MAN 18V48/60TS

Two-stage turbocharged diesel engine

MAN Diesel & Turbo
Powering the world – responsibly

MAN Diesel & Turbo is the world’s leading provider of large-bore diesel engines
and turbomachinery. Our product portfolio includes two-stroke and four-stroke en-
gines for marine and stationary applications, turbochargers and propellers, as well
as gas and steam turbines, compressors and chemical reactors.

MAN solutions can be found in ship propulsion, engine-based power plants and
turbomachinery trains for the oil & gas and process industries. We support our
global customers with a comprehensive range of after-sales services under the
MAN PrimeServ brand.

MAN Diesel & Turbo has always been committed to increasing fuel efficiency and
reducing emissions. Today, this commitment ensures that our customers are able
to meet increasingly strict emissions regulations and plays a vital role in reducing
the environmental impact of global trade and industry.

MAN 18V48/60TS – Two-stage turbocharged diesel engine 3

 The Best in its Class
MAN 18V48/60TS

Two turbochargers in sequence provide a new dimension in engine performance

and operational flexibility. A wide load range from 1,050 to 1,200 kW/per cylinder,
a specific fuel oil consumption of 7323 kJ/kWh at 1,050 kW/cyl. and reduced NOX
emissions set a new benchmark for four stroke diesel engines.

Turbochargers from MAN Diesel & Turbo
Turbochargers are the core of this innovative new con-
cept – and MAN Diesel & Turbo is the only engine
manufacturer that also designs and builds turbo-
chargers. This unique expertise translates into excep-
tional efficiency and reliability.
Two-stage turbocharging
The idea is simple: just place two of MAN’s most effi-
cient turbochargers upstream from the engine, one
after the other. The result: the engine gets twice the
charge air pressure, while turbocharger efficiency is
increased significantly.
A single turbocharger, such as MAN Diesel & Turbo’s
well known TCA88, is highly efficient; however, it has
a limited pressure ratio. A specially designed com-
pressor, as in the TCA88/RCF23, can increase the
pressure ratio – but also has the effect of decreasing
efficiency. The only solution to this dilemma is two-
stage turbocharging.
The MAN 18V48/60TS deploys MAN Diesel & Turbo’s
tried and tested TCA88 and TCA77 standard turbo-
chargers in sequence. The TCA88 is located up-
stream and provides the low pressure turbocharger,
while the TCA77 forms the high pressure turbocharg-
er, next to the engine. In this configuration, both tur-
bochargers can achieve pressure ratios over 6 bars
and efficiencies of more than 76 percent.

4 MAN 18V48/60TS – Two-stage turbocharged diesel engine

A New Dimension
Ultimate power

The diesel engine MAN 18V48/60TS For the two-stage turbocharged MAN 18V48/60TS,
The MAN 48/60 type diesel engine is a perfect exam- only a few modifications were made to the standard
ple of proven technology and robust design. Over engine:
800 units have been sold since the product was
launched in 1988. They are now operating in a range „„Adapted fuel injection nozzles
of applications in power generation and marine pro- „„Three-ring piston with higher compression ratio
pulsion. Thanks to its high efficiency, the 18 cylinder „„Modified camshaft for enhanced Miller timing
engine is the MAN 48/60 engine family’s best-selling „„Additional charge air bypass valve for low smoke
configuration. emissions during engine start up

Comparison two-stage (MAN 48/60TS) – one-stage turbo charging (MAN 48/60B)

78
MAN 48/60TS (TCA88 + TCA77)
TC efficiency tot-tot [%]

76

74

72
MAN 48/60B (TCA88)
70

68

66

64
1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

Pressure ratio

MAN 18V48/60TS – Two-stage turbocharged diesel engine 5

 Standard Components, Proven Design
Low pressure Turbocharger
Low pressure Turbocharger
Standard components, proven design
The overall design of the two-stage turbocharged
MAN 18V48/60TS has been kept as simple as possi-
ble. Apart from the modifications described above,
the engine is standard, with the high pressure turbo-
charger directly mounted to it.
The low pressure turbocharger is located upstream
from the engine, on its own steel frame. The combus-
tion air and exhaust gas piping between both turbo-
chargers is fitted with compensators, ensuring com-
plete insulation from vibrations.
An air blower is situated below the steel frame of the
low pressure turbocharger. Active during engine start-
up and low part-load operation (up to 25 percent
load), it cares for low smoke emissions even during
these operation phases.
6 MAN 18V48/60TS – Two-stage turbocharged diesel engine
Lowest fuel oil consumption or NOx emissions
The excess combustion air from the turbochargers
provides greater operational flexibility. The high charge
air pressure can be used for enhanced Miller Cycling,
delivering significant fuel savings and further reducing
NOx emissions.
As a result, the MAN 18V48/60TS diesel engine’s
extremely low specific fuel oil consumption of only
7323 kJ/kWh makes it the most cost-effective in its
class.
Alternatively, the excess combustion air can be lev-
eraged to significantly increase the engine’s power
output, up to 1,200 kW/cylinder. Although this does
not save as much fuel, it does allow for a greater re-
duction of NOx emissions within a wide operation
range. NOx emissions of 1,850 mg/Nm³ down to
1,480 mg/Nm³ make the MAN 18V48/60TS the clean-
est diesel engine in its power range.
Two-stage turbocharging is a modular system: its de- Effects of Two-Stage Turbocharging
sign enables most MAN Diesel & Turbo power plants 1,200
Power output kW/Cyl.

