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Marine Propulsion & Auxiliary Machinery

Marine Propulsion & Auxiliary Machinery

MAN opts for two-stage technology for flagship engine

Tue 26 Jun 2018

MAN opts for two-stage technology for flagship engine
Dr Gunnar Stiesch (MAN): Load pick-up for its two-stage turbocharger is the same as for a single-stage (credit: MAN)

Engine licensee Kawasaki builds MAN turbochargers for its own engines

Successors to MAN’s 48/60CR engines now feature a high-pressure two-stage turbocharging system. New MAN 45/60CR marine diesels will initially be available in 12V and 14V cylinder configurations offering power outputs of 15,600 kW and 18,200 kW respectively. The two-stage turbocharger module, a concept that the company has pioneered for large-bore engines, was an integral element of the 45/60CR’s design, delivering higher boost pressures and charging efficiencies.

The MAN TCX system is based on low-pressure and high-pressure turbochargers arranged in series, with new units designed specifically for the duties required. “We are the only company in the market that develops both engines and turbochargers,” said MAN Energy Solutions head of engineering engines, Dr Gunnar Stiesch, when announcing the new engine.

“This unique, in-house competence allows us to truly tailor-design this engine for optimised two-stage turbocharging and to unleash its full potential,” he went on. “It is also noteworthy that, despite the turbocharging being two-stage, load pick-up behaviour is the same as for the single-stage turbocharged 48/60CR engine. Operators thus profit from maximised peak pressure and optimal utilisation of the Miller Cycle.”

The MAN 45/60CR engines also feature common-rail injection systems incorporating MAN’s ECOMAP capability for optimum performance and emissions control, but the two-stage turbocharging also helps to deliver market-leading levels of fuel consumption. MAN sees this as key need for lifecycle cost-critical applications, such as cruise liners and ropax and roro carriers. The first V-engines will be available from the end of 2020 and will be followed by in-line engines from 2022.

Seeing the continued importance of the service sector, MAN continues to enhance its networks and, in 2017, reinforced its support for marine engines in both Europe and South America. These developments have been built on existing commercial ties between service companies and MAN Engines, some of which have been in place for decades. “MAN Engines is responding to the increasing quality requirements for a global service network”, explained MAN Engines head of marine Claus Benzler.

The new MAN Engine representatives include Diesel Power of Sweden, PME Power System Group in the UK, Poweras of Poland and Eilers y Cia, operating in Chile. As exclusive importers of MAN marine engines, these companies are also now responsible for activities on new engine projects and will provide additional customer centres in their own countries. This structure will enable these marine engine specialists to provide full service support for yachts and working boats engines.

For some engine builders, the solution to selecting suitable turbochargers is to manufacture their own products. This is the case for the Japanese company Kawasaki. To complement its licensing agreement with MAN Energy Solutions for building two- and four-stroke engines, the company also builds TCA and TCR turbochargers.

The smallest unit in the current range is the TCR22 radial turbocharger, capable of meeting the demands of two-stroke engines of up to 6,200 kW per turbocharger or 6,500 kW per turbocharger in four-stroke applications. For higher powers, the Kawasaki-MAN axial turbine TCA55 product is suitable for 9,000 kW in two-stroke and 10,400 kW applications. Larger two-stroke engines of up to 18,600 kW per turbocharger have the option of using TCA66 or TCA77 products.

Built to MAN specifications, these turbochargers can deliver maximum pressure ratios of between 4.6:1 and 5.4:1, depending on the build and application. These high-efficiency turbochargers have low noise emissions, are simple to install and maintain and are designed for long service lives. There is also an option to add the MAN Variable Turbine Area (VTA) system, which enables air delivery to be optimised across different engine loads.

For Kawasaki, typical two-stroke applications of the products include the TCA55 on the 6S50MC-C7 engines and the TCA66 and TCR22 on 7S60ME-C8.2 engines.

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