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ENCOUNTER<br />

The World of MAN Diesel & Turbo


Contents<br />

Editorial 5<br />

6<br />

<strong>Magazine</strong><br />

Power Plants 6<br />

Turbomachinery 14<br />

Marine Engines & Systems 22<br />

MAN PrimeServ 30<br />

14<br />

Gas – a bridge to the future 38<br />

Products and Services 40<br />

At a glance 42<br />

22<br />

Imprint 43<br />

30<br />

Encounter 3


Executive and<br />

Supervisory Board<br />

Dr Georg Pachta-Reyhofen<br />

Chairman of the Supervisory Board of MAN Diesel & Turbo SE,<br />

Chief Executive Officer of MAN SE<br />

Dr Hans-O. Jeske<br />

Frank Burnautzki<br />

Arnd Löttgen<br />

Dr Peter Park<br />

Chief Technology Officer,<br />

Chief Procurement<br />

Chief Manufacturing<br />

Chief Financial Officer<br />

Turbomachinery<br />

Officer<br />

Officer, Engines,<br />

Power Plants<br />

Wilfried von Rath<br />

Dr Stephan Timmermann<br />

Chief Human Resources<br />

Marine Systems,<br />

Officer<br />

After Sales<br />

4 Encounter


Editorial<br />

Dear Readers,<br />

each of the many and diverse projects that we<br />

accomplish with our customers is fascinating in<br />

its own right. Whether it relates to commercial<br />

shipping, the oil and gas industry, the production<br />

of basic materials or cement, cruise liners or<br />

decentralized power generation, every project has<br />

its own intriguing story. It tells of technological<br />

expertise, of convinced customers and not least<br />

of the deployment of our workforce numbering<br />

over 14,000 people.<br />

Just recently we have realized a wide variety of<br />

projects that demonstrate the trust that our<br />

customers worldwide put in our ability to solve<br />

even the most difficult problems: floating power<br />

plants that supply energy where it is urgently<br />

needed. Efficient drives for the world’s biggest<br />

ships, which are also the cleanest thanks to our<br />

technology. A 24/7 service capability thanks to<br />

specialists working day and night for our customers<br />

across the globe. Dedication leading to longterm<br />

partnerships, such as with the customer<br />

who has been won over repeatedly for more than<br />

20 years by our innovative turbomachinery.<br />

Our work is characterized by the needs of a globalized<br />

world with a growing population and its demand<br />

for more energy, increasing trade and rising<br />

production, paralleled by the quest for improved<br />

resource efficiency. Whether as a supplier of marine<br />

engines or complete power plants, turbochargers,<br />

compressors, chemical reactors or turbines,<br />

MAN Diesel & Turbo makes an important<br />

contribution to all of these. How we do it is what<br />

we want to show you in this magazine, with reference<br />

to a few examples.<br />

I hope you find it an interesting read.<br />

Yours truly<br />

Dr Jan Dietrich Müller<br />

Vice President<br />

Group Communications & Marketing<br />

MAN Diesel & Turbo SE<br />

Encounter 5


Power Plants<br />

Hungry<br />

for power<br />

The global demand for electrical energy will<br />

rise by around 40 percent by the year 2035. A large<br />

part of this energy will be generated decentrally.<br />

6 Encounter


Decentralized energy generation is especially important in newly<br />

industrializing countries, where electrical power is the economic driver<br />

and must be supplied quickly and reliably, regardless of the extent and<br />

condition of the electricity grids. It is important to industrial companies<br />

worldwide that cover their energy requirements with their own power<br />

plants, and for supplying remote areas and islands far removed from<br />

any power infrastructure.<br />

Decentralized energy can compensate for the variations in the supply of<br />

electricity generated from renewable resources, ensure an uninterrupted<br />

supply of power to energy-intensive processes and stabilize the growth<br />

dynamics of booming “megacities”.<br />

Whether powered by diesel distillates, biofuel or natural gas, MAN engines<br />

operate with a high level of efficiency in all time and climate zones on<br />

the planet to ensure that people and companies can reliably utilize the<br />

electrical energy that underpins progress.<br />

Encounter 7


Power Plants<br />

Africa – like here<br />

in Nairobi, expansion<br />

of the economy is<br />

accompanied by a rising<br />

energy demand.<br />

Continent of opportunities<br />

As the second-largest continent, Africa is home to over a billion people – with a fast-growing<br />

economy and a rising energy demand.<br />

It is predicted that many African states will<br />

generate important growth stimuli for the<br />

global economy in the future. The need to<br />

catch up with the rest of the world is huge, especially<br />

in the energy sector: the International<br />

Energy Agency (IEA) estimates African electricity<br />

consumption at 500 kWh per capita, equivalent to<br />

a fifth of the global average.<br />

Africa is already by now a strong sales market for<br />

MAN Diesel & Turbo. In 2013 alone, the company<br />

received orders for power plants to the value of<br />

over 100 million euros. The first MAN gas power<br />

plant in Africa was handed over to a customer in<br />

Gabon. The plant’s generators are driven by four<br />

51/60DF engines operating in gas mode.<br />

Another technological debut will be achieved<br />

on the continent in the course of 2014 when the<br />

first diesel combined cycle power plant from<br />

MAN on the African continent is transferred to<br />

the client. At the plant in Thika, Kenya, five<br />

18V48/60 engines and one MAN MARC 2 steam<br />

turbine will deliver 88 MW of electrical power.<br />

The steam turbine uses the exhaust heat of the<br />

engines to generate 6.8 MW, equivalent to nine<br />

percent more electrical energy, from the same<br />

quantity of fuel.<br />

8 Encounter


Diesel power plants are ideal to reliably serve even remote or slightly developed areas such as islands with electricity.<br />

