Contents

CHAPTER I................................................................................................................................................ 2
INTRODUCTION ....................................................................................................................................... 2
1.1 Background ............................................................................................................................. 2
1.2 Problem Formulation and Scope ............................................................................................ 3
CHAPTER II .............................................................................................................................................. 4
LITERATURE REVIEW ............................................................................................................................... 4
1.1 KRI Tombak 629 Specification ................................................................................................. 4
2.2 Combustion Theory................................................................................................................. 5
2.3 Combustion Process................................................................................................................ 5
2.4 Turbocharger........................................................................................................................... 6
2.4.1 Turbocharger Lag ............................................................................................................ 7
2.4.2 Correlation of turbine power and speed fluctuations .................................................... 8
2.5 Turbocharging Techology........................................................................................................ 8
2.5.1 Turbocharger Type .......................................................................................................... 9
CHAPTER III ........................................................................................................................................... 11
METHODOLOGY .................................................................................................................................... 11
3.1 General.................................................................................................................................. 11
3.2 Bachelor Thesis Methodology............................................................................................... 11
3.2.1 Indentification and Problem Formulation of the Problem ........................................... 11
3.2.2 Study Literature ............................................................................................................ 11
3.2.3 Data Collection .............................................................................................................. 11
3.2.4 Engine Simulation Using Engine Simulation Software (GT Suite) ................................. 11
3.2.5 Engine Performance Data Validation ............................................................................ 12
3.3 Conclusions and Recommendations ..................................................................................... 12
3.4 Flowchart Thesis ................................................................................................................... 12
CHAPTER IV ........................................................................................................................................... 14
SCHEDULE ............................................................................................................................................. 14
REFERENCES .......................................................................................................................................... 15
 CHAPTER I
INTRODUCTION
1.1 Background

Indonesia as an archipelago country with a long coastline distance, this country have a solid issue
about national security in marine sector. Patrol boat is an option to secure the marine sector of
indonesia, which is designed for coastal defence duties. As we know patrol boat has a unique main
engine operating conditions. Patrol boat is designed with a high engine power output, the unique of
patrol boat main engine operating conditions is because the function of patrol boat itself, there are
two phase of patrol boat condition operate at high speed and low speed. High speed operating
condition required for pursuit a target, while slow speed is required for a coastal patrol condition.

Engine with a high power output is designed with a turbocharger that work efficient in high speed
condition. Basically turbocharger is a device to help the combustion process of main engine become
optimal. Turbocharger is a pump that driven by a turbine from exhaust gas, the turbine wheel is
connected to the compressor. The compressor pumping an air to combustion chamber to achieve
an optimal combustion process.

Dynamic main engine operating conditions is a behaviour how engine operate. Conventional
turbocharger can not be apply in patrol ship with such condition. The dynamic main engine
operating conditions on patrol boat need a special treatment, an conventional turbocharger that
only efficient at high speed without notice at slow speed condition is blunder logical way of thinking.
Every turbocharger have a working optimum area as it designed before.

Turbocharging technology will play a crucial role on patrol boat which have a unique behave of
dynamic main engine operating conditions. Turbocharger main role for doing an optimal combustion
process will completely fail, because turbocharger not working in designed work area. The problem
happen when patrol boat cruising at slow speed, at low load engine operation the turbine not
rotating at optimal condition so the compressor also suck a minimum air flow for completing the
combustion process.

KRI Tombak 629 is one of Indonesian patrol boat with 60 metres length and 28 knots maximum
speed. KRI Tombak is using 2 MTU 16V4000M73 engine with 2880 kW, and each engine has 2
turbocharger. KRI Tombak is design to operate in 20 knots speed but due to reduce the fuel
consumption and most of her duties just to oversee and patrol so this ship operate in only 15 knots
speed (economical speed). It can be said that KRI Tombak behave like dynamic main engine
conditions. This is a problem to be response for finding the suitable turbocharger technology and
analyzing the characteristic, which turbocharger technology that suitable for KRI Tombak conditions.
1.2 Problem Formulation and Scope
With a problem happen because operating main engine at a dynamic conditions, a coventional
turbocharger can not supply enough compressed air because engine operate at low load operation
make an air temperature and compressed air not covered the need of combustion process. KRI
Tombak 629 Patrol Boat is an interesting issue to invistigate because the dynamic main engine
operating conditions, that operate the speed at high and slow speed.

