0704 ATUC Exhaust Valve + ME

1

MAN Diesel A/S 32006.02.01 (4140 / PWN)

MAN Diesel A/S 42006.02.01 (4140 / PWN)

MAN Diesel A/S 222006.02.01 (4140 / PWN)

2

MAN Diesel A/S 23

Actuator Piston

Main Piston

Damper Piston

Distance Disc

Exhaust Valve Spindle

R0.1 max (sharp edged)

L

Crossbar (Distance: 47-51.2mm)

Orifice (0.7mm)

Piston Rings

2006.02.01 (4140 / PWN)

MAN Diesel A/S 242006.02.01 (4140 / PWN)

MAN Diesel A/S 252006.02.01 (4140 / PWN)

3

MAN Diesel A/S 26

Actuator Piston New Standard

Damper Piston

Positioning element

Main Piston

Compression pressure will beunaffected:

By grinding of the exhaust valve seating throughout the lifetime of the engine.

During cold-running of the engine.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 272006.02.01 (4140 / PWN)

MAN Diesel A/S 282006.02.01 (4140 / PWN)

4

MAN Diesel A/S 292006.02.01 (4140 / PWN)

MAN Diesel A/S 302006.02.01 (4140 / PWN)

MAN Diesel A/S 322006.02.01 (4140 / PWN)

5

MAN Diesel A/S 34

Shut off and release the air spring on the valve

Next to the engine side manoeuvring stand.

If Drop-down time within 30 minutes

Then check and overhaul.

If Drop-down time within 30 min and 1 hours

Keep under observation.

If Drop-down time more than 1 hours

OK.

Check of spindle drop-down time.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 35

Check the air spring tightness.

Connect compressed air to the air cylinder A

Disconnect return drain pipe from the oil cylinder C

Check if air is coming out from:

Oil bore B

Leakage coming from spindle stem sealing.

Hole for drain oil C

Leakage coming either from safety valve D

or

Leakage coming from air piston.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 362006.02.01 (4140 / PWN)

6

MAN Diesel A/S 38

MC EXHAUST VALVE

For new Plant Specification after April 2002

Sealing oil system - PrincipleSealing oildosage unit Consumption ~ 1l/day/cylinder

Supply fromLeak oil chamber

New air cylinder

New spindle guide

Single sealing ring

Sealing oil

2006.02.01 (4140 / PWN)

MAN Diesel A/S 392006.02.01 (4140 / PWN)

MAN Diesel A/S 40

Exhaust Valve Sealing Oil Dosage Unit

1. Vertical cross section, pressure low

2006.02.01 (4140 / PWN)

7

MAN Diesel A/S 41

2. Horizontal cross section, pressure low. Needle connected to output.


Spring tension 4 5 bar

2006.02.01 (4140 / PWN)

MAN Diesel A/S 42

3. Pressure high. Needle connected to input and charged with oil.


10 15 bar oil pressure.


2006.02.01 (4140 / PWN)

MAN Diesel A/S 43

4. Pressure decreasing. Needle charge not released yet.



10 15 bar oil pressure.

2006.02.01 (4140 / PWN)

8

MAN Diesel A/S 44

5. Pressure low. Needle connected to output, charge delivered.


2006.02.01 (4140 / PWN)

MAN Diesel A/S 452006.02.01 (4140 / PWN)


MAN Diesel A/S 46

Sealing oil / stem lubrication by controlled oil level inside the air spring housing

A minimum oil level inside the air cylinder is secured by a stand pipe to the safety valve. This ensures a controlled oil level,high enough, to have oil on top of the sealing ring.

Furthermore, a new safety valve adjustment corresponds to this high oil level (23 bar).

The oil, to the top of the sealing ring, is passing through 3 bores in flange. As a safety precaution, in case of a sealing ringleakage, an orifice is placed in each bore.

NEW Exhaust Valve Sealing Oil.

2006.02.01 (4140 / PWN)

9

MAN Diesel A/S 47

Controlled Oil Level (COL)

Safety valve adjustment 23 bar

Min. level controlled by stand pipe

Spring air/non-return valve

Sealing ring

Oil reservoir above stem sealing ring

Simplification, replaces sealing oil system

MAN Diesel A/S 48

Modification of exhaust valve with Low Spindle Guide to controlled oil level

NEW Exhaust Valve Sealing Oil.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 49

ELVA on-off valveELVA on-off valve

Exhaust valve ActuatorExhaust valve Actuator

Exhaust valve spindleExhaust valve spindle

High pressurehydraulic oil inlet

High pressurehydraulic oil inlet

MembraneaccumulatorMembraneaccumulator

Hydraulicpush rodHydraulicpush rod

To drainTo drain

2006.02.01 (4140 / PWN)

