MAN Energy Launches Common-Rail Injection System for Four-Stroke Engines

MAN Energy Solutions released a new common-rail injection system for its medium-speed, four-stroke engine portfolio: the CR 2.2 common-rail fuel-injection system to replace its CR 1.6 predecessor. The CR 2.2 system allows precise and flexible control of injection pressure, timing, and duration throughout complete operating ranges. Engine performance, emissions, and fuel consumption can be optimized with precise control.

“This new common-rail generation integrates the experience and lessons learned from the previous CR generation,” said Stefan Eefting, Senior Vice President and Head of MAN PrimeServ Germany. “A key development is that we have reduced our dependency on suppliers and brought production completely in-house, which – in dispensing with external partners –simplifies the technical side of things. The result is a modular system that can easily be adapted to different engine sizes.”

The CR 2.2 generation contains an optimized and uniform high-pressure pump, a newly developed injector, and the CR 1.6 valve group, with initial introduction on the MAN 49/60DF engine. According to MAN Energy, it can have up to 38% increased rail-pressure across all applications and over 33% increased target time-between-overhaul intervals for most components. The CR 2.2 system features 35% fewer high-pressure connections, enabling reduced leakage risk and greater service compatibility.

CR 2.2 common-rail fuel-injection system; Image Credits: MAN Energy Solutions

“Common-rail 2.2 brings multiple benefits for engines and engine performance,” said Alexander Knafl, Senior Vice President, Head of Engineering R&D Four-Stroke, MAN Energy Solutions. “In general, it offers improved performance and increased robustness compared to its predecessor and has already successfully accumulated over 30,000 engine test hours running on DMA and HFO.”

Additional CR 2.2 features include:

• An increased system pressure up to 2,200 bar, adhering to future emission limits and offering optimized fuel consumption
• An electronically controlled injector and accumulator to ensure maximum stability during injection events
• A reduced modular design to simplify engine service and maintenance
• A platform for fuels such as HVO and FAME
• Delivers lower fuel-oil consumption, soot emissions, mechanical load, vibration, and noise

MAN Energy Engine News

This week, MAN Energy Solutions agreed to deliver 16 20V35/44G gas engines with a 172-MW total capacity for two power plants in Indonesia and one in East Malaysia, located on the island of Borneo. Both Indonesian power plants will operate with low-emission natural gas and generate electricity for the national grid.

Five gas engines, with a 52-MW total capacity, will be deployed as generator sets (gensets) at a newly constructed power plant in Batam, Indonesia. The city is located on an island across from Singapore and contains 1.2 million residents—it is an upcoming industrial and commercial hub in Southeast Asia. Four additional 20V35/44G TS gensets, equipped with two-stage turbocharging and 50-MW total capacity, will be installed at a power plant in Cikarang—a suburb of Indonesia’s capital, Jakarta.

Seven gas engines with a 70-MW total capacity will drive a decentralized power plant in Sipitang, East Malaysia. The power plant will use natural gas and supply electricity to a nearshore, under construction floating LNG terminal that will enter commercial operation by 2027.