TCA - The Benchmark.pdf

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TCAThe benchmark



MAN Diesel & Turbo Aspiring to turbocharger perfection

MAN Diesel & Turbo is the world’s leading designer and manufacturer of large exhaust

gas turbochargers 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.

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 Turbo’s absolute commitment to reducing emissions while increasingfuel efficiency and power density starts with our active partnership in the emissions

law making process and ends with the delivery of turbochargers that achieve an ideal

synthesis of product characteristics.

2 TCA – The ben chmark 3 TCA – The benc hmark



TCA – The Benchmark

MAN Diesel & Turbo has more than

60 years unprecedented experience

of producing turbochargers with plainbearings and uncooled hot gas casings.

Modern turbochargers are crucial to generate high

power and increased fuel efficiency for a wide range

of engines, including ship propulsion systems, diesel

and gas power plants and rail traction applications.

The new s eries of TC A turbo chargers is available in

2-stroke and 4-stroke versions for diesel, dual fuel and

gas engines. They have been developed to provide

a robust and reliable platform for engine appli cations

ranging from approx. 3 MW up to 30 MW output per

turbocharger. Integral design combined with advanced

materials has improved turbocharger efficiency, simpli-

fied installation on the engine, and has extended times

between overhauls. Using fewer parts than any other

generation has reduced maintenance and service

times, which ensures lower life cycle costs.

The TCA range contributes to fuel oil savings and

meets all environmental emission standards.




Enjoy the Benefits

Turbine

Newly developed wide-chord turbineblades without damping wire Increases efciency

New turbine nozzle ring Extended life-time

Optional variable turbine area (VTA) Reduces SFOC at part load

New optimised turbine outlet diffusor Increases efciency

New optimised turbine inlet casing Increases efciency

Bearings

Reduced shaft diameter Minimises mechanical losses

High performance thrust bearings Minimises mechanical losses

Floating journal bearing bushes Optimises damping behaviour

Compressor

N ew ly d ev el op ed c om pr es so r w he el R ed uc es n oi se e mi ss io n. I nc re as edefciency and optimisation of the

engines operating line (in the map)

Optional internal re-circulation Increases surge margin

Newly developed compressor volute Increases efciency

New compressor diffusor vanes Increases efciency

Optional Jet Assist Fast rotor acceleration

Easy Maintenance

Thrust bearing inspection withoutshaft removal Reduces service time

Compressor wheel change Basic tooling without dismantlingcompressor casing

Easy replacement of turbine blades Reduces service time

Extended Parts Life-Time Low maintenance costs

Design Features

Air cooled casings No corrosion

Post lubrication tank Safe operation

Lubrication by engine lube oil system Simple and reliable

Integrated oil piping and oil venting system Compact design

Integrated sealing air supply Compact design

Reduced number of parts Low maintenance costs

Integrated burst protection Safe operation

Features Benefits Vital components that increase engine power by more than 300%.

Integrated air seal,oil piping and venting system

High-perfomanceplain bearings

Resistantcontainment area

High-efficiencypatented difussor

Whisperingsilencer

Uncooledcasings

High-capacity flowcross sections

Easy to service low-noisecompressor wheel

High-efficiency widechord turbine blades




Turbine

All c omponents of th e TCA turbocharger have been

optimised with regard to flow control and stress

reduction by means of modern 3D CFD and FEM

calculations.

The result is a t urbine with very stiff and high-wear

resistant wide-chord blades, which are supported in

the turbine disc by means of a ‘fir tree foot’.

A damping wire is therefore no longer necessary,

which makes maintenance work easier and improves

efficiency.

Bearings

The rotor is running on two internal radial bearings

with floating bushes and a separate thrust bearing.

The advanced desi gn provides high er safety margin s.

Bearing points with small diameters could be realised

by optimising both the rotor dynamics and the shaft/

hub connection of the compressor wheel and turbine

shaft.

The result is low ci rcumferential speeds of t he bearing

bushes and minimisation of the friction losses which

contributes to a higher total efficiency.

Special features of the floating bearing bushes are

very quiet running and minimal bearing wear. The ex-

pected service life of the bearing body is up to 50,000

hours.

Easy handling and short maintenance times were

essential requirements for the support design. For

exam ple neither the compressor casing nor the tur-

bine rotor has to be disassembled for removal of

the thrust bear ing. I. e. a bearing inspection can be

carried out in normal harbor lay days.




Patented shaft/hub connection

Compressor

The compressor wheel operates at a circumferential

speed well over 500 m / s which results in very high

centrifugal forces. The standard design of resistant

aluminium alloy in combination with a specially adap-

ted machining process ensures a long service life for

this stressed component.

A compress or wheel suita ble for use in very high

pressure conditions has been developed specifically

for the TCA series, utilising advanced 3D CFD and

FEM calculations. The benefit is optimised geometry,

which ensures a high efficiency at a safe surge margin

within the whole operating range. In addition, noise is

considerably reduced.