10

MAN Diesel A/S 50

ME Exhaust Valve

S50MC-CS50MC-C S50ME-CS50ME-C

Hydraulic damper for fixed valve stroke introduced

Hydraulic damper for fixed valve stroke introduced

Air spring size for closing the exhaust valve reduced

Air spring size for closing the exhaust valve reduced

New valve spindle design introducedNew valve spindle design introduced

2006.02.01 (4140 / PWN)

MAN Diesel A/S 522006.02.01 (4140 / PWN)


MAN Diesel A/S 532006.02.01 (4140 / PWN)


11

MAN Diesel A/S 54

ME Exhaust Valve & Actuator

2006.02.01 (4140 / PWN)

MAN Diesel A/S 55

The ME EngineExhaust Valve Timing

0

10

20

30

40

50

60

70

80

90 110 130 150 170 190 210 230 250 270 290Dg. C. A.

Early closingLate closing

Early openingLate opening

Referencemm

2006.02.01 (4140 / PWN)

MAN Diesel A/S 56

ME Exhaust Valve System

ELVA on-off valveELVA on-off valve

Exhaust valve ActuatorExhaust valve Actuator

Exhaust valve spindleExhaust valve spindle

To drainTo drainHigh pressure hydraulic oil inletHigh pressure hydraulic oil inlet

MembraneaccumulatorMembraneaccumulator

Hydraulicpush rodHydraulicpush rod

2006.02.01 (4140 / PWN)

12

MAN Diesel A/S 57

Hydraulic Cylinder Units (HCU)

HCUs mounted on an common base plate.HCUs mounted on an common base plate.

High pressure oil inletfrom the HPSHigh pressure oil inletfrom the HPS

Double wall high pressure pipeDouble wall high pressure pipe

2006.02.01 (4140 / PWN)

MAN Diesel A/S 58

Actuator for Exhaust Valve

The ELVA valve which drives the actuatoron the exhaust side has two positions,open or shut.

When it is opened with a binary signal from theengine control system, the hydraulic oil is forced in and pushes the pistons upwards,thusopening the engines exhaust valve via thehydraulic push rod.

The pressure is permanently maintaineduntil the ELVA valve is activated to blockthe pressure when the required exhaust phaseis completed.

The exhaust valve is returned to its closed position by the force from the air spring.

Unpressurised hydraulic oilPressurised hydraulic oil

ELVA

Actuator

2006.02.01 (4140 / PWN)

MAN Diesel A/S 59

Exhaust Valve Actuator

Mounted on top of the distributor block.

Hydraulic push rod for opening/closing the exhaust valve

Two-stage piston.Second stage

First stage

High pressure oil inlet

Mounted on top of the distributor block.

Hydraulic push rod for opening/closing the exhaust valve

Two-stage piston.Second stage

First stage

High pressure oil inlet

2006.02.01 (4140 / PWN)

13

MAN Diesel A/S 60

S70me-c

Exhaust ActuatorTop cover

Minimesh

Actuator house

Actuator Piston

1. Step

2.Step

2006.02.01 (4140 / PWN)

MAN Diesel A/S 61

Exh. Valve

Oil inlet to damper

Drain pipes

Feed back sensor

2006.02.01 (4140 / PWN)

MAN Diesel A/S 62

Self-adjusting damper pistonSelf-adjusting damper piston

Hydraulic nut/measuring coneHydraulic nut/measuring cone

Outlet lube oilOutlet lube oil

DamperDamper

Air inletAir inlet

Inlet lube oilInlet lube oil

Contact less sensor with integrated electronicsContact less sensor with integrated electronics

ME Exhaust Valve

2006.02.01 (4140 / PWN)

14

MAN Diesel A/S 632006.02.01 (4140 / PWN)

MAN Diesel A/S 64

Tightening of Damper on Exhaust Valve Spindle

Hydraulic Jack& Support

Damper

Air Piston

Spindle

2006.02.01 (4140 / PWN)

MAN Diesel A/S 652006.02.01 (4140 / PWN)

15

MAN Diesel A/S 662006.02.01 (4140 / PWN)

MAN Diesel A/S 672006.02.01 (4140 / PWN)

MAN Diesel A/S 682006.02.01 (4140 / PWN)

16

MAN Diesel A/S 692006.02.01 (4140 / PWN)

MAN Diesel A/S 70

Safety Valve

Safety Valve:Adjustment of openingpressure: 21 bar

2006.02.01 (4140 / PWN)

MAN Diesel A/S 712006.02.01 (4140 / PWN)

17

MAN Diesel A/S 722006.02.01 (4140 / PWN)

MAN Diesel A/S 73

Exh. Valve

2006.02.01 (4140 / PWN)

MAN Diesel A/S 752006.02.01 (4140 / PWN)

18

MAN Diesel A/S 762006.02.01 (4140 / PWN)

MAN Diesel A/S 77

421

If running with an open exhaust valve

THEN.