As in the rest of the world, the importance of natural<br />

gas as a commodity will increase further in<br />

Africa too. The north in particular has plentiful<br />

reserves and the distribution infrastructure is<br />

growing. Large gas deposits also exist in the south<br />

of Nigeria, while further deposits are being explored<br />

or have already been tapped on parts of the<br />

east and west coast. “The customer potential for<br />

our gas and dual fuel engines in Africa is growing<br />

in parallel with the expansion of the transport<br />

infrastructure,” explains Hans-Jürgen Wio, Head<br />

of the Power Plants Business Unit. “For regions<br />

without suitable links and particularly remote regions<br />

in which mine operators are often active, for<br />

example, HFO engines (heavy fuel oil) are a better<br />

option.”<br />

As the business grows, so the company’s local<br />

presence is also increasing. In addition to sites in<br />

South Africa, Kenya and Senegal, the sales network<br />

is being developed further. Plans are in hand to<br />

open a sales office in Nigeria this year. “With an<br />

estimated number of 160 million inhabitants and<br />

a growing middle class, the need for power is constantly<br />

increasing in Nigeria. While the south of<br />

the country is rich in gas and therefore a promising<br />

market for gas engines in the future, the north<br />

tends to prefer power generation based on HFO,”<br />

says Dr Markus Ostermeier, an expert on Africa<br />

in the Business Development department of the<br />

Power Plants Business Unit.<br />

Apart from its own organization, MAN is also exploiting<br />

further inroads into the African market.<br />

“We are working with various EPC partners (engineering,<br />

procurement, construction) on the continent.<br />

Many globally active EPCs are already superbly<br />

positioned in Africa,” says Hans-Jürgen Wio.<br />

Encounter 9


Power Plants<br />

The Power of Friendship<br />

Floating power plants supply electricity to Lebanon.<br />

Floating power plants –<br />

here in the form of specially<br />

built power barges or as<br />

reconstructed ships with<br />

their own propulsion<br />

MAN Diesel & Turbo and the Turkish energy<br />

company Karadeniz are working<br />

together to create floating power<br />

plants. They are converting decommissioned bulk<br />

carriers, heavy lift vessels and barges into mobile<br />

power plants or so-called “power ships”. These can<br />

be deployed at sea to deliver electricity to places<br />

where it is urgently needed.<br />

Power ships are not a new idea: they were first<br />

used back in the 1930s. Then, as now, their primary<br />

purpose was to restore the power supply<br />

following natural disasters or in emergency situations.<br />

Power ships also help to bridge capacity<br />

bottlenecks in the electricity supply, for instance<br />

in regions where the infrastructure is poorly developed.<br />

Karadeniz is the only company in the world to<br />

operate an entire fleet of power ships and extend<br />

it further. The ships have generating capacities<br />

of between 45 and 500 MW. In the medium term,<br />

the overall capacity of the fleet is expected to<br />

increase to around 2 GW.<br />

The floating power plants are operating as part of<br />

the Karadeniz initiative “The Power of Friendship”<br />

and are intended to offer a seaborne remedy to<br />

the urgent power supply problems in countries of<br />

the Middle East, Africa and Asia. The fleet is expected<br />

to be deployed to 15 different countries.<br />

The two latest examples are currently moored in<br />

Lebanon, stabilizing the power supply to the capital<br />

Beirut. Since spring 2013 the “Karadeniz Power<br />

Ship 9”, the Fatmagül Sultan with a capacity of approx.<br />

180 MW, has been feeding electricity into<br />

Beirut’s power grid. It is fired by eleven 18-cylinder<br />

V51/60 dual fuel engines from MAN Diesel & Turbo<br />

that can be operated using either heavy fuel oil<br />

or gas.<br />

The tenth power ship, the Orhan Bey, was deployed<br />

last summer to boost the supply, anchoring<br />

off the Jiyyeh power plant operated by the<br />

Lebanese state electricity enterprise “Électricité<br />

du Liban”. The Orhan Bey is also equipped with<br />

MAN 18V51/60DF engines, making available a<br />

further 120 MW for the grid.<br />

10 Encounter


Both installations were conceived as so-called<br />

power barges. The power plants are not installed<br />

on vessels with their own drive, but on floating<br />

platforms or “barges” and are towed to their destinations.<br />

“The power barge configuration offers the<br />

option of higher generating capacities, because<br />

we don‘t have to take existing superstructures<br />

into account,” explains Hans-Jürgen Wio, who is<br />

heading the Power Plants business unit.<br />

“The concept of the Karadeniz power ships can<br />

make an important contribution to improving the<br />

electricity supply of regions with poor infrastructure<br />

and thus also their economic development<br />

in the medium term. The mobile power plants<br />

provide power quickly and reliably to places where<br />

it is urgently required and thus contribute directly<br />

to improving the living conditions locally,”<br />

says Wio.<br />

The gas engine growth market<br />

Interview with Hans-Jürgen Wio, Senior Vice President and Head of the Power Plants<br />

business unit at MAN Diesel & Turbo<br />

For efficient<br />

generation of power<br />

and heat, natural gas<br />

is ideally suited.<br />

Mr. Wio, gas seems to have been the all-dominant<br />

topic in the power plant sector for some time.<br />

Why is that so?<br />

The whole world is experiencing a natural gas<br />

boom that is fuelled to a significant extent by<br />

growing global reserves and new exploration and<br />

production techniques. The “Golden Age of Gas”<br />

has dawned, according to the International Energy<br />

Agency. This trend does not exclude decentralized<br />

power generation using medium-speed engines;<br />

natural gas has now become one of the main energy<br />

sources in this market segment too. In 2012,<br />

the global market for gas and dual fuel engines<br />

was bigger than that for diesel/HFO engines for<br />

the first time. The market for gas engines is also a<br />

key growth market for us.<br />

What are the main drivers for this market growth?<br />

The fuel must be available. In the case of natural<br />

gas, this means that a suitable pipeline network<br />

must exist. As the worldwide production volume<br />

increases and LNG (liquefied natural gas), which is<br />

transported by sea, becomes more important<br />

and available, these networks are being expanded<br />

increasingly even in emerging countries. The<br />

market for gas engine power plants is growing<br />

with the infrastructure. On the other hand, the<br />

advances made in exploration and production<br />

technology mean that even smaller gas deposits<br />

can be opened up profitably. These can then be<br />

exploited for power and heat production directly<br />

at the gas source, as in many parts of Russia,<br />

for example.<br />

Encounter 11


Power Plants<br />

Markets for gas and dual<br />

fuel engines are growing<br />

worldwide.<br />

Is MAN Diesel & Turbo ready for the “Golden Age<br />

of Gas” in terms of products?<br />

There is a long tradition of gas technology at MAN.<br />

Our dual fuel engines have been offering our customers<br />

complete flexibility in the choice of fuel<br />

for many years. With our 35/44G engine we have<br />

also positioned what is currently the most productive<br />

pure gas engine of its capacity class in the<br />

market. This forms the heart of the gas power<br />

plant that we are currently constructing for VW in<br />

Braunschweig. We will expand this segment into<br />

the 20 megawatt class from the end of 2014 with<br />

the 51/60G. We are thus ideally positioned to service<br />

the growing market segment for gas engine<br />

power plants with an output of over 100 megawatts.<br />

The gas engines are part of the BLUEFIRE portfolio,<br />

is that correct?<br />

Correct, we have been presenting the integrated<br />

natural gas portfolio of MAN Diesel & Turbo as<br />

part of the global BLUEFIRE campaign since 2012.<br />

With our technologies we are a valuable partner<br />

and supplier at virtually all stages of the natural<br />

gas value creation chain, from production via<br />

transport and energy recovery to storage. It is important<br />

that our customers, who now seek complete<br />

solutions instead of single products to an<br />

increasing extent, are aware of that.<br />

Why is that?<br />

It is all to do with the changing structures in global<br />

markets. Power plant orders are part of a global<br />

project business. Many investors have no direct<br />

reference to the energy sector and are therefore<br />

looking not for single components, but for complete<br />

solutions for providing electricity and/or<br />

heat efficiently.<br />

Can MAN Diesel & Turbo service this trend?<br />

We are a manufacturer of high-quality, worldleading<br />

power generation engineering and a reliable<br />

partner and competent contact for our customers,<br />

from component to complete solution.<br />

Our EPC competence and EPC readiness, even for<br />

larger power plants, are skills that are key to our<br />

competitiveness. Together with the customer we<br />

thus find a solution to virtually any challenge.<br />

A reliable power supply for Saudi Arabia’s<br />

cement industry<br />

MAN Diesel & Turbo is building a complete diesel power plant for Saudi Arabia’s United<br />

Cement Industrial Company.<br />

Roughly 160 km south of Jeddah, Saudi<br />

Arabia’s most important Red Sea port, the<br />

Saudi United Cement Industrial Company<br />

(UCIC) is constructing a new cement works capable<br />

of producing around 5,000 tonnes of cement a<br />

day. Lime and clay, the raw materials used in cement<br />

production, are extracted nearby in the<br />

middle of the Saudi Arabian desert. The power for<br />

the new cement works will be supplied by five<br />

MAN 20V32/44CR engines. UCIC has commissioned<br />

MAN Diesel & Turbo to construct a complete<br />

power plant for the cement works in its capacity<br />

as an EPC (Engineering, Procurement, and<br />

Construction) supplier. As well as supplying the<br />

12 Encounter


Power plant with<br />

Motor Combined Cycle.<br />

The company also has the<br />

right products available<br />

for utilizing waste heat.<br />

engines, MAN is thus responsible for constructing<br />

all the necessary ancillary installations, from the<br />

machine hall and the cooling system to the processing<br />

and disposal system. A consortium partner<br />

handles the local deliveries and services.<br />

UCIC’s new cement works is being built in a very<br />

hot, sandy region in which temperatures in summer<br />

can hit 50 degrees Celsius. The reliability of<br />

the MAN engines when operating under such extreme<br />

conditions was a decisive purchasing criterion.<br />

The design of the plant is also being optimized<br />

with regard to the climatic conditions.<br />

“Saudi Arabia is a key market for our power plant<br />

division and we have extensive experience there,”<br />

says Alexander Stöckler, Head of Sales for the<br />

MENA region in the Power Plants business unit of<br />

MAN Diesel & Turbo. “We see great potential above<br />

all in the field of decentralized power plant solutions<br />

for independent power generation, for example<br />

for cement works or steel plants.”<br />

Cement is the most commonly used material of<br />

all, with global production running at 2.8 billion<br />

tonnes, and Saudi Arabia is one of the 20 biggest<br />

cement manufacturers in the world. Saudi Arabia’s<br />

requirement for cement will increase in the<br />

medium term, as the country’s development<br />

plans envisage a host of construction and infrastructure<br />

projects.<br />

Five MAN engines take<br />

care of a reliable power<br />

supply in the Arabian<br />

desert.<br />

Encounter 13


Turbomachinery<br />

Elementary<br />

parts<br />

Whether in production or power generation,<br />

turbomachines are indispensable components.<br />

14 Encounter


The car you use to drive to work and the fuel in its tank, the clothes you wear,<br />

