2018 • A supplement to Marine Propulsion & Auxiliary Machinery
“In the end, it’s an investment in sustainability” Wayne Jones, senior vice president and head of MAN PrimeServ Diesel , see page 42
Napier is a world leader in the design, manufacture and support of industrial turbochargers.
next generation turbochargers Napier NT1 turbochargers are designed and built to oďŹ€er cutting-edge performance, reliability and eďŹƒciency. The Napier NT1 product family incorporates state-of-the-art turbocharger designs, achieving pressure ratios of up to 6.0:1.
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3 Pressure continues to rise for turbocharging
4 MAN Energy Solutions puts emphasis on both products and services 7 Technological developments help ABB improve efficiency 10 KBB innovates to meet operational trends 12 Rolls-Royce adds power to MTU turbochargers 13 Napier consolidates its NT1 range 15 Mitsubishi’s MET-MB series gains a further frame size 16 Focused production gives PBS Turbo its independence 17 Hedemora set to launch its HD6800
18 MAN Energy Solutions opts for two-stage technology for flagship engine 19 Wärtsilä unites engine and turbo expertise 20 Mitsui successfully tests MAN TCT40
23 Algarmani 23 Daewin 24 Gulf Turbo 25 Istanbul Marine Turbine Services 25 La Meccanica 26 Marine Partner 29 Tru-Marine 30 Turbo Belgium 33 Turbo Service International 33 Turbo Cadiz 34 TurboSpares 37 Turbo Internacional 37 Zeppelin 38 Turbo USA
41 R&D drives turbocharger improvements
42 Repair, replace or upgrade?
Special supplement to Marine Propulsion & Auxiliary Machinery published July 2018 Executive Editor: Paul Gunton t: +44 20 8370 7003 e: firstname.lastname@example.org Brand Manager – Sales: Tom Kenny t: +44 7432 156 339 e: email@example.com Sales Manager: Rob Gore t: +44 20 8370 7007 e: firstname.lastname@example.org Sales: Paul Dowling t: +44 20 8370 7014 e: email@example.com Sales: Jo Lewis t: +44 20 8370 7793 e: firstname.lastname@example.org Head of Sales – Asia: Kym Tan t: +65 6809 1278 e: email@example.com Production Manager: James Millership t: +44 20 8370 1718 e: firstname.lastname@example.org
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45 A comprehensive listing of service centres globally
www.rivieramm.com ISSN 2055-5164 (Print) ©2018 Riviera Maritime Media Ltd
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Worldwide Turbocharger Guide 2018
‘I can find the full potential of your turbocharger.’ ABB Turbo Hero Mike Kautsky
— Unlock the full potential of your equipment with ABB Turbo Heroes. How do you define Original Service by ABB Turbocharging? As your original equipment manufacturer (OEM), we have the unique expertise and insights to unlock the full potential of your turbocharger. Our service experts do not only restore the original performance of your ABB turbocharger. We continuously enhance your turbocharger’s efficiency for maximum output and asset value. ABB Turbo Heroes at Your Service. turboheroes.com
COMMENT | 3
PRESSURE CONTINUES TO RISE FOR TURBOCHARGING
T Paul Gunton, Editor
his year has seen a number of changes in the marine sector, with one significant example being the steady rise in crude oil prices. It seems unlikely that these will return to earlier highs but the risks of instability in the world economy, combined with geopolitical trends, could see prices pushing further upwards. Yet the past few years of lower oil prices have not reduced the pressure on engine or turbocharger manufacturers to slow their development plans. The drive for reducing operating costs remains a key aim across the marine sector. Added to this, the slowdown in demand for marine transport may now be accelerated by trade barriers, resulting in further downward pressure on costs. The upshot of this is likely to be continued demand for increased engine and turbocharger efficiencies, keeping performance up and operating costs down. This will, of course, come on top of the need for development work to deliver products that meet IMO emissions limits and EEDI targets. It seems that the pressure on turbocharger manufacturers is relentless. Despite the negative factors, commercial and legislative demands – alongside the need for competition between suppliers – undoubtedly drive improvements. Although it may seem that year-to-year changes are slow, new products and systems are continually emerging into the marketplace. More two-stage turbocharger products are now entering serial production and the use of sequential turbocharging is also on the increase. With slow-steaming still a common practice, new systems that optimise turbocharger use, but still maintain operational flexibility, can be attractive investments and payback times for the right systems are relatively short. Although the costs might have once appeared difficult to justify, hybrid turbocharging is now starting to become not just a practical possibility, but also an economically-feasible proposition. This technology can be seen in a number of
turbocharger manufacturers’ portfolios or at least in their business plans. With developments in high-speed electric motor-generators and in power electronics, the size and cost penalties of hybrid systems are becoming less onerous and the advantages are beginning to grow. All this seems to point towards more and better integration of equipment alongside optimum relationships between turbochargers, engines and power management. This is not a new concept but technological improvements are helping to make this a reality. Intelligent tuning of engines helps them to operate more efficiently at all load points and turbocharging systems are becoming more aligned to these requirements. Add technologies such as valve management and advanced fuel injection into the equation and the shape of marine power and propulsion packages is now advancing well beyond the limits of technology that were perceived only a few years ago. Associated with this, the other word that has now entered common vocabulary is ‘digitalisation’. Although often perceived as a topic in itself, we have been progressing towards a more digital world for many years and this opens more opportunities for turbocharging, in terms of control, monitoring and diagnostics. With relative costs for instrumentation and remote monitoring dropping significantly, often as a result of digital technology, there is more opportunity than ever for early diagnosis of potential problems allowing remedial action to be efficiently planned and executed. This brings us to the importance of structured and high-quality maintenance and repair services. Despite the huge benefits of the digital age, the reliability of mechanical equipment will continue to be only as good as its original quality and the care and maintenance it receives in service. Whatever happens to oil prices and all the other pressures on the sector, this fundamental point will continue to underpin the confidence needed for future investment. WTG
Worldwide Turbocharger Guide 2018
4 | TURBOCHARGER MANUFACTURERS MAN
MAN ENERGY SOLUTIONS PUTS EMPHASIS ON PRODUCTS AND SERVICE Wide power range covers most engine types and sizes, using all fuel types MAN’s Ecocharge two-stage turbocharging concept – seen here on test in 2015 – is available for engine powers of up to 20,000 kW (credit: MAN Energy Solutions)
ith equipment installed on 50,000 engines worldwide, MAN Energy Solutions, of Augsburg, Germany, is one of the world’s leading suppliers of turbocharging solutions. Covering engine capacities from 300 kW to 30,000 kW per turbocharger, the range meets the demands of both two- and four-stroke marine propulsion engines and auxiliary power packages. MAN turbochargers are designed to operate on engines using all types of marine liquid fuels, including both medium and heavy fuel oils, and increasingly popular gas fuel alternatives. The MAN portfolio is headed up by the TCA series, for two- or four-stroke engine applications power capabilities of up to 30,000 kW per turbocharger. These axial flow turbine units can run with engine exhaust-gas temperatures of up to 650°C
Worldwide Turbocharger Guide 2018
and can deliver charge air pressure ratios of up to 5.5:1. Available in six frame sizes, they feature low-loss floating bearings with all oil pipework integrated into the design to allow simple installation. Noise emissions levels are low and a major service advantage for the TCA is the ability to change compressor wheels without needing to re-balance the full rotor. The achievement of IMO Tier II emissions levels is unquestioned, but MAN technologies also provide a range of possibilities to assist in meeting vessel EEDI targets. With the EEDI measuring point set at 75% of engine maximum continuous rating, however, this is not the only driver for operators in seeking higher efficiencies. Many vessels now use slow steaming to reduce fuel use and major savings can be made when engines are operating in the 25-50% power band.
To optimise slow-steaming savings for vessels with multiple engine turbochargers fitted, a turbocharger cut-out system is a viable option. This can be used at lower engine powers and enables one or more turbochargers to be isolated either automatically or manually, resulting in optimised turbocharging. Although not directly contributing to EEDI at these loads, fuel savings up to 6 g/kWh can be achieved. The system also assists in meeting Tier II emissions targets. Further options available in the MAN range include electronic control tuning (ECT) for the engine and variable turbine area (VTA) for the turbocharger. With the latter, delivery of charge air can be matched exactly with fuel injection rates at all engine speeds and loads, reducing specific fuel oil consumption by up to 5 g/kWh and making a positive contribution to EEDI.
MAN TURBOCHARGER MANUFACTURERS | 5
Where required, exhaust gas bypass (EGB) technology can also be added, allowing better matching at lower engine loads and spilling excess exhaust gas at higher loads. Again, up to 5 g/kWh fuel savings are possible using this approach and there can also be a noticeable benefit at the 75% EEDI measuring point. A step-change in turbocharger technology is also available from MAN Energy Solutions with its two-stage MAN Ecocharge solution. Available for engine powers of up to 20,000 kW, these turbocharging systems can operate at efficiencies of up to 80% and deliver pressure ratios of up to 10.5:1, which enable increased power density combined with the lower emissions resulting from Miller
cycle valve timing. The company already has extensive experience in two-stage applications with 2,000 turbochargers having been delivered for this purpose and about 10M operating hours accrued. The first stage of Ecocharge systems use a TCA, TCR or new TCT design turbocharger with a TCX unit – specifically designed for higher pressures – providing a second-stage boost. Available in eight frame sizes, the TCX has a turbine of mixed flow design and can operate at high air-side pressures and in engine exhaust gas temperatures of up to 650°C. Intercooling between compressor stages is available and the result is both increased efficiency and a package that will assist engine manufacturers in meeting stringent IMO
emissions limits. Its turbocharger family offers what the company describes as class-leading efficiencies but work is also well advanced with systems for IMO Tier III compliance, having favoured high-pressure selective catalytic reduction (SCR) and exhaust gas recirculation (EGR) systems as solutions for two-stroke engines. For high-pressure EGR using the ‘short route’ approach, MAN units can be fitted with an electrical turbo blower (ETB) to overcome the pressure difference between the exhaust gas and the scavenge air receiver. The variable speed of the ETB drive motor allows accurate control of the volume of exhaust gas recycled to the inlet and hence the optimum emissions performance of the engine.
GLOBAL NETWORK PLAYS KEY ROLE IN MAN SERVICE PLAN A key part of MAN Energy Solutions’ customer service is its ability to support equipment throughout its life using its worldwide MAN PrimeServ network. The company sees customer support as critical to business success, not only for aftermarket needs but also as a factor for new equipment orders. Its experience is that the global ability of PrimeServ to deliver this support provides customers with the confidence that through-life service demands will be met efficiently and effectively. This is particularly important for the marine industry where vessel routes will often vary, making competent local support for both engines and turbochargers essential. The PrimeServ network consists both of its own facilities and those of licensed associate companies but, in all cases, engineers and technicians are fully trained and certified by MAN Energy Solutions before licensees are approved to provide repair and maintenance services. All engines and turbochargers are covered and rapid delivery of spare parts to PrimeServ workshops ensures equipment downtimes are kept to a minimum. Many regular spares are held at worldwide locations but the company’s logistics systems enable most parts to be delivered within 24-48 hours, even if not held in local stocks. PrimeServ engineers undergo continuous training to ensure they are fully up to date in their knowledge of equipment and overhaul processes. This is assisted by regular information updates through service bulletins and video clips. Close coordination is maintained with all licensees, ensuring all work carried out meets company standards and is fully quality assured. Service is available on a 24/7 basis and backed up by technical support from MAN engineers and technical experts. The result is a cost-effective and efficient support service for turbochargers and engines throughout their operating lives. Full overhaul facilities are available in service centres but in-situ inspection and assessment work can be carried, out using borescopes to evaluate turbocharger condition. Vibration measurement and analysis can also be carried out on units in operation to evaluate likely root causes in the event of any
vibration problem being identified. In addition to new part supplies, MAN Energy Solutions offers repair and reconditioning services for key turbocharger parts at its Augsburg base. This allows operators the option of a potentially lower-cost route to extending the service lives of installed units. Examples of repairs include turbine shaft and bearing surface recovery, diffuser wall recovery and weld repairs to address minor damage of compressor wheels. Where damage is significant, an in-house laboratory is available for assessment work to confirm the feasibility of part repair. A further service offered through MAN PrimeServ is the modernisation and upgrade of existing equipment to maximise reliability, availability and efficiency in operation. This can include upgrades of engine components but also the re-matching or full upgrade of turbochargers. As turbocharger performance has a major influence on engine power and efficiency, the retrofit of an existing engine with the latest MAN turbocharger technology can both extend operational life and significantly improve engine economic and environmental performance. WTG PrimeServ engineers undergo continuous training at centres such as this one in Copenhagen (credit: MAN PrimeServ)
Worldwide Turbocharger Guide 2018
PBS Turbo Aspiring Engines since 1957
PBS Turbo Turbocharges TCR NR/S Engineering Support Since 1957, PBS Turbo is experienced in production and sales of turbochargers for gas and diesel engines with outputs from 250 kW to 3,000 kW incl. delivery of spare parts and technical support. More than 115,000 delivered turbochargers around the world lead to outstanding experience in design, development and production of turbochargers.
