Kalevi Tervo, Dr. Tech., R&D Senior Principal Engineer ......© ABB Slide 2 ABB Marine Main offering May 3, 2016 Automation Maneuvering Power Management Propulsion Control Steering

© ABBSlide 1

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

May 3, 2016

© ABBSlide 2

ABB MarineMain offering

May 3, 2016

Automation

Maneuvering

Power Management

Propulsion ControlSteering ControlAzipod Control

Protection

Online Advisory, IntegratedOperations, IoTSP

OnboardAdvisory

© ABBSlide 3

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

May 3, 2016

© ABBSlide 4

1. Motivation2. The Challenge3. The Solution4. Results5. What’s Next?

Contents

May 3, 2016

© ABBSlide 5

Motivation

May 3, 2016

© ABBSlide 6

Hero StoryTraditional way of working

May 3, 2016

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj2sIfDs8fLAhUGDZoKHQUOCrAQjRwIBw&url=https://commons.wikimedia.org/wiki/File:World_map_without_Antarctica.svg&bvm=bv.117218890,d.ZWU&psig=AFQjCNHWw8VJP6CNjpu_BwedjPXz-g8HUA&ust=1458293157639565

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiAj8f_ssfLAhUhCpoKHTlIA6oQjRwIBw&url=https://en.wikipedia.org/wiki/Albert_Einstein&bvm=bv.117218890,d.ZWU&psig=AFQjCNEtdrMhbYxkcAJuU3OVI5VmdeyFdQ&ust=1458292999539732

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiI9-SRtMfLAhXMNJoKHSAdBZ4QjRwIBw&url=http://www.texample.net/tikz/examples/control-system-principles/&bvm=bv.117218890,d.ZWU&psig=AFQjCNHpZUbzqGpTxnAifVkJHIhIjijhpw&ust=1458293322895516

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwizgIb5s8fLAhWKDZoKHecbBpwQjRwIBw&url=https://flyawaysimulation.com/downloads/files/4492/fsx-finnair-airbus-a350-900/&bvm=bv.117218890,d.ZWU&psig=AFQjCNH18w2Q-xN7ewN-avkDhBHoccKimw&ust=1458293274576795

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi6rp7cssfLAhVFG5oKHU14D6gQjRwIBw&url=http://www.vectortemplates.com/raster-batman.php&bvm=bv.117218890,d.ZWU&psig=AFQjCNEmZp3uS6if1-vDZRG_OHZukyQFBA&ust=1458292945958174

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwizgIb5s8fLAhWKDZoKHecbBpwQjRwIBw&url=https://flyawaysimulation.com/downloads/files/4492/fsx-finnair-airbus-a350-900/&bvm=bv.117218890,d.ZWU&psig=AFQjCNH18w2Q-xN7ewN-avkDhBHoccKimw&ust=1458293274576795


http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj3gIHK8JjMAhWDF5oKHSTKDPkQjRwIBw&url=http://emojipedia.org/loudly-crying-face/&psig=AFQjCNF7Gaar0Wy28tRUOo6kfMbuJuWRJw&ust=1461092694339393

© ABBSlide 7

Transportation of Fresh GoodsHuge electrical energy consumption

May 3, 2016

• 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

http://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwio3YyurcfLAhXkYpoKHf6iDbMQjRwIBw&url=http://news.bbc.co.uk/2/hi/business/7700818.stm&psig=AFQjCNFnSYAvByhAIAMffKhKgojjeVZRVA&ust=1458291401743607

https://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjVyuiPrMfLAhXHQJoKHWgmDLAQjRwIBw&url=https://heatinghelp.com/blog/how-do-you-define-high-efficiency/&psig=AFQjCNFIolrA9qFa7HKkuXLsrZcWNf3hoA&ust=1458291160291161

http://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjrsqDep8fLAhWrAJoKHfRgA6gQjRwIBw&url=http://alltommat.se/sa-har-valjer-du-den-perfekta-avokadon-tricket-du-inte-kommer-fatta-hur-du-kunnat-leva-utan/&psig=AFQjCNH54m_g6cXakZnLdlVVxIP61D9lHw&ust=1458289969954862

http://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj_0oipp8fLAhXoKJoKHQy4Ap4QjRwIBw&url=http://saltmarshrunning.com/2014/09/10/why-runners-love-bananas/&psig=AFQjCNH26N_MPmSwpGYLxJHpGU07yJh3ZA&ust=1458289879559496

http://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiahMaOrsfLAhWGO5oKHb4WAp4QjRwIBw&url=http://www.cnc-line.com/services/reefer&psig=AFQjCNGC0j6sEjE-HWfj0bX1SLuE7Hgwlg&ust=1458291713588539

http://www.google.fi/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwir7s24rsfLAhWlCpoKHYVKB54QjRwIBw&url=http://www.ronka.fi/kuluttajat/tuotteet/tuote/naudan-sisafile.html&bvm=bv.117218890,d.ZWU&psig=AFQjCNHxu8EUuz0ysUNSE-qJV_UNZ9vjnw&ust=1458291793598060

https://en.wikipedia.org/wiki/File:M%C3%A6rsk_Mc-Kinney_M%C3%B8ller_passing_Port_Said_in_the_Suez_Canal_on_its_maiden_voyage.jpg

© ABBSlide 8

Waste Heat Recovery SystemPower Turbine Generator (PTG) Application

May 3, 2016

ABB Marine scope

© ABBSlide 9

The Challenge

May 3, 2016

© ABBSlide 10

• 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

May 3, 2016

© ABBSlide 11

The Solution

May 3, 2016

© ABBSlide 12

Development processModel-based development

May 3, 2016

Conceptdevelopment

Simulation modeldevelopment

Function description

Implementation onPLC

HIL testing

Mechanical FATtest

Harbor and seaacceptance tests

© ABBSlide 13

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

May 3, 2016

© ABBSlide 14

Development and test platformReal actuators

May 3, 2016

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

https://www.speedgoat.ch/Portals/0/big/performance_default_600.png

© ABBSlide 15

Results

May 3, 2016

© ABBSlide 16

• 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

May 3, 2016

© ABBSlide 17

What’s Next?

May 3, 2016

© ABBSlide 18

Ongoing workIntegrated Marine Systems Laboratory

May 3, 2016

© ABBSlide 19

Hero StoryRevised

May 3, 2016

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj2sIfDs8fLAhUGDZoKHQUOCrAQjRwIBw&url=https://commons.wikimedia.org/wiki/File:World_map_without_Antarctica.svg&bvm=bv.117218890,d.ZWU&psig=AFQjCNHWw8VJP6CNjpu_BwedjPXz-g8HUA&ust=1458293157639565

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiAj8f_ssfLAhUhCpoKHTlIA6oQjRwIBw&url=https://en.wikipedia.org/wiki/Albert_Einstein&bvm=bv.117218890,d.ZWU&psig=AFQjCNEtdrMhbYxkcAJuU3OVI5VmdeyFdQ&ust=1458292999539732

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiI9-SRtMfLAhXMNJoKHSAdBZ4QjRwIBw&url=http://www.texample.net/tikz/examples/control-system-principles/&bvm=bv.117218890,d.ZWU&psig=AFQjCNHpZUbzqGpTxnAifVkJHIhIjijhpw&ust=1458293322895516



May 3, 2016

Kalevi Tervo, Dr. Tech., R&D Senior Principal Engineer ......© ABB Slide 2 ABB Marine Main offering May 3, 2016 Automation Maneuvering Power Management Propulsion Control Steering

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