The force and form locking co mpressor wheel attach -

ment on the turbine shaft permits assembly and di-

sassembly of the compressor wheel, without having

to use an unwieldy hydraulic tool. This new shaft/hub

connection protected by a MAN Diesel & Turbo patent

reduc es replacement time substantially and makes

maintenance easy.

Pressure and mach number distribution

Ty pe Ma x. superc har ge d e ng ine out put [kW]

2-stroke

le*= 9 kg/kWh

π e **= 4.0

4-stroke

le*= 6,5 kg/kWh

π e **= 5.0

TCA33 - 5,400

TCA44 6,000 8,200

TCA55 8,000 10,400

TCA66 11,500 14,800

TCA77 16,500 21,000

TCA88 27,000 30,000

* Specic air consumption ** Compressor pressure ratio

Turbocharger programme

ETA TC [-]Compressure pressure ratio π [-]

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5

0.80

0.75

0.70

0.65

0.60

0.55

0.50

Range of turbocharger efficiencyTurbocharger application range

Compressorpressureratio p C tot

Compressure volume flow V C tot [m 3 /s]

four-stroke version two-stroke version

TCA33

TCA55

T CA 44 T CA 55 T CA 66 T CA 77 T CA 88

TCA66 TCA77 TCA88 TCA88-25

9105 6 15 20 30 40 50 60874

TCA44

6.0

5.5

5.0

4.5

4.0

3.5

3.0

0.80

0.75

0.70

0.65

0.60

0.55




The uncooled ca sings of the T CA series are desig ned

in accordance with the ‘pipeless engine’ principle. All

supply pipes are fully integrated within the casing.

Only one oil supply and discharge pipe and a venting

pipe have to be connected externally.

Due to a robust structure and the material thickness of

the casing walls, the TCA turbocharger will not require

any additional burst protection; and the rigid connec-

tion of the turbine outlet, bearing and compressor ca-

sing by means of tie rods offers additional safety.

Newly developed one and two socket compressor

spirals permit optimum attachment of the turbochar-

ger to the engine. The stiff insert piece is part of the

patented burst protection in the compressor.

CasingsNozzle Ring

TCA nozzle rings are manufactured from highly re-

sistant materials which ensures a long service life.

Optimum matching of the turbocharger to the corre-

sponding engine is obtained by individually adapting

nozzle rings.

As an option a vari able turbine area ( VTA) permits op-

timum adaptation of the ‘flow cross section’ to the

corresponding load condition of the engine and there-

fore reduces both fuel consumption and pollutant

emissions, especially at part load operation (Fig. 1).

Fig. 1. Patented variable nozzle ring

Benefits of VTAn Up to 4 g/kWh lower fuel consumptionn Lower soot and smoke emissionn Lower CO 2 emissionsn Low er particle emissionsn Suitable for TCA and TCR

turbochargersn Retrofit packagesn Sh ort payback timen VTA cuts fuel consumption

and reduces emissions

An es sential item of t he deve lopment work was the

design of the (patented) turbine outlet diffuser, which

effectively converts kinetic energy remaining down-

stream of the turbine wheel into pressure. Simultane-

ously the outlet diffuser acts as an integrated burst

protection within the turbine.

A further vital poi nt is the reducti on of noise emis sion.

This is due to the compact design (the noise emit-

ting surface area is greatly minimised), combined with

newly developed insulation of the turbine outlet and

compressor casing.

In order to permit optimum mounting to the engine all

casings can be installed and turned in steps of 15°.

Stiff insertpiece

Massive contain-ment area

Compressordiffuser

Stiff connectionof compressorvolute

Stiff connection of turbineinlet and outlet casing

Patented turbineoutlet diffusor

Coverring

Massivecontainment

area

1312 TCA – The ben chmark TCA – The benc hmark



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 deli very of spare par ts is of utmost impor tance

to avoid down times. MAN Diesel & Turbo has an

efficient pro cessing and stock despatch system

allowing parts to be delivered within 24 hours.

Continuous training of engineers, combined with regu-

lar service bulletins and video clips ensures the world-

wide service network is always up to date.

A customer feedback programme als o contribu tes to

maintaining a high standard of service.

Close co-ordination with all licensees ensures that

‘products built under licence’ are fully covered by our

global network.

Enjoy the benefitsn Knowledgeable partners in more than 150 service

stations worldwiden A one stop servi ce for turbocharger s, diesel and

gas enginesn Around the clock af ter sales serv icen Largest turbocharger ‘license net’ with full

exchangeability of spare partsn A hig h avai lability of s pare parts through an i ntel-

ligent central stocking systemn Attractive price/ performance ratio

World Class Service Around the clock

14 TCA – The ben chmark



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MAN Diesel & Turbo

86224 Augsburg, GermanyPhone +49 821 322-0Fax +49 821 [email protected]

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