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Transcript of RT-flex Control Elements -  · RT-flex Control Elements RT-flex Training ... RT-flex Control...

  • Wrtsil Land & Sea Academy Page 1 Chapter 30 30-Apr-09

    RT-flex Control Elements

    RT-flex Training

    Function of the different Hydraulic- and Pneumatic

    Components

    Chapter 30

  • Wrtsil Land & Sea Academy Page 2 Chapter 30 30-Apr-09

    RT-flex Control Elements Overview

    Injection ControlExhaust Valve Control

    Servo oil pressure controlFuel pressure control

    Control oil pumps control

    Valve stroke measurementICU stroke measurement

    Crank angle detection

    Auxiliary Functions

    Main FunctionsStarting Valve Control

  • Wrtsil Land & Sea Academy Page 3 Chapter 30 30-Apr-09

    RT-flex Control Elements Injection Control Unit (ICU)

    The ICU controls the timing and volume of the injection.

    Each ICU has 3 (or 2) rail valves to pre- control its own injection control valve. The injection control valves control the movement of the fuel quantity piston.

  • Wrtsil Land & Sea Academy Page 4 Chapter 30 30-Apr-09

    RT-flex Control Elements ICU

    WECS-9520 controlServo (control) oil

    supply 200 bar

  • Wrtsil Land & Sea Academy Page 5 Chapter 30 30-Apr-09

    RT-flex Control Elements ICU

  • Wrtsil Land & Sea Academy Page 6 Chapter 30 30-Apr-09

    RT-flex Control Elements ICU Cross-Section

  • Wrtsil Land & Sea Academy Page 7 Chapter 30 30-Apr-09

    RT-flex Control Elements ICU

    Fuel rail

    Servo rail

    Rail valves

    Injection control valves

    Fuel quantity piston

    Fuel quantity sensor

    Fuel nozzles

    (Size 4: Control rail)

  • Wrtsil Land & Sea Academy Page 9 Chapter 30 30-Apr-09

    RT-flex Control Elements ICU, new leak drain (96C-B)

    New piping layout separates leak drain from injection pipes and from ICU internals.

    Inspection plug for visual check of leak.

  • Wrtsil Land & Sea Academy Page 10 Chapter 30 30-Apr-09

    RT-flex Control ElementsFuel overpressure regulating valve:

    In case of the fuel pressure in intermediate accumulator pipe or fuel rail pipe rises to ~1050 bar, the overpressure regulating valve releases fuel to the fuel return line. The opening pressure is pre-adjusted by valve manufacturer. Shims are used to give the right position to the knurled screw, means if the screw is fully screwed down to shims, 1050 bar are set

    for new building RT-flex84T-D and 96C-Bengines opening pressure is 950 barfor in-service RT-flex84T-D and 96C-Bsee Service Letter RT-flex-07/07

    The min. opening pressure, means when knurled screw is screwed fully out, is around 500 bar (engine still operational).During normal operation, main bearing oil pressure keeps the valve closed. When the opening fuel pressure is reached, main bearing oil is released, pressure above piston drops and fuel is released.

    Fuel Overpressure Regulating Valve

  • Wrtsil Land & Sea Academy Page 11 Chapter 30 30-Apr-09

    RT-flex Control Elements Shutdown Valve

    Shutdown Solenoid valve

    MB-oil supply

    Oil filter

    Lever for manual de- pressurising for mainte- nance work

    Piston

    Solenoid valve leak drainEngine shutdown function:

    A shutdown is initiated by energizing the solenoid valve (energized from safety system, not WECS). In this way, main bearing oil pressure above piston is released, resulting in fuel pressure drop down engine stops

  • Wrtsil Land & Sea Academy Page 12 Chapter 30 30-Apr-09

    RT-flex Control Elements (exhaust) Valve Control Unit (VCU)

  • Wrtsil Land & Sea Academy Page 13 Chapter 30 30-Apr-09

    RT-flex Control Elements VCU

  • Wrtsil Land & Sea Academy Page 14 Chapter 30 30-Apr-09

    RT-flex Control Elements VCU (general working principle)

    The valve control unit is pre-controlled by the rail valve. At a certain crank angle, it gets an exhaust valve open impulse signal from WECS. Servo oil flows via rail valve to the lower side of the 3/2 way valve spindle and moves it up. Thus, servo oil flow to the VCU-cylinder is enabled. Via bores in the VCU-piston, oil flows into the lower side of the piston and moves it towards the upper end.

    the exhaust valve opens

    At another calculated angle, WECS-9520 transmits an exhaust valve close signal to the rail valve. The 3/2 way valve spindle moves down, releasing the oil from the VCU-piston underside allowing the oil volume in the exhaust valve to return to the VCU. The servo oil underneath the VCU piston is drained to the servo oil return pipe.

    the exhaust valve is closing

    Due to certain control bores or chamfers, the VCU- piston has a progressive movement. Means, it starts to move fast and slows down, as it gets closer to the end stop. The losses of servo oil through the orifice on the exhaust valve side is compensated in the VCU with servo- or main bearing oil.