PBS Turbo s.r.o. . Vlkovská 279 . 595 01 . Velká Bíteš . Czech Republic . Tel.: +420-566 822 210 . Fax: +420-566 531 925 . www.pbsturbo.cz
ABB TURBOCHARGER MANUFACTURERS | 7
Technological developments help ABB improve efficiency
xceeding an industry efficiency benchmark and launching digital solutions that enhance performance and deliver cost savings reflects a commitment by ABB Turbocharging to consistently deliver value for customers, the company told Worldwide Turbocharger Guide. Based on the MAN Energy Solutions efficiency benchmark, ABB Turbocharging said it had raised industry standards for low-speed turbocharging efficiency with an additional 2% increase, measured on a low-speed test-bed engine at a Hyundai facility in South Korea. The efficiency of three of the latest-generation ABB A180-L turbochargers was measured, fitted to an MANdesigned 8G95ME-C9.5 engine. Hyundai had manufactured the turbochargers under licence and measurements were recorded using the latest wireless technology equipment to ensure highest data accuracy. This 2% efficiency increase figure now offers the potential for annual fuel savings of up to US$35,000 per vessel for operators, depending on fuel price and load profile, ABB predicted. Announcing the achievement, ABB Turbocharging senior general manager, product group low speed, Arie Smits, described that measurement on an actual engine as “confirmation of our promise and commitment to continue to push for highest efficiencies and value for our customers.” ABB A100-L series singlestage turbocharger products are specifically designed
for low-speed two-stroke engine applications. With high efficiencies and pressure ratios, they also feature wide compressor maps for maximum operational flexibility. The smallest A100-L product starts the series, from a capacity of below 10 m3/s, with the largest A190-L capable of
products. Sharing many common features, this newest generation of turbochargers for low-speed engines includes an advanced design compressor that delivers 30% more volume flow for its size and a significantly improved power-to-weight ratio. A further advantage, ABB said, is
Test results on an engine show 2% efficiency gain, “raising industry standards” exceeding 50m3/s. The new efficiency record was set at well over 75% load and at higher charge pressures, with compressor pressure ratios of up to 5.0:1. Complementing the 100-L range, ABB Turbocharging has introduced its latest A200-L
that costs of some spare parts are proportionally reduced, with potential savings of up to 25% for operators. ABB’s engineers have developed the A200-L to meet the requirements of the latest generations of low-speed twostroke engines, operating on
both diesel and gas fuels. They have been able to provide the same high pressure ratios and efficiency levels, but within a smaller and lighter envelope that requires reduced installation space on engines. To further enhance efficiencies, A100-L and A200-L turbocharger operation can be combined with ABB’s high-pressure tuning (HPT) technology. HPT is suitable for electronically controlled two-stroke engines, fitted with high-pressure turbochargers when operating at lower loads. A more regular practice might be to include exhaust gas bypass or variable turbine geometry systems, ABB noted, saying that HPT reduces the need for these features and delivers improvements by delaying the closure of the exhaust valves, compared with conventional timing. Scavenging air pressure is increased, resulting
ABB’s A200-L has an advanced compressor design giving an improved power-to-weight ratio (credit: ABB)
Worldwide Turbocharger Guide 2018
8 | TURBOCHARGER MANUFACTURERS ABB
in higher peak firing pressures and greater efficiencies, with a simple and reliable tuning and turbocharging arrangement. In a further development, ABB has now launched its Flexible Integrated Turbocharging System for Two-Stroke Engines (FiTS2). This provides marine operators with the flexibility for vessels to run at high loads without cost penalties while still enabling fuel savings at part- and low-load, with rapid return to full engine output levels when required. The sequential turbocharging system enables fuel savings of up to 6 g/kWh (3-5%) compared with fuel consumption levels typically achievable with conventional turbocharging systems on low-speed diesel engines, ABB reported. Depending on the price of fuel and the load profile to be met by the engine, fuel savings over 10 years can amount to US$0.5M for a VLCC and well over US$1M for a container vessel, the company predicted. In addition to the A100-L and A200-L products, which are available for engine powers of up to 30,000 kW per turbocharger, ABB Turbocharging offers TPL-B and VTR series products for low-speed two-stroke applications. The TPL-B is available in five frame sizes covering engine outputs from 3,000 kW to 28,000 kW per turbocharger. The design is described as simple and modular and the products can deliver pressure ratios of up to 4.5:1. Part count is minimised to enable easy maintenance and low lifecycle costs. VTR products, which are also suitable for four-stroke medium-speed heavy-duty diesel engines, are available in a power range from 70018,500 kW per turbocharger. For medium-speed engines, the ABB Turbocharging
Worldwide Turbocharger Guide 2018
portfolio includes A100-M products for marine and stationary applications, with power output from 500-6,000 kW per turbocharger. Pressure ratios can be as high as 5.8:1 and turbocharging efficiencies can exceed 60%. The products feature exceptionally wide compressor maps, the company said. For diesel and gas engines in the power range of 2,500 kW to 12,500 kW, TPL-A and TPC-C products are available. These turbochargers are of rugged construction and are designed for long service with low running costs. TPS and VTC products are available for lower power engines, typically of up to 3,000 kW per turbocharger. The MXP turbocharger, ABB’s first dedicated turbocharger designed specifically for smallbore medium-speed marine auxiliary diesel engines of up to 2MW power output, is included in the portfolio. For demanding mediumspeed applications, ABB offers the Power2 two-stage turbocharging system. It is the most potent power booster for four-stroke engines, as well as being the most compact twostage turbocharging system of its kind. High pressure ratios up to 12:1 and turbocharging efficiency boost engine power density and save 10 g/kWh of fuel, for six-figure savings in annual fuel costs, ABB said. NOx emissions are also reduced by up to 60%, an optimised layout results in a 20% smaller footprint and an extractable cartridge reduces overhaul time by 30%, it said. ABB Turbocharging also offers products for highspeed engines, including the A100-H, which is suitable for duties including marine power generation in the power range of 500-6,000 kW. For duties up to 3,300 kW, TPS-D/E and TPS-F turbochargers are available.
ABB Smart data analysis
Speed Temperature Engine load
Two-way customer communication Trend display Failure detection Remote support
ABB Ability connects devices and systems (credit: ABB)
DIGITAL SOLUTIONS ‘CAN SAVE TIME AND MONEY’ ABB Turbocharging launched its first digital solutions for enhanced performance, operational flexibility and lower operating costs for marine customers at the Marintec China exhibition in December 2017. Fleet operators can save time and money with ABB’s Tekomar Xpert, the company said, which incorporates engine performance analytical software that evaluates deviations and quantifies potential fuel oil savings for any two-stroke diesel main engines on marine vessels. Advanced diagnostics, combined with intelligence, allow ship operators to focus on optimising operations, rather than lengthy analysis. ABB Turbo Systems acquired Tekomar Group in 2017 and has since upgraded Tekomar Xpert to its 2.0 version. The new software version enhances efficiencies, especially for fleet managers, with connectivity as a key benefit, the company said, as the software integrates with almost any onboard platform. The software also provides a platform on which engine licensors and builders can work in co-operation. ABB Ability is ABB’s unified, cross-industry digital offering with devices, systems, solutions and services, and is a platform that helps customers to increase productivity and lower costs. Looking ahead, ABB plans to integrate Xpert further into ABB Ability, which it said will enable ship management companies to understand more about vessel operations and achieve better business performance from their fleets. ABB Turbocharging has also extended its ‘Sicherheitskonzept’ (‘Safety Concept’, or ‘SIKO’) to create ABB Ability Digital SIKO. This provides “a paradigm shift towards predictive maintenance”, ABB said, by following a data-driven assessment approach that considers the real conditions under which the turbocharger rotor is operating. Digital SIKO offers operators and owners a unique level of reliability and lifecycle cost management, the company advised, saying that, like the traditional SIKO – which is still available and valid – “Digital SIKO ensures the reliability and safety of ABB turbochargers.” WTG
Economy or ecology? We have the energy for both.
We are investing all of our energy into creating solutions for sustainable prosperity. Thatâ€™s why we have changed our name from MAN Diesel & Turbo to MAN Energy Solutions. Step by step, we advance marine, power, and industry solutions. This is future in the making. For customers, stakeholders, and society. www.man-es.com
10 | TURBOCHARGER MANUFACTURERS KBB
KBB INNOVATES TO MEET OPERATIONAL TRENDS KBB has developed turbochargers that blur the boundary between singleand two-stage turbochargers
ompressorenbau Bannewitz (KBB Turbo) has brought its 60+ years of experience of developing turbochargers to address current trends towards two-stage turbocharging. Its ‘Knowledge to Boost’ (K2B) developments are described below, but it also sees the importance of closing the gap between single- and twostage turbocharging products. With current demands for single-stage systems still predominating, KBB continues to push the boundaries of pressure ratio capabilities with its ST27-EP products. The company began serial production of its ST27 single-stage turbocharger series in 2010, with the largest ST7 product being released in 2014. To date, approaching 5,000 units have been delivered with the
range covering the needs of engines with power outputs from 500 kW to 5,000 kW and above per turbocharger. KBB’s more recent ST27-EP series products are now lifting pressure ratio capabilities from 5.5:1 up to 6:1 to meet increasing requirements of dual-fuel and strong Miller cycle engines. To a great degree, this capability has been achieved by optimising KBB’s impeller cooling technology, which is applied in cases where pressure ratios of above 5.2:1 are required by engines. With no cooling, the temperature limit of the aluminium material is reached at 5.2:1, but a safe operational margin is achieved with standard cooling arrangements. The upgraded cooling now available further increases temperature margins, allowing ST27-EP products to achieve
A KBB ST6-EP turbocharger, part of its successful ST27-EP range (credit: KBB)
Worldwide Turbocharger Guide 2018
6:1 performance while still using less than 2% of the compressor airflow for cooling. Wide compressor maps are also maintained on the EP series to ensure good onengine operability. ST27-EP products retain turbine designs from – and geometrically interchangeable with – HPR series turbochargers. The products have been designed to extend service intervals and component lives, reducing through-life costs for operators. Other features include the ability for rapid service and quick and easy replacement of wear components. There are also options for supplying compressor and turbine washing equipment, speed measurement facilities, intake silencing and casing insulation. Water cooling of the bearing casing is also available on request, for specific hightemperature applications. “We continue to see a strong demand for efficient, high pressure ratio, single-stage turbocharger products,” said KBB engineering director Klaus Buchmann. “By increasing the pressure ratios achievable from ST27-EP products, we can still provide highly cost-effective solutions for engines that do not yet need to make the move to two-stage systems.” KBB had already anticipated market demands for even higher pressure ratios and,
with its K2B products, already has two-stage turbocharger systems available to meet these. Based on a low-pressure stage using a radial or axial turbine turbocharger and coupled with a high-pressure stage radial product, the K2B system offers pressure ratios of up to 10:1 for engine powers of 500 kW to 5,000 kW. The low-pressure stage uses an LPR series turbocharger for most flow-rate requirements. It is available in five frame sizes and is based on knowledge and experience gained from HPR and ST series turbochargers. For the highest volume flow requirements, the axial turbine HPA7000 turbocharger is available, capable of delivering approaching 10 m3/s of charge air at pressure ratios of over 3.5:1. To compliment the first stage, KBB has developed a new turbocharger to deliver the final boost pressure to the engine. The radial turbine HSR product also comes in five frame sizes and is based on HPR and ST turbocharger design technology. KBB has released two systems to the marketplace: the first for engine outputs of 1.5-2.5 MW and a larger system for 4-5 MW engines. These have been designed for compact installation and are suitable for use on both in-line and V engines, running on MDO, HFO or gas fuels. As previously
KBB TURBOCHARGER MANUFACTURERS | 11
Pressure Ratio [-]
5.0 4.5 4.0 3.5
8 9 10
Air Flow Rate [m3/s] The five members of the ST27-EP family cover a wide range of operating conditions (credit: KBB)
reported, KBB has now gained considerable operating experience with the K2B, notably since 2014 on Yanmar six-cylinder main propulsion MDO/HFO engines. In addition to proving highly satisfactory in operation, significant reductions in fuel consumption have been confirmed. “We see a slowly increasing demand for two-stage systems in the coming years, with drivers such as the introduction of IMO Tier III emissions limits now approaching” said KBB managing director Dr Roman Drozdowski. “Although capital costs are unavoidably higher than for single-stage turbocharging, operating costs will compensate for this, making K2B a realistic and viable solution,” he said.
Meeting IMO Tier III
As engine manufacturers focus more closely on the solutions required for IMO Tier III there are clearly a number of different possibilities to consider. ST27-EP turbochargers are already capable of meeting
of IMO Tier II’s engine emissions limits and IMO Tier III compliance can also be achieved when these are used in combination with exhaust gas after-treatment technologies such as selective catalytic reduction (SCR). The higher charge pressures available from two-stage turbocharging systems also present an opportunity, but exhaust gas recirculation (EGR) can also be used to control NOx emissions. With this in mind, KBB has developed its Exhaust Recirculation Turbocharger (ERT) product specifically for EGR duties; it is suitable for both single-stage and two-stage turbocharging applications. The EGR system takes a proportion of the engine exhaust gas and returns this to the charge air system. A big advantage of this approach is its compact nature compared with large SCR installations. For single-stage turbocharging, the ERT takes exhaust gas upstream of the main turbocharger turbine, dividing this into two streams.
