mtu opv systems

A Tognum grouP BrAnd

Power. Passion. Partnership.

OPV PowerPack

navy

© T

KM

S B

loh

m +

Vos

s N

ord

seew

erk

e G

mbH

Task Speed Time Power

Intercept, SAR 23 kn 5% 100% of MCR*

Transit 18 kn 20% 48% of MCR*

Patrolling in operational zone 11 kn 55% 12% of MCR*

Loitering in operational zone 5–8 kn 20% <10% of MCR*

* MCR – Maximum Continuous Rating

MTU is one of the world’s leading manufacturers of large diesel engines and complete drive systems and is, alongside MTU Onsite Energy, the core company of the Tognum Group. MTU engines and systems are constantly setting new standards. At the highest technological level and recognized as reliable, powerful and highly efficient, they prove them-selves in the most difficult off-highway tasks in the world day by day. A particularly intensive partnership connects us to shipping. For decades we have developed, produced, and managed complete, individually configured propulsion and on-board power systems for military and governmental vessels. Since 1950 more than 30,000 engines in total have been supplied to navies around the world and taken into operation. As a technology leader in naval applications MTU is constantly developing innovative propulsion systems to meet the customer’s requirements.

MTU relies on the expertise of RENK With their experience and expertise of more than 130 years, the specialist for intelligent connections between engines and machines develops individual solutions , which are always customized to the demands of the clients. RENK special transmissions and drive technology and test system components are known for their precision, reliability, and quality.

Expertise from one sourceMTU analyzed the demands made on offshore patrol vessels (OPVs) in daily use as part of a comprehensive market study. On the basis of these findings, MTU, in close collaboration with RENK, developed a propulsion system which is specially designed for the requirements of OPVs, and which comprehensively fulfils these requirements. – Low cost of ownership– High redundancy, due to cascaded operation – Unrestricted low-load capability – Use of engines that allow a high level of logistical standardization within the fleet– Highly integrated propulsion modules for the least possible integration

effort– Close matching of power outputs for a wide range of ship designs– Compact and low-weight design

With the OPV PowerPack, MTU offers a fully integrated system from a single source, covering mechanical, electrical and control interfaces.

For our customers this means:– One central contact partner– Minimized interfaces – Professional logistics

The OPV PowerPack combines the expertise of two technology leaders in Naval Business – creating a solution of the highest quality with unique benefits for the user.

The OPV PowerPack:Power to the core.An innovative development by MTU in close collaboration with RENK.

Operation of Offshore Patrol Vessels

The operation of offshore patrol vessels is dominated by loitering and patrolling in the operational zone, rarely exceeding ship speeds of 12 kn. During deployment an economic speed is chosen. The full speed potential of the ship is used only for intercept and SAR missions. Interestingly, many OPV designs currently under construction seem to ignore this fact. They feature propulsion systems that neither are capable of nor designed to meet the operational requirements, since they use merchant marine engines which are optimized for operation at 70% MCR and higher.

2 | Navy | OPV PowerPack

Since the introduction of the 200-nautical-mile Exclusive Economic Zone (EEZ), many navies have commissioned OPVs. OPVs increase the flexibility of the fleet when completing their primary missions and also cover an extensive range of tasks.

Investment and operating costs are major factors when procuring OPVs. The required cost-effectiveness should not, however, be to the detriment of its availability which depends considerably on the redundancy and flexibility of the drive system. With well-engineered commercial off-the-shelf systems (COTS), MTU, together with RENK, offers solutions which fulfill economic and operative requirements in equal measure.

OPV PowerPack | Navy | 3

3 | Marine | OPV PowerPack®

Simple. Robust. Versatile.The OPV PowerPack impresses with unique benefits.

