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ME ENGINE

TRAINING COURSE

MAN B&W Diesel


1. General description
of ME engine
MAN B&W Diesel, Company Presentation ME - Engines
MAN B&W Diesel MAN B&W Diesel

by
Preben Noeies

MAN B&W Diesel


MAN B&W Diesel
06.01 4140/PWN <1> MAN B&W Diesel 06.01 4140/PWN <2>

The Founding of the Company History


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 W. Wain C. C. Burmeister
Burmeister & Wain (B&W)
MAN B&W Diesel 06.01 4140/PWN <3> MAN B&W Diesel 06.01 4140/PWN <4>

Rudolf Diesel 1858 1913


The First Diesel Engine and the Patent Certificate
MAN B&W Diesel MAN B&W Diesel
The First B&W Diesel Engine

The first B&W four-


stroke diesel engine
was delivered in 1904

Engine No. 1
Type: 140
Customer: N. Larsen,
Carriage Manufacturer,
Frederiksberg,
Denmark

MAN B&W Diesel 06.01 4140/PWN <5> MAN B&W Diesel 06.01 4140/PWN <6>

1
The First Diesel Engine
Engine Development 1912 - 1952 for Ocean-going Ship Propulsion
MAN B&W Diesel MAN B&W Diesel

1912: Single-acting crosshead four-stroke direct reversible


Type: 8150-X Power: 1,250 IHP M/S Selandia, delivered to the Danish East Asiatic Company in
(Introduced on M/S Selandia) 1912, is the worlds first ocean-going diesel motor ship.
1922: Supercharging by electrically driven blower
1924: Double-acting four-stroke Type: 6840D Power: 6,750 BHP Type: DM 8150-X (2 x 8 cylinder engines)
(Twin engine installation introduced on M/S Gripsholm) Power: 2,500 IHP total
1929: Double-acting two-stroke engine Type: 662-WF-140 Ships speed: 11 knots
Power: 7,000 IHP (Introduced on M/S Amerika)
1932: Single-acting two-stroke engine with exhaust valves
Type: 50-VF-90
1938: Tests with heavy fuel on M/S Transilvania
1952: The worlds first turbocharged two-stroke engine
Type: 674VTBF-160 Power: 7,500 BHP
(Introduced on M/S Dorthe Mrsk)

MAN B&W Diesel 06.01 4140/PWN <7> MAN B&W Diesel 06.01 4140/PWN <8>

First Ocean Going Vessel The Worlds First Turbocharged


MAN B&W Diesel
with Fully Reversible Diesel Engines
MAN B&W Diesel
Two-stroke Diesel Engine
M/S Selandia
M/S Dorthe Mrsk, delivered
Main engines: 2 x 1250 IHK
B&W engines type DM8150X to the Danish company A. P.
Mller by Odense Steel
Shipyard in 1952, is the first
ship to be powered by a
turbocharged two-stroke
diesel engine

Engine type: 674VTBF-160


Power: 7,500 BHP @ 115 r/min

MAN B&W Diesel 06.01 4140/PWN <9> MAN B&W Diesel 06.01 4140/PWN < 10 >

Engine Development 1952 - 1980 The History of MAN B&W Diesel


MAN B&W Diesel MAN B&W Diesel

1952: The worlds first turbocharged two-stroke engine In 1758 Eisenhtte St. Antony is established in Oberhausen
Type: 674VTBF-160 Power: 7,500 BHP
(Introduced on M/S Dorthe Mrsk) In 1840 Sander'sche Maschinen Fabrik is established in Augsburg

1967: Introduction of the K-EF range of engines, as well as the


In 1843 Baumgarten establishes a workshop in
large K98FF type (3,800 BHP/cyl. @ 103 RPM)
Copenhagen
1973: Delivery of the first K-GF engine
Gutehoffnungshtte Burmeister & Wain M.A.N.
1976: The first to introduce modern long stroke diesel engines Actienverein (GHH) (1865) Maschinenfabrik
Type: L-GF, with a stroke-bore ratio of 2.5:1 is established in B&W Motor A/S Augsburg-Nrnberg
1978: The first with constant pressure turbo charging of modern 1873 (1974) (1908)
uniflow scavenged diesel engines
In 1921 GHH In 1979/80 B&W Motor A/S is taken over
1979: The first to test a rotating air-spring on exhaust valves in acquired a majority by M.A.N., and M.A.N. B&W Diesel A/S is
service in M.A.N. established
1980: The first to introduce layout flexibility, as well as a specific
In 1986 M.A.N. was merged into GHH and renamed MAN AG
fuel oil consumption below 140 g/BHPh Type: L-GFCA
The divisions were hived off to form individual public limited companies
MAN B&W Diesel 06.01 4140/PWN < 11 > MAN B&W Diesel 06.01 4140/PWN < 12 >

2
Diesel Chronicle MAN B&W Diesel A/S
A Historical Overview Since 1843
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 06.01 4140/PWN < 13 > MAN B&W Diesel 06.01 4140/PWN < 14 >

The MAN Group - 2005 MAN B&W Diesel Group


MAN B&W Diesel MAN B&W Diesel

61,259 employees
Turnover 14,9 billion
PBT 453 million

Industrial Services

Commercial Printing Machines Diesel Engines Turbo Machines Further Industrial Industrial Services Financial Services
Vehicles Holding* MAN Aktiengesellschaft Mnchen
MAN MAN Roland MAN MAN RENK MAN Ferrostaal AG MAN Financial 100%
Nutzfahrzeuge AG Druckmaschinen B&W Diesel AG Turbomaschinen AG Aktiengesellshaft Services GmbH
AG MAN
Technologie AG
MAN DWE GmbH 67% 100% 100%
Schwbische
Httenwerke GmbH S.E.M.T. Pielstick MAN B&W Diesel Ltd MAN B&W Diesel AG MAN B&W Diesel A/S
France England Germany Denmark
Turnover 7,4 billion Turnover 1,6 billion Turnover 1,4 billion Turnover 0,7 billion Turnover 3,2 billion

MAN B&W Diesel 06.01 4140/PWN < 15 > MAN B&W Diesel 06.01 4140/PWN < 16 >

Locations of MAN B&W Diesel Worldwide Service Network


MAN B&W Diesel MAN B&W Diesel

Great Britain Denmark


Paxman MAN B&W Diesel A/S
Ruston 2173 employees
Mirrlees Blackstone Frederikshavn Two-stroke engines
678 employees Research and development
Four-stroke engines Marine propulsion
Marine propulsion Copenhagen Power generation
Military marine Service
Holeby
Power generation Rostock Spare parts
Rail traction Stockport Licensor
Hamburg
Four-stroke engines
Colchester Complete propulsion package
France GenSets
Pielstick Power generation
709 employees Licensor
Four-stroke engines
Paris Germany
Marine propulsion Augsburg MAN B&W Diesel AG
Military marine
Saint-Nazaire 2474 employees
Power generation
Jouet Four-stroke engines
Rail traction
Service Research & development
Licensor Marine propulsion
Power generation
Service Service Centres 20
Licensor
AuthorisednRepair Shops 55
Licensees 15
Total 6 034
MAN B&W Diesel 06.01 4140/PWN < 17 > MAN B&W Diesel 06.01 4140/PWN < 18 >

3
Two-Stroke Licensees Two-stroke Licensees
MAN B&W Diesel MAN B&W Diesel

China Croatia Japan


HHM 1980 Uljanik 1954 Mitsui 1926
DMD 1980 Split 1984 Makita 1981
YMD 1989 Hitachi 1951
Kawasaki 1981

Korea Poland Russia


Hyundai 1976 Cegielski 1959 Bryansk 1959
Doosan 1983
STX 1984

Spain Vietnam
IZAR Manises 1941 Vinashin 2004

As at August 2004

MAN B&W Diesel 06.01 4140/PWN < 19 > MAN B&W Diesel 06.01 4140/PWN < 20 >

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 06.01 4140/PWN < 21 > MAN B&W Diesel 06.01 4140/PWN < 22 >