1. Close valve 420

2. Open valve 421Mount pressure gauge at

minimess point 455

Check that the HCU is

pressure free.

SPECIAL RUNNING CONDITIONS

2006.02.01 (4140 / PWN)

MAN Diesel A/S 78


Connect the mini-mesh hose between top flange on actuator

point 540 and point 425at the hydraulic block

2006.02.01 (4140 / PWN)

19

MAN Diesel A/S 79

421

2. Close valve 421

1. Open valve 420


2006.02.01 (4140 / PWN)

MAN Diesel A/S 80

98ME Special Running

Mount pressure gauge at minimess point 455

Check that the HCU is pressure free.

Close valve 420

Open valve 421

2006.02.01 (4140 / PWN)

MAN Diesel A/S 81

Close valve 531

Shut off oil to damper


2006.02.01 (4140 / PWN)

20

MAN Diesel A/S 82

Disconnect air supply to air cylinder

Drain off air pressure from

air cylinder with a mandrel


2006.02.01 (4140 / PWN)

MAN Diesel A/S 83

Remove plug screw and mount

tools to keep exhaust valve open


2006.02.01 (4140 / PWN)

MAN Diesel A/S 84

Reconnect air supply under air piston

Open damper oil supply


2006.02.01 (4140 / PWN)

21

MAN Diesel A/S 85


Mount pressure gauge at minimess point 455

Check that the HCU is pressure free.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 86


Disconnect air supply to air cylinder

Drain off air pressure from

air cylinder with a mandrel

Remove the tools which kept the

exhaust valve open and mount

the plug screw.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 87

Open valve 420


Close valve 421

Open damper oil supply, valve 531

Reconnect air supply under air piston

2006.02.01 (4140 / PWN)

22

MAN Diesel A/S 88

ME-B Engine

3333553.2006.05.11 (2200/OZS)

Hydraulicdual-Cylinder Unit

Hydraulic oil linein containment

Reduced camshaft diameter Bearings only near cams

Cam-activated exhaust valves

Fuel cams omitted

MAN Diesel A/S 89

ME-B Exhaust Valve

Dura SpindleW-seat

Exhaust valve for S35/40ME-Breused from S35MC and S42MC

MAN Diesel A/S 90

Small Bore Electronic InjectionME-B System Layout

Injection valvesInjection valves

Pressure Pressure boostersboosters

ELFIELFIValvesValves

Hydraulic oilHydraulic oilrailrail

Camshaft drivenCamshaft drivenexhaust exhaust

actuatorsactuators

Light camshaftLight camshaft

Dual cylinderDual cylinderHCUHCU

23

MAN Diesel A/S 91

ME-B Camshaft

Gear wheel for starting air distributor

Exhaust cam

Chain wheel

MAN Diesel A/S 92

ME-B Camshaft

OZS/2200/20061006

Bearing supports only at the exhaust cams

MAN Diesel A/S 93

ME-B Camshaft

OZS/2200/20061006

Axial bearings

OverhangingChainwheel

24

MAN Diesel A/S 122

Areas for possible improvements on the MC Exhaust Valve1983 - 2005

K90MCK98MC

Self-adjusting damper

Cast iron/high spindle g.

HVOF

Modified cooling

Controlled oil level

Cr sealing ring

U-seal

DuraSpindle

Hardened steel W-seat

Closing damper

Spindle guide

Spindle stem

Water cooling

Sealing system

Sealing ring

Viton sealing

Spindle seat

Bottom piece seat

Improved ItemsItems

MC EXHAUST VALVE

2006.02.01 (4140 / PWN)

MAN Diesel A/S 1232006.02.01 (4140 / PWN)

MAN Diesel A/S 127

MC EXHAUST VALVE

Chamber seat W-seat

2006.02.01 (4140 / PWN)

25

MAN Diesel A/S 128

The longer lifetime on the seat area is achievedwith the new geometry of the W-seat, whichretains the temperature reducing features of thechamber seat and combines them with the benefit of the two narrow concentric contact areas.

The effect is that all carbon particles which aretrapped between the spindle and bottom pieceare crushed and squeezed out and thereforeeliminated without giving rise to any appreciablerisk 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.

