TCS-PTG

Savings with extra power

MAN Diesel & Turbo Aspiring to turbocharger perfection

MAN Diesel & Turbo is the worlds leading designer and manufacturer of large exhaust gas turbochargers and thermal efficiency systems for low and medium speed diesel and gas engines. As an integral part of a leading developer and builder of two-and four-stroke, low and medium speed engines, the MAN Diesel & Turbo Business Unit Turbocharger has a deep understanding of all the core technologies of large engines and their interaction with the turbocharger and thermal efficiency systems. The result is world and market leading turbocharger technology. More than ever before, the development focus at the MAN Diesel & Turbo Business Unit Turbocharger is the environmental performance of low and medium speed diesel and gas engines. The contribution of high efficiency exhaust gas turbochargers to this goal has been and will continue to be considerable. MAN Diesel and Turbos absolute commitment to reducing emissions while in creasing fuel effi ciency and power density starts with our active partnership in the emissions law making process and ends with the delivery of turbochargers and thermal efficiency systems that achieve an ideal synthesis of product characteristics.

TCS-PTG Savings with extra power

TES Thermal Efficiency Systems A proven method of increasing efficiency in 2-stroke diesel power systems

Power Turbine & Gear (PTG) Cross Section

TCS-PTG Components
Generator Coupling Gear Box Power Turbine Control Flaps

+ Control cabinet + Software

The Turbocharger Business Unit of MAN Diesel & Turbo has launched an updated product in its TES range of proven efficiency-enhancing solutions for 2-stroke engines in marine and stationary applications. With the TCS-PTG (Turbo Compound System with Power Turbine and Generator) up to 5% of additional power can be extracted from the main engine exhaust gases. Depending on the size of the MAN Diesel & Turbo engine involved, a maximum of 4,700 kW can be produced.

The additional power output from the TCS-PTG sys tem is in the form of 50 or 60 Hz electrical energy for the onboard power grid. The power turbine is in serted into the exhaust gas system parallel to the turbocharg ers. It drives an electrical generator via a reduction gearbox and receives up to 13% of the exhaust gas flow, diverted from the main engine exhaust gas receiver.

With this TCS-PTG stand alone solution in operation, auxiliary engine fuel, emissions and maintenance costs can be saved and generator set maintenance more flexibly planned and carried out with the ship underway! Furthermore the TCS-PTG reduces a ships Energy Efficiency Design Index (EEDI).

Used in combination with MAN Diesel & Turbo high efficiency turbochargers on the main engine, and depending on fuel oil prices, payback periods as short as 2 to 3 years can be achieved.

TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

Enjoy the Benefits

Technical data
TCS-PTG based on TCR TCS-PTG18 TCS-PTG20 TCS-PTG22 TCS-PTG based on TCA TCS-PTG55 Max. output Pel* 1,000 kW 1,400 kW 2,500 kW Max. output Pel* 3,700 kW

Extraction of exhaust gas to power turbine before turbochargers

Turbochargers Funnel (Boiler)

* The performace data vary to individual layout parameters. Available power based on typical 2-stroke-conditions with MAN Diesel & Turbo high efficiency TCA turbochargers on the main engine (Turbine = 3.9; TEG = 490 C).

Generator Components
Exhaust gas turbine Newly developed high efficiency turbine New turbine nozzle ring with extended lifetime Bearing arrangement with long lifetime Axial: based on most modern TCA series Radial: based on most modern TCR series Gearbox High efficiency high speed gearbox reducing turbine speed to generator speed Couplings Gearbox to generator: high flexible coupling Generator Synchronous generator Exhaust gas system Control valves for power turbine operating range Fast acting emergency valves for emergency shutdown Control and safety equipment
64.0 68.0
Enlarge gap for maximum power!