The ERT turbine is driven by one and the second is fed to the compressor, after primary cooling. The compressor discharge is then fed, via a further cooler, into the air feed, downstream of the main turbocharger aftercooler. The resultant intake mixture has the effect of reducing temperatures in the combustion process and, hence, NOx formation. A similar arrangement is available for two-stage turbocharging but this also allows the possibility of a ‘semi-short’ system where high-pressure exhaust gas leaving the engine can be fed, via a cooler, to the intake of the high-pressure turbocharger, thus potentially avoiding the need for an ERT. The KBB ERT20 is currently available for EGR applications and has been developed specifically for this purpose. It is suitable for engines in the power range from 500 kW to 2 MW and has a number of specialised features, including a titanium impeller for specific application requirements. The aggressive nature of
the exhaust gas has also necessitated the optimisation of coatings and the use of alternative materials to cope with higher temperatures, prevent damage from corrosion and soot formation and withstand impact damage that would otherwise be caused by particles in the gas flow. Turbocharger thermodynamics are also designed to be specific to the gas flows and bearings: shaft sealing and oil supply can cater for both operating conditions and circumstances where the EGR system is turned off. The current KBB standard product portfolio comprises the ST27 and ST27-EP products, radial turbine HPR and axial turbine M40 series, and the K2B two-stage system. Other specialist products are available, such as the ERT20, and the company offers a full aftermarket support service for maintenance, overhaul and spare parts. A customisation service is also available for meeting specific application requirements or duty changes, including part-load reoptimisation. A further initiative now being developed by KBB focuses on improving turbocharger instrumentation and condition monitoring. At present, the majority of turbochargers carry little instrumentation and, where this is fitted, it is likely to be limited to speeds, temperatures and pressures. KBB’s vision is to develop turbocharger monitoring to the level where condition-based maintenance (CBM) can be effectively introduced. This principle is being increasingly used to achieve cost-effective and timely machinery maintenance on major capital equipment and KBB believes that there is an opportunity for CBM to be extended to turbocharging systems. WTG
Worldwide Turbocharger Guide 2018
12 | TURBOCHARGER MANUFACTURERS ROLLS-ROYCE
Rolls-Royce adds power to MTU turbochargers Electric assistance will give MTU engines more effective turbocharging, reducing fuel consumption MTU plans to launch engines equipped with this hybrid technology onto the market by 2021 (credit: MTU)
erman engine builder MTU, part of Rolls-Royce Power Systems, has always been proactive in turbocharger development, seeing this as an essential element in overall engine design. Its ZRT turbochargers have contributed strongly to the success of its engines, with class-leading power-to-weight ratios. Rolls-Royce has now taken a further step by acquiring technology for electrically assisted turbocharging, aiming to bring products to series production on MTU engines by 2021. It has acquired G+L innotec, giving it exclusive rights for this new technology, which was originally developed for offhighway engines with power outputs above 450 kW. G+L innotec, based in Germany, had already successfully demonstrated hybrid electrical turbocharging technology in its Cross-Charger concept, also referred to as ‘turbo by wire’. Its principles are protected by patents and, to date, the technology has not been available to the engine marketplace. Rolls-Royce now plans to apply
Worldwide Turbocharger Guide 2018
electrical assistance to turbocharging its MTU engines. “Electrically-assisted charging is a milestone on the way to hybridising the engine,” said MTU director of development, turbocharging and fluid systems, Johannes Kech. “Using this technology, it will be possible for us to develop agile, low-consumption engines.” Its electrically-assisted turbocharging system incorporates an electric drive coupled with a traditional MTU turbocharger design. This enables the turbocharger to accelerate more quickly, speeding the build-up of charge and reducing the phenomenon often referred to as turbo-lag. It will make MTU marine engines capable of more rapid acceleration when power demand increases, particularly from levels of low engine power or speed. This introduces the possibility of reducing both engine fuel consumption and exhaust emissions in a range of applications. Engine response speed is of great importance for many high-speed marine applications but the system will also enable more rapid start-up
and loading of emergency diesel generating sets. It is equally suited to engines running on gas fuel. The electric motor used to boost the turbocharger is a permanent magnet unit, installed outboard of the air compressor wheel, with electrical windings integrated into the compressor casing. The induced air is not subjected to any restriction, because of a large gap between the rotor magnets and the field windings. This ‘media gap’ motor is controlled by a purpose-designed power electronics system, which optimises the electrical boost and delivers power rapidly to the motor in response to sudden load demands. To date, the collaboration between MTU and G+L innotec has resulted in MTU turbochargers being equipped with this electric drive and successfully tested to evaluate their operational potential. The next stage for the companies is preparation for series production. The first applications are planned to be for marine vessels and emergency generating sets, along with land vehicles.
This latest MTU development follows a history of innovation in turbocharging high-speed engines. In addition to the turbochargers themselves, as used in traditional single-stage applications, MTU has introduced a range of configurations to maximise the performance, flexibility and responsiveness of its engines. One example of this is in sequential single-stage turbocharging systems, where individual turbochargers are configured in parallel and brought into operation sequentially, as required by engine speeds and loads. MTU has also developed two-stage turbocharging systems to provide its engines with even higher boost pressures, enabling increased power outputs and improved emissions performance. Sequential twostage turbocharging systems operate in a similar manner to single-stage systems but with a pair of turbochargers being added to
NAPIER TURBOCHARGER MANUFACTURERS | 13
or removed from operation as necessary. More advanced regulated two-stage configurations have also been applied, where the exhaust gas flow from the cylinders is split, with part passing through the highpressure turbocharger turbine and the balance diverted through a bypass, using a controllable wastegate valve. Downstream of this the full exhaust mass flow then re-combines to drive the low-pressure turbine stage. Such systems, combined with the efficient design of the individual MTU turbochargers themselves, have enabled the company to keep pace with the demands for good emissions performance and IMO compliance. To meet IMO Tier III emissions levels, MTU has further adapted its approach for its Series 4000 marine engines, introducing further enhancements to the turbocharging system, combustion process and fuel injection. By combining these with a new selective catalytic reduction system, NOx emissions have been reduced by 75% compared with IMO II limits. Furthermore, particulates have been reduced by 65% compared with the US Environmental Protection Agency’s Tier 3 limits, without the need for additional diesel particulate filtration.
Woodward buys L’Orange
MTU has traditionally produced its own turbochargers but, in 2016, the company increased the involvement in MTU’s turbocharging business of injection specialist L’Orange, also part of Rolls-Royce Power Systems. This move has since been followed, in April 2018, by an agreement that Woodward, of Colorado, USA, is to acquire the L’Orange business. However, L’Orange will continue to be a partner and key supplier for both MTU and RollsRoyce Bergen engines with an initial longterm agreement for 15 years. Woodward chairman and chief executive Thomas Gendron said at the time that “L’Orange is an excellent strategic and financial fit for Woodward and this transaction exemplifies our acquisition strategy to invest in markets with solid long-term fundamentals.” He said the acquisition “brings innovative technology, bolsters relationships with key customers and enhances the profitability of our Industrial segment.” The current L’Orange turbocharger portfolio has been mainly developed for MTU engines and is based on small, medium and large series products. These start with ZR1 turbochargers, capable of delivering up to 0.9 m3/s of charge air at
maximum pressure ratios of 5.2:1. ZR3 products have higher capacities, offering between 0.8 and 2.0 m3/s with higher pressure ratio capabilities of up to 5.5:1. The largest ZR5 turbochargers in the current range extend capacities further, to a maximum air delivery of 3.5 m3/s. All products feature wide compressor maps to enable maximum flexibility in engine operation and rotor components are designed for high numbers of load cycles, a key requirement for many high-speed engines. The milled centrifugal compressors are available in aluminium or in titanium where high temperature operation is required. Designs feature vane-less diffusion and the turbine section is also nozzle-free. Turbine wheels are of radial or mixedflow design and the rotor is mounted in maintenance-free plain bearings. A double piston ring seal system ensures low blow-by and the overall turbocharger designs have features for containment protection, to maximise equipment safety in operation. Well suited to marine, power generation and industrial applications, L’Orange also offers a remanufacturing option for these products. This effectively gives the turbochargers a second life cycle and improved economics for operators.
Napier consolidates its NT1 range Nearly two years since its launch at the SMM exhibition in Germany in 2016, Napier Turbochargers’ NT1-14A model remains its largestcapacity unit, covering engine outputs between 5 MW and 8 MW. At the time of last year’s edition of Worldwide Turbocharger Guide, the company had indicated that an even larger model, the NT1-16A was planned, able to support engines of up to 12 MW, but there is currently no information available about progress on that project. Its three-unit NT1 range offers the highest pressure ratio (6:1) available for this type of turbocharger, the company’s literature notes. Despite this, its compressor wheel is made from aluminium, rather than a more expensive material such as titanium, which helps keep costs down “with no compromise on performance or durability”, it notes. It also emphasises efficiency and it is notable that Napier turbochargers were specified for engine upgrades on the three largest ships operated by the Norwegian coastal passenger operator Hurtigruten. As Marine Propulsion reported in June last year, they played a part in bringing Midnatsol, Trollfjord and Finnmarken up to IMO Tier II standards for NOx emissions. As well as the benefits brought by new installations, many ship operators gain from Napier’s overhaul and remanufacturing service, which it offers at its factory in the UK. It is available for its NT series and many of its NA turbochargers. During an overhaul, each turbocharger is stripped own and
assessed to identify where parts need to be repaired or replaced to bring it back to as-new operating efficiencies. It also offers an exchange service, under which it stocks a matching unit to a customer’s own turbocharger which it will swap over when needed and restore the worn unit ready for future use. Napier’s overhauls will only use its OEM components and certificates of conformity and authenticity can be provided. WTG
Napier’s NT-14A turbocharger – seen here during its development testing – remains the company’s most powerful unit (credit: Napier)
Worldwide Turbocharger Guide 2018
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sub RUNNING HEAD | 15
An MET60MB turbocharger: more than 2,000 MET-MB turbochargers have now been sold (credit: MHI)
MET-MB series gains a further frame size New model extends MHI’s established range of turbochargers
itsubishi Heavy Industries (MHI) of Japan has added a new frame size to its turbocharger range with the launch of the MET37MB. Designed to fit between the MET33MB and MET42MB products, this provides a more optimised capacity for engines such as the WinGD in-line X35-B and X40-B series. It is also well matched to the Japan Engine Corporation (J-ENG) 6UEC33LSE-C2 engine, which has now seen its first delivery with a commercial selective catalytic reduction (SCR) system. The engine will provide the propulsion for a 600-TEU container vessel built by Taizhou Kouan Shipbuilding. Originally developed in 2008, the MET-MB series is now available in 10 frame sizes. MET turbochargers now claim the world’s largest market share for two-stroke marine engines and maintain an excellent reputation with both shipowners and operators. In support of this, MHI announced in January of this year that its production of MET-MB series turbochargers had passed the 2,000-unit level. Shortly afterwards, this was followed by the news that over 15,000 radial type MET turbochargers had been produced, following steadily-increasing levels of production to over 1,000 units per annum in recent years. In response to demands for increased energy efficiency, MHI has also developed hybrid turbocharger technology, working in association with Calnetix Technologies of California, USA. A high-speed permanent magnet electric generator, integrated into the turbocharger construction, enables electrical power to be generated from the engine exhaust. This is often sufficient to satisfy ship power requirements without the operation of an auxiliary generating set, significantly reducing operating costs. The Calnetix Magnaforce generator is housed within the turbocharger air inlet silencer, resulting in the total package length being only 313 mm greater than for a standard MET-MB turbocharger. When the engine is running at full load, the generator can deliver electrical power up to the equivalent of 5% of the main engine
power output. Furthermore, when the vessel is slow-steaming, the generator can act as a motor to boost the turbocharger’s speed, enhancing engine performance and reducing fuel consumption. The hybrid unit is fully controlled through state-of-the-art power electronics, which connect the generator to the ship’s grid and manages both power-out and power-in modes. Hybrid technology is currently available as an option for seven MET-MB series turbocharger frame sizes. An alternative solution for slow-steaming is the adoption of an MHI variable turbine inlet (VTI) turbocharger, to maximise turbocharger efficiency at low-load conditions. Using the VTI system, the area of the nozzle throat can be narrowed to increase boost and improve fuel efficiency by 2-3 g/kWh. Compared with a turbocharger cut-out arrangement, VTI offers a simple, reliable and flexible solution for increasing the scavenge air pressure of two-stroke engines during partial-load operation, improving the engine’s fuel efficiency. The VTI mechanism switches the nozzle between two conditions, based on the addition of a ring to divide the nozzle into inner and outer sections. By closing a valve on the inlet casing, flow to the inner ring is shut off, effectively reducing the nozzle area. A simple construction, however, is retained and the MET turbocharger construction also allows turbine blades and nozzle to be inspected and cleaned by removing only the inner section of the turbine inlet casing. This reduces the time and effort required for inspection and maintenance, therefore cutting in-service costs. VTI is available on the seven largest products in the MET-MB series, with the largest frame size able to deliver a maximum airflow of 65.8 kg/sec at 3.5:1 pressure ratio, or 64.2 kg/sec at 4.2:1. These products can also be equipped with MHI’s integrated exhaust gas bypass system, which can be provided as a retrofit kit for existing applications if required. Further products in the MHI portfolio include MET-MA, MRC and MRII Series turbochargers, with information available on the MHI website. WTG
Worldwide Turbocharger Guide 2018
16 | TURBOCHARGER MANUFACTURERS PBS
Focused production gives PBS Turbo its independence Sales strategy seeks out new markets to diversify into non-marine markets
zech Republic-based PBS Turbo (PBST) is a key supplier to many of the world’s enginebuilders. A clear focus on MAN TCR turbochargers, with a power range of up to 2,700 kW per turbocharger, allows PBST to act as an independent supplier. The current range is based on five frame sizes, from TCR10 to TCR18, these being well suited to medium- and high-speed engine applications. PBST has paid particular attention to the development of the TCR series and the lowest capacity TCR10 turbocharger has efficiency levels of approximately 60% and can deliver pressure ratios of greater than 5.2:1. This has helped many engine manufacturers to meet IMO emissions limits, which usually demand higher charge air pressures to assist in keeping NOx levels to a minimum. The TCR10 incorporates compressor wheel cooling technology and has improved rotor sealing arrangements, with both these features being checked through long-term testing. The bearings are water-cooled and this feature, alongside materials used on the turbine side of the product, enable the turbocharger to operate reliably on engines with high exhaust gas temperatures. The result is a product that is both stable and flexible in operation and has good compressor surge margins. PBST has worked with MAN Energy Solutions in developing the MAN TCX turbocharger for two-stage high-pressure applications and built a dedicated test stand for this product at its Velká Bíteš facility. When used in two-stage packages, these products are rated for pressure ratios of up to 10.5:1. A total of eight frame sizes are currently available and twostage packages can also be supplied with integrated intermediate and after-coolers.
