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                           MTUreport
                              The magazine of the MTU and MTU Onsite Energy brands I Issue 02 I 2012 I www.mtu-online.com




                       Burning question
                       What possibilities can alternative fuels offer?

                       Quiet success
                       Hybrid railcar makes its debut

                       Ships of the desert
                       Shipbuilding in the United Arab Emirates
Editorial                                                                                                                                                     04                                      18   22




                                                                                                                                                                                                                                                                                           Contents
                                        Joachim Coers, Chairman and CEO                                                                                                                               30                                           36                                              40
                                        of Tognum AG and Chairman of MTU
                                        Friedrichshafen GmbH




                       Dear Readers,
                       What will we be running our engines on in 10, 50 or even 100 years? On gas, water or still       02   Editorial                                                 Marine                                                  MTU Report Europe
                       on diesel? Or is there another fuel that nobody has yet thought of? The cover story of this                                                                22	 Super	Saver
                       issue of MTU Report may help to provide some of the answers. Tognum Chief Technology                  Technology                                               A routine job that never gets boring: Life               Energy
                       Officer Dr. Ulrich Dohle, Karlsruhe University’s Dr. Ulrich Spicher, Paul Melles from the                                                                      aboard a search-and-rescue vessel.                 44	 Source	of	power
                       Dutch shipping company Doeksen and our development team leader, Dr. Philippe Gorse,              04	 Burning	question                                                                                                 An MTU Onsite Energy gas turbine
                       explain in a series of interviews where they see the future of fuel and which engines we             When will off-highway engines run on                  30	 Ships	of	the	desert                                    generates eco-friendly and economical
                       are developing at Tognum for that future. But there is one thing I should make very clear            water? Not for a long time. But alternative               Where ten years ago there was desert,                  heat and electricity at the Halle CHP
                       here and now: the diesel engine will continue to be the core unit of our drive systems.              fuels such as petrol, ethanol and gas are                 Abu Dhabi Ship Building is now construc-               plant.
                       We will be doing everything to make it even cleaner and more efficient. But we will also             already on the agenda today. Experts from                 ting modern corvettes and patrol boats.
                       be looking to the future. And that tells us that at some time or other, the world’s oil              the fields of research, development and                                                                            Rail
                       resources will run out. When precisely is very difficult to predict, but the days of cheap oil       economics explain which fuels they think                   Energy                                            50	 Goodbye	slowcoach
                       are already a thing of the past right now. At the same time, gas is becoming increasingly            have the brightest future.                            36	 Defense	mechanism                                      With over 20,000 kilometers of track,
                       economical and the development of synthetic fuels is advancing. So it is only logical that                                                                     The energy demand in data centers is                   Romania has more railway lines than any
                       we should also develop alternative engine concepts.                                              14   News                                                     enormous. MTU Onsite Energy emergency                  other European country – but many of its
                                                                                                                                                                                      backup gensets ensure that electricity is              locomotives and railcars are well past their
                       Nevertheless, the present of off-highway drive systems remains the diesel engine. That is             Developments                                             never in short supply.                                 best. They are now being upgraded with
                       clear from the latest selection of fascinating engine applications featured in this issue of                                                                                                                          MTU engines and Powerpacks.
                       MTU Report. They power corvettes in the Arab Emirate of Abu Dhabi, monster haul trucks                Rail                                                      Mining
                       in a Canadian coal mine, a lifeboat on the German Baltic and emergency backup genera-            18	 Quiet	success                                         40	 To	Haul	and	Back                                   	   Talking of…
                       tors for data centers in the USA.                                                                    Railcars with the MTU Hybrid Power-                       The work performed by MTU-powered                  56	 Tell	us	your	story!
                                                                                                                            pack can save up to 25 percent on fuel                    haul trucks in a Canadian coal mine is as              Would you like to see yourself or your
                       I know that you, our readers, like the variety and international diversity of the articles           consumption and substantially lower their                 heavy-duty as it gets. But the engines keep            application featured in MTU Report?
                       in MTU Report. That is what you told us in the survey in the last issue of MTU Report in             exhaust and noise emissions at the same                   on running smoothly thanks to rigorous                 Then write to us.
                       which we asked for your opinions. Measured on a scale from one to five, with one as the              time.                                                     servicing by the mine operator.
                       best mark, you gave MTU Report an overall grade of 1.5. Thank you! And it is not just our                                                                                                                         57 Talking	of...
                       readers who like our magazine. The jury for the BCP Award, Europe’s biggest corporate
                       publishing prize, praised the publication too. They awarded MTU Report the silver medal
                       for the second year running. All of those accolades are a spur to our editorial team to




                                                                                                                                                                                                                                                                                                   N ew s
                       continue to inspire you with more exciting reports and articles about the uses of our drive                                                                                         	        silver	Award	for	MTU	Report
                       systems and energy plants – regardless of whether they are fueled by diesel or gas.
                                                                                                                                                                                                           We are delighted to reveal that MTU Report has received the silver medal at the Best
                                                                                                                                                                                                           of Corporate Publishing Awards for the second year running. With over 700 entries,
                       Best regards                                                                                                                                                                        the BCP is the largest corporate media competition in Europe, making it the “business
                                                                                                                                                                                                           media Oscar”. MTU Report was also nominated for an Econ Award. This prize is
                                                                                                                        Cover picture: Chemists at the MTU laboratory test                                 presented by German business paper Handelsblatt and publishing house Econ-Verlag
                                                                                                                        various fuels. To investigate their evaporation pat-                               in recognition of companies and organizations that set standards in corporate commu-
                                                                                                                        terns, the fluids are brought to the boil in a flask on                            nication. The gold, silver and bronze award winners will be announced in November
                                                                                                                        a hotplate. The high temperatures then make for a                                  2012.                                                           MTU Report 01/12 I 3
                                                                                                                        fascinating and colorful display.
2 I MTU Report 02/12
Technology      Alternative fuels




              Burning




                                                                                                                                                                                                                                                 M e MO
                                                                                                                                                                  Glossary of alternative fuels

                                                                                                                                                                  Biodiesel. Unlike conventional diesel fuel, biodiesel is not obtained
                                                                                                                                                                  from mineral oil but from vegetable oil which is transesterified with
                                                                                                                                                                  roughly ten percent methanol and then purified. The resulting biodiesel




              question
                                                                                                                                                                  is very similar in its combustibility and fluidity to conventional diesel
                                                                                                                                                                  fuel. However, rising food prices caused by competing demands for maize
                                                                                                                                                                  have raised doubts about this type of fuel. The breakthrough is expected
                                                                                                                                                                  with the arrival of second-generation biodiesel. In contrast with the early
                                                                                                                                                                  biodiesel, this later variety uses the entire plant so that three times as
                                                                                                                                                                  much biodiesel can be produced from the same crop acreage. As yet,
                                                                                                                                                                  however, the production processes remain uneconomical.

                                                                                                                                                                  Bio-ethanol. Bio-ethanol is a spark-ignition fuel that is produced like
                                                                                                                                                                  conventional alcohol by the fermentation of sugar (glucose) with the aid
                                                                                                                                                                  of micro-organisms and then purified by thermal separation processes.
                 Engines that run on water – it is a nice thought. “But         For a long time, electric motors were seen as the best                            The world’s largest producer of ethanol fuel is the USA, where 45 billion
                                                                                                                                                                  liters were made in 2010. It is closely followed by Brazil, where bio-etha-
                 right now we are a long way from that,” says Professor         replacement for internal combustion engines. There are al-
                                                                                                                                                                  nol is produced from sugar cane. As with first-generation biodiesel, this
                 Ulrich Spicher, Head of the Institut für Kolbenmaschi-         ready quite a number of electric cars on the roads. But po-                       method of ethanol production is in competition with the food market.
                 nen (“Piston Engines Institute”) at Karlsruhe Universi-        wering a megayacht, a high-speed ferry or a monster haul                          New processes in which vegetable waste such as straw or wood chip-
                 ty. However, Tognum Chief Technology Officer, Dr. UI-          truck with electric motors is inconceivable at present. The                       pings are used are not economically viable, however. That is because
                 rich Dohle explains, MTU is already developing                 inadequate storage capacity of the batteries, which results                       such second-generation ethanol production processes are more complica-
                                                                                                                                                                  ted as they require an extra stage. The raw material in this case is cellu-
                 engines that run on alternative fuels such as gas or           in a very short vehicle range, still presents the developers
                                                                                                                                                                  lose which first has to be extracted from the plant then separated into
                 ethanol.                                                       with major problems. Hybrid solutions such as the one                             starch and finally broken down into its sugar components. Only then can
                                                                                MTU is currently testing out in a railcar for Deutsche Bahn                       it be fermented into alcohol.
                 How long will oil reserves last? Experts have been trying to   are a possible alternative. But even they cannot do without
                 answer that question for decades. Another 30 years? Ano-       a diesel engine.                                                                  Liquefied natural gas. LNG is natural gas that has been cooled
                 ther 50 years? So far, all the answers put forward have been                                                                                     to minus 164 degrees Celsius and liquefied. It occupies roughly one
                                                                                                                                                                  600th of the space required by natural gas in gaseous form. LNG has
                 wrong. Despite all the prophecies of doom, there are still     Experts predict that the internal combustion engine will not
                                                                                                                                                                  been used as propulsion fuel in the shipping industry for many years –
                 ample reserves of oil, and fossil fuels shape the market for   lose its dominant position. But in the future, not every off-                     though so far mostly on LNG tankers which transport the fuel and use
                 off-highway vehicles right around the world. But things will   highway engine will run on diesel. Instead, there will be a                       their cargo to run their engines at the same time. In the beginning, the
                 not stay that way. Although nobody can definitively predict    mix of very diverse fuels. Diesel will no longer be crude-oil                     LNG was burned to produce heat for generating steam, which was then
                 how much more oil will be found, we know for certain right     based as it can now also be produced synthetically. Bio-                          used to power a steam turbine which drove the propeller. Today, the
                 now that the growing demand for oil is forcing the price ra-   genic fuels such as ethanol are already in demand in the                          tankers are driven by engines that can run on either LNG or heavy oil.
                                                                                                                                                                  As LNG is cleaner than the other fuels used for marine engines, i.e. heavy
                 pidly upwards. It is foreseeable that crude-oil based fuels    off-highway market, especially in North America and Bra-                          oil and diesel, it is predicted to have a big future as a marine fuel in the
                 will not be sufficient on their own to cover the inexorab-     zil. And gas remains a consideration simply on the basis of                       face of increasingly stringent emission restrictions.
                 ly rising global demand for energy. Furthermore, optimizing    its wide availability. On the next few pages, experts from a
                 diesel engines so that they meet the ever-tighter emission     variety of fields explain where the fuel issue is heading and                     Compressed natural gas. CNG is a highly compressed form of
                 limits for soot particulates and nitrogen oxides is becoming   which products MTU will be offering clients along the way.                        natural gas which can be as much as 99 percent methane. Natural gas is
                                                                                                                                                                  often found together with oil underground and is formed in the absence
                 increasingly costly. Alternatives are now called for.
                                                                                                                                                                  of air at high temperatures and under high pressure from deposits of
                                                                                                                                                                  dead micro-organisms, algae and plankton. When it is burned, it produ-
                                                                                                                                                                  ces 24 percent less carbon dioxide emissions. And natural gas is a good
                                                                                                                                                                  alternative from the safety aspect too – if there is a leak in the fuel
                                                                                                                                                                  system, it simply evaporates into the atmosphere. Natural gas is the
                                                                                                                                                                  most-used gas fuel for motor vehicles in Germany.

                                                                                                                                                                  Biogas. Biogas is a combustible gas which, in contrast with natural
                                                                                                                                                                  gas, is produced by the fermentation of any type of biomass. Biogas
                                                                                                                                                                  plants can ferment not only organic waste but also specially grown
                                                                                                                                                                  energy crops. The gas could also be used as a fuel for other types of
                                                                                                                                                                  power unit. For sufficient quantities of fuel to be carried by mobile
                                                                                                                                                                  machinery and vehicles, however, it would have to be compressed to
                                                                                                                                                                  around 200 to 300 bar and have the CO2 content largely removed.
                                                                                                         To investigate the evaporation patterns of fuels, they
                                                                                                         are brought to the boil in a flask on a hotplate. The
                                                                                                         high temperatures then make for the fascinating and
                                                                                                         colorful display pictured on the following pages.