and the paper in your printer – almost every product you use comes into<br />

contact with turbomachinery at some time in the manufacturing process. And<br />

the chances are that the machine in question carries the MAN Diesel & Turbo<br />

logo. They are seldom visible to the consumer, yet turbomachines are indispensable<br />

components of industrial manufacturing processes and modern<br />

power generation.<br />

They also help to resolve a contradiction – because manufacturers and<br />

consumers demand more and less at the same time. To cover the needs of a<br />

growing global population, more fuel and more plastic, more steel and more<br />

power must be produced – but with fewer resources and fewer emissions.<br />

MAN Diesel & Turbo plays a key role in this with its turbines and compressors<br />

that it is developing continuously to make them more efficient.<br />

Around 10,000 of the company‘s turbomachines are installed around the<br />

world. Robust, efficient and reliable, these essential components generally<br />

work round the clock, day in and day out.<br />

It isn’t the massive leaps that propel us forward to a resource-efficient future,<br />

but rather precise, made-to-measure solutions for a host of applications in<br />

industry and power generation – so that efficiency and flexibility rise and<br />

emissions continue to fall.<br />

Encounter 15


Turbomachinery<br />

Barking up the right tree<br />

Small, decentralized biomass power plants have experienced a boom in recent years. And the<br />

highly efficient MARC ® steam turbines from MAN Diesel & Turbo have participated in this boom.<br />

As a renewable ressource,<br />

wood is a favored carrier<br />

of energy.<br />

Oliver Keil reaches into the large pile of<br />

freshly cut chips of landscaping materials<br />

and removes a largish piece. Then he<br />

sticks the two metal tips of his measuring instrument<br />

into it. The foreman on the day shift at the<br />

biomass cogeneration plant of Energieversorgung<br />

Oberhausen AG, or evo for short, reads off the<br />

moisture level of the new shipment. “This fuel is<br />

never the same, it’s a natural product,” he explains.<br />

“The water content and calorific value are<br />

always different and we coordinate the firing continuously<br />

to this to generate a steady supply of<br />

steam.”<br />

Evo’s power plant came on stream in 2011. Since<br />

then, it has been turning 40,000 tonnes of wood<br />

per year into power for around 6,000 households<br />

and district heating for roughly 3,500 homes. In<br />

doing so it saves approximately 20,000 tonnes of<br />

CO 2 . A MARC 1 steam turbine from MAN Diesel &<br />

Turbo converts the steam pressure reliably into a<br />

rotary movement to drive a generator. “This biomass<br />

plant is one of 63 in Germany equipped with<br />

a turbine from the MARC series,” says Dr Kristin<br />

Abel-Günther.<br />

The Head of Sales from MAN Diesel & Turbo in<br />

Hamburg has witnessed how German and Austrian<br />

plant manufacturers have built up their technology<br />

leadership in Europe in the last few years.<br />

“A sort of typical power plant for the timber processing<br />

industry and for decentralized cogeneration<br />

of heat and electricity has become established<br />

that then became an export hit,” she<br />

explains. “For this reason we adapted at an early<br />

stage to certain boiler sizes and developed the<br />

MARC 1 to be able to equip even power plants of<br />

between 1.5 and 4 megawatts.”<br />

16<br />

Encounter


[1] [2]<br />

[1] [2] Wood – in decentralized plants<br />

like here at evo AG, the combustible<br />

is converted to electricity and heat.<br />

[3] [4] Biomass power plants of French<br />

Dalkia Group in Angers and Tours<br />

[3] [4]<br />

Highly efficient steam<br />

turbines are essential<br />

components for the<br />

conversion of energy.<br />

The proven, highly efficient modular turbine concept<br />

of the MARC series suited these concepts perfectly.<br />

Word got around, and in 2010 the French<br />

Dalkia Group, which specializes in the construction<br />

of sustainable power plants, agreed a strategic<br />

partnership with MAN Diesel & Turbo. “Under<br />

this agreement we have received orders for six<br />

steam turbines,” recounts Abel-Günther, “which<br />

have now all been delivered and commissioned.”<br />

In this project, she and the Hamburg plant were<br />

able to draw on the full support of colleagues<br />

from MAN Diesel & Turbo in France: “During the<br />

long project execution period in particular, a contact<br />

was always at the customer’s disposal in their<br />

own country and language, which speeded many<br />

processes up.”<br />

Encounter 17


Turbomachinery<br />

Classic networking<br />

Natural gas: transportation of this sought-after raw material is based on efficient<br />

technology, minimal environmental impact – and trust.<br />

Chief engineer Heidi<br />

Bernhardt – for more than<br />

20 years Gascade has<br />

relied on technology by<br />

MAN Diesel & Turbo.<br />

Natural gas – to ensure supplies of the important<br />

commodity to industry and consumers<br />

worldwide, we mainly rely on a<br />

vast network of pipelines. In the case of Europe, for<br />

example, it is especially the network in Germany<br />

which is of strategic importance due to its central<br />

position. Pipelines, gas storage facilities and compressor<br />

stations – one of the main operators of<br />

this key infrastructure in Germany is Gascade<br />

Transport GmbH. Responsible for the transportation<br />

of around one-fifth of the gas that flows<br />

through Germany, Gascade is part of a consortium<br />

of the industry giants BASF (Germany) and<br />

Gazprom (Russia) – and a long-term customer of<br />

MAN Diesel & Turbo.<br />

According to engineer Heidi Bernhardt, who is in<br />

charge of systems engineering at Gascade: “Almost<br />

all our compressor stations are equipped<br />

with MAN technology – whether turbines or compressors.”<br />

And that is not a recent development, as<br />

she emphasizes: “We have been working very suc-<br />

[3]<br />

cessfully with MAN Diesel & Turbo and its predecessor<br />

companies for more than twenty years<br />

since the establishment of our parent company<br />

Wingas.” In fact, they have links with several MAN<br />

technology locations, for example the turbomachinery<br />

works in Oberhausen in the west of<br />

Germanyor the Swiss site in Zurich.<br />

In comparison with other fossil fuels, natural gas<br />

is relatively environmentally friendly. However,<br />

Gascade makes sure that this does not just apply<br />

to its end use as a fuel. Thanks to the employment<br />

of efficient technologies, energy consumption<br />

and emissions in the transmission of the gas are<br />

kept as low as possible. As a lighthouse project<br />

Gascade has set up a compressor station in German<br />

Mallnow close to the Polish border. “Mallnow<br />

is a central hub in our transmission network,”<br />

states Heidi Bernhardt: “Natural gas comes into<br />

Germany here from the Russian gas fields via our<br />

Polish neighbors.”<br />

Four MAN compressors are used in Mallnow for<br />

the onward transfer of the gas. These are driven<br />

by three of the company’s gas turbines. The<br />

special feature here is a steam turbine that acts<br />

as the fourth drive unit, fuelled by steam<br />

generated out of the gas turbines exhaust heat.<br />

The innovative concept of Gascade and MAN<br />

Diesel & Turbo is working well and the output<br />

of the station has been increased by around a<br />

quarter – all this without interrupting ongoing<br />

operation, without additional energy inputs and<br />

without additional emissions.<br />

18 Encounter


In a highly dynamic market environment such as<br />

that of natural gas, Gascade has placed its trust in<br />

MAN Diesel & Turbo technology for over 20 years.<br />

The latest project example is a further Gascade<br />

compressor station near the city of Cologne,<br />

where Gascade has again opted for an efficient<br />

solution from MAN for expanding the station.<br />

With a total of nine compressor stations Gascade<br />

operates a pipeline network of around 2,300 km<br />

and therefore makes a significant contribution to<br />

supplying Germany and Europe with natural gas.<br />

When choosing its suppliers, Gascade naturally<br />

focuses on technical and commercial factors. But<br />

it is something else that counts for even more, as<br />

Heidi Bernhardt explains: “Collaboration over such<br />

a timescale is based to a large extent on trust.”<br />

Compressor stations<br />

like here in Mallnow<br />

are securing a reliable<br />

gas supply.<br />

By land and sea<br />

Whether for gas exploration, transport or storage, MAN Diesel & Turbo’s HOFIM compressor<br />