Worldwide Turbocharger Guide 2018
Another successful collaboration project between the companies has been the Electrical Turbo Blower (ETB), designed to work with exhaust gas recycling systems. The first examples are being produced at Velká Bíteš and the products have already received preliminary sales release status. First deliveries to customers will be in August. To support its products, PBST maintains its own production, quality control, validation and engineering teams. The company now has a fleet of 19,000 turbochargers in the field. This is split between approximately 11,000 TCR and 8,000 NR units. Production volumes have also ramped up significantly, with 2,600 units being produced last year – double the output seen five years ago. Of these, close to 90% were delivered for newbuildings, with the balance meeting service requirements. The company now plans to raise production further, to a total of 3,000 units per annum by 2020. PBST cites the reason for this business success as being diversification in sales. While still strongly supporting the marine industry, increased focus has been placed on new applications, including stationary gensets, mining and drilling power and combined heat and power plants. PBST believes the confidence of these new customers has been gained through its product quality and customer satisfaction from supplier score-cards. It also credits its delivery reliability, which is currently running at 95%, as another important success factor. From an organisational perspective, a recent major change has been the appointment of Thomas Winter, previously the head of validation assessment at MAN Energy Solutions, to head PBST’s engineering. Both companies are confident
PBS Turbo manufactures MAN TCR turbochargers (credit: PBST/obrjen.com)
this will help develop further synergies, benefiting customers of the business’s engineering and production functions. In support of the after-market, PBST maintains a network of service partners offering round-the-clock assistance, 365 days a year, from centres throughout Europe and beyond. Repairs can be carried out at many global locations, where feasible, typically using plasma spraying or welding techniques, and exchange units can be provided for rapid turn-around demands. Turbochagers can also be modernised and upgraded and all factorybuilt units undergo verification testing. WTG
HEDEMORA TURBOCHARGER MANUFACTURERS | 17
Hedemora set to launch its HS6800 Adding a further frame size will extend its technology and complete the HS turbocharger series
HS turbochargers will be available in four frame sizes (credit: Hedemora Turbo and Diesel)
edemora Turbo and Diesel is set to expand its HS turbocharger range when it introduces its new HS6800 product later this year. It follows development of the HS7800 and completes the current series, which also includes HS4800 and HS5800 frame sizes. HS6800 and HS5800 turbochargers share the same interfaces, giving operators an opportunity to upgrade earlier installations and boost engine performance. Design principles are shared with other HS turbocharger products and service intervals will be at 24,000 hours. New volutes now give an improved airflow capacity of up to 6.8 kg/sec and the same unique and compact designs ensure good on-engine vibration characteristics. The new HS6800 will deliver pressure ratios of up to 4.5:1 at the same high efficiency levels as the company’s other products. A prototype HS6800 was built in 2017, with initial testing carried out on the company’s own purpose-built rig. Hedemora is now planning to formally release the product as part of its sales portfolio. “After the successful testing of the HS7800, the new HS6800 has also performed well in our own test laboratories and is delivering predicted performance results,” said Hedemora Turbo and Diesel senior sales manager Ernst Dahlin. It will be suitable for both new engines and retrofits, which are an important element of Hedemora’s business. Data is gathered and analysed as necessary to enable preliminary matching requirements and an installation configuration to be established. Where necessary, Hedemora engineers will run tests to confirm the best matching points for the turbocharger and engine combination. Hedemora cited a retrofit example on a railway installation that has demonstrated successful operation in worst-case conditions in one of the world’s most extreme application environments: temperatures range from -55°C up to +45°C, air conditions can be dirty and operating altitudes rise to 2,000 m. Hedemora engineers were on hand during the project,
monitoring running parameters and checking for any adjustments required to achieve best performance. The result has been enhanced engine efficiency, decreased fuel consumption and lower exhaust temperatures. Because of these results, Hedemora and its customer have signed a long-term partnership agreement. With the addition of the HS6800, the HS turbocharger range will cover six frame sizes, including the smaller HS430 and HS550 products, spanning a potential engine power range from 740 kW to 4,200 kW based on a single turbocharger installation. There are comprehensive engine matching options available from a wide range of compressor and turbine wheel capacities. Added to these are a selection of nozzles and diffusers to meet any specified engine requirements. The HS6800 design also features dual row diffusers, as available on the HS7800, which provide these turbochargers with wider compressor maps. Further options are available for interface connections, with single and double compressor volutes and a wide choice of exhaustgas intakes, based on single or multiple inlet passages. Compressor shrouds can also be supplied as standard or with anti-surge features to provide a controlled degree of internal air recirculation, increasing surge margins at part-load operating conditions. From its headquarters in Hedemora, Sweden, full support services are provided for all HS turbocharger products and critical components can be shipped within 48 hours of order placement. Field staff are available for site service work, which requires only two simple special tools in addition to standard hand tools. Full turbocharger overhauls can be carried out at Hedemora, these being validated by a full test cell proof run. Hedemora turbochargers have been certified to the requirements of Turkish Lloyd and type approved by the Russian Maritime Register of Shipping. The company is also approved to ISO 9001:2008, ISO 14001:2004 and by the Wärtsilä Part Quality Assurance Plan. WTG
Worldwide Turbocharger Guide 2018
18 | ENGINEBUILDERS PERSPECTIVE
MAN ENERGY SOLUTIONS OPTS FOR TWO-STAGE TURBO FOR FLAGSHIP ENGINE Engine licensee Kawasaki builds MAN turbochargers for its own engines
uccessors to the MAN 48/60CR engines now feature a high-pressure two-stage turbocharging system. New MAN 45/60CR marine diesels will initially be available in 12V and 14V cylinder configurations, offering power outputs of 15,600 kW and 18,200 kW respectively. The two-stage turbocharger module, a concept that the company has pioneered for large-bore engines, was an integral element of the 45/60CR’s design, delivering higher boost pressures and charging efficiencies. The MAN TCX system is based on low-pressure and highpressure turbochargers arranged in series, with new units designed specifically for the duties required. “We are the only company in the market that develops both engines and turbochargers,” said MAN Energy Solutions head of engineering engines, Dr Gunnar Stiesch, when announcing the new engine. “This unique in-house competence allows us to truly tailor-design this engine for optimised two-stage turbocharging and to unleash its full potential,” he went on. “It is also noteworthy that, despite the turbocharging being two-stage, load pick-up behaviour is the same as for the single-stage turbocharged 48/60CR engine. Operators thus profit from maximised peak pressure and optimal utilisation of the Miller cycle.” The MAN 45/60CR engines also feature common-rail injection systems incorporating the company’s Ecomap capability for optimum performance and emissions control, but the two-stage turbocharging also helps to deliver market-leading levels of fuel consumption. MAN Energy Solutions sees this as a key need for lifecycle cost-critical applications, such as cruise liners and ropax and roro carriers. The first V-engines will be available from the end of 2020 and will be followed by in-line engines from 2022. Seeing the continued importance of the service sector, MAN Energy Solutions continues to enhance its networks and, in 2017, reinforced its support for marine engines in both Europe and South America. These developments have been built on existing commercial ties between it and service companies, some of which have been in place for decades. The enginebuilder “is responding to the increasing quality requirements for a global service network”, explained the head of marine for its MAN engines, Claus Benzler. The new MAN engine representatives include Diesel Power of Sweden, PME Power System Group in the UK, Poweras of Poland and Eilers y Cia, operating in Chile. As exclusive importers of MAN marine engines, these companies are also now responsible for activities on new engine projects and will provide additional
Worldwide Turbocharger Guide 2018
customer centres in their own countries. This structure will enable these marine-engine specialists to provide full service support for yachts and workboat engines. For some enginebuilders, the solution to selecting suitable turbochargers is to manufacture their own products. This is the case for the Japanese company Kawasaki. To complement its licensing agreement with MAN Energy Solutions for building two- and fourstroke engines, the company also builds TCA and TCR turbochargers. The smallest unit in the current range is the TCR22 radial turbocharger, capable of meeting the demands of two-stroke engines of up to 6,200 kW per turbocharger or 6,500 kW per turbocharger in four-stroke applications. For higher powers, the Kawasaki-MAN axial turbine TCA55 product is suitable for 9,000 kW in two-stroke and 10,400 kW applications. Larger two-stroke engines of up to 18,600 kW per turbocharger have the option of using TCA66 or TCA77 products. These turbochargers can deliver maximum pressure ratios of between 4.6:1 and 5.4:1, depending on the build and application. They are high-efficiency turbochargers have low noise emissions, are simple to install and maintain and are designed for long service lives. There is also an option to add the MAN Variable Turbine Area (VTA) system, which enables air delivery to be optimised across different engine loads. For Kawasaki, typical two-stroke applications of the products include the TCA55 on the 6S50MC-C7 engines and the TCA66 and TCR22 on 7S60ME-C8.2 engines. WTG
Dr Gunnar Stiesch (MAN Energy Solutions): Load pick-up for its two-stage turbocharger is the same as for a single-stage
ENGINEBUILDERS PERSPECTIVE | 19
WÄRTSILÄ UNITES ENGINE AND TURBO EXPERTISE Turbocharger technology and service developments form part of Wärtsilä’s collaborative strategy
lthough marketleading equipment is important for new installations, the ability to offer combined engine and turbocharger service expertise is seen as a major benefit for operators. Wärtsilä has a history of collaborative work with suppliers and the field of turbocharging is no exception. This work has encompassed both technological areas and operational and service activities but always with the common aim of products and services being of marketleading capability and quality. In 2010, Wärtsilä joined forces with ABB Turbo Systems to develop practical twostage turbocharging designs for its large diesel engines. That relationship continues to deliver results and this year it contributed to announcement of Wärtsilä’s latest gas-fuelled version of its successful Wärtsilä 31 engine, the 31SG; the diesel version of the engine has proved highly popular in marine sector applications. Its fuel efficiency is the result of a range of new technologies, including two-stage turbocharging, high-pressure fuel injection and adjustable valve actuation. The 31SG now continues this trend, being able to deliver simple-cycle efficiency levels in excess of 50%. These figures are achievable both as a result of engine technology and two-stage turbocharging The spark-ignited Wärtsilä 31SG, which in its 20-cylinder form produces 12 MW of
power, operates at a brake mean effective pressure of 30 bar, which allows it to take full advantage of the significantly higher pressure ratios delivered by its two-stage turbocharging. Further benefits of the combination are increased flexibility and rapid response to changing load demands. The engine can operate continuously at load factors as low as 10% but can also step up to full load within two minutes. “The Wärtsilä 31SG is now available and represents a new-generation answer to the rapidly evolving need for greater flexibility and better efficiency in power generation,” said Wärtsilä Energy Solutions director, technology and product management, Niklas Wägar. “It is the world’s most efficient four-stroke combustion engine and … with efficiency, flexibility, and the environment playing such prominent roles in today’s energy market considerations, the Wärtsilä 31SG is the right engine at the right time.” In addition to engine developments, Wärtsilä and ABB Turbocharging have continued to work closely on turbocharger service support. In 2017 they signed an agreement to expand the scope of this cooperation and ABB granted Wärtsilä ‘authorised service provider’ status for routine maintenance work on all ABB turbochargers fitted to Wärtsilä four-stroke engines. Under this arrangement customers will see benefits from high levels of optimised engine performance over
Turbocharging plays a key role in making the Wärtsilä 31SG efficient (credit: Wärtsilä)
product lifecycles. In addition, turbocharger upgrade packages will be developed delivering opportunities for efficiency improvements and reduction in engine downtimes, with associated operation cost savings. The agreement is a development of the cooperation arrangements between the companies, originally put in place in 2005, and currently in place for a six-year period. It applies to all ABB turbochargers on Wärtsilä four-stroke engines and covers approximately 27,000 ABB units. To ensure optimum management of these installations, Wärtsilä and ABB will share specific service data and maintenance information and ABB turbochargers are now included in Wärtsilä’s online services. Wärtsilä sees this
strategy as an important step in developing an analytical approach to turbocharger lifecycle performance optimisation. “Being able to look at the whole installation increases its availability and efficiency, optimising service speed and agility,” said Wärtsilä Services vice president, four-stroke engine services, Tomas Hakala. “Customers can reduce their operational risk, ensure optimal tuning and save time by being able to overhaul their ABB turbocharger at the same time as the engine,” he said. Wärtsilä’s perspective is based on the importance of expanding its capabilities as a global provider. It can now improve its customer service by offering ABB turbocharger maintenance, in addition to engine expertise, from 25 global locations. WTG
Worldwide Turbocharger Guide 2018
20 | ENGINEBUILDERS PERSPECTIVE
Mitsui successfully tests MAN TCT40 During the past year Mitsui Engineering & Shipbuilding (MES) has continued its work with MAN Energy Solutions and the companies are co-operating closely on turbocharging issues. MES engine scavenging pressure requirements have increased significantly in recent years and the company acknowledges that the use of single-stage turbocharging is now very close to its limit. Despite the adoption of two-stage turbocharging for four-stroke engines, however, MES plans to retain singlestage configurations for two-stroke in the immediate future. With the continued drive towards better performance, this could limit efficiencies, particularly in the smaller capacity range, but MES is now paying increased attention to optimising selection and matching of turbochargers to engines and applications. As part of this drive, MES has begun testing MAN TCT type turbochargers, with the first TCT40 product having been successfully shop-tested on an engine in MES’ Tamano factory. Designed for engine outputs from 2,100 kW to 25,000 kW per turbocharger, the TCT product is optimised for two-stroke application and can boost to a pressure ratio
MES trains its technicians in assembling and overhauling its turbochargers (credit: MES)
of up to 5.0:1. It also offers a 10% higher specific airflow for 40% cent less weight than a MAN TCA model. MES also sees good EEDI performance as significant to the industry. “Better EEDI figures will become more important and one of the ways to improve these is to use a wasteheat recovery system,” said MES associate director Masaki Ohtsu. “In our case, we have applied a turbo hydraulic system (THS) to the turbocharger rotor shaft.” Installed at
the compressor end, the THS enables excess energy to be taken from the shaft for use as hydraulic power. Although application numbers are low, MES expects them to grow in the future. MES and MAN Energy Solutions are committed to further co-operation. This includes R&D into integrating engine and turbocharging developments to achieve maximum engine efficiencies and operational flexibility. WTG
TURBOCHARGER SERVICE WORLDWIDE LARGE NAPIER SPARE PARTS WAREHOUSE Click here to have a look at our turbocharger workshop.
