TCS-PTG Savings with extra power
TES Thermal Efficiency Systems A proven method o increasing efciency in 2-stroke diesel power systems
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 system is in the form of 50 or 60 Hz electrical energy for the onboard po wer grid. The power turbine is inserted into the exhaust gas system parallel to the turbochargers. 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!
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
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Enjoy the Benefits
Technical data TCS-PTG based on TCR
Max. output Pel*
TCS-PTG18
850 kW
TCS-PTG20
1,250 kW
TCS-PTG22
2,200 kW
TCS-PTG based on TCA
Max. output Pel*
TCS-PTG55
3,300 kW
TCS-PTG66
4,700 kW
* The perormace data vary to individual layout parameters. Available power based on typical 2-stroke-conditions with MAN Diesel & Turbo high efciency TCA turbochargers on the main engine (∏ Turbine = 3.3; T EG = 450 °C).
Components Exhaust gas turbine
Newly developed high eiciency turbine New turbine nozzle ring with extended lie time Bearing arrangement with long lie time Axial: based on most modern TCA series Radial: based on most modern TCR series
Gearbox
High eiciency high speed gearbox reducing turbine speed to generator speed
Couplings
Gearbox to generator: high lexible coupling
Generator
Synchronous generator suited to marine applications Asynchronous generator suited to stationary applications
Exhaust gas system
Control valves or power turbine operating range Fast acting emergency valves or emergency shutdown Control and satey equipment
Optional: Variable Turbine Area (VTA) or exhaust gas t urbine
Increasing eiciency and lexibility o operation
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TCS-PTG – Savings with extra power
Extraction of exhaust gas to power turbine before turbochargers.
Turbochargers
Funnel (Boiler)
Generator
Coupling
Exhaust Exhaust gas receiver
Main engine
Board grid
Gearbox
gas turbine
Maximum power output with MAN Diesel & Turbo TCA high eicient turbochargers on the main engine and TCA/TCR based power turbine Turbocharger Efciency B&W de
50.0
60.0
Engine Load in % 70.0 80.0
90.0
100.0
Max. Turbocharger Efciency
72.0
68.0
Enlarge gap or maximum power!
64.0 Min. Charging Efciency 60.5%
TCS-PTG – Savings with extra power
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Estimation of Fuel Oil Saving Potential of TCS-PTG Units
TCS-PTG-systems oer enormous saving potentials in
Example – 12K98ME7 with 3x TCA88 turbochargers
2-stroke engine applications. By generating additional
on a container vessel
power output, both uel oil costs and CO emissions ² can be reduced at the auxiliary engines. For stationary
1 With main engine output at SMCR, exhaust gas
applications additional power can be generated which
tial o an applicable TCS-PTG system can be esti-
can be supplied directly to the grid. For estimating the
mated. For this example a 12K98ME7 with 74,760
saving potential o these systems, diagrams 1 to 3
kW at 97 rpm at SMCR is chosen. Best application
based on ISO ambient reerence conditions) help to
or this engine is a TCS-PTG55 with a power output
quantiy the advantages or an individual application
o 3,150 kW electrical.
pressure ratio and temperature known, the poten-
case. 2 Estimation o an appropriate load proile is done
Diagrams and estimates are based on the use o high
with help o diagrams 1 & 2.
eiciency TCA turbochargers on the main engine. The layout o such a turbo compound system must
3 Calculation o average TCS-PTG power output:
be custom designed to take account o variables like exhaust gas pressure, temperature and mass low. In
a TCS-PTG load is dependent on main engine load (dia-
this way each individual system may vary in terms o
gram 1). By combining the TCS-PTG load points rom
perormance.
