Profile search-and-rescue team

                        Marketing Section


                      FOR NAVAL

NAVAL FORCES V/2008                         83

Especially in the area of military navigation,                                                            offering excellent fuel consumption in the par-
when it is a matter integrating combined pro-                                                             tial load range.
pulsion systems, there is no way around the                                                               STEFAN MÜLLER: For frigates and larger
propulsion systems from MTU Friedrichsha-                                                                 vessels, partial and full electrical propulsion
fen. There is no other company that can                                                                   systems are being developed, promising higher
match the know-how and the product inno-                                                                  redundancy, operational flexibility and survival
vation of MTU.                                                                                            capabilities. From our point of view, purely
With more than 70 navies all over the world,                                                              mechanical propulsion systems – especially
over 16,000 MTU propulsion units are in use.                                                              MTU diesel engine & gas turbine systems – con-
For more than 50 years, specific propulsion                                                               tinue to have an edge in comparison to electri-
concepts for patrol boats or speedboats, cor-                                                             cal propulsion systems, in particular with regard
vettes, frigates or mine detection ships have                                                             to economy and power/weight ratio and thus
been developed for this use, including com-                                                               they are a favored option among potential pro-
plete subsystems and power generation units.                                                              pulsion systems.
MTU also occupies an outstanding position            Stefan Müller,
in the area of submarines. But what direction        Director Application Center Marine.                  NAVAL FORCES: Worldwide deployment
is the market for military propulsion systems                                                             without a reliable home country infrastructure
headed? What solutions and concepts does                                                                  to fall back on requires a high degree of auton-
MTU have to offer for the international                 On the one hand, modern naval forces must         omy for the platforms. What demands does that
navies? And how does MTU set itself apart            be in a position to provide seaborne support to      place on the propulsion systems?
from its rivals as technological leader?             military or humanitarian operations on a global      CHRISTIAN BEINER: The need for suitable,
NAVAL FORCES’ questions were answered                level, whilst, on the other hand, they must be       well trained and self-sufficient crews to proper-
by MTU’s navy experts Nadine Buhmann,                able to protect navigation routes and coastlines     ly perform these tasks is growing; however, this
Stefan Müller and Christian Beiner.                  against conventional and asymmetrical threats.       need can no longer be met by some navies and
                                                     STEFAN MÜLLER: The answer to this new                thus a high degree of automation for floating
NAVAL FORCES: What are the main chang-               global situation is a variety of small and cost-     platforms is necessary. Smaller, highly qualified
es in the external influences on modern navies       efficient units to safeguard national territorial    crews must be in a position to grasp the highly
and what is the effect on the naval vessel pro-      waters, and seaworthy vessels fully complying        complex processes on board of a military ves-
curement process?                                    with military capability requirements, offering      sel, which must be based on easily controlled
CHRISTIAN BEINER: Since the end of the               long sea endurance time and a broad range of         automation systems, and to ensure the availabil-
Cold War, deployment doctrines for naval forc-       weapon systems.                                      ity of the ship, no matter if the ship suffers a
es have changed fundamentally. Terrorism, pira-         What emerges from the demand for long sea         defect or is in an actual conflict. For this reason,
cy, the potential proliferation of weapons of        endurance time and autonomy in the area of           MTU’s automation systems are modular in
mass destruction within third party countries,       deployment is a fundamentally different techni-      design and can be modified to comply with the
the emergence of new states and the significance     cal, logistical and operational ship design. What    specific requirements, and can be supplement-
of the export business for many industrial coun-     is required is a vessel on-station time of several   ed by additional modules such as Battle Dam-
tries confronts navies with far-reaching new         years in the area of deployment with local main-     age Control.
challenges. Essentially, these consist of two sep-   tenance options, without scheduled shipyard
arate sets of requirements necessitating flexible    repairs or return to home port.                      NAVAL FORCES: Time and again, we hear
military platform options.                                                                                about stagnating budgets for new developments,
                                                     NAVAL FORCES: What is the current trend in           whilst, at the same time, political ambitions are
Christian Beiner,                                    the market for military vessel propulsion systems    heading towards ensuring more security in ter-
Vice President Application Center Engines.           in view of these changing external conditions?       ritorial waters. In your opinion, what effects
                                                     NADINE BUHMANN: Requirements placed                  does that have on your business?
                                                     on propulsion systems may vary depending on          STEFAN MÜLLER: Over the last few years,
                                                     the relevant market segment, and so may trends.      significant cost constraints on shipbuilding com-
                                                     For patrol vessels and boats, diesel engines         panies have led to cutbacks in construction
                                                     remain the No.1 choice due to their reliability,     capacities. However, in order to keep risks for
                                                     efficiency and maintainability. If required, they    shipbuilders manageable, there is an ever-
                                                     are supplemented by electric propulsion systems      increasing demand on propulsion system man-
                                                     for slow speed maneuvering which may lead to         ufacturers to take on technical and commercial
                                                     problems, particularly for medium-speed              system responsibility for complete propulsion
                                                     engines. In principle, this is not required with     systems. In order to be able to continue to offer
                                                     MTU high-speed engines, since the engines are        cutting-edge technology at reasonable prices, it
                                                     also capable of unlimited low-load operation –       is predominantly the positive experiences gained
                                                     whilst – due to the technology applied – also        in commercial shipbuilding that are being incor-