Highly integrated and compact: the conceptThe OPV PowerPack integrates the following into one steel frame: two MTU high-speed diesel engines from the successful Series 4000, a RENK reduction gear ASL 2 x 104, all necessary pumps, filters, heat exchangers and control systems for operation, as well as a replenishment oil tank including all piping and wiring. As a result of this highly integrated solution, both potential interfaces and the expenditure of installation are greatly minimized.The following components can also be integrated upon request:– Starting air receivers – Exhaust silencers– Exhaust-gas after treatment– Propeller– ShaftThe OPV PowerPack is available with MTU 12V and 16V 4000 M73/M73L engines.

Straightforward and fast: installation on the vesselThe integration cost for propulsion systems is a major factor for every shipyard: the fewer the systems to be coordinated and installed, the lower the integration effort. Typical medium-speed engines require a large num-ber of off-engine systems. Not so with the OPV PowerPack: with the already highly integrated components installed on the frame, the installation effort is greatly reduced. All relevant systems are installed, piped and cabled in the factory, tested and quality-ensured in workshop conditions

With the OPV PowerPack, installation, alignment, and commissioning are easy and worry-free.

Simple and flexible: the benefits For shipyards – High design and installation efficiency through simple and

cost-effective integration – even in existing designs – Easy and compact – for space and weight-saving installation – High system flexibility and compatibility with different propellers

and shafts– Built-in IMO Tier 3 capability – Long-lasting, sustainable overall concept

For navies– Low total cost of ownership– Maximum reliability and availability through redundant design with

four engines – Ideally suited for the dominant low-load operation of OPVs– High potential for logistical standardization within the fleet – Low expenditure for training, parts inventory, and tools – Fast onboard replacements means enhanced MTTR (mean time to repair)– Optimal support service worldwide through the intensive MTU service

network – More-than competitive TBOs of 32,000 hrs or even higher due to

cascaded operation

OPV PowerPack – Models and Technical Data

Product PP-12 PP-12L PP-16 PP-16L

Brake power [kW] 3840 4320 5120 5760

Length [m] 6.0 6.0 6.0 6.0

Width [m] 3.5 3.5 3.5 3.5

Height above centerline DE crankshaft [m] 1.8 1.8 1.8 1.8

Weight (dry) [Tkg] 34 34 36 36

Subject to technical progress

MTU Propulsion Monitoring and Control System Callosum_MC

MTU Callosum_MC as a part of the propulsion package monitors and controls the diesel engines, the gearbox and the CP-Propeller for the port and starboard plant. The system provides the specifically configured equipment ”according to classification regulation“ for the engine room as well as for the remote operator stations in MCR and Bridge control stands, connected by redundant data bus. It ensures simplified installation and optimized operation.


Low-load operationThe MTU Series 4000 – as all MTU diesel engines – is optimized for economic operation. Sequential turbo charg-ing, i.e. the load dependent switching of turbo chargers, high-pressure common rail fuel injection systems and MTU’s own engine controllers ensure reliable and economic opera-tion from idle to nominal speed.The OPV PowerPack allows a cascaded approach to opera-tion – already known in diesel-electric power plants. Matching available power with the current power demand, the already excellent low-load capability of the OPV PowerPack is further improved without compromising reliability and maintenance frequency.The OPV PowerPack, best suited for extended low-load operation, best suited for OPVs!

Comparison of installation volume

OPV PowerPack

Medium SpeedEngine


5 | Marine | OPV PowerPack®

20 30 40 50 60 70 80 90 100

20 30 40 50 60 70 80 90 100

100

90

80

70

60

50

40

30

20

10

0

100

90

80

70

60

50

40

30

20

10

0

OPV PowerPack Operating Modes

RENK Reduction Gear ASL 2 × 104Input: max. 2 x 2,880 kW @ 2,050 rpmOutput speed range: 270 – 320 rpmHorizontal offset: 2 x 1,000 mmVertical offset: 300 mm (output is lower)

