Friedrichshafen, 5 May 2009. The market debut of MTU’s new Series 1600 kicks off in the fall of 2009 with the 12V engine designed for emergency and peak-shaving power generation applications (GenDrives). The 6-cylinder in-line unit and the 8 and 10-cylinder
V-engines will be brought onto the market in turn in 2010. With a swept volume of 1.75 liters per cylinder, the 50-Hertz versions of the Series 1600 for GenDrives produce between 270 and 635 kW (300 to 715 kVA). 60-Hertz models deliver between 285 and 670 kW (250 to 600 kWe).
The Series1600 rounds off MTU’s program of proven genset engines for the lower power segment and means that the Tognum Group is able to provide a complete range of MTU GenDrive engines from 270 to 6,250 kW. Engines from MTU are reliable and compact and they combine dynamic running characteristics with high power density. They are ideal for emergency power generation which demands units that can be easily integrated in existing buildings and that can withstand rapid load imposition in large stages while also maintaining stable control response. With its new Series 1600 units, MTU is now bringing these features to engine classes in the lower power range.
The engines in the new series, and their crankcases in particular, have been designed with extremely high levels of rigidity, making them both mechanically robust and smooth-running. During operation, this minimizes torsional vibration and reduces the load on the generator. Connection of the generator to the engine during assembly is straightforward. Series 1600 engines come with 2-point, 3-point or 4-point mounting systems to provide a range of anchoring options. They are designed for both rigid and resilient mounts, making them extremely versatile across a range of different applications. Their quiet, low-vibration operating characteristics suits these units ideally for gensets in noise-sensitive locations such as hospitals. Apart from locations inside buildings, such as cold-storage units or data-processing centers, gensets powered by these compact Series 1600 engines are also ideal for mobile applications, generating power, for example, for construction sites, concerts and football games or for emergency rescue operations.
For emergency gensets, load imposition characteristics (rapid provision of power in emergencies) are an essential quality feature. Single-stage turbocharging means that Series 1600 engines deliver rapid power ramp-up from standstill and they are designed to easily exceed the load-switching capabilities demanded by ISO 8528-5 G3.
Fuel costs are crucial to the economic efficiency of genset engines. Low specific fuel consumption not only lowers plant operating costs, it is also a vital factor in environmental considerations due to reduced carbon dioxide emissions. Compliant with US emissions standard EPA Tier 2 (> 560 kW) for genset engines in emergency power applications, these engines consume less than 195 g/kWh of diesel (Tier 2) and less than 200 g/kWh of diesel (Tier 3) in the relevant operating ranges. Their outstanding fuel consumption figures at maximum engine power also mean reduced heat dissipation requirements and consequently, less expensive cooling systems for the genset.
As with all its new engine series, MTU equips its Series 1600 units with its own ADEC (Advanced Diesel Engine Control) system which was developed and is manufactured in-house. This system was specially enhanced to precisely match the needs of Series 1600 engines. The ADEC communicates with the genset plant control systems via interfaces. This facilitates faster and more efficient data exchange between plant and engine and improves the start, load acceptance and operating characteristics of the entire unit. The ADEC interfaces are identical to those of all other MTU engines so that GenDrive manufacturers who already produce larger gensets incorporating Series 2000 and 4000 engines, can now employ their same plant control systems for smaller gensets based on Series 1600 engines.
The three key technologies of turbocharging, injection and electronics have always formed the core of MTU’s expertise. For Series 1600 GenDrive engines, these technologies were employed so that current emissions regulations can be met exclusively by using in-engine techniques for emission avoidance. The new low-nitrogen-oxide and low-soot combustion process secures compliance with emission levels set in US EPA Tier 2 (> 560 kW) and EPA Tier 3 (< 560 kW) for the steady-state ISO 8178-4 D2 test cycle. Long-term emissions stability was a central factor in the conception and balancing of the engine management and the injection and combustion systems. As a result, the engines will not exceed permissible emissions limits at any point throughout their entire service life. They satisfy the EPA requirement for compliance with limit values over a period of 8,000 hours of operation and they achieve this without the use of expensive technologies such as exhaust recycling or 2-stage turbocharging. First-generation engines are designed for EPA Tier 2/3. Current legislation means that gensets for emergency power applications can continue to be sold with these emissions specifications in the future. From 2014, engines supplied for peak-shaving and continuous power generation will be Tier 4 compliant.
In addition to supplying the engine itself, with its capability for simple, straightforward integration in power generation plants, the Tognum Group also provides comprehensive consultation services, systems expertise and complete solutions for customers. The scope of development services available likewise goes beyond the genset unit to encompass the design and provision of plant control facilities, cooling systems, acoustic damping equipment, pipeline systems and also includes project management and processing. For systems development, MTU’s wide range of expertise in engine development, application engineering and electronics can also be called upon. Under its MTU Onsite Energy brand, Tognum supplies complete power generation units as “Plug & Play” solutions based on its Series 1600 engines. For GenDrive operators, MTU maintains a comprehensive network of Service Centers in every region of the globe and, if the operator requires it, his plant and engine control systems can be accessed via the Internet for remote diagnostics. A 24/7 hotline service is available for remote plant management and, if requested, plant data can be stored at MTU and documented in a service history log.
The Series 1600 provides a robust and commercially competitive engine concept for power generation units that meets even the most exacting demands for reliability, efficiency and environmental compatibility.
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