Based on the description above the statement problem for this thesis are presented:

1. How to modify the Turbocharger on KRI Tombak 629 in order to optimizing the main engine
conditios(dynamic main engine conditions)?
2. How the characteristic of Modiffied Turbocharger on KRI Tombak 629?

1.3 Probem limitation

The problem limitation is to completing how far will the thesis to be done:

1. The simulation using a software to completing the bachelor thesis.

2. Simulation only used to find the performance of the engine which had been installed by
turbocharger
3. The experiment will be done to compare the efficiency and performance of the engine which
had been installed by turbocharger with a different specification.

1.4 Objectives

This bachelor thesis have purposes to:

1. Knowing the right step to select turbocharger on dynamic main engine operating conditions
(Patrol Boat)
2. Knowing the selected turbocharger which had been installed on KRI Tombak 629 already match
with the engine or not

1.5 Benefits

Benefit to be gained in tis bachelor thesis are:

1. Recommendation for user of application turbocharger in marine diesel engine to improve engine
performance
2. Consideration of choosing turbocharger with best efficiency according to marine diesel engine
basic specification and performance.
 CHAPTER II
LITERATURE REVIEW

1.1 KRI Tombak 629 Specification

KRI Tombak (629) is a War-Patrol ship quick ship missile with a 60 meters length, this ship is a second
generation made by PT PAL Surabaya. Previously, PT PAL has made KCR 60M first generation with
the name KRI Sampari (628) were handed over on May 28, 2014 at Pier Warship Division PT. PAL
Indonesia Ujung Surabaya. The warship will strengthen the ranks Alutsista Quick Ship Unit (Satkat)
Koarmatim, with the ship's commander Marine Lt. Col.Hreesang Wisanggeni.

Figure 2.1.2 KRI Tombak Ship

(source : http://www.indomiliter.com/kri-sampari-628-generasi-pertama-kcr-60-tni-al/)

KCR 60M KRI TOMBAK SPECIFICATION ( TNI AL)

 Ships Name : KRI Tombak-629

 Ships Type : High Speed Patrol Vessel 60M
 Main Engine : 2x2880 kW (MTU 16V400M73L)
 Launch Date : 28 Mei 2014
 Main Dimension
o Length of All (LOA) : 60,00 M
o LPP : 54,82 M
o Ship Wide : 8,10 M
o Ship Height (H) : 4,85 M
o Draft (T) : 2,60 M
 Economic Speed :15 Knots
 Cruising Speed : 20 Knots
 Maximum Speed : 28 knots
 Crew Number : 55 Orang
 Gross Tonnage (GT) : 378,09
 Net Tonnage (NT) : 197,82.

KRI Tombak is design to operate in 20 knots speed but due to reduce the fuel consumption
and most of her duties just to oversee and patrol so this ship operate in only 15 knots speed
(economical speed). Can be concluded that KRI Tombak is operating in dynamic engine operating
conditions.

2.2 Combustion Theory

On motor fuel, the combustion process is a chemical reaction that takes place very quickly between
the fuel with oxygen which generate heat resulting pressure and high temperature of the gas. The
need oxygen for combustion is obtained from the air which requires a mixture of oxygen and
nitrogen, as well as some other gas with a relatively small percentage and can be ignored. The
chemical reaction between a fuel and oxygen derived from the air will produce combustion products
whose composition depends on the quality of combustion. Type of combustion process in terms of
the result of combustion output :