MAN B&W Diesel A/S,


MAN B&W Diesel A/S, Copenhagen Research Centre
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 23 > MAN B&W Diesel 06.01 4140/PWN < 24 >

4
Research engine 4T50ME-
4T50ME-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 9 m/s

MAN B&W Diesel 06.01 4140/PWN < 25 > MAN B&W Diesel 06.01 4140/PWN < 26 >

MAN B&W Diesel A/S,


Frederikshavn (ALPHA) Designations
MAN B&W Diesel MAN B&W Diesel

Cross Section
S90 MC-C

MAN B&W Diesel 06.01 4140/PWN < 27 > MAN B&W Diesel 06.01 4140/PWN < 28 >

Designations Development of the ME-


ME-engine
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 Start of service test on M/T Bow Cecil
2003 First production engine
MAN B&W Diesel 2005.05.01 (4140/PWN) < 29 > MAN B&W Diesel 2005.05.01 4140/PWN < 30 >

5
Reference List
Two-stroke Marine Engines
MAN B&W Diesel MAN B&W Diesel

ME Programme
Vessels with ME engines lined up awaiting delivery.
Type On order/delivered In service

K98ME/ME-C 42 2
S90ME-C 2
K90ME-C 8
K80ME-C 17
L70ME-C 16
S70ME-C 72 7
S65ME-C 3 3
S60ME-C 40 1
S50ME-C 10 7
Stena Arctica ( 7S60ME-C)
Total 210 20
Captain Kostichev ( 7S60ME-C)
Pavel Chernysh ( 7S60ME-C) As at 2004.08.26

Cape Brindisi ( 6S70ME-C)


As at 2005.11.01 Total: 5,860,589 kW
MAN B&W Diesel < 31 > MAN B&W Diesel 2005.05.01 4140/PWN

Hydraulic Cylinder Unit 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 06.01 4140/PWN < 33 > MAN B&W Diesel 06.01 4140/PWN < 34 >

Engine Room at Bow Cecil 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 06.01 4140/PWN < 35 > MAN B&W Diesel 06.01 4140/PWN < 36 >

6
The ME Engine
7S50ME-C in M/V Bow Firda Hydraulic Power Supply (HPS)
MAN B&W Diesel MAN B&W Diesel

Generates the power


necessary for fuel oil
injection and exhaust
valve opening

Hydraulic Power Supply

MC ME
MAN B&W Diesel 06.01 4140/PWN < 37 > MAN B&W Diesel 06.01 4140/PWN < 38 >

The ME Engine
Hydraulic Power Supply (HPS) 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
start-up pumps. After start, the engine
Main components: driven pumps will take over the supply.

Self-cleaning filter with 10-micron filter mesh

Accumulators
Redundancy filter with 25-micron filter mesh Self cleaning
filter 10 Safety and
accumulators block
Start-up
Start up pumps: pumps
x
Start-up
High pressure pumps with supply pressure of 175 bar pumps
Engine driven
Low pressure pumps for filling the exhaust valve push rod axial piston
pumps
with supply pressure of 4 bar

Engine driven axial piston pumps supplying high pressure oil to


The hydraulic power
the Hydraulic Cylinder Unit with oil pressure up to 250 bar supply uses the
engine system oil
Redundancy filter 25
MAN B&W Diesel 06.01 4140/PWN < 39 > MAN B&W Diesel 06.01 4140/PWN < 40 >

The ME Engine Hydraulic Oil Loop HPS 7S60ME-C


MAN B&W Diesel MAN B&W Diesel

Fuel oil pressure


booster
Exhaust valve actuator Redundancy Filter 25
Fuel 10 bar Hydraulic Self Cleaning Filter 10
cylinder unit
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
block
Fine aut. filter

Main lube
pump
Servo oil
Piston cooling
+ bearings Engine Driven Axial Piston Pumps
Servo oil
return to sump
Chain Wheel and Step-up Gear
From sump Shielding with Drain
Safety and Accumulators Block
Engine driven EL. driven
hydraulic pumps hydraulic pumps
and Alarm Functions
Electrically Driven Start-up Pumps
MAN B&W Diesel 06.01 4140/PWN < 41 > MAN B&W Diesel 06.01 4140/PWN < 42 >

7
ME Engine, Pump Drive
and Moment Compensator
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 43 > MAN B&W Diesel 06.01 4140/PWN < 44 >

Large Bore ME - Aft end mounted HPS.


5-8K/L/S60-90MC-C & 7K98ME(-C) 60-98ME-C HPS
MAN B&W Diesel MAN B&W Diesel

Engines with moment Engines without


compensator moment compensator Filter station

Identical
HPS units
Hydraulic pumps
Identical
chain
tightening Step-up gear
arrangement

Chain tightener
wheel

MAN B&W Diesel 06.01 4140/PWN < 45 > MAN B&W Diesel 06.01 4140/PWN < 46 >

Hydraulic Power Supply


6S70ME-
6S70ME-C Step-up gear
MAN B&W Diesel MAN B&W Diesel

25
Redundancy Filter 25

10
Self Cleaning Filter 10

Gear wheels:
Case hardened
Simple spur wheels
DIN standard

Engine Driven Axial Piston


Shielding with Drain Pumps

and Alarm Functions Chain Wheel and Step-


Step-up Gear
(2510/JRL)

MAN B&W Diesel 06.01 4140/PWN < 47 > MAN B&W Diesel 06.01 4140/PWN < 48 >

8
Engine driven high pressure pumps Filter unit
MAN B&W Diesel MAN B&W Diesel

Self cleaning filter Redundancy filter


with 10-micron filter with 25-micron
mesh filter mesh

Supplied by Bosch Rexroth

Supplied by Boll&Kirscher

MAN B&W Diesel 06.01 4140/PWN < 49 > MAN B&W Diesel 06.01 4140/PWN < 50 >

Safety block Start-up pumps


MAN B&W Diesel MAN B&W Diesel

Safety and control


valves
Three types:

Line break valves 2 x 15 kW for 50-60ME-C


2 x 25 kW for 70-80ME-C
2 x 38 kW for 90-98ME-C

Basically the same


block on all 60-
98ME/ME-C

MAN B&W Diesel 06.01 4140/PWN < 51 > MAN B&W Diesel 06.01 4140/PWN < 52 >

7S50ME-C
7L70ME-C electrical HPS Hydraulic Power Supply
MAN B&W Diesel MAN B&W Diesel

Accumulator

Safety and
accumulator block

3 engine driven axial


Gearbox and chain drive is piston pumps with
flow controlled by
replaced by:
ECS
3 electrically driven pumps Generates hydraulic
230 kW each oil pressure up to
250 bar
Redundancy: Can
operate on two
pumps

Gear Box

MAN B&W Diesel 06.01 4140/PWN < 53 > MAN B&W Diesel 06.01 4140/PWN < 54 >

9
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 06.01 4140/PWN < 55 > MAN B&W Diesel 06.01 4140/PWN < 56 >

Engine Driven Pump (Viken 1436) 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 06.01 4140/PWN < 57 > MAN B&W Diesel 06.01 4140/PWN < 58 >

ME-C Engines
Double Wall Pipe S70ME-C Double Wall Pipe
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 06.01 4140/PWN < 59 > MAN B&W Diesel 06.01 4140/PWN < 60 >

10
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
9
6 7 7 Fuel oil
6 Pressure Booster
1 10

Hydraulic Exhaust
8 Valve Actuator

ELFI
Proportional Valve

4
ELVA
On/Off Valve
5

Distribution Block

MAN B&W Diesel 06.01 4140/PWN < 61 > MAN B&W Diesel 06.01 4140/PWN < 62 >

Oil Channel in the Distributor Block 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
Manually operated
valve for isolation of
oil to the actuators in
case of need for The HCU is found on the upper gallery
overhauling
One unit in front of each cylinder
running engine
X-ray picture of the Distributor Block
MAN B&W Diesel 06.01 4140/PWN < 63 > MAN B&W Diesel 06.01 4140/PWN < 64 >

ME Control Valves Hydraulic Cylinder Units


MAN B&W Diesel MAN B&W Diesel
12K98ME-
12K98ME-C
Fuel Oil
MAN B&W ELVA ELFI Exhaust Valve Actuator
FIVA Pressure Booster

