Kalevi Tervo, Dr. Tech., R&D Senior Principal Engineer ......© ABB Slide 2 ABB Marine Main offering...
Transcript of Kalevi Tervo, Dr. Tech., R&D Senior Principal Engineer ......© ABB Slide 2 ABB Marine Main offering...
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Model-Based Development of Waste HeatRecovery Systems for Container Ships
Kalevi Tervo, Dr. Tech., R&D Senior Principal Engineer, ABB Marine, Nordic MATLAB EXPO, Stockholm, April 21 2016
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ABB MarineMain offering
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Automation
Maneuvering
Power Management
Propulsion ControlSteering ControlAzipod Control
Protection
Online Advisory, IntegratedOperations, IoTSP
OnboardAdvisory
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Key drivers• Energy efficiency,• Safety and environmental
sustainability• Information technology
Risks and safety• Lots of people onboard (up
to 8000)• Lots of cargo onboard
(18000 containers, hundredsof thousands tons of oil)
• Big size up to 160000 DWT• Large investment (up to 1
billion USD)
ABB MarineDrivers and risks
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1. Motivation2. The Challenge3. The Solution4. Results5. What’s Next?
Contents
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Hero StoryTraditional way of working
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Transportation of Fresh GoodsHuge electrical energy consumption
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• Transportation of fresh goods isgrowing
• Reefer containers require a lot ofelecrical power
• Typically auxiliary power plant >10 MW
• Diesel generators supplying 10MW consume > 2000 kg/h ofmarine diesel oil
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Waste Heat Recovery SystemPower Turbine Generator (PTG) Application
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ABB Marine scope
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• Customer project of 14 ships• 1,6 MW electrical power from exhaust gas waste heat
• Functionalities that has not been done by any other company• New product for ABB• Less than two years development time• 14 deliveries within 1 year
The ChallengeTight schedule
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Development processModel-based development
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Conceptdevelopment
Simulation modeldevelopment
Function description
Implementation onPLC
HIL testing
Mechanical FATtest
Harbor and seaacceptance tests
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WHRS simulator§ Exhaust gas system, Power turbine§ Gearbox and generator, braking resistor unit§ Three-phase network with varying loads§ Diesel generators§ Main switchboard, synchronizers and circuit breakers
Simulated 3rd party control systems§ Power Management System§ Engine Control System§ Diesel engine governor
Electrical system§ SimPowerSystems (2nd generation / Specialized technology)§ Synchronous generator, AVR (Excitation system), measurements, loads, circuit breakers
Other toolboxes§ Signal processing toolbox§ Control systems toolbox
Simulation modelSystems and toolboxes
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Development and test platformReal actuators
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Speedgoat Performance real-time targetmachine
IOEtherCAT
Modbus RTU
WHRS Local Control Unit
Modbus RTU Modbus TCP ModbusTCP
cpmPlusRTDB
IO
ProfibusDP
Instrument air 8bar
Actual pos.
Pneumatic control valve
Fast closing ESD valve
Valve cmd.
1 MW Brakingresistor unit Cmd.
Act.
Electrical power
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• More than 60 % of the development cost were used for simulation and testing at the laboratory• > 85 % of the control software issues fixed before the first handover of the system, > 95 % of the critical issues• Many of the issues would not have been found during sea trials
• Require certain sequence of events to happen• >1000 operation hours for control system before first delivery• Software updates were tested at laboratory before updating the software onboard
• Cargo ships travel around the world with tight schedules§ WHRS system cannot be tested at dock§ à Minimum time onboard is one voyage (3-30 days)§ Total costs of one service trip onboard > 10000 USD
Results
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Hero StoryRevised
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