      4 I MTU Report 02/12                                                                                                                                                                                                       MTU Report 02/12 I 5
                                                                                                                                                                                                                                                                                                                   Technology




                                                            “Synthetic fuels offer
                                                            big possibilities”

                                                            > How long will off-highway vehicles con-            > Is gas an alternative?                           immense improvement in environmental emis-          > When will we be able to produce these              > If you had all possible means at your
                                                            tinue to be powered by large-scale diesel            For mobile applications I see only limited use     sions. Until now, we have always had problems       fuels economically?                                  disposal, what would an engine that you
                                                            engines?                                             for natural gas. It has much lower energy den-     with the various fuels available throughout the     Certainly before too long. Here at the Univer-       would build for an off-highway vehicle
                                                            We will undoubtedly still see diesel engines in      sity than liquid fuels as we know them today       world the quality is not always the same and it     sity of Karlsruhe we are working intensively on      such as a heavy-duty haul truck look like?
                                                            use in the off-highway sector for a long time        and gas-powered vehicles need considerably         is difficult to adjust engines to cope with these   producing second-generation synthetic fuels          I have a vision of it in mind: my engine would
                                                            to come. Diesel and petrol will certainly still      larger tanks for the same travel range. It         differences. Synthetic fuels could provide a        economically and we are very close to achie-         achieve 99.99% pollutant-free fuel combustion
                                                            be the most-used fuels by some distance in           makes more sense to use natural gas in stati-      simple solution to this problem.                    ving that aim. As yet, synthetic fuels are still     and would obviously be highly efficient with
                                                            ten years’ time. It is virtually certain that die-   onary applications both to generate electricity                                                        somewhat more expensive than conventional            drive efficiency rates around 50% and perhaps
                                                            sel engines will still be in use 50 years from       and to provide thermal energy for heating. It is   > A criticism often laid against biofuels           diesel or petrol, but I am certain that the pen-     even higher. That is when the researcher in me
                                                            now, but these engines will no longer operate        a different matter with LPG (Liquefied Petro-      is that their production is in competition          dulum will soon swing in the other direction.        takes over. Theoretically, it is possible. Only
                                                            exclusively on conventional diesel fuel ob-          leum Gas) which is actually a waste product        with food production. When will second-                                                                  the future will show how close we can actually
                                                            tained from mineral oil. General public dis-         because it is produced from the gas that is        generation biofuels that are made from              > And when will the first engines be                 get to that theoretical vision in practice. Ob-
                                                            cussion on the issue always associates petrol        burned off when drilling for oil. LPG is liquid,   waste products rather than food crops be            fueled with hydrogen?                                viously, I am extremely keen to see the dual-
                                                            and diesel fuel with mineral oil which will one      has a high energy density and is ideally suited    available and economical?                           Well, it certainly will not be in the very near      fuel engine we are currently developing with
                                                            day cease to be available the assumption             for use as a fuel for petrol engines.              For me, this is the essential factor in deciding    future unless we happen to have a glut of elec-      MTU in operation in a haul truck. This parti-
                                                            being that the internal combustion engine will                                                          whether we are going to use them at all. Un-        tricity and cannot work out how to store it.         cular engine operates with a single main fuel
                                                            also cease to exist. This is, of course, com-        > What possibilities do synthetic fuels            der no circumstances should the biomass             The problem with hydrogen is that it needs a         such as petrol or ethanol or with a mixture of
                                                            pletely wrong because internal combustion            offer?                                             we need for fuels come from food crops or           great deal of electricity to produce it. Theoreti-   both fuels. Natural gas can also be used as
                                                            engines are not dependent on fuels obtained          Synthetic fuels not only hold great potential      from the food production chain. Food must           cally it is possible, and if we ever have a large    the main fuel. The second fuel, which is only
                                                            from mineral oil. The future will not be built       for engine developers, they could also make        always take precedence over fuels. We can-          surplus of electricity then we can do it. But as     needed in small amounts, is used to ignite the
                                                       CV




Professor Ulrich Spicher, Head of the                       on mineral oil. Although the latest prognoses        a decisive contribution towards securing safe      not have a situation where some people have         I assume that is not going to happen, we can         main fuel. This system achieves combustion
Institute für Kolbenmaschinen at Karlsruhe                  assume that we still have enough mineral oil         energy supplies for mobile applications. At        nothing to eat because we want to fuel our          discount hydrogen as a fuel.                         which is extremely low in pollutant emissions
University.                                                 for the next 100 years, there will come a time       present, internal combustion engines under         cars. However, the synthetic fuels I am talking                                                          and extremely clean and which also offers low
                                                            when the wells run dry.                              development have to be adapted to match the        about here come from waste products such as                                                              fuel consumption. It takes us a little closer to
Professor Ulrich Spicher, has been in charge of the
Institut für Kolbenmaschinen at Karlsruhe Univer-                                                                different qualities and characteristics of fuels   straw, grass cuttings or leaves or from plants                                                           the vision I mentioned earlier. So far, however,
sity since 1994. He studied mechanical engineering                                                               in use worldwide. Although many of these cha-      which are unsuitable as nutrition. And we want                                                           the engine is still a little underpowered for this
at the RWTH in Aachen, gaining his doctorate in                                                                  racteristics are positive, there are also some     to go even further and produce fuel from the                                                             application and we still have work to do on
1982. After a number of years as departmental                                                                    which are not ideally suited for engine opera-     waste we produce such as plastics. I am quite                                                            that score. Nevertheless, I have no doubt that
head at what is now FEV GmbH, the world’s largest
                                                                                                                 tion and development. With diesel fuel, one of     sure that this will happen.                                                                              in cooperation with our colleagues from MTU,
independent development services provider in the
field of internal combustion engines and vehicle
                                                                                                                 them would be the evaporation characteris-                                                                                                                  we will manage to achieve our aim.
engineering, he was appointed head of the Karls-                                                                 tics. The different constituent components
ruhe Institut für Kolbenmaschinen in 1994. The                                                                   of diesel evaporate at different temperatures
establishment enjoys worldwide renown in the                                                                     ranging from 220 to 360 degrees Celsius. That
area of research and analysis into internal com-                                                                 leads to unclean combustion and, therefore,
bustion in spark-ignition and diesel engines and all
                                                                                                                 more soot production. The particular problem
aspects of fuel and air mixing and exhaust after-
treatment.                                                                                                       here is that fuel constituents which evaporate
                                                                                                                 at high temperatures can produce dirty com-
                                                                                                                 bustion and an increase in particulate emis-
                                                                                                                 sions. For diesel engines, synthetic fuels could
                                                                                                                 be created which would overcome this pro-
                                                                                                                 blem and which, ideally, could even achieve
                                                                                                                 completely soot-free combustion. A globally
                                                                                                                 standardized fuel such as this would mean an




6 I MTU Report 02/12                                                                                                                                                                                                                                                                                   MTU Report 02/12 I 7
                                                                                                                                                                                                                                                                                  Technology




                                                         “We can’t do without the
                                                          internal combustion engine”
                                                         > Dr. Dohle, the age of fossil fuels may not      a couple more percentage points in efficien-        > MTU has been selling gas engines for a              > Ethanol is mainly available in South
                                                         yet be over, but the era of cheap oil surely      cy may well be possible. But it all comes at        long time, but so far only for static power           America, biodiesel in Europe – so there
                                                         is. What does that mean for MTU as a              a cost. The engines will need cooled exhaust        generation applications. What are the key             are major regional differences in fuel
                                                         manufacturer of diesel engines?                   recirculation, high injection pressures of up       differences between a static and a mobile             availability. Will MTU have to offer diffe-
                                                         First and foremost, it does not by any means      to 2,500bar, very sophisticated turbocharging       gas engine?                                           rent engines on every continent?
                                                         signal the end of the diesel engine. On that      and further fine-tuning of all the components       The particular feature of gas engines in mo-          We will offer engines to suit regions where a
                                                         point, I agree with Prof. Spicher. The diesel     involved. With gas engines, the cost of emis-       bile applications is that, like diesels, they run     specific fuel is available. Our Series 1600 is
                                                         engine will still be with us for some time yet    sion control is considerably lower. And once        in transient operation across the entire per-         being designed to run on different fuels with-
                                                         but some of our customers will be looking for     the fuel prices are significantly lower than for    formance map. At present, we only run our             out major modifications to the engine. We
                                                         alternatives. The natural gas reserves, for in-   diesel engines, the gas engine will have a lot      gas engines in stationary situations at a fixed       have a basic engine that will be modified by
                                                         stance, are vast and the time will come when      going for it.                                       speed.                                                varying the fuel supply system. It will also be
                                                         gas is more economical as a fuel than diesel.                                                                                                               provided with an ethanol or petrol injection
                                                         At that point we will offer gas engines across    > Bi-fuel engines, dual-fuel engines, pure          > How do you assess the future of                     system in addition to the diesel injection sys-
                                                         as wide a range of applications as we do die-     gas engines – there are many possibilities          biogenic fuels?                                       tem.
                                                         sel engines today. Gas engines certainly pre-     and variations for running internal com-            I do not think that pure biodiesel will become
                                                         sent a very interesting prospect for shipping.    bustion engines on alternative fuels.               established as a main fuel for engines. With          > You have spent your entire professional
                                                         From 2016, coastal waters in particular will be   Which types of engine are you actually              first-generation biodiesel, cost and yield are        life working with diesel engines. How sad
                                                         subject to strict emissions limits which die-     working on at present?                              completely out of proportion. To produce              for you was the realization that diesel is
                                                         sel engines will only be able to achieve with     We are working on gas-only engines as well          enough biodiesel, a significant proportion of         not the fuel of the future?
                                                         the aid of very costly modifications. In such a   as on bi-fuel and dual-fuel engines that can        the planet´s agricultural land would have to          Well, that realization is not especially new.
                                                         situation it definitely makes sense to use gas    be run on various fuels. Stationary natural         be devoted to maize or soya – and that land           When I wrote my first dissertation as a student
                                                         engines.                                          gas and biogas engines have been part of            is needed grow food crops to feed the world’s         in 1977, I accepted the notion that oil reser-
                                                    CV




Dr. Ulrich Dohle, Tognum Chief Technology                                                                  our range for a long time. And we are cur-          population. That problem does not arise with          ves would only last for another 30 years. So,
Officer                                                  > What possibilities do you still see for         rently bench-testing one of our Series 1600         second-generation biodiesel because it is             by that reckoning, they should have run out
                                                         increasing the efficiency of MTU drive            engines using ethanol as fuel together with         produced from complete plants or bio-waste.           in 2007. Today we are still talking about 30
Dr. Ulrich Dohle is Vice Chairman of Tognum AG
                                                         systems so that they not only produce             homogeneous-charge combustion and con-              Nevertheless, the processes involved are high-        more years. My son is studying drive systems
and heads the Technology & Operations Division.
He studied mechanical engineering at the Rhine-
                                                         lower emission levels but also require less       trolled ignition which involves injecting a small   ly complex and expensive and they will be             engineering and I confidently expect that he
Westphalia Univeristiy of Technology in Aachen,          fuel?                                             amount of diesel fuel.                              difficult to establish. With ethanol it is a diffe-   and his generation will still get plenty of useful
specializing in internal combustion engines, and         The diesel engine undoubtedly still has poten-                                                        rent picture. In Brazil, for example, it is produ-    service out of the internal combustion engine.
gained his doctorate in the field of static com-         tial for further improvement. Over the past       > What percentage of Tognum’s develop-              ced relatively economically from sugar cane           The glorification of the electric motor over
bustion. From 1984 to 2009, he worked for Robert         decade we have worked extremely hard to           ment capacity is used on diesel engines,            and it is available in adequate quantities. Etha-     recent years has been more worrying. But the
Bosch GmbH in Stuttgart. A member of the senior
                                                         make our engines cleaner and more economi-        and how much on engines that can be run             nol is not currently used in large engines but I      euphoria is gradually waning and the realiza-
management from 1998, Dr. Dohle was in charge of
the largest of the Bosch divisions as Chairman of        cal. And we have succeeded in that. The new       on alternative fuels?                               expect that that could well change.                   tion is taking hold that we will not be able to
the Diesel Systems arm until his move to Tognum.         Series 2000 and 4000 engine generations will      Very roughly, at present we use 80% of our                                                                dispense with the internal combustion engine
                                                         comply with the upcoming Tier 4final emissi-      capacity on diesel engines and 20% on gas           > What are the consequences of using                  for the next few decades.
                                                         ons legislation without having to use exhaust     and ethanol engines. But I would expect that        biogenic fuels for the internal workings of
                                                         aftertreatment systems. And we have even          distribution to move towards a 50:50 share          MTU diesel engines?
                                                         managed to lower their fuel consumption as        over the next few years.                            Some second-generation biodiesel is cleaner-
                                                         well. Theoretically, those two aims are mutual-                                                       burning than mineral fuels so that it causes no
                                                         ly exclusive. Our development engineers have                                                          engine problems. Additions of 7% biodiesel in
                                                         achieved excellent results here and I think                                                           fuel are standard today.




8 I MTU Report 02/12                                                                                                                                                                                                                                                      MTU Report 02/12 I 9
                                                                                                                                                                                                                                                         Technology




                                                         “LNG is the marine fuel
                                                          of the future”
                                                         > Mr. Melles, up to now all of your ferries        > So is the availability of LNG now                  > What makes you so certain that LNG is            > And is LNG economically attractive as
                                                         have been run on diesel. Why the change?           guaranteed?                                          the right fuel for ships?                          well?
                                                         We became interested in the idea as long ago       Well, it is certainly not perfect. When we first     There are several reasons. Number 1: gas will      That depends on what you compare it to. At
                                                         as 2000 when the first LNG-powered ferry           looked at it in 2000, we would have had to buy       definitely be available for much longer than       present it is cheaper and cleaner than diesel
                                                         went into service in Norway. We were plan-         the fuel from Portugal or Norway; now at least       mineral-oil-based fuels. Number 2: engines         fuel but more expensive than heavy oil. Of
                                                         ning to build a a new ferry in 2004 and wanted     you can get it in Zeebrugge and next year very       fueled by LNG easily comply with the emission      course, nobody knows how the prices will
                                                         to invest in a progressive technology. But the     probably in Rotterdam as well. It isn’t ideal by     limits which diesel engines can only meet with     develop in the future. But basically we can
                                                         availability of LNG was still very poor in those   any means, but is enough to start with. The          the aid of complex exhaust aftertreatment          assume that the LNG price will fall relative
                                                         days and the authorities in the Netherlands        shipping industry tends to be conservative,          systems. We are talking about emission levels      to the cost of diesel because oil will become
                                                         were not doing anything to change the situa-       everyone wants to be absolutely certain the          for nitrogen oxides and soot particulates that     increasingly more difficult and, therefore, more
                                                         tion either. So we shelved the plans in 2004.      technology works; nobody wants to be the first       are 95 percent lower. And when the first ECAs      expensive to extract. But only those who sell
                                                         But we never gave up our interest in LNG. And      to try something new. But as long as nobody          (Emission Control Areas) in the North Sea are      the fuel know the precise answer and I am not
                                                         as we now need a new ferry again, we are           puts their faith in LNG, nobody will invest in       set up in 2015, vessels that do not meet the       privy to their plans.
                                                         looking at the idea once more. The ferry is        expanding the infrastructure. So, as I am sure       emission standards will no longer be allowed
                                                         to be very eco-friendly – made of aluminum,        that LNG is the marine fuel of the future, we        in coastal areas. So I will then have the choice   > Can you also see LNG as a fuel for
                                                         and the electricity for the onboard services       are willing to take the first steps with our ship-   of either a diesel engine with a costly exhaust    luxury yachts?
                                                         will partly be provided by solar panels. We are    ping business. We want to make our findings          aftertreatment system or an LNG engine. The        Certainly, why not? Yacht owners hate black
                                                         aiming to have the concept finished by the         and our data available to the industry and use       third reason is to do with noise pollution. LNG    and smelly fumes and want to have a compact
                                                         end of the year so that we can start the tende-    what we hope will be our positive experiences        engines are much quieter than diesel engines.      engine room. Above all they want to be able to
                                                         ring process next year.                            to persuade other ship operators to fuel their       That is an important factor for passenger fer-     sail their yachts in coastal waters too. When
                                                                                                            fleets with LNG.                                     ries in particular. And there is another thing     they become part of the designated ECAs in
                                                                                                                                                                 that is important to me – once we have a           the near future, they will be subject to much
                                                    CV




Paul Melles, Managing Director                                                                                                                                   functioning LNG system on board, we will also      stricter emission limits. But LNG is not just a
Doeksen Shipping                                                                                                                                                 be able to run it on biogas – and then we will     fuel for ships. There are already trucks that
                                                                                                                                                                 have a completely carbon-neutral ferry, which      run on LNG in the Netherlands. And the more
Paul Melles has worked at Doeksen for 25 years
                                                                                                                                                                 is our ultimate aim.                               vehicles that are fueled by LNG, the better the
continuously apart from a very brief interlude.
He was Technical Manager in 1999 when he
                                                                                                                                                                                                                    infrastructure will become.
became Technical Director of the holding com-
pany Koninklijke Doeksen BV for two years. He
came back to Doeksen as Managing Director in
2001. The company operates a total of six ferries
to the Dutch islands of Terschelling and Vlie-
land in the North Sea.




