ME Engine Training Course - MAN B&W Diesel.pdf
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ME ENGINE TRAINING COURSE
MAN B&W Diesel
1. General description of ME engine
ME - Engines
MAN B&W Diesel, Company Presentation MAN B&W Diesel
MAN B&W Diesel
by Preben Noeies
MAN B&W Diesel © MAN B&W Diesel
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© MAN B&W Diesel
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History
The Founding of the Company MAN B&W Diesel
MAN B&W Diesel
In 1843 Hans Heinrich Baumgarten establishes a mechanical workshop in Copenhagen In 1846 a partnership is established with Carl Christian Burmeister and they establish a company named ”Baumgarten & Burmeister” The activities include a mechanical workshop and a foundry In 1854 a shipyard is established In 1861 Hans Heinrich Baumgarten retires from the company William Wain joins the company in 1865, and the name of the company is changed to Burmeister & Wain (B&W) © MAN B&W Diesel
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W. Wain
© MAN B&W Diesel
Rudolf Diesel 1858 – 1913 The First Diesel Engine and the Patent Certificate
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C. C. Burmeister
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The First B&W Diesel Engine
MAN B&W Diesel
MAN B&W Diesel
The first B&W fourstroke diesel engine was delivered in 1904
Engine No. 1 Type: 140 Customer: N. Larsen, Carriage Manufacturer, Frederiksberg, Denmark
© MAN B&W Diesel
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© MAN B&W Diesel
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1
The First Diesel Engine for Ocean-going Ship Propulsion
Engine Development 1912 - 1952 MAN B&W Diesel
1912:
MAN B&W Diesel
Single-acting crosshead four-stroke direct reversible Type: 8150-X – Power: 1,250 IHP (Introduced on M/S Selandia)
M/S Selandia, delivered to the Danish East Asiatic Company in 1912, is the world’s first ocean-going diesel motor ship.
1922:
Supercharging by electrically driven blower
1924:
Double-acting four-stroke – Type: 6840D – Power: 6,750 BHP (Twin engine installation introduced on M/S Gripsholm)
Type: DM 8150-X (2 x 8 cylinder engines)
1929:
Double-acting two-stroke engine – Type: 662-WF-140 Power: 7,000 IHP (Introduced on M/S Amerika)
Ship’s speed: 11 knots
1932:
Single-acting two-stroke engine with exhaust valves Type: 50-VF-90
1938:
Tests with heavy fuel on M/S Transilvania
1952:
The world’s first turbocharged two-stroke engine Type: 674VTBF-160 – Power: 7,500 BHP (Introduced on M/S Dorthe Mærsk)
© MAN B&W Diesel
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Power: 2,500 IHP total
© MAN B&W Diesel
First Ocean Going Vessel with Fully Reversible Diesel Engines MAN B&W Diesel
MAN B&W Diesel
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The World’s First Turbocharged Two-stroke Diesel Engine
M/S ”Selandia” M/S Dorthe Mærsk, delivered to the Danish company A. P. Møller by Odense Steel Shipyard in 1952, is the first ship to be powered by a turbocharged two-stroke diesel engine
Main engines: 2 x 1250 IHK B&W engines type DM8150X
Engine type: 674VTBF-160 Power: 7,500 BHP @ 115 r/min
© MAN B&W Diesel
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© MAN B&W Diesel
< 10 >
MAN B&W Diesel
In 1758 Eisenhütte St. Antony is established in Oberhausen
The world’s first turbocharged two-stroke engine Type: 674VTBF-160 – Power: 7,500 BHP (Introduced on M/S Dorthe Mærsk)
1967:
Introduction of the K-EF range of engines, as well as the large K98FF type (3,800 BHP/cyl. @ 103 RPM)
1973:
Delivery of the first K-GF engine
1976:
The first to introduce modern long stroke diesel engines Type: L-GF, with a stroke-bore ratio of 2.5:1
1978:
The first with constant pressure turbo charging of modern uniflow scavenged diesel engines
1979:
The first to test a rotating air-spring on exhaust valves in service
1980:
The first to introduce layout flexibility, as well as a specific fuel oil consumption below 140 g/BHPh – Type: L-GFCA
© MAN B&W Diesel
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The History of MAN B&W Diesel
Engine Development 1952 - 1980 MAN B&W Diesel
1952:
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In 1840 Sander'sche Maschinen Fabrik is established in Augsburg In 1843 Baumgarten establishes a workshop in Copenhagen Gutehoffnungshütte Actienverein (GHH) is established in 1873
Burmeister & Wain (1865) B&W Motor A/S (1974)
M.A.N. Maschinenfabrik Augsburg-Nürnberg (1908)
In 1921 GHH acquired a majority in M.A.N.
In 1979/80 B&W Motor A/S is taken over by M.A.N., and M.A.N. B&W Diesel A/S is established
In 1986 M.A.N. was merged into GHH and renamed MAN AG The divisions were hived off to form individual public limited companies < 11 >
© MAN B&W Diesel
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2
MAN B&W Diesel A/S A Historical Overview Since 1843
Diesel Chronicle MAN B&W Diesel
MAN B&W Diesel
1933 The first to introduce uniflow on a two-stroke engine 1952 The first to introduce turbocharging on two-stroke slow speed diesel engines 1978 The first with constant pressure turbocharging of modern uniflow engines 1981 The first to demonstrate engine efficiency of more than 50% corresponding to specific fuel oil consumption figures below 125 g/BHPh 1994 The first to introduce an engine with power above 90,000 bhp 1996 The first to introduce a new generation of compact engines 1998 The first to introduce the Environmentally Friendly prop. system 2000 The first to put an electronically controlled engine into service
MAN B&W Diesel © MAN B&W Diesel
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< 13 >
© MAN B&W Diesel
The MAN Group - 2005
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MAN B&W Diesel Group
MAN B&W Diesel
MAN B&W Diesel
61,259 employees Turnover € 14,9 billion PBT € 453 million
Services
Industrial Commercial Vehicles
Printing Machines
Diesel Engines
Turbo Machines
Further Industrial Holding*
Industrial Services Financial Services
MAN Nutzfahrzeuge AG
MAN Roland Druckmaschinen AG
MAN B&W Diesel AG
MAN Turbomaschinen AG
RENK Aktiengesellshaft MAN Technologie AG MAN DWE GmbH Schwäbische Hüttenwerke GmbH
MAN Ferrostaal AG
Turnover € 7,4 billion
© MAN B&W Diesel
Turnover € 1,6 billion
06.01
Turnover € 1,4 billion
Turnover € 0,7 billion
MAN Aktiengesellschaft München 100%
MAN Financial Services GmbH
67% S.E.M.T. Pielstick France
MAN B&W Diesel AG Germany
MAN B&W Diesel A/S Denmark
Turnover € 3,2 billion
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© MAN B&W Diesel
Locations of MAN B&W Diesel
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Worldwide Service Network
MAN B&W Diesel
MAN B&W Diesel
Great Britain Paxman Ruston Mirrlees Blackstone 678 employees Four-stroke engines
Frederikshavn
Copenhagen
• Marine propulsion • Military marine • Power generation • Rail traction
• Marine propulsion • Military marine • Power generation • Rail traction • Service • Licensor
Holeby Rostock Hamburg
Stockport
Paris Augsburg Saint-Nazaire
Denmark MAN B&W Diesel A/S 2173 employees Two-stroke engines • Research and development • Marine propulsion • Power generation • Service • Spare parts • Licensor Four-stroke engines •Complete propulsion package •GenSets •Power generation •Licensor
Colchester
France Pielstick 709 employees Four-stroke engines
Jouet
Germany MAN B&W Diesel AG 2474 employees Four-stroke engines • Research & development • Marine propulsion • Power generation • Service • Licensor
Service Centres
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AuthorisednRepair Shops 55 Licensees
Total 6 034 © MAN B&W Diesel
100%
100% MAN B&W Diesel Ltd England
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© MAN B&W Diesel
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Two-Stroke Licensees
Two-stroke Licensees
MAN B&W Diesel
MAN B&W Diesel
China HHM DMD YMD
1980 1980 1989
Korea Hyundai Doosan STX
1976 1983 1984
Spain IZAR – Manises
Croatia Uljanik Split
1954 1984
Poland Cegielski
1959
1941
Vietnam Vinashin
Japan Mitsui • Makita Hitachi Kawasaki
Russia Bryansk
1926 1981 1951 1981
1959
2004
As at August 2004 © MAN B&W Diesel
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© MAN B&W Diesel
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MAN B&W Diesel A/S, Copenhagen MAN B&W Diesel
MAN B&W Diesel
Main Office Warehouse
Production of Key Components
Factory Administration R&D Centre
© MAN B&W Diesel
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© MAN B&W Diesel
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MAN B&W Diesel A/S, Research Centre
MAN B&W Diesel A/S, Copenhagen MAN B&W Diesel
© MAN B&W Diesel
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© MAN B&W Diesel
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4
Research engine 4T50ME4T50ME-X
MAN B&W Diesel A/S, Holeby
MAN B&W Diesel
MAN B&W Diesel
Engine type
4T50MX
Initial engine output 10,200 BHP Engine speed
123 r/min
Cylinder diameter
500 mm
Piston stroke
2200 mm
Stroke to bore ratio 4.4 : 1 Firing pressure
180 bar
Mean effective pressure Mean piston speed
© MAN B&W Diesel
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9 m/s
< 25 >
© MAN B&W Diesel
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MAN B&W Diesel A/S, Frederikshavn (ALPHA)
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Designations
MAN B&W Diesel
MAN B&W Diesel
Cross Section S90 MC-C
© MAN B&W Diesel
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© MAN B&W Diesel
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Development of the MEME-engine
Designations MAN B&W Diesel
MAN B&W Diesel
1991
Start of Intelligent Engine Project
1993
4T50MX equipped with Electronic Engine Control equipment
1997
4T50MX with 2nd generation control equipment
1997/98
Design - Production - Installation of mechanical/hydraulic components for service test on M/T "Bow Cecil"
1997/98
Design and implementation of governor functionality, and service test onboard ”Shanghai Express”
1998/2000 Design - Production - Test - Installation of Engine Control System on M/T ”Bow Cecil” 2000 2003 © MAN B&W Diesel
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© MAN B&W Diesel
Start of service test on M/T ”Bow Cecil” First production engine 2005.05.01
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Reference List Two-stroke Marine Engines MAN B&W Diesel
MAN B&W Diesel
ME Programme Vessels with ME engines lined up awaiting delivery. On order/delivered
Type
Stena Arctica
( 7S60ME-C)
Captain Kostichev
( 7S60ME-C)
Pavel Chernysh
( 7S60ME-C)
Cape Brindisi
( 6S70ME-C)
© MAN B&W Diesel
In service
K98ME/ME-C
42
2
S90ME-C K90ME-C K80ME-C L70ME-C S70ME-C S65ME-C
2 8 17 16 72 3
7 3
S60ME-C S50ME-C Total
40 10 210
1 7 20
As at 2004.08.26
As at 2005.11.01 < 31 >
© MAN B&W Diesel
Hydraulic Cylinder Unit
Total: 2005.05.01
5,860,589 kW 4140/PWN
Engine Room of M/T ”Bow Cecil”
MAN B&W Diesel
MAN B&W Diesel
ME systems connected for service test
Fuel Booster pump
© MAN B&W Diesel
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< 33 >
© MAN B&W Diesel
Engine Room at Bow Cecil
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7S50ME-C in M/V Bow Firda
MAN B&W Diesel
MAN B&W Diesel
Inspection onboard Bow Cecil after 4137 running hours as ME engine
© MAN B&W Diesel
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© MAN B&W Diesel
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6
The ME Engine Hydraulic Power Supply (HPS)
7S50ME-C in M/V Bow Firda MAN B&W Diesel
MAN B&W Diesel
Generates the power necessary for fuel oil injection and exhaust valve opening
Hydraulic Power Supply
MC © MAN B&W Diesel
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© MAN B&W Diesel
ME 06.01
The ME Engine Hydraulic Power Supply (HPS)
4140/PWN
< 38 >
HPS Hydraulic Power Supply
MAN B&W Diesel
MAN B&W Diesel
Before engine start, the hydraulic oil pressure used in the mechanical/hydraulic mechanical/hydraulic system for controlling the actuators is generated by electrical driven start start-up t-up pumps. After start, the engine star driven pumps will take over the supply.