Figure 3. Combustion Process Diesel Engine

2.3 Combustion Process

The combustion in a diesel engine is a complex process. It depends on many factors such as engine
design particularly combustion chamber design, fuel properties, injection pressure and injection
timing of fuel (Kouremenos,1999). There are extensive research results showing that fuel injection
and air motion have great effects on mixture preparation, combustion and combined improvement
of smoke and NOx emission. The injection parameters employed should match with the combustion
chamber design to attain improved performance and emissions from the DI diesel engine. Fuel
injection characteristics have significant effects on diesel engine performance and emissions. For
example, a further injection delay with a higher injection rate, decrease NOx and soot emission
simultaneously. Based on the analysis of diesel combustion heat release rate, if the premixed
combustion is controlled within a reasonable limit, the combustion temperature will be lower to
some extent and the combustion generated NOx emission will thus be lowered; if the diffusion
combustion process keeps fast and ends sharply, the soot emission will be reduced. The combustion
is required to occur in a short period of time in an internal combustion engine, there are five
essential requirements to ensure this:
 Correct Air/fuel ratio
There must be sufficient oxygen to burn not only the hydrogen and oxygen present but also
any other combustibles, such as sulphur. To be effective and efficient all the fuel must be
burnt in the cylinder i.e. all the hydrogen must be burnt to water and all the carbon must be
burnt to carbon dioxide. As the time for combustion is short excess air must be supplied to
increase the possibility of the fuel being in close proximity to the oxygen molecules. The
correct maintenance of the scavenge system including turbocharger suction filters is
therefore essential.
 Atomisation
To ensure that the fuel breaks down into its constituent elements as quickly as possible it is
atomized, which means it is injected into the cylinder under pressure through a small orifice
(high surface area/volume ratio allowing rapid oxidation).
 Mixing
Atomised fuel made up of fine droplets does not penetrate well into the cylinder
combustion space, mixing with the air is promoted by giving the a swirling motion.
 Injection Timing
As the fuel burns it creates a pressure wave which acts against the piston.
If the injection is too late, the piston is travelling down the liner. The pressure wave created
by ignition moves rapidly down to meet the piston causes excessive shock loading on the top
of the crown (this is the characteristic 'Diesel knock' of engines when started from cold). Less
power is derived as the correct pressure does not act on the piston during the early stages of
the stroke. If the injection is too early then very high temperatures and high peak pressures
can be generated caused by the rapid combustion period occurring when the space available
is very small. This can lead to increased engine efficiency but also to overloading of the
bearings, particularly the top end bearings.
 Compression temperature
The diesel engine is a compression ignition engine, this means that the ignition of the fuel is
reliant on the temperatures generated by the compression of the combustion air. The
compression ratio is set at the design stage to give the correct temperature. However, loss
of compression, say by a leaky exhaust valve or piston rings can lead to a late timing of
ignition. A similar effect can occur if the cylinder parts are not kept at the correct
temperature.

2.4 Turbocharger

Turbocharger is an application which part of the main engine, it is a device to help increse the
performance of main engine itself. The principle work of turbocharger is driven the mass flow of air
that entering to the combustion chamber and helping to increase the pressure ratio of combustion
process. With using output gas after combustion process, the output gas which spooling the turbine
that have a connected structure with the compressor, so the speed of compressor rely to the speed
of turbine. How fast the compressor move is depend from the output gas, when the compressor
rotating it suck air from surrounding air in enviroment and the air is entering to the turbocharger
system that finally the driven air entering the combustion process.

Figure 4. Turbocharger Principle work

2.4.1 Turbocharger Lag

Turbocharger lag is the time required to change power output in response to a throttle change,
noticed as a hesitation or slowed throttle response when accelerating as compared to a
naturally aspirated engine. This is due to the time needed for the exhaust system and
turbocharger to generate the required boost which can also be referred to as spooling. Inertia,
friction, and compressor load are the primary contributors to turbocharger lag. Superchargers
do not suffer this problem, because the turbine is eliminated due to the compressor being
directly powered by the engine.
Turbocharger applications can be categorized into those that require changes in output power
(such as automotive) and those that do not (such as marine, aircraft, commercial automotive,
industrial, engine-generators, and locomotives). While important to varying degrees,
turbocharger lag is most problematic in applications that require rapid changes in power output.
Engine designs reduce lag in a number of ways:

