cool, cool Cleaning procedure – times and temperature There are a number of aspects to observe, such as injecting the correct amount of water at the correct pressure during washing. For the TPS and A100 turbochargers which were the subject of Cool-down Washing Drying the CPI project, ABB Turbocharging rec- ommends a pressure of 1.5 bar to ensure the correct water flow quantity. 10 min. 10 min. 10 min. Engine load One of the most essential factors in
430°C successful turbine washing is observing the specified temperature limits and time windows to reduce the thermal stress on Time the hot turbine parts. This is needed because the sudden cooling of the exhaust gases as water enters the tur- bine housing represents a considerable thermal loading on the components. involved injecting water for three times At the same time, ABB Turbocharging Reduction of the thermal shock will 30 seconds at three minute intervals and recognizes that the person in the best increase the lifetime of the parts. one a continuous ten minute burst of position to judge the necessity for tur- This means allowing the turbocharger’s water. In practice it was found that the ten bine washing and to schedule the task is hot gas (turbine-side) parts to cool down minute method was considerably more the engine operator. Thus, the CPI also before washing. effective, and this information was pub- resulted in a recommendation to engine To achieve this level, the engine lished as ABB Turbocharging’s Service users to optimize the cleaning procedure should be run at reduced load for a total News 03/2012 (TPS turbocharger turbine on their specific engine application by period of 30 minutes. This overall time is cleaning in operation: Recommendation varying the washing interval as needed. made up of: for procedure change) and distributed The instruction manual supplied with the – 10 minutes before injecting the water to both engine users and ABB service turbocharger should be used as a guide. into the turbine to allow the turbo - personnel. charger to cool down – the 10 minutes for the washing proce- dure – 10 minutes after water injection to allow the turbine parts to dry out. Important considerations for turbocharger cleaning For detailed information on the subject of during engine operation turbine washing during operation, the following documentation is available: n Make sure the correct amount of water is injected (see instruction manual). – Operation Manual specific to the turbo- n Optimize the cleaning procedure for your specific plant conditions (i.e. vary charger installed the washing interval accordingly). – Service News 03/2012 – TPS turbo - n Adhere to the specified temperature limits and time windows to reduce the charger turbine cleaning in operation: thermal stress on the hot turbine parts. Recommendation for procedure change n Allow the hot gas parts to cool down before washing to reduce thermal – Service News 07/2014 – A100-M stress. This has a direct influence on the lifetime of the parts! turbocharger turbine cleaning during operation. Table 1.
Parameters for wet cleaning of turbines (two- and four-stroke engines)
n Cleaning interval: approximately every 50 to 200 hours n Water injection duration: 10 minutes continuous n Turbocharger inlet temperature: maximum 430 °C n Water pressure: 1.5 bar over-pressure or 2.5 bar absolute pressure
Table 2.
ABB charge! 1|16 25 Recipe Bentos and cherry blossom
Eastertime is celebrated in different ways around the world. In Japan, this year as every year, it is a fair bet that staff at ABB, IHI Corporation and Turbo Systems United were looking forward to Hanami.
Text Jonathan Walker, Photography iStockphoto
eaning literally “flower view- or night-time party with food and drink Japanese word for “convenient”, a bento ing”, Hanami is the Japan- beneath the blossoming cherry trees. is simply a box for food, usually with a ese tradition of enjoying the The celebration is bitter-sweet – the number of compartments to keep the M cherry blossom for which blossoms only last a few days and are various elements separate. Japan is so famous – and celebrating its easily dispersed by wind or rain, stress- But bentos can be ornate or merely arrival. The sakura bloom from the end of ing the Buddhist belief in the transience functional and a traditional bento holds March to early May all over Japan, and of reality. rice with fish or meat accompanied by such is the importance of this symbol of pickled or cooked vegetables. They can spring that there is even a blossom fore- The bento be filled at home or bought as a take- cast service, the sakura-zensen, operated A popular way of catering at the par- away meal from restaurants, the typical by the Japanese weather bureau. Hanami ties is to take along a bento full of your Japanese izakaya eating place or street generally consists of holding a day-time favorite food. Derived from an archaic vendors all around Japan.
26 ABB charge! 1|16 Acknowledgments
Published by Chicken Kara-age ABB Turbo Systems Ltd Address P.O. Box CH-5401 Baden/Switzerland Phone: +41 58 585 7777 Fax: +41 58 585 5144 www.abb.com/turbocharging e-mail: [email protected]
Photos ABB Turbo Systems Ltd HHI iStockphoto Michael Reinhard IHI Polar Research Institute of China
Cover photo: Corbis
Printer Dietschi Print & Design AG, Olten/Switzerland
Layout, typography, electronic publishing A popular bento meal is chicken Domino Style & Type AG, Gebenstorf/Switzerland kara-age, a Japanese version of fried chicken. Reprints require the publisher’s written consent.
© 2016 ABB Turbo Systems Ltd, Baden/Switzerland Ingredients (serves two) All rights reserved 500 g boneless chicken with skin 3 tbs. corn or potato starch (katakuriko) 2 tbs. plain flour Vegetable oil for deep frying 1 tbs. soy sauce ½ tbs. ginger 1 clove of garlic Salt, to taste
Preparation 1. Crush the garlic and mix with the soy sauce, ginger and salt to make the marinade. 2. Cut the meat into 50 mm (2 inch) pieces and marinate for a minimum of 30 minutes. 3. Mix the starch and the flour, coat the chicken pieces in the mixture. 4. Heat the oil in a deep fat fryer to a suitable temperature and cook the chicken pieces until golden brown outside and well-cooked inside (use a meat thermometer to be sure). 5. Place the fried chicken pieces on a paper towel to soak up the excess oil. 6. Serve with lemon or lime wedges and fill the other compartments of the bento with rice and the pickled or cooked vegetables of your choice.
Bon appetit!
ABB charge! 1|16 27 Customized service support. With you every step of the way.
Assuring the availability of your application is a critical part of securing your business. The right service reduces downtimes and increases your application’s performance and lifetime. Getting your service plan from ABB Turbocharging guarantees depend- able delivery of results and lower total cost of ownership of your turbocharger. We are dedicated to providing our customers a comprehensive turbocharging service offering 24/7, 365 days a year at any one of our 100+ ABB-owned Service Stations in 50+ countries across the globe. Get the right service. www.abb.com/turbocharging