10 I MTU Report 02/12                                                                                                                                                                                                                        MTU Report 02/12 I 11
                                                                                                                                                                                                                                                                                                                Technology




                                                          “Petrol engine with
                                                           compression ignition”
                                                          Petrol engines in the off-highway sector –     > What gave a manufacturer of diesel                > What are the biggest changes on the              > The aim was to produce an engine that
                                                          up to now the two have appeared mutual-        engines the idea of developing a petrol             engine compared with a conventional                satisfied Tier 4 final emissions regulations
                                                          ly exclusive. But rising oil prices and the    engine?                                             diesel engine?                                     without using an exhaust aftertreatment
                                                          increasingly widespread availability of        There are several reasons. Although present-        Firstly the fuel injection system, of course.      system. Have you achieved that?
                                                          synthetic and biogenic fuels are breaking      day diesel engines are clean and produce            As well as diesel, we now also have to deli-       Yes, we have. Even though this engine is not
                                                          down the barriers. MTU is currently wor-       hardly any harmful emissions, they have to          ver ethanol/petrol to the combustion cham-         planned as a Series solution for Tier 4 final, it
                                                          king with the Karlsruhe Institute of Tech-     be made more and more complex to achieve            ber. This is done by injection into the engine’s   still emits 93%less nitrogen oxide and 40%less
                                                          nology on the testing of a petrol engine       such low emission levels. In addition, there        charge-air pipe and the fuel then enters the       soot than required by the North American
                                                          that can be operated economically and          are already signs that in some regions petrol/      cylinder together with the intake air. To pre-     legislation from 2014 for this power class. So
                                                          also meets Tier 4 emissions standards          ethanol will be cheaper than diesel and thus        vent the spark-ignition fuels igniting too soon    we can do without an SCR system in future at
                                                          without external emission control sys-         economically an attractive proposition for          and in an uncontrolled manner, we have had         all events. Although the HC and CO emissions
                                                          tems. It is based on the MTU Series 1600       off-highway vehicles. Like petrol, ethanol is       to lower the oxygen content in the combusti-       are slightly higher than from the diesel engine,
                                                          diesel unit for industrial applications. But   a spark-ignition fuel. It is made from crops        on chamber. We do that by using a very high        we can control them with a simple oxidation
                                                          it only uses diesel for ignition. The engine   such as sugar cane or maize. Because plants         exhaust recirculation rate of as much as 60        catalytic converter.
                                                          mainly runs on ethanol or petrol. The          are used as the energy source, global emissi-       percent. By comparison, the recirculation rate
                                                          advantage is that the ethanol-and-air mix-     ons of greenhouse gases can be reduced by           on our Series 4000 Tier 4 final diesel engine is   > You are currently testing the combustion
                                                          ture is extremely homogeneous, which           using this type of fuel in internal combustion      between 30 and 40%. To achieve that high rate      process on an MTU Series 1600 engine. Is
                                                          means that much lower levels of nitrogen       engines. In North and South America in par-         while simultaneously obtaining high engine         it conceivable that the system could be
                                                          oxides and soot particulates are produced      ticular, the fuel is already in widespread use,     performance, we also need large amounts of         transferred to more powerful engines?
                                                          during combustion than with a conventio-       though only in road-going vehicles. In the off-     air in the combustion chamber. For that pur-       Yes, I would think so. Our primary aim with the
                                                          nal diesel engine. Two prototypes are          highway sector by contrast, ethanol is almost       pose we have developed a special two-stage         Series 1600 unit is to show that the system
                                                          being bench-tested at present.                 unknown. Not least among the reasons for            controlled turbocharging system with interme-      works. We view this engine as a trial unit on
                                                     CV




Dr. Philippe Gorse, MTU new engine concept                                                               that is that as yet there is no suitable engine     diate cooling.                                     which we can develop and test technologies
development team leader                                                                                  available. But we aim to change that situation.                                                        that we need for the engines of the future. If
                                                                                                                                                             > What are the proportions of diesel and           the combustion process works on this engine,
Dr. Philippe Gorse has been team leader in the                                                           > Can the engine only run on ethanol or             ethanol?                                           we will investigate whether it can also be
MTU Pilot Development Department since 2009                                                              can it use petrol too?                              That depends on the operating point. We have       transferred to other engines. But before then
and is responsible for new engine concept develop-
ment. Before that he spent two years as a project
                                                                                                         Our aim is to develop an engine that can run        developed an ECU that precisely calculates         there is still a great deal of work to be done to
manager in Pilot Development. He graduated in                                                            on both petrol and ethanol. In the long term,       the fuel ratio according to power output and       make this new combustion process produc-
mechanical engineering at the University of Karls-                                                       using natural gas is also conceivable. To be        engine speed. At up to 25 percent, the diesel      tion-ready.
ruhe in 2001. He subsequently gained his doctorate                                                       able to offer such fuel-versatility, a great deal   content is highest at low power outputs. As
there and also worked as a member of the scienti-                                                        of development work on the fuel system, the         output increases, the diesel proportion dimi-
fic staff.
                                                                                                         combustion process and the engine manage-           nishes so that it is only about five percent at
                                                                                                         ment is still required.                             rated output.                                                                                           Text and Interviews: Lucie Dammann
                                                                                                                                                                                                                                                                     Pictures: Robert Hack




                                                                                                                                                                                                                                                                                           O N L IN e
                                                                                                                                                                                                                                                          More	on	this...
                                                                                                                                                                                                                                                          prof. dr. ulrich Spicher and
                     Both MTU and the Karlsruhe                                                                                                                                                                                                           dr. philippe gorse explain the
                     Institut für Kolbenmaschinen                                                                                                                                                                                                         dual-fuel engine.
                     are currently testing an                                                                                                                                                                                                             Don’t have a QR code reader?
                     MTU dual-fuel engine.                                                                                                                                                                                                                Go to http://bit.ly/MluAKv




12 I MTU Report 02/12                                                                                                                                                                                                                                                                                   MTU Report 02/12 I 13
 News


                                                                             New Board
                                                                             Member with
                                                                             Responsibility
                                                                             for Sales



                                                                             Dr. Michael Haidinger took up his post as
                                                                             Tognum’s new Sales Director on 1st July 2012.

                                                                                                                               MTU engines power the hydrostatic drive system in Bomag landfill compactors.     Delegates from Tognum subsidiary Tognum America Inc. held discussions with
                                                                                                                                                                                                                representatives of the White House and the US Department of Education on a
                             On July 1, 2012, Dr. Michael Haidinger (51) joined the Executive Board at Tognum AG, assuming                                                                                      planned training program at high schools in Aiken County in the state of South
                        responsibility for Sales. He succeeds Peter Kneipp (52) who left the Executive Board at the end of
                                                                                                                               Landfill compactors
                                                                                                                                                                                                                Carolina.
                        February 2012 by mutual consent in order to pursue a new professional challenge. In addition to
                        responsibility for Global Distribution and Service, Dr Haidinger has also taken over the Engines and
                        Onsite Energy business units which had previously been managed on an interim basis by Tognum
                        Chairman Joachim Coers alongside his duties as CEO.                                                                                                                                     Vocational training made
                                 Before joining the Tognum Board, Haidinger was President of Rolls-Royce Deutschland and a
                        member of the Supervisory Board of Tognum AG. “In Michael Haidinger, the Board has gained a new
                                                                                                                               For the first, time MTU is supplying engines to Bomag GmbH, the global
                                                                                                                               market leader in the field of compaction technology. Part of the French          in Germany
                        colleague who is an extremely experienced manager with many years of success at international          Fayat Group, the company is equipping all its new 32, 37, 47 and 55-tonne
                        level. At Rolls-Royce he was responsible for 3,500 employees at six facilities in Germany and the UK   landfill compactors with MTU Series 400 and Series 500 engines.                  In the autumn of 2012, MTU is starting a new training program at its
                        as well as in North and South America. With his help we will continue to implement our consistent            Landfill compactors are special vehicles that help to spread out and       Aiken plant in the USA. It combines high-school education, technical
                        strategy of growth at Tognum,” said Coers.                                                             compress waste on landfill sites. Compaction is aided by the heavy weight        instruction in the classroom and practical learning at the MTU plant in
                                 Born in Austria, Haidinger has worked at various international companies in the aerospace     of the vehicle and its drum-like wheels with spikes or blades that shred,        Aiken. The aim is to offer more young Americans better training and
                        industry since 1989, including DASA, Fairchild/Dornier, Airbus, Eurocopter and (since 2006) Rolls-     work and compress the waste. Bomag landfill compactors are designed              entry into a career without having to graduate from college.
                        Royce. In the course of his career he has held responsibility for a range of areas including sales,    specifically for the tough demands of spreading and compacting refuse on             Representatives of Tognum America visited the White House to
                        contract management, after-sales, service and distribution. At Rolls-Royce, Haidinger was prima-       landfill sites. The degree of compaction achieved is decisive to the efficien-   discuss the program with representatives of the US Department of
                        rily responsible for directing the company’s global activities involving business jet engines and he   cy of a waste disposal site.                                                     Education. They met the leaders of the Aiken County Public School
                        dealt with a wide portfolio of customers. In this as in previously held positions, he acquired ex-           The engines offer power outputs of up to 440 kilowatts and are based       District, the Aiken County Career and Technical Center, the Aiken
                        tensive experience with customers in the civil sector as well as in both national and internatio-      on Mercedes-Benz Type OM 460 LA and M 502 LA commercial vehicle                  Technical College and the Apprenticeship Carolina organization.
                        nal governmental business. During his time at Rolls-Royce, revenues in his area of responsibility      engines. They meet EU III B emission standards without requiring an SCR          Together with Tognum America, the group put forward a vision offe-
                        more than doubled. Dr Michael Haidinger is married and has two children. “I am very pleased with       exhaust aftertreatment system. For the EU IV and EPA Tier 4 final emis-          ring high-school students a career boost in industrial manufacturing
                        my appointment to the Tognum Board. The company has an outstanding record of success and               sion limits that come into force as of 2014, MTU will supply Bomag with          through the new training program.
                        enormous potential for growth. I look forward to being able to use the extensive experience I have     prototypes of the next generation of engines. Initially these will be Type 6R
                        gained with international customers to support Tognum in its strategy of growth,” said Haidinger.      1000, 6R 1300 and 6R 1500 units. The MTU engines provide the new land-
                                                                                                                               fill compactors with the necessary power for their hydrostatic drive system.
                                                                                                                               That converts the engine power into torque and thus into forward thrust or
                                                                                                                               speed. So the vehicles can operate efficiently on steep slopes, move large
                                                                                                                               mounds of rubbish and change direction quickly. As well as landfill compac-
                                                                                                                               tors, Bomag offers a wide range of compaction equipment from lightweight
                                                                                                                               compactors through tandem rollers to ground compactors, soil consolida-
                                                                                                                               tors and recyclers, road layers and millers.




14 I MTU Report 02/12                                                                                                                                                                                                                                                    MTU Report 02/12 I 15
News




                                                                                                                                                             The MTU Onsite Energy logo was officially unveiled in Ruhstorf as part of a   The MTU Onsite Energy CHP module, which is based on the Series 4000 engine,
                                                                                                                                                             staff celebration.                                                            generates between 764 and 2,135 kWe and runs on natural gas.