84                                                                                                                                   NAVAL FORCES V/2008

porated into military vessel construction, both      justify a costly, separate, full military qualified   sion system, speeds of more than 30 knots can
in terms of propulsion and automation systems.       engine development program. Therefore, it is          be reached, which are usually feasible only by
NADINE BUHMANN: Stagnating budgets                   necessary to develop a marine engine series,          means of gas turbines – with significantly
combined with increasing demands in terms of         initially aimed at the commercial market, in          reduced life cycle costs.
presence and scope of missions requires a high-      order to ensure the cost-effectiveness of any new        With supply vessels, tenders or mine hunt-
er number of vessels built for “low intensity”       development. Thereafter, design changes to            ers, i.e., units for which high speeds are not
missions (such as offshore patrol vessels). All      comply with specific military requirements, such      important, the diesel engine is the first choice
of this under significant cost constraints. With-    as battle damage resistance, signature reduction      as a reliable and economical propulsion system,
in this context, commercial propulsion systems       or NBC protection, can be incorporated. The           whether as the main propulsion system or to
are successfully utilized. With highly complex       MTU 1163 and 8000 series are examples of this,        supply the on-board power generators.
ships such as corvettes and frigates, cost con-      both being enhanced models developed from its
straints are comparable, which ultimately leads      predecessor. In particular, they are reworked as      NAVAL FORCES: What distinguishes MTU
to risks being “passed on” to the suppliers.         a fully fledged and reliable product for the mil-     as the technological leader in the naval seg-
                                                     itary market.                                         ment?
                                                                                                           CHRISTIAN BEINER: Especially in the area
                                                     NAVAL FORCES: Hybrid propulsion systems               of military navigation, when it is a matter inte-
                                                     seem to be of growing significance in new pro-        grating combined propulsion systems, there is
                                                     curement plans. How do you assess this trend?         no way around the propulsion systems from
                                                     CHRISTIAN BEINER: The use of hybrid pro-              MTU Friedrichshafen.
                                                     pulsion systems, i.e., the combination of diesel-        Especially in the areas of shock resistance and
                                                     mechanical and diesel-electric propulsion             noise protection with naval propulsion systems,
                                                     systems, can have many advantages, provided           the MTU experts with their knowledge and ref-
                                                     the application profile is carefully assessed in      erences are leaders worldwide. In addition, MTU
                                                     advance. Increased redundancy, reduced life           has the special ability to meet even complex
                                                     cycle costs, if applicable, and the possibility of    logistic and documentation requirements.
                                                     producing an acoustically optimized “silent run-         As system provider, MTU is in a position to
                                                     ning” propulsion system are basic keywords in         supply all necessary units and modules from a
                                                     this context. Electrical auxiliary propulsion         single source for a complete propulsion system,
Nadine Buhmann,                                      systems are frequently used to reduce the low-        from the drive unit and propeller all the way to
Director Sales & Application Engineering,            load performance of the diesel engine, which          automation hardware and software. In the pro-
Sales Region 1.                                      can have a considerable influence on the main-        cess, it accompanies the customer in project
                                                     tenance intervals, especially with medium-speed       planning, develops expertise for system design
                                                     engines without sequential turbo-charging.            and accompanies installation in the shipyard all
NAVAL FORCES: Procurement cost is one                   The new generation of high-speed MTU               the way to maintenance and supply of replace-
thing, while discussions regarding maintenance       engines with sequential turbo-charging and com-       ment parts according to the NATO standard.
costs for the platforms are only just beginning.     mon rail fuel injection has unlimited low-load
How do you approach this issue?                      capabilities and does not need electric auxiliary     NAVAL FORCES: How important is the com-
NADINE BUHMANN: Low power/weight                     propulsion units for this operational range.          plex of After Sales, Service & Maintenance con-
ratio, high power density, the utilization of mod-   Hybrid propulsion systems make sense when             tracts?
ern materials and a consistent application of key    additional requirements need to be taken into         NADINE BUHMANN: Along with favorable
technologies such as common rail injection,          consideration, which is why the proportion of         procurement and maintenance costs, the ease of
intelligent turbo-charging and automation of         such configurations in new developments is            maintenance and the after sales service are sig-
engines are typical characteristics of MTU’s die-    clearly rising.                                       nificant factors as to whether a purchase is
sel engines as technological leaders in this area.                                                         made. However, not all navies want to let a sup-
Not only do these key technologies enhance the       NAVAL FORCES: Does this mean the end of               plier know where the respective units are locat-
power output of the vessels’ propulsion units,       the classic diesel engine propulsion system in        ed. MTU has adapted to this and offers custom-
but also reduce fuel consumption and mainte-         naval applications?                                   ers the option of long-term maintenance con-
nance costs. The current trend towards diesel-       STEFAN MÜLLER: The marine diesel engine               tracts, thus facilitating long-term operating cost
electric and hybrid propulsion systems should        still has a key position among commercial, aux-       projections.
also be noted.                                       iliary military and full military vessel propul-         With more than 1,100 service centers world-
CHRISTIAN BEINER: Modern automation                  sion systems. The question of which combina-          wide, MTU is a reliable global partner for
systems contribute to reducing ship crews, whilst    tion the engine is used in with other propulsion      repairs and on-hand remanufactured or original
integrated training programs shorten the train-      units, such as a gas turbine, depends primarily       spare part supplies. Our after sales program is
ing time required for the crew - who are mostly      on the purpose the respective ship is used for.       complemented by worldwide training courses,
conscripts and whose average period of service       The benefits high-speed diesel engines can offer,     videos and technical documentation. In addi-
has been reduced in the last few years.              such as highly efficient fuel and oil consump-        tion, we offer planning and design of workshops
                                                     tion, high power density, reliability, ease of        and test facilities.
NAVAL FORCES: To what extent do develop-             maintenance and favorable emission character-
ments in commercial navigation affect military       istics are enough to secure its position as the       NAVAL FORCES: Thank you very much for
navigation?                                          number one choice of propulsion systems for           this interview which will give our internation-
STEFAN MÜLLER: Engine quantities poten-              military vessels.                                     al readership an excellent overview of the prod-
tially emerging from the market for frigates, cor-      In combination with several engines, such as       ucts and services of MTU and the philosophy
vettes and coastal warships are not sufficient to    a CODAD (combined diesel and diesel) propul-          behind them.                              NAFO

