Post on 04-Jun-2018
8/13/2019 TCR - The Cutting Edge
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TCRThe cutting edge
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TCRThe cutting edge
MAN Diesel & Turbo has more than 60 years unprecedented experience of produ-
cing turbochargers with plain bearings and uncooled hot gas casings.
What would a state-of-the-art diesel engine be without a turbocharger? With speed
rates of over 70,000 rpm and circumference speeds faster than the speed of sound,
the turbocharger is one of the most important engine components. As it “inhales”
air into the engine, which is indispensable for combustion, it is often referred to as
the engine’s lung.
A modern turbocharger is able to increase the engine output by more than 300%.
Following MAN Diesel & Turbo’s successful and trend-setting design philosophy,
TCR turbochargers feature plain bearings and uncooled casings. These new
turbochargers were designed to meet with the special demands that are made
upon HFO, MDO and gas engines. They cover the complete range of possible appli-
cations, such as propulsion and stationary engines, gensets and traction engines,
all of which are subject to the strictest requirements with regard to size and weight.
As compared to the previous generation, these new turbochargers offer the advan-
tage of greater compactness and lighter weight without making any concessions
with regard to efficiency and performance. Hightech materials ensure an extended
service life and easier maintenance.
The new TCR turbocharger sets new standards for radial-flow turbochargers. Its big
brother, the TCA type, has already proved a success as an axial-flow turbocharger.
3 TCR – The cutting edge
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Enjoy the Benefits
Turbine
New CFD-optimised profiled rotor blades, nozzle ring,inlet and outlet casing Increased efficiency
Constant and pulse pressure turbocharging
Optional variable turbine geometry Excellent adaption to variable engine conditions
Bearings
High performance plain bearings Minimised mechanical losses, extended service life
Optimised shaft diameter Increased efficiency
Compact plain bearing concept Ideal rotor dynamic behaviour
Compressor
New CFD-optimised compressor wheel, diffuser ring
and compressor volute Increased efficiency
Extended pressure ratio and specific volume flow Meeting future engine requirements and environmental regulations
Optional internal flow recirculation (IRC) Extended surge margin
Optional jet assist Excellent rotor acceleration
Easy Maintenance
Extended inspection intervals Less service stops required
Easy access to compressor wheel Reduced service time
Reduced number of components Low maintenance costs
New compressor wheel fixation Reduced service time
Increased life time of parts Low maintenance costs
Smart Design for Convenient Installation
Uncooled casings Less connections and no corrosion
Lubrication by the engine lube oil system Simple installation, less sources of errors
Integrated oil inlet and oil drain “Pipeless” design
Piston ring sealing No sealing air required
Others
Suitable for HFO, MDO, dual fuel and gas engines
Compliance with present and future engine standards
and environmental regulations
Containment proven Safe operation
Low moment of inertia Excellent transient behaviour
New developed silencer Low noise
Features Benefits
4 TCR – The cutting edge
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Vital components that increase engine power by more than 300%
Diffusor Plain
bearings
Compressor
wheel
Gas admission
casing
Gas outlet
casing
Nozzle
ring
Turbine wheel
with shaft
Whispering
silencer
Compressor
volute
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Turbine
All the flown-through components of the TCR turbo-
charger have been flow and stress optimised by means
of modern 3D-CFD and FEA calculations. Part or full
load optimisation is possible by means of a variety of
different rotor/nozzle ring flow area combinations.
Turbine wheel
n New CFD-optimised profiled rotor blades, nozzle
rings, inlet and outlet casing for increased efficiency
n Constant and pulse pressure turbocharging
n Variable nozzle ring (optional )
6 TCR – The cutting edge
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Bearing
The TCR bearing includes tried and tested aspects of
the radial and axial bearing design of the NR series,
such as the floating radial bearing bushes coupled
with new detail solutions like the non-rotating radi-
al bearings. The new “semi-floating” design permits
most reliable operation and low wear.
The most evident modification is the axia l bear ing
now being arranged between the radial bearings.
Semi-floating journal bearings with squeeze oil damper
This arrangement enabels an extremely space-saving
bearing design. For easy servicing, all bearings are
housed in a bearing body.
n Semi-floating bearings with squeeze oil damper
n Compact bearing concept with centre thrust bearing
n Oil pressure adjusted by the turbocharger manu-
facturer
n Piston ring sealing without sealing air
7 TCR – The cutting edge
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Compressor
By applying up-to-date 3D CFD and FEA calculations,a
new compressor wheel geometry has been created
with further improved efficiencies. Depending on the
application, part-load and full-load optimisation is
possible by means of flow area combinations.
TCR turbochargers can be optionally equipped with
the IRC system (internal recirculation) which is able to
provide a larger compressor characteristic map with
increased surge margin ability.
The compressor wheel is mi lled from a high resistant
aluminium alloy that can withstand intake conditions
within a wide temperature spectrum.
A new type of compressor wheel attachment, with a
new designed retainer, simplifies maintenance and
extends the service life of this component which is
subject to great stresses.