                                                                                                                                                             Aggretech renamed MTU                                                         Modular CHP plants now
                        The Seacor Lynx will be powered by four MTU diesel engines.     As of now Tognum offers MTU onboard generator sets with outputs
                                                                                                                                                             Onsite Energy Systems                                                         sold in America
                                                                                        ranging from 5 to 280 kilowatts for commercial vessels and yachts.
                                                                                        Pictured here: genset with rated output of 90 kW at 1,500 rpm or     Aggretech, the subsidiary recently acquired by Tognum, is now trading         MTU Onsite Energy branded modular CHP plants are available as of now in
                                                                                        99 kW at 1,800 rpm.                                                  under the new name MTU Onsite Energy Systems GmbH. By taking                  the North American market. Buyers can choose between two versions. The
                                                                                                                                                             over the electricity generator producer from Ruhstorf near Passau in          small units with Series 400 engines produce between 128 and 358 kilowatts
                        Wildcat                                                         5 to 3,000kw range for
                                                                                                                                                             April this year, Tognum is aiming to expand its business in localized
                                                                                                                                                             energy plants and its onsite energy product portfolio. The products
                                                                                                                                                                                                                                           of electrical output and can be fueled by natural gas, biogas, landfill gas or
                                                                                                                                                                                                                                           sewage gas. The large units with Series 4000 engines run on natural gas and
                        action                                                          onboard gensets
                                                                                                                                                             already made in Ruhstorf will now be marketed as “Aggretech by MTU            generate between 764 and 2,135 kilowatts of electricity. The modules pro-
                                                                                                                                                             Onsite Energy”.                                                               duce electricity and heat at the same time (combined heat and power or
                        Two new Seacor Marine offshore supply ships will have                                                                                     “The new name for this subsidiary underlines the fact that MTU           CHP generation). MTU Onsite Energy sells its CHP modules via a network of
                        a top speed of 46 knots courtesy of quadruple MTU Se-           Tognum has agreed a general contract with onboard generator          Onsite Energy Systems is a fundamental component of Tognum’s de-              authorized dealers in the USA, Canada and Mexico.
                        ries 4000 Type 16V 4000 M73L engines. Seacor Mari-              producer Northern Lights Inc. of Seattle/Washington (USA)            centralized energy generation business,” explained Ulrich Kemnitz,                CHP plants have been used successfully in Europe and Asia for more
                        ne is a leading operator of supply ships for the oil and        for the purchase of onboard generator sets with output ratings       Executive Vice President with responsibility for Onsite Energy opera-         than 35 years. The large choice of usable fuels provides a broad spectrum of
                        gas industry and has once again opted for the 3,860 hp          from 5 to 280 kilowatts. The Tognum sales organization will          tions at Tognum. “As well as customized solutions, we will be extending       applications from agricultural businesses to community facilities, hospitals,
                        propulsion systems supplied by MTU for its latest craft.        sell the gensets as MTU-branded units for commercial vessels         the Tognum product portfolio by the addition of standard systems and          universities and production plants. “Because of the growth in population and
                        Seacor Lynx and Seacor Leopard are both 190 feet in             and leisure craft in combination with MTU propulsion systems.        will shortly be concentrating assembly of standard system diesel gen-         the accompanying economic growth, we will have a constantly increasing de-
                        length, carry up to 150 passengers and can transport as         This means that the Tognum Group has extended its product            sets with MTU Series 1600, 2000 and 4000 engines in Ruhstorf.”                mand for energy all over the world, and this technology makes it possible to
                        much as 150 tonnes of cargo on deck.                            portfolio at the lower end so that it now offers the full spec-                                                                                    generate power and heat right where they are needed – reliably, highly effici-
                            “The large distances and the need to convey crews           trum of onboard power generators across a range of power                                                                                           ently and ecologically,” said Ulrich Kemnitz, Executive Vice President Onsite
                        and urgently required supplies to the drilling rigs quickly     outputs from 5 to 3,000 kilowatts. So Tognum is now able to                                                                                        Energy at Tognum.
                        demands fast ships,” explains Joe McCall of Seacor Ma-          offer advice, sales and service for the entire engine room from
                        rine. “With their high power-to-weight ratio and low fuel       a single source.
                        consumption, MTU engines are the units best suited to
                        the hull configurations of the new Seacor Lynx and Seacor
                        Leopard,” McCall expands. And he adds that, “Dealer
                        support and many years of experience with MTU also pla-
                        yed an important part.” The ships will be equipped with         MTU on the Adriatic                                                  In brief:
                        MTU’s Callosum automation system. An integrated ship
                        monitoring and control system, it monitors not only the         In order to oversee its internal waters, territorial sea and eco-    UIC certification for new rail engine                                         Supplier Award winners
                        propulsion engines but also the onboard generators and          logical as well as fisheries protection zones, the Republic of       Tognum has obtained the UIC Certificate 623 for the V16 version of            For the second year in succession, Maschinenfabrik Spaichingen has
                        a large number of other ship’s services. It allows the ope-     Croatia recently started operating the patrol boat “Marino           the MTU Series 4000 R84 engine for rail applications. Based on testing        won Tognum’s award for Best Supplier of Finished Parts. The top-rated
                        rative personnel to literally see everything that the ship is            c”.
                                                                                        Jakomini´ A twin installation of high-performance MTU 16V            according to UIC procedures, which includes not only an endurance test        unfinished parts supplier was Giesserei Heunisch. The winner in the new
                        doing at one time on a single screen.                           2000 engines at 1,050 kW each enables the coast guard to             but also measurement of the exhaust emissions, the engine has demons-         Onsite Energy award category was Hering and the number-one compo-
                                                                                        manoeuvre the vast area quickly and efficiently: with speeds         trated its mechanical qualities and its compliance with the EU IIIB emis-     nent supplier was Zeulenroda Präzision Maschinenbau.
                                                                                        of up to 28 knots (52 km/h), the vessel and its crew of se-          sion standard.
                                                                                        ven promptly reach their destination to observe, monitor and                                                                                       Breaking new ground in Poland
                                                                                        control other boats and vessels.                                     Quality management in Aiken accredited                                        The Tognum Group has turned the first sod for the construction of the
                                                                                                                                                             Tognum America’s MTU plant in Aiken recently successfully passed              new production plant in the Polish city of Stargard Szczecinski. Tognum
                                                                                                                                                             an audit for accreditation to the ISO 9001:2008 standard for quali-           subsidiary MTU Polska will start producing the first components for
                                                                                                                                                             ty management processes. The site had already obtained ISO 14001              MTU-brand engines there in the second half of 2013.
                                                                                                                                                             environmental certification in March this year.




16 I MTU Report 02/12                                                                                                                                                                                                                                                                              MTU Report 02/12 I 17
                                                                                                                                                                                                                                     Rail
                                                                                                                                                   Just one press of a button by the train driver is all that is required to switch over to
                                                                                                                                                   electric traction mode.




                                                                                                                       Fuel consumption up to 25 percent lower                   hybrid traction system with a diesel engine and
                                                                                                                       and almost silent operation even on routes                electric motor,” Lehmann explains. As part of a
                                                                                                                       without overhead power lines. Both are                    joint pilot project with Deutsche Bahn subsidiary
                                                                                                                       made possible by the new MTU Hybrid Po-                   DB RegioNetz Verkehr GmbH Westfrankenbahn,
                                                                                                                       werpack. It is currently undergoing testing in            MTU converted a Class 642 railcar with diesel-
                                                                                                                       a railcar in Germany and is expected to be                mechanical traction to hybrid power. Since May
                                                                                                                       approved for use on local services by the end             2012 it has been in action at shows and in prac-
                                                                                                                       of the year.                                              tical trials. Approval for operation on passen-
                                                                                                                                                                                 ger services is scheduled for the end of the year.
                                                                                                                       All of a sudden silence descends. Not even the            The project has been subsidized by the German
                                                                                                                       distinct hum of the MTU diesel engines is to be           Federal Ministry for Transport, Construction and




          Quiet
                                                                                                                       heard. They have gone quiet too. Almost noise-            Urban Development as part of the Electric Trans-
                                                                                                                       lessly, the red Siemens Desiro VT 642 railcar             port Model Regions program which is coordinated
                                                                                                                       glides past the green forests and white houses            by NOW GmbH, Germany’s national organization
                                                                                                                       of the hilly Bavarian landscape. Just before              for hydrogen and fuel cell technology.
                                                                                                                       everything fell silent, there was a soft click – just
                                                                                                                       the press of a button by the train driver was all         Fuel consumption up to 25 percent lower
                                                                                                                       that was required to switch the diesel engine of          The Hybrid Powerpack has been developed from
                        Since May 2012 the hybrid railcar has been in action




          success
                        at shows and in practical trials.
                                                                                                                       the new MTU Hybrid Powerpack off and the elec-            the proven MTU underfloor traction modules. Up
                                                                                                                       tric motor on. A smile spreads over the face of           to now they have contained only a single power
                                                                                                                       MTU project manager Ingo Lehmann. He and his              unit, a diesel engine. The Hybrid Powerpack has
                                                                                                                       team have been working on this special hybrid             not only a 315-kilowatt Type 6H 1800 R75 die-
                                                                                                                       powerpack for years. It has long since demons-            sel unit but also a up to 400-kilowatt electric
                                                                                                                       trated its capabilities on the test bench. Now it is      motor. And MTU has also incorporated an SCR
                                                                                                                       being tested out on the German railway.                   exhaust aftertreatment system with an urea tank
                                                                                                                                                                                 in the hybrid power module to comply with EU
                                                                                                                       Approval for passenger service by end                     IIIB emission standard which came into force as
                                                                                                                       of the year                                               of 2012. In this configuration, the Hybrid Power-
                                                                                                                       “The VT 642 is something new in Continental               pack is also suitable for ecologically repowering
                                                                                                                       Europe. It is the first railcar to be powered by a        existing diesel railcars. As a parallel hybrid unit,


                                                                               «The VT 642 is the first railcar in Continental Europe to be
                                                                                                                                                                                 the underfloor traction module can be operated
                                                                                                                                                                                 in diesel-only or electric-only mode or in diesel-
                                                                                                                                                                                 electric mode. And that pays dividends. Both fuel
                                                                               powered by a hybrid traction system with a diesel engine and                                      consumption and carbon dioxide emissions can


                                                                                              »
                                                                                                                                                                                 be reduced by as much as 25 percent.
                                                                               electric motor.   Ingo Lehmann, MTU Friedrichshafen



18 I MTU Report 02/12                                                                                                                                                                                              MTU Report 02/12 I 19
                                                                                                                                                                                                                                                                                                                        Rail




                                                                                                                                                                                                                                                  Me MO
                                                                                                                                                                          Brake	&	save

                                                                                                                                                                          When a train brakes, it releases large amounts of energy in the form
                                                                                                                                                                          of heat. Normally, that energy simply dissipates and is not used.
                                                                                                                                                                          However, it can be used to drive the train and MTU’s Hybrid Power-
                                                                                                                                                                          pack makes use of the principle involved: A specially developed
                                                                                                                                                                          crankshaft starter-generator (CSG) absorbs the kinetic energy, con-
                                                                                                                                                                          verts it to electrical energy and stores it in a lithium-ion battery.
                                                                                                                                                                          When the train moves off, the current flows from the battery to the
                                                                                                                                                                          CSG which re-converts the electrical energy to kinetic energy, dri-
                                                                                                                                                                          ving the crankshaft. Depending on demand, a frequency converter
With the MTU Hybrid Powerpack railcars can reduce both fuel consumption and carbon dioxide emissions by as much as 25 percent.                                                                                                                            Conventional Powerpacks form the basis for the MTU hybrid system.
                                                                                                                                                                          controls the flow of energy from the battery to the drive unit and
                                                                                                                                                                                                                                                          However, they have been modified to create enough space for the
                                                                                                                                                                          back.
                                                                                                                                                                                                                                                          hybrid technology. That means that they can be fitted in trains as



                                                       «This project is a significant milestone along the way to
                                                                                                                                                                                                                                                          part of routine repowering operations.


Energy from braking
The new traction system enables recovery of
the kinetic energy from braking by converting it       universal use of low-emission and environmentally friendly
into electrical energy using an alternator. Ingo
Lehmann, the man in charge of the rail hybrid
project at MTU, explains the principle: “Every
                                                       trains on non-electrified lines.
                                                                                       »
                                                       Claus Werner, DB RegioNetz Verkehrs GmbH
time the train brakes, the energy is stored in a
lithium-ion battery. And whenever it is required to
power the electric motor, the battery gives that       air conditioning by ten percent. The system will      adapted to different topographical conditions. It
energy back – when passing through a tunnel,           also be powered by energy from the lithium-ion        will thus be fundamentally transferrable to diffe-
arriving at a station or traveling through a densely   batteries.                                            rent classes and usable across Deutsche Bahn or
populated area.” The recovered braking energy is                                                             by other public transport companies. “This pro-
also used to supply auxiliary electrical equipment     “Significant milestone”                               ject is therefore a significant milestone along the
such as air conditioning compressors. It is a tech-    Following passenger-service approval, the hybrid      way to universal use of low-emission and environ-
nology that is particularly effective on local ser-    prototype will go into service with Deutsche Bahn     mentally friendly trains on non-electrified lines,”
vice routes involving stop-and-go operation with       subsidiary Westfrankenbahn on the route bet-          states Clause Werner, who is in charge of testing
frequent braking and acceleration phases.              ween Aschaffenburg and Miltenberg in the Lower        and approval of the hybrid railcar at DB Region-
                                                       Main region of Bavaria. With its 14 stops in the      Netz Verkehrs GmbH.
The division of tasks between MTU and Deut-            space of 37 kilometers, this route provides the
sche Bahn was clear – MTU developed the Hybrid         ideal situation for testing out the hybrid trac-      Text: Lucie Dammann
Powerpack and bench-tested it. Deutsche Bahn,          tion unit in stop-and-go conditions. The insights     Pictures: Robert Hack
for their part, integrated the components and          gained from passenger service operation there         Graphics: Roland Witsch
systems in the existing railcar and will have the      will inform related follow-on projects. The aim is
vehicle approved for local passenger service.          to convert more locomotives in the coming years
As another part of the project, the manufac-           and to develop the hybrid technology to the point     To find out more, contact:
turer Konvekta Schwalmstadt also developed and         where it is ready for series production as a trac-    Ingo Lehmann
tested out an eco-friendly CO2 air conditioning        tion unit for local transport railcars. The techno-   ingo.lehmann@mtu-online.com
system which will reduce the energy demand for         logy will be a modular concept so that it can be      Tel. +49 7541 90-3467                                                                                                                                                                            9




                                                                                                                                                                                                                                                                                            1 Diesel engine
                                                                                                                                                                                                                                                                                            2 Crankshaft Starter-Generator
                                                                                                             The lithium-ion batteries for traction and onboard                                                                                                                               (CSG)
                                                                                                             power supply on the railcar are mounted on the roof                                                                                                                            3 Gearbox
                                                                                                             of the vehicle together with the DC/DC transformer                                                                                                                             4 Exhaust aftertreatment system
                                                                                                             for onboard power supply, the central control cabinet,                                                                                                                         5 AdBlue® tank
                                                                                                             the air conditioner for the lithium-ion batteries, the   3                            5              2                 1         8             4   7                     6     6 Lithium-ion battery
                                                                                                             new-design air conditioning system for the passenger                                                                                                                           7 Traction power converter
                                                                                                             compartment and the auxiliary equipment power                                                                                                                                  8 System controller
                                                                                                             converter it requires.                                                                                                                                                         9 Onboard power supply




                                                                                                                                                                                                                                                                                                      MTU Report 02/12 I 21
Marine
                                                New lifeboat for Sassnitz station




                                                  Super
                                                  saver
 The lifeboat crew of the
 German Maritime Search
 and Rescue Service in Sass-
 nitz has a new home from
 home. A gleaming white,
 36.5-meter lifeboat with a
 top speed of 25 knots: the
 Harro Koebke. It started
 service a few weeks ago
 at its base on the island of
 Rügen. Now the lifeboat-
 men are making their oc-
 casional home comfortable
 and getting the boat ready
 for duty.




               Denmark
                           Rügen
   North Sea

                Hamburg

 Nether-
 lands         Germany             Poland
                                   MTU Brown    MTU Brown
                                   0-17-28-62   80% der Farbe   60%    40%    20%
                                   CMYK         CMYK            CMYK   CMYK   CMYK




                                   MTU Blue
                                   50-25-0-10
                                                MTU Blue
                                                80% der Farbe
                                                                60%
                                                                CMYK
                                                                       40%
                                                                       CMYK
                                                                              20%
                                                                              CMYK
                                                                                     Harro Koebke is the name of the new lifeboat stationed in Sassnitz. It is one of 15 rescue craft powered by MTU
                                   CMYK         CMYK



                                                                                     engines. The German Maritime Search and Rescue Service, DGzRS, has a total of 30 MTU engines in use.