Main components: • Self-cleaning filter with 10-micron filter mesh • Redundancy filter with 25-micron filter mesh
Accumulators
Self cleaning filter 10μ Start-up pumps
• Start up pumps:
Safety and accumulators block
x Start-up pumps
High pressure pumps with supply pressure of 175 bar Engine driven axial piston pumps
Low pressure pumps for filling the exhaust valve push rod with supply pressure of 4 bar • Engine driven axial piston pumps supplying high pressure oil to
The hydraulic power supply uses the engine system oil
the Hydraulic Cylinder Unit with oil pressure up to 250 bar Redundancy filter 25μ © MAN B&W Diesel
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© MAN B&W Diesel
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HPS 7S60ME-C
The ME Engine Hydraulic Oil Loop MAN B&W Diesel
MAN B&W Diesel
Fuel oil pressure Exhaust valve actuator booster
Redundancy Filter 25μ Hydraulic cylinder unit
Fuel 10 bar ELFI
ELVA
Self Cleaning Filter 10μ
200 bar
Alpha lubricator
Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU
Cyl. 4 CCU
Cyl. 5 CCU Cyl. 6 CCU Safety and Accumulator block
Fine aut. filter Main lube pump Piston cooling + bearings Servo oil return to sump
Servo oil
Engine Driven Axial Piston Pumps Chain Wheel and Step-up Gear Shielding with Drain
From sump Engine driven hydraulic pumps © MAN B&W Diesel
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EL. driven hydraulic pumps < 41 >
Safety and Accumulators Block
and Alarm Functions © MAN B&W Diesel
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Electrically Driven Start-up Pumps 4140/PWN
< 42 >
7
ME – Engine, Pump Drive and Moment Compensator MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
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< 43 >
© MAN B&W Diesel
Large Bore ME - Aft end mounted HPS. 5-8K/L/S60-90MC-C & 7K98ME(-C)
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60-98ME-C HPS
MAN B&W Diesel
MAN B&W Diesel
Engines with moment compensator
Engines without moment compensator
Filter station
Identical HPS units Hydraulic pumps Identical chain tightening arrangement
Step-up gear
Chain tightener wheel
© MAN B&W Diesel
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< 45 >
© MAN B&W Diesel
Hydraulic Power Supply 6S70ME6S70ME-C
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Step-up gear
MAN B&W Diesel
MAN B&W Diesel
Redundancy Filter 25μ 25μ Self Cleaning Filter 10μ 10μ
Gear wheels: •Case hardened •Simple spur wheels •DIN standard
Shielding with Drain
Engine Driven Axial Piston Pumps
and Alarm Functions
Chain Wheel and StepStep-up Gear
© MAN B&W Diesel
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(2510/JRL)
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< 47 >
© MAN B&W Diesel
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Filter unit
Engine driven high pressure pumps MAN B&W Diesel
MAN B&W Diesel
Self cleaning filter with 10-micron filter mesh
Redundancy filter with 25-micron filter mesh
Supplied by Bosch Rexroth Supplied by Boll&Kirscher
© MAN B&W Diesel
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< 49 >
© MAN B&W Diesel
Safety block
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Start-up pumps
MAN B&W Diesel
MAN B&W Diesel
•Safety and control valves
Three types: •2 x 15 kW for 50-60ME-C
•Line break valves
•2 x 25 kW for 70-80ME-C •2 x 38 kW for 90-98ME-C
Basically the same block on all 6098ME/ME-C
© MAN B&W Diesel
MAN B&W Diesel
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© MAN B&W Diesel
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7S50ME-C Hydraulic Power Supply
7L70ME-C electrical HPS
MAN B&W Diesel
Accumulator Safety and accumulator block 3 engine driven axial piston pumps with flow controlled by ECS
Gearbox and chain drive is replaced by: •3 electrically driven pumps
Generates hydraulic oil pressure up to 250 bar
•230 kW each
Redundancy: Can operate on two pumps
Gear Box © MAN B&W Diesel
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< 53 >
© MAN B&W Diesel
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El-driven Pumps (Viken 1436)
Engine Driven Pumps (Viken 1436)
MAN B&W Diesel
MAN B&W Diesel
Pump
Suction line
© MAN B&W Diesel
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< 55 >
© MAN B&W Diesel
Engine Driven Pump (Viken 1436)
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Hydraulic Cylinder Units (HCU)
MAN B&W Diesel
MAN B&W Diesel
HCUs mounted on common base plate Feed back, swash plate
Feed back, pilot valve
Pilot valve for swash plate control
Double walled high pressure pipe
High pressure oil inlet from the HPS
© MAN B&W Diesel
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< 57 >
© MAN B&W Diesel
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ME-C Engines Double Wall Pipe
Double Wall Pipe S70ME-C MAN B&W Diesel
MAN B&W Diesel
1.
Flange
2.
Outer Pipe
3.
Inner Pipe
4.
Sealing ring
5. Sealing ring 6. Sealing ring 7. Sealing ring 8. Screw
© MAN B&W Diesel
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© MAN B&W Diesel
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ME-C Engines Double Wall Pipe
Hydraulic Cylinder Unit
MAN B&W Diesel
MAN B&W Diesel
Final Design of Double Wall Pipe Between HCU Blocks with Additional Sliding Rings Item 7 and Dirt Sealing Ring Item 8
6
9 7
6
Fuel oil Pressure Booster
7 10
1
Hydraulic Exhaust Valve Actuator
8 ELFI Proportional Valve
4 ELVA On/Off Valve
5 Distribution Block
© MAN B&W Diesel
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< 61 >
© MAN B&W Diesel
Oil Channel in the Distributor Block
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Hydraulic Cylinder Unit (HCU)
MAN B&W Diesel
MAN B&W Diesel
The oil channels connect the NC-valve, the Fuel Oil Pressure Booster, the Exhaust Valve Actuator and the Accumulator No risk of oil leakage as pipe connection is avoided
X-ray picture of the Distributor Block © MAN B&W Diesel
06.01
Manually operated valve for isolation of oil to the actuators in case of need for overhauling – running engine
4140/PWN
< 63 >
© MAN B&W Diesel
ME Control Valves MAN B&W Diesel
MAN B&W Diesel
MAN B&W FIVA
ELVA
06.01
The HCU is found on the upper gallery
One unit in front of each cylinder
4140/PWN
Hydraulic Cylinder Units 12K98ME12K98ME-C Fuel Oil Pressure Booster
ELFI
FIVA valve © MAN B&W Diesel
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< 65 >
© MAN B&W Diesel
< 64 >
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Exhaust Valve Actuator
Integrated Alpha Lubricator < 66 >
11
MAN B&W Diesel
© MAN B&W Diesel
K98ME(-C) Hydraulic Cylinder Unit
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MAN B&W Diesel
< 67 >
© MAN B&W Diesel
K98ME(-C) HCU Distributor Block
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< 68 >
ME(-C) HCU Distributor Block MAN B&W Diesel
MAN B&W Diesel
The ME Engine Hydraulic Oil Loop
Fuel oil pressure booster
Exhaust valve actuator Hydraulic cylinder unit
Fuel 10 bar FIVA
200 bar
Alpha lubricator
Cyl. 1 CCU
Cyl. 2 CCU
Cyl. 3 CCU
Cyl. 4 CCU
Cyl. 5 CCU
Cyl. 6 CCU
Fine aut. filter
Piston cooling + bearings Servo oil return to sump
Main lube pump
Safety and accumulator block Servo oil
From sump Engine-driven hydraulic pumps © MAN B&W Diesel
MAN B&W Diesel
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< 69 >
© MAN B&W Diesel
06.01
EL. driven hydraulic pumps
4140/PWN
Hydraulic Cylinder Unit (HCU)
S60ME-C
MAN B&W Diesel
Fuel Oil Pressure Booster Exhaust Valve Actuator
FIVA Proportional Valve
Distribution Block
Alpha Lubricator
© MAN B&W Diesel
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< 71 >
© MAN B&W Diesel
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< 72 >
12
The ME Engine Alpha Cylinder Lubricator
ME Fuel Oil Pressure Booster
MAN B&W Diesel
MAN B&W Diesel
Save 0.3 g/bhp cylinder oil
MC-C
Inductive proximity switch for feed-back signal for control of piston movement
ME-C
Signal for lubrication from controller
Suction valve
Actuator piston
Outlets for cylinder liner lube oil injectors
Fuel plunger Fuel oil inlet pressure 8 bar
Injection plungers
Feed back position sensor
Hydraulic piston
Spacer for basic setting of pump stroke
Stroke adjusting screw
Drain oil outlet 200 bar servo Cylinder oil supply lube oil inlet Saves cylinder lube oil
© MAN B&W Diesel
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< 73 >
© MAN B&W Diesel
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Slide-type Fuel Valve
ME Fuel Injection System MAN B&W Diesel
MAN B&W Diesel
Suction valve
High pressure pipe
Slide fuel valve
Now used as standard
Fuel oil inlet 8 bar
Hydraulic piston
Possibility for retrofit
Membrane accumulator
ELFI Proportional valve
Conventional fuel valve Sac volume 1690 mm3
To drain
Slide-type fuel valve Sac volume 0 mm3
High pressure hydraulic oil – inlet © MAN B&W Diesel
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< 75 >
© MAN B&W Diesel
M E Exhaust Valve System
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ME Exhaust Valve
MAN B&W Diesel
MAN B&W Diesel
Self-adjusting damper piston
Hydraulic push rod
Hydraulic nut/measuring cone Contact less sensor with integrated electronics
Exhaust valve
Outlet lube oil
Exhaust valve Actuator
Inlet lube oil Damper Membrane accumulator ELVA on-off valve
Air inlet
To drain © MAN B&W Diesel
High pressure hydraulic oil – inlet 06.01
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< 77 >
© MAN B&W Diesel
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13
The ME Engine Exhaust Valve Timing
ME Starting Air System
MAN B&W Diesel
MAN B&W Diesel
MCMC-C design 80
MEME-C design Pilot air inlet
BlowBlow-off
70 60 Early closing Late closing Early opening Late opening Reference
mm
50 40 30
NCNC-valves
Connection for ECS
Starting air distributor
20 Starting valves
10
Starting valves
0 90
110
130
150
170
190
210
230
250
270
290
Dg. C. A.
The NC valve is mounted on the main starting pipe behind the cylinder cover © MAN B&W Diesel
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< 79 >
© MAN B&W Diesel
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Main Operating Panel in ECR - HMI MAN B&W Diesel
MAN B&W Diesel
Interview with the daily operators - finger touch to trackball -
Inspection onboard Bow Cecil after 4137 running hours as ME engine © MAN B&W Diesel
06.01
Main Operating Panel - HMI 4140/PWN
< 81 >
© MAN B&W Diesel
ME Tacho System
2005.05.01
(4140/PWN)
< 82 >
Service Experience
MAN B&W Diesel
MAN B&W Diesel
A shaft encoder solution has been prepared as an alternative to the standard mounted tacho ring
• 2 redundant set of sensors • Each set measure engine speed and crankshaft position for synchronisation of the control events •• Each set consist of four sensors. Two quadrature sensors measure on a trigger ring with 360 tooth and two marker sensors measures on one tooth – a semicircular ring Trigger segment with a sine-curved toothprofile The total trigger ring is build by 8 equal segments
© MAN B&W Diesel
2005.05.01
(4140/PWN)
< 83 >
© MAN B&W Diesel
2005.05.01
(4140/PWN)
< 84 >
14
Tacho System Angle Encoder MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2005.05.01
(4140/PWN)
< 85 >
© MAN B&W Diesel
06.01
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< 86 >
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Tacho System Angle Encoder MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
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< 87 >
© MAN B&W Diesel
Main Operating Panel (MOP)
Angle Encoder – 12K98ME MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 89 >
© MAN B&W Diesel
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< 90 >
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Multi Purpose Controller (MPC)
ME Engine Control System
MAN B&W Diesel
Bridge Panel
MAN B&W Diesel
Bridge
Plug for ID key
MultiMulti-Purpose Controller
Main Operatingg Panel
BACK-UP FOR MOP Control Room Panel
PC
Engine Control Room
DIP Switches
EICU B
EICU A
Engine Interface Control Unit A and B Local Operation Panel
Engine Control Unit A and B ECU B
ECU A
Control Network
Cylinders Control Unit 1 per cylinder ACU
CCU
Auxiliaries Control Unit 1, 2 and 3 © MAN B&W Diesel
06.01
Fuses in use are monitored by the alarm system
Engine Room/On Engine
4140/PWN
< 91 >
© MAN B&W Diesel
06.01
4140/PWN
< 92 >
Engine Control System MPC
MPC - configuration MAN B&W Diesel
MAN B&W Diesel
The MPC’s are software wise configured to 4 different controller functions: 1) Engine Interface Control Unit – EICU • 2 complete redundant units • Handles the interface to external systems 2) Engine Control Unit – ECU • 2 complete redundant units • Handles the engine specific control functions (the governor) 3) Cylinder Control Unit – CCU • 1 for each cylinder unit, redundancy by multiplicity • Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and starting air valves) 4) Auxiliary Control Unit – ACU • 3 units, redundancy by multiplicity • Handles the auxiliary systems (hydraulic power supply, aux blowers) © MAN B&W Diesel
06.01
4140/PWN
< 93 >
© MAN B&W Diesel
06.01
4140/PWN
< 94 >
06.01
4140/PWN
< 96 >
S70ME-C Engine Control System MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 95 >
© MAN B&W Diesel
16
The ME Engine Local Operating Panel (LOP)
M E SIMULATOR in Copenhagen
MAN B&W Diesel
MAN B&W Diesel
Local Operating Panel
Local Instrument Panel
The The Local Local Operation Operation Panel Panel is is located located on on the the middle middle gallery gallery on on the the manoeuvring manoeuvring side side of of the the engine. engine. © MAN B&W Diesel
06.01
Local Operation Panel
4140/PWN
< 97 >
© MAN B&W Diesel
06.01
4140/PWN
< 98 >
Normal Transport Conditions MAN B&W Diesel
MAN B&W Diesel
Tank top in a New building
© MAN B&W Diesel
06.01
4140/PWN
< 99 >
© MAN B&W Diesel
06.01
4140/PWN
< 100 >
Floating Crane Collapsed MAN B&W Diesel
MAN B&W Diesel
L60ME-C Bedplate © MAN B&W Diesel
06.01
4140/PWN
< 101 >
© MAN B&W Diesel
06.01
4140/PWN
< 102 >
17
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 103 >
© MAN B&W Diesel
Holding Down Bolts
06.01
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< 104 >
Installation Aspects
MAN B&W Diesel
MAN B&W Diesel
Side chocks, modified design
Previous design
© MAN B&W Diesel
06.01
4140/PWN
< 105 >
© MAN B&W Diesel
06.01
New design
4140/PWN
< 106 >
Installation Aspects MAN B&W Diesel
MAN B&W Diesel
End chocks Cast iron end chock liner
© MAN B&W Diesel
06.01
4140/PWN
< 107 >
© MAN B&W Diesel
06.01
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< 108 >
18
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 109 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 110 >
06.01
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< 112 >
06.01
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< 114 >
MAN B&W Diesel
06.01
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< 111 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 113 >
© MAN B&W Diesel
19
K98FF (1966) Versus K98MC (1999) MAN B&W Diesel
MAN B&W Diesel
2800 kW per cylinder © MAN B&W Diesel
06.01
4140/PWN
< 115 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
5720 kW per cylinder
4140/PWN
< 116 >
MAN B&W Diesel
L60MC-C Landing Crankshaft in Bedplate © MAN B&W Diesel
06.01
4140/PWN
< 117 >
MAN B&W Diesel
06.01
4140/PWN
< 118 >
06.01
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< 120 >
MAN B&W Diesel
L60MC-C © MAN B&W Diesel
© MAN B&W Diesel
06.01
4140/PWN
Crankshaft in Bedplate < 119 >
© MAN B&W Diesel
20
Bearings MAN B&W Diesel
MAN B&W Diesel
Crosshead
Crankpin
AlSn40
© MAN B&W Diesel
06.01
4140/PWN
Main
White metal
< 121 >
© MAN B&W Diesel
06.01
4140/PWN
< 122 >
Bearings Service Experience MAN B&W Diesel
MAN B&W Diesel
S50MC-C Main bearing lower shell - 18,000 hours
No remarks – excellent condition Thickness measurement of shell did not reveal indication of significant wear rate – less than 0.01 mm
© MAN B&W Diesel
06.01
4140/PWN
< 123 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 124 >
06.01
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< 126 >
MAN B&W Diesel
06.01
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< 125 >
© MAN B&W Diesel
21
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 127 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 128 >
06.01
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< 130 >
MAN B&W Diesel
06.01
4140/PWN
< 129 >
© MAN B&W Diesel
Earthing Device MAN B&W Diesel
MAN B&W Diesel
Spark erosion in main bearings Bronze: Propeller = + Potential difference < 50 mV V Main bearing
Current
Earthing device
Steel: Hull Intermediate shaft =÷ Propeller shaft © MAN B&W Diesel
06.01
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< 131 >
© MAN B&W Diesel
06.01
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< 132 >
22
MAN B&W Diesel
MAN B&W Diesel
L60ME-C A-Frame Mounted on Bedplate. © MAN B&W Diesel
06.01
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< 133 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 134 >
06.01
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< 136 >
06.01
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< 138 >
MAN B&W Diesel
06.01
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< 135 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 137 >
© MAN B&W Diesel
23
Crosshead bearings
Crosshead bearings
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 139 >
© MAN B&W Diesel
Crosshead bearings
4140/PWN
< 140 >
Crosshead bearings
MAN B&W Diesel
© MAN B&W Diesel
06.01
MAN B&W Diesel
06.01
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< 141 >
© MAN B&W Diesel
06.01
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< 142 >
06.01
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< 144 >
Crosshead bearings MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 143 >
© MAN B&W Diesel
24
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 145 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 146 >
06.01
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< 148 >
06.01
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< 150 >
MAN B&W Diesel
06.01
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< 147 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 149 >
© MAN B&W Diesel
25
MAN B&W Diesel
MAN B&W Diesel
Test equipment for Relief Valves
ONLY Hoerbiger type EVN and Mt Halla type HCSG-N
Approved by MAN B&W
© MAN B&W Diesel
06.01
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< 151 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 152 >
06.01
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< 154 >
MAN B&W Diesel
06.01
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< 153 >
© MAN B&W Diesel
Crankcase relief valve MAN B&W Diesel
MAN B&W Diesel
In case of a crankcase explosion, the pressure wave will send a large amount of oil mist to the engine room. The oil mist will be moved around by the ventilation. If oil mist meets a hot spot it can be ignited. Maintenance of the insulation is important! Relief valve to prevent flames to the engine room.