 Lowering the rotational inertia of the turbocharger by using lower radius parts and
ceramic and other lighter materials
 Changing the turbine's aspect ratio
 Increasing upper-deck air pressure (compressor discharge) and improving wastegate
response
 Reducing bearing frictional losses
 Using variable-nozzle or twin-scroll turbochargers
 Decreasing the volume of the upper-deck piping
 Using multiple turbochargers sequentially or in parallel
 Using an antilag system
  Using a turbocharger spool valve to increase exhaust gas flow speed to the (twin-scroll)
turbine

2.4.2 Correlation of turbine power and speed fluctuations

Turbocharger speed can be considered as the result of two contributions; a low frequency
component (mean value over a complete rotation) and high frequency component (fluctuation).
The high frequency is mainly due to the pulsating flow coming from the engine after exhaust
valves opening. Consequetly, the frequency of turbocharger speed fluctuatiom will always be
approximately equal to engine combustion frequency. The balance between power delivered by
the turbine and power required by the compressor can be written in the angular frequency
doamaintrough equation 1. (Ravaglioli, 2015)

( 𝑃T – 𝑃C ). JTC . 𝜔TC . 𝛼 TC

Equation 1.

Where:

𝑃T = Turbine Power

𝑃C = Compressor Power

Turbocharger mechanical efficiency

JTC = Turbocharger Inertia

𝜔TC = Turbocharger average speed

𝛼TC = Turbocharger average acceleration

2.5 Turbocharging Techology

Turbocharging technology will be the main actor in the near future to solving a problem about
energy saving and supporting environmental issue. An optimal turbocharging technology is still a
problem to be response as soon as posible. The developement of technology is already been proven
to help many human interest, so far tubocharging technology control is still a problem that must
develope.

Turbocharging technology by it means, to develope a knowledge about turbocharger efficiency to

help achieving a greater combustion process for main engine. More compressed air entering the
combustion chamber produce more greater output power. Engineering concept has been apllied for
a better turbocharging technology invention.Basically turbocharging technology is to manupulatting
an compressed airflow system that entering the combustion chamber. Many reseacrh developing
the turbocharger technology to achieve a higher compressed airflow, which help the process of
combustion.
2.5.1 Turbocharger Type
As mentioned before turbocharging technology are progressing to the next sophisticated level.
By the requirement need to make a greater combustion effeciency, turbocharger has been
developed to many types to support the work of main engine. Several turbocharger has been
proven to make a main engine look formidable to operate. Many engineering problem about
combustion effeciency depend on the optimal performance of turbocharger, the problem that
state turbocharger performance is corralated to the speed of main engine itself, e.g. when the
speed of main engine is running at the slow condition the turbocharger work at outside wide
operation range, the problem is overcome by applying once of the turbocharging technology
type.

2.5.1.1 Single-Turbo
Only a singgle number of turbocharger that supporting the main engine combustion process.
Single turbocharger have limitless variabilitty, differing the compressor wheel size and
turbine will lead to completely different torque characteristic. Single turbocharger have a
narrow effective RPM range, means the single turbocharger type will help the work of main
engine efficiently only in its design range.

Figure 5. Single-Turbo

2.5.1.2 Twin-Turbo
Basically twin-turbo is a technology which is same with single-turbo, coupled of turbocharger
with identic specification of each other. Splitting the duties equally to support the main
engine, moved by half of engine gas output. Providing similiar performance than a single-
turbo with less turbo lag.

Figure 6. Twin-Turbo
2.5.1.3 Sequential-Turbo
Sequential-turbo is a technology use two different specification turbocharger, this type of
turbocharger effective to use in low engine speed also in high engine. The typical of this
turbocharging technology support by two turbo, with larger high-flow turbochargers are not
as efficient at low RPM, resulting in lower intake manifold pressures under these conditions.
On the other hand, smaller turbos spool up quickly at low RPM but cannot supply enough air
at higher engine speed. At the low speed engine small turbocharger will operate, output gas
only circulating in small turbocharger system. When rpm preset attained secondary turbocharger
will activated.

Figure 7. Sequential-Turbo

2.5.1.4 Staged-Turbo
This turbocharging technology also support by two working turbocharger, it is for increasing
the air pressure for achieve a greater combustion process. Both turbocharger operate
constanly, the first turbocharger boosts pressure as much as possible, while the other
turbocharger function is working just like the ussual principle.

