Diesel Customer Information No.

298

Action Code:
When Convenient

General information Upgrade Products

MAN PrimeServ is known for its reliable service network for Possibilities and advantages
two- and four-stroke Diesel engines. Our PrimeServ Centers
and service partners provide after sales service for MAN
Diesel & Turbo engines worldwide. DCI / 298 - August 2010

Besides spare parts and technical service, MAN PrimeServ is Concerns

committed to offer modern technologies to already existing MAN Diesel & Turbo four-stroke
engine applications, so called “upgrade products”. Our engines 32/40, 40/54, 48/60, 58/64
upgrade program offers the opportunity to benefit from the
latest technological developments, even with old established Summary
engine types. Options for upgrade and retrofit regarding
various technologies
The upgrade program can be divided into dual-fuel
conversions, environmental technologies, modern engine Filing Advice
control and safety equipment as well as other products. Operating Instructions, Chapter 1

Dual Fuel upgrade of 48/60 to 51/60DF and 32/40

to 32/40DF
Our modern 51/60DF (dual-fuel) engine type is designed for
reliable operation with gaseous and liquid fuels. This engine
type allows the possibility to switch over immediately from gas
to Diesel operation and vice versa without power loss at
engine loads above 15 %.

Based on this engine type we offer upgrades from 48/60A

and 48/60B type engines to 51/60DF. With this upgrade you
can benefit from the environmental and economical
advantages to run your engines on gaseous fuels with almost
the same power output as before with liquid fuels.

MAN Diesel & Turbo SE PrimeServ PrimeServ PrimeServ

Head office (& postal address)
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 0
Fax: +49 (0) 821 322 3382
mandiesel-de@mandieselturbo.com
www.mandieselturbo.com
After Sales Augsburg
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 3509
Fax: +49 (0) 821 322 1530
primeserv-aug@mandieselturbo.com
After Sales Technical After Sales Commercial
Stadtbachstraße 1 Stadtbachstraße 1
86153 Augsburg 86153 Augsburg
Germany Germany
Phone: +49 (0) 821 322 1499 (24-h-hotline) Phone: +49 (0) 821 322 1799 (24-h-hotline)
Fax: +49 (0) 821 322 3838 Fax: +49 (0) 821 322 3574
primeserv-aug-technical@mandieselturbo.com primeserv-aug-commercial@mandieselturbo.com
MAN Diesel & Turbo – a member of the MAN Group
DCI / No. 298 - August 2010

When operating on gaseous fuels the 51/60DF engine uses a mixture of 99 % gas ignited by 1 % MDO pilot fuel.
This technology is applicable for stationary and marine engines. The conversion involves a change of the engine
bore from 480 mm to 510 mm, new cylinder liners and pistons, special 51/60DF cylinder heads, gas supply and
injection systems, common-rail pilot-fuel injection and engine automation.

For the 32/40 type engine we offer a suitable upgrade solution to 32/40DF in order to benefit from the dual-fuel
advantages as well. This upgrade is currently only available for stationary applications.

Environmental Technologies for NOx Reduction

In recent years, global and local regulations covering exhaust gas emissions from Diesel engines have become
progressively more stringent. They cover all applications on land and at sea. In particular emissions of NOx have
become a major issue. Besides the worldwide IMO legislation there are regional regulations which reward every kg
of NOx not emitted. Operators have an incentive to adopt NOx reduction systems on their plants.

MAN PrimeServ offers a variety of NOx reduction technologies. Recently we have informed you in Diesel Customer
Information 286 about engine internal measures incorporated in two upgrade kits for 32/40 type engines which
lower NOx emissions. Following we present more retrofit solutions.

Selective Catalytic Reduction (SCR)

SCR is a well proven exhaust gas after treatment using a reducing agent to transform harmful NOx to nitrogen (N2).
This after treatment technology currently provides the highest potential for NOx reduction. Depending on the
engine load a reduction of more than 85 % is possible. MAN PrimeServ offers SCR systems for its full product
range of four-stroke Diesel engines. This upgrade even complies with the upcoming IMO Tier 3 NOx emission level
in 2016.

