The Retrofit includes the research and study for the upgrading-conversion or/and replacement of old types of turbochargers with new ones, of more modern technology, aiming at the best performance of the engine.
The goal of supercharging an engine is to increase its power. Despite the differences between propulsion and generator systems, the purpose is similar: reaching the desired output power in such a manner that covers the application needs in a safe and optimum way.
Generally, the efficiency of a diesel engine decreases over time. This fact forces the engine to waste more fuel, in order in order to reach the desired operating point. Moreover, an old turbocharger model makes the efficiency of the engine-turbocharger (T/C) system even worse, leading to harmful consequences such as high temperature levels, heavy smoke emissions and increased soot formation on engine components. The aforementioned reduce the life time of critical engine’s components (exhaust valves, piston rings, piston head) leading to very frequent replacements of engines and T/C components.
Furthermore, over the years, there is a limited availability of spare parts for old T/C models. Thus the overall maintenance cost is higher. Eventually, the long term poor performance of the diesel engine increases the possibility of a fatal T/C breakdown which is apparently not cost efficient due to vessel’s frozen operating state and the idle time for retrofit. Consequently, it is clear that leaving your engine with an old T/C model increases the overall maintenance and operating costs, while the root of the problem (old T/C with low efficiency) is not solved.
When a customer is interested in a turbocharger Retrofit, a series of steps are necessary before a suggestion can be recommended. The main parameters of the engine and the operating conditions drive the T/C selection. Therefore, for the specific engine a list of candidate solutions is considered. The next step of methodology is the simulation of the engine with these possible T/C solutions. The inappropriate turbochargers are excluded and a fine tuning on the selected T/C is performed. Finally, the modification work that may be needed is carefully planned, based on the engine layout restrictions and optimum aerodynamic performance.