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Worldwide Turbocharger Guide 2018
Advertising Feature SERVICE PROFILES | 23
Algarmani is proud to be a PrimeServ partner
Part of the extensive range of spares available from Algarmani (credit: Algarmani)
With its main workshop strategically located within the Aden Free Zone container terminal in Yemen, Algarmani Trading Corp offers comprehensive facilities for operational support of both engines and turbochargers. Having initially built its trading relationship with MAN B&W Diesel, the company is now authorised by MAN Energy Solutions as a Service Partner and is part of its MAN PrimeServ Network. Algarmaniâ€™s Aden repair facility was opened in 2001 and is equipped to handle maintenance and repair of MAN turbochargers as well as those
of other major manufacturers, including ABB, Napier and Mitsubishi. The workshop is fully capable of overhauling both engines and turbochargers, boasting a range of static and portable machining equipment. Two static balancing machines are available, along with vibration measurement and analysis equipment and a portable balancing rig for on-site work. Full decarbonising and sand and glass bead blasting, facilities are available for cleaning components prior to repair work. Engine-block re-machining can also be carried out, in addition to crack testing and damage repair. Welding and metal spray repairs are carried out based on the use of well proven Castolin products and process techniques, with the company being the only repair shop in Yemen to offer these facilities. The business also offers high-tech spray-coating systems to recover worn or damaged shafts and other critical components that would otherwise prove costly to replace. To support its turbocharger service work, Algarmani maintains comprehensive stocks of spare parts to ensure availability for routine service needs, breakdowns and equipment repair. Alongside new OEM spares, refurbished parts can also be provided and long-term supply agreements are offered, providing operators with the benefits of fixed prices and assured parts delivery times. Certified to ISO 9001:2008, Algarmani operates a team of experienced and MAN-trained engineers and technicians. It has also recently expanded its coverage with the opening of a new business unit, based at Salalah in Oman.
Shanghai Daewin Marine Parts covers Chinaâ€™s coast ports With its strategically located head office, Shanghai Daewin Marine Parts offers marine operators a comprehensive spares supply service for main and auxiliary engines. It also offers full turbocharger spares and service capabilities. For main engines, parts for Sulzer RND, RLA, and RTA products are available, alongside those for Flex-RT50, Flex-RT60 and Flex-RT82 engines. MAN B&W, Pielstick and Mitsubishi parts are also available, including for UEC and UET series engines. Stocks are held for auxiliary engines including those for Daihatsu, Yanmar, MAN and Cummins machines. For turbocharger maintenance and service, the company offers facilities and expertise in all turbocharger types. Its can provide a wide scope of work, starting from routine maintenance and progressing to full repair and
overhaul work, which can be offered at all the major ports in China, from south to north. Overhauls can be carried out either on board vessels or in fullyequipped workshops. The companyâ€™s capabilities include component repair work such as turbine blade welding. Dynamic balancing is carried out to ensure vibration levels meet service requirements. The company can also supply turbocharger cartridges, which allow more rapid change-out work on site, minimising downtime for operators. Shanghai Daewin Marine Parts offers a comprehensive supply of turbocharger spares, including for ABB VTR, VTC, RR, TPS and TPL products. For MAN turbochargers, NR, NA, TCR and TCA spares are offered with Mitsubishi MET18 to MET71 products also covered, along with those for IHI AT, RH and RU
series turbochargers. Both new and repaired or refurbished spare parts are available, often supplied directly from stock. As well as engines and turbochargers, the company
provides comprehensive support to marine operators by supplying spares for equipment such as air compressors, pumps, hydraulics motors, AC motors and gearboxes.
Daewin can provide spare parts and complete cartridges, such as these for MAN NR29/S turbochargers (credit: Daewin)
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24 | SERVICE PROFILES Advertising Feature
Gulf Turbo and Turbo Solutions continue workshop expansion
ffering total turbocharger solutions, Gulf Turbo and Diesel provides comprehensive support to ship operators, covering the Middle East from service stations in the United Arab Emirates, Oman and Bahrain. Well known for its expertise in the field of turbochargers, the company offers global cover for service and spares supplies, with spare-part support from both OEMs and licensees. Facilities in the UAE are strategically located in Sharjah, Dubai and Fujairah, all convenient locations for vessel trade routes. Further afield, Turbo Solutions, based in Singapore, offers the same levels of support and workshop capabilities for all makes and models of marine turbocharger. The latest joint venture service station, JDM Gulf Turbo Solutions, is now operational in Pudong, Shanghai. Additional workshops will soon be opened in South China and on the Western Coast of India. Not all equipment repairs can be workshop-based so parts and field-service support can be provided to operators worldwide on a 24-hour, 365-days-per-year basis. Skilled and experienced field-service engineers, trained in Germany, Singapore, Korea and Japan, provide a quality service ashore or on vessels. Technical and field staff have an average of 15 yearsâ€™ experience in turbocharging, with many having worked with original equipment manufacturers. All workshops are equipped to the latest standards with machinery and tooling available to service all turbocharger types. Axial turbine reblading can be carried out as necessary and non-destructive testing, using penetrant and other systems, is used to check for damage and ensure component integrity. Any wear components are replaced and parts such as nozzle rings, which can suffer from the accumulation of hard exhaust deposits, can be blasted clean and assessed for condition and their potential for re-use. Casings can suffer from corrosion and erosion, so thickness measurements are carried out to confirm that there are no unacceptable levels of damage. To ensure these are leak-free and entirely safe for continued operation, pressure-testing facilities are available and all work carried out meets the requirements of OEM guidelines. Gulf Turbo is fully aware of the importance of accurate balancing for high-speed rotor shafts and the risks that imbalance can pose to turbochargers. When this exceeds permissible tolerances, the vibration produced risks wear on the bearings and potential damage to the entire turbocharger. To ensure vibration-free operation, dynamic balancing is carried out on rotors, typically using Schenck CAB 690 H balancing equipment. No rotors are allowed to leave the workshops without having been check-balanced and, where necessary, corrected to within required limits. Main spares stockholdings are maintained at the Gulf Turbo workshops in the United Arab Emirates and parts are usually
Worldwide Turbocharger Guide 2018
dispatched on the same day that order confirmations are received. Stocks cover a wide range of new and reconditioned turbocharger parts and the company is committed to providing only high-quality products at competitive prices. Parts available include bearings, nozzle rings, gas inlet and outlet casings, turbine blades and compressor wheels. A stock of commonly used spare parts is also maintained in the UAE and Singapore including genuine OEM spare parts for MET, MAN, Mitsui MAN, KBB, Napier and IHI turbochargers. Where required, complete turbochargers or cartridges can also be supplied. All Turbo Solutions and Gulf Turbo companies are certified to ISO 9001:2008 and are authorised repair agents for MHI MET Turbochargers. Engineers and technicians are trained to high levels of competence, including by OEM turbocharger manufacturers. Gulf Turbo is also the Co-operative Repair Shop for MES Techno Service for Mitsui, MAN and TCA Turbochargers in Dubai and Bahrain. KBB has appointed Gulf Turbo as its distributor in Bahrain. The company is proud of its reputation, which is supported by the fact that it receives many repeat orders from shipping companies.
All rotors leaving service workshops are accurately balanced to within required limits (credit: Gulf Turbo)
Advertising Feature SERVICE PROFILES | 25
IMTS has a strong base with worldwide capabilities Established in 1992, Istanbul Marine Turbine Service (IMTS) is the largest turbocharger service company in Turkey and has the largest number of available service engineers. The company maintains a strong network of service locations, both in Europe and stretching from North America to the Far East. These allow the company to offer around-the-clock support to customers on a global basis. With its headquarters located in Tuzla, Istanbul, IMTS has convenient access to the major shipyards at Tuzla and Yalova and the company has further affiliate workshops in the ports of Izmir and Mersin. With close links to the marine industry, all its service engineers are from marine backgrounds with oceangoing experience, including in roles of marine chief and first engineers. In addition to the marine sector, its business base extends to other areas of turbocharger service management; for example, it has long-term experience within power plant applications. The IMTS workshops are equipped to overhaul all types of turbocharger, including
Napier, KBB, MAN, Mitsubishi, ABB, IHI, SKBT and MTU. Facilities include all equipment needed for dynamic balancing and repairs; refurbishments can also be carried out under strict quality-control. Capabilities include shaft and blade repairs and components such as oil pumps and roller bearings can be reconditioned. The company is authorised as a service centre for both Napier and KBB turbochargers, with engineers and technicians trained by those OEMs. It is also a certified supplier
of genuine spare parts for those companies’ products. Russian turbocharger manufacturer SKBT has also approved IMTS as a service centre to provide support for operators of its turbochargers installed in marine applications. IMTS works to provide proactive support for all equipment operators, whether in marine or power plant sectors. “We are active in many fields and work seriously on maintenance contracts for major shipping companies,” said IMTS commercial operations director Metin Gungoren.
IMTS workshops can overhaul all types of turbocharger (credit: IMTS)
Over 30 years of La Meccanica turbocharger experience LMTD uses specialised equipment to service turbochargers of all sizes (credit: LMTD)
La Meccanica Turbo Diesel (LMTD) was founded in 1986 to provide workshop facilities to overhaul marine turbochargers. Over 30 years later, the company’s workshops in Genoa, Italy, have expanded to cover 1,400 m2 and the business has approximately 30 employees. It has expanded its base to cover cogeneration and automotive turbocharger applications and is now considered to be a specialist in overhauling and refurbishment of all turbine variants. Services cover both modern and legacy turbochargers and LMTD has experience with working on small turbochargers, such as those fitted to workboats, through to latestgeneration equipment installed on large vessels. Service and overhaul work can be undertaken either in the company’s fully-equipped workshop or on board vessels. If time allows, dockside overhauls can be carried out and technicians can also carry out work at sea. Expert staff are available for deployment worldwide and can address many turbocharger problems in situ, through carrying out operational fault investigation work such as vibration analyses. In many cases, rebalancing
work can also be carried out without returning equipment to the workshop. Where more significant equipment assessment and repair work is required, LMTD has suitable equipment in its Genoa workshop. This includes non-destructive testing facilities, such as for ultrasonic examination, and TIG and laser welding equipment where more significant component repairs are necessary. Rotor blade replacement can be carried out and blade repair through welding and re-profiling is also possible. Metal spraying techniques can be used to repair damaged surfaces. LMTD offers new and refurbished equipment installation and can upgrade older turbochargers to improved standards. The company is an authorised service agent for Mitsubishi and KBB Turbochargers and offers services for equipment from many other major manufacturers, including ABB, MAN and PBS Turbo. LMTD is approved by RINA to ISO 9001:2008 and is Italy’s only representative of Dantec’s Disatac, a worldwide leader in rotational speed measurement for turbocharging equipment.
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26 | SERVICE PROFILES Advertising Feature
Marine Partner invests in improved services for its clients China is continuing to develop as an important player in the marine market and an increasing number of service companies specialising in engines and turbochargers are emerging. Marine Partner offers both experience and depth of knowledge about turbochargers, engines, compressors and a wide range of other shipboard equipment. It has facilities in Shanghai and, since 2017, on Zhoushan Island, which saves time and money for its clients, In support of turbochargers, Marine Partner operates a specific repair team covering the whole of China and able to carry out overhauls either on board vessels or at fullyequipped workshops. Rotor repairs and refurbishments can be undertaken, including reblading and replacing turbine stage damping wire.
Marine Partner can overhaul and repair small and large turbochargers. Following dismantling and cleaning, components are inspected and fully assessed for condition. Worn or damaged components are replaced and the complete rotor is dynamically rebalanced in the workshop. Equipment is available for measuring wall thickness to assess any degradation of the casing and pressure testing can also be carried out to ensure integrity and gas tightness. Air filter silencers can be reconditioned. Comprehensive spare part stocks are maintained, both for immediate dispatch to operators and to support overhauls and repair work in the company’s workshops. Examples include parts suitable for ABB VTR, VTC, TPL and TPS products and MAN NR, NA, TCR and TCA turbochargers. The
company also holds components for MET, IHI, RU and RR turbocharger ranges. The company’s offerings for diesel engines are equally comprehensive. With parts in stock for engine suppliers including MAN, Sulzer, Mitsubishi and Mak, Marine Partner can recondition and repair many major engine components.
With a primary focus on turbochargers and engines, the company offers key services for marine and industrial operators in China and beyond. The company sees reliability as the most important service factor and operates with professional and qualified staff, on-call at all times. The company’s guiding principle is that ‘reliability means value’.