                          Czech                                                                                                                                                          MTU Report 02/12 I 23
                          Republic
Marine                                                                                                                                                                                           1



Monday morning on Rügen. The lifeboat Harro Koebke gleams in the sun-                  vice, the DGzRS. It is also the service’s biggest lifeboat operating in the
light. It is still quiet in Sassnitz harbor this early in the morning. The first few   Baltic Sea. It is stationed at Sassnitz on the island of Rügen. And its patch
pleasure boats are on their way to the famous Rügen chalk cliffs and a few             is the stretch of the Baltic Sea between Cape Arkona and the island of
sailing yachts are heading out into the Baltic Sea. Moored on the western              Greifswalder Oie off Rügen. The 36.5 meter craft replaces an old lifeboat
quay are a blue-and-white tug, next to it the Harro Koebke, and next to that           which was decommissioned after 34 years’ service. The permanent crew
a blue police launch. At first sight, everything appears in a slumber. Only            consists of eleven lifeboatmen, five of whom are on watch, i.e. on duty on
on board the lifeboat is the hum of activity to be detected. Actually, it is the       the lifeboat, at any one time. On average, the lifeboat crew spend 14 days
vacuum cleaner – affectionately named Fiffi by the crew – accompanied by               at a stretch on board, during which time they are on standby around the
the clatter of pans in the galley and the opening and closing of doors – the           clock. There is a tradition of sea rescue on Rügen going back more than
normal early morning routine on the Harro Koebke. Coxswain Hartmut Mühl-               100 years. The Harro Koebke is the fifth lifeboat to be stationed at Sassnitz.
wald and his five-man crew are preparing themselves and the lifeboat for a             Like its predecessor, the Wilhelm Kaisen, it is powered by MTU engines. Two
new day. A quiet morning like this is the best time for Jörg Bollnow and Dirk          Type 8V 4000 M70 units and one Type 16V 4000 M71 propel the vessel at
Neumann to finish the new net for rescuing people at sea and fixing it to              speeds up to 25 knots, that is a good 46 kilometers per hour.
the deck railings. “At the moment we are still settling in,” explains Captain
Mühlwald. Lots of things on board are not yet quite the way the lifeboatmen            The eleven crew members work together in alternating shifts. There are also
would like. “Before, on the Wilhelm Kaisen, we repaired and maintained;                twelve volunteer lifeboatmen who step in if there is an emergency. At least
now we are arranging things in the best possible way for rescue operations             five crew are on duty at a time. They get on well together, always ready with
and life on board,” relates the likeable coxswain, adding that, “We will und-          a joke and a smile. And they are a close-knit team; everyone knows what
oubtedly need six months before everything is the way we want.” Tanned                 their job is and trusts the others to do theirs. That is an important factor in
and weatherbeaten, he leans against the railings in his red overalls. His blue         rescue missions. “In emergency situations we have to be able to rely on one                               2
eyes proudly survey his new boat. He gives the impression of someone you               another,” explains Mühlwald. It is not just in a rescue operation that things
can rely on and who keeps his word. His two co-seamen, Bollnow and Neu-                have to be just right; the team has to work well in the day-to-day routine as
mann, are working on the net again. They say very little. Unsurprisingly,              well. Five of them live together in very cramped conditions onboard ship.
because that is the way of the North Germans. And when a word or two is                They each have their own cabin, of course, but they are only allowed off the
exchanged between these easy-going mariners, it comes out as a mixture                 ship for a very short time when on duty. “Our days consist of a lot of routi-
of typical plattdeutsch with a smattering of East German dialect. “That OK?”           ne work,” Mühlwald relates. “It starts with the seamen – you can tell them
“Yeah, fine”. Suddenly a shrill alarm sounds. A ship in trouble? A rescue              by their red trousers – making breakfast. In return, the crew with the green
call? The crew remains completely relaxed. Except for Captain Mühlwald,                trousers – the engineers – make supper,” he adds. There are no women on
who races to the bridge to see what’s up – and returns to his colleagues as            board. “That would be too complicated. However, the smaller vessels which
calm as before. False alarm. It was just the telephone ringing. “There are             are manned exclusively by volunteers, do have female crew members,”
one or two things here we still have to get used to,” Mühlwald explains.               Mühlwald points out.

Sassnitz lifeboat station                                                              Manfred Lucas is first engineer on the Harro Koebke. He is unmistakably
The lifeboat Harro Koebke and its dinghy Notarius form the second largest              the team’s calming influence. Relaxed, in control and rather thoughtful. In
unit of the fleet operated by the German Maritime Search and Rescue Ser-               the engine room in the innards of the lifeboat, he writes down all the impor-


                                                                                                                  Coffee break in the
                                                                                                                  mess: Jörg Bollnow, Ulf
                                                                                                                  Dietrich, Dirk Neumann,
                                                                                                                  Kai Trottnow, Manfred
                                                                                                                  Lucas and Coxswain
                                                                                                                  Hartmut Mühlwald (left
                                                                                                                  to right) are a close-knit
                                                                                                                  team.




                                                                                                                                               1 The newest of the
                                                                                                                                                 60 lifeboats operated
                                                                                                                                                 by the German Mari-
                                                                                                                                                 time Search and
                                                                                                                                                 Rescue Service: the
                                                                                                                                                 Harro Koebke is named
                                                                                                                                                 after a South German
                                                                                                                                                 businessman.
                                                                                                                                               2 No loose ends: Dirk
                                                                                                                                                 Neumann and Jörg
                                                                                                                                                 Bollnow make sure
                                                                                                                                                 that the net ropes
                                                                                                                                                 don’t fray.



                                                                                                                                                                         MTU Report 02/12 I 25
24 I MTU Report 02/12
Marine                                                                                                                                                                                   1



                                                                                    tant data from the display of each engine control stand. In his notebook, he
                                                                                    meticulously records the coolant temperatures, pressures and other ope-
The Maritime Rescue Coordination Center of the DGzRS in Bremen manages all          rating data of the three MTU engines. But most of the information, such
missions of the DGzRS fleet, as well as all Search & Rescue (SAR) actions in the    as the amount of fuel remaining or the fuel injection pressure is provided
German maritime zones. Around 180 full-time employees and 800 voluntary staff
                                                                                    as a data printout. “In the past we really had our work cut out. But today
man 60 rescue cruisers and lifeboats between the Ems estuary in the west and the
Bay of Pomerania in the east, performing over 2000 missions per year – round-the-   there are so many electronic systems that there is hardly anything we can
clock and in all weather conditions. In 2011 alone, the DGzRS crews carried out     repair ourselves any more,” Lucas recounts. There is a tinge of sadness in
2,106 missions, rescuing 1,323 people in distress or danger at sea.                 his voice when he says that. Lucas still remembers the old MTU Series 331
                                                                                    and 396 engines. He worked on them often enough. “The new automation
                                                                                    system, Callosum, is fantastic alright.” The Callosum system monitors and
                                                                                    controls not only the propulsion units but also the ship’s services. “So I
                                                                                    don’t have to go into the engine room as often when we’re at sea,” the
                                                                                    experienced engineer observes. “Any problems are now indicated on the
                                                                                    computer,” the man in the green overalls elucidates. He puts his glasses
                                                                                    back on and writes down some more figures. Very shortly afterwards,
                                                                                    Manfred Lucas is standing in the galley. Today there are mustard eggs on
                                                                                    the menu. “Manfred’s the only one who can cook them properly, so that’s
                                                                                    what we asked for,” enthuses engineer Kay Trottnow. A different member of
                                                                                    the crew does the cooking each day. “We always decide on the weekly meal
                                                                                    plan at the start of the shift on a Wednesday.” Lunch is served punctually at                        2
                                                                                    twelve every day – an important team ritual for everyone on board.

                                                                                    New home from home
                                                                                    The DGzRS began planning for the new lifeboat five years ago. The Sass-
                                                                                    nitz crew were involved in the process from the start. “The lifeboat service
                                                                                    granted many of our wishes, but not all. We would have liked a bigger life-
                                                                                    boat,” smiles coxswain Mühlwald. But that was too expensive. The DGzRS
                                                                                    is financed exclusively from voluntary donations and receives no contribu-
                                                                                    tions from the taxpayer. Construction of the boat at the Fassmer shipyard
                                                                                    finally started two and a half years ago. One of the crew was very often on
                                                                                    site. And when it came to installing the engines, it was obvious who would
                                                                                    be in attendance – Manfred Lucas. Now, only a few weeks after commissi-
                                                                                    oning, he is already familiar not only with the MTU engines but also all the
                                                                                    other systems on board. His worry at the moment is that the organic wa-
                                                                                    ter recycling plant is not working properly – it isn’t cleaning the waste wa-
                                                                                    ter. He measures the bacteria content every day. “We are gradually getting
                                                                                    on top of the problem,” he grumbles with a glance at a large test-tube con-
                                                                                    taining brown liquid. The planners brought others into the process besides
                                                                                    the Sassnitz crew. Lifeboatmen from Helgoland were also involved in the
                                                                                    discussions. The reason being that the lifeboat’s dinghy is an innovation.
                                                                                    “In the beginning, we weren’t convinced at all by this rigid-hull inflatable,”
                                                                                    Mühlwald admits. “Then the British company came over and we were able
                                                                                    to test out the dinghy together with the Helgoland crew. It completely con-
                                                                                    vinced us,” the skipper enthuses. The Sassnitz crew are now the first unit
                                                                                    in the DGzRS with a rigid-hull inflatable dinghy. The Helgoland station will
                                                                                    get the second in September. Engineer Kay Trottnow is completely in rap-
                                                                                    tures. He and two colleagues were sent to Scotland for a training course
                                                                                    on the new dinghy. “We had to tackle three or four-meter waves head-on at
                                                                                    full speed. It takes some nerve, but it was absolutely awesome.” The dinghy,
                                                                                    which is capable of 32 knots, is accommodated in the stern of the lifeboat.
                                                                                    Like the Harro Koebke, it is designed to be self-righting if it capsizes.



                                                                                    The mustard eggs made
                                                                                    by Manfred Lucas are a                                1 Engineer Kai Trottnow
                                                                                    special treat according to                              checks the oil level in
                                                                                    the rest of the crew. A                                 the MTU Type 16V
                                                                                    different member of the                                 4000 engine.
                                                                                    crew does the cooking                                 2 When the boat is at
                                                                                    each day.                                               sea, the first engineer
                                                                                                                                            monitors and controls
                                                                                                                                            the three MTU engines
                                                                                                                                            using the Callosum
                                                                                                                                            automation system.        MTU Report 02/12 I 27
                                                                                                                                                                                                                                                                                                                                        Marine



                                                                                                                                                                                                                                                               The three MTU engines produce a combined output of 4,785 hp capable of
                                                                                                                                                                                                                                                               propelling the lifeboat at speeds up to 46 knots.


                                                                                                                                                                    Anchors aweigh
                                                                                                                                                                    In the afternoon, the Harro Koebke heads out on an exercise. Before the
                                                                                                                                                                    engines can be started up, Manfred Lucas has to go down into the engine
                                                                                                                                                                    room. The MTU power units are always pre-heated. That helps them start
                                                                                                                                                                    up more easily. Lucas checks over the three engines and gives the goahead
                                                                                                                                                                    within a couple of minutes. Now the engines can be fired up. The deck un-
                                                                                                                                                                    derfoot vibrates slightly and the rich hum of the MTU diesels can be heard.
                                                                                                                                                                    The lifeboat glides slowly out of Sassnitz harbor. Past Europe’s longest
                                                                                                                                                                    dockside towards the famous chalk cliffs of Rügen. The bridge is a hive of
                                                                                                                                                                    activity. Seaman Dirk Neumann is at the helm. He attentively monitors the
                                                                                                                                                                    radar and the other instruments. Coxswain Mühlwald stands next to him
                                                                                                                                                                    with binoculars. Even though this is just a run out for the engines, the men
                                                                                                                                                                    still check the sea around them to make sure nothing is amiss. Neumann
                                                                                                                                                                    slowly takes the speed up to 25 knots. Manfred Lucas is sitting in the back-
                                                                                                                                                                    ground. He has come back up from the engine room and is checking on his
                                                                                                                                                                    engines on the Callosum monitor. Injection pressure, temperature and fuel
                                                                                                                                                                    consumption. “Everything OK,” calls Lucas, “Engines running smoothly.”
First outing for the fire pump: the middle engine, the V16 MTU Series 4000, drives the fire extinguisher pump. It has a range of 110 meters.
                                                                                                                                                                    Everything on the sea is OK too. A few sailing enthusiasts are taking advan-
                                                                                                                                                                    tage of the fine weather. But all are in good shape. “If necessary, we rescue
                                                                                                                                                                    people who fall ill at sea but primarily we deal with people whose vessels




                                                                                                                                                ON 	 TH e	 s P OT
                                                                                                                                                                    have got into trouble at sea,” relates Mühlwald. “Though yesterday we had
                                                                                                                                                                    to tow out a sailing yacht that had run aground in the shallows.”

                                                                                                                                                                    The crew is called out on rescue operations 60 to 80 times a year. In very
                                                                                                                                                                    urgent situations, they can call on the rescue helicopter. But in most cases,
                                                                                                                                                                    the team is accompanied by doctors from the local area. Below deck there
                                                                                                                                                                    is a small medical room equipped with all the necessary equipment such
                                                                                                                                                                    as oxygen cylinders and ECG. At least one of the crew is a trained para-
                                                                                                                                                                    medic. But all crew members are capable of the fundamentals. They all
                                                                                                                                                                    regularly attend courses, including the resuscitation course once a year.
                                                                                                                                                                    “Sometimes, a rescue operation involves towing a small boat back to port,”
                                                                                                                                                                    Mühlwald explains. For large ships, the tug is called out from Sassnitz har-
                                                                                                                                                                    bor. So that the exercise is not completely pointless, they test out the new
                                                                                                                                                                    fire extinguisher pump. Dirk Neumann brings the Harro Koebke gradually to
                                                                                                                                                                    a halt for the purpose. Once again, Lucas gives the go-ahead because this
                                                                                                                                                                    time the V16 Series 4000 has to be run up to maximum revs. It roars loud-
                                                                                                                                                                    ly and suddenly the water from the pump shoots over the bridge. The team
                                                                                                                                                                    tests panning right and left, though they can’t quite get the hang of chan-
                                                                                                                                                                    ging the elevation. “We need to practice that some more,” Mühlwald con-
                                                                                                                                                                    cludes. The lifeboat is, after all, the new member of the team.

