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 efficiency 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 & Tur-

The additional power output from the TCS-PTG sys

With this TCS-PTG stand alone solution in operati-

Used in combination with MAN Diesel & Turbo high

bo has launched an updated product in its TES range

tem is in the form of 50 or 60 Hz electrical energy

on, auxiliary engine fuel, emissions and maintenance

efficiency turbochargers on the main engine, and de-

of proven efficiency-enhancing solutions for 2-stroke

for the onboard power grid. The power turbine is

costs can be saved and generator set maintenance

pending on fuel oil prices, payback periods as short

engines in marine and stationary applications.

inserted into the exhaust gas system parallel to the

more flexibly planned and carried out with the ship

as 2 to 3 years can be achieved.

turbochargers.

underway!

Power Turbine and Generator) up to 5% of additional

It drives an electrical generator via a reduction gear-

Furthermore the TCS-PTG reduces a ships Energy

power can be extracted from the main engine exhaust

box and receives up to 13% of the exhaust gas flow,

Efficiency Design Index (EEDI).

gases. Depending on the size of the MAN Diesel &

diverted from the main engine exhaust gas receiver.

With the TCS-PTG (Turbo Compound System with

Turbo engine involved, a maximum of 4,700 kW can

be produced.

TCS-PTG Savings with extra power

TCS-PTG Savings with extra power

Enjoy the Benefits

Extraction of exhaust gas to power turbine before turbochargers

Technical data
TCS-PTG based on TCR

Max. output Pel*

TCS-PTG18

1,000 kW

TCS-PTG20

1,400 kW

TCS-PTG22

2,500 kW

TCS-PTG based on TCA

Turbochargers

Funnel (Boiler)

Max. output Pel*

TCS-PTG55

3,700 kW

*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

Coupling

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

Exhaust gas receiver

Main engine

Board grid

Gearbox

Exhaust
gas turbine

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

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

50.0

60.0

Engine Load in %
70.0
80.0

90.0

100.0

Max. Turbocharger Efficiency

72.0

Control valves for power turbine operating range

Fast acting emergency valves for emergency shutdown

68.0

Control and safety equipment

Enlarge gap for

maximum power!

64.0

Optional: Variable Turbine Area (VTA) for exhaust gas turbine

Increasing efficiency and flexibility of operation

TCS-PTG Savings with extra power

Min. Charging Efficiency 60.5%

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

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

from diagram 1 the average TCS-PTG load is ob-

Conclusions

tained as a percentage value:

In stationary applications additional power output can

1 W ith main engine output at SMCR, exhaust gas

pressure ratio and temperature known, the po-

be gained equivalent to nearly 100% of TCS-PTG reReadings out of Diagram 1 & 2

lated load.

stationary applications additional power can be gene-

tential of an applicable TCS-PTG system can be

1 10% of OH at 100% load

rated which can be supplied directly to the grid. For

estimated. For this example a 12S90ME-C9.2 with

2 80% of OH at 85% load

100% TCS-PTG power output

estimating the saving potential of these systems, dia-

69,720 kW at 84 rpm at SMCR is chosen. Suitable

3 10% of OH < 50% load

0% TCS-PTG power output

grams 1 to 3 (based on ISO ambient reference condi-

application for this engine is a TCS-PTG22 with a

tions) help to quantify the advantages for an individual

power output of 2,700 kW electrical. The TCS-PTG

application case.

is optimised for 85% SMCR and max. TCS-PTG

output is calculated as 4% of engine output: 4% x

Diagrams and estimates are based on the use of high

90% TCS-PTG power output

custom designed to take account of variables like ex-

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

= 89.0 %

100%

85% x 69,720 kW = 2,370 kW.

with help of diagrams 1 & 2.

Reduction of emissions
Reduction of a ships Energy Efficiency Design

Average TCS-PTG load is 89.0%

Save your money and save your environment with

Average TCS-PTG power output is 2.1 MW

MAN Diesel & Turbo TCS-PTG systems. Economically

3 Calculation of average TCS-PTG power output:

4 
Assuming 6,000 OH and above TCS-PTG average

and ecologically optimized vessels.

power output, approximately 2,100 tons of fuel oil

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

can be saved per year at the auxiliary engines (dia5 

Taking the current fuel prices in to account, annual

1 Load profile example

2 TCS-PTG load in relation to main engine load

3 Fuel oil savings in relation to operating hours

Engine power

TCS-PTG

Fuel oil

Engine load profile / % of operating hours (OH)

output /

Main engine power output / %

power
0

10

20

30

40

50

60

70

80

90

100

output / %

20

30

40

50

60

70

85

100

per year

100

100

7,000

90

90

6,000

80

80

5,000

70

70

4,000

60

60

3,000

50

2,000

40

1,000

10%

80%

50
40

TCS-PTG shut down below 50% engine load

10%

30

30

20

20

10

10

Main engine load profile

TCS-PTG Savings with extra power

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.