Coupling

Exhaust gas receiver

Main engine

Board grid

Gearbox

Exhaust gas turbine

Maximum power output with MAN Diesel & Turbo TCA high efficient turbochargers on the main engine and TCA/TCR based power turbine
Turbocharger Efficiency B&W def Engine Load in % 70.0 80.0

50.0

60.0

90.0

100.0

72.0

Max. Turbocharger Efficiency

Optional: Variable Turbine Area (VTA) for exhaust gas turbine Increasing efficiency and flexibility of operation
Min. Charging Efficiency 60.5%

TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

Estimation of Fuel Oil Saving Potential of TCS-PTG Units

TCS-PTG-systems offer enormous savings potential in 2-stroke engine applications. By generating addi tional power output, both fuel oil costs and CO emis sions can be reduced at the auxiliary engines. For stationary appli cations additional power can be generated which can be supplied directly to the grid. For estimating the saving potential of these systems, diagrams 1 to 3 (based on ISO ambient reference conditions) help to quantify the advantages for an individual application case. Diagrams and estimates are based on the use of high efficiency TCA turbochargers on the main engine. The layout of such a turbo compound system must be custom designed to take account of variables like exhaust gas pressure, temperature and mass flow. In this way each individual system may vary in terms of performance.

Example 12S90ME-C9.2 with 3 x TCA88 turbochargers on a container vessel

1  With main engine output at SMCR, exhaust gas pressure ratio and temperature known, the potential of an applicable TCS-PTG system can be estimated. For this example a 12S90ME-C9.2 with 69,720 kW at 84 rpm at SMCR is chosen. Suitable application for this engine is a TCS-PTG22 with a power output of 2,700 kW electrical. The TCS-PTG is optimised for 85% SMCR and max. TCS-PTG output is calculated as 4% of engine output: 4% x 85% x 69,720 kW = 2,370 kW. 2  Estimation of an appropriate load profile is done with help of diagrams 1 & 2. 3 Calculation of average TCS-PTG power output: a  TCS-PTG load is dependent on main engine load (diagram 1). By combining the TCS-PTG load points from diagram 2 with main engine load profile

from diagram 1 the average TCS-PTG load is obtained as a percentage value:

Readings out of Diagram 1 & 2
1 10% of OH at 100% load 2 80% of OH at 85% load 3 10% of OH < 50% load

Conclusions
In stationary applications additional power output can be gained equivalent to nearly 100% of TCS-PTG related load. For marine applications a TCS-PTG offers the following advantages:

90% TCS-PTG power output 100% TCS-PTG power output 0% TCS-PTG power output

b  Average TCS-PTG output is calculated as the following:

10% x 90% + 80% x 100% + 10% x 0% 100% = 89.0 %

High fuel oil saving potential on auxiliary engines n  Reduced running hours and thus reduced main
n

tenance of auxiliary engines

n n

Reduction of emissions Reduction of a ships Energy Efficiency Design

Index (EEDI) Average TCS-PTG load is 89.0% Average TCS-PTG power output is 2.1 MW 4  Assuming 6,000 OH and above TCS-PTG average power output, approximately 2,100 tons of fuel oil can be saved per year at the auxiliary engines (diagram 3). 5  Taking the current fuel prices in to account, annual cost savings can be estimated.
Please note: Main engines fuel consumption might increase between 0.0-1.8%, depending on the application and turbocharger efficiency. Also exhaust gas temperature will rise.

Save your money and save your environment with MAN Diesel & Turbo TCS-PTG systems. Economically and ecologically optimized vessels.

Make your vessel an ECO-Vessel.

1 Load profile example

Engine power output / % of SMCR 0 10 20 30 40 50 60 70 80 90 100 Engine load profile / % of operating hours (OH)

2 TCS-PTG load in relation to main engine load

TCS-PTG power output / % 0 10 20 30 40 3 50 60 70 85 2 100 1 Main engine power output / %

3 Fuel oil savings in relation to operating hours

Fuel oil savings / tons per year
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Payback time vs. average engine load

Average engine load / % Payback time
60 70 80 90 100

Average TCS-PTG power output / MW

100 90 80 70 60 50 40 30 20 10
Main engine load profile
TCS-PTG shut down below 50% engine load
10% 80% 10%

100 90 80 70 60 50 40 30 20 10

7,000 6,000 5,000 4,000 3,000 2,000 1,000

Calculation auxiliary engine fuel oil savings related to TCS-PTG power output 2.1 MW

Savings: ~2,100 t/y

Main engine operating hours (OH) per year

TCS-PTG shut down below 50% engine load

7,000 OH

6,000 OH

5,000 OH

TCS-PTG power output related to main engine power output

TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

Utilisation of TCS-PTG Within Ship Power System

TCS-PTG Output Versus Main- and Auxiliary Engine Output and Ship Power Demand

Main Engine: 12S90ME-C9.2 / SMCR: 69,720 kW

Case 1: Power demand base load = 2,750 kW
~ 1,850 kW

Ship Power Required Genset-Output

TCS-PTG Max Output At least 30% of max. genset output TCS-PTGoutput has to be reduced to allow genset run at 30% load