NAVAL FORCES V/2008                                                                                                                                       85


When it comes to the safety and reliability of     cycle costs. From project planning to commis-         PATROL VESSELS –
naval and government vessels, there can be         sioning, MTU handles project management and           MOBILITY AT HIGH SPEED
no compromises. All around the globe, naval,       system responsibility across the board from sim-         As flexible rapid-deployment units, patrol
coast-guard, police and other government           pler system configurations through to complex         boats and high-speed vessels contribute substan-
vessels are needed on 24/7-duty to perform         propulsion systems. In addition, our logistics        tially to national security. Their tasks range from
vital intervention, stabilization and support      support services provide complete, customized         anti-pirate duties, immigration surveillance and
roles.                                             service packages covering everything from spare       search-and-rescue operations through to intrud-
                                                   part and tool provisioning to installation support    er interception missions. The essential require-
                                                   and on-board training. That is why our world-         ments for a propulsion system called on to per-
                                                   wide clientele includes more than 70 navies.          form this range of functions are 100% reliabil-
                                                      The vast spectrum of applications covered by       ity and availability, excellent power/weight ratio,
                                                   MTU propulsion and on-board systems ranges            high speed and endurance. With offshore patrol
                                                   from fast patrol boats and offshore patrol ves-       vessels, these requirements also include ocean-
                                                   sels through to surface combat units such as cor-     going capabilities.
                                                   vettes, frigates and destroyers, and near-silent         Compact and powerful MTU diesel engines
                                                   submarine units. The latest class of combat ves-      with outputs up to 9,100kW cover the entire
The Swedish “Visby” class vessel is equipped       sels, the American Littoral Combat Ships, is also     application range – regardless of whether they
with a Combined Diesel and Gas Turbine             equipped with complete MTU propulsion                 are destined for patrol duties, for service in the
System (CODAG) Four TF 50 A gas turbines           systems.                                              most difficult weather conditions or for combat
and two MTU 16V 2000 N90 diesel engines                                                                  missions. For these vessels too, the integration
are connected to two gearboxes which power         GOVERNMENT VESSELS –                                  of automation systems means largely automat-
two Kamewa waterjets.                              WORKHORSES                                            ic operation of the propulsion system and other
                                                   IN CONTINUOUS COASTAL                                 areas of the ship, freeing the crew to concentrate
                                                   OPERATION                                             entirely on accomplishing its mission.
                                                      Search-and-rescue cruisers, buoy layers, sur-
                                                   vey vessels, pilot launches, sounding vessels,        CORVETTES AND FRIGATES –
                                                   harbor police and coast guard units – they all        CUTTING-EDGE
                                                   have one thing in common: they place challeng-        TECHNOLOGY FOR
                                                   ing demands on the propulsion system.                 PEACEFUL MISSIONS
                                                   Duty profiles involving switches between low-          Corvettes and frigates play a dominant role in
                                                   load operation and arduous full-power perfor-         most navies. Whether on national missions or
                                                   mance are typical for this type of vessel. MTU
With the Deepwater Program, the US Coast           diesel engines with their outstanding low-load        Excellent availability and powerful output
Guard is updating their air- and sea-borne         characteristics and acceleration capabilities         values at low unit prices characterize
fleets. The picture shows the National Security    prove themselves daily in single-shaft systems        MTU propulsion systems for fast patrol boats
Cutter “Bertolf”. The CODAG propulsion system      with reversing transmission gearboxes as well         such as the Super Dvora.
consists of two MTU 20V 1163 TB93 diesel           as in multi-shaft systems with multi-engine gear-
engines with a power output of 7,400kW (9,925      boxes. The engines cover a performance range
HP) each, and a General Electric LM2500 gas        from 300kW to 9,100kW and deliver the pow-
turbine for marine applications with a power       er for diesel-electric units, positioning rudders,
output of 22,000kW (29,500hp).
                                                   bow thruster control systems and for entire on-
                                                   board power systems. Since they operate exclu-
   MTU supports them in their mission with pro-    sively in sensitive coastal regions, certified com-
pulsion systems and cutting-edge technologies      pliance with IMO and EPA emission limits guar-
which are individually tailored to the task in     antees environmentally-friendly operation.
hand. High power density, low weight, compact-     In addition, integration of MTU ship automa-
ness and mechanical and thermal durability char-   tion systems facilitates largely automatic oper-
acterize MTU propulsion systems and these          ation of the propulsion system and other areas
strengths are complemented by simple opera-        of the ship all the way to complete vessel con-
tion, straightforward maintenance and low life-    trol.