© MAN B&W Diesel
06.01
4140/PWN
< 155 >
© MAN B&W Diesel
06.01
4140/PWN
< 156 >
26
Deformed Flame Arrester
Crankcase Explosion MAN B&W Diesel
MAN B&W Diesel
Cases of explosions where the cause is known Year
Cause of Explosion
1995
Bearing in PTO gearbox
1996
Inlet pipe for piston cooling oil falling off
Incorrect tightening
1997
Incorrect spring mounted in piston rod stuffing box
Unauthorised spare part
1997
Piston rod interference with cylinder frame
1999
Weight on chain tightener falling off
1999
Fire outside the engine
2000
Main bearing
2000
Camshaft bearing
2000
Incorrect shaft in camshaft drive
2001
Crankcase failure
2001
Piston crown failure
2001
Main bearing
2001
Crankpin bearing
2002
© MAN B&W Diesel
Inlet pipe for piston cooling oil falling off
06.01
4140/PWN
Cause of Failure
Incorrect tightening
Unauthorised spare part
Incorrect tightening
< 157 >
© MAN B&W Diesel
06.01
4140/PWN
< 158 >
Cylinder Liner and Frame Configuration MAN B&W Diesel
MAN B&W Diesel
S-MC
S-MC-C
Cylinder liner: Low position of mating surface cylinder cover/cylinder liner Slim cylinder liner Straightforward cooling jacket Cylinder frame:
Smaller and lighter Uncooled and straightforward design
© MAN B&W Diesel
06.01
4140/PWN
< 159 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 160 >
06.01
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< 162 >
MAN B&W Diesel
06.01
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< 161 >
© MAN B&W Diesel
27
ME – Engine, Pump Drive and Moment Compensator MAN B&W Diesel
MAN B&W Diesel
Filter station
Step-up gear Hydraulic pumps
2. Order Moment Compensator shaft Chain drive for 4” Duplex chain Pump drive can be arranged on fore or aft end of the engine S70MES70ME-C © MAN B&W Diesel
06.01
4140/PWN
< 163 >
© MAN B&W Diesel
06.01
4140/PWN
< 164 >
06.01
4140/PWN
< 166 >
06.01
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< 168 >
Vibration Aspects MAN B&W Diesel
MAN B&W Diesel
General terms Internal forces
Piston
Crosshead
S
α
T N
P S
© MAN B&W Diesel
06.01
4140/PWN
S
< 165 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 167 >
© MAN B&W Diesel
28
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 169 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 170 >
MAN B&W Diesel
Be sure that the counter weights are hanging downwards before mounting the tools for retightening of chains.
© MAN B&W Diesel
06.01
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< 171 >
© MAN B&W Diesel
06.01
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< 172 >
ME-C Engines Doubble Wall Pipe
Hydraulic Cylinder Units (HCU) MAN B&W Diesel
MAN B&W Diesel
HCUs mounted on common base plate
1.
Flange
2.
Outer Pipe
3.
Inner Pipe
4.
Sealing ring
5. Sealing ring 6. Sealing ring
Double walled high pressure pipe
7. Sealing ring High pressure oil inlet from the HPS
© MAN B&W Diesel
06.01
4140/PWN
8. Screw
< 173 >
© MAN B&W Diesel
06.01
4140/PWN
< 174 >
29
ME Fuel Oil Pressure Booster
K98ME(-C) Baseplate
MAN B&W Diesel
MAN B&W Diesel
MC-C
ME-C
Suction valve
Feed back position sensor
Fuel plunger Fuel oil inlet pressure 8 bar
Hydraulic piston
01-10-2003
(2500/KNB)
© MAN B&W Diesel
< 175 >
© MAN B&W Diesel
Hydraulic Cylinder Unit
4140/PWN
< 176 >
Hydraulic Cylinder Unit
MAN B&W Diesel
© MAN B&W Diesel
06.01
MAN B&W Diesel
06.01
4140/PWN
< 177 >
© MAN B&W Diesel
06.01
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< 178 >
06.01
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< 180 >
Hydraulic Cylinder Unit MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 179 >
© MAN B&W Diesel
30
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 181 >
© MAN B&W Diesel
06.01
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< 182 >
Hydraulic Cylinder Unit (HCU)
Hydraulic Cylinder Unit MAN B&W Diesel
MAN B&W Diesel
Fuel oil Pressure Booster
Accumulators pressurized with nitrogen of 105 bar
Hydraulic Exhaust Valve Actuator ELFI Proportional Valve
ELVA On/Off Valve Distribution Block
© MAN B&W Diesel
06.01
4140/PWN
< 183 >
© MAN B&W Diesel
Hydraulic Cylinder Unit (HCU)
06.01
4140/PWN
< 184 >
ME Fuel Injection System
MAN B&W Diesel
MAN B&W Diesel
Fuel injection
Valve actuation High pressure pipe Suction valve
ELFI Proportional Valve
Slide fuel valve
ELVA On/Off Valve Fuel Pump
Fuel oil inlet 8 bar
Exhaust Valve Actuator Hydraulic piston
Membrane accumulator
ELFI Proportional valve
To drain Accumulator © MAN B&W Diesel
06.01
4140/PWN
High pressure hydraulic oil – inlet
Distribution Block
< 185 >
© MAN B&W Diesel
06.01
4140/PWN
< 186 >
31
MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 187 >
© MAN B&W Diesel
06.01
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< 188 >
6S90MC-C
Service Experience MAN B&W Diesel
MAN B&W Diesel
1150 running hours Dosage 1.1 g/bhph Mobilgard 570 Liner No. 4
12K90MC, one year’s operation with Alpha ACC = S% * 0.25 g/bhph
© MAN B&W Diesel
06.01
4140/PWN
Maria A. Angelicoussis DW5127 Pascagoula 00.09.15
< 189 >
© MAN B&W Diesel
06.01
The ME Engine Alpha Cylinder Lubricator
4140/PWN
< 190 >
Cylinder Condition
MAN B&W Diesel
MAN B&W Diesel
Save 0.3 g/bhp cylinder oil
Inductive proximity switch for feed-back signal for control of piston movement
Timing of cylinder oil injection Pressure 25 bar
Signal for lubrication from controller
Injection pressure Alpha lubricator
Actuator piston
20 Outlets for cylinder liner lube oil injectors
Injection plungers
15
10 Spacer for basic setting of pump stroke
Stroke adjusting screw
Drain oil outlet 200 bar servo Cylinder oil supply lube oil inlet Saves cylinder lube oil
Injection pressure mechanical lubricator
Oil quill pressure
5
0 0 © MAN B&W Diesel
06.01
4140/PWN
< 191 >
© MAN B&W Diesel
10 06.01
20 4140/PWN
30
40
50
60
70
80
90 ms Time < 192 >
32
Combustion Chamber Design S-MC-C MAN B&W Diesel
MAN B&W Diesel
Piston with high top land
S-MC-C
Piston ring further away from combustion space
S-MC
Mating surface Top land
Lower mating surface between cylinder cover and cylinder liner
First piston ring special patented CPR ring
© MAN B&W Diesel
06.01
4140/PWN
< 193 >
© MAN B&W Diesel
06.01
4140/PWN
< 194 >
Combustion Chamber Layout MAN B&W Diesel
MAN B&W Diesel
Combustion chamber engines – Piston rings • High 1st piston ring to accommodate CPR design • Optimal pressure drop over the upper piston ring reduces the heat load on the second piston ring significantly • All piston rings Alu-coat Good performance of the piston ring pack means high reliability of the combustion chamber components and the cylinder condition
Controlled Pressure Relief (CPR) gaps
© MAN B&W Diesel
06.01
4140/PWN
< 195 >
© MAN B&W Diesel
06.01
4140/PWN
< 196 >
MAN B&W Diesel Service Alu-Coated Piston Ring
MAN B&W Diesel
MAN B&W Diesel
Genuine spare parts
Genuine spare parts A-A
Developed at our Research Centre •
Reduced running-in time by more than 50%
•
Thus saving cylinder oil
•
Thickness: about 0.3 mm
Alu-Coat
Piston ring with controlled pressure relief (CPR piston ring) A
© MAN B&W Diesel
06.01
4140/PWN
A
< 197 >
•
Reduced differential pressure on piston ring No. 2
•
Reduced temperature on piston ring No. 2
© MAN B&W Diesel
06.01
4140/PWN
< 198 >
33
Cylinder Condition MAN B&W Diesel
MAN B&W Diesel
Controlled pressure relief piston ring (CPR)
Large bore MC-S engines
90 and 98 bore engines A
F
1st ring: Type: CPR, RM14 High 2nd ring: Type: RM5, oblique cut with Alu-Coat Low 3rd ring: Type: RM5, oblique cut with Alu-Coat Low 4th ring: Type: RM5, oblique cut with Alu-Coat Low
F
F F
F A 3 mm © MAN B&W Diesel
06.01
4140/PWN
< 199 >
© MAN B&W Diesel
06.01
4140/PWN
< 200 >
Combustion Chamber Layout
Production MAN B&W Diesel
MAN B&W Diesel
Piston – high top land
Piston and piston rings
Cylinder cover Piston – high top land
Oros Piston
Liner diameter: 700 mm Liner wear:
Install:
Measuring point 5 =
ALU Coated
Piston Skirt Position in TDC
Piston Rings
0 – 0.70 mm
Standard PC-ring
0,70 – 1,4 mm Oversize PC-ring > 1,4 mm
No PC- ring
Cylinder liner
Piston cleaning ring
© MAN B&W Diesel
06.01
4140/PWN
< 201 >
© MAN B&W Diesel
“Bore polish” from topland deposits.
4140/PWN
< 202 >
“Bore polish” from topland deposits.
MAN B&W Diesel
MAN B&W Diesel
Example of, polished liner surface, from heavy deposits on the piston topland, rubbing against the liner surface.