is a product line with an extremely broad spectrum of application.<br />

When several hundred kilograms are rotating<br />

at more than 10,000 revolutions<br />

per minute, power and precision are required.<br />

The HOFIM compressor offers both. Manufactured<br />

at the Swiss technology plant of MAN<br />

Diesel & Turbo in Zurich, the High-speed Oil-free<br />

Integrated Motor compressor has all the features<br />

required to compress even challenging gas mixtures<br />

safely and without emissions, whether on<br />

land, offshore or even underwater. One crucial<br />

factor for the efficiency of the high-performance<br />

machine is the use of a technological highlight:<br />

for over 20 years MAN has been manufacturing<br />

compressors with active magnetic bearing technology.<br />

With MECOS AG, a spin-off from the Eidgenössische<br />

Technische Hochschule (ETH) Zurich, MAN Diesel &<br />

Turbo has recently even integrated a team of specialists<br />

for active magnetic bearings, and by doing<br />

so it is further consolidating its position as a leading<br />

supplier. The technology adds a touch of magic:<br />

the compressor shaft rotates in a hermetically<br />

encapsulated casing at well over 10,000 revolutions<br />

per minute – and floats in the process.<br />

The success of the HOFIM series is reflected in orders<br />

for various applications running into three<br />

figures. Another milestone was achieved in 2013<br />

when the first HOFIM was ordered for an offshore<br />

platform in the Norwegian North Sea. This was<br />

Power and precision:<br />

HOFIM compressor, here<br />

in tandem arrangement<br />

Encounter 19


Turbomachinery<br />

something of a coup, because the high demands<br />

made on equipment by the oil and gas industry<br />

when it comes to safety and reliability are even<br />

higher with regard to offshore applications.<br />

It is not just here that Norway is at the forefront<br />

of the oil and gas industry, as demonstrated by<br />

MAN Diesel & Turbo’s subsea project. Together<br />

with its development partner Aker Solutions, the<br />

company is developing the first HOFIM compressor<br />

to be installed as part of a subsea facility on<br />

the seabed for the Norwegian state oil company<br />

Statoil. Test runs with a pilot machine delivered<br />

at the end of 2013 are the final stages prior to a<br />

complete subsea module being anchored on the<br />

bed of the North Sea, where it will produce natural<br />

gas several hundred metres below the surface of<br />

the water.<br />

Operation on the seabed will add another string to<br />

the bow of the HOFIM series and the use of magnetic<br />

bearing technology. On land, at sea – as yet<br />

no HOFIM has been deployed in the air. But that<br />

day may yet arrive.<br />

Proven high-tech and new classics<br />

With a growing range of products MAN Diesel & Turbo supplies key components for the<br />

global air separation market.<br />

Up in the air: Extensive<br />

test runs have proven the<br />

reliability of the new<br />

MAX1 compressor.<br />

People need air – and not just for breathing.<br />

Huge volumes of air are separated into<br />

their component parts to produce oxygen<br />

and noble gases for numerous processes in industry<br />

and medicine. Although air is a virtually inexhaustible<br />

raw material, there are only a few major<br />

companies worldwide that have really focused on<br />

the technologies behind air separation.<br />

A compressor train that is able to take in and compress<br />

the ambient air in large volumes is vital for<br />

the efficiency and economic viability of the overall<br />

process. As the leader in this market segment,<br />

MAN Diesel & Turbo has definitely got what it<br />

takes – and with its recently launched AR-MAX1<br />

compressor generation has the potential to provide<br />

a driving force for the entire industry.<br />

20 Encounter


Air separation plant<br />

in China – a key sales<br />

market for machinery<br />

trains of the company.<br />

According to Jürgen Vinkenflügel who heads up<br />

MAN Diesel & Turbo’s Process Industry Business<br />

Unit, which has developed the AR-MAX1: “With<br />

this development our engineers have created a<br />

completely new product based partly on our proven<br />

axial compressor technology, but also to a large<br />

extent on the aircraft engine know-how of our development<br />

partner.” The result: AR-MAX1 has a<br />

power density never before achieved in an industrial<br />

compressor. Despite their increased output<br />

the AIRMAX trains are therefore extremely compact,<br />

being also advantageous for transportation<br />

purposes since with China as a key sales market<br />

the machinery has to be transported half way<br />

round the globe.<br />

Kenneth Zhang, Deputy Head of Region of the<br />

company in China and Managing Director of MAN<br />

Diesel & Turbo in Shanghai, has many years of<br />

experience of the Chinese market: “Over the last<br />

15 years MAN has clearly created market buzz with<br />

its isothermal compressor train and made the<br />

company itself a premium brand in the Chinese<br />

market. Technology from both MAN Germany and<br />

Switzerland is often preferred by Chinese technicians.<br />

With the new revolutionary MAX1 axial<br />

compressor technology, MAN again demonstrates<br />

its unshakable leading position with machines of<br />

this kind and is well poised to harvest the trendy<br />

large air separation project opportunities, further<br />

reinforcing MAN’s position in China.”<br />

Zurich in Switzerland or integrally geared compressors,<br />

steam turbines and axial compressors<br />

from its German technology sites.<br />

And the success story keeps on going. Almost as<br />

soon as the AIRMAX concept had been released<br />

for sale, a customer from China ordered the first<br />

four machines. Only a year later in 2013 orders had<br />

already been received for machine trains worth<br />

hundreds of millions of Euros. The close proximity<br />

to industry customers and the company’s many<br />

decades of experience are obviously paying off.<br />

Proven high-tech solutions, new classics and constant<br />

development activities – with the expanded<br />

product range of MAN Diesel & Turbo the air in<br />

this market is getting distinctly more rarefied.<br />

In the whole: machinery<br />

trains for air separation<br />

are a specialty of<br />

MAN Diesel & Turbo.<br />

With the development of AR-MAX1 and the<br />

AIRMAX concept MAN Diesel & Turbo expands<br />

its existing product range, also reflecting the<br />

wide-ranging string competence of the company,<br />

whether these are isotherm compressors from<br />

Encounter 21


Marine Engines & Systems<br />

Keeping<br />

the global<br />

supply chain<br />

going<br />

Trade and transport in the truest sense of the<br />

word are moved globally by shipping.<br />

22 Encounter


At this very moment, around 20 million containers are crossing the world’s<br />

oceans on ships. But it isn’t just containers that are involved; commodities<br />

are now traded worldwide, and capital and consumer goods are manufactured<br />

and distributed in complicated supply chains spanning the globe. This is made<br />

possible first and foremost by commercial shipping – because roughly 90%<br />

of all goods transported globally are carried on ships.<br />

Over 45,000 merchant vessels operate globally and one in every two of them<br />

is accompanied by MAN Diesel & Turbo: for example in the form of two-stroke<br />

diesel engines that drive large container ships, freighters and tankers. Or<br />

four-stroke engines, for example, that propel other types of merchant vessels,<br />

special ships and passenger ships.<br />

Globalization will cause further growth in goods traffic. Does this pose a<br />

challenge in terms of environmental compatibility? The ship is already the most<br />

