1|15 The customer magazine of ABB Turbocharging charge! Switzerland Exploring new frontiers The constant search for improvement 4 Research and development aiming at even better turbochargers Powerships with raised performance 14 How turbocharger upgrades increase power output Cruising on LNG? 20 Dual-fuel engines on cruise ships for the first time From the editor Focus on research and development CSCL Globe and MSC Oscar The Jungfrau test bed explores the limits of ABB turbochargers on the world’s biggest 04 turbocharging technology. 16 box ships. charge! 1|15 Being committed to continuously improv- A very important arm of our strategy is ing its products, ABB Turbocharging has that we are geared to long-term relations a long and strong tradition of research and sustainability. An example is the and development – an excellent reason strong relationship between ABB Turbo- for charge! 1|15 to focus on its R&D charging and AIDA Cruises underlined activities. Christian Roduner, Head of here in an interview with Jens Kohlmann, Technology, and Volkmar Haueisen, Head Director Yards & Strategic Projects at of R&D Turbocharger, share insights on AIDA Cruises. ABB Turbocharging has page 4. been the turbocharger supplier to AIDA Cruises since 1996 and has always been One of our latest innovations based on committed to being a reliable partner in R&D excellence is second-generation every area. Keywords here are reliability Power2. We are proud to announce its and environmental protection. presentation at Nor-Shipping in Oslo, Nor- way (June 2 – 5), at ABB Turbocharging’s How ABB Turbocharging improves the booth no. E02-13. Power2 is a genuine performance of the engines and reduces achievement. With clear benefits for the fuel consumption through their upgrades Magdalena Okopska marine industry, it is the result of a fasci- is presented in the report on page 14. Head of Market Communication nating technology development. Track the Karadeniz Energy Group, based in Turkey, ABB Turbocharging story of ABB’s two-stage turbocharging has floating power plants called Power- in this issue. ships to provide power in regions where electricity is not always accessible. Finally, charge! 1|15 also covers outstanding two- the recipe is inspired by and dedicated to stroke diesel turbocharging applications Karadeniz, which in Turkish stands for that go hand in hand with the rapidly “Black Sea region”. increasing size of box ships. Turn to page 16 to find out why vessel size and economies of scale are converging. 2 ABB charge! 1|15 Contents Dual-fuel technology on cruise ships Employee safety Jens Kohlmann (AIDA, center) discusses the ABB Turbocharging targets safe working 22 significance of using liquefied natural gas. 24 practices. Research and development Applications (R&D) 16 Powering the giants of the sea MSC Oscar and CSCL Globe, with capacities of more 4 The constant search for improvement than 19,000 TEU, are the biggest box ships afloat R&D’s role in providing customer benefits 20 Cruising on LNG? 7 Simplicity is often complicated Dual-fuel engines now running on AIDA cruise ships Quantum leaps achieved through R&D 22 What future does dual-fuel technology have in the 8 How can marine engines become more efficient? cruise industry? Research project Hercules proves the advantages of Interview with Jens Kohlmann, Director Yards & Strategic two-stage turbocharging Projects AIDA Cruises 10 Far beyond the current state of the art Research collaboration with Imperial College London focuses on non-steady state admission of turbines News 12 Testing Power2 on the Jungfrau 27 Opening and awards Evaluating the full potential of two-stage turbocharging Tips for the operator Service 28 Easy procedures as long-term investments 14 Powerships with raised performance Turbine Side Washing and coated turbine blades Turbocharger upgrades for Karadeniz Energy Group’s floating power plants 24 Arming a workforce for change Recipe Global safe working practices for ABB Turbocharging 30 A mariner’s legacy in Turkey employees Mıhlama, a tasty dish from Karadeniz, the Turkey’s Black Sea region ABB charge! 1|15 3 Research and development (R&D) Close-up of the Jungfrau test bed where the Power2® two-stage turbocharging system is currently being tested. 4 ABB charge! 1|15 Research and development (R&D) The constant search for improvement Customers benefit when turbochargers become lighter or more compact. But how are these results achieved? And what role do Hercules and Imperial College play? The research and development (R&D) department at ABB Turbocharging invites charge! behind the scenes. Text Tiziana Ossola Auf der Maur, Photography Michael Reinhard, ABB Turbo Systems Ltd erries need to lower their emis- Development processes sions, container shipowners Developing an all-embracing R&D would like to reduce fuel con- process for the blades involves a great F sumption and power station deal. Measurements and investigations operators want even shorter response in the fields of mechanics, aerodynamics times. These needs demand