© MAN B&W Diesel
06.01
06.01
4140/PWN
< 203 >
•
Example of heavy deposits on the piston topland, being polished from rubbing against the liner running surface
© MAN B&W Diesel
06.01
4140/PWN
< 204 >
34
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 205 >
MAN B&W Diesel
© MAN B&W Diesel
06.01
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< 206 >
06.01
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< 208 >
06.01
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< 210 >
MAN B&W Diesel
06.01
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< 207 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
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< 209 >
© MAN B&W Diesel
35
Exh. Valve (Viken 1436) MAN B&W Diesel
MAN B&W Diesel
Feed back sensor
Oil inlet to damper
Drain pipes
© MAN B&W Diesel
06.01
4140/PWN
< 211 >
© MAN B&W Diesel
06.01
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< 212 >
Slide-type Fuel Valve MAN B&W Diesel
MAN B&W Diesel
Now used as standard
Possibility for retrofit
Conventional fuel valve Sac volume 1690 mm3
© MAN B&W Diesel
06.01
4140/PWN
< 213 >
© MAN B&W Diesel
Slide Fuel Valve
06.01
Slide-type fuel valve Sac volume 0 mm3
4140/PWN
< 214 >
Slide-type Fuel Valve
MAN B&W Diesel
MAN B&W Diesel
In order to optimise combustion and to achieve a cleaner engine, we have developed a new generation of fuel valves, the so-called ”slide fuel valve”. The main benefits of this design, compared with the conventional design, are : • Reduced fouling of gas ways • Reduced fouling of piston top land and exhaust gas boiler
Further benefits : • Less smoke formation • Lower NOx emission levels • Lower fuel consumption
The difference between the slide fuel valve and the conventional type is the reduced (actually non-existent) sac volume.
Conventional fuel valve Sac volume 1690 mm3
SL 02-403 © MAN B&W Diesel
06.01
4140/PWN
< 215 >
© MAN B&W Diesel
06.01
4140/PWN
Slide-type fuel valve Sac volume 0 mm3 < 216 >
36
Slide-type Fuel Valve MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 217 >
© MAN B&W Diesel
06.01
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< 218 >
Fuel Valve, Spring Housing MAN B&W Diesel
MAN B&W Diesel
Malfunction due to incorrect tightening
Fuel Valve
Tightening torque for engines up to 70MC = 60Nm
SL 94-316
© MAN B&W Diesel
For large bore above 70MC = 65Nm
06.01
4140/PWN
< 219 >
© MAN B&W Diesel
6L80MC MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 220 >
Marks and Stamps on Fuel Valve Nozzle MC and MC-C Type
Marking must, as a minimum, consist of: Name, IMO id No. and nozzle size. Name: Manufacturer’s name/ trade mark IMO id No.: A unique identification No. which links the component with the design specification that was used at the time of manufacture, eg. MAN B&W part No. or licensee’s drawing No. Nozzle size: Diameter of nozzle hole.
Damaged Piston Crown Reason: Fuel valves in bad condition
Example of marking: The example shows how to mark a nozzle with hole diameter Ø 1.5 mm. with Part No. 1261573-1
© MAN B&W Diesel
06.01
4140/PWN
< 221 >
© MAN B&W Diesel
06.01
4140/PWN
< 222 >
37
ME Starting Air System
Starting Air valve (Viken 1436)
MAN B&W Diesel
MAN B&W Diesel
MCMC-C design
MEME-C design Pilot air inlet
BlowBlow-off
NCNC-valves
Starting valves
Starting air valve
Connection for ECS
Starting air distributor
Pilot valve for starting air valve
Starting valves
The NC valve is mounted on the main starting pipe behind the cylinder cover
© MAN B&W Diesel
06.01
4140/PWN
< 223 >
© MAN B&W Diesel
06.01
4140/PWN
< 224 >
06.01
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< 226 >
Auxiliary Systems MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
4140/PWN
< 225 >
© MAN B&W Diesel
7S60ME-C
MAN B&W Diesel A/S MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
06.01
Thank you for
Thank you for
your attention
your attention
4140/PWN
< 227 >
© MAN B&W Diesel
< 228 >
38
The ME Engine MAN B&W Diesel
You and
together
Simple & Safe
Thank you for your attention Preben Noeies © MAN B&W Diesel
06.01
4140/PWN
< 229 >
39
2. ME Concept
MAN B&W Diesel
1) Control system: - Multi Purpose Controller. - Main Operating Panel. - Local Operating Panel. 2) Tacho system. 3) Performance 4) Manoeuvring System © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
ME engine Hydraulic Loop MAN B&W Diesel
Fuel oil pressure Exhaust valve actuator booster Hydraulic cylinder unit
Fuel 10 bar ELFI
ELVA
200 bar
Alpha lubricator
Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU
Cyl. 5 CCU Cyl. 6 CCU Safety and Accumulator blok
Fine aut. filter Main lube pump
Servo oil
Piston cooling + bearings
Servo oil return to sump
From sump Engine driven hydraulic pumps © MAN B&W Diesel
L/73273-7.1/0403
EL. driven hydraulic pumps
(2600/RØL)
Engine Control System MPC & Network MAN B&W Diesel
• The Multi Purpose Controllers are identical hardware wise. • They have different soft ware configurations. • 2 redundant control networks are connecting all Multi Purpose Controllers and both Main Operating Panels. • A backup of the application- and setup- soft ware are stored on both Main Operation Panels. • At replacement, the new controller are automatically configured with correct soft ware via the control networks. © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
1
L/73273-7.1/0403
Piston cooling + bearings
Servo oil return to sump
© MAN B&W Diesel
ELFI
(2600/RØL)
From sump
Main lube pump
Fine aut. filter
Cyl. 4 CCU
ELVA
Servo oil
EL. driven hydraulic pumps
Safety and Accumulator blok
Hydraulic cylinder unit 200 bar
Engine driven hydraulic pumps
Cyl. 5 CCU Cyl. 6 CCU
Fuel oil pressure Exhaust valve actuator booster
Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU
Alpha lubricator
Fuel 10 bar
MAN B&W Diesel
ME engine Hydraulic Loop
Engine Control System Diagram
Plate 70317
On Bridge BRIDGE PANEL
In Engine Control Room Backup Operation Panel MOP B
MAIN OPERATION PANEL MOP A
EICU A
EICU B
In Engine Room/On Engine
LOCAL OPERATION PANEL - LOP
Actuators
Exhaust Fuel valve booster position position Cylinder 1 Cylinder 1
FIVA AL SAV Valve Cylinder 1 Cylinder 1 Cylinder 1
CCU Cylinder n
Sensors
CCU Cylinder 1
ACU 3
Sensors
ACU 2
ECU B
Fuel Exhaust booster valve position position Cylinder n Cylinder n
Act uat ors
ECU A
ACU 1
ECR PANEL
FIVA Valve SAV AL Cylinder n Cylinder n Cylinder n
M PUMP 5
M PUMP 4
M PUMP 3
M PUMP 2
M PUMP 1
M PUMP 2
M PUMP 1
AUXILIARY AUXILIARY BLOWER 1 BLOWER 2
Marker Sensor
AUXILIARY BLOWER 3
AUXILIARY BLOWER 4 Angle Encoders
AUXILIARY BLOWER 5
When referring to this page, please quote Operation Plate 70317, Edition 0003 MAN B&W Diesel A/S
Multi Purpose Controller - MPC MAN B&W Diesel
Battery for internal clock LED indicator Plug for ID key
DIP Switches
Fuses in use are monitored by the alarm system Power plug © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
LED information Code MAN B&W Diesel
The LED gives information, either as constant light of flashing. A flashing LED is a coded message from the controller.The code consists of 2 digits: 1. digit are given by red flashes on yellow background 2. digit are given by green flashes on yellow background The 2 digits are seperated by a 1 sec. yellow pulse.
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
2006-01-06
LED indication code MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2
Multi Purpose Controller (MPC) MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
Multi Purpose Controller (MPC) MAN B&W Diesel
Multi Purpose Controller
Supporting bracket for cables Amplifier
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
2006-01-06
MPC’s Nordic Brasilia – 6S70ME-C MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
3
MPC – configuration MAN B&W Diesel
The MPC’s are software wise configured to 4 different controller functions: 1) Engine Interface Conrol Unit – EICU • 2 complete redundant units • Handles the interface to external systems 2) Engine Control Unit – ECU • 2 complete redundant units (except with 4 or more engine driven pumps) • Handles the engine specific control functions (the govenor) 3) Cylinder Control Unit – CCU • 1 for each cylinder unit, redundancy by multiplicity • Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and starting air valves) 4) Auxilliary Control Unit – ACU • 3 units, redundancy by multiplicity • Handles the auxilliary systems (hydraulic power supply, aux blowers) © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 10 >
2006-01-06
< 11 >
2006-01-06
< 12 >
Engine Interface Control Unit – EICU MAN B&W Diesel
Interface to remote control systems: • Safety system • Alarm system • Telegraph system • Power management system
Operator inputs: • Control station selection - Bridge, Engine control room or Local control • Standby / Finished with engine
Speed set point – Filter between handle and govenor: • Slow down • Shaft generator • Controlling accelaration • Load control • Barred speed range
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
Speed Setpoint MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
4
Engine Control Unit – ECU MAN B&W Diesel
Start / stop logic • Prepare start (MOP or handle) • Repeated start, (total 3 attempts, reset by setting the handle in ’STOP’) • Start blocking • Slow turning • Manual air run
Engine speed control and limiters • Calculations of fuel index
The gov enor
• Limiters (start, max fuel all and individual, torque, scav.air, hydraulic press.) • Feed forward (pitch, PTO power)
Engine running mode control • Emission mode • Economy mode
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 13 >
2006-01-06
< 14 >
2006-01-06
< 15 >
Fuel Limiters MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
Cylinder Control Unit – CCU MAN B&W Diesel
Fuel injection control • Proportional valve • Feedback of plunger position only used for monitoring
Exhaust valve control • ON / OFF valve
FIVA VALVE
• Feedback signal for exh. Valve position, used in determination of valve timing
Cylinder lubrication • ON / OFF valve controling the alpha lubricator • Feedrate controlled in the ECU
Starting air valve control (timing of solenoid valve) • ON / OFF valve
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
5
Engine Control System CCU MAN B&W Diesel
Fiva valve, Fuel & exhaust Fuel plunger pos. feedback Exh. Spindle pos. feedback
Cylinder lubrication Starting air valve One CCU for every cylinder unit
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 16 >
2006-01-06
< 17 >
Auxiliary Control Unit - ACU MAN B&W Diesel
Control of Hydraulic Power Supply: • Engine driven pumps • Start-up pumps • Valves and pressure gauges
Individual control of aux blower: • Sequential start by different start delays • Engine contol blower / stop is decided in ECU
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
Engine Control System Auxiliary Blowers MAN B&W Diesel
Aux blower No. 1 is controlled by ACU 1 Aux blower No. 2 is controlled by ACU 2 Aux blower No. 3 is controlled by ACU 3 Aux blower No. 4 is controlled by ACU 1 Aux blower No. 5 is controlled by ACU 2
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 18 >
6
Engine Control System Hydraulic Pumps MAN B&W Diesel
El-pump 1 controlled by ACU 1 El-pump 2 controlled by ACU 2 Eng.driven pump 1 controlled by ACU 1, - Pressure controlled / follow mode
Eng.driven pump 2 controlled by ACU 2, - Pressure controlled / follow mode
Eng.driven pump 3 controlled by ACU 3, - Pressure controlled / follow mode
Eng.driven pump 4 controlled by ECU 1, - On-OFF
Eng.driven pump 5 controlled by ECU 2, - On-OFF © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 19 >
ME Starting Air System MAN B&W Diesel
MCMC-C design
MEME-C design Pilot air inlet
BlowBlow-off
NCNC-valves
Connection Connection for ECS
Starting Starting air distributor
Starting valves
Starting valves
© MAN B&W Diesel
< 20 >
Starting airand pilot air valve MAN B&W Diesel
Starting air valve
Pilot air valve
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 21 >
7
Engine Control System Control Panels MAN B&W Diesel
Bridge Control system is connected to EICU
Engine Control Room Panel is connected to EICU
Local Operating Panel LOP is connected to ECU
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 22 >
2006-01-06
< 23 >
2006-01-06
< 24 >
Main Operation Panel (MOP) MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
Main Operating Panel MOP MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
8
Main Operating Panel MOP MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 25 >
2006-01-06
< 26 >
2006-01-06
< 27 >
Local Operating Panel (LOP) with telegraph MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
Local Operating Panel (LOP) Without telegraph MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
9
Engine Control System Tacho System MAN B&W Diesel
There are 2 redundant tacho systems.
System A System B Standard is: angle encoders with one reference sensor on the flywheel (A-system)
Option is sensors at the flywheel © MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 28 >
Tacho system MAN B&W Diesel MMA Q2A
Q1A
MMB
Q1B
System A (powered from ECU A)
Q2B
MMA = Marker Master A MSA = Marker Slave A Q1A = Quadratur 1A Q2A = Quadratur 2A MSA
System B (powered from ECU B) MMB = Marker Master B MSB = Marker Slave B Q1B = Quadratur 1B Q2B = Quadratur 2B Trigger ring pos. 1
MSB
Semi-circular marking ring pos. 2
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 29 >
2006-01-06
< 30 >
ME Tacho-system MAN B&W Diesel
© MAN B&W Diesel
041104-ME 11-2003 Concept - 2500/KNB Tom Ballegaard/4140
10
ME Tacho-system MAN B&W Diesel
© MAN B&W Diesel
04-1104ME 11-2003 Concept
2500/KNB - Tom Ballegaard/4140
2006-01-06
< 31 >
2006-01-06
< 32 >
Angle encoder – 12K98ME MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
ME Tacho-system MAN B&W Diesel
• 2 redundant set of sensors. • Each set measure engine speed and crankshaft position for synkronisation of the control events. •• Each set consist of four sensors. Two quadrature sensors measure on a trigger ring with 360 tooth and two marker sensors measures on one tooth – a semicircular ring. Triggersegment with a sine-curved toothprofile The total trigger ring is build by 8 equal segments.
© MAN B&W Diesel
2200/OZS/030212 ME Concept -
Tom Ballegaard/4140
2006-01-06
< 33 >
11
Tacho sensors Nordic Brasilia – 6S70ME-C MAN B&W Diesel
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 34 >
Tacho sensors, replacement MAN B&W Diesel
Sensing distance to the highest point on the trigger / marker ring:
1.0 mm
The highest point is marked [T]
Highest point
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 35 >
2006-01-06
< 36 >
Quadratur sensor MAN B&W Diesel
Status LED
Ahead turning towards the dot
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
12
Performance curves MAN B&W Diesel
By changing the exh. Valve timing, the Pcomp can be adjusted, and then the Pmax can be kept constant in a bigger range.