eco-friendly and efficient mode of transport, taking the relationship between<br />

cargo volume, distance covered and CO 2<br />

emissions into account. To improve<br />

environmental efficiency further, MAN Diesel & Turbo is working continuously<br />

to make engines and systems even more efficient and even cleaner.<br />

The goal is to develop solutions for the maritime industry that combine flexibility<br />

with efficiency and economy as well as being environmentally friendly. The<br />

products of technology leader MAN Diesel & Turbo incorporate all these<br />

features to get passengers and commodities, capital goods and consumer<br />

items reliably to their destinations around the world.<br />

Encounter 23


Marine Engines & Systems<br />

Giants of efficiency<br />

Although new Triple E class container ships are the world’s largest vessels, they are more<br />

efficient and environmentally friendly than many smaller freighters.<br />

With a length of nearly 400 meters and a<br />

carrying capacity of 18,000 TEU freight<br />

containers, the Maersk Mc-Kinney<br />

Møller is the largest ship currently afloat on the<br />

world’s oceans. The flagship of the new Triple E<br />

class of the Danish shipping company Maersk set<br />

out on its maiden voyage on 15 July 2013. Maersk<br />

has ordered a total of 20 ships of this class from<br />

the South Korean shipbuilding company Daewoo.<br />

They are all destined for the world’s busiest container<br />

route, running between Asia and Europe,<br />

each powered by two 43,000 hp engines, supplied<br />

by MAN Diesel & Turbo.<br />

“Triple E” hereby signifies the fundamental principles<br />

that Maersk has realised in these ships,<br />

namely “Economy of scale”, “Energy efficient” and<br />

“Environmentally improved”. Thanks to its special<br />

hull, the ship class can carry an additional 2,500<br />

containers compared with its predecessors. A<br />

maximum load of 165,000 metric tons means<br />

roughly the equivalent of 36,000 cars, or 111 million<br />

pairs of gym shoes. As size and capacity break<br />

all records, they also represent a challenge in<br />

terms of environmental sustainability, especially<br />

in view of the Energy Efficiency Design Index<br />

newly released in January 2013 by International<br />

Maritime Organization (IMO). The index defines<br />

permissible levels of CO 2 emissions per metric ton<br />

of load and nautical mile travelled for newly constructed<br />

ships with the aim to reduce it by 20% to<br />

30% over the next 12 years. But can a ship of these<br />

record dimensions succeed in complying with<br />

ever more stringent emission standards? Indeed,<br />

it can. In spite of much increased capacity, the<br />

Triple E giants supposedly emit 50% less carbon<br />

dioxide per container carried. According to<br />

Maersk, this renders any of them the most energyefficient<br />

vessel of its kind.<br />

The key to this is found in the engine room. Rather<br />

than the standard number of just one, Maersk<br />

decided to opt for two main diesel engines by<br />

MAN Diesel & Turbo. Each of these S80ME-C engines<br />

has an ultra-long stroke, driving a four-blade<br />

propeller. The advantage? Two propellers improve<br />

pressure distribution, enhancing performance.<br />

Additionally a decreased rotary speed of around<br />

80 revolutions per minute allows for the installation<br />

of larger propellers, resulting in much im-<br />

24 Encounter


A length of about 400 meters, enough space for<br />

18,000 containers and equipped with two highly<br />

efficient diesel engines: the Triple E class.<br />

proved water flow. Together with the ship’s reduced<br />

top speed this ensures a reduction in<br />

fuel consumption of about 20% compared to the<br />

conventional E class operated by Maersk. The reduced<br />

environmental impact could set standards<br />

for the future and become a benchmarking instrument<br />

in the shipping industry – it seems that<br />

the Maersk Mc-Kinney Møller and its sister ships<br />

are marking a new beginning.<br />

Encounter 25


Marine Engines & Systems<br />

Tail wind for the cruise segment<br />

The cruise ship market is one of the strategic growth areas for the Medium Speed Business<br />

Unit at MAN Diesel & Turbo – and 2013 was indeed a successful year.<br />

T<br />

he Caribbean, Antarctica and the South Pacific<br />

– more and more people want to discover<br />

the world from on board ship. In<br />

2013, there were 21.3 million cruise passengers, of<br />

which 6.4 million were from Europe. These figures<br />

were announced by the CLIA (Cruise Lines Inter-<br />

national Association) in March at the Cruise Shipping<br />

trade fair in Miami. According to the forecasts,<br />

this growth looks set to continue over the<br />

coming years. Up to 2018, the industry plans to<br />

invest US$ 7.9 billion in new shipping developments<br />

– an extremely promising market for suppliers.<br />

2013 was a successful year in the cruise ship segment<br />

for MAN Diesel & Turbo. Well-known ship<br />

owners, including Viking Ocean Cruises, Norwegian<br />

Cruise Line and Carnival Cruise Lines, but<br />

also newcomers like Viking Ocean Cruises placed<br />

orders for a total of 23 engines. In these orders<br />

there was a particular emphasis by customers on<br />

the use of advanced technologies such as common<br />

rail and exhaust gas treatment systems. As<br />

cruise ships venture into the furthest corners of<br />

the globe with ever greater numbers of passengers<br />

26 Encounter


on board, environmental protection is a major<br />

issue, e.g. through maximum engine efficiency<br />

and compliance with prescribed emission limits.<br />

The orders that MAN Diesel & Turbo landed in<br />

2013 as a result of focused and sustained sales activities<br />

illustrate the contrasts in this segment. On<br />

the one hand there are the small super-luxury<br />

ships ordered by Viking Ocean Cruises, and on the<br />

other Norwegian Cruise Line and Carnival Cruise<br />

Lines placed orders for the largest ships in their<br />

respective fleets, which are able to accommodate<br />

between 4,000 and nearly 5,000 passengers. With<br />

its broad product range MAN Diesel & Turbo is<br />

coping with all these different requirements. <br />

Inside a luxury liner: low-emission drives are especially important in coastal<br />

areas.<br />

Gas engines conquer the world’s oceans<br />

Gas is becoming increasingly important in marine transport. And MAN Diesel & Turbo<br />

is able to supply the right engines for this.<br />

MAN Diesel & Turbo<br />

provides dual fuel engines<br />

for the world‘s cleanest<br />

container ships.<br />

Over the past years we have seen an inexorable<br />

rise in the use of gas as a fuel source.<br />

Slowly but surely, it is now also taking<br />

over the seas and oceans of the world. As early as<br />

in 2007, MAN Diesel & Turbo launched its first<br />

dual fuel engine – the 51/50DF – which was aimed<br />

specifically at the LNG (liquefied natural gas)<br />

tanker segment. The market has grown steadily<br />

since then and MAN Diesel & Turbo has benefited<br />

from this upward trend. In 2013, two customers<br />

from China and Japan ordered 35 x 51/60DF engines,<br />

worth in total around EUR 100 million. The<br />

new-build ships for CSLNG in Shanghai are the first<br />

large LNG tankers with a propulsion system based<br />

on dual fuel engines to be constructed in China.<br />

MAN Diesel & Turbo is now taking the next step<br />

and has brought to market its first two-stroke<br />

Encounter 27


Marine Engines & Systems<br />

Developed by<br />

MAN Diesel & Turbo,<br />

the huge engines<br />

(here: ME-GI) are<br />

built by licensees.<br />

engine which also runs on the dual fuel principle.<br />

Customers were immediately convinced by the<br />

concept of the ME-GI engine. At the end of 2012,<br />

shortly after the market launch, US ship owners<br />

TOTE ordered 8L70ME-GI engines for the first container<br />

ships to run mainly on liquefied natural gas<br />

(LNG) and which are therefore the most environmentally<br />

friendly container ships in the world.<br />

There are currently several dozen ME-GI and<br />

ME-LGI engines on the order books due for delivery<br />

in 2014 and 2015.<br />

With the ME-GI engine, previously liquefied natural<br />

gas is returned to its gaseous state and injected<br />

into the combustion chamber under high pressure.<br />

By contrast, the ME-LGI engine uses liquefied<br />

gas with a low ignition point, which is injected<br />

into the combustion chamber at significantly lower<br />

pressure. The LGI engine can be operated with<br />

various types of fuels such as methanol, ethanol<br />

and dimethyl ether (DME).<br />

One of the many benefits of dual fuel engines is<br />

their environmental compatibility especially in<br />

gas mode as CO 2 and nitrogen oxide emissions are<br />

significantly reduced and sulfur oxide, soot and<br />

particle emissions are practically non-existent.<br />

A further benefit is that MAN dual fuel engines<br />

allow ship owners and operators much more flexibility<br />

and ensure economic efficiency since the<br />

fuel can be switched in the short term according<br />

to availability and price. <br />

28 Encounter


A screw that saves fuel<br />

A six percent reduction in fuel consumption might not seem a huge saving to an automobile<br />

driver, but for a ship owner it can quickly add up to several thousand euros a day.<br />