                                                                                                                                                                    Text: Katrin Beck; Pictures: Robert Hack
  Katrin	overboard

  As a reporter, you are sometimes lucky enough not just to observe events as they happen but to actually be involved. Which is what                                To find out more, contact:
  happened to me when reporting on the lifeboat Harro Koebke. During my visit to Rügen, Coxswain Hartmut Mühlwald, said to me                                       Thomas Müller, t.mueller@mtu-online.com, Tel. +49 7541 90-5120
  that women visitors to the ship had to let themselves be rescued. Without hesitation I said, “Let’s do it!” So I was given an orange
  lifejacket and trousers. They let me keep my jeans and T-shirt on underneath; I just had to take off my trainers. The suit was slightly
  too big, but I wasn’t concerned about looks. The main thing was that it kept me dry. It had special neoprene cuffs and collar to keep
  the water out.




                                                                                                                                                                                                                                                  O N L IN e
  After the dinghy Notarius had been lowered into the water from the Harro Koebke, I had to jump into the harbor waters, which were                                                                                More	on	this...
  a none too welcoming 17 degrees. So it was a case of close your eyes and go! Or rather hold your nose and dive in! The lifejacket                                                                                more images and
  pulled me back up to the surface straight away. So there I lay like a ladybird on its back in the water. I found it very difficult to move.                                                                      impressions
  I could only paddle a bit this way and that. Fortunately, my rescuers arrived in the dinghy. They pulled a net underneath me and
                                                                                                                                                                                                                   Don't have a QR code reader?
  rolled me over the side of the dinghy on board. Saved! So that’s how it’s done! Thanks to the lifeboatmen for a fantastic experience.
                                                                                                                                                                                                                   Go to http://bit.ly/NjuGnA




28 I MTU Report 02/12                                                                                                                                                                                                                                                                                                   MTU Report 02/12 I 29
                                                                                                                                                                                                 Marine
          Shipbuilding in Abu Dhabi




                                                                                              «The Baynunah is our pride and
                                                                                              joy.
                                                                                                  »       Salim Kumar, Manager Business Development




                                                                                                                                                                 Salim Kumar is originally from India
                                                                                                                                                                 but has been working in Abu Dhabi for
                                                                                                                                                                 20 years.




                                                                                              "Ten years ago this was desert, and now we're         performance ships this soon," Salim says with a
          The Baynunah is the first large corvette to be built in the United Arab Emirates.
                                                                                              building modern ships like corvettes, missile         smile. Where the gigantic sheds now stand was
                                                                                              boats and fast patrol boats," relates Salim Kumar.    still sand then. The wealth of the emirate was ba-
                                                                                              He is proud to show us around the construction        sed on the extraction of oil and gas; other indus-
                                                                                              facilities of Abu Dhabi Ship Building. We walk past   tries hardly played a role. But that has changed.
                                                                                              gigantic steel plates, through covered and half-




          Ships of the
                                                                                              uncovered halls. There are ships everywhere –         Baynunah just the start
                                                                                              some of them still only empty hulls, some of them     The shipyard's CEO, Mohamed Salem Al Junai-
                                                                                              finished and ready to be launched into the sea        bi, is also proud of that progress. He is certain
                                                                                              right behind them. "At the front there is the Bay-    that the Baynunah is just the beginning. "It is our
                                                                                              nunah, our pride and joy," points out the manager     masterpiece," he states. And when saying so he
                                                                                              in charge of the shipyard's business development      speaks softly, almost as if wants to keep it to him-
                                                                                              for services. The Baynunah is one of a class of six   self. But he doesn't – quite the opposite. "The




          desert
                                                                                              modern corvettes – 70 meters long, eleven me-         Baynunah is a signal to our clients. It shows we
                                                                                              ters beam, with a draft of just three meters and a    have the capability to build such high-spec ships,"
                                                                                              displacement of 830 tonnes. Those six craft are       Al Junaibi is keen to point out. Up to now, the Gulf
                                                                                              to form the backbone of the Navy of the United        States have typically bought their naval vessels
                                                                                              Arab Emirates, whose territorial waters they will     from Europe. But the shipbuilders have adapted
                                                                                              patrol. And not only that – the Baynunah shows        this one to the special conditions in the Gulf re-
                                                                                              what has been achieved here in the last few ye-       gion. The high water temperatures in particular
                                                                                              ars. "When Abu Dhabi Ship Building was foun-          demand extensive modification of the cooling sys-
                                                                                              ded 16 years ago, I don't suppose anybody would       tems. In the future that shouldn't be necessary
                                                                                              have relied on it being able to build such high-      so often because Abu Dhabi Ship Building aims to



30 I MTU Report 02/12                                                                                                                                                             MTU Report 02/12 I 31
                                                                                                                                                                                                                                                                                                                                 Marine




                                                                     Mohamed Salem Al
                                                                     Junaibi founded the Abu
                                                                     Dhabi Ship Building yard
                                                                     16 years ago. The yard
                                                                     aims to provide an alter-
                                                                     native to the major Euro-
                                                                     pean yards.




             «The Baynunah is a signal to our clients. It shows we
             have the capability to build such high-spec ships.
                                                               »
             Mohamed Salem Al Junaibi, CEO Abu Dhabi Ship Building

                                                                                                                                                                Ten years ago there was nothing but desert here. Today it is the construction site for corvettes, patrol boats and supply vessels for the Oil & Gas industry.




become an alternative to the European shipyards.     Combined propulsion system                           for operation at full power, so at medium outputs     ble and powerful – which is exactly what we need           tracts with clients are expected to provide plan-                                           Iran
At the moment its clients still come from the Uni-   The ships are each powered by a combined pro-        they use disproportionately more fuel.                for our demanding contracts," he adds. A very              ning certainty and offer customers favorable
ted Arab Emirates and the other GCC countries,       pulsion system comprising four MTU 16-cylinder                                                             important aspect to him is the quality of the co-          terms for servicing their ships. And Salim Kumar,                                      Abu Dhabi
                                                                                                                                                                                                                                                                                           Saudi
Qatar, Bahrain, Oman, Kuwait and Saudi Arabia.       Series 595 engines. They drive three Rolls-Royce     Reliable and powerful                                 operation with the staff at MTU and Al Masaood.            the man in charge of developing this arm of the                 Arabia                United
But there is no reason it should always stay that    waterjets via three multi-engine gearboxes. When     It is not just the Baynunah Class corvettes that      "Along with the shape of the hull, the engines are         business, has more than government and naval                                          Arab
way, states Mohamed Salem Al Junaibi in his ac-      the corvettes need to travel at their maximum        are driven by MTU engines. "The majority of our       the key factor in ship design," he explains. "So           vessels in his sights. "Abu Dhabi is growing at an                                    Emirates
customed soft tone. Quiet it may be, but the tone    speed of 32 knots, the captain powers up all four    naval and government vessels have MTU en-             accordingly, we involve MTU in the planning of             enormous rate. Formula 1 attracts a large number                                                         MTU Brown    MTU Brown




does not conceal the confidence that the Baynu-      engines. For cruising at normal speeds, however,     gines," recounts Ahsan Al Rahim, who has ma-          the ships from a very early stage."                        of wealthy people and more and more harbors are
                                                                                                                                                                                                                                                                                                                                    0-17-28-62   80% der Farbe   60%    40%    20%
                                                                                                                                                                                                                                                                                                                                    CMYK         CMYK            CMYK   CMYK   CMYK




nah has given the shipyard. The first ship of the    one engine per gearbox is sufficient. The advan-     naged numerous major projects procurement at                                                                     being created," he explains, concluding that, "We                                                    Oman
                                                                                                                                                                                                                                                                                                                                    MTU Blue     MTU Blue
                                                                                                                                                                                                                                                                                                                                                                 60%    40%    20%
                                                                                                                                                                                                                                                                                                                                    50-25-0-10   80% der Farbe




class was subcontracted to the French shipyard       tage of this CODAD system is that at cruising        Abu Dhabi Ship Building. As examples he cites 34      Long-term maintenance contracts                            want to service and upgrade super yachts too in
                                                                                                                                                                                                                                                                                                                                                                 CMYK   CMYK   CMYK
                                                                                                                                                                                                                                                                                                                                    CMYK         CMYK




CMN and Abu Dhabi Ship Building delivered the        speeds, when the ships do not need to be going       patrol boats for the Critical National Infrastruc-    Cooperation is set to become even closer in futu-          future. In his view, the shipyard has the perfect
vessel this year and is due to complete the remai-   any faster than 15 knots, the engines are not con-   ture Authority and twelve patrol boats for the Uni-   re with the maintenance and through life support           conditions for doing so: air-conditioned and dust-
                                                                                                                                                                                                                                                                                                                                 Arabian
ning five by 2014.                                   stantly being driven at low to medium power. That    ted Arab Emirates Navy – all equipped with MTU        services for the ships. That will be the shipyard's        free sheds with all the latest equipment.                                                             Sea
                                                     is of benefit because the engines are optimized      Series 2000 power units. "The engines are relia-      next big mainstay. Long-term maintenance con-



32 I MTU Report 02/12                                                                                                                                                                                                                                                                                                  MTU Report 02/12 I 33
  Marine


                                                                                                                                                                                                               «Along with the shape of the hull,
                                                                                                                                                                                                               the engines are the key factor in ship
                                                                                                                                                                                                               design.
                                                                                                                                                                                                                      »         M. Ahsan Al Rahim, Manager Major Projects




                                                                                                                                                                                                                                                                            Ahsan Al Rahim headed the Project
                                                                                                                                                                                                                                                                            Procurement. He is more than satisfied
                                                                                                                                                                                                                                                                            with the excellent cooperation between
                                                                                                                                                                                                                                                                            MTU, Al Masaood and Abu Dhabi Ship
                                                                                                                                                                                                                                                                            Building.




                                                                                                                                                                                                                                                                            The corvette Baynunah is powered by
                                                                                                                                                                                                                                                                            four 16-cylinder MTU Series 595 diesel
                                                                                                                                                                                                                                                                            engines.

Most of the naval vessels constructed by Abu Dhabi Ship Building over the last ten years are powered by MTU engines.




                                          Vast market                                             pyard has only been in existence for 16 years. It    Specialists from all over the world                       is important to the CEO is to bring the best peo-
                                          Mike Stamford is a little more reserved in that re-     took European shipbuilders more than 40 years        That special atmosphere is something company              ple to Abu Dhabi. "Experts from all over the world
                                          gard. Hailing from UK, he has worked at the shi-        to be able to make ships of the size and quali-      boss Mohamed Salem Al Junaibi also picks out.             work here, and that is what makes us so success-
                                          pyard for five years and is the Director of Sales       ty that Abu Dhabi Shipbuilding is already produ-     He is one of many locals at Abu Dhabi Ship Buil-          ful."
                                          with specific responsibility for the new build na-      cing today.".He has worked at various shipyards      ding in management positions. "I feel like a father
                                          val and commercial vessels. And he makes it             around the world for 25 years now. Looking back,     who has to make sure that the staff from diffe-           Text: Lucie Dammann
                                          clear that it is obviously the main focus now. He       he sees one thing in particular that has changed:    rent cultures work together well and are happy,           Pictures: Robert Hack, Abu Dhabi
                                          reveals nothing about future contracts. And ven-        clients are better informed. "In the past we had     he says. And it's true: when you walk through             Ship Building
                                          tures only that, "The demand in the Gulf States is      to advise buyers much more extensively; today        the various sheds of the shipyard, you notice that
                                          enormous and there are lots of projects on the          they know pretty well exactly what they want," he    there are people from every continent working
                                          market." So many that he will not be able to take       observes. He has been in Abu Dhabi since 2007.       here. Eighty percent of them are foreign natio-           To find out more, contact:
                                          all of them on, because Abu Dhabi Ship Building         "Specialists from all over the world come to Abu     nals. Most of them live together in a staff village       Walid Magd E. Ibrahim
                                          cannot expand fast enough. Even if a lot is still       Dhabi to work. That gives it a very special atmos-   right next to the shipyard. There are leisure facili-     mtuauh@emirates.net.ae
                                          possible. "You have to look at it this way: the shi-    phere which is very enjoyable," he expands.          ties, shops and even a doctor's surgery. But what         Tel. +971 2 551 0707




34 I MTU Report 02/12                                                                                                                                                                                                                                                                       MTU Report 02/12 I 35
                                                                                                                                                                                                             Energy
                                                                 Gensets in data centers




                                                                Defense
             A data center looks unspectacular. But behind the myriad doors is hidden the entire knowledge of a
             corporation. Backup gensets make sure that it remains accessible if the mains electricity fails.
                                                                                                                  mechanism
                                                                                                                     Large data centers are notoriously hungry for power. Computer
                                                                                                                     servers depend on it to keep humming. So does the air conditio-
                                                                                                                     ning and ventilation equipment required to cool the servers down.
                                                                                                                     When a data center can improve its energy efficiency, it not only
                                                                                                                     reduces operating costs but it also provides additional safeguards
                                                                                                                     against power loss. Vantage Data Centers did just that in their faci-
                                                                                                                     lity in California, using novel energy-saving techniques and emer-
                                                                                                                     gency standby generator sets from MTU Onsite Energy.




