Exhaust Gas

Turbochargers
Programme 2011

Contents

Turbocharger Applications

The TCR Series

The NR/S Series

The NR/R Series

13

The TCA Series

17

The NA/S/T9 Series

21

The (TCS-) PTG Power Turbine Series

25

The Variable Turbine Area (VTA)

29

The TCX Series

33

Turbocharger Applications
Turbochargers type TCR, NR, TCA and NA
Straightforward design
Uncooled gas casings
In-board plain bearing arrangement
Lubrication by engine lube oil system
High availability, reliability, durability
High efficiency
Easy maintenance and servicing
Long lifetimes of components
Long intervals between overhauls

Applications for
Propulsion engines
Generating engines
Traction engines
Suitable for HFO, MDO and gas
engines

Special equipment
Tailormade solutions
Power turbines
Turbo compound systems
Variable Turbine Area (VTA)

MAN Diesel & Turbo TCR, NR, TCA and NA turbocharger programme
TCA44-2
TCR10

TCA55-2
TCA66-2

TCR12

TCA77-2

TCR14

TCA88-2

TCR16
TCR18
TCR20

TCR22

TCA33-4

NR12/S

TCA44-4

NR14/S

TCA55-4
TCA66-4

NR17/S

TCA77-4

NR 20/S

TCA88-4

NR24/S
NR29/S
NA29/S

NR34/S

NA34/S

NR15/R

NA40/S

NR20/R

NA48/S

NR24/R

NA57/T9
NA70/T9

NR26/R

1000

2000

3000

4000

5000

6000 6700

10000

20000

30000

Engine output per turbocharger (kW)

The TCR Series

The TCR Series

Benefits
Ultimate performance
Easy maintenance
Increased lifetime of wear parts
Simple installation
Extended application range
High power density, low weight
and compact design
Containment proven

Features
Overall completely new design

Turbine
New CFD optimised profiled rotor
blades, nozzle ring, inlet and outlet
casing for increased efficiency
Constant and pulse pressure
turbocharging
Optional variable nozzle ring

6.0

Compressor pressure ratio

C tot

MAN Turbocharger application ranges TCR

5.5
5.0
4.5

TCR10-42

TCR12-42 TCR14-42

TCR16-42

TCR10-41 TCR12-41 TCR14-41

TCR18-42

TCR16-41

TCR20-42

TCR18-41
TCR18-2

TCR22-42

TCR20-41
TCR20-2

TCR22-41
TCR22-2
TCR22-25

4.0
3.5
3.0
1

6 7 8

10

15

Compressor volume flow VC tot (m3/s)

high pressure four-stroke version

standard four-stroke version

two-stroke version

Bearings
High performance plain bearings
for minimised mechanical losses
Optimised shaft diameter for
increased efficiency
Compact plain bearing concept for
best rotor dynamic performance
Compressor
New CFD optimised compressor
wheel, diffusor ring and compressor
volute for increased efficiency
Extended pressure ratio and
specific volume flow
Internal flow recirculation for
extended surge margin (option)
New compressor wheel fixation
for easy servicing

Easy maintenance
Extended inspection intervals
Easy access to compressor wheel
Reduced number of parts

Smart design for convenient

installation
Uncooled casings
Lubrication by engine lube oil system
Integrated oil inlet and oil drain for
pipeless design
No sealing air required
Others
Compliance with present and future
engine standards and environmental
legal restrains
Containment proven
Low moment of inertia for best
dynamic behaviour

The TCR Series

Technical data
Turbine type
Max. permissible temperature
Pressure ratio
Suitable for HFO, MDO, Gas

Radial flow turbine

700C
up to 5.4

Turbocharger programme
Turbocharger
Max. supercharged engine
type
output (kW)

TCR10
TCR12
TCR14
TCR16
TCR18
TCR20
TCR22

2-stroke

4-stroke

le* = 8 kg/kWh
2,400
3,500
6,200

le* = 6.5 kg/kWh

550
800
1,200
1,750
2,600
3,800
6,500

* Specific air consumption

Max. permissible
speed
(rpm)
85,000
70,900
58,700
48,800
40,300
33,400
25,600

Mass
(kg)
40
100
135
205
350
600
1,400

The NR/S Series

The NR/S Series

Features
Compact in dimensions, simple in
design, trouble free, long service life,
easy to operate, HFO compatible up
to IF-700
In-board bearings lubricated by
the engines lube oil system:
compressor side: axial thrust
bearing and radial floating bush;
turbine side: floating bearing bush;
lifetime of bearings more than
25,000 hours