Payback time vs. average engine load

Average TCS-PTG power output / MW

Average engine load / %

savings / tons
0 10

Make your vessel an ECO-Vessel.

gram 3).
cost savings can be estimated.

Index (EEDI)
2 Estimation of an appropriate load profile is done

performance.

% of SMCR

High fuel oil saving potential on auxiliary engines

n 
Reduced running hours and thus reduced main
tenance of auxiliary engines

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

haust gas pressure, temperature and mass flow. In

this way each individual system may vary in terms of

ing advantages:
n

efficiency TCA turbochargers on the main engine. The

layout of such a turbo compound system must be

For marine applications a TCS-PTG offers the follow-

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 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

Utilisation of TCS-PTG Within Ship Power

System

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

TCS-PTG Output Versus Main- and Auxiliary Engine Output

and Ship Power Demand

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

Ship Power
Required
Genset-Output

At least 30%
of max. genset
output

TCS-PTG Max
Output

TCS-PTGStart

Power Management
System

When theoretical TCS-PTGoutput is at least 120% of

power required (having 20%
as buffer), the genset can
be shut down

20% Buffer

Genset
shut down

TCS-PTG-Output
100% Engine Load

85% Engine Load

50% Engine Load

~ 900 kW

2,750 kW

TCS-PTG Theoretical Output

TCS-PTGoutput has to be
reduced to allow
genset run at
30% load

Electric
Consumption

Main Engine Load

Base load: 2,750 kW

900 kW ~ 30%

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

6L32/40 3,000 kW

Genset off

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

7L32/40 3,500 kW

Genset off
7L32/40 3,500 kW

Genset off

Engine Start

7L32/40 3,500 kW

The Power Management System maximizes the TCS-PTG output within the

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

frame conditions set by main engine output and ship power demand.

~ 2,370 kW

Integration of TCS-PTG in Power Management System

7,250 kW

Yes

10

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

TCS-PTG22
2,370 kW ~ 85%

No

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

Base load: 2,750 kW

Yes

TCS-PTG only

Genset = 30% of
genset max. load

TCS-PTG =
max. output

Genset off

TCS-PTG = rest

Genset = rest (> 30%)

TCS-PTG Savings with extra power

Power Management
System

1,000 reefers: 4,500 kW

No

~ 4,880 kW

7,250 kW

Ship Power
Required

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

Electric
Consumption

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

TCS-PTG Savings with extra power

11

Schematic of the Valve System

Exhaust gas
receiver

Scope of Supply

One complete TCS-PTG unit includes

following items:

Funnel

Exhaust gas driven power turbine including:

Speed pick-up
Speed indicating instrument
Turbine cleaning device

EE

Gearbox

Coupling PTG-generator

Synchronous generator

Mounting of turbine, gearbox and generator

BP

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

12

Exhaust gas diverted before turbochargers

EE

Exhaust gas extraction

Valve

Control valve power turbine

Valve

Quick closing valve

BP

Bypass

Bypass dispensable exhaust gas

Valve

Exhaust gas bypass control valve

Orifice

TCS-PTG Savings with extra power

Thermodynamic layout

Orifice simulates p of power turbine in shut down

cases above 50% engine load

TCS-PTG Savings with extra power

13

World Class Service

Around the clock

PrimeServ Peace of mind for life

Enjoy the benefits

Customer support for turbochargers is vital MAN

Diesel & Turbo provides a worldwide service network

stations worldwide

for repairs and maintenance.

Knowledgeable partners in more than 150 service

A one stop service for turbochargers, diesel and

gas engines
A fast delivery of spare parts is of utmost importance

to avoid down times. MAN Diesel & Turbo has an effi

Around the clock after sales service


Largest turbocharger license net with full ex-

parts to be delivered within 24 hours.


A high availability of spare parts through an intel-

Continuous training of engineers, combined with regu-

Attractive price/performance ratio

changeability of spare parts

cient processing and stock dispatch system allowing

ligent central stocking system

lar 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.

14

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-N3 Printed in Germany GMC-AUG-08122

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