MAN 18V48/60TSTwo-stage turbocharged diesel engine

3MAN 18V48/60TS – Two-stage turbocharged diesel engine

MAN Diesel & Turbo is the world’s leading provider of large-bore diesel engines

and turbomachinery. Our product portfolio includes two-stroke and four-stroke en-

gines for marine and stationary applications, turbochargers and propellers, as well

as gas and steam turbines, compressors and chemical reactors.

MAN solutions can be found in ship propulsion, engine-based power plants and

turbomachinery trains for the oil & gas and process industries. We support our

global customers with a comprehensive range of after-sales services under the

MAN PrimeServ brand.

MAN Diesel & Turbo has always been committed to increasing fuel efficiency and

reducing emissions. Today, this commitment ensures that our customers are able

to meet increasingly strict emissions regulations and plays a vital role in reducing

the environmental impact of global trade and industry.

MAN Diesel & TurboPowering the world – responsibly

4 MAN 18V48/60TS – Two-stage turbocharged diesel engine

The Best in its ClassMAN 18V48/60TS

Two turbochargers in sequence provide a new dimension in engine performance

and operational flexibility. A wide load range from 1,050 to 1,200 kW/per cylinder,

a specific fuel oil consumption of 7323 kJ/kWh at 1,050 kW/cyl. and reduced NOX

emissions set a new benchmark for four stroke diesel engines.

Turbochargers from MAN Diesel & Turbo

Turbochargers are the core of this innovative new con-

cept – and MAN Diesel & Turbo is the only engine

manufacturer that also designs and builds turbo-

chargers. This unique expertise translates into excep-

tional efficiency and reliability.

Two-stage turbocharging

The idea is simple: just place two of MAN’s most effi-

cient turbochargers upstream from the engine, one

after the other. The result: the engine gets twice the

charge air pressure, while turbocharger efficiency is

increased significantly.

A single turbocharger, such as MAN Diesel & Turbo’s

well known TCA88, is highly efficient; however, it has

a limited pressure ratio. A specially designed com-

pressor, as in the TCA88/RCF23, can increase the

pressure ratio – but also has the effect of decreasing

efficiency. The only solution to this dilemma is two-

stage turbocharging.

The MAN 18V48/60TS deploys MAN Diesel & Turbo’s

tried and tested TCA88 and TCA77 standard turbo-

chargers in sequence. The TCA88 is located up-

stream and provides the low pressure turbocharger,

while the TCA77 forms the high pressure turbocharg-

er, next to the engine. In this configuration, both tur-

bochargers can achieve pressure ratios over 6 bars

and efficiencies of more than 76 percent.

5MAN 18V48/60TS – Two-stage turbocharged diesel engine

A New DimensionUltimate power

The diesel engine MAN 18V48/60TS

The MAN 48/60 type diesel engine is a perfect exam-

ple of proven technology and robust design. Over

800 units have been sold since the product was

launched in 1988. They are now operating in a range

of applications in power generation and marine pro-

pulsion. Thanks to its high efficiency, the 18 cylinder

engine is the MAN 48/60 engine family’s best-selling

configuration.

For the two-stage turbocharged MAN 18V48/60TS,

only a few modifications were made to the standard

engine:

�� Adapted fuel injection nozzles

�� Three-ring piston with higher compression ratio

�� Modified camshaft for enhanced Miller timing

�� Additional charge air bypass valve for low smoke

emissions during engine start up

Pressure ratio

TC

eff

icie

ncy

to

t-to

t [%

]

78

76

74

72

70

68

66

64 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

MAN 48/60B (TCA88)

MAN 48/60TS (TCA88 + TCA77)

Comparison two-stage (MAN 48/60TS) – one-stage turbo charging (MAN 48/60B)

Low pressure Turbocharger

Low pressure Turbocharger

6 MAN 18V48/60TS – Two-stage turbocharged diesel engine

Standard components, proven design

The overall design of the two-stage turbocharged

MAN 18V48/60TS has been kept as simple as possi-

ble. Apart from the modifications described above,

the engine is standard, with the high pressure turbo-

charger directly mounted to it.

The low pressure turbocharger is located upstream

from the engine, on its own steel frame. The combus-

tion air and exhaust gas piping between both turbo-

chargers is fitted with compensators, ensuring com-

plete insulation from vibrations.

An air blower is situated below the steel frame of the

low pressure turbocharger. Active during engine start-

up and low part-load operation (up to 25 percent

load), it cares for low smoke emissions even during

these operation phases.

Lowest fuel oil consumption or NOx emissions

The excess combustion air from the turbochargers

provides greater operational flexibility. The high charge

air pressure can be used for enhanced Miller Cycling,

delivering significant fuel savings and further reducing

NOx emissions.

As a result, the MAN 18V48/60TS diesel engine’s

extremely low specific fuel oil consumption of only

7323 kJ/kWh makes it the most cost-effective in its

class.

Alternatively, the excess combustion air can be lev-

eraged to significantly increase the engine’s power

output, up to 1,200 kW/cylinder. Although this does

not save as much fuel, it does allow for a greater re-

duction of NOx emissions within a wide operation

range. NOx emissions of 1,850 mg/Nm³ down to

1,480 mg/Nm³ make the MAN 18V48/60TS the clean-

est diesel engine in its power range.

