RT-flex mechanical features

RT-flex Training

Mechanical Features
(RT-flex Specific Parts only)

Chapter 20

Wrtsil Land & Sea Academy Page 1 Chapter 20 1-Nov-07

RT-flex mechanical features RT-flex specific parts only

Wrtsil Land & Sea Academy Page 2 Chapter 20 1-Nov-07

RT-flex mechanical features Overview, RT-flex84 and 96 (Size 4)

Rail Unit(s)
WECS-9520,
E90 Shipyard
Interface Box (SIB)
or at the free end
(smaller engines)

WECS-9520, E95
Cylinder Electronic
Unit Terminal boxes

Supply unit
Control oil
Automatic filter Pumps

Wrtsil Land & Sea Academy Page 3 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit

For engines with more than 7

cylinders, the rail unit is split in two
parts.

Both rail-sections (forward/aft) for

fuel-, servo- and control oil are
connected by high pressure pipes.
=> Same pressure in the related
rails of both halves.

WECS-9520 Cylinder-Electronic
Unit boxes are fitted on the outer
front side

SIB (E90) Box on free end or in the

middle of the rail unit depending on
the number of cylinders (up to 7
cylinders in the middle)

Protection bars

Wrtsil Land & Sea Academy Page 4 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit, Size 4

Wrtsil Land & Sea Academy Page 5 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Main Parts
Steam Fuel oil rail
Fuel oil rail: ICUs
The fuel rail contains high pressure fuel of
~ 600 - 800 bar delivered by the fuel pumps of
the supply.

For each cylinder, there is an Injection Control

Unit (ICU).
The rail is heated by a trace heating piping system.

Servo oil rail:

The servo oil rail contains fine filtered (6-micron) high
pressure servo oil, ~ 80 - 190 bar, delivered by the servo Control
oil pumps of the supply unit, depending on engine load. oil rail
For each cylinder there is a Valve Control Unit (VCU).
Servo oil rail
Control oil rail (some engine types only):
The control oil rail contains 200 bar control oil (constant pressure) delivered by the control VCUs
oil pumps.

Additional return/leakage piping:

One fuel ICU-leakage pipe
One common servo oil/control oil return pipe

Wrtsil Land & Sea Academy Page 6 Chapter 20 1-Nov-07

RT-flex mechanical features (fuel) Injection Control Unit (ICU)

RT-flex96C

Wrtsil Land & Sea Academy Page 7 Chapter 20 1-Nov-07

RT-flex mechanical features ICU, Size 4

Wrtsil Land & Sea Academy Page 8 Chapter 20 1-Nov-07

RT-flex mechanical features ICU
Fuel quantity sensor
Servo (control) oil side:
Fuel quantity piston The rail valves control the oil flow to the control oil
block.
Servo (control) oil side
Fuel side:
Servo oil The fuel control valves are actuated by pistons in the
Rail valves return control oil block. There is one valve for each injector.
The main body of the ICU includes the injection
quantity piston.
Fuel control Fuel Quantity Sensor in a housing kept away from
valves the hot block.

Control- and fuel oil side are entirely separated from

each other. Nevertheless, leakages of both systems
have a common drain.

Working principle:
Each ICU is pre-controlled by 2 or 3 rail valves to
Servo oil open or close the way for fuel from the rail to the
supply injection nozzles.
Fuel side Fuel for each injection, necessary stroke is calculated
and quantified, then injected, measured and corrected
for the next injection.
Wrtsil Land & Sea Academy Page 9 Chapter 20 1-Nov-07
RT-flex mechanical features Fuel Nozzle

Fuel nozzle with

venting spiral

Opening pressure 375 bar

Wrtsil Land & Sea Academy Page 10 Chapter 20 1-Nov-07

RT-flex mechanical features (exhaust) Valve Control Unit (VCU)

Valid for flex 50B, 58T (MKII),

60C (MKII), 68B, 84T-D

Wrtsil Land & Sea Academy Page 11 Chapter 20 1-Nov-07

RT-flex mechanical features VCU

Valid for flex 58T (MKI),

60C (MKI), 96C-B

Wrtsil Land & Sea Academy Page 12 Chapter 20 1-Nov-07

RT-flex mechanical features VCU

To exhaust valve
The servo oil supply from the servo oil rail to
3/2 way valve the 3/2 way valve is done via connecting
element. The 3/2 way valve is pre-controlled by
a rail valve (same type as for ICU).
Rail valve
Main bearing oil The servo oil return pipe has a back pressure
supply of ~2-3 bar to dampen pressure peaks.