The maximum pressure jump is the same as for MC engine because the combustion chambers are identical.
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 37 >
Exhaust valve timing MAN B&W Diesel
Exhaust valve movement 80 70 60 Early closing
mm
50
Late closing
40
Early opening Late opening
30
Reference
20 10 0 90
110
130
150
170
190
210
230
250
270
290
Dg. C. A. © MAN B&W Diesel
< 38 >
Pneumatic system MAN B&W Diesel
2 valves for redundancy No. 30 connected to ECU A No. 32 connected to ECU B
© MAN B&W Diesel
ME Concept - Tom Ballegaard/4140
2006-01-06
< 39 >
13
MAN B&W Diesel A/S
S70ME-C Project Guide
100
r/min
90 bar 80
20
70
18
16
MEP
Engine speed
14 bar(abs) Mean effective pressure
150
12
130
Maximum pressure
120
Cyl. Pressure
140
110
bar(abs)
4
100
90
3
P-scav
Compression pressure
deg.C 450
400 Exhaust gas temperature inlet to turbocharger
350
300 Exhaust gas temperature outlet from turbocharger
2
Exh. Gas Temp.
Scavenge air pressure
1
250 g/kWh
170 Specific fuel oil consumption
SFOC
180
160
150 50%
75%
100%
Load
1555
2333
3110
kW/cyl
178 25 61-7.0
Fig. 1.04: Performance curves
430 100 500
198 34 48
1.06
3. Hydraulic Power Supply
MAN B&W Diesel
1) System 2) Filter unit 3) Startup pumps
4) Engine driven pumps Drive system Pump principle
5) Valve block © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
The ME Engine Hydraulic Oil Loop MAN B&W Diesel
Fuel oil pressure Exhaust valve actuator booster Hydraulic cylinder unit
Fuel 10 bar ELFI
ELVA
200 bar
Alpha lubricator Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU
Cyl. 5 CCU Cyl. 6 CCU
Safety and Accumulator blok
Fine aut. filter Main lube pump
Servo oil
Piston cooling + bearings Servo oil return to sump From sump
ISO 4406: 13/16 NAS Code: 7
© MAN B&W Diesel
L/73273-7.1/0403
(2600/RØL)
Engine driven hydraulic pumps
EL. driven hydraulic pumps 2006-01-23
2006-01-23
Separat hydraulic system MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
1
Filter Unit, Schematic MAN B&W Diesel
Old plants = 10 µ New plants = 6 µ
© MAN B&W Diesel
¾ Older plants are equipped with a by25 µ
pass valve which opens at 0.8 bar after the filter
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
2006-01-23
2006-01-23
Filter unit MAN B&W Diesel
Single filter unit
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Filter unit MAN B&W Diesel
Filtering process © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Back flushing process
2
Backflushing line to Lub. Oil tank MAN B&W Diesel
¾ The purifier suction pipes have the same diameters but a different lenght. ¾ The purifier will suck primarily from the sump tank. ¾ The oil level in the 2 tanks will remain more or less equal due to the interconnection. ¾ When servo oil is back-flushed from the filter, the oil level in the servo oil tank will increase, and the purifier will suck from this tank until the level in the 2 tanks are equalized again. Then the suction will take place from the sump tank again.
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
2006-01-23
2006-01-23
Start up pumps, fixed MAN B&W Diesel
P2
P1
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Start up pumps, fixed MAN B&W Diesel
Automatic mode: ¾ Stopped at Finish With Engine. ¾ Master pump running at engine standby. (both pumps are running during pressure build up). ¾ Stopped via a timer at a specified engine RPM
Manual mode: ¾ Controlled by the operator via the Main Operating Panel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
3
El-driven pumps MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 10 >
2006-01-23
< 11 >
Engine driven pumps MAN B&W Diesel
P2
P1
Sensors for suction pressure. Low pressure = shut down © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Engine driven pumps MAN B&W Diesel
Automatic mode: ¾ The pressure set point is depending on the engine load. ¾ The pumps have two running modes, 1 in pressure control mode [Ctrl] (selected via the MOP screen), 2 in follow mode [Folw]. ¾ The [Ctrl] pump is running 50% and compensates immediately for deviations between actual pressure and set point. Over time the [Folw] pumps will take over the compensation while the [Ctrl] pump goes back to 50 %. ¾ In case the pressure controlling pump faces a failure, one of the other pumps will take over pressure control.
Manual mode: ¾ The pressure set point is set by the operator
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 12 >
4
Engine driven pumps MAN B&W Diesel
¾In case of control failure of a pump, the swash plate will be forced to maximum capacity in AHEAD direction. ¾Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3. ¾Pump Nos. 1, 2, and 3 have their own sensor for system pressure, connected to their controlling ACU ¾Pump Nos. 4 and 5 are controlled by a binary signal, either max capacity AHEAD or ASTERN. No. 4 is controlled from ECU A, and No. 5 from ECU B. ¾All pumps have sensors for suction pressure. If the pressure is to low, or all sensors are failing, a SHUT DOWN will be activated. © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 13 >
2006-01-23
< 14 >
Leak detection MAN B&W Diesel
Shut down level Alarm level © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Leak detection MAN B&W Diesel
Box for hydraulic pumps
Drainpipe
Sensor LS 1235 & JS 1236, ”vibrating fork” type. LS 1235 = Alarm
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
LS 1236 = Cancelable Shut Down
2006-01-23
< 15 >
5
© MAN B&W Diesel
Alarm level
MAN B&W Diesel
2006-01-23
Sensors for suction pressure. Low pressure = shut down
Hydraulic power supply - Tom Ballegaard/4140
Shut down level
Engine driven pumps
< 13 >
Engine driven pumps MAN B&W Diesel
Alarm level
Shut down level
© MAN B&W Diesel
Sensors for suction pressure. Low pressure = shut down
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 16 >
2006-01-23
< 17 >
2006-01-23
< 18 >
7S50ME-C Gear Box for HPS MAN B&W Diesel
Output wheel ……………… Intermediate wheel………………. Connections wheel…………… Gearwheel on crankshaft… Two rows of gears, one is spare. Spacer………..
Gear ratio - 12:1
© MAN B&W Diesel
ME – Engine, Pump Drive and Moment Compensator MAN B&W Diesel
© MAN B&W Diesel
L/73898-1.0/0303
(2600/RØL)
6
Chain tightener MAN B&W Diesel
Pressure: 70ME: 1500 bar 98ME: 2200 bar
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 19 >
2006-01-23
< 20 >
ME – Engine, Pump Drive MAN B&W Diesel
Hydraulic Pump
Step Up Gear
Chain wheel for 4” Duplex chain
© MAN B&W Diesel
Pump shaft principle MAN B&W Diesel
Gear end
High friction disc Pump end
© MAN B&W Diesel
2006-01-23
< 21 >
7
12K98ME(-C) HPS MAN B&W Diesel
Design of Hydraulic Power Supply (HPS)
• Mounting of HPS • Structure of HPS and Framebox • Design of components
© MAN B&W Diesel
2500/KNB
November 2003.
2006-01-23
< 22 >
2006-01-23
< 23 >
K98ME(-C) Pump drive MAN B&W Diesel
© MAN B&W Diesel
2510/ERA
Nov. 2003.
ME(-C) Hydraulic Power Supply MAN B&W Diesel
© MAN B&W Diesel
05-02-2004
(2500/KNB)
< 24 >
8
K98ME(-C) HPS MAN B&W Diesel
8-12K98ME/C
© MAN B&W Diesel
2510/ERA
< 25 >
Nov. 2003.
10-12K98ME/ME-C new design MAN B&W Diesel
5 x 500 ccm pumps Fore side
Aft side
© MAN B&W Diesel
2006-01-23
< 26 >
2006-01-23
< 27 >
8-9K98ME/ME-C new design MAN B&W Diesel
4 x 500 ccm pumps Fore side
© MAN B&W Diesel
Aft side
9
Axial piston pumps, principals MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 28 >
Axial piston pumps, principals MAN B&W Diesel
A: Swash plate
D: Pressure side
B: Cylinder block
R: Suction side
C: Distibutor valve
h: Stroke α: Swash plate angle Animation.lnk
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 29 >
2006-01-23
< 30 >
Axial piston pump MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
10
Axial piston pump MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 31 >
Engine driven pumps, Nordic Brasilia – 6S70ME-C MAN B&W Diesel
Pump
Sensor for suction pressure
Suction line
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 32 >
Engine driven pumps, Nordic Brasilia – 6S70ME-C MAN B&W Diesel
Feed back, swash plate
Feed back, pilot valve
Pilot valve for swash plate control
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 33 >
11
Engine driven pump, mechanical indication MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 34 >
2006-01-23
< 35 >
2006-01-23
< 36 >
Engine driven pump – 750 ccm MAN B&W Diesel
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
Engine driven pump dismantling MAN B&W Diesel
2.
1.
Weight: 500 ccm pump: 185 kg 750 ccm pump: 460 kg © MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
12
Valve block MAN B&W Diesel
To hydraulic cylinder unit (HCU)
P2 pressure
311 Safety valve. 10 – 12 cyl. 90 – 98 bore have 2 valves, one on each valve block
Safety system for leaking high pressure inner pipe
LPS From filter unit
© MAN B&W Diesel
Hydraulic power supply - Tom Ballegaard/4140
2006-01-23
< 37 >
2006-01-23
< 38 >
2006-01-23
< 39 >
K98ME/-C new design MAN B&W Diesel
Modulated Accumulator block Divided into fore and aft section Double wall substituted by flexible hoses Pump mounted N2_Accumulator (Pump depent)
© MAN B&W Diesel
K98ME/-C new design MAN B&W Diesel
Modulated Accumulator block Top mounted Fore section
Top mounted Aft section
© MAN B&W Diesel
13
Valve block, Fore, new design MAN B&W Diesel
Fore section Adaption flange (Engine depent)
Primary block, (Basic for all engines 60-98ME/-C)
Inlet block (Pump-depent: 2 or 3 ports)
© MAN B&W Diesel
2006-01-23
< 40 >
2006-01-23
< 41 >
Valve block, Aft, new design MAN B&W Diesel
Aft section Adaption flange (Engine depent)
Slave block, (Basic for all engines with middle chain drive 80-98ME/-C)
Inlet block (Pump-depent: 2 or 3 ports)
© MAN B&W Diesel
14
4. Hydraulic Cylinder Unit
MAN B&W Diesel
1) Distributor block 2) Komponents: FIVA Accumulators Cylinder lubricator 3) Highpressure pipes
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
2006-01-19
2006-01-19
Hydraulic Cylinder Unit HCU MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
Hydraulic Cylinder Unit HCU MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
1
ME(-C) Hydraulic Cylinder Unit MAN B&W Diesel
© MAN B&W Diesel
05-02-2004
(2500/KNB)
ME(-C) Hydraulic cylinder Unit (FIVA)
MAN B&W Diesel
© MAN B&W Diesel
03-11-2003
(2500/KNB)
FIVA MAN B&W Diesel
FIVA Degree Crank angle
-20
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
Injection start (0) Injection End (20) Exhaust valve open (110) Exhaust valve Close (270)
Approximate timing of events to be carried out by the FIVA valve On an ME- engine the timing of injection is variable and this is just an example.
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
2
Accumulator MAN B&W Diesel
1. Assemble without the diaphragm. Make the mark 1.
2.
© MAN B&W Diesel
2. Assemble with the diaphragm. Tighten until the ofset D06-216 is achieved
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
2006-01-19
2006-01-19
Accumulator Nitrogen check MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
Cylinder lubricator system MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
3
Cylinder lubricator system MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 10 >
Alpha Lubricator for MEME-Engine MAN B&W Diesel
Cylinder lub. oil inlet
Inductive proximity sensor for feed-back signal to control of piston movement
Signal for lubrication from controller
Level sensor for cylinder oil in lubricator
Outlets for cylinder liner lub. oil injectors
Injection plunger
Spacer for basic setting of pump stroke Non-return valve
Drain oil outlet
Stroke adjusting screw
200 bar system oil supply Actuator piston
Sealingring © MAN B&W Diesel
3331377/20041021 Hydraulic Cylinder
Unit (2200/OZS) - Tom Ballegard/4140
2006-01-19
< 11 >
Cylinder Lubricator MAN B&W Diesel
HCU Distributorblock
Cylinder lubricator
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 12 >
4
Cylinder Liners MAN B&W Diesel
Injection nozzle
Injection nozzle with non-return valve
© MAN B&W Diesel
3331050/20031212
Cylinder liner
(CBO/4100)
Cylinder Lubrication Demands MAN B&W Diesel
The purpose of the cylinder lubrication is as follows: (SL 05-455/HRJ) 1.
To create a hydrodynamic oil film seperating the piston rings from the liner, The oil amount needed to create an oil film is more or less independent of the fuel oil being used. The optimum is kept safely down to a feedrate of 0.55 g/kWh.
2.
To clean the piston rings, lands and ring grooves, This relies on the detergency properties of the cylinder oil. All approved cylinder oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh.
3.
To control corrosion, i.e. control the neutralisation af sulphuric acid. The combustion process creates highly corrosive sulphuric acids depending on the sulphur in the fuel. It has therefore been of paramount importance to design the combustion chamber and the cylinder oil so as to create the optimum balance of corrosion.
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 14 >
Adaptive Cylinder oil Control ACC (Service Letter SL05-455) MAN B&W Diesel
The ACC system feeds the oil proportionately to the engine load (which is proportional to the fuel oil being burnt), and to the sulphur content in the fuel.
By dosing the amount of cylinder oil and, thereby, the amount of alkaline additives proportionately to the total sulphur amount beeing burnt in the combustion chamber, a constant low corrosion level can be achieved.