Standard Components, Proven Design

7MAN 18V48/60TS – Two-stage turbocharged diesel engine

Po

wer

out

put

kW

/Cyl

.N

Ox m

g/N

m3 @

15%

O2

Effects of Two-Stage Turbocharging

Op. mode

1,200

1,150

1,100

1,050

1,000

1,850

1,800

1,750

1,700

1,650

1,600

1,550

1,500

Fue

l co

nsum

ptio

n kJ

/kW

h

7,400

7,375

7,350

7,325

7,300

Op. mode

1,050

1,850

7,323

1,100

1,740

7,366

1,200

1,480

7,379

Two-stage turbocharging is a modular system: its de-

sign enables most MAN Diesel & Turbo power plants

to be retrofitted with this solution.

Flexibility in fuels, flexibility in operations

Like the MAN 48/60 series standard engines the two-

stage turbocharged MAN 18V48/60TS can be oper-

ated with a wide range of different fuels:

�� Heavy fuel oils with a viscosity up to 700 cst

�� Marine diesel oil

�� Gas oil

Due to the unique features of two-stage turbocharging,

the MAN 18V48/60TS can be operated continuously

at shaft power outputs from 18,900 up to 21,600 kW.

For example, this allows power producers to operate

the engines at a normal load of 18,900 kW – taking

advantage of the extremely low fuel oil consumption

and giving them the possibility of a spinning reserve

up to 21,600 kW.

1 2 3

1 2 3

H

WA B

C

8 MAN 18V48/60TS – Two-stage turbocharged diesel engine

MAN 18V48/60TS Technical DataOutput, dimensions and weight

MAN 48/60TS

Bore 480 mm, stroke 600 mm 18V

Operational setup 1 2 3

Engine speed rpm 500 / 514 500 / 514 500 / 514

Frequency Hz 50 / 60 50 / 60 50 / 60

Electrical Genset power kWe 18,654 19,543 21,319

Electr. Genset heat rate at 100% load and efficiency 18V

World Bank 2007 / 2008 kJ/kWhe 7,419 7,463 7,678

Nominal generator efficiency: 98,7%; without pumps; 5% tolerance

Lube oil consumption kg / h 9.5 9.9 10.8

Tolerance: +20%

Dimensions

Genset A B C W H

dry mass (t) (mm) (mm) (mm) (mm) (mm)

407 13,148 5,410 24,510 4,700 9,023

Weights and dimensions are subject to final application

Engine type: MAN 18V48/60TS

Engine cycle: four-stroke

Turbocharging system: 2-stage, constant pressure

Low pressure TC type: MAN TCA88

High pressure TC type: MAN TCA77

Number of cylinders: 18

Bore: 480 mm

Stroke: 600 mm

Swept volume per cyl.: 108.6 dm³

Engine speed 50/60Hz: 500 / 514 rpm

Mean piston speed: 10.0 / 10.3 m/s

Cooling:

Cylinder cooling: HT cooling water

LP-TC charge air cooler: 2-stage HT and LT cooling water

HP-TC charge air cooler: 2-stage HT and LT cooling water

Starting method: compressed air with

blower for low part load

operation up to 25% load

Reference conditions according ISO 3046-1: 2002

The stated consumption figures refer to:

�� Ambient air pressure: 1,000 mbar

�� Relative humidity: 30%

�� Ambient air temperature: +25 °C (77 °F)

�� Charge air temperature:

According to engine type, corresponding to 25 °C

cooling water temperature before charge air cooler

Abbreviations:

TC Turbocharger

HP High pressure

LP Low pressure

HT High temperature

LT Low temperature

10 MAN 18V48/60TS – Two-stage turbocharged diesel engine

World-Class ServiceMarine propulsion, gensets, and stationary plants

The PrimeServ offering

The MAN Diesel & Turbo Group offers worldwide,

round-the-clock service, 365 days a year. In addi tion

to MAN Diesel & Turbo’s service headquarters in

Augsburg, Copenhagen, Frederikshavn, Saint-Nazaire,

Hamburg and Stockport, service centers on all contin-

ents provide comprehensive and continuous support.

MAN Diesel & Turbo engines are renowned for their

quality and durability. We are a global organization

with a strong local presence, delivering exceptional

field service management, tailor-made solutions, and

first-class technical support.

PrimeServ provides advice and assistance to custom-

ers throughout the product life cycle, from delivery to

resale. With our far-reaching network of service centers,

we respond rapidly to customer needs. Furthermore,

we offer outstanding service and unrivalled tech nical

expertise. Plus, we only use genuine spare parts

– safeguarding the longevity of your engine.

PrimeServ’s aim is to provide:

�� Prompt delivery of high-demand OEM spare parts

within 24 hours

�� Fast, reliable and competent customer support

�� Individually tailored O&M contracts

�� Ongoing training and qualification of operators

and maintenance staff

�� Global service, 24 hours a day,

365 days a year

�� Diagnosis and troubleshooting with our high-

performance Online Service

MAN Diesel & Turbo – a member of the MAN Group

MAN Diesel & Turbo86224 Augsburg, GermanyPhone +49 821 322-3897Fax +49 821 322-1460powerplant@mandieselturbo.compowerplants.man.eu

All data provided in this document is non-binding. This data serves informational purposes only and is 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. Copyright © MAN Diesel & Turbo. D2366483EN-N4 Printed in Germany GGKMS-AUG-05161