86                                                                                                                                 NAVAL FORCES V/2008

UN deployment, their main tasks are the protec-                                                          mance range from 500 to 1,200kW in snort
tion of territorial waters, participation in global      SERIES 396                                      mode and up to 1,350kW in surface operation,
peace-keeping measures and cooperation in cri-                                                           is specifically designed and adapted for sub-
sis management. They must be able to success-                                                            marine applications. In addition to customized
fully counter threats from other surface vessels,                                                        propulsion concepts, this series also includes
submarines and aircraft. With these vessels, reli-                                                       complete genset units with customer-defined
ability, availability and minimum crew size are                                                          generator and mounting systems and controlled
top priority factors. Long-range capabilities for                                                        magnetic compensation for components if
patrol missions, long sea endurance in conflict                                                          required. Our engines, complete genset units
areas and high speed for rapid redeployment to                                                           and mounting systems are optimized to cus-
far-off theatres of operation are just as indispens-                                                     tomer specifications for shock resistance,
able. The specifications for propulsion systems          As the top-selling high-performance engine      acoustics and EMC.
derive from these tasks. They must comply with           of its class, the MTU series 396 can be used
full military requirements such as shock resis-          in a number of ways in military vessels: the
tance, low acoustic, visual and infrared signa-          engines are used both as main propulsion         SERIES 8000
tures, electromagnetic compatibility, NBC pro-           units and for on-board power generation.
tection and gas-protection operation. In addi-           They supply power outputs of 1,000 to
tion, it is essential to keep operating costs such       2,150kW.
as fuel consumption to a minimum. MTU’s tail-            The diesel-electric propulsion systems of the
or-made propulsion solutions for large naval             series 396 specifically developed for use in
vessels meet stringent navy standards and                submarines have a power output range of 500
achieve high speeds even with high tonnage.              to 1,200kW in snorkel operation and up to
CODAD (combined diesel and diesel), CODOG                1,350kW in surface operation. Along with a
(combined diesel or gas turbine) and CODAG               low magnetic signature, these engines are
(combined diesel and gas turbine) systems are            also distinguished by excellent battle damage
all included in the company’s program. Modern            resistance, light operating noise and low
automation systems monitor and control all ship          underwater sound values.                         Series 8000 engines are used especially in
functions, from the propulsion system and dam-                                                            military and government vessels as proven
age control to the on-board power supply.                                                                 high-performance engines. The engines are
                                                        SUBMARINES – INVISIBLE                            used as main propulsion systems and, in
                                                        HUNTERS                                           addition, generate power for diesel-electric
MINE HUNTERS AND                                          For decades, MTU has played an outstand-        propulsion. They provide power outputs of
DRONE VESSELS –                                         ing role in the development and design of sub-    8,200 to 9,100kW.
CLEARING THE WAY                                        marine propulsion systems that set benchmarks     The engines are distinguished by high power
   Modern sea mines with high-level sensitiv-           globally. MTU’s 396 SE series with a perfor-      density, low weight, compactness and
ity, selectivity and artificial intelligence can only                                                     mechanical and thermal durability. Simple
be dealt with by using special-purpose platforms        Class 212 A submarines are currently the most     operation and maintenance and low life cycle
such as mine-hunters and drone vessels which            up-to-date submersible vessels in the German      costs optimize this propulsion system.
can secure their own fleet’s areas of operation         Navy and the Italian Marina Militare.
                                                        Apart from the conventional system consisting
and keep passages free for merchant shipping.           of lead acid batteries and a diesel generator
   The conditions under which these ships oper-         (engine: MTU 16V 396, generator:                 SUPPORT SHIPS –
ate dictate the strictest requirements for propul-      Piller, 1,050kW) an HDW fuel cell system is      THE SERVICE PROVIDERS
sion systems: minimal underwater acoustic char-         integrated in the overall system, which can      OF THE FLEET
acteristics, outstanding shock resistance and low       generate electricity when submerged                 Support ships are indispensable to the smooth
magnetic signatures. In addition, of course, our        and hence, cut off from the outside air.         operation of naval fleets. Regardless of wheth-
engines more than meet the criteria for factors                                                          er they are supply ships, tankers or environmen-
such as compactness, outstanding power/weight                                                            tal protection vessels they form the backbone of
ratio, reliability and dynamic reaction capabil-                                                         logistics operations.
ity. From the outset, MTU has been foremost in                                                              They have to perform in arduous continuous
the development of propulsion systems with low                                                           operation under the most varied and sometimes
magnetic and acoustic signatures. The MTU                                                                extremely dangerous conditions such as those
MRK technique reduces magnetic emissions                                                                 involving hazardous gases. For propulsion
from all ferromagnetic components to a stable                                                            systems, reliability, availability, wear resistance,
minimum. Our comprehensive facilities, includ-                                                           low consumption and ease of maintenance are
ing our own magnetic ranging facility, allow us                                                          the basis for economical operation.
to magnetically treat individual components                                                                 The integration of MTU ship automation
such as crankcases, conrods, gear elements and                                                           systems in support vessels can facilitate largely
drive shafts as well as to conduct measurements                                                          automatic operation of the propulsion system
on engines, gearboxes, generators and complete                                                           and other areas of the ship – all the way through
propulsion systems.                                                                                      to complete vessel control.                   NAFO

