ME ENGINE TRAINING COURSE

MAN B&W Diesel

1. General description of ME engine

ME - Engines

MAN B&W Diesel, Company Presentation MAN B&W Diesel

MAN B&W Diesel

by Preben Noeies

MAN B&W Diesel © MAN B&W Diesel

06.01

4140/PWN

<1>

© MAN B&W Diesel

06.01

4140/PWN

<2>

History

The Founding of the Company MAN B&W Diesel

MAN B&W Diesel

In 1843 Hans Heinrich Baumgarten establishes a mechanical workshop in Copenhagen In 1846 a partnership is established with Carl Christian Burmeister and they establish a company named ”Baumgarten & Burmeister” The activities include a mechanical workshop and a foundry In 1854 a shipyard is established In 1861 Hans Heinrich Baumgarten retires from the company William Wain s the company in 1865, and the name of the company is changed to Burmeister & Wain (B&W) © MAN B&W Diesel

06.01

4140/PWN

W. Wain <3>

© MAN B&W Diesel

Rudolf Diesel 1858 – 1913 The First Diesel Engine and the Patent Certificate

06.01

C. C. Burmeister

4140/PWN

<4>

The First B&W Diesel Engine

MAN B&W Diesel

MAN B&W Diesel

The first B&W fourstroke diesel engine was delivered in 1904

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

© MAN B&W Diesel

06.01

4140/PWN

<5>

© MAN B&W Diesel

06.01

4140/PWN

<6>

1

The First Diesel Engine for Ocean-going Ship Propulsion

Engine Development 1912 - 1952 MAN B&W Diesel

1912:

MAN B&W Diesel

Single-acting crosshead four-stroke direct reversible Type: 8150-X – Power: 1,250 IHP (Introduced on M/S Selandia)

M/S Selandia, delivered to the Danish East Asiatic Company in 1912, is the world’s first ocean-going diesel motor ship.

1922:

Supercharging by electrically driven blower

1924:

Double-acting four-stroke – Type: 6840D – Power: 6,750 BHP (Twin engine installation introduced on M/S Gripsholm)

Type: DM 8150-X (2 x 8 cylinder engines)

1929:

Double-acting two-stroke engine – Type: 662-WF-140 Power: 7,000 IHP (Introduced on M/S Amerika)

Ship’s speed: 11 knots

1932:

Single-acting two-stroke engine with exhaust valves Type: 50-VF-90

1938:

Tests with heavy fuel on M/S Transilvania

1952:

The world’s first turbocharged two-stroke engine Type: 674VTBF-160 – Power: 7,500 BHP (Introduced on M/S Dorthe Mærsk)

© MAN B&W Diesel

06.01

4140/PWN

Power: 2,500 IHP total

<7>

© MAN B&W Diesel

First Ocean Going Vessel with Fully Reversible Diesel Engines MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

<8>

The World’s First Turbocharged Two-stroke Diesel Engine

M/S ”Selandia” M/S Dorthe Mærsk, delivered to the Danish company A. P. Møller by Odense Steel Shipyard in 1952, is the first ship to be powered by a turbocharged two-stroke diesel engine

Main engines: 2 x 1250 IHK B&W engines type DM8150X

Engine type: 674VTBF-160 Power: 7,500 BHP @ 115 r/min

© MAN B&W Diesel

06.01

4140/PWN

<9>

© MAN B&W Diesel

< 10 >

MAN B&W Diesel

In 1758 Eisenhütte St. Antony is established in Oberhausen

The world’s first turbocharged two-stroke engine Type: 674VTBF-160 – Power: 7,500 BHP (Introduced on M/S Dorthe Mærsk)

1967:

Introduction of the K-EF range of engines, as well as the large K98FF type (3,800 BHP/cyl. @ 103 RPM)

1973:

Delivery of the first K-GF engine

1976:

The first to introduce modern long stroke diesel engines Type: L-GF, with a stroke-bore ratio of 2.5:1

1978:

The first with constant pressure turbo charging of modern uniflow scavenged diesel engines

1979:

The first to test a rotating air-spring on exhaust valves in service

1980:

The first to introduce layout flexibility, as well as a specific fuel oil consumption below 140 g/BHPh – Type: L-GFCA

© MAN B&W Diesel

4140/PWN

The History of MAN B&W Diesel

Engine Development 1952 - 1980 MAN B&W Diesel

1952:

06.01

06.01

4140/PWN

In 1840 Sander'sche Maschinen Fabrik is established in Augsburg In 1843 Baumgarten establishes a workshop in Copenhagen Gutehoffnungshütte Actienverein (GHH) is established in 1873

Burmeister & Wain (1865) B&W Motor A/S (1974)

M.A.N. Maschinenfabrik Augsburg-Nürnberg (1908)

In 1921 GHH acquired a majority in M.A.N.

In 1979/80 B&W Motor A/S is taken over by M.A.N., and M.A.N. B&W Diesel A/S is established

In 1986 M.A.N. was merged into GHH and renamed MAN AG The divisions were hived off to form individual public limited companies < 11 >

© MAN B&W Diesel

06.01

4140/PWN

< 12 >

2

MAN B&W Diesel A/S A Historical Overview Since 1843

Diesel Chronicle MAN B&W Diesel

MAN B&W Diesel

1933 The first to introduce uniflow on a two-stroke engine 1952 The first to introduce turbocharging on two-stroke slow speed diesel engines 1978 The first with constant pressure turbocharging of modern uniflow engines 1981 The first to demonstrate engine efficiency of more than 50% corresponding to specific fuel oil consumption figures below 125 g/BHPh 1994 The first to introduce an engine with power above 90,000 bhp 1996 The first to introduce a new generation of compact engines 1998 The first to introduce the Environmentally Friendly prop. system 2000 The first to put an electronically controlled engine into service

MAN B&W Diesel © MAN B&W Diesel

06.01

4140/PWN

< 13 >

© MAN B&W Diesel

The MAN Group - 2005

06.01

4140/PWN

< 14 >

MAN B&W Diesel Group

MAN B&W Diesel

MAN B&W Diesel

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

Services

Industrial Commercial Vehicles

Printing Machines

Diesel Engines

Turbo Machines

Further Industrial Holding*

Industrial Services Financial Services

MAN Nutzfahrzeuge AG

MAN Roland Druckmaschinen AG

MAN B&W Diesel AG

MAN Turbomaschinen AG

RENK Aktiengesellshaft MAN Technologie AG MAN DWE GmbH Schwäbische Hüttenwerke GmbH

MAN Ferrostaal AG

Turnover € 7,4 billion

© MAN B&W Diesel


06.01



MAN Aktiengesellschaft München 100%

MAN Financial Services GmbH

67% S.E.M.T. Pielstick

MAN B&W Diesel AG

MAN B&W Diesel A/S Denmark


4140/PWN

< 15 >

© MAN B&W Diesel

Locations of MAN B&W Diesel

06.01

4140/PWN

< 16 >

Worldwide Service Network

MAN B&W Diesel

MAN B&W Diesel

Great Britain Paxman Ruston Mirrlees Blackstone 678 employees Four-stroke engines

Frederikshavn

Copenhagen

• Marine propulsion • Military marine • Power generation • Rail traction

• Marine propulsion • Military marine • Power generation • Rail traction • Service • Licensor

Holeby Rostock Hamburg

Stockport

Paris Augsburg Saint-Nazaire

Denmark MAN B&W Diesel A/S 2173 employees Two-stroke engines • Research and development • Marine propulsion • Power generation • Service • Spare parts • Licensor Four-stroke engines •Complete propulsion package •GenSets •Power generation •Licensor

Colchester

Pielstick 709 employees Four-stroke engines

Jouet

MAN B&W Diesel AG 2474 employees Four-stroke engines • Research & development • Marine propulsion • Power generation • Service • Licensor