Fuel Water Emulsion (FWE)

The FWE technique is an engine internal measure to reduce NOx. Fresh water is mixed to fuel in order to form an
emulsion suitable for injection into the combustion chamber. In the case of heavy fuel oil, up to 20 % water can be
emulsified into the fuel resulting in a reduction of NOx of approximately 20 %. The water introduced into the
combustion chamber reduces the temperature level during the combustion process leading to reduced NOx
formation.The FWE system benefits from low investment and operation costs in comparison to the SCR system.

Diesel Customer Information »Upgrade Products« - Page 2 of 4

DCI / No. 298 - August 2010

MGO / MDO Operation Upgrades

In the course of environmental improvements in European ports, the EU Directive 2005/33EC was introduced on
the 1st of January 2010. By this Directive SOx emissions shall be significantly reduced. Ships at berth in EU
harbours are forced to be operated on distillate fuel with a sulphur content of less than 0.1 % sulphur. California
has established a comparable legislation within a 24 miles zone from coastline for diesel-electric engines. It is
foreseeable that other countries worldwide will issue similar rules.

Generally MAN Diesel & Turbo medium-speed engines can be operated on distillate fuels (MGO, MDO), if a few
technical issues are verified. Depending on the engine type the following items can be required to run HFO
designed engines on distillates: lubrication of inlet valve seat rings, sealing oil at fuel pumps, switched-off nozzle
cooling water system and mostly an additional fuel cooler in the fuel system.

MAN PrimeServ Augsburg is looking forward to prepare an individual quotation for your engines. Detailed
information regarding this issue is provided in Diesel Customer Information 295.

Engine Control and Safety Equipment

Governors

The requirements for engines and their control systems are becoming increasingly demanding. Modern speed
governors, fitted with digital control systems, are providing a wealth of advantages in comparison to the analogue
or mechanical governors. Considerable improvements can be achieved in regard to start behaviour, engine
smoothness, soot development on start-up, synchronization, parallel operation, communication with automation
systems and maintenance.

To adapt older engines accordingly, we offer a Speed Governor Upgrade comprising of a modern digital control
system with customised software, which replaces the existing governor (e.g. hydraulic governor). In principle most
analogue or mechanical governors can be upgraded. Detailed information regarding this upgrade are provided in
Diesel Customer Information 240.

Electronic Control Upgrades

Electronic engine control systems are continuously developing. The demand for more functions and better
performance of the control system is increasing. As the product cycles of electronic equipment are getting shorter,
the maintenance and spare part supply for older electronics becomes more difficult.

Diesel Customer Information »Upgrade Products« - Page 3 of 4

DCI / No. 298 - August 2010

Based on this situation we offer Electronic Control Upgrades individually engineered for each customer. The
advantages of such an upgrade are that older plants can be operated with high reliability through the incorporation
of state of the art of controlling and monitoring systems.

Splash Oil Monitoring System

One of our most recommended safety features on Diesel engines is the Splash Oil Monitoring System. This system
monitors the current lubricating oil temperature of the connecting rod big end bearing for each cylinder unit. In the
case where a defined maximum values is exceeded the system triggers an alarm and the engine is automatically
stopped.

The advantage is that this system detects mechanical failures of connecting rod bearings much faster compared to
well known safety systems like oil mist detectors. It can considerably restrict the extent and consequences of a
mechanical failure. Due to the positive experience we have gained since 1999, we have applied the system to our
standard engine safety equipment for our modern four-stroke engines with full acceptance of classification
companies. The Splash Oil Monitoring System can easily be retrofitted to all kind of Diesel engines, even to those
of other manufacturers. Detailed information is provided in Diesel Customer Information 175.

Should you be interested in more information regarding MAN Diesel & Turbo Upgrade products we ask you to
kindly contact us, so we can be of assistance, independent of general questions, detailed planning of a project or
a quotation.

Contact
Should you have any queries, our Technical Service will be pleased to be of assistance:

MAN Diesel & Turbo SE

86224 Augsburg
Tel.: +49 (0) 821 322-3344
Fax: +49 (0) 821 322-3838
E-mail: primeserv-aug-technical@mandieselturbo.com

Robert Glauber Jörn Holst

Senior Vice President Senior Manager
After Sales After Sales Technical

Please forward this information to your technical operational personnel and

remember to inform us of the current operating hours of your MAN Diesel & Turbo engines.

Diesel Customer Information »Upgrade Products« - Page 4 of 4