NAVAL FORCES V/2008                                                                                                                                       87
88   NAVAL FORCES V/2008
NAVAL FORCES V/2008   89


MTU’s links with the world of naval shipping      MISSION 24:                                          plicity: 3-click technology guarantees that eve-
are based on long and successful partner-         INTEGRATION,                                         ry operation can be accomplished with no more
ships. From German Class 143 fast patrol          INTELLIGENCE,                                        than three mouse-clicks.
boats through to the American National            INTUITION
Security Cutter, MTU propulsion and auto-                                                              CALLOSUM MC
mation systems are in service on virtually eve-      The integration of                                   At the heart of Callosum is the Callosum MC
ry type of vessel, in every naval application     state-of-the-art electron-                           integrated monitoring and control system. Cal-
and on all the oceans around the globe.           ic systems such as the                               losum MC with the latest generation of propul-
The company’s systems expertise in the naval      Callosum Product Series                              sion RCS (Remote Control System) and MCS
shipping sector covers the entire range of pro-   (developed as part of the                            (Monitoring and Control System) enables the
pulsion system configurations and associat-       Mission 24 program) allows the creation of opti-     ship’s crew to monitor the entire propulsion
ed components. Engines, gearboxes, control        mum, automated total solutions which guaran-         system, the on-board power supply and sub-
and monitoring systems, on-board power            tee the safety, efficiency and reliability of the    systems throughout the entire ship. Performance
supply units and other system components          on-board systems.                                    data collected from all areas of the vessel can be
are precisely coordinated to create units char-      With Callosum, MTU is now able to provide
acterized by maximum reliability and effi-        the automation system of the future. Developed
                                                                                                       The user-friendly Callosum MC enables the
ciency.                                           on the basis of decades of invaluable experience     ship’s crew to monitor the entire propulsion
Of course, MTU also provides fully coordi-        of naval practice and constant dialog with the       system, the on-board power supply
nated control and monitoring systems to           users, Callosum ensures that the technology func-    and subsystems throughout the entire ship.
ensure that its propulsion plants operate per-    tions absolutely reliably “on site.” This modular,
fectly.                                           complete system integrates various self-suffi-
This is particularly vital for modern naval       cient subsystems into a comprehensive intelli-
vessels where trouble-free interaction            gent structure. A network of several thousand
between the individual subsystems has a sig-      sensors continuously monitors and controls all
nificant influence on the efficient deployment    areas and functions of the vessel’s technology.
of the ship. Regardless of whether CODAG             User-friendly visualization of all processes
or CODLAG propulsion is planned, careful          utilizes a uniform interface which can be
selection and design of the systems involved      accessed on every networked screen on board.
is the key to achieving the decisive advantage    This man-machine interface incorporates the
on active duty.                                   paramount principle of Callosum, namely sim-