36 I MTU Report 02/12                                                                                                                                                                        MTU Report 02/12 I 37
                                                                                                                                             1   2
Top online companies count on Vantage Data Centers to pro-            sets for V2, but we plan on having a total of ten generator sets                                                                                      Energy
tect data used for social networking, social commerce, online         when the building is complete,” says Jennifer Fraser, Director
social gaming, cloud storage and video game development.              of Design Construction for Vantage Data Centers. “The facili-
Data security is of such high concern that the companies              ty is designed for growth and the self-contained generator sets
won’t even divulge their names to the outside world.                  are located outdoors so we can incrementally increase the
                                                                      number of generators more easily.” To comply with local envi-
At Vantage’s new 73,000-square-foot expansion facility —              ronmental ordinances, the generator enclosures are designed
called V2 — the name of its sole tenant is also kept private.         to reduce sound to 73 decibels. In addition, each generator-
Like other Vantage customers, it values Vantage’s commitment          drive engine is outfitted with a Diesel Particulate Filter (DPF)
to energy efficiency. According to Greg Ness, Vantage’s Chief         to capture any soot in the exhaust to comply with California’s
Marketing Officer, Vantage “develops highly efficient and cus-        strict air quality rules.
tomizable data centers that significantly reduce IT infrastruc-
ture, cooling costs and carbon emissions so customers can             Redundancy ensures reliability
substantially reduce their total cost of operations.”                 Like most data centers, the V2 facility has a backup plan to
                                                                      its backup plan. Redundancies are in place to prevent loss of
Lower temperatures, lower costs                                       data or service during utility outages, most often caused by
From the top down, the V2 facility was built to save energy.          lightning storms. According to Fraser, the facility has utility
                                                                                                                                                 1 Cabinets like these house the technological backbone of many corporations. The
Ness says that the V2’s cooling system utilizes an energy-effi-       feeds from two sources in addition to its Uninterruptible Po-
                                                                                                                                                   servers, air conditioning and ventilation systems require large amounts of energy.
cient design that allows cool outside air to flow down on the         wer Supply (UPS) systems and emergency standby generators.                 2 The new Vantage Data Centers installation covers 6,800 square meters of floor space.
racks of servers. Vantage also lowered the static pressure            If one utility feed fails, the second feed will automatically take         3 Six MTU Onsite Energy emergency backup gensets ensure that electricity is
inside the building, which has cut power consumption signi-           over and supply the facility. If both utility feeds fail, the UPS            never in short supply at the facility.
ficantly. Power Usage Effectiveness (PUE) is a measurement            system would supply power to the servers while all six genera-                                                                                                  3
of data center efficiency. According to the Uptime Institute,         tors start and take over the load. In the unlikely event that one
typical data centers have average PUEs above 1.9. Some even           or more of the generators did not start, there would still be
have a rating as high as PUE 3.0—meaning that two-thirds of           enough standby power to supply the load. The generators can
a facility’s power consumption would be used for cooling and          operate for approximately 24 hours before they need refueling.
only one-third for the IT equipment. Vantage’s V2 facility has a
PUE of 1.12, one of the best ratings in the industry.                  The data centers are also ready for other forces of nature.
Operational efficiencies also impact the emergency standby             Since earthquakes are common in Southern California, all


«The tests went so well that Vantage and their onsite                                                       enclosures and MTU Onsite
                                                                                                            Energy generator sets have
                                                                                                            been certified to withstand
engineer said it was one of the best performances they                                                      seismic activity. “All of Van-


                »
                                                                                                            tage Data Centers’ projects
ever witnessed.                      Steve Homan, Valley Power Systems                                      are designed to the Inter-
                                                                                                            national Building Code seis-
power system requirements. With lower energy demand, more              mic standard and carry a critical facility importance factor of
redundancy can be built into a system. This ensures excepti-           I=1.5,” says Fraser. Facilities that carry an I=1.5 rating have
onal reliability—which is crucial for data centers that need to        life-safety or mission critical issues that require emergency
maintain uptime at all times. Of course, engineering and de-           standby generator sets that can survive an earthquake and still
sign play a key role in reliability, too. Vantage found the quality    operate normally.
they needed in MTU Onsite Energy emergency standby genera-
tor sets. “MTU Onsite Energy generator sets were selected on           Passing the test
the basis of their superior load acceptance and performance—           Vantage didn’t leave anything to chance. The V2 emergency
their ability to be hit with full load and then quickly recover        standby power system endured rigorous testing to make sure
voltage and frequency,” says Steve Homan of Valley Power               all the components performed as designed. During this pro-
Systems, an MTU Onsite Energy distributor.                             cess, the generator sets undergo a utility power interruption.
                                                                       According to Homan, “The tests went so well that Vantage
A greater power                                                        and their onsite engineer said it was one of the best perfor-
Outside V2 in a weatherproof enclosure, the six 3,000 kW               mances they had ever witnessed.” The Vantage facility design
generator sets are standing by, ready to spring into action            is a model for energy efficiency, as well as power reliability.
at any time. Each generator set features an MTU 20V 4000               Through innovative building and mechanical systems, plus
generator-drive engine with approximately 20 percent more              careful integration of emergency standby power systems,
cylinder displacement than other engines of similar horsepo-           Vantage keeps massive amounts of data flowing, with no
wer. “The greater displacement supplies more reserve torque            stoppage in sight.
and help the generators absorb a full load in one step and
recover quickly,” says Homan. “The greater displacement also           Text: Robert Sheldon
reduces fuel consumption and reduces stress on the engine’s            Pictures: Fotolia, Vantage Data Centers
internal parts, improving reliability and longevity.”
                                                                       To find out more, contact:
Since online companies can grow rapidly, Vantage has a plan            Al Prosser, al.prosser@mtu-online.com
to expand. “We initially deployed these six standby generator          Tel. +1 507 385-8629

                                                                                                                                                                                                            MTU Report 02/12 I 39
                                                                                                                                                                                                                       01/12
38 I MTU Report 02/12
                          Marathon Performance in Canadian Coal Mine




                                                                                                                                             Mining
To Haul and Back
                          It’s a dirty job, but somebody’s truck has to           Today, more than 300 Series 4000 engines are
                          do it. At Canada’s largest surface coal mine,           installed in Liebherr trucks, working at about a
                          a fleet of trucks is put to the test daily, each        dozen mine sites around the world, according to
                          hauling 400-ton loads for Highvale Mine.                Adam Matlock, Senior Service Engineer for MTU
                          Equipped with meticulously maintained                   engines at Tognum America.
                          MTU Series 4000 engines, the vehicles have
                          accumulated impressive hours in extreme                 Working overtime
                          conditions. And they keep coming back for               The engines in Highvale’s Liebherr trucks are
                          more.                                                   20-cylinder Series 4000 models that provide
                                                                                  3,650 hp for hauling heavy overburden loads.
                          Covering almost 30,000 acres (120 km2), the             In late 2011, one of these engines was replaced
                          mine yields roughly 12 million tons of coal each        after a notable four-year run during which it
                          year. That’s an impressive haul. But before that        logged over 23,000 service hours, exceeding the
                          happens, the material that rests above the coal         engine’s maximum expected life by more than
                          (overburden) must be removed. This job is an            3,000 hours.
                          even larger undertaking. A small army of power
                          shovels, excavators, conveyors, trucks and explo-       This overachieving engine is planning a come-
                          sives must all work together to excavate the over-      back. Recently, it was sent to Wajax Power
                          burden and expose the valuable coal deposits            Systems in Edmonton, the local MTU servicing
                          underneath.                                             distributor, where it will be overhauled for reu-
                                                                                  se. Meanwhile at Highvale, the haul truck that
                          Power shovels load tons of overburden into huge         housed the engine is back on the job, powered by
                          haul trucks which travel, back and forth on rough,      a spare engine kept by the mine operator, Prairie
                          unstable terrain tirelessly. At Highvale, the hauling   Mines & Royalty Ltd. (PMRL) to minimize down-
                          fleet consists of ten trucks, including six Liebherr    time caused by engine replacements. The engi-
                          T 282 B diesel electric trucks capable of carrying      ne now being overhauled will serve as the spare
                          400-ton loads. Besides hauling heavy loads, the         when the work is completed.
                          trucks often operate in Canada’s notoriously cold
                          winters when temperatures can drop to 40 be-
                          low.

                          Extreme workloads and conditions are just part
                          of the daily routine at Highvale Mine. Equipped
                          with MTU Series 4000 diesel engines, Highvale’s         Alaska
                          trucks are up to the challenge. The engines, used                        Canada
                          in several different mine trucks in 12-, 16- or
                          20-cylinder configurations, have logged approxi-
                          mately three million hours in mining operations.                            Edmonton
                                                                                                                            MTU Brown    MTU Brown
                                                                                                                            0-17-28-62   80% der Farbe   60%    40%    20%
                                                                                                                            CMYK         CMYK            CMYK   CMYK   CMYK




                                                                                                                            MTU Blue     MTU Blue
                                                                                                                                                         60%    40%    20%
                                                                                                                            50-25-0-10   80% der Farbe
                                                                                                                                                         CMYK   CMYK   CMYK
                                                                                                                            CMYK         CMYK




                          Mining is a hard business. Not just for
                                                                                                                  The United
                          the mineworkers but also for the MTU
                                                                                                                  States
                          engines which perform the donkey work.
                          And without regular maintenance, it
                          simply would not be possible.                                                                  Cuba




  40 I MTU Report 02/12                                                                                        MTU Report 02/12 I 41
Mining                                                                                                        1

                                                                    1 The coal mine extends over more
                                                                      than 120 square kilometers in an
                                                                      area 70 kilometers west of Edmonton
                                                                      in the Canadian province of Alberta.
                                                                    2 There are six Liebherr Type T 282 B
                                                                      haul trucks in operation, each
                                                                      powered by a 20-cylinder MTU Series
                                                                      4000 engine producing 3,650 hp.




At Highvale, long engine life is crucial because       The secrets of long life
an engine overhaul is an added business expen-         In addition to following a routine maintenance
se. Equally important, exceptional engine relia-       schedule, owners of Series 4000 engines should
bility reduces vehicle downtime, which can cost        pay attention to fuel quality, according to Ran Ar-
the mine tens of thousands of dollars a day in         cher, Sales Manager for MTU mining engines at
lost revenue. “Minimizing downtime is more im-         Tognum America. Fuel contamination must be
                                                                                                                                                                                        The Highvale Mine in
portant than anything,” said Jim Richter, PMRL’s       minimized and the fuel must comply with lubricity                                                                                Canada has been in
truck maintenance planner at Highvale. “We have        requirements to facilitate the motion of injectors                                                                               operation since 1970.
a fairly small fleet, so truck availability needs to   and other components. In addition, Highvale tries                                                                                Each year the mine pro-
be very high.”                                         to improve fuel cleanliness by using systems that                                                                                duces 12 million tons of
                                                       filter fuel as it’s transferred from delivery trucks                                                                             coal which are used,
                                                                                                                                                                                        among other things, to
Maintaining high standards                             into fuel tanks.
                                                                                                                                                                                        fuel two combined heat-
Why did the engine exceed expectations by 3,000                                                               2                                                                         and-power stations gene-
service hours? This impressive feat was due to         Highvale’s haul truck fleet operates on high-qua-                                                                                rating 2,800MW annual-
MTU’s legendary high engineering standards and         lity fuel, said Richter, who believes this helped                                                                                ly.
disciplined adherence to the manufacturer’s main-      prolong the life of his 23,000-hour engine. The
tenance and fuel quality recommendations. PMRL         results are well worth the extra effort. “We don’t
personnel try to make sure that maintenance is         have any fuel issues with any of the equipment
performed within 50 hours of MTU guidelines.           we have here,” Richter said, adding that he’s
                                                       heard reports of injector-failure problems at other
MTU adheres to a proactive maintenance philo-          mines. When injectors fail, he explains, the result
sophy, unlike many of its competitors. “We’re a        is uneven fuel distribution in the cylinder, which
little more aggressive in our practices,” said Mat-    causes hot spots that can burn out pistons and
lock. “We don’t believe in running components          dry out cylinder walls—and ultimately cause engi-
until they break. Our philosophy is to proactively     ne failure.
replace components before they reach the end of
their life expectancy.”                                The longevity of haul truck engines at Highvale
                                                       is linked to preventative measures such as using
Matlock says preventative measures pay off in          clean fuel and performing recommended mainte-
the long run. It results in scheduled downtime,        nance on schedule. “If you’re careful about things
boosting mine production. In addition, replacing       like that,” said Archer, “MTU engines will run a
components before they break eliminates the            long time and help drive down operating costs.”




                                                                                                                                                                                                              Me M O
possibility that broken components will do further
damage to the engine or other components. “If          At Canada’s largest surface coal mine, Highvale             Tier 4 exhaust aftertreatment
a turbocharger breaks, for example, metal debris       haul trucks are expected to keep working well
traveling through the system could cause a cata-       into the future. Because there’s always more coal           A standout in MTU’s diverse lineup of mining engines is the Series
                                                                                                                   4000 engine family from 1,000 to 3,000 kW (1,350-4,020 hp). It
strophic failure of the entire engine,” he said.       to haul. And profits to be made.
                                                                                                                   delivers reliable, fuel-efficient performance down to -50°C
                                                                                                                   and up to 5,000 meters. Future generations of
At Highvale, preventative care follows a strict ti-    Text: Robert Sheldon                                        EPA Tier 4 final MTU mining engines will
metable. Key items on the engine maintenance           Pictures: Getty Images, Highvale Mine,                      meet EPA Tier 4 emissions standards
schedule include oil changes every 500 hours,          Tognum Corporate Archive                                    without requiring exhaust aftertreatment
engine valve inspections every 3,000 hours, fuel                                                                  — an industry exclusive. They will feature
                                                                                                                   cooled EGR, a two-stage turbocharging
injector change-outs every 6,000 hours and full        To find out more, contact:                                  system, an improved common rail fuel
service performed at the midpoint of an engine’s       Ran Archer                                                  injection with increased injection pressu-
life.                                                  ran.archer@mtu-online.com                                   re, and a new combustion process with
                                                       Tel. +1 248 560-9064                                        modified valve timing (Miller process).




42 I MTU Report 02/12
                                                                                  Energy
         Modernized CHP plant with MTU Onsite Energy gas turbine




         Source of
         power




         The LM 6000 PF Sprint gas turbine generates
         48 megawatts of electrical output.