To the upper part of the VCU/actuator pipe,

there is a main bearing oil inlet via a non-return
valve, in order to fill up the oil losses through
the orifice in the exhaust valve drive.
VCU cylinder
and piston

Connecting
element
Servo oil return

Shown for flex 58T (MKI),

60C (MKI), 96C-B

Wrtsil Land & Sea Academy Page 13 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Piping

Shown for RT-flex96C-B

Wrtsil Land & Sea Academy Page 14 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Piping

Shown for RT-flex96C-B

Wrtsil Land & Sea Academy Page 15 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Piping, Size 4
Control oil
high pressure
hoses

Trace heating

Fuel oil rail

ICU and injection high pressure

pipe leakage drain pipe
(connected to leakage collector
=> Alarm to AMS)

Servo oil rail Control oil rail

Main bearing oil supply pipe for Servo oil (and control oil)
upper side of VCU (flex96C-B common return pipe
only)

Wrtsil Land & Sea Academy Page 16 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Piping

At each inlet, there are shut-off valves, in order to

isolate individual HP-pipes in case of leakages.

Fuel-, servo- and control oil inlet to the rails are

between the two rail unit halves (if more than 7
cylinders).

For redundancy reasons there are for each

system two rising pipes connected to the two rail
unit halves.

The cross-connection high pressure pipes enable

a direct connection between each rail for

pressure equalization

if one HP pipe is broken, it can be shut-off on
both ends and the remaining one feeds both
rails

Wrtsil Land & Sea Academy Page 17 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Unit Piping

Rail unit general drain piping. Possible leaks of fuel, oil and water are collected for each
rail => Alarm to Alarm System Rail Unit (FWD), General Leak.
The leakage is drained to the sludge tank.

Wrtsil Land & Sea Academy Page 18 Chapter 20 1-Nov-07

RT-flex mechanical features Fuel Rail Pipe

Shown for RT-flex96C

The fuel rail pipe is made of one piece.

The bore has a shape of a peanut.

Wrtsil Land & Sea Academy Page 19 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Valves

Wrtsil Land & Sea Academy Page 20 Chapter 20 1-Nov-07

RT-flex mechanical features Rail Valve RV-2
Injection / Valve open

Rail valve are quick acting 3/2-way solenoid valves. Each cylinder unit has four
rail valves. Three of them are pre-controlling an ICU, one of them is
pre-controlling the VCU. Flex50 has only two rail valves per ICU.
Following an injection/return- or open/close command of WECS-9520, the
corresponding coils are energized for a very short time (normal operation
~1 ms, max. 4.5 ms), but with a high current impulse (~50-60A).
Iron core
This makes the valve spindle move towards the energized coil
(~0.3 mm stroke). Valve spindle
Control oil inlet
The high current impulse and the short travel of the valve
Inlet/outlet to ICU/VCU
spindle enable a very short actuation time, which is Outlet to return pipe
indispensable for precise injection- or exhaust valve control.

The rail valves are non-serviceable. Nevertheless, if dirt Coils

particles are suspected to influence proper operation, the
valves can be opened and blown out by air.
Pay attention to the assembly position of valve spindle.
Electric sockets

No injection / Valve close

Wrtsil Land & Sea Academy Page 21 Chapter 20 1-Nov-07
RT-flex mechanical features Exhaust Valve Drive (96C)

Damper Orifice
Main differences to a conventional
RTA-valve drive:
Oil inlet from
 The exhaust valve is actuated by a exhaust valve
double piston drive, in order to save oil actuator pipe
volume
 Two redundant exhaust valve stroke Double piston
sensors for monitoring drive

 One measuring cone for stroke sensors

Measuring cone
 Air spring piston runs directly in the
housing. Two exhaust valve Joint ring
stroke sensors
 The disc spring package is dampening
opening stroke in case of low air spring Air spring piston
pressure
Disc spring package

Exhaust valve spindle

Wrtsil Land & Sea Academy Page 22 Chapter 20 1-Nov-07

RT-flex mechanical features Supply Unit Drive

3-lobe cams Supply unit gearwheel

The supply unit is driven by the crankshaft, via Drawn for Size 4
two intermediate gearwheels.

3-lobe cams are mounted to the camshaft (size 0

and 3 with single lobe forged camshaft).

