Man VTA Project Manual
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Man VTA Project Manual

Man VTA Project Manual

Variable turbine area for tca turbocharger
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Summary of Contents for Man VTA

  • Page 3: Table Of Contents

    Cabling ............................26 Operation ............................. 27 Putting into Operation .......................27 VTA – Adjustment Ranges and Adjustment Speeds ..............27 Emergency Operation on Failure of the VTA Adjusting Device ..........27 Maintenance and inspection ......................29 Introductory Remarks .......................29 Cleaning the Variable Turbine Area ..................29 Maintenance of the Adjusting Device ..................29...
  • Page 4 MAN Diesel & Turbo Surge Tests ..........................31 Scope of supply ........................... 32 Delivery Scope, VTA and Equipment ..................32 Hardware ...........................32 Software ............................33 Cable Sets ..........................33 10 Retrofits – worldwide turbocharger service ..................35 10.1 Retrofitting a Variable Turbine Area ..................35 10.2 MAN | PrimeServ ........................35...

  • Page 5: Adjustable Turbine Nozzle Ring (Vta)

    Range of applications The VTA was designed for applications on turbocharged large diesel engines with different load profiles. Due to its adjustability, the VTA adapts the turbo- charging characteristics so that the engine works efficiently over a wide load range.
  • Page 6 MAN Diesel & Turbo 4 (38) EN-US...
  • Page 7 ▪ Exhaust gas temperatures at partial load reduced NOTE! In the dedicated “Economy Mode” (Mode 1.), the VTA rating must be adapted to the NOx limit values. Table 1: VTA range of applications on 2-stroke diesel engine EN-US 5 (38)
  • Page 8 Additional improvement of partial load performance by shifting the maximum efficiency towards a 4) Exhaust gas recirculation lower engine load 5) Humid air motor Table 2: VTA range of applications on 4-stroke diesel engine Application Functional principle Effect ▪ ▪...
  • Page 9 At partial load: ciency at a given power turbine “Closing” of the VTA to throttle output – see 1. the power turbine output, analo- gous to 1. Table 6: VTA range of applications on power turbine Application Functional principle Effect ▪ ▪...

  • Page 10: Application Examples

    VTA is closed towards partial load (“VTA closing”). In contrast, the scavenge air pressures for the VTA test specification TCA55-21004V with the nozzle ring remaining open for partial load (“VTA open” – ▲ dark line, bottom) and the initial specification TCA55-20027 with rigid nozzle ring are also shown (■...
  • Page 11 Figure 3: Turbocharger efficiencies with TCA55-21V on 6S46MC-C engine In the diagram Turbocharger efficiencies with TCA55-21V on 6S46MC-C engine, the efficiency characteristic of the VTA rating is plotted with the exist- ing specification optimized for full load. With a closing nozzle ring, a marked increase in the efficiency can be seen below 85% MCR.
  • Page 12 VTA position. Moreover, an open VTA position at partial load allows a more efficiency-optimized setting than a rigid turbine nozzle ring.

  • Page 13: Low-Speed Propulsion Engines From Man B&W

    Figure 5: Improvement of the thermal efficiency with a TCA55-41V on an 7L51/60DF engine Low-speed propulsion engines from MAN B&W The following tables summarize the fuel-saving potential existing for MAN B&W engines. All SFOC values refer to the SFOC for a load of 100% for a standard L engine.
  • Page 14 Partial load (50-85%) -4.5 Low load (25-70%) -5.5 Standard L engine – turbocharger without adjustable turbine nozzle ring VTA – turbocharger with adjustable turbine nozzle ring Table 9: Optimization potential – MC/MC-C/ME-B Tier II engines, SMCR = L 12 (38) EN-US...
  • Page 15 SFOC profile can be taken directly from the tables above. For example, an S70ME-C8.2 at a load of 65% and with an L SFOC of 169 g/kWh, optimized for partial load with VTA tuning, has a con- sumption of 169 - 6.5 g/kWh = 162.5 g/kWh.

  • Page 16: Overview Of Series

    100 kg 110 kg 140 kg 190 kg 1) m+ = weight increase of a TCA turbocharger with VTA compared with a TCA turbocharger of the same size with- out VTA Table 10: Weights of individual VTA components 14 (38)

  • Page 17: Casing Positions

    MAN Diesel & Turbo The VTA can generally be implemented in all TCA turbocharger types and sizes. To obtain weight specifications for VTA components of TCA turbochargers that are not listed here, please contact our Technical Sales department. e-mail: Turbochargers@mandiesel.com...

  • Page 18: Design

    Subassembly 511 Adjustment Device The principal components of the adjustment device are the two spindle drives (511.001) which are responsible for converting the rotational motion of the servomotors (512.020) to a linear motion for adjustment of the VTA. 16 (38) EN-US...

  • Page 19: Operation Method Of The Adjusting Device

    MAN Diesel & Turbo Operation Method of the Adjusting Device Servomotors The adjustable turbine nozzle ring is driven by two servomotors mounted on the adjustment device. The motor speed is reduced and the torque (512.020) increased by means of a planetary gear unit. A Cardan joint transfers the tor- que from the servomotor to the spindle drive.

  • Page 20: Systems

    Filling of fuel index transmitter or regulator ▪ Scavenge air pressure These parameters are processed in the Multi-purpose controller (MPC) of the VTA control system (VCS). The MPC supplies the VTA control system with signals for adjusting the VTA. The following parameters are output: ▪...
  • Page 21 MAN Diesel & Turbo Figure 11: Wiring diagram – VTA control system (VCS) on MC/MC-C two-stroke engine VTA on ME/ME-C/ME-B With this variant, the MPC responsible for the VTA control system (VCS) is electronically integrated into the engine control system (ECS) and controlled two-stroke engine by it.