FIVA valve Integrated Alpha Lubricator


MAN B&W Diesel 06.01 4140/PWN < 65 > MAN B&W Diesel 06.01 4140/PWN < 66 >

11
MAN B&W Diesel
K98ME(-C) Hydraulic Cylinder Unit MAN B&W Diesel
K98ME(-C) HCU Distributor Block

MAN B&W Diesel 06.01 4140/PWN < 67 > MAN B&W Diesel 06.01 4140/PWN < 68 >

ME(-C) HCU Distributor Block


MAN B&W Diesel MAN B&W Diesel

The ME Engine Hydraulic Oil Loop Fuel oil pressure Exhaust valve actuator
booster
Hydraulic
Fuel 10 bar
cylinder unit
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


Safety and
accumulator
Main lube
block
pump
Piston cooling Servo oil
+ bearings
Servo oil
return to sump

From sump
Engine-driven EL. driven
hydraulic pumps hydraulic pumps

MAN B&W Diesel 06.01 4140/PWN < 69 > MAN B&W Diesel 06.01 4140/PWN

S60ME-C Hydraulic Cylinder Unit (HCU)


MAN B&W Diesel MAN B&W Diesel

Fuel Oil Pressure Booster

Exhaust Valve Actuator

FIVA Proportional Valve

Distribution Block

Alpha Lubricator

MAN B&W Diesel 06.01 4140/PWN < 71 > MAN B&W Diesel 06.01 4140/PWN < 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 Signal for lubrication ME-C
for control of from controller
piston movement
Actuator piston Suction valve
Fuel plunger
Outlets
for cylinder liner Injection plungers Fuel oil inlet
lube oil injectors
Feed back pressure 8 bar
position sensor

Hydraulic piston
Spacer
for basic
Drain oil
setting of
outlet 200 bar servo
pump Cylinder
stroke lube oil inlet oil supply
Stroke adjusting screw
Saves cylinder lube oil

MAN B&W Diesel 06.01 4140/PWN < 73 > MAN B&W Diesel 06.01 4140/PWN < 74 >

ME Fuel Injection System Slide-type Fuel Valve


MAN B&W Diesel MAN B&W Diesel

Slide fuel
Suction valve valve Now used
High pressure pipe as standard

Fuel oil inlet


Hydraulic 8 bar
piston Possibility for
retrofit

ELFI Membrane
Proportional accumulator
valve

Conventional fuel valve Slide-type fuel valve


To Sac volume 1690 mm3 Sac volume 0 mm3
drain
High pressure hydraulic oil inlet

MAN B&W Diesel 06.01 4140/PWN < 75 > MAN B&W Diesel 06.01 4140/PWN < 76 >

M E Exhaust Valve System 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


Exhaust valve integrated electronics
Exhaust valve Outlet lube oil
Actuator
Inlet lube oil
Damper
Membrane
accumulator
ELVA on-off valve
Air inlet

To drain High pressure hydraulic oil inlet

MAN B&W Diesel 06.01 4140/PWN < 77 > MAN B&W Diesel 06.01 4140/PWN < 78 >

13
The ME Engine
Exhaust Valve Timing ME Starting Air System
MAN B&W Diesel MAN B&W Diesel

MC-
MC-C design ME-
ME-C design
Pilot air inlet
80 Blow-
Blow-off

70

60
Early closing
50
Late closing NC-
NC-valves
mm

40 Early opening Starting air Connection


distributor for
Late opening
30 ECS
Reference
20

10 Starting valves 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 06.01 4140/PWN < 79 > MAN B&W Diesel 06.01 4140/PWN

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 Main Operating Panel - HMI

MAN B&W Diesel 06.01 4140/PWN < 81 > MAN B&W Diesel 2005.05.01 (4140/PWN) < 82 >

ME Tacho System Service Experience


MAN B&W Diesel MAN B&W Diesel

2 redundant set of sensors


A shaft encoder solution has been prepared as an alternative
to the standard mounted tacho ring
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 tooth-


profile 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 4140/PWN < 86 >

Tacho System
Angle Encoder
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 87 > MAN B&W Diesel 06.01 4140/PWN < 88 >

Angle Encoder 12K98ME Main Operating Panel (MOP)


MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 89 > MAN B&W Diesel 06.01 4140/PWN < 90 >

15
ME Engine Control System Multi Purpose Controller (MPC)
MAN B&W Diesel MAN B&W Diesel

Bridge Bridge
Panel

Plug for ID key

BACK-UP FOR MOP


Multi-
Multi-Purpose Main
Control Room
Controller Operatingg PC
Panel Engine Control Room
Panel

DIP Switches

EICU A EICU B

Engine Interface Control Unit A and B


Local
Operation
Panel
Engine Control Unit A and B
Control Network
ECU A ECU B

Cylinders Control Unit 1 per cylinder


ACU CCU
Engine Room/On Engine Fuses in use are monitored by the alarm system
Auxiliaries Control Unit 1, 2 and 3
MAN B&W Diesel 06.01 4140/PWN < 91 > MAN B&W Diesel 06.01 4140/PWN < 92 >

Engine Control System


MPC - configuration MPC
MAN B&W Diesel MAN B&W Diesel

The MPCs 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 >

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 06.01 4140/PWN < 96 >

16
The ME Engine
M E SIMULATOR in Copenhagen
Local Operating Panel (LOP)
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 Local Operation Panel
middle
middle gallery
gallery on
on the
the manoeuvring
manoeuvring side
side of
of
the
the engine.
engine.
MAN B&W Diesel 06.01 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 06.01 4140/PWN < 104 >

Holding Down Bolts Installation Aspects


MAN B&W Diesel MAN B&W Diesel

Side chocks, modified design

Previous design New design

MAN B&W Diesel 06.01 4140/PWN < 105 > MAN B&W Diesel 06.01 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 4140/PWN < 108 >

18
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 109 > MAN B&W Diesel 06.01 4140/PWN < 110 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 111 > MAN B&W Diesel 06.01 4140/PWN < 112 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 113 > MAN B&W Diesel 06.01 4140/PWN < 114 >

19
K98FF (1966) Versus K98MC (1999)
MAN B&W Diesel MAN B&W Diesel

2800 kW per cylinder 5720 kW per cylinder

MAN B&W Diesel 06.01 4140/PWN < 115 > MAN B&W Diesel 06.01 4140/PWN < 116 >

MAN B&W Diesel 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 >

MAN B&W Diesel MAN B&W Diesel

L60MC-C Crankshaft in Bedplate


MAN B&W Diesel 06.01 4140/PWN < 119 > MAN B&W Diesel 06.01 4140/PWN < 120 >

20
Bearings
MAN B&W Diesel MAN B&W Diesel

Crosshead Crankpin Main

AlSn40 White metal

MAN B&W Diesel 06.01 4140/PWN < 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 06.01 4140/PWN < 124 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 125 > MAN B&W Diesel 06.01 4140/PWN < 126 >

21
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 127 > MAN B&W Diesel 06.01 4140/PWN < 128 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 129 > MAN B&W Diesel 06.01 4140/PWN < 130 >

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 4140/PWN < 131 > MAN B&W Diesel 06.01 4140/PWN < 132 >

22
MAN B&W Diesel MAN B&W Diesel

L60ME-C
A-Frame
Mounted on
Bedplate.
MAN B&W Diesel 06.01 4140/PWN < 133 > MAN B&W Diesel 06.01 4140/PWN < 134 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 135 > MAN B&W Diesel 06.01 4140/PWN < 136 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 137 > MAN B&W Diesel 06.01 4140/PWN < 138 >

23
Crosshead bearings Crosshead bearings
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 139 > MAN B&W Diesel 06.01 4140/PWN < 140 >

Crosshead bearings Crosshead bearings


MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 141 > MAN B&W Diesel 06.01 4140/PWN < 142 >

Crosshead bearings
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 143 > MAN B&W Diesel 06.01 4140/PWN < 144 >