Naturally, the engine is the first thing we<br />

normally consider when thinking about<br />

fuel savings, but also propeller-rudder<br />

bulb systems specially designed for the ship<br />

can make a significant contribution here. MAN<br />

Diesel & Turbo is therefore not only working<br />

on the development of increasingly efficient<br />

and frugal engines, it also offers a complete<br />

package for optimal propulsion solutions with its<br />

MAN Alpha propellers. What seemed at first<br />

glance to be a minor detail in fact had a major<br />

impact. The use of Kappel propeller blades<br />

alone reduces fuel consumption by up to six<br />

percent. Similar to the winglets on the wingtips of<br />

an aircraft, the tips of the propeller blades are<br />

curved in order to improve efficiency. This effect<br />

can still be increased in combination with other<br />

components such as, for example, rudders with<br />

so-called Costa bulbs. This increase in efficiency is<br />

achieved whether the propeller is installed in a<br />

new ship or retrofitted in an existing propulsion<br />

system, e.g. for “slow steaming” (sailing at reduced<br />

speed).<br />

Successful collaboration started more than ten<br />

years ago between MAN Diesel & Turbo and Jens<br />

Julius Kappel, who developed these special propeller<br />

blades. MAN Diesel & Turbo acquired the<br />

Kappel technology in 2012 and has been actively<br />

developing many aspects of the system over the<br />

past two years. Since August 2013 it has had a first<br />

licensing agreement with Dalian Marine Propeller<br />

Co., a subsidiary of the China Shipbuilding Industry<br />

Corporation (CSIC) Group. This has now<br />

opened up the pathway to the Chinese market for<br />

Kappel technology.<br />

Ships are utilizing fuel<br />

increasingly efficiently –<br />

MAN Diesel & Turbo<br />

is contributing here not<br />

only with its engines.<br />

Encounter 29


MAN PrimeServ<br />

Investing<br />

sustainably<br />

Return on investment or Return to recycling?<br />

The answer to this question depends on how<br />

capital goods are looked after.<br />

30 Encounter


Have you ever invested in a turnkey power plant? Do you use industrial compressors<br />

and turbines in your processes? Or maybe your latest investment was<br />

in an electronically controlled two-stroke engine delivering around 100,000 hp?<br />

MAN Diesel & Turbo supplies its products to a diverse range of industries – but<br />

its customers all have one thing in common: they value a long, efficient service<br />

life for their investment.<br />

No matter whether the machine is an engine or turbine, compressor or turbocharger,<br />

every hour of efficient operation increases the return on investment.<br />

That pleases engineers, controllers and the environment, because maximum<br />

efficiency equals minimal emissions. Professional advice forms the starting point:<br />

expansion, conversion or retrofit? Adaptation to a change in environmental<br />

regulations? Switching to different or additional fuels? Delivery of individual<br />

spares or an integrated concept that covers the overall service life? More<br />

power or less consumption? The choice is yours.<br />

Ultimately good service is a lasting investment – both in terms of environmental<br />

characteristics and in terms of decisions ensuring long-term sustainability.<br />

Because efficiency and availability are measured not in months or quarters,<br />

but in years or decades – for a return on investment instead of a return to<br />

recycling.<br />

Encounter 31


MAN PrimeServ<br />

Knowledge – the secret of long life<br />

Whether to its customers or its own personnel, in its Academies MAN PrimeServ imparts the<br />

knowledge required for optimal operation of engines and machinery.<br />

Shanghai, Rio de Janeiro, Fort Lauderdale, Piraeus<br />

in Greece or Saint Nazaire in France –<br />

they sound like holiday destinations but are<br />

in fact some of the 13 worldwide locations of MAN<br />

PrimeServ Academies. As an essential part of the<br />

extensive service portfolio, this is where knowledge<br />

is passed on to customers and employees to<br />

ensure maximum safety and efficiency in the operation<br />

of MAN Diesel & Turbo products.<br />

For customers and the staff<br />

In Brazil, for example, Marc Berger heads the MAN<br />

PrimeServ Academy in Petropolis, not far from<br />

the Brazilian capital Rio de Janeiro. Berger states:<br />

“Our range of training here in the operation of<br />

diesel engines and turbomachinery is just as attractive<br />

to our customers as to our own service<br />

engineers. We can provide training on the actual<br />

object itself – in English, Spanish or Portuguese.”<br />

At the MAN PrimeServ Academy in Shanghai, too,<br />

customers and employees can receive training in<br />

the MAN Diesel & Turbo spectrum of products.<br />

According to Ralph Klaunig, Head of MAN<br />

PrimeServ China: “Most of our customers naturally<br />

come from China, but we have others from<br />

all over the world. Quite frequently when a ship<br />

with a MAN diesel engine is at anchor in the har-<br />

32 Encounter


Whether it’s Asia, the Americas or Europe –<br />

customers and the company’s own personnel are<br />

trained in the Academies of MAN PrimeServ.<br />

bor, the crew have already booked a training<br />

session to improve their knowledge around the<br />

management of engines and turbochargers.”<br />

Individual training courses<br />

Tailor-made packages are a major feature. Outside<br />

the Academies, specifically tailored training may<br />

take place on site, on board ship or at the customer’s<br />

facilities, too. All this is aiming for one goal:<br />

safe, efficient and professional operation of engines<br />

and machines, enabled by extensive skills<br />

and a profound knowledge base for operators and<br />

service personnel.<br />

Whether it is Rio or Shanghai – although the training<br />

has nothing to do with holidays, it certainly<br />

helps customers feel more relaxed. Only when<br />

operating and service personnel are optimally<br />

trained can machines and engines run reliably<br />

over many years or even decades. Knowledge<br />

transfer in MAN PrimeServ Academies – supplying<br />

knowledge for a long and efficient life cycle.<br />

Encounter 33


MAN PrimeServ<br />

Service engineer Thijs<br />

Jansen: on duty on behalf<br />

of the customers.<br />

Globetrotter with special knowledge<br />

The service engineers of MAN PrimeServ are constantly on duty on behalf of the client.<br />