Exhaust Valve Spindle & Bottom Piece 98MC/MC-C 26MC

16,000 h between overhauls60-100,000 h lifetime for spindle> 30,000 h lifetime for bottom piece

2006.02.01 (4140 / PWN)

MAN Diesel A/S 1292006.02.01 (4140 / PWN)

MAN Diesel A/S 1312006.02.01 (4140 / PWN)

26

MAN Diesel A/S 1322006.02.01 (4140 / PWN)

MAN Diesel A/S 1332006.02.01 (4140 / PWN)

MAN Diesel A/S 137

MC EXHAUST VALVE

Valve spindle for engine types: K/L/S-MC/-C/-S1983 - 1992: 26 - 50 MC Alloy 5060 - 90 MC Stellite 6

1992 2002:26 - 50 MC Alloy 50S50MC / 60 - 98 MC Nimonic

2002 - :26 - 50 MC DuraSpindle S50MC / 60 - 98 MC Nimonic

1983 1996: Cr stem coating

1996 - : HVOF stem coating

(INCO 625 on request)

Cr (0.25 mm) HVOF (0.15 mm)

Stellite 6

SNCrW

Nimonic

Alloy 50

2006.02.01 (4140 / PWN)

27

MAN Diesel A/S 1392006.02.01 (4140 / PWN)

MAN Diesel A/S 1422006.02.01 (4140 / PWN)

MAN Diesel A/S 1482006.02.01 (4140 / PWN)

MC EXHAUST VALVE Sealing Rings

28

MAN Diesel A/S 154

Design

Features:Damped valve closing by means of oil cushion

New sealing air chamber suitable for air as well as oil sealing medium

Hardened steel chamber-type bottom piece

HVOF coating on Nimonic spindles

Improvements:Mechanical stop for spindle movement combined with safety valve in actuator

Smaller bottom piece

Cooling water connection between cylinder cover and valve housing through bores in valve housing

Strengthened design of damper piston

Cast iron liner in hydraulic cylinders

Cast iron single bush for valve stem

Verification:Calculation and service tests

Exhaust valve K90MC-C K98MC-C

2006.02.01 (4140 / PWN)

MAN Diesel A/S 155

Exhaust Valve Bottom Piece

K98MC, K98MC-C

Original design Modified design

New tool for handling(instead of bolt assembly)2 pcs.

Increased diameter0.15 taper

Decreased diameter

HardenedW-seat

2006.02.01 (4140 / PWN)

MAN Diesel A/S 1562006.02.01 (4140 / PWN)

29

MAN Diesel A/S 1572006.02.01 (4140 / PWN)

MAN Diesel A/S 168

MAN B&W Diesel A/SRolled exhaust valve spindles

DuraValve

2006.02.01 (4140 / PWN)

MAN Diesel A/S 169

Exhaust Valve Spindle - Plate

Inconel 718/Rene 220

Ni-Cr-W valve steel

MIG/MAG welding on valve seat

2006.02.01 (4140 / PWN)Inconel 625

Inconel 718

HVOF

SNCrW

30

MAN Diesel A/S 170

GMAW of Inconel 718, Rene 220

Austenitic stainless

valve steel

Rolling process, 10 t load

MC EXHAUST VALVE

Welding and rolling preparation of DuraSpindle

MAN Diesel A/S 172

Exhaust valve Rolling equipment

BackgroundThe roller is pressed against a rotating spindle at a pressure of 10 tons. The combination of the deformationand the subsequent heating in the oven imparts a hardness to the interial which has not been seen before.

2006.02.01 (4140 / PWN)

MAN Diesel A/S 173

MC EXHAUST VALVE

Rolled seat area of 50MC DuraSpindle

2006.02.01 (4140 / PWN)

31

MAN Diesel A/S 175

Hardness profile (as rolled)

Hardness profile(as rolled and heat treated)

Effect of rolling and heat-treatment on seat hardness

MC EXHAUST VALVE

MAN Diesel A/S 176

MC EXHAUST VALVE

Nimonic spindle & chamber seat, S60MC, 25.500 service hrs

DuraSpindle & chamber seat, S60MC, 33.900 service hrs

2006.02.01 (4140 / PWN)

MAN Diesel A/S 177

MC EXHAUST VALVE

Nimonic spindle & W-seat, S60MC, 25.500 service hrs

DuraSpindle & W-seat, S60MC,33.900 service hrs

2006.02.01 (4140 / PWN)

32

MAN Diesel A/S 178

DuraSpindle & Chamber-seat, S60MC, 44.122 service hrs

MC EXHAUST VALVE

MAN Diesel A/S 179

Nimonic spindle & W-seat, S60MC, 25.500 service hrs

DuraSpindle & W-seat,S60MC, 40.042 service hrs

MC EXHAUST VALVE

MAN Diesel A/S 185

06 May 2006

3333522.2006.04.05 (2160/CEJ)

E N G I N E E R I N G T H E F U T U R EE N G I N E E R I N G T H E F U T U R E

THANK YOU FOR YOUR ATTENTION

33

MAN Diesel A/S 2452006.02.01 (4140 / PWN)

0704 ATUC Exhaust Valve + ME

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Transcript of 0704 ATUC Exhaust Valve + ME