– Input and output flange at the same or opposite ends– Double helical gears for optimum gear mesh and noise behavior in both

single- and twin-engine mode– Integrated multi-disk clutches for both engines– Integrated thrust bearing– Main shafts accommodated in sleeve bearings– OD Box can be installed on free shaft end– All auxiliary components mounted on gear: cooler, filters, hydraulic valves,

sensors, controls, 2 primary gear-driven pumps, one standby pump

MTU Series 4000 MarineMTU Series 4000 Marine has proven itself thousands of times over. It sets the standard in modern marine propulsion. The latest generation has the following key features:– Four-stroke diesel engine– Direct fuel injection with second-generation common rail technology,

electronically controlled– Second-generation engine management system ADEC – Sequential turbo charging– 12V, 16V, 20V 4000; V-angle 90°– Available power range 1,920–4,300 kW– IMO and EPA Tier 2-certified– Built-in IMO Tier 3 capability– Highly integrated– Capable of extended full-load operation

More than 60% of the ship speed can be achieved on one engine at nominal propeller pitch.

Single engine operation

Ship Speed 6 kn 11 kn 18 kn 23 kn

Power Demand [% of MCR] < 10 12 48 100

Time at load point [%] 20 55 20 5

Time at load point [h] 400 1100 400 100

Number of engines operating 2 2 2 4

Time [h] per engine p.a. 200 550 200 100

Assumption: 2000 h p.a. at sea

Twin engine operation

OPV PowerPack: maximum availability and long TBO intervals due to redundant design with four enginesThe mean operating time per engine (according to the consecutive box section) and p.a. is 1,050 h out of 2,000 h per ship. TBO of the engines (12V, 16V) = 20,000 hTBO of the OPV PowerPack = 38,000 h with even loading of the engines

Engine Speed [%] = Ship Speed at Nominal Propeller Pitch

Engine Speed [%] = Ship Speed at Nominal Propeller Pitch

Pow

er [

%]

Pow

er [

%]

Engine MCR

Curve

P~n3

(Propeller Curve)

Engine MCR

Curve

P~n3

(Propeller Curve)


OPV PowerPack® | Marine | 6

DetroitFriedrichshafen

Singapore

23

76

8

9

Ensuring Your Missions. Worldwide.

India, Coast Guard, Offshore Patrol Vessels

2 USA, Coast Guard, “Legend” Class Cutters

3 Spain, Navy, Maritime Action Vessel (BAM)

4 Germany, Coast Guard, Fishery Protection

Vessels

Turkey, Coast Guard, Search and Rescue

Vessels

6 Oman, Navy, Oceanic Patrol Vessels

7 Venezuela, Navy, Offshore Patrol Vessel

8 USA, Coast Guard, “Sentinel” Class Cutters

9 Brazil, Navy, Patrol Vessel NPa500

Australia, Navy, “Armidale” Class Patrol

Vessel

Taiwan, Coast Guard, Offshore Patrol Vessel

Republic of Korea, Coast Guard, Various

Patrol Vessels

References of newly built typical OPVs

MTU provides more than 1,030 points of

contact with 109 distributors in 115 countries

worldwide.


A Tognum grouP BrAnd

Europe I Middle East I Africa I Latin America, MTU Friedrichshafen GmbH, 88040 Friedrichshafen, Germany, T +49 7541 90 7015, F +49 7541 90 7081, [email protected], www.mtu-online.com I Asia I Australia I Pacific, MTU Asia Pte. Ltd., 1 Benoi Place, Singapore 629923, Republic of Singapore, T +65 6861 5922, F +65 6861 3615, [email protected], www.mtu-online.com.sg I USA I Canada I Mexico, MTU Detroit Diesel, Inc., 13400 Outer Drive West, Detroit, Michigan 48239, USA, T +1 313 592 7806, F +1 313 592 5137, [email protected], www.mtudetroitdiesel.com

EA 0

6 15

7 (5

2 1E

) 1/

09 ·

Prin

ted

in G

erm

any

· VM

D 2

009-

07 H

· Pr

inte

d on

chl

orin

e-fr

ee p

aper

. Sub

ject

to a

ltera

tion

due

to te

chno

logi

cal a

dvan

ces.

mtu opv systems

Documents