The experience gained so far from a large number of vessels operating at a feed rate factor of 0.34 g/kWh x S% has been very positive.
Long term tests with first 0.29 g/kWh x S%and later 0.26 g/kWh x S% have been succesful, indicating that an optimum lubrication level is witin the following algoritm:
F x S% where ”F” is in the range of 0.26 to 0.34 g/kWh
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 15 >
5
Adaptive Cylinder oil Control ACC (Service Letter SL05-455) MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 16 >
2006-01-19
< 17 >
2006-01-19
< 18 >
Auxiliaries: Cylinder Lubricators MAN B&W Diesel
Minimum feed rate
Sulphur % (0 – 5 %)
Feed rate factor ”F”
(0.5 – 2.0 g/kWh)
(0.25 – 1.5)
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
Adjustment of cylinder oil lubrication MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
6
© MAN B&W Diesel
MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
Adjustment of cylinder oil lubrication
2006-01-19
< 18 >
ME Lubrication Back Up Signal
S903-0031
In case of CCU failure (and the CCU can not be changed immediately), activation of the ME lubricator can be achieved as follows. Note: In case of CCU failure, the engine is running at “Slow Down” mode. A temporary cable from ECU A or B plug J52 is connected to solenoid valve on the lubricator of the failing CCU. See figure 1. The activation signal from J52 on ECUA/B is random.
LUBRICATOR ACTIVATION BACK UP
Fig. 1
OVDC GND IN/OUT v_IN 24VDC
SOLENOID VALVE LUBRICATOR
0
1
2
3
4
5
6
7
8
9
+ECU A/B
A B C D C
+ECU A/B
J52
ME lubricator
/
A1
1
2
/
A2
=SOLENOID VALVE
S9030031C01
1x2x0,75 mm² WLUB_BACK UP
SOLENOID VALVE LUBRICATOR
When referring to this page, please quote S-Instruction S903 Edition 0031 MAN B&W Diesel A/S
Page 1
Emergency cylinder lubrication MAN B&W Diesel
© MAN B&W Diesel
9
In case of CCU failure, where the CCU cannot be changed immediately, the cylinder lubrication can be achieved by a temporary cable from one of the ECU units, plug 52, to the solenoid valve on the lubricator on the unit in question.
9
The lubrication will be with random timing.
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 19 >
2006-01-19
< 20 >
Emergency cylinder lubrication MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
Hydraulic Cylinder Unit L70ME
HCU Distributer block Double wall pipe Double wall pipe
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 21 >
7
HCU - Valves MAN B&W Diesel
Instructions Valve No.
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 22 >
Hydraulic Cylinder Units (HCU) MAN B&W Diesel
HCU’s mounted on an common base plate.
Double wall high pressure pipe High pressure oil inlet from the HPS
© MAN B&W Diesel
Hydraulic Cylinder Units MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 24 >
8
HCU return oil pipes MAN B&W Diesel
Double bottom base plate for HCU. Return oil from the HCUs is collected here and via the vertical pipes led back to the crankcase.
Return pipes from HCU
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 25 >
2006-01-19
< 27 >
ME-C Engines Doubble Wall Pipe MAN B&W Diesel
1.
Flange
2.
Outer Pipe
3.
Inner Pipe
4.
Sealing ring
5. Sealing ring 6. Sealing ring 7. Sealing ring 8. Screw
© MAN B&W Diesel
0902
(2600/RØL)
Tool for high pressure doublepipe MAN B&W Diesel
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
9
Two-Stroke Diesel Engines. MAN B&W Diesel
© MAN B&W Diesel
2500/KNB
April 2003.
Two-Stroke Diesel Engines. MAN B&W Diesel
© MAN B&W Diesel
2500/KNB
April 2003.
Two-Stroke Diesel Engines. MAN B&W Diesel
© MAN B&W Diesel
2500/KNB Hydraulic
April 2003. Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 30 >
10
Hydraulic Cylinder Unit (HCU) Leakage MAN B&W Diesel
Fuel oil pressure booster
Exhaust valve actuator Hydraulic cylinder unit
Unit 1
© MAN B&W Diesel
Unit 2
Safety and Accumulator Block
ELVA
ELFI
Unit 3
Unit 4
Unit 5
Unit 6
Hydraulic Cylinder Unit - Tom Ballegard/4140
Valve 315
2006-01-19
< 31 >
Hydraulic Cylinder Unit (HCU) Leakage MAN B&W Diesel
HCU
Leakage check between 2 HCUs: • Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block. • Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between. • Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining. • Mount a pressure gauge on minimesh coupling 435. • Close valve 315, and build up pressure in the inner pipe with the start-up pumps. • If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If not, try the next pipe! © MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
< 32 >
1
HCU
© MAN B&W Diesel
Hydraulic Cylinder Unit - Tom Ballegard/4140
2006-01-19
• If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If not, try the next pipe!
• Close valve 315, and build up pressure in the inner pipe with the start-up pumps.
• Mount a pressure gauge on minimesh coupling 435.
• Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining.
• Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between.
• Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block.
Leakage check between 2 HCUs:
MAN B&W Diesel
Hydraulic Cylinder Unit (HCU) Leakage
< 32 >
2
Therefore, we have revised our Guiding Cylinder Oil Feed Rates (see enclosures 1-3) for the purpose of optimising the cylinder lube oil consumption (CLOC). Cylinder lubrication demands The purpose of cylinder lubrication is as follows: 1. to create a hydrodynamic oil film separating the piston rings from the liner, 2. to clean the piston rings, ring lands and ring grooves, 3. to control corrosion, i.e. control the neutralisation of sulphuric acid. Re 1: The oil amount needed to create an oil film is more or less independent of the fuel oil being used. Measurements of the oil film have also revealed that when the feed rate for optimum oil film is reached, no further increase of the oil film is obtained from an increase of the feed rate. This optimum is kept safely down to a feed rate of 0.55 g/kWh. Re 2: Cleaning of piston rings, ring lands and grooves is essential, and relies on the detergency properties of the cylinder oil. All approved cylinder oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh. Re 3: The combustion process creates highly corrosive sulphuric acids depending on the sulphur in the fuel. It has therefore been of paramount importance to design the combustion chamber and the cylinder lube oil so as to create the optimum balance of corrosion. Cylinder lubrication dosage The optimal corrosion control is achieved by a combination of the cooling water design of the cylinder liner, the sulphur content in the fuel, the cylinder lube oil alkalinity, and our new lubrication principle, the ACC algorithm system (Adaptive Cylinder oil Control). The ACC system feeds the oil proportionately to the load (which is proportional to the fuel oil amount being burnt) and to the sulphur content in the fuel. By dosing the amount of oil and, thereby, the amount of alkaline additives proportionately to the total sulphur amount being burnt in the combustion chamber, a constant and controlled low corrosion level can be achieved. The experience gained so far from a large number of vessels operating at a feed rate factor of 0.34 g/kWh x S% has been very positive. However, long term tests with, first 0.29 g/kWh x S% and later 0.26 g/kWh x S% have been successful, indicating that an optimum lubrication level is within the below algorithm: F x S%, where “F” is in the range of 0.26 to 0.34 g/kWh
3
ACC algorithm with a BN 70 cylinder oil: 1.70 1.60 1.50 1.30 1.20 1.10 1.00 0.90 0.80
, 70 BN
Average dosage: 0.8 g/kWh
Fx
he ,w % S
r
= eF
[0.
/k W 4]g 3 . 0 26-
h
0.70 0.60
Average sulphur worldwide
Absolute dosage (g/kWh)
1.40
0.50 0.40 0.30 0.20 0.10 0.00 0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Sulphur %
On the world market, the average sulphur content in fuels for large two-stroke engines is 2.7%. This would result in an average cylinder oil dosage of around 0.8 g/kWh. The 0.8 g/kWh multiplied with the yearly production of kWh can be directly used in the calculation of the yearly cylinder oil consumption. The ACC principle, with the algorithm F x S% where “F” is in the range of 0.26-0.34 g/kWh, satisfies the need for neutralising additives. However, due to the physical need for a certain amount of oil to create a hydrodynamic oil film, the present lower limit is set in the range of 0.60-0.70 g/kWh, which according to the above diagram will be reached with around 2% sulphur. Running on fuels with a varying sulphur content Although fuel sulphur levels above 4% are rather rare, running on high-sulphur fuels has accounted for a major part of cylinder wear in the past. Therefore, increasing the oil dosage according to the ACC algorithm is necessary, and very beneficial economically, to prevent the excessive wear associated with such fuels. However, on low-sulphur fuels, below 2% sulphur content, the engine will, according to the above diagram, be overdosed with alkaline additives. This may lead to cylinder condition problems and, in severe cases, to scuffing.
4
Overdosing with alkaline additives has two negative effects, which may both lead to the so-called “bore-polish” phenomenon: •
A surplus of alkaline additives has a strong tendency to accumulate on the piston top land, and may grow in thickness to an extent where it interferes with the cylinder liner running surface, in spite of the PC ring (piston cleaning ring). This is most pronounced in the middle and lower part of the liner (where the liner is exposed the least to heat) and in the exhaust side (where the PC-ring is less effective). The result of this negative effect is called mechanical bore-polish.
•
The other negative effect of overdosing with alkaline additives may be that corrosion (so-called cold-corrosion) is suppressed completely, thereby, limiting the necessary “refreshment” (open graphite structure) of the liner surface. The result of this is called chemical bore-polish. In other words, corrosion should be controlled rather than prevented.
The occurrence of the above negative effects is time-dependent. This means that a surplus of alkaline additives can be accepted for a certain period, depending on the severity of the overdosing. For example: when running on a fuel with 1% sulphur and using a normal BN 70 cylinder oil, theoretically, a dosage in the range of 0.26 to 0.34 g/kWh is called for according to the ACC algorithm. However, in order to fulfil the lower limit set at 0.600.70 g/kWh for hydrodynamic reasons, the amount of additives applied is consequently higher than needed. Such overdosing of alkaline additives should be limited to one or two weeks, and to temporary running on low-sulphur fuels in restricted areas. If low-sulphur fuels are used predominantly, we advise using a low-BN cylinder oil, either a BN 40 or BN 50 oil. The diagram overleaf shows the algorithm using a BN 40 cylinder oil versus a “normal” BN 70 cylinder oil.
5
ACC algorithm with BN 40 versus BN 70 cylinder oils 1,70 1,60 1,50
Absolute dosages (g/kWh)
1,40 1,30 1,20 1,10 1,00 0,90 0,80
BN
0,70
,F 40
x
h ,w % S
e er
F
=
0 /4 70
x
[
34 0. 26 0.
,F 70 N B
x
W /k ]g
h
F ere h ,w S%
=[
h kW ]g/ 4 .3 6 -0 0.2
0,60 0,50 0,40 0,30 0,20 0,10 0,00 0
1
2
3
4
5
Sulphur %
Experience has shown that satisfactory running on fuels containing almost no sulphur (gas oil, kerosene, etc.) can be obtained using a low-BN cylinder oil. If a BN 40 cylinder oil is used, the ACC algorithm should be: F x 70/40 x S%, where “F” is in the range of 0.26-0.34 g/kWh If low-sulphur fuels are bunkered regularly, in-between normal or high-sulphur fuels, a two-tank system should be considered, offering the possibility of changing between lowBN and normal-BN cylinder oils. Questions or comments regarding this SL should be directed to our Dept. 2300. Yours faithfully MAN B&W Diesel A/S
Carl-Erik Egeberg Encl.
Ole Grøne
Encl. 1 for SL05-455/HRJ
Guiding Cylinder Oil Feed Rates S/L/K-MC/MC-C/ME/ME-C, Mk 6 and higher, with Alpha ACC lubrication system
Basic setting
Standard BN 70 cylinder oil
BN 40 cylinder oil
0.26-0.34 g/kWh x S% 0.19-0.25 g/bhph x S%
0.26-0.34 g/kWh x 70/40 x S% 0.19-0.25 g/bhph x 70/40 x S%
Minimum feed rate
0.60-0.70 g/kWh 0.45-0.50 g/bhph
Maximum feed rate during normal service
1.7 g/kWh 1.25 g/bhph
Part-load control
Running-in new or reconditioned liners and new piston rings
Feed rate:
Proportional to engine load Below 25% load, proportional to MEP (Mean Effective Pressure) Alu-coated or hard-coated piston rings: Non-coated:
Engine load:
First 5 hours: From 5 to 250 hours: From 250 to 500 hours: First 15 hours: From 15 to 250 hours: From 250 to 500 hours:
1.7 g/kWh 1.5 g/kWh 1.2 g/kWh 1.7 g/kWh 1.5 g/kWh 1.2 g/kWh
Alu-coated or hard-coated piston rings:
Stepwise increase to max. load over 5 hours
Non-coated:
Stepwise increase to max. load over 15 hours
Running-in new rings in already run-in and well running liners:
Alu-coated or hardcoated piston rings Non-coated rings Feed rate
Manoeuvring and load change situations.
During starting, manoeuvring and load changes, the feed rate should be increased by 25% and kept at this level for ½ hour after the load has stabilised.
Lubrication of cylinders that show abnormal conditions:
Frequent scavenge port inspections of piston rings and cylinder liners are very important for maintaining a safe cylinder condition. If irregularities are seen, adjustments of the lube oil rate should be considered. In case of scuffing, sticking piston rings or high liner temperature fluctuations, the feed rate should be raised by 25-50%.
HRJ/JCB September 2005
: No load restrictions : Stepwise increase to max. load over 5 hours : Basic setting +25% for 24 hrs.