90                                                                                                                               NAVAL FORCES V/2008

                                                                                                          MTU has supplied the entire propulsion and
                                                                                                          power generation systems for the US Navy
                                                                                                          X-Craft. The CODOG propulsion system
                                                                                                          consists of two ultra-compact LM 2500 gas-
                                                                                                          turbine modules each producing 25,000 kW,
                                                                                                          two 16V 595 engines developing 4,320 kW,
                                                                                                          the CODOG transmission, the MCS 5 Type 2
                                                                                                          electronic monitoring and control system
                                                                                                          for the engines and on-board equipment,
                                                                                                          and four S60 gensets for supplying the entire
                                                                                                          vessel with electricity.

                                                                                                          this purpose. Customized simulation-software
                                                                                                          facilitates the creation of stress situations or par-
                                                                                                          ticular scenarios designed to accelerate the
retrieved directly at the control consoles by the    Power Management System (EPMS); fire alarm           crew’s decision-making capabilities. The pro-
crew and visualized on color screens. In action,     system (FDS); customized consoles and other          cess involves the crew in action whether they
this means the crew has rapid access to a current    hardware products.                                   are on board or at a land-based training center
data overview.                                                                                            and the range of scenarios extends from engine
    The flexible, user-friendly automation system    CALLOSUM DC                                          damage all the way to breaching of the ship’s
with its integrated alarm system substantially          Another essential component of Callosum is        hull. Integration of the training system into Cal-
enhances ease of operation as well as vessel         Callosum DC, a battle damage control system          losum via the vessel’s normal man-machine
security and makes it possible to keep the crew      (BDCS) geared to the “battle within”.                interface gives the simulations a high level of
needed for missions to a minimum.                       The Callosum DC vessel security system pro-       authenticity so that the crew’s awareness of how
    MTU’s processor-controlled RCS (Remote           tects against and limits damage due to leaks, fire   the vessel works is very effectively developed.
Control System) is the logical supplement to the     and NBC contamination following collisions or
MCS (Monitoring and Control System).                 weapon strikes. Detectors and warning units          CALLOSUM MT
    Callosum MC controls propulsion systems          installed in every room provide a rapid situation       Callosum automation system technology is
which incorporate engines and gas turbines con-      overview in case of incidents. The warning sig-      rounded off by Callosum MT, an integrated ser-
nected to fixed propellers, variable-pitch pro-      nals can be evaluated acoustically and visually      vice and maintenance system designed for duty
pellers, water jets or Voith Schneider propellers.   on monitors in a central operating station. An       at sea without putting into port. An electronic
It is also suitable for combined systems such as     automatic control protocol based on ‘kill cards’     diagnostic program constantly monitors all pro-
CODAD (combined diesel and diesel), CODOG            makes it possible to contain damage due to pow-      pulsion-related processes. If malfunctions or
(combined diesel or gas turbine), CODAG              er outages, system failures or leaks etc. indepen-   irregularities occur or replacement parts are
(combined diesel and gas turbine), CODAE             dently of human decisions or to make decision        needed due to wear, the diagnostic system alerts
(combined diesel and electric), CODLAG (com-         supports available. The 3-click technology           the vessel’s crew. The order can then be trans-
bined diesel electric and gas turbine) and other     guides operators quickly and reliably to the         mitted to base via storage medium, mobile tele-
configurations. Equipment includes monitors,         source of the damage.                                phone, network or satellite. In addition, the
control levers and keypads for travel mode selec-                                                         ship’s systems can be remotely monitored from
tion. The modular design means that MTU can          CALLOSUM TR                                          land by satellite. Technical documentation and
adapt the system to all types of naval vessels,         Perfect mastery of this automation system         3D videos providing detailed coverage of eve-
from fast patrol boats to destroyers, to meet the    under all circumstances is only possible through     ry component and every maintenance procedure
customer’s needs. Additional systems can be          intensive crew training and MTU has integrat-        completely round off MTU’s program and
integrated into Callosum MC without any prob-        ed an on-board and land base training system         ensure comprehensive vessel availability with-
lems due to its open structure, e.g. Electrical      (OBTS/LBTS) into the Callosum program for            out maintenance-related interruptions. NAFO
All areas of the ship can be monitored by            Callosum TR supports the land-base and
Callosum DC – any disturbances or                    on-board training. The crew members can              Callosum MT offers perfect support capabilities
abnormalities are directly reported to the crew,     familiarize themselves thoroughly with the           for repair and maintenance work at sea.
thus facilitating the initiation of immediate        highly complex process and the interaction           This serves to significantly extend the vessel’s
counter-measures.                                    of all systems on board of a naval vessel.           dwell time at sea.