24
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 145 > MAN B&W Diesel 06.01 4140/PWN < 146 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 147 > MAN B&W Diesel 06.01 4140/PWN < 148 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 149 > MAN B&W Diesel 06.01 4140/PWN < 150 >

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 4140/PWN < 151 > MAN B&W Diesel 06.01 4140/PWN < 152 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 153 > MAN B&W Diesel 06.01 4140/PWN < 154 >

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
Crankcase Explosion Deformed Flame Arrester
MAN B&W Diesel MAN B&W Diesel

Cases of explosions where the cause is known

Year Cause of Explosion Cause of Failure

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 Incorrect tightening
1999 Fire outside the engine
2000 Main bearing
2000 Camshaft bearing
2000 Incorrect shaft in camshaft drive Unauthorised spare part
2001 Crankcase failure
2001 Piston crown failure
2001 Main bearing
2001 Crankpin bearing
2002 Inlet pipe for piston cooling oil falling off Incorrect tightening

MAN B&W Diesel 06.01 4140/PWN < 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 06.01 4140/PWN < 160 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 161 > MAN B&W Diesel 06.01 4140/PWN < 162 >

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
S70ME-
S70ME-C

MAN B&W Diesel 06.01 4140/PWN < 163 > MAN B&W Diesel 06.01 4140/PWN < 164 >

Vibration Aspects
MAN B&W Diesel MAN B&W Diesel

General terms
Internal forces
Piston

Crosshead

N
P S
S

MAN B&W Diesel 06.01 4140/PWN < 165 > MAN B&W Diesel 06.01 4140/PWN < 166 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 167 > MAN B&W Diesel 06.01 4140/PWN < 168 >

28
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 169 > MAN B&W Diesel 06.01 4140/PWN < 170 >

MAN B&W Diesel 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 4140/PWN < 171 > MAN B&W Diesel 06.01 4140/PWN < 172 >

ME-C Engines
Hydraulic Cylinder Units (HCU) Doubble Wall Pipe
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

Double walled high 6. Sealing ring


pressure pipe 7. Sealing ring
High pressure oil inlet 8. Screw
from the HPS

MAN B&W Diesel 06.01 4140/PWN < 173 > MAN B&W Diesel 06.01 4140/PWN < 174 >

29
K98ME(-C) Baseplate ME Fuel Oil Pressure Booster
MAN B&W Diesel MAN B&W Diesel

MC-C ME-C

Suction valve Fuel plunger

Fuel oil inlet


Feed back pressure 8 bar
position sensor

Hydraulic piston

01-10-2003 (2500/KNB)

MAN B&W Diesel < 175 > MAN B&W Diesel 06.01 4140/PWN < 176 >

Hydraulic Cylinder Unit Hydraulic Cylinder Unit


MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 177 > MAN B&W Diesel 06.01 4140/PWN < 178 >

Hydraulic Cylinder Unit


MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 179 > MAN B&W Diesel 06.01 4140/PWN < 180 >

30
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 181 > MAN B&W Diesel 06.01 4140/PWN < 182 >

Hydraulic Cylinder Unit Hydraulic Cylinder Unit (HCU)


MAN B&W Diesel MAN B&W Diesel

Fuel oil
Pressure Booster Accumulators
pressurized with
Hydraulic Exhaust nitrogen of 105 bar
Valve Actuator

ELFI
Proportional Valve

ELVA
On/Off Valve

Distribution Block

MAN B&W Diesel 06.01 4140/PWN < 183 > MAN B&W Diesel 06.01 4140/PWN < 184 >

Hydraulic Cylinder Unit (HCU) ME Fuel Injection System


MAN B&W Diesel MAN B&W Diesel

Fuel injection Valve actuation


High pressure pipe Slide fuel
valve
Suction valve
ELFI Proportional Valve

ELVA On/Off Valve


Fuel Pump Fuel oil inlet
Exhaust Valve Actuator
8 bar
Hydraulic
piston
Membrane
ELFI accumulator
Proportional
valve

To
drain High pressure hydraulic oil inlet
Accumulator Distribution Block

MAN B&W Diesel 06.01 4140/PWN < 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 4140/PWN < 187 > MAN B&W Diesel 06.01 4140/PWN < 188 >

Service Experience 6S90MC-C


MAN B&W Diesel MAN B&W Diesel

1150 running hours


Dosage 1.1 g/bhph
Mobilgard 570
Liner No. 4

12K90MC,
Maria A. Angelicoussis DW5127 Pascagoula 00.09.15
one years operation with Alpha ACC = S% * 0.25 g/bhph

MAN B&W Diesel 06.01 4140/PWN < 189 > MAN B&W Diesel 06.01 4140/PWN < 190 >

The ME Engine
Alpha Cylinder Lubricator Cylinder Condition
MAN B&W Diesel MAN B&W Diesel

Save 0.3 g/bhp cylinder oil Timing of cylinder oil injection


Inductive proximity switch
for feed-back signal Signal for lubrication Pressure
for control of from controller 25 bar Injection pressure
piston movement Alpha lubricator
Actuator piston
20
Outlets
for cylinder liner
lube oil injectors Injection plungers
15

10

Spacer
for basic Drain oil Oil quill pressure Injection pressure
setting of 5 mechanical lubricator
outlet 200 bar servo
pump Cylinder
lube oil inlet oil supply
stroke Stroke adjusting screw
Saves cylinder lube oil
0
0 10 20 30 40 50 60 70 80 90 ms Time
MAN B&W Diesel 06.01 4140/PWN < 191 > MAN B&W Diesel 06.01 4140/PWN < 192 >

32
Combustion Chamber Design S-MC-C
MAN B&W Diesel MAN B&W Diesel

Piston with high S-MC-C S-MC


top land

Piston ring further


away from Mating
combustion space 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


MAN B&W Diesel Alu-Coated Piston Ring MAN B&W Diesel

Genuine spare parts


Genuine spare parts
A-A
Developed at our Alu-Coat
Research Centre
Piston ring with controlled pressure
Reduced running-in relief (CPR piston ring)
time by more than 50%
A A

Thus saving cylinder oil


Reduced differential pressure on
Thickness: about 0.3 mm piston ring No. 2

Reduced temperature on
piston ring No. 2

MAN B&W Diesel 06.01 4140/PWN < 197 > 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
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
F F Low
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

Oros Piston Piston high top land

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 06.01 4140/PWN < 202 >

Bore polish from topland deposits. 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 Example of heavy deposits
on the piston topland, being
against the
polished from rubbing
liner
against the liner running
surface. surface

MAN B&W Diesel 06.01 4140/PWN < 203 > MAN B&W Diesel 06.01 4140/PWN < 204 >

34
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 205 > MAN B&W Diesel 06.01 4140/PWN < 206 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 207 > MAN B&W Diesel 06.01 4140/PWN < 208 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 209 > MAN B&W Diesel 06.01 4140/PWN < 210 >

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 4140/PWN < 212 >

Slide-type Fuel Valve


MAN B&W Diesel MAN B&W Diesel

Now used
as standard

Possibility for
retrofit

Conventional fuel valve Slide-type fuel valve


Sac volume 1690 mm3 Sac volume 0 mm3

MAN B&W Diesel 06.01 4140/PWN < 213 > MAN B&W Diesel 06.01 4140/PWN < 214 >

Slide Fuel Valve 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 Slide-type fuel valve
SL 02-403
Sac volume 1690 mm3 Sac volume 0 mm3

MAN B&W Diesel 06.01 4140/PWN < 215 > MAN B&W Diesel 06.01 4140/PWN < 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 4140/PWN < 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 For large bore above 70MC = 65Nm

MAN B&W Diesel 06.01 4140/PWN < 219 > MAN B&W Diesel 06.01 4140/PWN < 220 >

Marks and Stamps on Fuel Valve Nozzle


6L80MC MC and MC-C Type
MAN B&W Diesel MAN B&W Diesel

Marking must, as a minimum, consist of: Name, IMO id No. and nozzle size.
Damaged Piston Crown Name: Manufacturers name/ trade mark
Reason: Fuel valves in bad IMO id No.: A unique identification No. which links the component
with the design specification that was used at the time of
condition manufacture, eg. MAN B&W part No. or licensees drawing
No.
Nozzle size: Diameter of nozzle hole.