n New CFD-optimised compressor wheel, diffuser
ring and compressor volute for increased efficiency
n Extended pressure ratio and specific volume flow
n Internal flow recirculation (IRC) for extended
surge margin (optional)
n New compressor wheel fixation for easy servicing
n Jet assist for quick rotor acceleration (optional)
Insert piece with jet assist bores, diffusor
Compressor
pressure
ratio πC tot
V/V totred
0.50 1.00 1.50 2.00 2.50
5.00
4.50
4.00
3.50
3.00
2.50
2.001.50
1.00
Compressor with IRC Compressor without IRC Operation line
Compressor map with and without internal
recirculation (IRC)
5.00
4.50
4.00
3.50
3.00
2.50
2.00
1.50
8 TCR – The cutting edge
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Type Supercharged engine output [kW] Max. permissible Mass
2-stroke
le*= 8 kg/kWh
4-stroke
le*= 7 kg/kWh
Speed
[rpm] [kg]
TCR10 - 600 84,700 40
TCR12 - 800 70,850 100
TCR14 - 1,200 58,700 135
TCR16 - 1,800 48,800 205
TCR18 2,400 2,700 40,250 350
TCR20 3,500 3,900 33,450 600
TCR22 6,400 6,900 25,600 1,400
*Specific air consumption
Turbocharger programme
Range of Turbocharger
efficiency ( TC ) 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
standard version high pressure version
Compressor pressure ratio π
Compressor
pressure
ratio
high pressure four-stroke version standard four-stroke version two-stroke version
3 41 2 5 6 7 8 10 15
TCR10-42
TCR10-41
TCR12-42 TCR14-42 TCR16-42 TCR18-42 TCR20-42 TCR22-42
TCR12-41 TCR14-41 TCR16-41 TCR18-41 TCR20-41 TCR22-41
TCR 18-21 TCR 20-21 TCR 22-21 TCR 22-25
πC tot
6.0
5.5
5.0
4.5
4.0
3.5
3.0
Compressor volume flow VC tot [m3 /s]
0.80
0.75
0.70
0.65
0.60
0.55
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Nozzle Ring
TCR nozzle rings are manufactured from an extre-
mely resistant material which ensures a long service
life. Optimum adaptation of the turbocharger to the
respective engine is achieved by means of individually
selected flow areas (matching).
A variable nozzle ring is optionally available. The va-
riable nozzle ring permits optimum adaptation of the
flow cross-section to the corresponding load condi-
tions of the engine, thus reducing fuel consumption
and pollutant emissions as well as improving dynamic
load acceptance.
10 TCR – The cutting edge
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Whispering Silencer
The entirely newly developed silencer cast from alumi-
nium reduces sound imission to less than 105 dB(A).
The radially arranged silencer segments have a f low-
optimised design and contribute to the high efficiency
of the turbocharger. The filter mat on the silencer
circumference is easy to clean whenever necessary.
Whispering silencer with patented radially inserted damping plates
11 TCR – The cutting edge
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Casing
The uncooled casing of the TCR series has been
designed in accordance with the “pipeless engine“
principle. All supply pipelines are integrated in the
casing. The compressor and turbine casings have
measuring connections for monitoring the pres-
sure and temperature. A speed pick-up is also
included in the scope of supply. The casings, which
are manufactured from SiMo steel or ductile cast iron
respectively are designed and have been tested to be
containment proof.
Claw connections facilitate fast disassembly and allow
the casing to be rotated into any required position.
The casings are heat insulated and comply with the
SOLAS requirements. The turbine outlet casing comeswith a wide inspection hatch that provides good
access to the turbine wheel for inspection and cleaning.
Integrated turbine and compressor washing devices
are optionally available. The DIN flange of the flow-op-
timised turbine outlet casing allows it to be easily fitted
to the exhaust gas pipe. Alternatively, a simple and
spacesaving 90° elbow can be supplied.
n Uncooled casings
n Lubrication by means of the engine lube oil system
n Integrated oil inlet and oil drain for pipeless engine
n Ports for pressure and temperature measurement
on compressor and turbine side
n Containment proven
n Continuously rotatable
n Turbine outlet casing with DIN f langen SOLAS conformity
Elasticated
bolt
Stiff insert
piece
Massive contain-
ment area
Stiff connection of
compressor volute
Stiff connection
of turbine inlet
and outlet casing
Massive contain-
ment area
Wide inspection
hatch
Patented turbine
outlet diffusor
12 TCR – The cutting edge
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The best maintenance would be if no maintenance
were necessary at all. In this respect the new TCR
series features extended maintenance intervals of up
to 30,000 operating hours.
When designing the turbocharger, great care was
taken to ensure that servicing – even though seldom –
can be carried out as easily as possible. For example,
the compressor wheel can be taken out without dis-
mantling the compressor casing. On the turbine side,
the outlet casing comes with a wide inspection hatch
that provides good access to the turbine wheel for
inspection and cleaning.
MAN Diesel & Turbo has also reduced the number ofscrews and components to a minimum, developed
a complete set of special tools and included a large
number of pull-off screws and other helpful features to
assist the service engineer during assembly.
n Extended maintenance intervals
n Easy access to compressor and turbine wheel
n Reduced number of components
Maintenance
Easy access to compressor wheel
13 TCR – The cutting edge
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World Class Service
Around the clock
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 delivery of spare parts is of utmost importance
to avoid down times. MAN Diesel & Turbo has an
efficient processing 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 also contributes to
maintaining a high standard of service.
Close coordination with all licensees ensures that
‘products built under licence’ are fully covered by our
global network.
Enjoy the benefits
n Knowledgeable partners in more than 150 service
stations worldwide
n A one stop service for turbochargers, diesel and
gas engines
n Around the clock after sales service
n Largest turbocharger ‘license net’ with full
exchangeability of spare parts
n A high availabil ity of spare parts through an intel-
ligent central stocking system
n Attractive price/performance ratio
14 TCR – The cutting edge
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C o p y r i gh t © MA N
D i e s e l S E
•
S u b j e c t
t om o d i fi c a t i oni n t h e i n t e r e s t of t e c h ni c a l pr o gr e s s .
•
D 2 3 6 6 3 2 4 E N -N 8 P r i n t e d i n G e r m a n y M C - 0 9 1 1 1
MAN Diesel & Turbo
86224 Augsburg, Germany
Phone +49 821 322-0
Fax +49 821 322-3382
turbochargers@mandieselturbo.com
www.mandieselturbo.com
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