1,200
to be retrofitted with this solution.
1,150
1,100
1,100
Flexibility in fuels, flexibility in operations 1,050
1,050
1,000
Like the MAN 48/60 series standard engines the two-
stage turbocharged MAN 18V48/60TS can be oper- Op. mode 1 2 3
ated with a wide range of different fuels:
1,850
1,850
1,800
NOx mg/Nm3 @15%O2

„„Heavy fuel oils with a viscosity up to 700 cst

1,750
„„Marine diesel oil 1,740
1,700
„„Gas oil
1,650
1,600
Due to the unique features of two-stage turbocharging,
1,550
the MAN 18V48/60TS can be operated continuously
1,500
at shaft power outputs from 18,900 up to 21,600 kW. 1,480
For example, this allows power producers to operate Op. mode 1 2 3
the engines at a normal load of 18,900 kW – taking
7,400
Fuel consumption

advantage of the extremely low fuel oil consumption 7,379

7,375 7,366
and giving them the possibility of a spinning reserve
kJ/kWh

7,350
up to 21,600 kW. 7,323
7,325
7,300

MAN 18V48/60TS – Two-stage turbocharged diesel engine 7

 MAN 18V48/60TS Technical Data
Output, dimensions and weight

A B
C W

MAN 48/60TS

Bore 480 mm, stroke 600 mm 18V

Operational setup 1 2 3

Engine speed rpm 500 / 514 500 / 514 500 / 514

Frequency Hz 50 / 60 50 / 60 50 / 60
Electrical Genset power  kWe 18,654 19,543 21,319

Electr. Genset heat rate at 100% load and efficiency 18V

World Bank 2007 / 2008 kJ/kWhe 7,419 7,463 7,678

Nominal generator efficiency: 98,7%; without pumps; 5% tolerance

Lube oil consumption kg / h 9.5 9.9 10.8

Tolerance: +20%

Dimensions

Genset A B C W H
dry mass (t) (mm) (mm) (mm) (mm) (mm)

407 13,148 5,410 24,510 4,700 9,023

Weights and dimensions are subject to final application

8 MAN 18V48/60TS – Two-stage turbocharged diesel engine

Engine type: MAN 18V48/60TS Reference conditions according
ISO 3046-1: 2002
Engine cycle: four-stroke
Turbocharging system: 2-stage, constant pressure The stated consumption figures refer to:
Low pressure TC type: MAN TCA88
High pressure TC type: MAN TCA77 „„Ambient air pressure: 1,000 mbar
„„Relative humidity: 30%
Number of cylinders: 18 „„Ambient air temperature: +25 °C (77 °F)
Bore: 480 mm „„Charge air temperature:
Stroke: 600 mm According to engine type, corresponding to 25 °C
Swept volume per cyl.: 108.6 dm³ cooling water temperature before charge air cooler
Engine speed 50/60Hz: 500 / 514 rpm
Mean piston speed: 10.0 / 10.3 m/s Abbreviations:
TC Turbocharger
Cooling: HP High pressure
Cylinder cooling: HT cooling water LP Low pressure
LP-TC charge air cooler: 2-stage HT and LT cooling water HT High temperature
HP-TC charge air cooler: 2-stage HT and LT cooling water LT Low temperature

Starting method: compressed air with

blower for low part load
operation up to 25% load
 World-Class Service
Marine propulsion, gensets, and stationary plants

The PrimeServ offering PrimeServ’s aim is to provide:

The MAN Diesel & Turbo Group offers worldwide, „„Prompt delivery of high-demand OEM spare parts
round-the-clock service, 365 days a year. In addi­tion within 24 hours
to MAN Diesel & Turbo’s service headquarters in „„Fast, reliable and competent customer support
Augsburg, Copenhagen, Frederikshavn, Saint-Nazaire, „„Individually tailored O&M contracts
Hamburg and Stockport, service centers on all contin­ „„Ongoing training and qualification of operators
ents provide comprehensive and continuous support. and maintenance staff
„„Global service, 24 hours a day,
MAN Diesel & Turbo engines are renowned for their 365 days a year
quality and durability. We are a global organization „„Diagnosis and troubleshooting with our high-
with a strong local presence, delivering exceptional performance Online Service
field service management, tailor-made solutions, and
first-class technical support.

PrimeServ provides advice and assistance to custom-

ers throughout the product life cycle, from delivery to
resale. With our far-reaching network of service centers,
we respond rapidly to customer needs. Furthermore,
we offer outstanding service and unrivalled tech­nical
expertise. Plus, we only use genuine spare parts
– safeguarding the longevity of your engine.

10 MAN 18V48/60TS – Two-stage turbocharged diesel engine

All data provided in this document is non-binding. This data serves informational
purposes only and is not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject to changes and will
be assessed and determined individually for each project. This will depend on
the particular characteristics of each individual project, especially
specific site and operational conditions. Copyright © MAN Diesel & Turbo.
D2366483EN-N4 Printed in Germany GGKMS-AUG-05161

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