Example of marking:
The example shows how to mark a nozzle with hole
diameter 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

MC-
MC-C design ME-
ME-C design
Pilot air inlet
Blow-
Blow-off

NC-
NC-valves Starting air valve
Starting air Connection
distributor for
ECS

Pilot valve for


Starting valves Starting valves starting air valve

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 >

Auxiliary Systems
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 06.01 4140/PWN < 225 > MAN B&W Diesel 06.01 4140/PWN < 226 >

MAN B&W Diesel A/S 7S60ME-C


MAN B&W Diesel MAN B&W Diesel

Thank you for Thank you for


your attention your attention

MAN B&W Diesel 06.01 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 <1>

ME engine
Hydraulic Loop
MAN B&W Diesel

Fuel oil pressure


Exhaust valve actuator
booster
Fuel 10 bar Hydraulic
cylinder unit
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
Fine aut. filter blok

Main lube
pump
Servo oil
Piston cooling
+ bearings
Servo oil
return to sump

From sump
Engine driven EL. driven
hydraulic pumps hydraulic pumps

MAN B&W Diesel L/73273-7.1/0403 (2600/RL) <2>

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 <3>

1
ME engine
Hydraulic Loop
MAN B&W Diesel

Fuel oil pressure


Exhaust valve actuator
booster
Fuel 10 bar Hydraulic
cylinder unit
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
Fine aut. filter blok

Main lube
pump
Servo oil
Piston cooling
+ bearings
Servo oil
return to sump

From sump
Engine driven EL. driven
hydraulic pumps hydraulic pumps

MAN B&W Diesel L/73273-7.1/0403 (2600/RL) <2>


Engine Control System Diagram Plate 70317

On Bridge
BRIDGE PANEL

In Engine Control Room


Backup Operation Panel MAIN OPERATION PANEL
MOP A ECR PANEL
MOP B

EICU A EICU B

In Engine Room/On Engine


LOCAL OPERATION
PANEL - LOP

ECU A ECU B

CCU CCU
ACU 1 ACU 2 ACU 3 Cylinder 1 Cylinder n
Sensors

Sensors
Actuators

Act uat ors


Fuel Exhaust
booster valve Fuel Exhaust
position position booster valve
position position
Cylinder 1 Cylinder 1 FIVA FIVA
Cylinder n Cylinder n
AL SAV Valve AL SAV Valve
Cylinder 1 Cylinder 1 Cylinder 1 Cylinder n Cylinder n Cylinder n

AUXILIARY AUXILIARY
BLOWER 1 BLOWER 2
M PUMP 1
M PUMP 2

M PUMP 1
M PUMP 2
M PUMP 3
M PUMP 4
M PUMP 5

Marker Sensor

AUXILIARY AUXILIARY
BLOWER 3 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 <4>

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 <5>

LED indication code


MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 <6>

2
Multi Purpose Controller (MPC)
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 <7>

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 <8>

MPCs Nordic Brasilia 6S70ME-C


MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 <9>

3
MPC configuration
MAN B&W Diesel

The MPCs 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 >

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 2006-01-06 < 11 >

Speed Setpoint
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 12 >

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


The gov
Calculations of fuel index
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 >

Fuel Limiters
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 14 >

Cylinder Control Unit CCU


MAN B&W Diesel

Fuel injection control


Proportional valve

Feedback of plunger position only used for monitoring


FIVA
Exhaust valve control
ON / OFF valve
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 2006-01-06 < 15 >

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 >

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 2006-01-06 < 17 >

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

MC-
MC-C design ME-
ME-C design
Pilot air inlet
Blow-
Blow-off

NC-
NC-valves
Starting
Starting air Connection
Connection
distributor for
ECS

Starting valves Starting valves

MAN B&W Diesel < 20 >

Starting air-
and 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 >

Main Operation Panel (MOP)


MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 23 >

Main Operating Panel MOP


MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 24 >

8
Main Operating Panel MOP
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 25 >

Local Operating Panel (LOP)


with telegraph
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 26 >

Local Operating Panel (LOP)


Without telegraph
MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 27 >

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
Q1A
Q2A

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 MSB
pos. 1

Semi-circular
marking ring
pos. 2

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 29 >

ME Tacho-system
MAN B&W Diesel

MAN B&W Diesel 04-ME


04-11- Concept - 2500/KNB
11-2003 Tom Ballegaard/4140 2006-01-06 < 30 >

10
ME Tacho-system
MAN B&W Diesel

MAN B&W Diesel 04ME


04-
-11- Concept
11-2003 - Tom Ballegaard/4140
2500/KNB 2006-01-06 < 31 >

Angle encoder 12K98ME


MAN B&W Diesel

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 32 >

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 tooth-


profile The total trigger ring is build by 8
equal segments.

MAN B&W Diesel ME Concept -


2200/OZS/030212 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 >

Quadratur sensor
MAN B&W Diesel

Status LED

Ahead turning towards the dot

MAN B&W Diesel ME Concept - Tom Ballegaard/4140 2006-01-06 < 36 >

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
50
Late closing
mm

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

Engine speed
70 18

MEP
16

14
bar(abs)
Mean effective pressure 150 12

140

Cyl. Pressure
130
Maximum pressure

120
bar(abs)
110 4

100

Compression pressure
90 3

P-scav
deg.C

Scavenge air pressure 450 2


Exh. Gas Temp.

400

Exhaust gas temperature 350 1


inlet to turbocharger

300

Exhaust gas temperature


outlet from turbocharger 250
g/kWh
180
SFOC

170

Specific fuel oil


consumption 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 <1>

The ME Engine
Hydraulic Oil Loop
MAN B&W Diesel

Fuel oil pressure


Exhaust valve actuator
booster
Fuel 10 bar Hydraulic
cylinder unit
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
Fine aut. filter Accumulator
blok
Main lube
pump
Servo oil
Piston cooling
+ bearings
Servo oil
return to sump

From sump ISO 4406: 13/16


Engine driven EL. driven
NAS Code: 7 hydraulic pumps hydraulic pumps

MAN B&W Diesel L/73273-7.1/0403 (2600/RL) 2006-01-23 <2>

Separat hydraulic system


MAN B&W Diesel

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <3>

1
Filter Unit, Schematic
MAN B&W Diesel

Old plants = 10 Older plants are equipped with a by-


New plants = 6 pass valve which opens at 0.8 bar
25 after the filter

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <4>

Filter unit
MAN B&W Diesel

Single filter unit

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <5>

Filter unit
MAN B&W Diesel

Filtering process Back flushing process


MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <6>

2
Backflushing line to Lub. Oil tank
MAN B&W Diesel

The purifier suction pipes have the same


diameters but a different lenght.
The purifier will suck primarily from the sump
tank.
The oil level in the 2 tanks will remain more or
less equal due to the interconnection.
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 <7>

Start up pumps, fixed


MAN B&W Diesel

P2

P1

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <8>

Start up pumps, fixed


MAN B&W Diesel

Automatic mode:
Stopped at Finish With Engine.
Master pump running at engine
standby. (both pumps are running
during pressure build up).
Stopped via a timer at a specified
engine RPM

Manual mode:
Controlled by the operator via the
Main Operating Panel

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 <9>

3
El-driven pumps
MAN B&W Diesel

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 10 >

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 2006-01-23 < 11 >

Engine driven pumps


MAN B&W Diesel

Automatic mode:
The pressure set point is depending on the engine load.
The pumps have two running modes, 1 in pressure control mode [Ctrl]
(selected via the MOP screen), 2 in follow mode [Folw].
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 %.
In case the pressure controlling pump faces a failure, one of the other pumps
will take over pressure control.

Manual mode:
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

In case of control failure of a pump, the swash plate will be forced to


maximum capacity in AHEAD direction.

Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.

Pump Nos. 1, 2, and 3 have their own sensor for system pressure,
connected to their controlling ACU

Pump 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.

All 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 >

Leak detection
MAN B&W Diesel

Shut down level

Alarm level
MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 14 >

Leak detection
MAN B&W Diesel

Box for hydraulic pumps

Drainpipe

Sensor LS 1235 & JS 1236, vibrating fork type.