Totally water-free design

Optimised flow components
Extended range of application
Pressure ratio of up to 4.5
High efficiency level
Ample margin to cope with

future diesel technology

requirements

Total pressure ratio

C tot

MAN Turbocharger application ranges NR/S

4.5
4.0

NR12/S

NR14/S

NR17/S

NR20/S

NR24/S

NR29/S

NR34/S

3.5
3.0
2.5
2.0

1.5

0.7 0.8 0.9 1

1.5

2.5

3.5 4 4.5 5

Intake volume flow VC tot (m3/s)

10

11

The NR/S Series

Technical data
Turbine type
Max. permissible temperature
Pressure ratio
Suitable for HFO, MDO, Gas
Turbocharger programme
Turbocharger
type
NR12/S
NR14/S
NR17/S
NR20/S
NR24/S
NR29/S
NR34/S

Max. supercharged
engine output (kW)
le* = 7 kg/kWh
670
950
1,350
1,870
2,690
3,820
5,400

Max. permissible
speed
(rpm)
75,000
64,000
52,600
44,700
37,300
31,300
26,300

(kg)
155
190
260
350
505
780
1,450

Length
(mm)
855
655
1,030
1,162
1,468
1,778
1,881

Width
(mm)
400
400
700
714
745
930
1,102

Height
(mm)
430
420
640
676
835
1,026
1,121

Overall dimensions
Turbocharger
type
NR12/S
NR14/S
NR17/S
NR20/S
NR24/S
NR29/S
NR34/S
* Specific air consumption

12

Radial flow turbine

650C (opt. 720C)
up to 4.5

Mass

The NR/R Series

13

The NR/R Series

Features
Compact in dimensions, simple in
design, trouble free, long service
life, easy to operate, HFO compatible
up to IF-700
Totally water-free design
In-board floating bearing arrange-
ment lubricated by the engines lube
oil system; lifetime of bearings more
than 25,000 hours

More than 30,000 units delivered

worldwide for diesel engines of
various applications and makes
High efficiency over a wide
operating range, resulting in low
fuel consumption and lower gas
temperatures; pressure ratio of
up to 4.0

MAN Turbocharger application ranges NR/R

NR15/R

Total pressure ratio

C tot

3.5

NR20/R

NR24/R

NR26/R

3.0
2.5

2.0

1.5

0.6

0.7 0.8 0.9 1

1.5

Intake volume VC tot (m3/s)

14

15

The NR/R Series

Technical data
Turbine type
Max. permissible temperature
Pressure ratio
Suitable for HFO, MDO, Gas
Turbocharger programme
Turbocharger
type
NR15/R
NR20/R
NR24/R
NR26/R

Max. supercharged
engine output (kW)
le* = 8 kg/kWh
800
1,400
2,000
2,700

Max. permissible
speed
(rpm)
57,000
44,000
36,000
31,500

Length
(mm)
714 722
899 957
860 1,110
1,023 1,308

Width
(mm)
500 520
660 690
695 765
800 820

Overall dimensions
Turbocharger
type
NR15/R
NR20/R
NR24/R
NR26/R
* Specific air consumption

16

Radial flow turbine

650C
up to 4.0

Mass
(kg)
200
400
550
800

Height
(mm)
520 670
705 730
735 740
780 850

The TCA Series

17

The TCA Series

Turbine
Newly developed, wide-chord
turbine blades without damping
wire for increased efficiencies
New turbine nozzle ring
New optimised turbine outlet
diffusor
New optimised turbine inlet casing
Variable Turbine Area VTA (option)

Bearings
Reduced shaft diameter for
minimised mechanical losses
High performance bearings for
minimised mechanical losses
Journal bearings for optimised
damping behaviour

Compressor
Newly developed compressor
wheel with reduced noise emission,
increased efficiency and optimisation
to the engines operating line
New compressor diffusor vanes
Newly developed compressor volute
Internal Recirculation IRC (option)

Compressor pressure ratio

C tot

MAN Turbocharger application ranges TCA

6.0
5.5
5.0

TCA33

TCA44

TCA55 TCA66 TCA77

TCA88

4.5
4.0
3.5

TCA44

TCA55 TCA66 TCA77 TCA88 TCA88-25

3.0
4

6 7 8 9 10

15

20

30

40

50 60

Compressor volume flow VC tot (m3/s)

four-stroke version

18

two-stroke version

Smart design for simple installation

Easy maintenance
Thrust bearing inspection without
Uncooled casing
Lubrication by engine lube oil system
shaft removal
Compressor wheel change with basic
Integrated oil piping and oil
tooling and without dismantling of
venting system
Integrated sealing air supply
compressor casing
Easy replacement of turbine blades
Reduced number of parts
Integrated burst protection
Extended lifetime of wear parts like
Floating journal bearings
Floating thrust bearing disk
Cast nozzle rings
Turbine blades
Compressor wheel
Optional titanium compressor wheel