diagram 2 with main engine load proile rom diagram 1 the average TCS-PTG load is obtained as a percentage value:
1 Load proile example
2 TCS-PTG load in relation to main engine load
Engine power
TCS-PTG
Engine load proile / % o operating hours (OH)
output / % o SMCR
power 0
10
20
30
40
50
60
70
80
90 100
output / %
100
100
90
90
80
Main engine power output / %
10%
80%
10%
10
20
30
40
50
60
70
79
70
70
60
60
50
0
50 TCS-PTG shut down below 50% engine load
40 Main engine load profle
30 20 10
TCS-PTG shut down below 50% engine load
TCS-PTG power output related to main engine power output
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TCS-PTG – Savings with extra power
85
100
Readings out o Diagram 1 & 2
Conclusions
10% o OH at 100% load
100% TCS-PTG power output
In stationary applications additional power output can
80% o OH at 85% load
79% TCS-PTG power output
be gained equivalent to nearly 100% o TCS-PTG re-
10% o OH < 50% load
0% TCS-PTG power output
b Average TCS-PTG output is calculated as the ollowing:
lated load. For marine applications a TCS-PTG oers ollowing advantages:
10 % x 100 % + 80 % x 79 % + 10 % x 0 %
n
High uel oil saving potential on auxiliary engines
n
Reducing running hours and thus maintenance o
= 73.2 %
100 %
auxiliary engines Average TCS-PTG load is 73.2%
n
Reduction o emissions
Average TCS-PTG power output is 2.3 MW Save your money and save your environment with 4 Assuming 6,000 OH and above TCS-PTG average
power output, approximately 2,800 tons o uel oil
MAN Diesel & Turbo TCS-PTG systems. Economically and ecologically optimized vessels.
can be saved per year at the auxiliary engines (dia-
Make your vessel an “ECO-Vessel”.
gram 3). 5 Taking the current uel prices in to account, annual
cost savings can be estimated.
3 Fuel oil savings i n relation to operating hours Fuel oil
Payback time vs. average engine load
Average TCS-PTG power output / MW
Average engine load / %
savings / tons per year
7,000
Please note: Main engines uel consumption might increase between 0.0-1.8%, depending on the application and turbocharger eiciency. Also exhaust gas temperature will rise.
Payback 0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
time
60
70
80
90
100
Calculation auxialiary engine uel oil savings related to TCS-PTG power output 2.3 MW
6,000 5,000 4,000 3,000
Savings: ~2,800 t/y
2,000 1,000 Main engine operating hours (OH) per year 7,000 OH
6,000 OH
5,000 OH
TCS-PTG – Savings with extra power
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Schematic of the Valve System
Exhaust gas
Funnel
receiver
EE
BP
2
3
1
08
EE
Exhaust gas extraction
1
Valves
BP
Bypass
2
Valves
Control and emergency valve bypass
3
Oriice
Oriice simulates Δp o power turbine in shut down cases above 50% engine load
TCS-PTG – Savings with extra power
Exhaust gas diverted beore turbochargers Control and emergency valve power turbine Bypass dispensable exhaust gas
Scope of Supply
One complete TCS-PTG unit includes following items: 1 Exhaust gas driven power turbine including:
Speed pick-up Speed indicating instrument Turbine cleaning devi ce Operating manuals Set o tools
2 Gearbox
3 Coupling PTG-generator
4 Synchronous or asynchronous generator
5 Mounting o turbine, gearbox and generator on base rame
6 Control and saety equipment consisting o:
Control valves Emergency valves TCS-PTG-control cabinet incl. TCS-PTG-sotware
7 Thermodynamic layout
TCS-PTG – Savings with extra power
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World Class Service Around the clock
PrimeServ – Peace of mind for life
Enjoy the benefits
Customer support or turbochargers is vital – MAN
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Diesel & Turbo provides a worldwide service network or repairs and maintenance.
Knowledgeable partners in more than 150 service stations worldwide
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A one stop service or turbochargers, diesel and gas engines
A ast delivery o spare parts is o utmost importance
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to avoid down times. MAN Diesel & Turbo has an ei-
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cient processing and stock despatch system allowing parts to be delivered within 24 hours.
Around the clock ater sales service Largest turbocharger ‘license net’ with ull exchangeability o spare parts
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A high availability o spare parts through an intelligent central stocking system
Continuous training o engineers, combined with regular service bulletins and video clips ensures the worldwide service network is always up to date. A customer eedback programme also contributes to maintaining a high standard o service. Close co-ordination with all licensees ensures that ‘products built under licence’ are ully covered by our global network.
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TCS-PTG – Savings with extra power
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Attractive price/perormance ratio
C o p y r i g h t © M A N D i e s e l & T u r b o • S u b j e c t t o m o d i f c a t i o n i n t h e i n t e r e s t o t e c h n i c a l p r o g r e s s . • D 2 3 6 6 3 5 0 E N -N 1 P r i n t e d i n G e r m a n y M C 0 4 1 0 2
MAN Diesel & Turbo
86224 Augsburg, Germany Phone +49 821 322-0 Fax
+49 821 322-3382
[email protected] www.mandieselturbo.com