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                                                                                              CODAG (Combined Diesel and Gas Turbine)
                                                                                          Principle: two diesel engines and one gas turbine power the
                                                                                      propeller via two main gearboxes and one multi-input gearbox.
                                                                                  If only one diesel engine or the gas turbine is being operated,
                                                                             both propellers are evenly supplied with propulsive power via the
                                                                         multi-input gearbox. Whenever both diesel engines are in operation,
                                                                    this gearbox can be uncoupled. By using a two-level gearbox, the diesel engine
                                                                can power the vessel up to cruising speed.

                                                   CODAG:                                                CODLAG:
                                                   INCREASED FLEXIBILITY                                 THE PROPULSION SYSTEM
                                                   WITH LOW WEIGHT                                       OF THE FUTURE
                                                      This is achieved by linking diesel engines to         A modern enhancement of this technology is
                                                   powerful gas turbines in a power range extend-        the CODLAG (combined diesel electric and gas
                                                   ing to several tens of thousands of kilowatts.        turbine) propulsion system. The diesel engines
                                                   CODAG (combined diesel and gas turbine) pro-          drive the generators that produce power for the
Along with the latest ship automation              pulsion systems as installed by MTU in the Ger-       electric motors. The gas turbine acts via two
systems, MTU supplies propulsion systems           man Class 124 frigates or in the new class of         gearboxes on two shafts with variable pitch pro-
specifically configured for individual vessels     coastal warships, the Littoral Combat Ships of        pellers, alone or in combination. The diesel-
and including the necessary subsystems such        the US Navy, are typical of these propulsion          electric propulsion system propels the ship in
as generators for electric power or control        systems.                                              cruising mode. The turbine is switched in to
units. MTU’s project system specialty, which          With the CODAG principle, two diesel               achieve full speed. In addition, the generators
is geared to the customer’s needs, is based on     engines and a gas turbine act on the propellers       supply the ship with the operating current need-
knowledge and experience gained from sup-          or water jets via two main gearboxes and a con-       ed, without additional gensets (on-board power
plying many thousands of propulsion                necting gearbox. If only one diesel engine or the     units) having to be installed. Since the diesel
systems; it reflects the core expertise under-     gas turbine is running, both propellers are uni-      engines no longer act directly on the drive shaft,
pinning the technological lead which MTU           formly supplied with propulsion force via the         they can be used in a low-noise application at
has built up from its headquarters in Frie-        connecting gearbox. If both diesels are in oper-      another location on the ship. Linkage to
drichshafen, Germany.                              ation, this gearbox can be decoupled. The ves-        rechargeable batteries facilitates creep mode for
The reorientation of strategies by navies          sel can be brought up to cruising speed with a        naval vessels. The gearbox configuration is less
throughout the world has given rise to             two-stage gearbox. The primary advantage of           complex and maintenance costs are reduced. The
increasing demand for ever more economi-           this propulsion system is the efficient fuel con-     diesel engine can be used within its optimum
cal, powerful and innovative propulsion            sumption of the diesel engines in cruising mode       speed/output range for power generation.
systems at every level starting from the sim-      and the possibility of limiting the performance          What are prospectively the most modern war-
plest configurations with gearboxes connect-       and size of the diesel engines to a minimum in        ships in the French and Italian navies, the
ing one or more diesel engines to a drive shaft.   order to cut down on installation space and           FREMM frigates (Frégates Européennes Mul-
Apart from achieving a moderate, low-con-          weight. If maximum speed is required, the ship’s      timissions (French) or Fregate Europee Multi-
sumption cruising speed, these propulsion          two diesel engines and the gas turbine can run        missione (Italian)) are equipped with MTU’s
systems are expected to provide enormous           in parallel to deliver 38,000 kW output. The          CODLAG propulsion systems. Four 16V Series
power reserves for humanitarian or combat          advantage over a classic CODOG propulsion             4000 diesel engines, each producing 2,200kW,
operations above 25 knots.                         system is that it requires only one gas turbine for   linked to four electric generators deliver the
                                                   almost the same output.                               power for the frigate’s electric propulsion

92                                                                                                                                 NAVAL FORCES V/2008

                                               CODLAG (Combined Diesel Electric And Gas Turbine)
    The diesel engines power generators which, in turn, generate electricity for two electric motors.
    The gas turbine powers the propeller shafts via a gearbox, either separately or in combination.
                The diesel-electric propulsion system powers the vessel in the cruising mode.
                                  The turbine is put into operation if top speed is required.

   Hybrid-Propulsion is provided by two systems which
      are completely independent of one another.
          Conventional diesel engine and high-
              performance electric motor.