LS 1235 = Alarm LS 1236 = Cancelable Shut Down

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 15 >

5
Engine driven pumps
MAN B&W Diesel

Alarm level Shut down level


Sensors for suction pressure. Low pressure = shut down
MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 13 >
Engine driven pumps
MAN B&W Diesel

Alarm level Shut down level


Sensors for suction pressure. Low pressure = shut down
MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 16 >

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 2006-01-23 < 17 >

ME Engine, Pump Drive


and Moment Compensator
MAN B&W Diesel

MAN B&W Diesel L/73898-1.0/0303 (2600/RL) 2006-01-23 < 18 >

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 >

ME Engine, Pump Drive


MAN B&W Diesel

Hydraulic Pump

Step Up Gear

Chain wheel for


4 Duplex chain

MAN B&W Diesel 2006-01-23 < 20 >

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 >

K98ME(-C) Pump drive


MAN B&W Diesel

MAN B&W Diesel 2510/ERA Nov. 2003. 2006-01-23 < 23 >

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 Nov. 2003. < 25 >

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 >

8-9K98ME/ME-C new design


MAN B&W Diesel

4 x 500 ccm pumps

Fore side Aft side

MAN B&W Diesel 2006-01-23 < 27 >

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
: Swash plate angle
Animation.lnk

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 29 >

Axial piston pump


MAN B&W Diesel

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 30 >

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 >

Engine driven pump 750 ccm


MAN B&W Diesel

MAN B&W Diesel Hydraulic power supply - Tom Ballegaard/4140 2006-01-23 < 35 >

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 2006-01-23 < 36 >

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 >

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 2006-01-23 < 38 >

K98ME/-C new design


MAN B&W Diesel

Modulated Accumulator block

Top mounted Fore section

Top mounted Aft section

MAN B&W Diesel 2006-01-23 < 39 >

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 >

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 2006-01-23 < 41 >

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 <1>

Hydraulic Cylinder Unit


HCU
MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 <2>

Hydraulic Cylinder Unit


HCU
MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 <3>

1
ME(-C) Hydraulic Cylinder Unit
MAN B&W Diesel

MAN B&W Diesel 05-02-2004 (2500/KNB)

ME(-C) Hydraulic cylinder Unit


MAN B&W Diesel
(FIVA)

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 <6>

2
Accumulator
MAN B&W Diesel

1. Assemble without the


diaphragm. Make the mark
1.

2. Assemble with the diaphragm.


Tighten until the ofset D06-216
2.
is achieved

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 <7>

Accumulator
Nitrogen check
MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 <8>

Cylinder lubricator system


MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 <9>

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 ME-


ME-Engine
MAN B&W Diesel

Cylinder lub. Inductive proximity sensor


oil inlet 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 Injection plunger
lub. oil
injectors

Spacer for
basic setting of
pump
stroke
Drain 200 bar system oil supply
Non-return valve Stroke oil
adjusting outlet Actuator
screw piston
Sealingring

MAN B&W Diesel Hydraulic Cylinder


3331377/20041021 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 Cylinder liner
valve

MAN B&W Diesel 3331050/20031212 (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 >

Auxiliaries:
Cylinder Lubricators
MAN B&W Diesel

Sulphur % Minimum feed rate


(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 2006-01-19 < 17 >

Adjustment of cylinder oil


lubrication
MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 < 18 >

6
Adjustment of cylinder oil
lubrication
MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 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 fail-
ing CCU.

See figure 1. The activation signal from J52 on ECUA/B is random.

Fig. 1
LUBRICATOR
ACTIVATION
BACK UP

SOLENOID
VALVE
LUBRICATOR
IN/OUT

24VDC
OVDC
GND

v_IN

0 1 2 3 4 5 6 7 8 9

ME lubricator
J52
+ECU A/B

C
D
B
+ECU A/B

1x2x0,75 mm
/ /
2

WLUB_BACK UP
=SOLENOID VALVE

A1
A2
S9030031C01

SOLENOID
VALVE
LUBRICATOR

When referring to this page, please quote S-Instruction S903 Edition 0031 Page 1
MAN B&W Diesel A/S
Emergency cylinder lubrication
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.

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 < 19 >

Emergency cylinder lubrication


MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 < 20 >

Hydraulic Cylinder Unit


MAN B&W Diesel 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 >

MAN B&W Diesel


Hydraulic Cylinder Units (HCU)
HCUs 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 >

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/RL)

Tool for high pressure doublepipe


MAN B&W Diesel

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 2006-01-19 < 27 >

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

Safety and
Accumulator
ELFI ELVA
Block

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Valve 315

MAN B&W Diesel Hydraulic Cylinder Unit - Tom Ballegard/4140 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
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 >
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 indepen-
dent 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
h
1.40 /k W
.3 4]g
1.30 0
26-
Absolute dosage (g/kWh)

1.20 = [0.
1.10 r eF
he
1.00 %,w
S
0.90 , Fx
70
0.80 Average dosage: 0.8 g/kWh BN
0.70
0.60

Average sulphur worldwide


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 0.60-
0.70 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


h
1,70 W
/k
1,60 ]g
34
1,50 -0.
26
1,40 [ 0. h
kW
1,30 0
x
4]g/
/4 .3
Absolute dosages (g/kWh)

70 6 -0
1,20 = 0.2
F
F =[
1,10 e
h er ere
h
1,00 ,w ,w
0,90 S %
x S%
x ,F
0,80 ,F N70
40 B
0,70 BN
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 low-
BN 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 Ole Grne

Encl.
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

Standard BN 70 cylinder oil BN 40 cylinder oil

0.26-0.34 g/kWh x S% 0.26-0.34 g/kWh x 70/40 x S%


Basic setting
0.19-0.25 g/bhph x S% 0.19-0.25 g/bhph x 70/40 x S%

0.60-0.70 g/kWh
Minimum feed rate
0.45-0.50 g/bhph

Maximum feed rate 1.7 g/kWh


during normal service 1.25 g/bhph
Proportional to engine load
Part-load control
Below 25% load, proportional to MEP (Mean Effective Pressure)
Alu-coated or First 5 hours: 1.7 g/kWh
hard-coated From 5 to 250 hours: 1.5 g/kWh
Feed piston rings: From 250 to 500 hours: 1.2 g/kWh
Running-in rate: First 15 hours: 1.7 g/kWh
new or Non-coated: From 15 to 250 hours: 1.5 g/kWh
reconditioned From 250 to 500 hours: 1.2 g/kWh
liners and
Alu-coated or
new piston
hard-coated Stepwise increase to max. load over 5 hours
rings Engine piston rings:
load:
Non-coated: Stepwise increase to max. load over 15 hours

Alu-coated or hard-
Running-in new rings in
coated piston rings : No load restrictions
already run-in and well
Non-coated rings : Stepwise increase to max. load over 5 hours
running liners:
Feed rate : Basic setting +25% for 24 hrs.

During starting, manoeuvring and load changes, the feed rate


Manoeuvring and load
should be increased by 25% and kept at this level for hour after
change situations.
the load has stabilised.