The servo oil pumps are driven by individual

pinions, having a mechanical fuse (reduced
diameter in pinion), in order to protect the gear-
drive in case of a pump seizure. The servo oil
pump gearwheel is hydraulically fitted as well.
Camshaft bearing
Since the supply unit, i.e. fuel pumps and servo covers
oil pumps have no timing, means they just supply
fuel or oil, the camshaft doesnt have to have a
determined position compared to crankshaft. Servo oil
pump drive
However the position of the cams relative to
gearwheel
each other must be respected. 2nd intermediate and pinions
gearwheel

Wrtsil Land & Sea Academy Page 23 Chapter 20 1-Nov-07

RT-flex mechanical features Supply Unit, Size 4

Wrtsil Land & Sea Academy Page 24 Chapter 20 1-Nov-07

RT-flex mechanical features Supply Unit
Fuel intermediate
Fuel side: accumulator
The jerk-type fuel oil pumps deliver fuel
into the intermediate accumulator. To keep Fuel outlet
the rail pressure (600 - 900 bar), the pump Electric actuators to rail
flow rate is regulated via regulating linkage
Servo oil collector
and el. actuators, by pressure set point block
signals from WECS.

From the accumulator there are two outlets,

connecting the accumulator to the fuel rail
via two rising pipes.

Servo oil side:

The servo oil pumps are made by Dynex or Servo oil
outlet to rail Fuel pumps
Bosch. They deliver servo oil into servo oil
collector block with a pressure of ~ 80 -190
bar. There are two outlets from the collector
block, connecting to the servo oil rail via two
rising pipes.

The number of fuel- and servo oil pumps Servo oil pumps 2nd intermediate
depends on the number of cylinders. (shown here as Bosch)
gearwheel

Wrtsil Land & Sea Academy Page 25 Chapter 20 1-Nov-07

RT-flex mechanical features Supply Unit
Shutdown & Shutdown solenoid
overpressure valve
regulating
valve
Fuel drain

Shown
size 4

Fuel inlet from Fuel return to mixing

booster unit tank via pressure Intermediate accumulator with
retaining valve. two safety valves (1250 bar).

Wrtsil Land & Sea Academy Page 26 Chapter 20 1-Nov-07

RT-flex mechanical features Fuel Pump

Wrtsil Land & Sea Academy Page 27 Chapter 20 1-Nov-07

RT-flex mechanical features Fuel Pump
Buffer space

Fuel pumps: Non return valve

Pump cylinder
The jerk-type fuel pumps deliver a
variable quantity of fuel to the
Pump plunger
intermediate accumulator and fuel rail, in
order to maintain the demanded rail Pump cover
Regulating sleeve
pressure.
They do not have any timing. Compression spring
To change the feed quantity, the pump Regulating rack
plunger is turned by the regulating rack.
Upper housing
The roller guide/roller assembly and
regulating sleeve are lubricated by main Roller guide
bearing oil via a double orifice.

Roller Lower housing

Wrtsil Land & Sea Academy Page 28 Chapter 20 1-Nov-07

RT-flex mechanical features Fuel Pump

Wrtsil Land & Sea Academy Page 29 Chapter 20 1-Nov-07

RT-flex mechanical features Fuel Pump

Plunger position at regulating linkage position:

Pos: 0 Pos: 5 Pos: 10

No delivery Half delivery Full delivery

Wrtsil Land & Sea Academy Page 30 Chapter 20 1-Nov-07

RT-flex mechanical features Regulating Linkage

Fuel pump regulating linkage:

Electric fuel pump actuators
The regulating linkage is moved by Woodward
(ProAct IV) electric actuators. They receive a
position set point signal from WECS.
One actuator controls two fuel pumps (the
arrangement of actuators can differ among
engine cylinder numbers).

The torque from linkage shaft to fork lever is

transmitted in both directions via torsional
springs. If a regulating rack of a pump is stuck
for some reason, the springs will compensate,
Local position so the other pump can still be regulated.
indication (0-10).
No load indicator !!
Torsional springs
Fork lever

Additional spring to push the rack,

in case of failure, to full position

Wrtsil Land & Sea Academy Page 31 Chapter 20 1-Nov-07

RT-flex mechanical features Supply Unit, Servo Oil (96C)
Servo oil pumps arrangement:
The servo oil pumps supply oil to the collector block, which has two high pressure outlet pipes to the
servo oil rail. A safety valve limits the max. pressure to 230 bar.
The number of servo oil pumps depends on the number of cylinders. If one pump fails, the engine can
still be operated.
Flow sensor
Safety valve Non return valves
at each inlet

High pressure
pipes

Collector Block

Oil supply Servo oil

pumps

Bosch pumps arrangement (some engines only). Dynex pumps arrangement

Wrtsil Land & Sea Academy Page 32 Chapter 20 1-Nov-07
RT-flex mechanical features Servo oil pump Dynex
Suction port

Compensator valve with solenoid

HP-outlet
(Inch-type thread!)