Encl. 2 for SL05-455/HRJ
Adjusting Alpha Lub. using ACC, BN 40 Cylinder Oil ACC factor g/kWh x S% 0,26
0,27
0,29
0,30
0,31
0,33
0,34
g/kWh
HMI setting
0 1,1 1,1 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0
0 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,9 2,9
0,61 0,61 0,65 0,71 0,77 0,83 0,89 0,95 1,01 1,07 1,13 1,19 1,25 1,31 1,37 1,43 1,49 1,55 1,61 1,73 1,70
56 56 60 66 71 77 82 88 93 98 104 109 115 120 126 131 137 142 148 160 156
Sulphur content % 0 1,4 1,5 1,6 1,7 1,8 2,0 2,1 2,2 2,4 2,5 2,6 2,8 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8
HRJ/JCB September 2005
0 1,3 1,4 1,5 1,6 1,8 1,9 2,0 2,1 2,3 2,4 2,5 2,6 2,8 2,9 3,0 3,1 3,3 3,4 3,5 3,6
0 1,2 1,3 1,4 1,5 1,7 1,8 1,9 2,0 2,1 2,3 2,4 2,5 2,6 2,7 2,9 3,0 3,1 3,2 3,3 3,4
0 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,2 2,3 2,4 2,5 2,6 2,7 2,8 3,0 3,1 3,2 3,2
0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1
Encl. 3 for SL05-455/HRJ
Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil ACC factor g/kWh x S% 0,26
0,27
0,29
0,30
0,31
0,33
0,34
g/kWh
HMI setting
0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5
0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5
0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,65 0,68 0,71 0,75 0,78 0,82 0,85 0,88 0,92 0,95 0,99 1,02 1,05 1,10 1,12 1,16 1,19 1,22 1,26 1,29 1,33 1,36 1,39 1,43 1,46 1,50 1,53
56 56 56 56 56 56 56 56 56 56 56 59 63 66 69 72 75 78 81 84 88 91 94 97 100 103 106 109 113 116 119 122 125 128 131 134 138 141
Sulphur content % 0,0 0,5 1,0 1,1 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,5 2,6 2,8 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8 3,9 4,1 4,2 4,3 4,5
HRJ/JCB September 2005
0,0 0,5 1,0 1,1 1,2 1,4 1,6 1,8 2,0 2,2 2,3 2,4 2,5 2,6 2,8 2,9 3,0 3,1 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,3 4,4 4,5
0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,6 1,8 2,0 2,1 2,3 2,4 2,5 2,6 2,7 2,9 3,0 3,1 3,2 3,3 3,5 3,6 3,7 3,8 3,9 4,0 4,2 4,3 4,4 4,5
0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,6 1,8 1,9 2,0 2,2 2,3 2,4 2,5 2,6 2,7 2,8 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5
0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,8 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,5
5. Fuel System
MAN B&W Diesel
1) Fuel oil pressure booster 2) Adjustments
© MAN B&W Diesel
2006-01-26
ME Fuel Oil Pressure Booster MAN B&W Diesel
S50MCS50MC-C
S50MES50ME-C
Fuel Plunger
Suction Valve
Fuel oil oil inlet pressure 8 bar
Feed back Position sensor
Hydraulic actuator
7S50ME7S50ME-C
© MAN B&W Diesel
2006-01-26
2006-01-26
98ME(-C) Fuel Oil Pressure Booster MAN B&W Diesel
© MAN B&W Diesel
01-10-2003
(2500/KNB)
1
Fuel Injection System MAN B&W Diesel
High pressure pipe Suction valve
Slide Fuel valve
Fuel plunger Fuel oil inlet 8 bar Hydraulic piston Membrane accumulator
ELFI / FIVA Proportional Valve
7S50ME7S50ME-C To drain
High pressure hydraulic oil - inlet
© MAN B&W Diesel
2006-01-26
Fuel Oil Injection MAN B&W Diesel
Phase 1 1.
The pistons move to the bottom position.
2.
The fuel inlet is open.
3.
Hydraulic oil leaves the hydraulic oil chamber via the ELFI valve.
4.
The accumulators are supplied by the Hydraulic Power Supply. The pressurised hydraulic oil is held back by the closed ELFI valve.
ELFI Valve
Unpressurised fuel oil Pressurised fuel oil Unpressurised hydraulic oil Pressurised hydraulic oil
© MAN B&W Diesel
2006-01-26
Fuel Oil Injection MAN B&W Diesel
Phase 2 5.
The ELFI valve is activated upwards, closing the return flow and opening for the flow of pressurised hydraulic oil. The oil passes through the ELFI valve and fills the hydraulic chamber.
6.
The high pressure forces the pistons upwards.
7.
The fuel oil inlet is closed.
8.
The pressure on the fuel oil rises and exceeds the force of the spring in the cylinder’s fuel injection valve.
ELFI Valve
Unpressurised fuel oil Pressurised fuel oil Unpressurised hydraulic oil Pressurised hydraulic oil
© MAN B&W Diesel
2006-01-26
2
Fuel index adjusment MAN B&W Diesel
Index offset at 100 % load
Index offset at 0 % load
Individual Chief limiter
© MAN B&W Diesel
2006-01-26
Adjustment of maximum pressure MAN B&W Diesel
Timing of fuel injection (corresponding to VIT adjustment on the MC engine)
© MAN B&W Diesel
2006-01-26
Hydraulic Cylinder Unit L70ME MAN B&W Diesel
Hydraulic pushrod
Exh. Valve actuator Fuel Oil Pressure Booster
Double wall pipe
© MAN B&W Diesel
Fuel oil pressure booster - Tom Ballegaard/4140
2006-01-26
3
Fuel Oil Pressure Booster, S70ME MAN B&W Diesel
© MAN B&W Diesel
Fuel oil pressure booster - Tom Ballegaard/4140
2006-01-26
< 10 >
2006-01-26
< 11 >
2006-01-26
< 12 >
Suction Valve, S70ME MAN B&W Diesel
© MAN B&W Diesel
Fuel oil pressure booster - Tom Ballegaard/4140
Fuel Oil Pressure Booster Maintenance manual, S70ME MAN B&W Diesel
Fuel pump: • Pump housing nuts, tightening torque:
1000 Nm
• Pump housing, weight:
160 kg
• Top cover studs, screwing in torque:
270 Nm
• Fuel pump complete, weight:
322 kg
• Hydraulic plunger, weight:
38 kg
Top cover: • Top cover nuts, tightening torque:
410 Nm
• Outlet seat, max grinding diameter:
26 mm
• Top cover, weight:
124 kg
Suction valve: • Suction valve, tightening torque:
© MAN B&W Diesel
Fuel oil pressure booster - Tom Ballegaard/4140
460 Nm
4
Fuel Oil Pressure Booster, K98ME MAN B&W Diesel
© MAN B&W Diesel
Fuel oil pressure booster - Tom Ballegaard/4140
2006-01-26
< 13 >
2006-01-26
< 14 >
2006-01-26
< 15 >
Suction Valve, K98ME MAN B&W Diesel
© MAN B&W Diesel
Fuel Oil Pressure Booster Maintenance manual, K98ME MAN B&W Diesel
Fuel pump: • Hydraulic pressure mounting:
2200 bar
• Hydraulic pressure dismantling:
2000 – 2400 bar
• Booster housing, weight:
260 kg
• Booster complete, weight:
700 kg
• Hydraulic plunger, weight:
70 kg
Top cover: • Fuel plunger weight:
35 kg
• Top cover, weight:
260 kg
Suction valve: • Suction valve, tightening torque:
© MAN B&W Diesel
1165 Nm
5
6. Exhaust System
B&W MAIN OFFICE COPENHAGEN
ME EXHAUST VALVE
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
2006.01.16
(4140 / PWN)
MAN B&W Diesel
2006.01.16
(4140 / PWN)
© MAN B&W Diesel
1
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
MAN B&W Diesel
Hydraulic push rod
Exhaust valve Actuator
Exhaust valve spindle
High pressure hydraulic oil – inlet ELVA on-off valve
Membrane accumulator
To drain © MAN B&W Diesel
2006.01.16
(4140 / PWN)
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 10 >
The ME Engine Exhaust Valve Timing
ME Exhaust Valve & Actuator MAN B&W Diesel
MAN B&W Diesel
mm 80
Early opening Late opening
Reference
Early closing Late closing
70 60 50 40 30 20 10 0 90 110 130 150 170 190 210 230 250 270 290 Dg. C. A. © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 11 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 12 >
2
Hydraulic Cylinder Unit
Hydraulic Cylinder Units (HCU) MAN B&W Diesel
MAN B&W Diesel
HCU’s mounted on an common base plate. Fuel oil Pressure Booster Hydraulic Exhaust Valve Actuator
ELFI Proportional Valve
ELVA On/Off Valve
Double wall high pressure pipe
Distribution Block
High pressure oil inlet from the HPS © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 13 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 14 >
Two-Stroke Medium Bore ME – Engine, Design Concept
HCU MAN B&W Diesel
MAN B&W Diesel
HCU Unit – 60ME-C. Hydraulic pushrod
Fuel Pump
Exhaust Valve Actuator Exh. Valve actuator
Elva Elfi
ELVA valve
Alpha Lubricator
Double wall pipe
Plug Valve
Common supply of HP Oil © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 15 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 16 >
Exhaust Valve Actuator
Actuator for Exhaust Valve MAN B&W Diesel
MAN B&W Diesel
The ELVA valve which drives the actuator on the exhaust side has two positions, open or shut. Actuator
When it is opened with a binary signal from the engine control system, the hydraulic oil is forced in and pushes the pistons upwards,thus opening the engine’s exhaust valve via the hydraulic push rod.
ELVA
•
Mounted on top of the distributor block.
•
Hydraulic push rod for opening/closing the exhaust valve
•
Two-stage piston. Second stage
The pressure is permanently maintained until the ELVA valve is activated to block the pressure when the required exhaust phase is completed.
First stage
The exhaust valve is returned to its closed position by the force from the air spring.
•
High pressure oil inlet
Unpressurised hydraulic oil Pressurised hydraulic oil © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 17 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 18 >
3
S70me-c
ME Exhaust Valve
MAN B&W Diesel
MAN B&W Diesel
S50MC-C
Exhaust Actuator
S50ME-C Air spring size for closing the exhaust valve reduced
Top cover Minimesh Actuator house
Hydraulic damper for fixed valve stroke introduced
Actuator Piston New valve spindle design introduced
1. Step
2.Step
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 19 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 20 >
Exh. Valve MAN B&W Diesel
MAN B&W Diesel
Feed back sensor
Oil inlet to damper
Drain pipes
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 21 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 22 >
2006.01.16
(4140 / PWN)
< 24 >
ME Exhaust Valve MAN B&W Diesel
MAN B&W Diesel
Self-adjusting damper piston
Hydraulic nut/measuring cone Contact less sensor with integrated electronics
Outlet lube oil
Inlet lube oil Damper
Air inlet
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 23 >
© MAN B&W Diesel
4
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 25 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 26 >
Safety Valve MAN B&W Diesel
MAN B&W Diesel
Safety Valve: Adjustment of opening pressure: 21 bar
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 27 >
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 28 >
ME Exhaust valve S50MC-C
S50ME-C Air spring size for closing the exhaust valve reduced.
Hydraulic damper for fixed valve stroke introduced.
New valve spindle introduced.
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 29 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 30 >
5
Exhaust Valve Top
Exh. Valve MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 31 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 32 >
2006.01.16
(4140 / PWN)
< 34 >
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 33 >
© MAN B&W Diesel
Spindle Rotation Check MAN B&W Diesel
MAN B&W Diesel
Rod for checking spindle rotation Reaches contact with the air piston by activation.
Note! The rod must only be activated for shorter periods
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 35 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 36 >
6
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 37 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 38 >
2006.01.16
(4140 / PWN)
< 40 >
2006.01.16
(4140 / PWN)
< 42 >
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 39 >
© MAN B&W Diesel
Tightening of Damper on Exhaust Valve Spindle MAN B&W Diesel
MAN B&W Diesel
Hydraulic Jack & Support Damper Air Piston
Spindle
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 41 >
© MAN B&W Diesel
7
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 43 >
© MAN B&W Diesel
Dismantling of High Pressure Pipe
2006.01.16
(4140 / PWN)
< 44 >
Hydraulic Cylinder Unit (HCU)
MAN B&W Diesel
MAN B&W Diesel
Valve actuation Be sure that the area around the working space is completely clean before and during dismantling of the hydraulic system.
ELVA On/Off Valve Exhaust Valve Actuator
Shut off the oil supply.
Close valve 420 and open valve 421 Distribution Block © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 45 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 46 >
Dismantling of High Pressure Pipe
Hydraulic Cylinder Unit (HCU) MAN B&W Diesel
MAN B&W Diesel
Fuel injection
Valve actuation
ELFI Proportional Valve
Close the valve 531 for
Fuel Pump
the actuator oil supply
ELVA On/Off Valve Exhaust Valve Actuator
and the valve 536 for damper oil supply.
Accumulator © MAN B&W Diesel
2006.01.16
Distribution Block
(4140 / PWN)
< 47 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 48 >
8
Dismantling of High Pressure Pipe
Overhaul of High Pressure Pipe
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 49 >
© MAN B&W Diesel
Overhaul of High Pressure Pipe
2006.01.16
(4140 / PWN)
< 50 >
Mounting of High Pressure Pipe
MAN B&W Diesel
MAN B&W Diesel
Open the valve 531 for the actuator oil supply and the valve 536 for damper oil supply.
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 51 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 52 >
Exh. Valve Sealing Air / Oil Dosage Unit
Mounting of High Pressure Pipe MAN B&W Diesel
MAN B&W Diesel
Close valve 421 and open valve 420
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 53 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 54 >
9
Sealing Oil system. MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 55 >
MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 56 >
2006.01.16
(4140 / PWN)
< 58 >
MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 57 >
© MAN B&W Diesel
Exhaust Valve Sealing Oil Dosage Unit
Exhaust Valve Sealing Oil Dosage Unit
MAN B&W Diesel
MAN B&W Diesel
1. Vertical cross section, pressure low
2. Horizontal cross section, pressure low. Needle connected to output.
Spring tension 4 – 5 bar
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 59 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 60 >
10
Exhaust Valve Sealing Oil Dosage Unit
Exhaust Valve Sealing Oil Dosage Unit
MAN B&W Diesel
MAN B&W Diesel
4. Pressure decreasing. Needle charge not released yet.
3. Pressure high. Needle connected to input and charged with oil.
Spring tension 4 – 5 bar
Spring tension 4 – 5 bar
10 – 15 bar oil pressure. © MAN B&W Diesel
2006.01.16
10 – 15 bar oil pressure.