technical and materials science deliver precise solutions. The path to them leads to the data, creating the scientific prerequisites research and development department for the new design. Proof that a compo- at ABB Turbocharging. It has one aim: nent both functions and benefits the developing turbochargers with benefits overall system comes from a series of for the customer. Volkmar Haueisen, Head tests and qualifications. The knowledge of the department R&D Turbocharger, acquisition process progresses step by cites an example: “If we want to increase step, culminating in new product release efficiency by changing the shape of the and industrial production. compressor wheel, we must first work to ABB Turbocharging maintains global acquire the necessary basic knowledge. research partnerships with hand-picked That way we can be sure that the new academic institutions and industrial blades are shaped and configured so partners. The aim is clear: “We want the that they function perfectly.” latest findings for the best performance,” ABB charge! 1|15 5 Research and development (R&D) Christian Roduner, Head of Technology, (left) and Volkmar Haueisen, Head of R&D Turbocharger, in the ABB Turbocharging test center in Baden, Switzerland. Haueisen says. The research presented flows on the turbine.” This has now been The team makes the difference in this edition of charge! – based on the delivered. The “R” in R&D is completed. From an engineer’s standpoint a turbo- Hercules study and work at Imperial The “D” is undergoing testing. Haueisen: charger might look like a fairly straight- College London – demonstrates what “What improves the response of the total forward piece of machinery, but as research delivers. system? A possible measure might be Roduner explains: “It is a piece of turbo- a new configuration of the turbine stage machinery which requires a great deal of Hercules and two-stage turbocharging or parts of it.” With the emphasis on research to get the best out of it.” Con- R&D processes are more like “might”. Do systematic adaptations make ducting R&D with all its ramifications is marathons than sprints. Hercules is a sense technically? And if so, will they a matter of corporate culture. And it ten-year study – an average timespan for also be economically viable? These are requires people to implement it. Roughly an undertaking of this technical com- the questions that ABB Turbocharging’s 200 research and development engi- plexity. Forty partners from science and developers take with them into the next neers, technicians and students on industry participated. “Hercules sets a stage of their work. internships are at work on tomorrow’s milestone,” Head of Technology Christian turbochargers at ABB Turbocharging’s Roduner notes, drawing a positive bal- Who profits from research? own R&D laboratories and test facilities ance. “The research program delivered From the point of view of a coopera- in Baden, Switzerland. They know the the proof that two-stage turbocharging tion partner at the forefront of science, technology of turbochargers inside out on large engines is capable of achieving ABB Turbocharging has available a and exactly what research means. By benefits such as improved fuel efficiency, unique fund of data and findings. “We embracing the spirit of invention, the higher power density and lower emis- have a whole constellation of informa- team is making possible today what was sions. Among other things, Hercules has tion,” Haueisen says. The company’s inconceivable yesterday. enabled us to quickly turn the idea into research activities have, after all, been at industrial hardware.” The second genera- a constantly high level for many decades. tion of Power2 two-stage turbocharging That is an inspiring starting point. “These system today stands shortly before its data benefit the academic institutions we product release. cooperate with because they can use The study at Imperial College in London them in their classes and hence enrich was purely scientific, Haueisen explains. their research in this area, without ABB “We wanted to gain basic knowledge Turbocharging having to reveal any of its about the effects of pulsating exhaust product know-how.” 6 ABB charge! 1|15 Research and development (R&D) Simplicity is often complicated ABB Turbocharging quantum leaps at a glance. Comments from the technology department. Second generation Power2 – high A200-L – smaller and more Turbine washing for efficiency in a compact system compact stable performance “Power2 achieves highest pressure “The A200-L turbocharger is the result “Turbines are fouling in operation, ratios at highest efficiency, and high of a development trend which R&D has especially on engines burning heavy turbocharging efficiency translates followed single-mindedly in recent years: fuel oil (HFO). The answer is turbine into high engine efficiency. That means steady increases in the specific flow washing and is the result of complex higher engine power with lower fuel capacity of the turbocharger while main- R&D work.