Wärtsilä improves power efficiency of gas engines with Electric Turbo Compounding systems in Turkey

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RESULTS: “WÄRTSILÄ CASE STUDY 0302 BOWMAN POWER GROUP

ZeroOver

600 Accelerated payback on an entire power plant project

1.5%Over

650MWh

Over

12,200

additional free power generated

impact on engine operation and reliability

of free energy generated in total

trouble free engine shut-downs and start-ups

system running hours

Customer: Wärtsilä

Engine: Wärtsilä 34SG

Fuel type: Gas

We were looking for ways to improve the

efficiency of our plant. The Bowman ETC system

delivered on its promise, even when the engine

was run at part load.

Ozan Emre Erdoğan, Plant Chief Engineer

As Wärtsilä is committed to sustainability, and

providing environmentally sound products and services,

the company continually seeks new and creative

solutions to enhance its offer to customers.

Since the early 1990’s, Turkey has placed increasing

importance on its investment in technology, with

the Technology Development Foundation of Turkey

providing extensive support for industrial research and

R&D activities. Having a commitment to environmental

protection, the country is also working towards joining

the European Union Emission Trading Scheme to

further reduce its carbon footprint.

In 2011, Wärtsilä began working with

Bowman Power Group, in Bermeo, Spain,

to evaluate the effectiveness of Bowman’s

Electric Turbo Compounding (ETC) exhaust

recovery system.

Wärtsilä was seeking ways to improve engine efficiency

and deliver additional power output without increasing

fuel consumption. The trials in Spain demonstrated that

the ETC system would increase net power output by

1.4%, with no impact on engine operation.

Based on this success, in 2012 Wärtsilä’s Energy

Solutions division challenged Bowman to prove the

long-term performance of the system over a 4,000

hour trial in Tirenda, Turkey, with rigorous durability

tests carried out on a 9MW Wärtsilä 34SG engine,

in a Wärtsilä operated power plant.

Typically, the Bowman ETC system is integrated on

engines in the 200kW to 1.2MW range. The Tirenda

trial offered a new challenge for the Bowman team,

to demonstrate system performance on a much

larger engine.

WÄRTSILÄ CASE STUDY 0504 BOWMAN POWER GROUP

COUNTRY AND SECTOR PROFILE

THE CHALLENGE

Wärtsilä is a global provider of power

solutions for the power industry, and marine,

gas and oil sectors, with customers in over

170 countries. The company is a leader in the

energy sector, with a strong focus on engine

optimisation and technological innovation.

• Maintain performance

over 4,000 hour

trial period

• Demonstrate system

performance with

zero impact on

engine operation

• Demonstrate ETC system

capability to automatically handle

multiple system shutdowns and

start-ups in tandem with engine

operation, i.e. no intervention

required with ETC system

• Consistently deliver

an increased power

output of 1% or more

KEY CUSTOMER REQUIREMENTS:

The Bowman system,

bespoke design for

off-engine integration.

The system recovers exhaust gas which is normally lost

through the exhaust outlet, and generates additional

usable electricity, thereby improving the overall

efficiency of the engine.

Prior to integration, baseline engine efficiency data was

gathered by the Bowman team, and the ETC system

was installed on a Wärtsilä 34SG engine in March 2013.

The system has generated over 650MWh of additional

free energy, with zero increase in fuel consumption.

This equates to an extra 1.5% additional power,

significantly increasing overall power plant efficiency.

As a result of the long-term trials, Wärtsilä has

calculated that the combination of the Bowman system

with the company’s engines will accelerate the payback

on an entire power plant project, where engines are

in operation for more than 2,000 hours per year. The

two companies have developed an extensive project

pipeline to supply in excess of 1.3GW of stationary

power capacity over the next two years, with several

production orders currently in hand.

WÄRTSILÄ CASE STUDY 0706 BOWMAN POWER GROUP

THE SOLUTION

THE RESULTS

Wärtsilä required an off-engine solution, so

the Bowman engineering team designed a

bespoke application in which the ETC system

is housed within a frame, and connected via

a valve system to the engine.

To date, (October 2019) the Bowman

system has been in continuous operation

for over 12,200 hours, and automatically

handled more than 600 engine shut-downs

and start-ups without impact on system

performance or reliability.

Final stages of installation,

with the Bowman system

connected to the Wärtsilä

34SG via a bespoke

valve system.

GET IN TOUCHTo find out more about Bowman’s ETC

technology, or talk to our Business

Development team, contact us via:

Telephone: +44 (0)23 8023 6700

Email the team: webenquiries@bowmanpower.co.uk

Visit the website: www.bowmanpower.co.uk