44 I MTU Report 02/12                                              MTU Report 02/12 I 45
                        1                                                                                                                                                          Energy




                            If you want to produce energy efficiently and                                                               ly organs. He refers to the gray heat pipes that
                            ecologically, you are generally talking about                                                               run through the plant from the gas turbine to the
                            renewable energy sources. Germany aims to                                                                   steam turbine as arteries. And the heat recovery
                            produce its electricity solely from renewable                                                               boiler and heat exchangers in between are com-
                            resources by 2050. Atomic power is to be                                                                    pared to secondary organs that complete the
                            phased out as quickly as possible. But buil-                                                                system.
                            ding new wind farms, photovoltaic arrays or
                            hydroelectric plants costs time and money.                                                                  The control room is the brain. It is on the second
                            So where will the electricity come from in                                                                  floor of the building. “It’s like the human body
                            the meantime? The solution adopted by the                                                                   – the plant only works efficiently when all the
                            municipal energy company in Halle is effici-                                                                components work properly together,” Jungsch ex-
                            ent and ecological – but does not use renew-                                                                plains. The fuel-efficiency is around 83.5 percent.
                            able energy. They are modernizing their co-                                                                 The changeover from old to new turbine was
                            generation plant with a new gas turbine that                                                                stressful for him. But he didn’t lose sleep over
                            will provide both heat and electricity.                                                                     it. “I trust my own capabilities and those of my
                                                                                                                                        staff. It’s like riding a bike, once you’ve learned
                            You might think that completing 110,000 hours                                                               how to do it, you never forget.” And by the by,
                            of service would be a reason for celebration. But                                                           the power station expert reveals that, as an engi-
                            for the municipal energy company in the Ger-                                                                neer, the most interesting part of the CHP plant
                            man city of Halle it means that its old gas turbi-                                                          for him is the gas turbine. “There are any number
                            ne has reached the end of its useful life. So they                                                          of steam turbines. But you don’t see as many
                            had a choice. Either to have the old gas turbine                                                            gas turbines.” And he should know, looking after
                            completely overhauled or to buy a new one. “We                                                              three of them as he does. The new one is an LM
                            opted for a new gas turbine because it is more                                                              6000 PF Sprint, while another CHP plant in Halle
                            efficient,” explained Wolfgang Jungsch, Heat Ge-                                                            has two LM 2500 units. The latter each have an
                        2   neration Manager at EVH GmbH, a subsidiary of                                                               output of 30 megawatts and have been in service
                                                                                 He knows the Halle-Trotha plant like the back of his
                            the Halle municipal utility company. The likea-      hand: Wolfgang Jungsch is Heat Generation Manager      since 2005. And they too are used to generate
                            ble engineer, who walks through the power sta-       at the Halle energy company.                           electricity and heat for Halle in combination with
                            tion in his white hard hat as if it were his own                                                            a steam turbine. In the past, the old gas turbine
                            living room, is a real expert on gas turbines. He                                                           in Halle-Trotha was sometimes shut down com-
                            has worked here since 1989 and also looks after      Power plant as organism                                pletely in the summer if the energy demand was
                            another combined heat and power plant in Hal-        The new gas turbine is in the Halle-Trotha CHP         low. Because the new smaller units were more
                            le. Two MTU Onsite Energy gas turbines produce       plant. The plant is operated by Heizkraftwerk          efficient.
                            heat and electricity there too.                      Halle-Trotha GmbH, a joint venture between Leip-
                                                                                 ziger VNG – Verbundnetz Gas Aktiengesellschaft         Assembled, installed and commissioned by
                                                                                 and Stadtwerke Halle GmbH, the municipal ener-         MTU Onsite Energy
                                                                                 gy provider. Between them, the two companies           The new Type LM 6000 PF Sprint gas turbine has
                                                                                 have invested around 23.5 m euro in the conver-        been in operation since 1st June. Depending on
                                                                                 sion of the jointly owned power plant. The power
                                                                                 station stands on the banks of the River Saale,
                                                                                 almost in a greenfield location on the edge of an                                           Berlin
                                                                                                                                                       Netherlands




                                                                                                                                                                                                                  MAP
                                                                                 industrial estate. Electricity has been generated      Britain
                                                                                 here since 1924 – initially in a coal-fired power                                 Halle an der Saale
                            1 The Halle-Trotha CHP
                                                                                                                                                    Belgium
                                                                                 plant. Since 1969, Halle has employed combined
                              plant has been in operati-                                                                                                        Germany
                                                                                 heat and power generation at its Trotha site. The
                              on since 1994. It has re-                                                                                                                    Czech
                              cently installed a new gas
                                                                                 present CHP plant was built in 1994, a structure                                          Republic
                              turbine supplied by MTU                            visually divided into two parts – the bottom half           France                                MTU Brown    MTU Brown




                                                                                 made of red brick, the top half of grayish-blue
                                                                                                                                                                                   0-17-28-62   80% der Farbe   60%    40%    20%
                                                                                                                                                                                   CMYK         CMYK            CMYK   CMYK   CMYK



                              Onsite Energy.
                                                                                                                                                                                      Aus-
                            2 The combined gas and                               metal sheeting. The chimney on the roof looks                                                        tria
                                                                                                                                                                                   MTU Blue     MTU Blue



                              steam turbine plant only
                                                                                                                                                                                                                60%    40%    20%
                                                                                                                                                                                   50-25-0-10   80% der Farbe




                                                                                 like an upturned funnel. So nothing spectacular
                                                                                                                                                                                                                CMYK   CMYK   CMYK
                                                                                                                                                                                   CMYK         CMYK




                              achieves its fuel energy
                                                                                 – from the outside. Inside it is a completely diffe-
                              utilization rate of 83.5                                                                                                                   Italy
                              percent thanks to the                              rent story. “The gas turbine in its reddish orange
                              perfect interaction bet-                           container is the heart of the plant,” says Jungsch,
                              ween all its components.                           who likes to compare the CHP plant with bodi-


46 I MTU Report 02/12
                                                                                                                                                                     MTU Report 02/12 I 47
Energy                                                                                                                                          Right: The LM 6000 is
                                                                                                                                                new territory for
                                                                                                                                                experienced service
                                                                                                                                                engineer Thorsten Bosch.
                                                                                                                                                Up to now he has looked
                                                                                                                                                after MTU Onsite Energy
                                                                                                                                                gas turbines in the lower
                                                                                                                                                power classes.


the outside temperature, it will produce between
40 and 48 megawatts of electrical energy. The
gas turbine itself is supplied by General Electric
from Cincinnati, Ohio, in the USA. In Germany it
was assembled into a complete CHP module in
Friedrichshafen. “It was the first gas turbine of
this power class that we had put together,” re-
lates Andreas Görtz, Gas Turbine Sales and Ap-
plication Department Manager at MTU Onsite
Energy. MTU staff mounted the gas turbine on a
frame on which it is housed by the reddish oran-
ge acoustic enclosre. It also has to be hooked up                                                                    less electricity and heat. If it’s a cold winter, on
with the gearbox, generator, the air supply sys-                                                                     the other hand, demand rises. As a result, the de-
tem and all of the control systems. Although the                                                                     mand patterns have changed so much that they
assembly principle was familiar from the smaller                                                                     are difficult for energy providers to predict. And
gas turbines like the LM 2500 that MTU had sup-                                                                      energy suppliers like the Halle municipal plant
plied to the other power plant in Halle, the di-                                                                     don’t have it any easier. “Gas and steam turbi-
mensions of the LM 6000 were much larger and                                                                         ne plants combine flexibility with high levels of
more demanding for all concerned. Installing the                                                                     efficiency and fuel energy utilization. With the
gas turbine, for which MTU Onsite Energy was                                                                         modernized Halle-Trotha plant we can react to
also responsible, proved a real test. “We had to                                                                     the fluctuating market demands, which chan-
integrate the entire installation with all its ancilla-                                                              ge almost on a daily basis,” explains Professor
ry systems in an existing heat and power plant,”                                                                     Matthias Krause, Managing Director of the Hal-
Görtz emphasizes. But only a small part of the                                                                       le municipal energy company and Heizkraftwerk
                                                          The commissioning of the Halle-Trotha CHP plant
power station building could be taken down. So            marks the fulfillment of the “Halle Energy Pact”. Stadt-   Halle-Trotha GmbH. The Halle-Trotha modernized
the major part had to fit inside the existing plant       werke Halle and EVH undertook to meet the entire           CHP plant will respond to the heat requirements
as it was. And that was successfully achieved.            electricity needs of the city of Halle without using       of the city and the national power demand. At the
                                                          nuclear energy as of June 2012.                            warmer times of year, it mainly generates elec-
Six large, blue flaps form the entry point for the                                                                   tricity to cover peak and medium-load demand.
air into the power plant circulation system. The                                                                     In the winter, electricity and heat are provided by
air filter system removes dust particles from the                                                                    the CHP plant at Halle-Trotha. Krause sees the
air and then passes it on to the gas turbine. It          electricity from the gas and steam turbines is en-         new gas turbine as the right solution: “The gre-
is then forced into the combustion chamber un-            ough to supply a third of the population in Halle.         at flexibility of the gas turbines means they can
der pressure by the compressor blades. There                                                                         fill precisely the gap that renewable energies are
it mixes with natural gas and is ignited. The gas-        Energy generators must adapt                               unable to cover. From our viewpoint, gas turbine
and-air mixture burns at approximately 1,200              Roughly 15 percent of Germany’s electricity co-            technology is a bridging technology between the
degrees Celsius. In the turbine section that fol-         mes from combined heat and power plants.                   present and the age of renewables – flexible, effi-
lows, the gas expands and in so doing converts            The Federal Government wants that figure to                cient and kind to the environment.”
thermal energy into mechanical energy to drive            rise to 25 percent by 2025. But it isn’t just the
the generator. The generator in turn produces             Government’s demands that make energy gene-                Text: Katrin Beck
up to 48 megawatts of electricity for the nati-           ration tricky for power plant operators. The gene-         Pictures: Robert Hack
onal power grid. The hot exhaust air at a tem-            ral circumstances surrounding power plant use
perature of 500 degrees passes into the steam             have changed dramatically in the last 15 years.            To find out more, contact:
turbine. The gas turbine drives the generator to          Today, many people are saving energy becau-                Andreas Görtz
produce electricity. The steam boiler uses the hot        se their homes are better insulated, for example.          andreas.goertz@mtu-online.com
exhaust from the gas turbine to produce high-             And then, if the winter is mild, they need much            Tel. +49 7541 90 4810
pressure steam. That steam depressurizes in the
steam turbine. In so doing it produces electri-
city and useful heat at the same time. That me-
                                                                                                                                                                      ON L I N e




                                                                                                                                    More	on	this...
ans that 90% of the energy from the natural gas
                                                                                                                                    Impressions of a power plant                                                                                                                  1 Exhaust diffuser        2 Low-pressure turbine
fuel used in the gas turbine is utilized. The steam
                                                                                                                                                                                                                                                                                  3 Combustion chamber      4 High-pressure compressor
flows through the district heating systems at tem-                                                                                  Don’t have a QR code reader?                                                1                       2      3        4           5             5 Low-pressure compressor
peratures up to 130 degrees Celsius and heats                                                                                       http://bit.ly/M3Ajtf
somewhere around half the homes in Halle. The                                                                                                                                      The intake air is first compressed in the low-pressure compressor and then further compressed by the high-pressure compressor before passing into
                                                                                                                                                                                   the combustion chamber. There gas is mixed with the air, is ignited and burns. In the low-pressure turbine, the gas-and-air mixture expands and
                                                                                                                                                                                   releases the energy that drives the turbine. The exhaust diffuser directs the hot air to the steam boiler.

48 I MTU Report 02/12
Rail                     MTU conquers the Romanian rail market one train at a time




                         Goodbye
                         slowcoach



                          With 20,730 kilometers of track, the Romanian railway
                          system is one of the longest in Europe. But the 1,200 loco-
                          motives and 300 railbuses often trundle along the deteri-
                          orating tracks at little more than walking pace. With the
                          help of modern diesel engine technology from MTU
                          things are set to get better on the Romanian railways.
                          Railcars are to be fitted with modern Powerpacks from
                          Friedrichshafen and old locomotives repowered with Se-
                          ries 4000 diesel engines.


                                                                                        Only in major cities such as Cluj-Napoca have the Romanian railway stations been
                                                                                        renovated. Many of the trains that stop here dawdle in at walking pace.

 50 I MTU Report 02/12                                                                                                                                                     MTU Report 02/12 I 51
Rail




                                                                                                                                                                         New from old: Romanian railway engineering company Remarul is transforming crumbling old railbuses into shiny modern transport conveyances. As part of the process
                                                                                                                                                                         they are fitting modern MTU Diesel Powerpacks. They will make the railcars fit for purpose on Romania’s updated local rail transport services.




The fitters at the Romanian railway engineering company Remarul treat the diesel engines supplied by MTU as if they were as fragile as an egg. They are to be used for
modernizing railcars and so will make a decisive contribution to updating the dilapidated Romanian railway system.




                                                                                                                                                                                                                                                                                        Czech        Poland




                                                                                                                                                                                                                                                                                                                                                                  MAP
                                                                                                                                                                                                                                                                                        Republic Slovakia               Ukraine

                                                                                                                                                                                                                                                                                        Austria
                                                                                                                                                                                                                                                                                                  Hungary           Cluj-Napoca Molda-
                                                                                                                                                                                                                                                                                                                                via
                                                                                                                                                                                                                                                                                           Croatia              Romania            MTU Brown    MTU Brown
                                                                                                                                                                                                                                                                                                                                   0-17-28-62   80% der Farbe   60%    40%    20%
                                                                                                                                                                                                                                                                                                                                   CMYK         CMYK            CMYK   CMYK   CMYK




                                                                                                                                                                                                                                                                                                                                   MTU Blue     MTU Blue
                                                                                                                                                                                                                                                                                                                                                                60%    40%    20%
                                                                                                                                                                                                                                                                                                                                   50-25-0-10   80% der Farbe
                                                                                                                                                                                                                                                                                                                                                                CMYK   CMYK   CMYK
                                                                                                                                                                                                                                                                                                                                   CMYK         CMYK




                                                                                                                                                                                                                                                                                                                        Bulgaria


                                                                                                                                                                                                                                                                                                                                 Turkey



   52 I MTU Report 02/12
                                                                                                                                                                                                                                                                                                                     MTU Report 02/12 I 53
Rail




                                                                                                         M e MO
  Railway	modernization	in	Romania

  Romania is investing 17 billion euro, partly financed by the EU, in modernizing its railways. MTU is
  supplying the manufacturer Remarul 16 Februarie S.A. with Type 16V4000 R41 diesel engines for
  repowering locomotives and Type 6H1800 R84P Powerpacks for new and refitted railcars. The Roma-
  nian rail network extends to over 20,730 kilometers of track. Operating on it is a fleet of roughly
  1,200 locomotives and around 300 railcars.




                                                                                                                  There are old and new locomotives to be seen on the grounds of the Remarul rolling stock plant. They are being modernized as part of the process of modernizing the
                                                                                                                  Romanian railways as a whole.



Two thousand kilowatts of concentrated diesel power for revitalizing worn-out old Romanian locomotives.




                                                                                                                                                                                                                                                                ON L IN e
                                                                                                                                                                                                                            More	on	this...
                                                                                                                                                                                                                            A video tells the story in brief.
                                                                                                                                                                                                                            Don’t have a QR code reader?
                                                                                                                                                                                                                            Go to http://bit.ly/QaUxTJ




   54 I MTU Report 02/12
                                                                                                                                                                                                                                                                            MTU Report 02/12 I 55
  Talking of …
                                                                                                               Talking of...                                                                                       Alternative fuels




Tell us your story
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56 I MTU Report 02/12                                                                                                                                                                                                                                               MTU Report 02/12 I 57

								
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