Constantly in demand – this is daily routine<br />

for the service specialists of MAN<br />

PrimeServ. Just like Thijs Jansen, who as<br />

senior service engineer is mainly on the move<br />

throughout the year to ensure smooth operations.<br />

Take Vlissingen, for example: a special duty ship<br />

for the oil and gas industry is moored in the harbor<br />

of the Dutch town. Jansen and his colleagues<br />

are taking care of servicing the turbocharger,<br />

which helps to boost the performance of the<br />

diesel engines.<br />

Vlissingen, Vancouver or Valparaiso – the locations<br />

to which the service specialists are deployed are as<br />

manifold as the products of MAN Diesel & Turbo.<br />

On an island in the Caribbean or in the bowels of a<br />

huge crude oil carrier, on an offshore rig or in the<br />

Australian outback, every day of delay means<br />

less for the customer: less mileage for a ship, less<br />

production by an industrial enterprise or less<br />

electricity for a small town.<br />

The Vlissingen job was planned well in advance –<br />

and thus tends to be an exception. As Jansen says,<br />

“In our profession, you never know what task<br />

awaits you tomorrow. Sometimes, you might not<br />

even have a clue as to where you’ll be going from<br />

one hour to the next.” To be able to respond in the<br />

minimum of time worldwide, MAN PrimeServ is<br />

present on all five continents, with 116 sites worldwide<br />

at the end of 2013. Based on this network,<br />

Jansen and his colleagues work to keep things<br />

moving anywhere in the world, even if occasionally<br />

nothing works any more.<br />

34 Encounter


Whether it’s scheduled maintenance or emergency<br />

service, value retention or a performance improvement,<br />

MAN PrimeServ has specialists who<br />

know the machines at least as well as the engineers<br />

who designed them for every single product<br />

of MAN Diesel & Turbo. Service engineers like<br />

Jansen are genuine specialists who speak the language<br />

of their customers: marine business or oil<br />

and gas industry, primary industry, chemical production<br />

or mining, every sector has its own special<br />

features.<br />

At any rate, Thijs Jansen is satisfied – the job in<br />

Vlissingen has been successfully finished, and at<br />

the beginning of 2014, the same customer placed<br />

his next service order. Meanwhile, Jansen’s home<br />

base has shifted to another hub in the worldwide<br />

network of MAN PrimeServ, namely Qatar on the<br />

Arabian peninsula. So this follow-up order will be<br />

carried out by his fellow colleagues. Jansen doesn’t<br />

know yet where his next job will take him. But one<br />

thing is certain: it will definitely not be boring.<br />

Service jobs require<br />

excellent collaboration<br />

and a sense of touch.<br />

A milestone in better customer service<br />

At the end of 2013, MAN Diesel & Turbo launched an internal webshop for ordering spares.<br />

The aim: to meet customer requests even faster.<br />

Products from MAN Diesel & Turbo are in use<br />

all over the world – on every ocean, in the<br />

Amazon jungle and in the remotest regions<br />

of Africa. Customers receive fast, reliable customer<br />

service via more than 100 branches of the<br />

MAN PrimeServ after-sales organization located<br />

worldwide. This requirement also exists in respect<br />

of ordering spare parts, which need to be delivered<br />

to where they are needed in the minimum of<br />

time, regardless of region or time zone.<br />

To meet this objective, an internal webshop<br />

was launched at the end of 2013 that can be<br />

used by the global organization to order online.<br />

Encounter 35


MAN PrimeServ<br />

From sealing rings<br />

to a crankshaft<br />

weighing several tons –<br />

MAN PrimeServ provides all<br />

parts as Original Equipment<br />

Manufacturer.<br />

Customers continue to receive a personal service<br />

while the internal processes are executed automatically<br />

and in a standardized manner in the<br />

background. Customer quotations and order handling<br />

are thus dealt with in a matter of seconds,<br />

independently of time zones. The telephone and<br />

e-mail communication required previously to<br />

check on the progress of an order can be dispensed<br />

with, because the entire order history is available<br />

online. This saves time and ensures a faster, improved<br />

service to the customers.<br />

The project has set standards in respect of international<br />

spread and standardization. The locations<br />

responsible for spare parts in Copenhagen,<br />

Frederikshavn, Holeby (Denmark), Saint-Nazaire<br />

(France), Stockport (United Kingdom) and Augsburg<br />

(Germany) worked closely together to offer<br />

the global organization the entire range of engines<br />

and turbochargers in the webshop. To do<br />

this it was necessary to clean up the master data<br />

of 5,000 engines and 6,000 turbochargers. These<br />

had to be standardized and prepared for availability<br />

in an electronic process.<br />

Following the start of the roll-out in Belgium, Singapore,<br />

Canada and Greece, the internal webshop<br />

will be available to the entire global organization<br />

by the middle of 2014.<br />

36 Encounter


A second life<br />

Together with MAN PrimeServ a 40-year-old machinery train is relocated from western<br />

Europe to the Middle East – general overhaul included.<br />

When a machinery train changes hands<br />

after 40 years in service, one can probably<br />

speak with confidence of quality. A<br />

machinery train that was constructed by one of<br />

MAN Diesel & Turbo’s predecessors for the production<br />

of basic chemicals in Portugal is being<br />

transported to the Middle East. Once adapted to<br />

the current technical and environmental requirements,<br />

it will be commissioned there as an economical<br />

solution for a new client.<br />

on this rather unusual order,” says Enrico Enghardt,<br />

Head of Sales at the turbomachinery competence<br />

center of MAN Diesel & Turbo in Oberhausen. And<br />

while most employees embark on a well-deserved<br />

retirement after 40 years of service, this “senior”<br />

machinery train is thus going on another journey<br />

before being put into operation in its new home at<br />

the end of 2014.<br />

Fertilizer production with<br />

second-hand machinery –<br />

economical solutions<br />

rendered possible by<br />

MAN PrimeServ.<br />

As with used cars, there is a global market for used<br />

machinery in industry too: after the previous operator<br />

opted for a new train from MAN Diesel &<br />

Turbo to increase its production volume, a new<br />

owner was found for the old train in the Middle<br />

East. Apart from a general overhaul, adaptation is<br />

naturally required to the new operating conditions,<br />

for instance the higher ambient temperatures.<br />

And who would be better suited to this task<br />

than the original manufacturer?<br />

“The satisfactory experience that the old and new<br />

operators have enjoyed in the past with MAN was<br />

a key factor in the decision to choose MAN to take<br />

Encounter 37


a bridge<br />

to the future<br />

THE IMPORTANCE of natural gas is rising rapidly among<br />

the fossil fuels.<br />

Following coal in the 19th century and oil in the 20th, is gas now assuming the mantle as the key fossil<br />

fuel? The International Energy Agency (IEA) thinks so at any rate and has already dubbed the 21st century<br />

the “Golden Age of Gas”. And the fact is that if the current growth trend continues, natural gas will<br />

overtake coal and oil in the next ten to twenty years, to judge by its share of global primary energy consumption.<br />

One thing is certain – thanks to its high level of availability, its versatility and its comparatively benign<br />

effect on the environment, natural gas will become increasingly important to all key applications such<br />

as transportation and the provision of power and heat. Low-pollutant combustion – as far as possible<br />

devoid of dust, soot and sulfur – and low CO 2 emissions are central arguments in favor of gas.<br />

This process starts right at the beginning of the natural gas value creation chain. Turbomachinery is in<br />

operation across the globe to ensure that natural gas can be extracted safely, efficiently and reliably.<br />

Compressors and turbines likewise play a vital role in subsequent transportation, conditioning and further<br />

processing to produce chemical feedstocks or liquid fuels – and demand is growing.<br />

This is because natural gas is becoming increasingly widespread as a fuel in road, rail and especially<br />

maritime transport. Natural gas is transported globally to a growing extent in the form of Liquefied<br />

Natural Gas (LNG). This is an attractive alternative to gas pipelines, especially where large distances are<br />

involved, and customers are not tied to one supplier. LNG tankers and other types of vessels are now<br />

propelled by gas or dual fuel engines. As the global LNG infrastructure becomes more dense, it is foreseeable<br />

that liquefied natural gas will also offer an economical, environmentally friendly alternative fuel<br />

source for a host of other types of ships. Approximately half of the world‘s shipping traffic is now powered<br />

by a wide variety of MAN ship propulsion systems. Gas engines account for a rapidly growing share<br />

of this figure.<br />

In heat and power generation, decentralized solutions will increasingly ensure an energy supply for the<br />

future in light of a rapidly growing proportion of regenerative energy sources – and not just in Germany,<br />

although this is a prime example. In the wake of its decision, enshrined in law, to phase out nuclear energy<br />

by 2022, the Federal Republic is pursuing a particularly ambitious goal: to increase the proportion<br />

38 Encounter


of net power generation from renewable energy in stages from 21 percent in 2011 to 80 percent in 2050.<br />