19

The TCA Series

Technical data
Turbine type
Max. permissible temperature
Pressure ratio
Suitable for HFO, MDO, Gas

Axial flow turbine

500C 2-stroke / 650C 4-stroke
up to 5.5

Turbocharger programme
Turbocharger
Max. supercharged engine
type
output (kW)

TCA33
TCA44
TCA55
TCA66
TCA77
TCA88

2-stroke

4-stroke

le* = 9 kg/kWh
6,200
8,000
11,600
16,600
27,200

le* = 6.5 kg/kWh

5,300
7,900
10,400
14,800
20,900
29,800

Max. permissible
speed
(rpm)
27,800
22,700
20,000
16,900
14,200
12,000

(kg)
1,140
1,970
3,290
5,510
9,250
15,790

Width
(mm)
895
1,075
1,275
1,515
1,800
2,138

Height
(mm)
966
1,160
1,377
1,636
1,944
2,309

Mass

* Specific air consumption

Overall dimensions
Turbocharger
type
TCA33
TCA44
TCA55
TCA66
TCA77
TCA88

20

Length
(mm)
1,735
2,084
2,472
2,937
3,490
4,144

The NA/S/T9 Series

21

The NA/S/T9 Series

Features
In-board arrangement of plain
bearings, lubricated by the engines
lube oil supply system; lifetime of
bearings more than 25,000 hours
One-part compressor wheel milled
out of high-strength aluminium alloy.
The continuously backward bent
blades lead to stable characteristics
at a high efficiency level up to pres-
sure ratios of 4.5 for NA/S (up to 4.2
for NA/T9)
Enlarged turbine blades made of
high-quality material with improved
blading efficiency

All casings of the NA/S turbo chargers of waterless design

The bearing casings of NA57/T9
and NA70/T9 are water-cooled
No corrosion of turbine casings
with heavy fuel oil operation
Excellent acceleration behaviour
due to a low moment of inertia
of the rotor
Profiled nozzle ring
Simple maintenance and long
service life

MAN Turbocharger application ranges NA/S/T9

Total pressure ratio

C tot

4.5
4.0
3.5

NA29/S

3.0

NA34/S

NA40/S

NA48/S

9 10

15

NA57/T9

NA70/T9

2.5
2.0

1.5

3.5 4

4.5

20

25

30

35 40

Intake volume VC tot (m3/s)

22

23

The NA/S/T9 Series

Technical data
Turbine type
Max. permissible temperature
Pressure ratio
Suitable for HFO, MDO, Gas
Turbocharger programme
Turbocharger
type
NA29/S
NA34/S
NA40/S
NA48/S
NA57/T9*
NA70/T9**
Overall dimensions
Turbocharger
type
NA29/S
NA34/S
NA40/S
NA48/S
NA57/T9**
NA70/T9***

Max. supercharged
engine output (kW)
le* = 8 kg/kWh
3,600
5,100
7,300
11,000
16,100
24,500

Length
(mm)
1,023 1,308
1,268 1,990
1,435 2,286
1,807 2,709
1,994 2,879
2,502 3,547

* Specific air consumption

** Pressure ratio up to 4.2
*** Pressure ratio up to 4.0

24

Axial flow turbine

650C
up to 4.5

Max. permissible
speed
(rpm)
31,300
26,300
22,400
18,600
15,000
12,000

Width
(mm)
890
950
1,130
1,322
1,537
1,920

Mass
(kg)
1,050
1,350
2,200
3,700
5,100
9,800

Height
(mm)
920
1,355 1,440
1,540 1,630
1,759 1,879
2,033 2,133
2,550

The (TCS-) PTG Power

Turbine Series

25

The (TCS-) PTG Power Turbine Series

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 suited to marine applications
Asynchronous generator suited to stationary applications

Exhaust gas system

Control valves for power turbine operating range
Fast acting emergency valves for emergency shutdown
Control and saftey equipment

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

Increasing efficiency and flexibility of operation

Funnel (boiler)

Turbochargers
Exhaust gas receiver

Main engine

Gearbox
Coupling
Generator

Exhaust gas turbine

Board grid

26

PTG

TCS-PTG

27

The (TCS-) PTG Power Turbine Series

Technical data
Turbine type
Max. permissible temperature
Output shaft speed
Suitable for HFO, MDO, Gas

Radial or axial
550C
1,800 rpm (1,500 rpm)

Power turbine programme

Radial flow turbine
Max. output
(kW)

28

= 3.6

(TCS-) PTG18
(TCS-) PTG20
(TCS-) PTG22

960
1,400
2,420

Axial flow turbine

(TCS-) PTG55
(TCS-) PTG66

3,650
5,140

Max. flow rate

(kg/s)
Temperature before
turbine 450C
6.7
9.7
16.6

23.2
32.7

Speed
(PT 1/min)