An ABB VTR714 turbocharger being assembled in Marine Partner’s workshop (credit: Marine Partner)
Westcon Turbo was established in 2003 when Turbo Norway and Westcon merged following many years of successfully working together. The last 12 months have seen the company pass a significant milestone: it has moved into the spare part business and opened a fully equipped workshop with storage facilities in Drammen, close to Norway’s main international airport. From its workshop in Ølensvåg, Norway, Westcon Turbo specialises in the repair and maintenance of turbochargers for marine engines. The scope of services includes: repair of damaged shafts, journals, turbine blades and nozzle rings; turbocharger rotor balancing; rotor shaft cleaning by glass pearl blasting ; rotor shaft re-blading; ultra sonic sound measurement of wall thickness; and water pressure testing of gas casings. It also carries out assignments on turbochargers for powerplants. Westcon Turbo AS – Norway N-5582 Ølensvåg - Norway (Norway) t: + 47 53 77 50 17 • Fax: +47 53 77 50 01 e: email@example.com • www.westcon.no Worldwide Turbocharger Guide 2018
Tu r b o S o l u t i o n s
TOTAL TURBOCHARGER SOLUTIONS
Trained & Experienced Personnel Spare Part Supply 7 / 24 Service
Balancing, Reblading, Repairs & Reconditioning
Global cover for service and spares
+65 6898 5169
53, Tuas View Loop, Singapore 637703. Tel : +65 6898 5169 Fax : +65 6898 9190 Email : firstname.lastname@example.org
ABB ● MAN MET ● IHI MAN B&W WARTSILA BV/DNV/GL/LR Tel: +86 21 58400725 email@example.com
Advertising Feature SERVICE PROFILES | 29
Tru-Marine sees technical innovation as the key to business success
s a one-stop shop for turbocharger service, Tru-Marine offers coverage for the majority of global marine turbocharger products. The company portfolio includes major names such as MET Turbo, KBB, Kawasaki and Napier. Established in 1977, it has built a strong reputation in the marketplace and offers full-service facilities from both scheduled overhauls to emergency repairs on board vessels. Tru-Marine serves the industry from eight locations worldwide, including Singapore, China, the United Arab Emirates, the Netherlands and the US. In over 40 years of operation it has gained extensive experience in turbocharger technology. Comprehensive spares supply, maintenance and overhaul services are fundamental to the business but the company also offers repair and reclamation of high-value components such as turbine blades and shafts. This work is carried out using modern equipment for laser-aided reclamation of shafts, and high velocity oxygen fuel (HVOF) coating application. The company specialises in many aspects of turbocharger component recovery and has adopted innovative technology to develop solutions to reclaim worn or damaged turbocharger components. To do this, Tru-Marine established its own research and development facilities over 20 years ago and has gained further knowledge and expertise through collaboration with other institutions. One example of this is in the development of competent gas tungsten arc-welding processes for turbine blade repair. One recently-publicised development was the availability of turbine nozzle rings treated with Tru-Marineâ€™s Supercoat technology, which offers enhanced protection against corrosion and wear. With erosion of nozzle rings being a common problem in aggressive operating conditions, vessels can suffer unplanned down times, resulting in the need for prompt emergency service work to be carried out. Using HVOF technology, Tru-Marine launched its Supercoat method to offer improved resistance to premature wear of nozzle rings and increase component life. The system uses molten or semimolten coating materials, sprayed onto the surface of the nozzle ring by a high-temperature and high-velocity gas stream. The resultant coating has a very high hardness level and outstanding adhesion to the surface of the nozzle. This durable coating provides excellent wear resistance and improved corrosion protection, due to its highdensity coating compared with the base material. The high velocities employed, combined with the fine powder qualities used, produce a smooth as-sprayed surface with a high-quality finish. Tru-Marine technology developments have continued to retain their pace over recent years and the company has set up a learning scheme to complement its services. This includes a mentorship programme, offering a structured learning programme in association with Singapore Aero Engine Services Ltd (SAESL). SAESL
Applying a Tru-Marine Supercoat to a nozzle ring using HVOF (credit: Tru-Marine)
is a joint venture between Rolls-Royce and Singapore Airlines Engineering and is well known for its aero engine and component repair services for the Rolls-Royce Trent engine family. With the regular introduction of new repair and advanced remanufacturing techniques, Tru-Marine has now added 3D printing â€“ or additive manufacture â€“ to its portfolio with the first production of a printed marine turbocharger nozzle ring. This example demonstrates the ability to print in a super-alloy material and, following positive test results, the nozzle has been confirmed as acceptable for use in turbocharger applications. This new technology offers considerable opportunities for the future remanufacture of many mechanical components, including for the turbocharger sector. Working with business partners, Tru-Marine plans to continue collaboration on, and investment in, research and development work and presently allocates around 3% of its sales revenue towards this every year. It is also committed to further automation of its processes and believes this goes hand-in-hand with digital transformation. The business has already applied robotics and increased automation to its repair processes and is now developing its warehouse operations to process digital orders. Having exhibited at Asia Pacific Maritime in March this year and Posidonia in June, Tru-Marine will next be represented at SMM 2018 in Hamburg, Germany, 4-7 September.
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30 | SERVICE PROFILES Advertising Feature
Turbo Belgium offers a strategic workshop location Decade of progress brings continuous improvement to Turbo Belgium
elebrating its 10-year anniversary in 2018, Turbo Belgium is committed to continued improvement of its facilities and further developing its support for turbocharger spare parts and field service. “We are proud to say that we have established excellent co-operation with our clients during recent years,” said its business development manager Jan Vanheukelom. “Furthermore, our global market position in field-service work, spare-parts supply and repair works has expanded.” Having moved to a new workshop in Vosseschijnstraat, in the Port of Antwerp, the company has now installed new stateof-the-art Schenck balancing equipment to support its other turbocharger overhaul facilities. Using this computerised equipment, experienced operators can return repaired rotors to their required balance limits by precision grinding of the defined correction planes. If required, Lloyd’s Register surveyors
can witness balancing, with full certification being provided. Where rotor rebuilds are carried out, Turbo Belgium is fully equipped to fit new components but also specialises in repairing and reconditioning turbine blades and compressor wheels. This ability often allows the company to offer a fully-assured but more economical solution to the client. Turbo Belgium has the experience and equipment to provide service for a wide range of turbocharger types and is an authorised repair agent for Mitsubishi turbochargers. It maintains a workforce of trained engineers and technicians, on hand and able to travel to locations worldwide at short notice. Working with approved global partners, it is a member of the Turbo World Services group and offers onboard marine services as well as workshop overhauls and repairs. “We often work with repeat orders from various shipping companies and with shore-based power plants,” Mr Vanheukelom
Turbo Belgium can return damaged rotors to as-new balance standards (credit: Turbo Belgium)
Worldwide Turbocharger Guide 2018
said. “This allows us to measure, monitor and continuously improve the quality of service and spare-parts performance.” The company’s warehousing facilities stock a wide range of turbocharger parts, including both new and reconditioned items. Original equipment mManufacturer parts are available as well as alternative Europeanmade parts, which carry a one-year warranty. The net worth of stock held is currently in excess of US$1.5M. For specific spare parts,a such as rotors and casings, the Turbo World Services group can also provide Lloyd’s Register certification. To assist in the correct identification of parts for customers, Turbo Belgium has developed a comprehensive computerised database with part specifications for turbochargers. Given the ship’s name, engine type, or turbocharger serial number, a search of this database can quickly identify the correct part specifications required. The company is able to quote parts for all turbocharger types and, for bearings, Turbo Belgium can supply NTNSNR products, which cover a wide range of bearing designs. It can also supply oil pumps on either a direct sale or an exchange basis. With a policy of delivering high-quality spares, service and technical assistance to customers, 24 hours a day and seven days a week, Turbo Belgium offers one-year warranties on both its spares supplies and service work. Having more recently expanded its stock base, the company is now confident in its abilities to deliver a wider range of turbocharger spare parts at short notice. As well as Lloyd’s Register certification on specific items, the company has approvals from Bureau Veritas and has now gained ISO9001:2015 certification. In addition to facilities in its headquarters in Belgium, it also maintains a network of partners in Europe, the Middle East and beyond.
TOTAL TURBOCHARGER SOLUTIONS
Trained & Experienced Personnel Spare Part Supply 7 / 24 Service Balancing, Reblading, Repairs & Reconditioning Global cover for service and spares
D U BA I
A72-4, S.A.I.F. Zone, P. O. Box : 9148, Sharjah, UAE Tel : +971 6 557 3134 Fax : +971 6 557 3135
132B, Dubai Maritime City, P.O. Box: 25128 Dubai, UAE Tel : +971 4 438 5570 Fax : +971 4 438 5572
CY P RUS
B A H R AI N
Tel : + 357 960 88 990
ASRY Shipyard, P. O. Box : 50917, Hidd, Kingdom of Bahrain G E R M A NY Tel : +973 1746 4134 Tel : + 49 151 2990 1179 Fax : +973 1767 1259 E : firstname.lastname@example.org E : email@example.com
– Diesel and turbocharger
service, repair and parts – Dynamic balancing – Ultrasonic cleaning – Chemical cleaning
– Ancillary equipment serviced – Breakdown and voyage repairs
01326 377160 | service@PowerFal.co.uk | PowerFal.co.uk No 32736
Turbo Solutions 53, Tuas View Loop, Singapore 637703 Tel : +65 6898 5169 Fax : +65 6898 9190
Advertising Feature SERVICE PROFILES | 33
Service quality is a core value for TSI
TSI’s Rotterdam workshops are equipped to provide a wide range of repair and restoration services (credit: TSI)
Turbo Service International (TSI) has been an independent company offering flexible services for all types of marine turbochargers since 1989. Its purpose-built workshops in Rotterdam are supported by facilities in Houston, Malta and Southampton. It also maintains partnerships in Dubai, Hong Kong, China, Singapore and Turkey.
Every turbocharger or component received at TSI’s workshops first undergoes rigorous inspection, with assessments carried out by trained professional staff. Condition and wear analyses are carried out with reports provided to the equipment owners or operators. Where required, specialised weld repair methods are used to restore parts such
as damaged turbine blades and shafts to their original form, offering significant savings compared with replacement parts. All repairs are subject to stringent tests to ensure conformity and are underwritten by TSI’s 12-month warranty. The company can also provide new and reconditioned parts for direct sale or on an exchange basis. This includes turbocharger components and other ancillaries. With considerable expertise in bearings, TSI partners with major European supplier NTNSNR to market a full range of high-quality roller bearings. This enables the company to supply quality-assured bearings to both marine and power-station markets worldwide. With a 24-hour dedicated breakdown team, TSI can respond immediately to equipment breakdowns,
from supplying spare parts through to organising logistic support and service-engineer visits worldwide. To achieve this, the company works with logistics partners that have close relationships with airlines, ensuring priority services when required. This ‘door-to-deck’ service covers the entire supply chain from collection to delivery on-board, including the management of all necessary customs and port authority requirements. Every TSI engineer regularly attends OEM factory courses to ensure their skills are kept up to date and the company can offer a quality and costeffective alternative to OEM service. “We pride ourselves on our flexibility and will always react immediately to customer demands,” said TSI office manager Sarah Key.
HS retrofits available from Turbo Cadiz With 32 years of experience in turbocharger and heat-exchanger maintenance, Turbo Cadiz operates from a strategic location close to the major maritime area of Algeciras Bay. A significant aspect of Turbo Cadiz’s business is its experience of replacing older turbochargers with new and more efficient products. In particular, the company provides retrofit HS turbochargers to a number of engine types, including GE, Ruston, ALCO and Wärtsilä. In all, five engine types have been retrofitted with HS4800 turbochargers and 18 with the larger HS5800 units. These units, built in Hedemora, Sweden, are well-known for their high efficiency levels. The company’s philosophy is that good turbocharger maintenance is essential for engine performance, reducing fuel consumption and exhaust gas temperatures. It has staff qualified to work on turbochargers produced by a number of manufacturers, including Mitsubishi, Napier and KBB, and has over 10 years’ experience with MAN and ABB products. The Turbo Cadiz workshop facilities in Cadiz Bay cover 3,000 m² and provide modern industrial equipment for all aspects of turbocharger service, overhaul and refurbishment. Closed-circuit industrial washing equipment and ultrasonic cleaning tanks are available, along with micro-blasting facilities, for detailed part cleaning prior to repair or re-assembly work. Balancing machines can accommodate rotors weighing up to 3,000 kg and 1,700 mm in diameter. In addition to typical marine equipment, the company also has experience in small turbochargers, down to automotive capacities, and with air compressors, being an
agent for the German manufacturer, Sauer. The company also operates service centres in Las Palmas and Tangier, with these being fully equipped to provide comprehensive turbocharger repair facilities for customers. Turbo Cadiz maintains its quality certification and, in 1994, was one of the first Spanish companies to obtain ISO 9001 approval, issued by Bureau Veritas. It has since added environmental certification to ISO 14001 and OHSAS 18001.
Turbo Cadiz can service a wide range of turbochargers (credit: Turbo Cadiz)
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34 | SERVICE PROFILES Advertising Feature
Bearing technology is a key skill for TurboSpares Specialist materials and precision workmanship deliver reliable products
urboSpares was established in 1996 by Peter Roos and remains a family business in the Port of Rotterdam. It has built its reputation on rapid response times with high-quality service levels for turbochargers in marine, industrial and power-generation applications. It keeps a large stock, enabling it to supply a wide range of turbocharger spare parts at short notice. These include parts from original equipment manufacturers and alternative European-made spares, all of which carry a one-year warranty. The company specialises in supplying quality parts for major turbocharger brands including ABB, KBB, MAN, Napier, IHI, MET and PBS. All components leaving the TurboSpares workshop are fully inspected and securely packed to ensure safe shipment. Typical part supplies range from smaller turbocharger components, such as sealing bushes, gaskets and O-rings to larger components including gas inlet and outlet casings, rotor assemblies, cartridges or even entire turbochargers. Complete service overhaul kits are also available from stock for ABB TPS products, including TPSD/E turbochargers and higher-temperature TPS-F units. TurboSpares acknowledges that turbochargers are among the most important engine components and that they are safety-critical components, not only in themselves but also for engines’ and ships’ operation. Given the necessary IMO identifications numbers, it can therefore deliver spare parts against the correct specification, as registered in technical files, fully in compliance with IMO requirements. Such critical parts include nozzle rings, compressor wheels, diffusers and turbine shafts. A particular focus of the TurboSpares’ business is in bearing technology, with the company being an authorised workshop for SLF hybrid ball and roller bearings. The combination of TurboSpares’ technical expertise and the specially-designed SLF
Worldwide Turbocharger Guide 2018
hybrid bearings enables the company to deliver highly reliable assemblies, based on standard and special bearings in a range from 30 mm outer diameter upwards. One example of this technology is the special design available for ABB VTR-4 series turbochargers. For these bearing assemblies, TurboSpares uses the Germandesigned and made SLF precision bearings at P4 grade accuracy. The rolling elements are made of ceramic silicon nitride (Si3N4), the rings from X30 high-alloy steel and the cage from polyether ether ketone – known as ‘PEEK’. The advantages of using ceramic materials for rolling elements include more reliable performance, less false brinelling and reduced wear and heat generation. TurboSpares maintains a fully-equipped workshop with facilities for cleaning, blasting and balancing of high-speed rotating equipment. Shaft repairs and re-blading can be carried out and non-destructive testing equipment is available, including for UV penetrant crack inspection and for wall thickness measurement. The company has recently upgraded its balancing capabilities with the installation of new state-of-the-art equipment that now enables full balance analysis to be carried out using a visual computerised system. After balance correction, a full technical report is
produced that is added to the customer’s comprehensive service report. The company offers full overhaul facilities for turbochargers and the option of a cartridge exchange service, including overhaul-and-warehousing, for the ABB TPS product range. Under this arrangement, TurboSpares will overhaul and store spare cartridges for operators, enabling these to be called off for use at short notice, thus significantly reducing ship downtime. With continued emphasis on needs for preventative maintenance, TurboSpares also offers operators the opportunity for turbocharger monitoring systems. Early detection of potential problems, thus preventing serious and un-anticipated failures, helps to support equipment throughout its life cycle and reduce unplanned outages. An example of this technology is the availability of systems to measure shock pulses in bearing housings and provide accurate information on the mechanical state of the bearing surfaces. Alongside vibration monitors, speed transmitters and exhaust-gas temperature sensors, these shock sensors present operators with greatly improved opportunities to monitor turbocharger operation and diagnose and address potential problems.