    Rail valve

    VCU piston

    3/2 way valve spindle

    Actuator pipe withmain bearing oil

    The servo oil return pipe has a back pressure of ~2-3 bar, in order to dampen pressure peaks.

  • Wrtsil Land & Sea Academy Page 15 Chapter 30 30-Apr-09

    RT-flex Control Elements VCU

    The servo oil supply from the servo oil rail is done via connecting element.

    To compensate the intended oil loss through the constant orifice in the exhaust valve drive upper housing, there is a main bearing oil inlet via a non-return valve.

    VCU cylinder

    Main bearing oilsupply, (non returnvalve at inlet)

    3/2 way valve

    Connecting element

    Servo oil return/outlet

    To exhaust valve drive

    Filter insert

    Rail valve

    Valid for flex 58T (MKI), 60C (MKI), 96C-B

  • Wrtsil Land & Sea Academy Page 16 Chapter 30 30-Apr-09

    RT-flex Control Elements VCURail Valve

    3/2 way valve

    VCU piston

    Servo oil supply

    To exhaust valve drive

    Servo oil return

    HP-hoses to/from ICU

    The VCU sits directly on the servo rail.

    In order to refill the intended oil loss through the constant orifice in the exhaust valve drive upper housing, there is an internal orifice to the upper part of the VCU/actuator pipe.

    Valid for flex 50B, 58T (MKII), 60C (MKII), 68B, 84T-D

  • Wrtsil Land & Sea Academy Page 17 Chapter 30 30-Apr-09

    RT-flex Control Elements VCU

    Servo rail

    Rail valve Slide rod Piston

    Position sensor

    Spring air

    Exhaust valve

    *) internal from servo rail or external from lube oil

    Oil supply *)

  • Wrtsil Land & Sea Academy Page 19 Chapter 30 30-Apr-09

    RT-flex Control Elements Automatic Filter

    Servo oil and control oil is fine filtered before it enters the pumps and hydraulics. The automatic filter has cartridges of nominal 6 m. There is an bypass filter of 36 m mesh size.

    The reason for filtering is to increase the lifetime and safety margin of all hydraulic components.

    Control box with indications

  • Wrtsil Land & Sea Academy Page 20 Chapter 30 30-Apr-09

    RT-flex Control Elements Automatic Filter

    The back flushing is automatically initiated by the control box either

    A) standard: Time controlled (after 1 hour)

    B) or: if the differential pressure across the filter becomes too high (0.35 bar)

    The filter "sludge" goes back to the crankcase. It is filtered system oil which is clean enough for normal use.

    In the filter control box the back flushing is initiated either by time or differential pressure. Flushing cycles are counted. Failure messages are generated if necessary (Over current, differential pressure high etc)

    Inside the box there are switches/buttons to switch from Operation to Adjust. For detailed information please consult filter makers manuals.

  • Wrtsil Land & Sea Academy Page 21 Chapter 30 30-Apr-09

    RT-flex Control Elements Air system

    Air is used for:

    Actuation of automatic start valve

    Starting of engine

    Spring air supply

    (Oil mist detector)

    Flushing of automatic filter for servo and control oil

    (OMD)(SHD valve)

  • Wrtsil Land & Sea Academy Page 22 Chapter 30 30-Apr-09

    RT-flex Control Elements Air supply

    From starting air bottles (30 bar)

    From control air supply (7-9 bar)

    To air springs To automatic main starting valve

    through turning gear

    (OMD)(SHD valve)

  • Wrtsil Land & Sea Academy Page 23 Chapter 30 30-Apr-09

    RT-flex Control Elements Control air supply unit

  • Wrtsil Land & Sea Academy Page 24 Chapter 30 30-Apr-09

    RT-flex Control Elements Air system (size 0)

    Air is used for:

    Actuation of automatic start valve

    Starting of engine

    Spring air supply

    (Oil mist detector)

    Flushing of automatic filter for servo and control oil

  • Wrtsil Land & Sea Academy Page 25 Chapter 30 30-Apr-09

    RT-flex Control Elements Air supply (size 0)

    From control air supply (7-9 bar)

    To air springs and automatic main starting valve through turning gear

  • Wrtsil Land & Sea Academy Page 26 Chapter 30 30-Apr-09

    RT-flex Control Elements Main starting valve

  • Wrtsil Land & Sea Academy Page 27 Chapter 30 30-Apr-09

    RT-flex Control Elements Starting air

    RT-flex TrainingOverviewInjection Control Unit (ICU)ICUICUICU Cross-SectionICUICUICU, new leak drain (96C-B)Fuel Overpressure Regulating ValveShutdown Valve(exhaust) Valve Control Unit (VCU)VCUVCU (general working principle)VCUVCUVCUVCUAutomatic FilterAutomatic FilterAir systemAir supplyControl air supply unitAir system (size 0)Air supply (size 0)Main starting valveStarting airicu.pdfRT-flex TrainingOverviewInj