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                                                                                                        developed in light of duties undertaken by the
  SERIES 4000 / 4000 GENSETS                                                                            German Navy off the Horn of Africa and the
                                                                                                        coast of Lebanon.
                                                                                                           The KWB-009 design incorporates a high
                                                                                                        degree of integrated automation. The mis-
                                                                                                        sion/deployment-oriented crew size is 15 to
                                                                                                        max. 27 persons on rotating shift duty. Propul-
                                                                                                        sion is provided by two systems which are com-
                                                                                                        pletely independent of one another. One is a con-
                                                                                                        ventional MTU 20V1163 TB93 diesel engine
                                                                                                        with an output of 7,400kW. The other is a
                                                                                                        7,000kW high-performance electric motor with
                                                                                                        operating current generated either via an HST
                                                                                                        gas turbine generator or 12V 2000 gensets. An
                                                                                                        option for fuel-cell generated on-board power is
                                                                                                        also planned.
                                                                                                           Exhaust emissions from the gas turbines and
                                                                                                        diesel engines are cooled. They can either be dis-
                                                                                                        charged below the water line via the water out-
                                                                                                        flow stream of the water jets which are equipped
                                                                                                        with a coaxial exhaust emission nozzle or, as
                                                                                                        was previously standard, via a flush deck smoke-

     Series 4000 gensets are high-performance engines that meet the requirements of navies as           GENSETS
  main propulsion systems. With 8, 12 16 or 20 cylinders and apower output range of 1,750kW                In addition to propulsion systems and auto-
  to 3,010kW, the most powerful engine in its class worldwide is also available as on-board             mation system technology for vessels of every
  power generator for 50 and 60Hz applications and complies with the tightened restrictions of          kind, MTU also supplies genset units for on-
  the TIER II emission levels.                                                                          board power, heat, light, comfort and safety.
     The 4000 series genset is particularly clean and economical, whilst providing increased per-       These supply and standby gensets are subject
  formance levels. The 4000 genset complies with EPA emission values, with NOx emission                 to the same military specifications and stan-
  values below 1,700mg/mN3. In addition, the engine is furnished with the ADEC system                   dards as the larger units used for propulsion.
  (Advanced Diesel Engine Control) that takes over engine control duties.                                  MTU supplies a multitude of different cus-
                                                                                                        tomized systems providing high levels of shock
                                                                                                        resistance and the best possible acoustic insu-
motors. A high-performance Type LM 2500 gas        HYBRID PROPULSION                                    lation for structure-borne and air-borne noise.
turbine linked to these electric motors acceler-                                                        These genset solutions in the 396, 2000 and
ates the vessel to a maximum speed of over 25        One of the next steps on the way to a “com-        4000 series excel not only in terms of reliabil-
knots (15.5 knots without the LM 2500 gas tur-     pletely electric ship” (CES) is currently under      ity and power output but also as far as compact-
bine). The medium-voltage generators each pro-     research by MTU R&D specialists working on           ness and low emissions are concerned. As
duce 6,600 volts, meeting on-board power           an integrated electric hybrid propulsion and         systems providers, we also provide complete
requirements for the entire vessel. The engine-    power generation system projected for use in the     systems for on-board power generation. An
generator unit is installed in special-purpose     new, ocean-going German coast guard boat, the        automatic facility which can be integrated into
shock and acoustic encapsulation. The stealth      KWB-009. This is a multi-purpose coast guard         the ship’s automation system, if required, is
characteristics of the FREMM frigates make sig-    boat, designed with export in mind as a fully        likewise available to monitor and control all
nature detection extremely difficult.              electric, future-oriented, ocean-going vessel        electric power-generating units.          NAFO

  With its two business units, “Engines” and       and propulsion systems for ships, for heavy agri-    gas engines, fuel cells and gas turbines that gen-
“Onsite Energy & Components,” the Tognum           cultural, rail and military vehicles, and for the    erate both electricity and heat. In 2007, Tognum
Group is one of the world’s leading suppliers of   oil and gas industry. The portfolio of the “Onsite   generated revenue of more than €2.8 billion and
engines, propulsion systems and distributed        Energy & Components” business unit includes          employs approximately 8,600 people. With 26
energy systems. These products are based on        decentralized energy systems of the brand MTU        fully consolidated subsidiaries, more than 130
diesel engines with up to 9,100 kilowatts (kW)     Onsite Energy, fuel-injection systems from           sales partners and 1,100 authorized dealers,
power output, gas engines up to 2,000kW, fuel      L’Orange, and drive shafts from Rotorion. The        Tognum’s sales and service structure has a glo-
cells up to 363kW and gas turbines up to           energy systems comprise diesel engines for           bal reach. The shares of Tognum AG (ISIN:
45,000kW. The product portfolio of the “En-        emergency power generation, basic and peak           DE000A0N4P43) have been listed in the
gines” business unit comprises MTU engines         load, and cogeneration power plants based on         MDAX share index since 2007.                NAFO

94                                                                                                                                NAVAL FORCES V/2008

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