PowerGen 2002: mtu introduces new Genset Engine 20V 4000

• Most powerful engine in the world for 1500/1800 min-1 applications
• Good power-to-weight ratio enables new genset concepts
• Fuel optimized version consumes 192 g/kWh at full load
• Innovative technology with maintenance friendly design
• Technical data on the 20V 4000 - Genset Engine (permanent current/emergency current)

Most powerful engine in the world for 1500/1800 min-1 applications

Milan - At PowerGen Europe, mtu presents for the first time the new generator engine 20V 4000. With a maximum output of 3010 kW it is the most powerful engine in the world that can be used at both 1500 and1800 rpm as a genset engine suitable for 50 and 60 hertz applications.

For use in operations and regions where strict exhaust regulations are in force, mtu offers the 20V 4000 in an emission optimized version, in which the engine complies with all current valid emission regulations, including the German Clean Air Act (TA Luft) and the American EPA Tier 1. Alternatively, the 50 hertz version of the engine can be adjusted for optimal consumption - fuel consumption is then particularly low.

Good power-to-weight ratio enables new genset concepts

The 20V 4000 is a very light engine, which can be easily accommodated in large building complexes where emergency gensets are often installed in the upper floors. This is particularly advantageous where performance of up to 3000 kW is demanded, since up to now this performance class could only be covered by single-engine gensets with medium-speed engines. These are considerably heavier than high-speed diesel engines and therefore have much higher installation costs, such as laying foundations and damming mechanical vibrations. The use of the 20V 4000 is also more cost-effective than multi-engine generator systems because all peripheral components, from the generator to the cooling and control systems only have to be purchased once.

Fuel optimized version consumes 192 g/kWh at full load

As a genset engine in the fuel optimized 50 hertz version the 20V 4000 consumes around 192 g/kWh at full load. In the emission optimized 60 hertz version, in which the engine complies with the limits of the EPA Tier 1 and the German Clean Air Act (TA Luft), this value is around 203 g/kWh. Oil consumption, at 0.3 percent of fuel consumption, is also very low. Thanks to an efficient oil filter system and an optional cleaning system, oil changes are only necessary every 1,000 hours. In operation the 20V 4000 is very user-friendly with long maintenance intervals. The first major overhaul in the operation of continuous power applications is not due until after 30,000 hours.

Innovative technology with maintenance friendly design

The 20V 4000 is the only engine in its performance class that has the efficient and flexible Common Rail injection system. It is the most innovative injection system currently in use in large diesel engines. All injection parameters that influence combustion can be specified. This includes the time and duration of injection and the level of injection pressure throughout the performance map. And this applies not just at a fixed speed, but to the whole range of rotational speeds. For example, high injection pressure of 1400 bar is also available at idle speed, a feature that other injection systems do not offer. The Common Rail injection, in combination with the electronic control, enables both fuel consumption and emissions to be kept particularly low. Moreover it lowers the level of mechanical vibrations, especially at idle speed and partial load operation.

A further technical highlight of the 20V 4000 is the charging system. Two efficient turbo chargers from mtu are used in the 20V 4000. The ZR 205 turbos rotate at up to 48,000 revolutions per minute and transport up to 12,000 cubic meters of air per hour into the combustion chambers. Turbos of this type are not offered on the market. Therefore, over many years, mtu has built up competence to develop and manufacture turbo chargers itself.

Like all modern engines from mtu the 20V 4000 is controlled by the electronic engine management system MDEC (mtu Diesel Engine Control). The system enables the engine to be easily integrated into complete generator systems and to be included into integral controls alongside with other propulsion components like cooling, gears, generators and pumps.

The performance of the 20V 4000 is 35 percent higher than that of the 16V 4000. This is achieved not only through four additional cylinders, but also through enlarging the cubic capacity in the cylinders. Though the bore is the same size (165 mm), the lift has been extended from 190 to 210 mm. The robust gray cast iron crankcase which extends well below the centerline of the crankshaft has large inspection-hole covers in its sides, which make inspection and maintenance work easier. The camshaft is situated at the center in the V of the crankcase, which activates valves - two each for inlet and two for outlet. But otherwise the V of the engine is largely free. Here additional components can be placed later on, i.e to lower emission levels even further in the future.

Technical data on the 20V 4000 - Genset Engine (permanent current/emergency current)
50 hertz	2000 kW - 2670 kW
60 hertz	2060 kW - 3010 kW
Displacement	89.81 l
Displacement per cylinder	4.49 l
Bore	165 mm
Stroke	210 mm
Rated speed	1500/1800 min-1
Dimensions (L x W x H)	3516 x 2457 x 2252 mm
Weight (dry)	9450 kg
Power-to-weight ratio, min.	3,1 kg/kW
Fuel consumption	around 192 g/kWh (50 Hz. fuel optimized)
	around 203 g/kWh (60 Hz. emission optimized)
Injection	Common Rail System / 900 - 1.400 bar
Loading	2 mtu Loader ZR 205
V angle	90 degrees
TBO (continuous power)	max. 30,000 hours
Cooling system	two circuit