  • Page 22: Cooling Water System

    Wiring diagram – VTA control system (VCS) for stand-alone variant. Figure 13: Schematic sketch – VTA control (VCS) for Stand-alone variant Cooling Water System The cooling water system is used for cooling the spindle drives of the adjust- ment device.
  • Page 23 Water quality The cooling water must generally be taken from the high temperature area of the engine cooling water circuit (HT). For maintenance work on the VTA, it is advisable to install a shut-off option here. Connections, Screwed sockets are provided on the turbocharger side for connecting the cooling water.

  • Page 24: Inflation Air

    MAN Diesel & Turbo Inflation Air Functional principle of the The sealing air system is used to seal the VTA. The sealing air prevents the exhaust gas from penetrating under the inner sealing air system IAS guide ring. (Inflation Air System)
  • Page 25 TCA55 TCA66 TCA77 TCA88 Table 13: Pipe connection for the sealing air system 549.000 510.020 501.001 501.001 Gas-admission casing 510.020 Holding ring 549.000 Inflation air pipe, compl. Figure 15: VTA inflation air pipe on the TCA Turbocharger EN-US 23 (38)

  • Page 26: Engine Room Planning

    VTA Control System (VCS) Control cabinet The control cabinet for the VTA control system is designed for installation in engine rooms. It is to be mounted on the floor. The control cabinet must be installed in a location that is suitable for inspec- tion.

  • Page 27: Multi Purpose Controller (Mpc)

    MAN Diesel & Turbo Multi Purpose Controller (MPC) The switch box for the engine control system is designed for installation in the engine room. It is to be mounted on a wall, preferably near other switch boxes of the engine control system.

  • Page 28: Cabling

    Connecting cables The cable length between the servomotor (turbocharger) and the frequency inverter (VTA control cabinet) is max. 50 m. A max. length of up to 100 m can be achieved subject to consultation and project clarification with MAN Diesel & Turbo.

  • Page 29: Operation

    Following integration of the VTA control system into the engine control sys- tem, calibration of the frequency inverter/controller (reference run) is required. There is a special function for this in the VTA control system. Referencing is carried out in the factory.
  • Page 30 ▪ If the voltage supply to the VTA control system is still present, the electric brakes in the servomotors are activated. These can be deactivated using switch S2 in the control cabinet of the VTA control system.

  • Page 31: Maintenance And Inspection

    Maintenance and inspection Introductory Remarks The control system of the VTA is designed in such a way that maintenance and inspection is only required when prompted by the system. The maintenance intervals for the VTA correspond to those of a turbocharger with rigid nozzle ring.

  • Page 32: Matching

    Compare also with the Project Guide “TCA Turbochargers”. Adjusting the Charging Air Pressure If the VTA is used, this naturally dispenses with the need to exchange a noz- zle ring. Furthermore, the charge pressure is infinitely adjustable. Matching generally involves checking a complete VTA motion and control program rather than a single fixed component.

  • Page 33: Surge Tests

    1. Load reduction from 75% to 25% within 10 seconds for checking the surge stability in closed condition of the VTA, whereby the maximal igni- tion pressure must not be exceeded. 2. Load reduction from 100% to 50% according to standard procedure, yet with activated movement program.

  • Page 34: Scope Of Supply

    The equipment and scope of supply for the adjustable turbine nozzle ring may vary depending on the specific application. The following tables list which components are included in the scope of supply of MAN Die- sel & Turbo and which components must be procured by the customer.

  • Page 35: Software

    ME-B ● Scavenge air/charge air pressure sensor ● Scope of supply of MAN Diesel & Turbo (●) Is a component of the ECS and is already present Scope of supply of engine manufacturer Table 18: Scope of supply – hardware...
  • Page 36 PC (MOP) Power connecting cable (●) Screen (MOP) ● Scope of supply of MAN Diesel & Turbo (●) Is a component of the ECS and is already present Scope of supply of engine manufacturer Shipyard Table 20: Scope of supply – cable sets...

  • Page 37: Retrofits - Worldwide Turbocharger Service

    MAN Diesel & Turbo I PrimeServ Turbocharger 10.2 MAN | PrimeServ Contact persons The following table contains addresses for MAN Diesel & Turbo in Germany, together with telephone and fax numbers for the departments responsible and ready to provide advice and support on request. Augsburg plant...

  • Page 38: Worldwide Service Addresses

    Fax +49 821 322 3299 e-mail Turbochargers@mandieselturbo.com Internet http:// www.mandieselturbo.com/turbocharger 10.3 Worldwide service addresses Internet MAN Diesel & Turbo service addresses and authorized service partners (ASP) can be found on the Internet under MAN | PrimeServ Worldwide Net- work: www.mandieselturbo.com/primeserv 36 (38) EN-US...
  • Page 39 2.4 (15) Adjustment speed 6.2 (27) IAS – Inflation Air System 4.3 (22) Application examples Increased scavenge air pressure 1.2 (8) VTA on 2-stroke diesel engine 1.2 (8) VTA on 4-stroke gas-powered 1.2 (10) engine Lambda window 8.2 (30) Cables 5.5 (26)
  • Page 40 MAN Diesel & Turbo Range of applications for the 1.1 (3) Thermal efficiency 1.2 (10) adjustable turbine nozzle ring Turbocharger efficiency 1.2 (9) Range of applications for the VTA Overview 1.1 (3) Retaining ring 4.3 (22) Retrofits 10.1 (35) VCS – Definition 4.1 (18)

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