MTU boosts Series 4000 power range to 4,300kW

Cleaner, more powerful and shock-resistant Series 4000 high speed engines are offered by MTU Friedrichshafen for naval applications, the new version benefiting from refinements based on 10 years’ experience with the earlier 165mm-bore generation

Improved shock resistance, electromagnetic compatibility and acoustic signatures in MTU’s new version Series 4000 high speed engine are said to fulfil the strictest military requirements, such as the latest Nato standards. Compliance with tougher US emission limits (EPA Tier 2), notably on NOx, is also reported.

Output per cylinder has been increased by over 26 per cent (from 170kW to 215kW) at a rated speed of 2,170 rpm. A V12-cylinder model can thus now deliver 2,580kW, while the V16 model yields 3,440kW. The upper power limit of the Series 4000 range is significantly extended by the introduction of a V20-cylinder model with outputs up to 4,300kW.

Fuel consumption has also been reduced slightly, despite the reduction in emissions, making the new Series 4000 engine an attractive replacement for MTU’s older 190mm-bore Series 595 design. Replacing a V12-cylinder Series 595 engine generating 3,240kW with a new 16V4000 engine delivering 3,440kW yields a fuel saving of around 10 per cent, the company says.

A similar rise in fuel economy results from replacing a V16-cylinder Series 595 engine (4,320kW) with the new 20V4000 model (4,300kW).

Switching to the Series 4000 engine also fosters space savings. While otherwise comparable in size to the Series 595 engine, the new engine is around half-a-metre lower and 1.5 tons lighter; and since compliance with emission requirements has been achieved without the need for an exhaust gas after-treatment system it will fit the same footprint as its predecessor.

Similar interfaces facilitate exchanges with both Series 595 and older Series 4000 engines to create more compact installations. A modular design underwrites flexibility for configuring to the requirements of vessels ranging from patrol boats to corvettes.

Advances in fuel injection, turbocharging and electronic management systems are cited as contributors to the higher performance and lower emissions of the new Series 4000 engine by Dr Gerd-Michael Wolters, MTU executive vice president, engineering and operations: “A common rail fuel system of the next generation (the original Series 4000 engine pioneered the concept in marine engines) exploits a high pressure in-line pump and LEAD injectors with individual fuel accumulators to achieve a virtually constant pressure of 1,800 bar across the entire engine operating range.”

Progress in MTU’s own-design turbocharger development is also tapped. The new engines are fitted with two turbochargers (for 12- and 16-cylinder models) or four turbochargers (for the 20-cylinder model), which can be switched-in in line with the engine speed. A well proven single-stage sequential charging system fosters optimum performance across the engine performance map, it is claimed.

MTU’s latest generation ADEC (Advanced Diesel Engine Control) electronic management system is another important element. Its features include triple injection electronics (pilot, main and after-injection) which promote optimum control of the injection process to secure low pollution, high efficiency combustion (see also page 27).

Additionally, the ADEC system allows remote scanning and Internet read-out of engine data, such as the number of operating hours. Data can also be copied to another engine governor for maintenance planning purposes.

• Continuing sales of its venerable 230mm-bore Series 1163 high speed ‘frigate’ engine are meanwhile reported by MTU. Two V16-cylinder models will power a 1,500-tonne displacement ship ordered by the Korean Coast Guard. MTU is also supplying a comprehensive automation package. The MCS-5 Type 2 monitoring and control system covering the propulsion, power generation and ship’s services will be complemented by an RCS-5CPP remote control system for the propellers.

A similar automation and control system is specified as part of the modernisation package for the Indian Navy’s Ajay P34 anti-submarine corvette, which was commissioned in 1990 with two 16V Series 1163 main engines. In this case, an RCS-5 remote control system will serve the fixed pitch propellers. MP
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