Frequent scavenge port inspections of piston rings and cylinder


liners are very important for maintaining a safe cylinder condition.
Lubrication of cylinders
If irregularities are seen, adjustments of the lube oil rate should be
that show abnormal
considered.
conditions:
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
Encl. 2 for SL05-455/HRJ

Adjusting Alpha Lub. using ACC, BN 40 Cylinder Oil

ACC factor g/kWh x S%


HMI
0,26 0,27 0,29 0,30 0,31 0,33 0,34 g/kWh
setting
Sulphur content %
0 0 0 0 0 0 0 0,61 56
1,4 1,3 1,2 1,2 1,1 1,1 1,0 0,61 56
1,5 1,4 1,3 1,3 1,2 1,1 1,1 0,65 60
1,6 1,5 1,4 1,4 1,3 1,3 1,2 0,71 66
1,7 1,6 1,5 1,5 1,4 1,4 1,3 0,77 71
1,8 1,8 1,7 1,6 1,5 1,5 1,4 0,83 77
2,0 1,9 1,8 1,7 1,6 1,6 1,5 0,89 82
2,1 2,0 1,9 1,8 1,7 1,7 1,6 0,95 88
2,2 2,1 2,0 1,9 1,8 1,8 1,7 1,01 93
2,4 2,3 2,1 2,0 2,0 1,9 1,8 1,07 98
2,5 2,4 2,3 2,2 2,1 2,0 1,9 1,13 104
2,6 2,5 2,4 2,3 2,2 2,1 2,0 1,19 109
2,8 2,6 2,5 2,4 2,3 2,2 2,1 1,25 115
2,9 2,8 2,6 2,5 2,4 2,3 2,2 1,31 120
3,0 2,9 2,7 2,6 2,5 2,4 2,3 1,37 126
3,2 3,0 2,9 2,7 2,6 2,5 2,4 1,43 131
3,3 3,1 3,0 2,8 2,7 2,6 2,5 1,49 137
3,4 3,3 3,1 3,0 2,8 2,7 2,6 1,55 142
3,6 3,4 3,2 3,1 2,9 2,8 2,7 1,61 148
3,7 3,5 3,3 3,2 3,0 2,9 2,9 1,73 160
3,8 3,6 3,4 3,2 3,1 3,0 2,9 1,70 156

HRJ/JCB
September 2005
Encl. 3 for SL05-455/HRJ

Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil

ACC factor g/kWh x S%


HMI
0,26 0,27 0,29 0,30 0,31 0,33 0,34 g/kWh
setting
Sulphur content %
0,0 0,0 0,0 0,0 0,0 0,0 0,0 0,60 56
0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,60 56
1,0 1,0 1,0 1,0 1,0 1,0 1,0 0,60 56
1,1 1,1 1,1 1,1 1,1 1,1 1,1 0,60 56
1,2 1,2 1,2 1,2 1,2 1,2 1,2 0,60 56
1,4 1,4 1,3 1,3 1,3 1,3 1,3 0,60 56
1,6 1,6 1,4 1,4 1,4 1,4 1,4 0,60 56
1,8 1,8 1,6 1,6 1,5 1,5 1,5 0,60 56
2,0 2,0 1,8 1,8 1,6 1,6 1,6 0,60 56
2,2 2,2 2,0 1,9 1,8 1,7 1,7 0,60 56
2,4 2,3 2,1 2,0 2,0 1,9 1,8 0,60 56
2,5 2,4 2,3 2,2 2,1 2,0 1,9 0,65 59
2,6 2,5 2,4 2,3 2,2 2,1 2,0 0,68 63
2,8 2,6 2,5 2,4 2,3 2,2 2,1 0,71 66
2,9 2,8 2,6 2,5 2,4 2,3 2,2 0,75 69
3,0 2,9 2,7 2,6 2,5 2,4 2,3 0,78 72
3,2 3,0 2,9 2,7 2,6 2,5 2,4 0,82 75
3,3 3,1 3,0 2,8 2,7 2,6 2,5 0,85 78
3,4 3,3 3,1 3,0 2,8 2,7 2,6 0,88 81
3,6 3,4 3,2 3,1 2,9 2,8 2,7 0,92 84
3,7 3,5 3,3 3,2 3,0 2,9 2,8 0,95 88
3,8 3,6 3,5 3,3 3,2 3,0 2,9 0,99 91
3,9 3,8 3,6 3,4 3,3 3,1 3,0 1,02 94
4,1 3,9 3,7 3,5 3,4 3,2 3,1 1,05 97
4,2 4,0 3,8 3,6 3,5 3,3 3,2 1,10 100
4,3 4,1 3,9 3,8 3,6 3,4 3,3 1,12 103
4,5 4,3 4,0 3,9 3,7 3,5 3,4 1,16 106
4,4 4,2 4,0 3,8 3,6 3,5 1,19 109
4,5 4,3 4,1 3,9 3,8 3,6 1,22 113
4,4 4,2 4,0 3,9 3,7 1,26 116
4,5 4,3 4,1 4,0 3,8 1,29 119
4,4 4,2 4,1 3,9 1,33 122
4,5 4,3 4,2 4,0 1,36 125
4,5 4,3 4,1 1,39 128
4,4 4,2 1,43 131
4,5 4,3 1,46 134
4,4 1,50 138
4,5 1,53 141

HRJ/JCB
September 2005
5. Fuel System
MAN B&W Diesel

1) Fuel oil pressure


booster

2) Adjustments

MAN B&W Diesel 2006-01-26 <1>

ME Fuel Oil Pressure Booster


MAN B&W Diesel

S50MC-
S50MC-C S50ME-
S50ME-C

Suction Valve Fuel Plunger

Fuel oil
oil inlet
pressure 8 bar
Feed back
Position sensor

Hydraulic actuator

7S50ME-
7S50ME-C

MAN B&W Diesel 2006-01-26 <2>

98ME(-C) Fuel Oil Pressure Booster


MAN B&W Diesel

MAN B&W Diesel 01-10-2003 (2500/KNB) 2006-01-26 <3>

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
ELFI / FIVA accumulator
Proportional
Valve

7S50ME-
7S50ME-C
To drain High pressure hydraulic oil - inlet
MAN B&W Diesel 2006-01-26 <4>

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 ELFI
chamber via the ELFI valve. Valve

4. The accumulators are supplied by the


Hydraulic Power Supply. The pressurised
hydraulic oil is held back by the closed ELFI
valve.

Unpressurised fuel oil


Pressurised fuel oil
Unpressurised hydraulic oil
Pressurised hydraulic oil

MAN B&W Diesel 2006-01-26 <5>

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 ELFI
upwards.
Valve
7. The fuel oil inlet is closed.
8. The pressure on the fuel oil rises and
exceeds the force of the spring in the
cylinders fuel injection valve.

Unpressurised fuel oil


Pressurised fuel oil
Unpressurised hydraulic oil
Pressurised hydraulic oil

MAN B&W Diesel 2006-01-26 <6>

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 <7>

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 <8>

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 <9>

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 >

Suction Valve, S70ME


MAN B&W Diesel

MAN B&W Diesel Fuel oil pressure booster - Tom Ballegaard/4140 2006-01-26 < 11 >

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: 460 Nm

MAN B&W Diesel Fuel oil pressure booster - Tom Ballegaard/4140 2006-01-26 < 12 >

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 >

Suction Valve, K98ME


MAN B&W Diesel

MAN B&W Diesel 2006-01-26 < 14 >

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: 1165 Nm

MAN B&W Diesel 2006-01-26 < 15 >

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) <1> MAN B&W Diesel <2>

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) <3> MAN B&W Diesel 2006.01.16 (4140 / PWN) <4>

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) <5> MAN B&W Diesel 2006.01.16 (4140 / PWN) <6>

1
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) <7> MAN B&W Diesel 2006.01.16 (4140 / PWN) <8>

MAN B&W Diesel MAN B&W Diesel

Hydraulic
push rod

Exhaust valve Exhaust valve


Actuator spindle

High pressure
hydraulic oil
inlet

ELVA on-off
valve Membrane
accumulator

To drain

MAN B&W Diesel 2006.01.16 (4140 / PWN) <9> MAN B&W Diesel 2006.01.16 (4140 / PWN) < 10 >

The ME Engine
ME Exhaust Valve & Actuator Exhaust Valve Timing
MAN B&W Diesel MAN B&W Diesel

mm Early opening Reference Early closing


80 Late opening 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 Units (HCU) Hydraulic Cylinder Unit
MAN B&W Diesel MAN B&W Diesel

HCUs 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

High pressure oil inlet Distribution Block


from the HPS

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 13 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 14 >

HCU Two-Stroke Medium Bore


ME Engine, Design Concept
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 >

Actuator for Exhaust Valve Exhaust Valve Actuator


MAN B&W Diesel MAN B&W Diesel

The ELVA valve which drives the actuator Mounted on top of the distributor block.
on the exhaust side has two positions,
open or shut. Hydraulic push rod for opening/closing
Actuator the exhaust valve
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 engines exhaust valve via the ELVA Two-stage piston.
hydraulic push rod. Second stage

The pressure is permanently maintained


First stage
until the ELVA valve is activated to block
the pressure when the required exhaust phase
is completed.