Wrtsil Land & Sea Academy Page 33 Chapter 20 1-Nov-07

RT-flex mechanical features Servo oil pump Dynex

Wrtsil Land & Sea Academy Page 34 Chapter 20 1-Nov-07

RT-flex mechanical features Servo oil pump Bosch, flex96C-B

The Bosch servo oil pumps are axial piston swash-

plate type pumps. They supply oil to the collector
block and via two high pressure pipes to the servo
oil rail. A safety valve limits the max. pressure to
230 bar.
The number of servo oil pumps depends on the
number of cylinders. If one pump fails, the engine
can still be operated at full load.
When the engine turning direction is reversed, the
swash-plate of the pumps needs to be reversed.
Control oil is used to move the swash-plate to
position.

Wrtsil Land & Sea Academy Page 35 Chapter 20 1-Nov-07

RT-flex mechanical features Servo oil pump Bosch

Swashplate angle encoder Case drain Control oil inlet Leak oil return
Visual indication High pressure
outlet

Non return
Valve / anti
cavitation port
Proportional
valve solenoid- Anti cavitation
Proportional inlet (from
valves valve position servo oil main
transmitter Proportional supply pipe)
valve

HP-outlet pressure
transmitter

Main oil inlet

Wrtsil Land & Sea Academy Page 36 Chapter 20 1-Nov-07

RT-flex mechanical features Servo oil pump Bosch

The Bosch-Rexroth pumps have its own

regulating system, getting pressure
setpoint signals and ahead/astern signals
from WECS.
The anti-cavitation port avoids cavitation
in the pump body, if a pump does not
move the swashplate to the appropriate
engine running direction. (pump tries to
suck in from HP-outlet pipe).
In such a case, the non-return valve at
anti-cavitation port opens. Servo oil from
main supply pipe is sucked in via anti-
cavitation port and delivered out again
via main inlet. The oil will thus flow "idle"
through the pump.
This is default in case of black out, the B,B1 Pressure Port SAE 1 1/2 "
swashplate swings to ASTERN position SB Anti Cavitation Port SAE 2 "
S Suction Port SAE 3 "
to prevent servo oil overpressure due to
P,SP Control Pressure Port M18x1.5
windmilling engine without servo oil Rkv Pilot Fluid Drain M22x1.5
consumption. R(L) Return (Aeration) M42x2

Wrtsil Land & Sea Academy Page 37 Chapter 20 1-Nov-07

RT-flex mechanical features Control Oil Pumps, Size 4

HP-Inlets from pumps

Drain valve for leakage (with orifice)

3 shut of valves for outlets Kraus & Wimmer

2 Pressure retaining valves

2 Overpressure relief valves

Pressure transmitter
for leak detection
(signal to Alarm System)

2 (3) HP-outlets for double wall Bucher

pipes -> control oil rails

Wrtsil Land & Sea Academy Page 38 Chapter 20 1-Nov-07

RT-flex mechanical features Automatic Filter

The automatic filter unit filters the servo (and control-) oil to 6 m.
The by-pass filter has a mesh
size of 36 m.
The filter "sludge" goes back to
the crankcase.

Wrtsil Land & Sea Academy Page 39 Chapter 20 1-Nov-07

RT-flex mechanical features Crank Angle Sensor (CA)

The crank angle sensors are located on the free end of the crankshaft (or Geislinger Damper).

The crank angle signal is absolutely indispensable

for engine operation.
At least one of the sensors must be working. If one
fails, WECS-9520 can detect the failure and will
keep working with the healthy signal (plausibility
check). In case both sensors fail, the engine will
stop without delay.

There is no emergency operation

possible without at least one CA
sensor!

Wrtsil Land & Sea Academy Page 40 Chapter 20 1-Nov-07

RT-flex mechanical features CA-Sensor

They are separated from the crankshaft by a special coupling. They create an exact digital signal of the
actual crankshaft position (0.360) The CA sensors have a resolution of 0.1

The spring loaded coupling absorbs all longitudinal and axial movement of the crankshaft. It drives a shaft
which is supported by two ball bearings. The bearings are oil lubricated. From the shaft a toothed belt
drives each sensor.

Shielded BUS cables transmit the signals to the

WECS-9520 control.

CA-Sensors are delivered in a box

CA-Sensor, complete with holder and cable.

Wrtsil Land & Sea Academy Page 41 Chapter 20 1-Nov-07

RT-flex mechanical features CA-Sensor

Wrtsil Land & Sea Academy Page 42 Chapter 20 1-Nov-07

RT-flex mechanical features CA-Sensor

Connection unit CA Sensors

Wrtsil Land & Sea Academy Page 43 Chapter 20 1-Nov-07