Electric Consumption

~ 900 kW

2,750 kW

When theoretical TCS-PTGoutput is at least 120% of power required (having 20% as buffer), the genset can be shut down

Power Management System

TCS-PTG Theoretical Output 20% Buffer Base load: 2,750 kW

TCS-PTG22 1,850 kW ~ 78% (Max: 2,370 kW at 85% MCR)

900 kW ~ 30%
6L32/40 3,000 kW

TCS-PTGStart

TCS-PTG-Output
100% Engine Load

Genset shut down

85% Engine Load 50% Engine Load Engine Start

Main Engine Load

90% MCR 85% MCR 75% MCR 65% MCR 50% MCR

Genset off
7L32/40 3,500 kW

Genset off
7L32/40 3,500 kW

Genset off
7L32/40 3,500 kW

The Power Management System maximizes the TCS-PTG output within the frame conditions set by main engine output and ship power demand.

Case 2: Power demand with 1,000 reefer containers = 7,250 kW

~ 2,370 kW Electric Consumption ~ 4,880 kW

Integration of TCS-PTG in Power Management System

Ship Power Required
7,250 kW
1,000 reefers: 4,500 kW

7,250 kW

Power Management System

TCS-PTG can deliver at least 120% of the required power

No

Genset at minimal load (30%) + TCS-PTG can deliver rest?

No

TCS-PTG22 2,370 kW ~ 85%

Base load: 2,750 kW

2,250 kW 75%
6L32/40 3,000 kW

Yes
TCS-PTG only Genset off

Yes
Genset = 30% of genset max. load TCS-PTG = rest TCS-PTG = max. output Genset = rest (> 30%)

90% MCR 85% MCR 75% MCR 65% MCR 50% MCR

2,630 kW 75%
7L32/40 3,500 kW

Genset off
7L32/40 3,500 kW

Genset off
7L32/40 3,500 kW

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TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

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Schematic of the Valve System

Scope of Supply

Exhaust gas receiver

Funnel

One complete TCS-PTG unit includes following items:

n

Exhaust gas driven power turbine including:

EE

Speed pick-up Speed indicating instrument Turbine cleaning device

n

Gearbox Coupling PTG-generator Synchronous generator Mounting of turbine, gearbox and generator

n BP n 3 4 n

on base frame
n

Control and safety equipment consisting of:

Control valves Emergency valves TCS-PTG-control cabinet incl. TCS-PTG-software Generator control cabinet
1 2 n

Thermodynamic layout

EE 1 2 BP 3 4

Exhaust gas extraction Valve Valve Bypass Valve Orifice

Exhaust gas diverted before turbochargers Control valve power turbine Quick closing valve Bypass dispensable exhaust gas Exhaust gas bypass control valve Orifice simulates p of power turbine in shut down cases above 50% engine load

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TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

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World Class Service Around the clock

PrimeServ Peace of mind for life

Customer support for turbochargers is vital MAN Diesel & Turbo provides a worldwide service network for repairs and maintenance. A fast delivery of spare parts is of utmost importance to avoid down times. MAN Diesel & Turbo has an effi cient pro cessing and stock dispatch system allowing parts to be delivered within 24 hours. Continuous training of engineers, combined with regular service bulletins and video clips ensures the worldwide service network is always up to date. A customer feedback program also contributes to maintaining a high standard of service. Close coordination with all licensees ensures that products built under license are fully covered by our global network.

Enjoy the benefits

n

Knowledgeable partners in more than 150 service A one stop service for turbochargers, diesel and Around the clock after sales service  Largest turbocharger license net with full exchangeability of spare parts

stations worldwide
n

gas engines
n n

 A high availability of spare parts through an intelligent central stocking system

Attractive price/performance ratio

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TCS-PTG Savings with extra power

All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions. CopyrightMAN Diesel & Turbo. D2366459EN-N2 Printed in Germany GMC-AUG-0712xx

MAN Diesel & Turbo 86224 Augsburg, Germany Phone +49 821 322-0 Fax +49 821 322-3382 info-de@mandieselturbo.com www.mandieselturbo.com

MAN Diesel & Turbo a member of the MAN Group