The roadmap foresees a regenerative share of 35 percent by 2020.<br />

The planned transformation of the energy landscape will not be achieved by dispensing completely with<br />

fossil-fired power plant capacity: conventional generating capacity is needed for the present, not only to<br />

cover electric base load requirements but also to provide so-called balancing energy. This is because the<br />

volatility of power generation rises as renewable energies come increasingly into play – for instance,<br />

because sun and wind parameters change constantly. Balancing energy evens out power supply and<br />

demand, thus preventing the electricity grid from collapsing.<br />

Gas-fired power stations are now the facility of choice among fossil-fuel power plants for supplying balancing<br />

energy as well as for base load purposes. On account of their very short start-up and load regulating<br />

times they are extremely flexible, suitable for decentralized use and have a favorable CO 2 balance.<br />

Gas power plants are even more interesting from the environmental, efficiency and cost point of view if<br />

they generate combined heat and power. Fuel utilization levels of more than 85 percent can be achieved<br />

by cogeneration, and the 90 percent level is within reach. Here a gas engine or gas turbine drives a<br />

generator to produce power, while the waste heat from the generator drive is used either for heating<br />

purposes, to heat service water or for process heat in industrial production.<br />

The system options with cogeneration are many and diverse. For instance, a steam turbine can be connected<br />

in series to generate further electricity using the surplus waste heat. Cogeneration is an efficient<br />

technology – and with its portfolio spanning gas engines and gas and steam turbines, MAN Diesel &<br />

Turbo offers a broad, flexible spectrum of decentralized power generating technologies to realize the<br />

transformation in the energy landscape that is required to meet climate objectives.<br />

Whether in transportation or for producing electricity and heat, whether as a replacement for coal<br />

and oil or to complement regenerative energy sources, natural gas will form the basis for the transition<br />

to a preferably regenerative future. MAN Diesel & Turbo will play a part in this with its clear strategic<br />

orientation and an extensive range of natural gas products.<br />

Encounter 39


Products and Services<br />

Marine Engines & Systems<br />

Turbomachinery<br />

One in every two ships plying the world’s<br />

oceans is powered by a MAN diesel engine.<br />

MAN Diesel & Turbo is the world market leader<br />

in two-stroke diesel engines, which drive large<br />

container ships, freighters or tankers. The<br />

company’s extensive range of four-stroke engines<br />

is used to drive all kinds of merchant ships,<br />

special vessels and passenger vessels.<br />

As one of the world’s leading suppliers of<br />

turbomachinery, MAN Diesel & Turbo offers one<br />

of the broadest product ranges in this field. The<br />

diversity of products reflects a wide circle of<br />

customers, for whom the company designs and<br />

manufactures single compressors and turbines<br />

or complete machinery trains.<br />

• Two-stroke and four-stroke engines for marine<br />

applications<br />

• Output range from 450 kW to 87 MW<br />

• Marine GenSets from 450 kW to 11.2 MW<br />

• Fuels: heavy fuel oil, diesel, gas, dual fuel<br />

• Propellers and complete marine propulsion<br />

systems<br />

• Axial and radial turbochargers for two-stroke<br />

and four-stroke engines, injection systems,<br />

systems electronics<br />

• Compressors, gas turbines and steam turbines<br />

for the oil & gas industry, the process industry<br />

and power generation<br />

• Turnkey machinery trains including drive and<br />

expanders<br />

• Reactors for the chemical and petrochemical<br />

industry, special apparatus for science<br />

40 Encounter


Power Plants<br />

MAN PrimeServ<br />

With its range of large stationary diesel and gas<br />

engines for use in power plants, MAN Diesel &<br />

Turbo is a reliable partner for power generation<br />

in almost all environmental and infrastructure<br />

situations. Our engines work reliably, even in<br />

extreme climatic regions, are ideally suitable<br />

for combined heat and power solutions and<br />

are efficient partners for renewable energy<br />

technologies, for instance in hybrid power<br />

plants. Power plant operation and maintenance<br />

are also part of our spectrum of services.<br />

MAN PrimeServ is MAN Diesel & Turbo’s<br />

after sales service brand, covering far more than<br />

just routine servicing of engines and machinery<br />

or the simple delivery of spare parts. Besides<br />

technical service for all products, its business<br />

activities include individual consulting,<br />

extensive support and also comprehensive<br />

service agreements.<br />

Two-stroke and four-stroke engines from<br />

1,100 kW to 80 MW<br />

Diesel and gas power plants up to 300 MW<br />

Combined heat and power plants,<br />

motor combined cycle<br />

Excellent fuel flexibility: diesel, heavy fuel oil,<br />

biofuels, gas, dual fuel<br />

Operation and maintenance, complete services<br />

Expandable, modular concepts<br />

• Individual consulting, service agreements and<br />

contracts<br />

• Maintenance, spare parts supply and repairs<br />

• Retrofits, upgrades, rerates, relocations<br />

• Online monitoring and diagnosis<br />

• Customer training in MAN PrimeServ<br />

academies<br />

• Worldwide network of service hubs:<br />

24/7 OEM service around the globe<br />

Encounter 41


At a glance<br />

MAN Diesel & Turbo: Worldwide more than 14 400 employees (2013)...<br />

Germany<br />

Augsburg<br />

Oberhausen<br />

Hamburg<br />

Berlin<br />

Deggendorf<br />

Denmark<br />

Frederikshavn<br />

Kopenhagen<br />

Czech Republic<br />

Velká Bíteš<br />

France<br />

St. Nazaire<br />

Switzerland<br />

Zurich<br />

China<br />

Changzhou<br />

India<br />

Aurangabad<br />

Production sites<br />

MAN PrimeServ/<br />

sales and service hubs<br />

…Order intake (2013): …Revenue (2013):<br />

Marine Engines & Systems: 44.6 %<br />

Marine Engines & Systems: 38.4 %<br />

Turbomachinery: 34.7 %<br />

3,407 Mio €, of which: 3,396 Mio €, of which:<br />

Turbomachinery: 41.1 %<br />

Power Plants: 20.7 %<br />

Power Plants: 20.5 %<br />

...as part of the MAN Group:<br />

MAN SE<br />

Commercial Vehicles<br />

Power Engineering (incl. Renk)<br />

42 Encounter


Imprint<br />

Publisher<br />

MAN Diesel & Turbo SE<br />

Stadtbachstr. 1<br />

86153 Augsburg, Germany<br />

Phone +49 821 322-0<br />

Edited by<br />

MAN Diesel & Turbo SE<br />

Group Communications & Marketing<br />

Felix Brecht<br />

Design<br />

adtention Werbeagentur<br />

Wuppertal, Germany<br />

Printing<br />

Druckpartner Druck- und Medienhaus<br />

Essen, Germany<br />

Picture credits<br />

All graphics and images: MAN Diesel & Turbo, plus:<br />

cover: Luc Beziat/Photographer’s Choice/Getty <strong>Image</strong>s<br />

page 3/6/14/21/36: Hauke Dressler<br />

page 4: Simon Katzer<br />

page 8: Walter Zerla/Cultura Travel, Stone/Getty <strong>Image</strong>s<br />

page 9: Kivera Photographe<br />

page 16: Photo Bleu Marine/J-F Couty<br />

page 17: Thomas Urner, Photo Bleu Marine/J-F Couty<br />

page 18: Thomas Urner<br />

page 24/25: dpa picture alliance, imagine china<br />

page 26: Ingrid Fiebak Fotografie<br />

page 27: TOTE Inc.<br />

page 30: Carsten Paul<br />

page 34/35: Frank von Groen<br />

page 37: Steven Lewarne/E+/Getty <strong>Image</strong>s<br />

This <strong>Magazine</strong> is available in English and German.<br />

Download from www.mandieselturbo.com or man.eu.<br />

MAN Diesel & Turbo – a member of the MAN Group<br />

All information provided in this magazine is intended for general<br />

guidance only and is not intended to be used as a substitute for<br />

specific technical or commercial information and advice.<br />

Encounter<br />

43


MAN Diesel & Turbo SE<br />

Stadtbachstr. 1<br />

86153 Augsburg, Deutschland<br />

Phone +49 821 322-0<br />

Fax +49 821 322-3382<br />

info-de@mandieselturbo.com<br />

www.mandieselturbo.com

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