This ABB VTR 454 bearing unit includes a cage made from PEEK (credit: TurboSpares)
TURBOCHARGER PARTS, SERVICE, & REPAIR
Nº ES073883-1 / ES073885-1
Committed to provide a high quality service whenever & wherever our customer requires it.
Tel: +34 91 872 01 81 24h: +34 679 988 103 Email: firstname.lastname@example.org www.turbointernacional.com
We are specialised in service and repair of all makes of turbochargers including ABB, MET, MAN, Napier, KKK, IHI, etc among various other makes. Our service station in Sharjah, UAE, is equipped with all machineries and tools to service and repair all type turbochargers. Our skilled and experienced service engineers and technicians can provide a 24/7 quality service.
Sharjah, United Arab Emirates (UAE)
We extend the following services at our service station. • Shaft gland strip and renewal • Repair and renewal of turbine blades of rotor shafts • Dynamic computerised balancing as per manufacturers’ guidelines • Blasting/cleaning of nozzle rings, turbine blades, rotors and other parts as per manufacturer’s guidelines • Ultrasonic gauging of casings • Hardness test of compressor wheels as per manufacturers’ guidelines • Hydro Pressure testing of casings • Dye penetrate tests as per manufacturers’ guidelines • General workshop machineries like welding machines, drilling machines, lathes, etc for handling any type of special jobs • Inspection of all turbocharger components with digital measuring tools and instruments.
Spare parts stock:
We also have a stock of wide range of turbocharger spares to cater for emergency situations like breakdowns on board ships.
TURBOMOT MARINE ENGINEERING LLC PO Box 31076, Sharjah, United Arab Emirates T: +971 6 538 4456 F: +971 6 538 6845 E: email@example.com E: firstname.lastname@example.org E: email@example.com www.turbomot.com
ALGARMANI TRADING CORP. ADEN AUTHORIZED REPAIR SHOP ALGARMANI TRADING CORP. Algarmani Building, Taiz St. P.O. Box 20533 Sana’a, Republic of Yemen Tel: + 967 1 625882 Fax: + 967 1 625883 firstname.lastname@example.org Turbocharger & Engine Services • Engine Block, Cylinder head & Crack repair • Portable in-situ Machine for Engine Blocks • Repair of Rotor &
Shaft ends • Repair & Change Turbine Blades • Spray Coating • Balancing Welding • Spare-part supply
WWW.ALGARMANI.COM advert.indd 1
AUTHORIZED SERVICE PARTNER OF
Advertising Feature SERVICE PROFILES | 37
PBS Turbocharger retrofits a key strength for Turbo Internacional One factor that makes Turbo Internacional stand out as a business is its specific expertise with PBS turbochargers. This encompasses both service and repair work and the retrofit of new turbochargers to replace older units. These retrofits can often be direct replacements, with minimum modification necessary, using PBS Turbo PTR, NR and TCR products, but updated equipment can also be supplied. For vessel operators, these new units provide superior reliability and can also increase engine efficiency in many cases, resulting in lower costs. In recent years Turbo Internacional, which has its head office in Madrid, Spain, has successfully carried out retrofits on engines made by Jenbacher, Deutz, Sulzer, Caterpillar and Yanmar. Turbo Internacional also services ABB, Mitsubishi, MAN, Napier and KBB turbochargers. Units are dismantled before structural and body parts are micro-blasted and recoated. Felt layers, securing features and filter elements are renewed, returning the units to as-new condition. The company maintains comprehensive stocks of spare parts for ABB and PBS turbochargers, including casings, nozzle rings and compressor wheels. Turbine blades, shafts and bearings are also held in readiness for routine overhaul or breakdown work. Non-stock parts for these turbochargers and for MAN, Napier, KBB
& Mitsubishi products can also be supplied on short delivery times to minimise downtimes for operators should unexpected parts demands occur. The Turbo Internacional main workshop is equipped to refurbish, repair and rebalance turbocharger rotors of up to 1,800 kg in weight. Specialist weld and metal spray repairs can be carried out and facilities are available for crack detection, hardness
testing and hydrodynamic testing. Using specialised repair techniques, rotor shafts can be returned to OEM specification levels and high-quality blade repairs can also be carried out. Turbo Internacional also has a workshop in the Canary Islands that can carry out complete turbocharger overhauls, and it maintains co-operative agreements with companies in Asia and America to offer services in these territories.
Turbo Internacionalâ€™s workshops can handle heavy components (credit: Turbo Internacional)
WORLDWIDE SUPPORT FOR ENGINES AND TURBOCHARGERS FROM ZEPPELIN POWER SYSTEMS The Zeppelin Group operates from 190 global sites with a workforce of around 8,000 employees and sales revenues of â‚Ź2.75Bn (US$3.2Bn) in its 2017 financial year. With a long-standing association with Caterpillar Corp, the group distributes Cat, MaK and EMD marine engines with system outputs of up to 16.8 MW for main or auxiliary propulsion and ship auxiliary power. Markets include cargo vessels, ferries, cruise ships, yachts and specialist vessels, both for seagoing or inland waterway operations. In the field of turbocharging, Zeppelin services include providing overhauls, exchanging cartridges, spare parts and retrofits. Advice and consultancy is available and customised service agreements can be developed to suit the needs of all operators. For Cat and MaK engines, the company offers services for Cat, Napier, KBB and KKK turbochargers with certified workshops providing comprehensive repair and retrofit facilities. At the Hamburg and Achim sites specifically, Zeppelin can carry out full overhauls or supply exchange cartridges and spare parts.
Zeppelin stressed the benefits of rapid cartridge exchange, which offers a cost-efficient option for operators, and the high availability of original spare parts. Defined repair agreements are also available, whether work is carried out on board vessels or at service centres. Exchange cartridges are held in all standard specifications for turbochargers including Napier NA295, NA297, NA355, NA357 and NA457 units and NT1 frame sizes. For KBB, its HPR and ST3 to ST7 products are covered alongside turbochargers for Cat 3400, 3500, 3600 and C280 applications. In most cases these cartridges can be delivered and exchanged in one business day. For Napier turbochargers, Zeppelin is an authorised service agent and workshops are certified and equipped with tooling and facilities to enable all work to be handled efficiently by fully-trained turbocharger technicians. Full service contracts further enable Zeppelin to provide 24-hour customer service for engines and turbochargers with rapid availability of technicians and spare parts on a global basis. Zeppelin Power Systems is one of six strategic business units of the Zeppelin Group.
Worldwide Turbocharger Guide 2018
38 | SERVICE PROFILES Advertising Feature
TurboUSA focuses on servicing newer-generation products Investment takes facilities beyond ‘workshop’ status to offer high-quality repairs
any service companies specialise in older turbochargers but TurboUSA’s business has shifted its focus more towards newer generations. To facilitate this, the company has invested heavily in the new tooling required for these units and in training for its staff. Although not authorised as an agent for ABB or MAN turbochargers, TurboUSA now has a team of experienced engineers fully capable of servicing and reconditioning newergeneration turbochargers from those manufacturers. These include ABB TPS and TPL series and MAN TCA and TCR series products. The company is authorised by MHI as a service agent, covering all MET turbocharger types. TurboUSA has a ‘technical centre’ at its Fort Lauderdale, Florida, base, rather than simply a workshop. Its name reflects the company’s major investment in technical equipment including measurement and inspection tools and high-technology repair facilities, setting it apart from a basic overhaul and replacement facility. Combined with extensive staff training, this has made the centre capable of repairing or reconditioning components to a high standard, providing a rapid and lower-cost alternative to fitting new parts. Repair capabilities include laser metal cladding, shaft hot metal spray recovery and blade repair, with TurboUSA having the only Lloyd’s Register-approved thermal spray shaft repair process in the Americas. This provides customers with the assurance of repaired parts being of high quality. Unlike cold repair procedures, where a new layer is applied to the shaft at below 300°C, the TurboUSA process operates at approximately 1,200°C, fully fusing the new sprayed layer to the underlying material. This technology permits machined surfaces, such as keyways and threads, to be treated and allows the shaft to be balanced on new layers without risking damage. The thermal spray process works well for an entire shaft repair but in cases where only limited sections require attention, laser metal cladding is often the best solution. Using this system a fully-
TurboUSA staff, seen here attending to a turbocharger on board, can travel to any location (credit: TurboUSA)
Worldwide Turbocharger Guide 2018
automated laser beam is directed to the damaged section only, reducing the risk of heat damage to adjacent areas. The powder coating material used in the process is driven by inert gas and directed accurately, through a nozzle, onto the surface being laser repaired. The result is a very strong metallurgical bond to the original material. TurboUSA delivers both hot metal spray and laser metal cladding repaired components with a one-year warranty. To assess returned equipment and ensure repairs are carried out to the highest standards, the technical centre also has comprehensive non-destructive testing equipment. This includes both ultrasonic and ultraviolet crack-detection methods. For components such as casings, hydrostatic testing facilities are also available. In all cases, rebuilt or repaired rotors are dynamically balancing before shipment or re-assembly into casings to ensure trouble-free operation. TurboUSA has made a multi-million-dollar investment in spare-part stocks to ensure the best levels of customer service. The company has decades of experience in maintaining older turbocharger types but has now expanded its stocks to cover newer products, having seen operators increasingly moving towards the use of new and more efficient turbocharging equipment. As an ISO 9001:2000 certified company, TurboUSA only sources spare parts from world-class manufacturers and, regardless of turbocharger brand, is committed to a policy of one year’s warranty on all parts sold. TurboUSA offers a one-stop-shop service, whether that is for routine maintenance or an overhaul or for emergency repairs. Trained staff are available around the clock to cover these contingencies and can travel to any location. The company has a strong field-service presence in North America, Central and South America and the Caribbean. It also has two Europe-based field-service engineers and has a strategic partnership with Rotterdam-based TurboNL to provide further support to European customers. WTG
TurboUSA has the only Lloyd's Register-approved thermal spray shaft repair process in the Americas (credit: TurboUSA)
The company has sophisticated purpose-built workshops in Southampton, Rotterdam, Athens, Houston and Malta and strategic locations worldwide. Being an independent company allows the flexibility to offer services for all models of marine turbochargers. Our expert engineers are all trained to OEM standards. All work is covered by a comprehensive 12-month warranty, making the company a cost effective and reliable alternative to the OEM.
www.tsi.eu.com SPECIALISTS IN TURBOCHARGER REPAIR AND SERVICE
We are available 24/7 to assist with your urgent turbocharger requirements. Our specialist team are here to help.
Call us 24/7 on +44 2380 861 000
or email: Parts Enquiries | email@example.com - Service Enquiries | firstname.lastname@example.org
Shanghai Daewin Marine Parts Co., Ltd.
Your Reliable Spares Supplier for Turbocharger & Marine Diesel Engine
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Istanbul Deri Organize San. Sitesi. 1.Yol X5-A Parsel Aydinli-Orhanli Mevkii Tuzla, Istanbul Tel: 0090 216 394 04 73/74 Fax: 0090 216 394 04 75 email@example.com
24/7 Call: 0090 532 682 90 97
RESEARCH & DEVELOPMENT | 41
RESEARCH AND DEVELOPMENT DRIVE TURBOCHARGER IMPROVEMENTS Older vessels often have engines optimised for higher ship speeds but reducing speed has become a common practice. Other actions are then needed to optimise engine performance in these conditions. One method is through turbocharger cut-out. But a paper published in the Journal of Mechanical Science and Technology suggests that turbocharger cut-out can produce higher torsional exciting forces, possibly causing engine structural problems. Higher peak pressures are also known to produce an increase in torsional forces on the engine body, risking potentially higher vibration in propulsion shafting systems at low loads. In ship enginerooms, turbochargers can be one of the major noise sources and emissions must be kept to necessary levels to meet exposure requirements. Studies into this have been carried out at Harbin Engineering University, in China, which has published a paper based on
the performance of a radial-flow inlet silencer. Detailed results were presented at the 2017 International Congress on Sound and Vibration, held in London. These supported the principle that empirical formulae and numerical simulation could be used to predict the attenuation effects of an inlet silencer design. The study also concluded that a novel design of silencer would provide a highly compact solution. There are many other instances of Chinese university research projects. One recent example is the study of twostroke marine diesel engine operation with turbocharger cut-out, conducted jointly by contributors from Shanghai Jiao Tong University, China, and Strathclyde University in the UK. Another university conducting turbocharger research is the University of Huddersfield, in the UK, which is working with BorgWarner Turbo Systems. This collaboration is based on automotive-scale products but covers aspects that
Electric boosting to meet IMO Tier III engine needs The impending introduction of IMO Tier III emissions limits has driven continued development in both engine and turbocharger designs and MAN Energy Solutions has selected two routes to meet the NOx levels required. For two-stroke engines, these involve high-pressure selective catalytic reduction (SCR) and exhaust gas recirculation (EGR) systems. The implication for turbocharging is the need to recycle cooled exhaust gas into the scavenge air receiver. This requires boosting due to the pressure difference between the exhaust and the scavenge air receiver. To meet the requirements, MAN Energy Solutions has developed an Electrical Turbo Blower, (ETB), driven by a high-speed electric motor. Two frame sizes are currently available: the ETB30 and ETB40, with maximum powers of 200 kW and 300 kW respectively. The ETB30 is suitable for engine powers from 5 MW to 23 MW and the ETB40 suits engines starting at 15 MW rating and rising to the largest MAN 85 MW unit.
are equally applicable to largerscale turbochargers. To assist with development, turbocharger manufacturers also work with companies such as Austrian specialist AVL, of Graz. AVL is currently working directly with manufacturers on new developments and offers analytical programs that enable manufacturers to carry out advanced compressor and turbine component design and
turbocharger matching. In the UK, Ricardo provides software and technical assistance and consultancy for engine and turbocharger manufacturers, including its well-known Wave simulation software. This enables performance and acoustic simulations to be carried out based on virtually any intake, combustion and exhaust system configuration.