(4140 / PWN)
< 61 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 62 >
2006.01.16
(4140 / PWN)
< 64 >
2006.01.16
(4140 / PWN)
< 66 >
Exhaust Valve Sealing Oil Dosage Unit MAN B&W Diesel
MAN B&W Diesel
5. Pressure low. Needle connected to output, charge delivered.
Spring tension 4 – 5 bar
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 63 >
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
Grinding set-up for exhaust spindle.
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 65 >
© MAN B&W Diesel
11
MAN B&W Diesel
MAN B&W Diesel
Small dent marks on the seating are acceptable and need NOT to be ground away if they don’t make blow-by.
K98MC/ME
Small dent marks on the spindle seating are acceptable and need NOT to be ground away if they don’t make blow-by. © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 67 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 68 >
2006.01.16
(4140 / PWN)
< 70 >
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 69 >
© MAN B&W Diesel
MC EXHAUST VALVE MAN B&W Diesel
MAN B&W Diesel
Bottom piece for engine types: K/L/S-MC/-C/-S 1983 - 1992: 26 - 50 MC 60 - 90 MC
Cooled Alloy 50 Cooled Stellite 6
1992 – 1997: 26 - 50 MC Cooled Alloy 50 60 - 90 MC Semi-cooled hard. steel
1997 - 2000: 26 - 42 MC Cooled hard.steel 46 - 98 MC Semi-cooled hard. steel
2000 – : 26 - 42 MC 46 - 98 MC
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 71 >
© MAN B&W Diesel
2005.05.25
4140/PWN
Cooled W-seat Semi-cooled W-seat
< 72 >
12
MAN B&W Diesel
Exhaust Valve Spindle & Bottom Piece 98MC/MC-C – 26MC
MC EXHAUST VALVE Chamber seat
MAN B&W Diesel
The longer lifetime on the seat area is achieved with the new geometry of the W-seat, which retains the temperature reducing features of the chamber seat and combines them with the benefit of the two narrow concentric contact areas.
W-seat
The effect is that all carbon particles which are trapped between the spindle and bottom piece are crushed and squeezed out and therefore eliminated without giving rise to any appreciable risk dents.
The spindle and seat are fit for further use provided that : • There is contact along the entire inner circumference of the seat. • There are no blow-by tracks across the inner part of the seats.
© MAN B&W Diesel
2005.05.25
4140/PWN
< 73 >
MAN B&W Diesel
© MAN B&W Diesel
2005.05.25
4140/PWN
< 74 >
2005.05.25
4140/PWN
< 76 >
2005.05.25
4140/PWN
< 78 >
MAN B&W Diesel
2005.05.25
4140/PWN
< 75 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
16,000 h between overhauls 60-100,000 h lifetime for spindle > 30,000 h lifetime for bottom piece
© MAN B&W Diesel
MAN B&W Diesel
2005.05.25
4140/PWN
< 77 >
© MAN B&W Diesel
13
MAN B&W Diesel
MAN B&W Diesel
If water leaks from between valve seat and cylinder cover the upper sealing ring must be changed.
If water leaks from one or both holes the lower sealing ring must be changed. © MAN B&W Diesel
2005.05.25
4140/PWN
< 79 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 80 >
Bottom Piece Design MAN B&W Diesel
MAN B&W Diesel
Exhaust Valve Small/medium bore
References of W-seats running for more than 36000 hours without any grinding and only very small dent marks New seal for bottom piece lower groove
Hole for indication of cooling water leakage from the lowermost sealing ring or gas leakage from the combustion chamber U-type sealing ring (Teflon with a spring back-up) Connect compressed air to the air spring to keep the exhaust valve closed during mounting
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 81 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 82 >
2006.01.16
(4140 / PWN)
< 84 >
Bottom Piece W-Seat MAN B&W Diesel
MAN B&W Diesel
U-Type Sealing Ring: Heat the sealing ring in 100°C hot water for at least five minutes before mounting
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 83 >
© MAN B&W Diesel
14
MAN B&W Diesel
MAN B&W Diesel
MC EXHAUST VALVE
Valve spindle for engine types: K/L/S-MC/-C/-S
Cr (0.25 mm) HVOF (0.15 mm)
Nimonic
1983 - 1992: 26 - 50 MC 60 - 90 MC
Alloy 50 Stellite 6
1992 – 2002: 26 - 50 MC S50MC / 60 - 98 MC
Alloy 50 Nimonic
2002 - : 26 - 50 MC S50MC / 60 - 98 MC
DuraSpindle Nimonic
SNCrW
Alloy 50
1983 – 1996:
Cr stem coating
Stellite 6 1996 - :
HVOF stem coating
(INCO 625 on request) © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 85 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 86 >
Exhaust Valve Nimonic Spindle MAN B&W Diesel
MAN B&W Diesel
Formation of dent marks is an inevitable consequence of service on heavy fuel oil. Dent marks may appear harmful, but will in general have no influence on the performance of the exhaust valve seat.
HVOF-coating
If indications of blow-by are found, then the seat must be ground. Vane wheel for gas driven spindle rotation
Base Material: Nimonic 80A
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 87 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 88 >
2006.01.16
(4140 / PWN)
< 90 >
Design Features MAN B&W Diesel
MAN B&W Diesel
HVOF: High Velocity Oxy-Fuel Process
Coating applied on the exhaust valve stem only
Highly wear-resistant mixture of metal carbide and super alloy
Thermally sprayed coating
Thickness: about 0.25 mm
This process is performed by:
MAN B&W Copenhagen
MAN B&W Singapore
MAN B&W Hamburg
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 89 >
© MAN B&W Diesel
15
Exhaust Valve Nimonic Spindle MAN B&W Diesel
MAN B&W Diesel
Formation of dent marks is an inevitable consequence of service on heavy fuel oil. Dent marks may appear harmful, but will in general have no influence on the performance of the exhaust valve seat.
HVOF-coating
Vane wheel for gas driven spindle rotation
If indications of blow-by are found, then the seat must be ground. Base Material: Nimonic 80A
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 91 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 92 >
2006.01.16
(4140 / PWN)
< 94 >
MC EXHAUST VALVE MAN B&W Diesel
MAN B&W Diesel
Valve spindle stem sealing ring
HVOF - ring
Cr - ring
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 93 >
© MAN B&W Diesel
MAN B&W Diesel A/S Rolled exhaust valve spindles
MC EXHAUST VALVE
MAN B&W Diesel
MAN B&W Diesel
”DuraValve”
Welding and rolling preparation of DuraSpindle
Welded Ni-base alloy
10 t
Inconel 718 / Rene220
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 95 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 96 >
16
Exhaust valve – Rolling equipment
MC EXHAUST VALVE
MAN B&W Diesel
MAN B&W Diesel
Rolled seat area of 50MC DuraSpindle
• Background The roller is pressed against a rotating spindle at a pressure of 10 tons. The combination of the deformation and the subsequent heating in the oven imparts a hardness to the interial which has not been seen before. © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 97 >
© MAN B&W Diesel
MC EXHAUST VALVE
2006.01.16
(4140 / PWN)
< 98 >
MC EXHAUST VALVE
MAN B&W Diesel
MAN B&W Diesel
Section of rolled and heat treated 35 MC DuraSpindle seat
Nimonic spindle & chamber seat, S60MC, 25.500 service hrs
DuraSpindle & chamber seat, S60MC, 33.900 service hrs
Hardness distribution of section © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 99 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 100 >
2006.01.16
(4140 / PWN)
< 102 >
MC EXHAUST VALVE MAN B&W Diesel
MAN B&W Diesel
Nimonic spindle & W-seat, S60MC, 25.500 service hrs
DuraSpindle & W-seat, S60MC,33.900 service hrs
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 101 >
© MAN B&W Diesel
17
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 103 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 104 >
2006.01.16
(4140 / PWN)
< 106 >
2006.01.16
(4140 / PWN)
< 108 >
Exhaust Valve Bottom Piece MAN B&W Diesel
MAN B&W Diesel
K98MC, K98MC-C Original design
Modified design
New tool for handling (instead of bolt assembly) 2 pcs.
Increased diameter 0.15° taper
Hardened W-seat
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
Decreased diameter
< 105 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 107 >
© MAN B&W Diesel
18
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 109 >
MAN B&W Diesel
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 110 >
2006.01.16
(4140 / PWN)
< 112 >
2006.01.16
(4140 / PWN)
< 114 >
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 111 >
MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 113 >
© MAN B&W Diesel
19
Design Features MAN B&W Diesel
MAN B&W Diesel
HVOF: High Velocity Oxy-Fuel Process •
Coating applied on the exhaust valve stem only
•
Highly wear-resistant mixture of metal carbide and super alloy
•
Thermally sprayed coating
•
Thickness: about 0.25 mm
This process is performed by: •
MAN B&W Copenhagen
•
MAN B&W Singapore
•
MAN B&W Hamburg
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 115 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 116 >
SPECIAL RUNNING CONDITIONS MAN B&W Diesel
MAN B&W Diesel
IF running with an open exhaust valve THEN…. Mount pressure gauge at “minimess” point 455 Check that the HCU is pressure free.
421 © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 117 >
© MAN B&W Diesel
SPECIAL RUNNING CONDITIONS
2006.01.16
1.
Close valve 420
2.
Open valve 421
(4140 / PWN)
< 118 >
SPECIAL RUNNING CONDITIONS
MAN B&W Diesel
MAN B&W Diesel
Connect the mini-mesh hose between top flange on actuator point 540 and point 425 at the hydraulic block
1. Open valve 420 421 © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 119 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
2. Close valve 421 < 120 >
20
98ME Special Running
98ME Special Running
MAN B&W Diesel
MAN B&W Diesel
Close valve 531 Shut off oil to damper Close valve 420
Open valve 421 Mount pressure gauge at “minimess” point 455 Check that the HCU is pressure free. © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 121 >
© MAN B&W Diesel
98ME Special Running
2006.01.16
(4140 / PWN)
< 122 >
98ME Special Running
MAN B&W Diesel
MAN B&W Diesel
Disconnect air supply to air cylinder
Drain off air pressure from air cylinder with a mandrel
Remove plug screw and mount tools to keep exhaust valve open
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 123 >
© MAN B&W Diesel
98ME Special Running
2006.01.16
(4140 / PWN)
< 124 >
98ME Special Running
MAN B&W Diesel
MAN B&W Diesel
Open damper oil supply
Reconnect air supply under air piston
Mount pressure gauge at “minimess” point 455 Check that the HCU is pressure free.
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 125 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 126 >
21
98ME Special Running
98ME Special Running MAN B&W Diesel
MAN B&W Diesel
Remove the tools which kept the Disconnect air supply to air cylinder
Open damper oil supply, valve 531
exhaust valve open and mount Reconnect air supply under air piston
the plug screw.
Open valve 420 Drain off air pressure from air cylinder with a mandrel
Close valve 421 © MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 127 >
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 128 >
MAN B&W Diesel A/S MAN B&W Diesel
Thank you for your attention Preben Noeies
© MAN B&W Diesel
2006.01.16
(4140 / PWN)
< 129 >
22
7. MOP Displays
MAN B&W Diesel
Going through all screens: ¾Alarms… ¾Engine: ¾Auxiliaries… ¾Maintenance… ¾Admin… © MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
2006-01-05
2006-01-05
Engine: Operation MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
Access Level MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
1
Engine: Status MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
2006-01-05
2006-01-05
Engine: Process Information Running Mode
MOP displays - Tom Ballegaard/4140
Engine: Process Information Speed Control
MOP displays - Tom Ballegaard/4140
2
Engine: Cylinder Load MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
2006-01-05
2006-01-05
Engine: Cylinder Pressure MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
Auxiliaries: Hydraulic System MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
3
Auxiliaries: Scavenge Air MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
< 10 >
2006-01-05
< 11 >
2006-01-05
< 12 >
Auxiliaries: Cylinder Lubricators MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
Maintenance: System View, I/O Test MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
4
MAN B&W Diesel
© MAN B&W Diesel
MAN B&W Diesel
© MAN B&W Diesel
Maintenance: System View, I/O Test ECU-A
MOP displays - Tom Ballegaard/4140
2006-01-05
< 13 >
2006-01-05
< 14 >
2006-01-05
< 15 >
Maintenance: System View, I/O Test ECU-A, Channel-35
MOP displays - Tom Ballegaard/4140
Maintenance Invalidated Inputs MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
5
Maintenance Network Status MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
< 16 >
2006-01-05
< 17 >
2006-01-05
< 18 >
Admin.: Version MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
Admin.: Set Time MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
6
Alarms: Alarm List MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
< 19 >
2006-01-05
< 20 >
2006-01-05
< 21 >
Alarms: Alarm List MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
Alarms: Event Log MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
7
Alarms: Manual Cut-Out List MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
2006-01-05
< 22 >
2006-01-05
< 23 >
Alarms: Channel List MAN B&W Diesel
© MAN B&W Diesel
MOP displays - Tom Ballegaard/4140
8
8. PMI
MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
2006-02-19
2006-02-19
2006-02-19
PMI system MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
PT diagram MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
1
PT diagram - zoomed MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
2006-02-19
2006-02-19
2006-02-19
PV diagram MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
Balanced plot, Pmax - Pcomp MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
2
Balanced plot, Pi MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
2006-02-19
2006-02-19
Calculated values MAN B&W Diesel
© MAN B&W Diesel
PMI system - Tom Ballegaard / 4140
3
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