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

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 S50ME-C
Exhaust Actuator
Top cover Air spring size
for closing the
Minimesh exhaust valve
reduced Hydraulic damper for
Actuator house
fixed valve stroke
introduced

Actuator Piston
New valve spindle
1. Step
design introduced

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 >

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 2006.01.16 (4140 / PWN) < 24 >

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 2006.01.16 (4140 / PWN) < 28 >

MAN B&W Diesel MAN B&W Diesel


ME Exhaust valve

S50MC-C S50ME-C

Air spring
size for
closing the
exhaust valve Hydraulic damper for
reduced. 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
Exh. Valve Exhaust Valve Top
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 31 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 32 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 33 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 34 >

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 2006.01.16 (4140 / PWN) < 38 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 39 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 40 >

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 2006.01.16 (4140 / PWN) < 42 >

7
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 43 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 44 >

Dismantling of High Pressure Pipe 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 ELVA On/Off Valve
hydraulic system. 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 >

Hydraulic Cylinder Unit (HCU) Dismantling of High Pressure Pipe


MAN B&W Diesel MAN B&W Diesel

Fuel injection Valve actuation

ELFI Proportional Valve


Fuel Pump Close the valve 531 for
ELVA On/Off Valve the actuator oil supply
Exhaust Valve Actuator
and
the valve 536
for damper oil supply.

Accumulator
Distribution Block

MAN B&W Diesel 2006.01.16 (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 2006.01.16 (4140 / PWN) < 50 >

Overhaul of High Pressure Pipe 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 >

Mounting of High Pressure Pipe Exh. Valve Sealing Air / Oil Dosage Unit
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 2006.01.16 (4140 / PWN) < 56 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 57 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 58 >

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 Spring tension


4 5 bar 4 5 bar

10 15 bar 10 15 bar
oil pressure. oil pressure.
MAN B&W Diesel 2006.01.16 (4140 / PWN) < 61 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 62 >

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 2006.01.16 (4140 / PWN) < 64 >

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 2006.01.16 (4140 / PWN) < 66 >

11
MAN B&W Diesel MAN B&W Diesel

Small dent marks on the


seating are acceptable
and need NOT to be
K98MC/ME
ground away if they dont
make blow-by.

Small dent marks on the spindle seating are acceptable and


need NOT to be ground away if they dont make blow-by.
MAN B&W Diesel 2006.01.16 (4140 / PWN) < 67 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 68 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 69 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 70 >

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 Cooled Alloy 50
60 - 90 MC 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 Cooled W-seat
46 - 98 MC Semi-cooled W-seat

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 71 > MAN B&W Diesel 2005.05.25 4140/PWN < 72 >

12
Exhaust Valve Spindle &
Bottom Piece 98MC/MC-C 26MC
MAN B&W Diesel MC EXHAUST VALVE MAN B&W Diesel

Chamber seat W-seat 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.
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 16,000 h between overhauls
part of the seats.
60-100,000 h lifetime for spindle
> 30,000 h lifetime for bottom piece

MAN B&W Diesel 2005.05.25 4140/PWN < 73 > MAN B&W Diesel 2005.05.25 4140/PWN < 74 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2005.05.25 4140/PWN < 75 > MAN B&W Diesel 2005.05.25 4140/PWN < 76 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2005.05.25 4140/PWN < 77 > MAN B&W Diesel 2005.05.25 4140/PWN < 78 >

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 - References of W-seats


Small/medium bore running for more than 36000
hours without any grinding
and only very small dent marks
New seal for
bottom piece Hole for indication of cooling
lower groove 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 >

Bottom Piece W-Seat


MAN B&W Diesel MAN B&W Diesel

U-Type Sealing Ring:


Heat the sealing ring in 100C hot
water for at least five minutes
before mounting

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 83 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 84 >

14
MAN B&W Diesel MAN B&W Diesel MC EXHAUST VALVE
Valve spindle for engine types: K/L/S-MC/-C/-S
1983 - 1992:
26 - 50 MC Alloy 50
60 - 90 MC Stellite 6

Cr (0.25 mm) 1992 2002:


HVOF (0.15 mm) Nimonic
26 - 50 MC Alloy 50
S50MC / 60 - 98 MC Nimonic

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

1983 1996: Cr stem coating


Alloy 50 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 HVOF-coating
the performance of the exhaust valve
seat.

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 >

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 2006.01.16 (4140 / PWN) < 90 >

15
Exhaust Valve Nimonic Spindle
MAN B&W Diesel MAN B&W Diesel

Formation of dent marks is an


inevitable consequence of service HVOF-coating
on
heavy fuel oil.

Dent marks may appear harmful, but


will in general have no influence on Vane wheel for gas
driven spindle rotation
the performance of the exhaust
valve
seat.

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 >

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 2006.01.16 (4140 / PWN) < 94 >

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 2006.01.16 (4140 / PWN) < 98 >

MC EXHAUST VALVE 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 >

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 2006.01.16 (4140 / PWN) < 102 >

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 >

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 Decreased
W-seat diameter

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 105 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 106 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 107 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 108 >

18
MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 109 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 110 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 111 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 112 >

MAN B&W Diesel MAN B&W Diesel

MAN B&W Diesel 2006.01.16 (4140 / PWN) < 113 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 114 >

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.

1. Close valve 420


421
2. Open valve 421
MAN B&W Diesel 2006.01.16 (4140 / PWN) < 117 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 118 >

SPECIAL RUNNING CONDITIONS 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
2. Close valve 421
MAN B&W Diesel 2006.01.16 (4140 / PWN) < 119 > MAN B&W Diesel 2006.01.16 (4140 / PWN) < 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 2006.01.16 (4140 / PWN) < 122 >

98ME Special Running 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 2006.01.16 (4140 / PWN) < 124 >

98ME Special Running 98ME Special Running


MAN B&W Diesel MAN B&W Diesel

Open damper oil supply

Reconnect air supply Mount pressure gauge at minimess point 455


under air piston
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 Open damper oil supply, valve 531

exhaust valve open and mount


Disconnect air supply to air cylinder
Reconnect air supply
the plug screw.
under air piston

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:


Alarms
Engine:
Auxiliaries
Maintenance
Admin
MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <1>

Engine:
Operation
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <2>

Access Level
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <3>

1
Engine:
Status
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <4>

Engine:
Process Information
MAN B&W Diesel Running Mode

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <5>

Engine:
Process Information
MAN B&W Diesel Speed Control

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <6>

2
Engine:
Cylinder Load
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <7>

Engine:
Cylinder Pressure
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <8>

Auxiliaries:
Hydraulic System
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 <9>

3
Auxiliaries:
Scavenge Air
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 10 >

Auxiliaries:
Cylinder Lubricators
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 11 >

Maintenance:
System View, I/O Test
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 12 >

4
Maintenance:
System View, I/O Test
MAN B&W Diesel ECU-A

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 13 >

Maintenance:
System View, I/O Test
MAN B&W Diesel ECU-A, Channel-35

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 14 >

Maintenance
Invalidated Inputs
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 15 >

5
Maintenance
Network Status
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 16 >

Admin.:
Version
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 17 >

Admin.:
Set Time
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 18 >

6
Alarms:
Alarm List
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 19 >

Alarms:
Alarm List
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 20 >

Alarms:
Event Log
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 21 >

7
Alarms:
Manual Cut-Out List
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 22 >

Alarms:
Channel List
MAN B&W Diesel

MAN B&W Diesel MOP displays - Tom Ballegaard/4140 2006-01-05 < 23 >

8
8. PMI
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <1>

PMI system
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <2>

PT diagram
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <3>

1
PT diagram - zoomed
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <4>

PV diagram
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <5>

Balanced plot, Pmax - Pcomp


MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <6>

2
Balanced plot, Pi
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <7>

Calculated values
MAN B&W Diesel

MAN B&W Diesel PMI system - Tom Ballegaard / 4140 2006-02-19 <8>