Wärtsilä uses ABB turbochargers on its engines; now the companies are sharing performance data (credit: Wärtsilä)
Wärtsilä and ABB work together to improve performance analyses In agreement with turbocharger manufacturer ABB, Wärtsilä is taking steps to expand its analytical approach to performance. Under the agreement, specific service data will be shared to assist analysis of potential performance improvements and to develop upgrades. “Customers can reduce their operational risk, ensure optimal tuning and save
time by being able to overhaul their ABB turbocharger at the same time as the engine,” said Wärtsilä Services vice president, four-stroke engine services, Tomas Hakala. As a result of this co-operative work Wärtsilä and ABB have started to offer upgrade packages, delivering improvements to both performance and fuel efficiency. WTG
Worldwide Turbocharger Guide 2018
42 | CASE STUDIES
Repair, replace or upgrade? Operators must balance their options against cost and performance benefits
Turbocharger overhauls can make a significant difference to engine performance (credit: ABB)
perators have a range of possibilities when turbocharging equipment is reaching the end of its service life. For some it is better to replace and gain the benefits of more modern and efficient equipment, but this may involve significant cost. For others there may be different factors to consider and overhauling existing equipment may be a more attractive option. One of the larger upgrade contracts placed in recent years has been the MAN PrimeServ contract from Royal Caribbean Cruises Ltd (RCCL) to retrofit turbochargers aboard four of its cruise ships. Covering a total of 30 turbochargers on 22 engines, the scope included retrofit kits and technical support. Grandeur of the Seas and Enchantment of the Seas, both powered by four MAN 12V48/60 engines, were retrofitted with 16 TCA55 turbochargers, while Horizon and Zenith, each powered by two 9L40/54B and five 6L40/54B engines, were retrofitted with four NA40/S and 10 NA34/S turbochargers. At the time the order was placed, in December 2015, senior vice president and head of MAN PrimeServ Diesel Wayne Jones, said that the upgrade would boost engine performance, extend engine their lives and support the entire operation both from a technical and cost perspective. “In the end it’s an investment in sustainability,” he said. He was equally confident that the work would deliver results that would exceed RCCL’s expectation of the project. The retrofits, which required about 10 days’ work per engine, showed a reduction in exhaust gas temperatures of 60°C, improving both engine efficiencies and costs for the operators. Another example of a turbocharger upgrade will be carried out on the cruise ship Amadea, operated by Monaco-based V.Ships Leisure and owned by Phoenix Reisen. The work is due to be done in October, although it may start earlier, and will involve retrofitting two MAN TCA66 turbochargers to an MAN 7L58/64 engine to replace the original units. These will
Worldwide Turbocharger Guide 2018
be supplied with fully pre-engineered retrofit kits for ease and speed of installation. A turbocharger efficiency increase of an estimated 6% is expected, delivering fuel savings of the order of 3 g/kWh. In addition, compressor surge margins will be increased and the engine response to load demand will be improved. The new installation will also conform fully to SOLAS requirements. A number of land-based examples also illustrate the potential benefits of turbocharger overhauls. One example was the decision last year by the owners of Battery Point power station in Scotland to overhaul its 60-year-old ABB VTR turbochargers. This avoided the need for lengthy recertification work. Battery Point provides a secure source of power for the islands of Lewis and Harris, generating a maximum of 23 MW of electrical power. The VTR turbochargers at the station have been maintained by ABB throughout their life, so regular maintenance had extended their operating life. ABB believes that its services have saved millions of pounds over the plant’s lifetime. Turbocharger upgrades can also increase revenue for power stations, an ABB study in 2016 suggested. It showed that a 64% rate of return on investment resulted from the combination of increased output and reduced fuel consumption of three engines in one power plant. In another example it found that payback time for a power station upgrade was less than a year. It is not only turbocharger manufacturers that offer upgrades; engine manufacturers also see the business potential in this area. Wärtsilä, for example, offers performance optimisation through turbocharger upgrades for its Wärtsilä 38, 46 and 50 engines. Turbochargers require a major overhaul at 50,000 hours with the replacement of major rotating parts. As an alternative, Wärtsilä offers the option of upgrade packages, which offer the advantage of the latest turbocharger technology to be adopted, giving the potential for fuel consumption reductions of up to 4%. WTG
TURBOCHARGER SERVICE & SPARE PARTS 24/7 AROUND THE GLOBE • SERVICE 24/7 Team of experienced engineers New Schenck balancing equipment and state of the art ultrasonic cleaning machine New workshop located in the Port of Antwerp, dock 140 • SPARE PARTS New & reconditioned parts with 1 year of warranty Bearings & oil pumps on direct sale base or on exchange base Varied stock of + 2m EUR NETWORK OF PARTNERS WORLDWIDE ISO 9001:2015 certified
Vosseschijnstraat 140 2030 ANTWERP – Belgium T+32 3 685 20 24 firstname.lastname@example.org
WE ARE THE LEADING INDEPENDENT PROVIDER OF SPARES AND SERVICE FOR INDUSTRIAL AND MARINE TURBOCHARGERS.
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Massive stock inventory of spares ranging from nozzle rings to casings, and bearings to rotating parts.
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SERVICE DIRECTORY | 45
WORLDWIDE TURBOCHARGER SERVICE AND SPARES SPECIALISTS ARGENTINA TurboGen www.turbogen.com Turbomotor S.R.L. www.turbomotor.com.ar
AUSTRALIA MAN Diesel & Turbo Australia Pty Ltd www. australia.man-es.com MTQ Engine Systems (Aust) Pty Ltd www.mtqes.com.au Royston Australia www.royston.co.uk Wärtsilä Australia www.wartsila.com/aus
BAHAMAS Grand Bahama Shipyard Ltd www.grandbahamashipyard.com
BAHRAIN Gulf Turbo - Bahrain www.gulfturbo.com
BANGLADESH Dalwin Marine Bangladesh Ltd www.dalwin.com
www.daewin.cn Tru-Marine Cosco (Tianjin) Engineering Co., Ltd www.trumarine.com Tru-Marine Machinery Engineering Guangzhou Co., Ltd www.trumarine.com Tru-Marine Machinery Engineering Shanghai Co., Ltd www.trumarine.com Turbo Diesel Engineering Corp www.turbodieseleng.com
COLOMBIA Ferrostaal de Colombia Ltda www.ferrostaal.com
CROATIA Motortech Consulting d.o.o. www.motortech.hr
CYPRUS Wenzel Marine Trading & Consultants Ltd www.wenzelmarine.com
CZECH REPUBLIC MTC Ltd www.mtcltd.ru
MAN Diesel & Turbo Benelux NV www.benelux.man-es.com Turbo Belgium www.turbobelgium.com
Turbomotores Ecuatorianos S.A. www.grupotme.com
DLC Diesel www.dlcdiesel.com.br Metalock Brasil Ltda www.metalock.com.br Turbogen do Brasil Ltda www.turbogen.com.br
BULGARIA Seny Ltd www.senyltd.com
CANADA Allied Marine & Industrial Inc www.allmind.com Dynamic Engineering Inc www.dynamicengineering.com
CHILE Maestranza Diesel Ltda www.md.cl Turbodal SA www.turbodal.cl
CHINA Coroland (Shanghai) Co., Ltd www.coroland.com JDM Gulf Turbo Solutions www.jdmgts.com Marine Partner Ltd www.marine-partner.com Shanghai Daewin Marine Parts Ltd
Pon Power AS www.pon-cat.com
EGYPT Meridian Marine Ship Repair & Supply Co www.meridianmarine.org Sea Princess Maritime Services Company www.spmarine.net
FRANCE Sud Moteurs www.sudmoteurs.fr Wenex Equipements SA www.wenex.fr
GERMANY Barthels + Lüders www.barthels-lueders.com H. Albert GmbH www.albert-gmbh.de Turbinen & Motoren-Service GmbH www.turbinen-motoren.de Zeppelin Power Systems GmbH & Co. KG
www.zeppelin-powersystems.com GREECE Eltrak S.A. www.eltrak.gr Turbo General
www.generalturbos.com Turbomed SA www.turbomed.gr Turbotechniki Ltd www.turbotechniki.com Turbo Service International www.turbosi.com
GUATEMALA Elliott Turbocharger Guatemala S.A. www.elliott-guatemala.com
HUNGARY Ferryker Turbo Kft www.ferrykerturbo.hu
ICELAND Stalsmidjan EHF www.stalsmidjan.is
INDIA Dalwin Marine Turbo Engineering Pvt Ltd www.dalwin.com Malwi Marine www.malwimarine.com Tru-Marine Vigil Engineering Services Pvt Ltd www.trumarine.com Wärtsilä India Private Limited www.wartsila.com/ind
INDONESIA PT Assindo Perniagaan Internasional www.ptapijak.com PT Dynamic Turbocharger Systems www.dynamicturbocharger.com
ISRAEL Radion Engineering Co Ltd www.radion.co.il
ITALY La Meccanica Turbo Diesel Srl www.mtd.it Palumbo SpA www.palumbo.it
JAPAN Showa Co., Ltd www.turbo110.com
LEBANON Joseph Tehini & fils www.tehini.com
MALTA Palumbo Malta Shipyard www.palumbo.it
MEXICO Maquinaria Industrial Moderna, S.A. de C.V. www.maquimsa.com.mx Resource Power Group www.rpgmarine.com
Worldwide Turbocharger Guide 2018
46 | SERVICE DIRECTORY
NETHERLANDS ANTILLES Curacao Drydock Company Inc www.cdmnv.com
THE NETHERLANDS Independent Waiver Service www.waiver.nl Marine Bearing Solutions BV www.marinebearingsolutions.nl Tru-Marine Rotterdam BV www.trumarine.com Turbo Diesel Engineering Europe BV www.turbodieseleng.com Turbo NL B.V www.turbonl.com Turbo Service International www.turbosi.com TurboSpares BV www.turbospares.com Wärtsilä Netherlands B.V. www.wartsila.com/nld
Tru-Marine www.trumarine.com.sg Turbo Solutions www.turbosolutions247.com
Tru-Marine Pte Ltd Shj Br www.trumarine.com Wärtsilä Gulf FZE www.wartsila.com/are
DORMAC (pty) Ltd www.dormac.net
AET Engineering Ltd www.aet-turbos.co.uk A R Turbo Engineering Ltd www.arturbo.co.uk Bartech Marine Engineering www.bartechmarine.com DMI Marine BV www.dmiglobal.com Global Turbocharger Solutions www.globalturbochargersolutions.com PowerFal Ltd www.powerfal.co.uk Royston Diesel Power www.royston.co.uk Turbo Dynamics www.turbodynamics.co.uk Turbo Service International www.turbosi.com
SOUTH KOREA DSK Co Ltd www.dskworld.com Jonghap Maritime Inc www.jonghap.co.kr
Turbo 3 www.turbo3.com Turbo Cadiz SL www.turbocadiz.com Turbo Internacional www.turbointernacional.com
NZ Marine Turbochargers Ltd www.turbocharger.co.nz
NORWAY SEVI AS www.sevi.no Westcon Turbo AS www.westcon.no Wärtsilä Norway AS www.wartsila.com/nor
Colombo Dockyard Plc www.cdl.lk
SWEDEN HS Turbochargers www.hedemoratd.com
Shirazi Trading Co (Pvt) Ltd www.shirazitrading.com.pk
Taknas Thailand Co. Ltd www.taknasth.com World Tech Engineering www.worldtech.co.th
TRINIDAD & TOBAGO
Diesel Engine Services (Panama), S. A. www.dieselenginespanama.com
Resource Power Group www.rpgmarine.com
Turbo Engine Recovery, Inc. http://www.turboenginerecovery.com
POLAND PPUH Nauta Turbo Sp. z.o.o. www.nautaturbo.com.pl
PORTUGAL Lisnave – Estaleiros Navais, SA www.lisnave.pt
RUSSIA Baltic Turbo Ltd www.balticturbo.ru MTC Ltd www.mtcltd.ru Wärtsilä Vostok LLC www.wartsila.com/rus
SINGAPORE Cell (Singapore) Pte Ltd www.cellspore.com.sg Dalwin Marine Pte Ltd www.dalwin.com MTQ Corporation Limited www.mtq.com.sg Pmax One Technologies Pte Ltd www.pmax.com.sg
Worldwide Turbocharger Guide 2018
La Tunisie Industrielle www.sti-tunisia.com
TURKEY GTS turbo Ltd www.gtsturbo.com Istanbul Marine Turbine Service Ind & Tra. Co. Ltd www.istmarin.com
UNITED ARAB EMIRATES Albwardy Marine Engineering LLC www.albwardymarine.com Goltens Dubai www.goltens.com Gulf Turbo - Dubai www.gulfturbo.com Gulf Turbo - Fujairah www.gulfturbo.com Gulf Turbo - Sharjah www.gulfturbo.com Topaz Marine Repair (Nico Middle East Limited) www.topazworld.com TurboLink www.linkmarine.ae Turbomot Marine Engineering LLC www.turbomot.com
UNITED STATES OF AMERICA Cameron Compression System www.c-a-m.com/cs Dresser-Rand www.dresser-rand.com Eastern Turbo co., Ltd www.easternturbo.com Globe Turbocharger Specialties, Inc. www.globeturbocharger.com Motor Service Hugo Stamp, Inc www.mshs.com Resource Power Group www.rpgmarine.com Tru-Marine Houston, LLC www.trumarine.com Turbo Diesel Engineering www.turbodieseleng.com Turbo Service International www.turbosi.com Turbo USA www.turbo-usa.com Wärtsilä North America, Inc. www.wartsila.com/usa
VENEZUELA Ferrostaal de Venezuela SA www.ferrostaal.com
YEMEN Algarmani Trading Corp www.algarmani.com
DISCLAIMER: While every care has been taken in the compilation of this directory, Riviera Maritime Media Ltd will not be held responsible for any loss, damage or inconvenience caused by reliance placed on the information contained in it or through omission or errors.
This annual supplement details innovation and product development by turbocharger manufacturers, and also the services and facilities offere...
Published on Jul 12, 2018
This annual supplement details innovation and product development by turbocharger manufacturers, and also the services and facilities offere...