Figure 8. Staged-Turbo
 CHAPTER III
METHODOLOGY
3.1 General
The methodology is a description of the steps carried out in a study. Methodology in this thesis
include all activities carried out to solve a problem or process of analysis and evaluation of the
problems this thesis.

3.2 Bachelor Thesis Methodology

In order to find the parameters of turbocharger output from the system, the data will be collected
from many research related to the topic of this thesis. The methodology used in this thesis can be
described as follows:

3.2.1 Indentification and Problem Formulation of the Problem

This thesis begins with indentif and formulating the problems regarding to the experiment to
be carried as well limitation issue. It aims to simplify the problem, make it compact and easier
in the final project.

3.2.2 Study Literature

Literature study conducted with collecting references to the turbocharger, the characteristics
of turbocharger, and engine performance. The goal is to strengthen the basic theory problems
as in the analysis. Literature used can be collected from websites, books, journals, papers,
final project, and other related sources.

3.2.3 Data Collection

Data that use in this bachelor thesis is looking for a ship that usually load at slow speed ship
condition, which operate under the design of the maximum load of the main engine.
Parameters of variable to completing this bachelor thesis are:
 Engine Specification
 Turbocharger Specification

3.2.4 Engine Simulation Using Engine Simulation Software (GT Suite)

Analysis the characteristic of turbocharger based on engine performance parameter and using
simulation software to identify some turbocharger , to know every characteristic of chosen
turbocharger. The simulation compared between the initial of turbocharger with the data of
chosen turbocharger to know where is the suitable one for the main engine condition. Result
of the engine performance will be compared to analyze the characteristics of every type of
selected turbocharger, the match turbocharger is one with helping the main engine operate at
low speed effeciently.
 3.2.5 Engine Performance Data Validation
At this stage, the output data from simulation process not exactly resulted the correct data of
engine performance. The output data obtained as a result from engine simulation might be
had some of error. Looping the step of the simulation stage to find failures and corrected the
input data. If the data has been obtained correctly, next step is already to continue.

3.3 Conclusions and Recommendations

Conclusions are expected in this thesis is able to answer the problem. This thesis aims to know the
main characteristics of turbocharger system. Written advice based on data from the discussion well
as the fact that there is, and given to the improvement of this bachelor thesis in order to become
better.

3.4 Flowchart Thesis

The methodology is a description of the steps carried out in a study. Methodology in this thesis
include all of activities carried out to solve the problem or process of analysis and also to evaluate
thesis problems. Methodology of this thesis can be viewed trough flowcharts final project in the next
page.
 START

Study Literature:
-Books
-Types of Turbocharger&Characterisitic
-Papers
-Combuction Process
-Journals
-Low Load Operation
-Websites

Data Collection:

-Engine Specification

-Engine Performance

- Turbocharger Specification on
every chosen type

Engine Simulation with

GT-Power Software

Engine performance data

Validation

Engine performance data

NO
validation (is the performance
same with actual engine?)

YES

Simulating every type of chosen turbocharging

Technology with GT-Power software

Make a characteristic analysis of every chosen

Turbocharger

Conclusions and
Recomendations

FINISH
CHAPTER IV

SCHEDULE
 REFERENCES

Kech, D. J. (t.thn.). Turbocahrging: Key technology for high-performance engine. MTU, 6.

Pradana, A., & Aguk Zuhdi Muhammad Fathallah. (2016). Turbocharger Characteristic Analysis of 93
kW Marine Diesel Engine. Jurnal Teknik ITS, 5.

V.Ravaglioli, N.Cavina, A. Cerofolini, E. Corti, D. Moro, & F. Ponti. (2015). Automotive turbocharger
power estimation based on speed fluctuation analysis. ATI 2015-70th Conference of the ATI
Engineering Association, 7.

http://www.popularmechanics.com/cars/how-to/a12765/4306310/

http://www.indomiliter.com/kri-sampari-628-generasi-pertama-kcr-60-tni-al/