34,000
28,000
21,000

16,000
13,500

The Variable Turbine Area

(VTA)

29

The Variable Turbine Area (VTA)

The VTA system consists of a nozzle ring equipped with adjustable vanes which
optionally replace the fixed-vane nozzle rings in MAN Diesel & Turbos standard
TCA and TCR turbochargers.
By altering the pitch of the adjustable vanes, the pressure of the exhaust gases
on the turbine is regulated and thus the volume of charge air can be precisely
matched to the quantity of injected fuel at all points in an engines load and speed
range. The result is reduced specific fuel consumption, reduced emissions HC
and CO2 and improved engine response.
Benefits
Up to 5g/kWh lower fuel consumption
Lower soot and smoke emission
Lower CO emissions
2
Lower particle emissions
Suitable for TCA and TCR turbochargers
Retrofit packages
Short payback time
VTA cuts fuel consumption and reduces emissions

30

The Variable Turbine Area (VTA)

The tables below summarise the optimisation possibilities available with MAN
B&W type engines. All SFOC figures are relative to the SFOC at 100% load for
a standard L1 engine.
SFOC optimised
load range
High load (85100%)
Part load (50-85%)
Low load (25-70%)

Tuning methods
Standard L1 engine
VTA
VTA

SFOC change (g/kWh)

35%

50%

65%

80%

100%

3.5
0.5
1.5

1
4
6

3.5
6.5
8.5

3.5
4.5
3.5

0
0.5
0.5

Table 1: Optimisation possibilities ME/ME-C engines, SMCR = L1

SFOC optimised
load range
High load (85-100%)
Part load (50-85%)
Low load (25-70%)

Tuning methods
Standard L1 engine
VTA
VTA

SFOC change (g/kWh)

35%
4
2
1

50%
0
2
3

65%
2.5
4.5
5.5

80%
3
4
3

100%
0
2
1

Table 2: Optimisation possibilities MC/MC-C/ME-B engines, SMCR = L1

For a specific L1 engine, the SFOC profile can be found directly from the above
tables. For example, an S70ME-C8.2 running at 65% load with an L1 SFOC of
169 g/kWh and optimised for part load with VTA tuning has a consumption of 169
6.5 g/kWh = 162.5 g/kWh.
The above tuning methods are also available for derated engines with different
SMCR.
Only high-load optimisation is possible for engines with conventional efficiency
turbochargers.
The methods and options mentioned will be explained in the following.

31

The Variable Turbine Area (VTA)

Fuel savings with MAN B&W low speed propulsion engines
SFOC
High-load optimised
Part-load optimised (VTA tuning)
Low-load optimised (VTA tuning)

3 g/kWh

1 g/kWh

5 g/kWh
35

100 % SMCR
engine load

Fig. 1: ME/ME-C engines

SFOC

High-load optimised
Part-load optimised (VTA tuning)
Low-load optimised (VTA tuning)

2 g/kWh
1 g/kWh
3 g/kWh
35

Fig. 2: MC/MC-C/ME-B engines

32

100 % SMCR
engine load

The TCX Series

33

MAN Diesel & Turbo Introduces Two-Stage Turbocharging

with New TCX Generation
TCX features compact architecture and low-pressure ratio-optimised flow components
Development of the next generation of large-bore diesel engines has the reduction
of exhaust emissions as a primary target. Reducing engine emissions through
internal measures is achieved by increasing the mean effective pressure. This
requires high charge-air pressures but cannot be achieved through single-stage
turbocharging. However, two-stage turbocharging enables the charge-air pressure
to be increased substantially while simultaneously reducing exhaust emissions,
despite the increased specific engine output. MAN Diesel & Turbo is now ready
to bring two-stage turbocharging to the market with the introduction of its TCX
generation.
In comparison to single-stage turbochargers, the TCX series incorporates
characteristic features especially suited for lower-pressure ratios per stage:
Optimised component characteristics at low-pressure ratios
The use of pressure-ratio reduction for the benefit of air capacity increase
The use of pressure-ratio reduction for the benefit of dynamic behaviour
Compactness in order to minimise ad ditional space (and weight) require ments for the two-stage turbocharger system including intercoolers
Matching of compressor and turbine capacities to accommodate
low-pressure ratios
Wider application ranges per turbocharger size

34

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 D2366355EN-N4 Printed in Germany
GMC-AUG-03112

MAN Diesel & Turbo

86224 Augsburg, Germany
Phone +49 821 322-0
Fax +49 821 322-3382
[email protected]
www.mandieselturbo.com