Service Centres

06.01

4140/PWN

20

AuthorisednRepair Shops 55 Licensees

Total 6 034 © MAN B&W Diesel

100%

100% MAN B&W Diesel Ltd England

< 17 >

© MAN B&W Diesel

15

06.01

4140/PWN

< 18 >

3

Two-Stroke Licensees

Two-stroke Licensees

MAN B&W Diesel

MAN B&W Diesel

China HHM DMD YMD

1980 1980 1989

Korea Hyundai Doosan STX

1976 1983 1984

Spain IZAR – Manises

Croatia Uljanik Split

1954 1984

Poland Cegielski

1959

1941

Vietnam Vinashin

Japan Mitsui • Makita Hitachi Kawasaki

Russia Bryansk

1926 1981 1951 1981

1959

2004

As at August 2004 © MAN B&W Diesel

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 istration R&D Centre

© MAN B&W Diesel

06.01

4140/PWN

< 21 >

© MAN B&W Diesel

4140/PWN

< 22 >

MAN B&W Diesel A/S, Research Centre

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

© MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 23 >

© MAN B&W Diesel

06.01

4140/PWN

< 24 >

4

Research engine 4T50ME4T50ME-X

MAN B&W Diesel A/S, Holeby

MAN B&W Diesel

MAN B&W Diesel

Engine type

4T50MX

Initial engine output 10,200 BHP Engine speed

123 r/min

Cylinder diameter

500 mm

Piston stroke

2200 mm

Stroke to bore ratio 4.4 : 1 Firing pressure

180 bar

Mean effective pressure Mean piston speed

© MAN B&W Diesel

06.01

4140/PWN

9 m/s

< 25 >

© MAN B&W Diesel

06.01

MAN B&W Diesel A/S, Frederikshavn (ALPHA)

4140/PWN

< 26 >

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 >

Development of the MEME-engine

Designations MAN B&W Diesel

MAN B&W Diesel

1991

Start of Intelligent Engine Project

1993

4T50MX equipped with Electronic Engine Control equipment

1997

4T50MX with 2nd generation control equipment

1997/98

Design - Production - Installation of mechanical/hydraulic components for service test on M/T "Bow Cecil"

1997/98

Design and implementation of governor functionality, and service test onboard ”Shanghai Express”

1998/2000 Design - Production - Test - Installation of Engine Control System on M/T ”Bow Cecil” 2000 2003 © MAN B&W Diesel

2005.05.01

(4140/PWN)

< 29 >

© MAN B&W Diesel

Start of service test on M/T ”Bow Cecil” First production engine 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. On order/delivered

Type

Stena Arctica

( 7S60ME-C)

Captain Kostichev

( 7S60ME-C)

Pavel Chernysh

( 7S60ME-C)

Cape Brindisi

( 6S70ME-C)

© MAN B&W Diesel

In service

K98ME/ME-C

42

2

S90ME-C K90ME-C K80ME-C L70ME-C S70ME-C S65ME-C

2 8 17 16 72 3

7 3

S60ME-C S50ME-C Total

40 10 210

1 7 20

As at 2004.08.26

As at 2005.11.01 < 31 >

© MAN B&W Diesel

Hydraulic Cylinder Unit

Total: 2005.05.01

5,860,589 kW 4140/PWN

Engine Room of M/T ”Bow Cecil”

MAN B&W Diesel

MAN B&W Diesel

ME systems connected for service test

Fuel Booster pump

© MAN B&W Diesel

06.01

4140/PWN

< 33 >

© MAN B&W Diesel

Engine Room at Bow Cecil

06.01

4140/PWN

< 34 >

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 Hydraulic Power Supply (HPS)

7S50ME-C in M/V Bow Firda MAN B&W Diesel

MAN B&W Diesel

Generates the power necessary for fuel oil injection and exhaust valve opening

Hydraulic Power Supply

MC © MAN B&W Diesel

06.01

4140/PWN

< 37 >

© MAN B&W Diesel

ME 06.01

The ME Engine Hydraulic Power Supply (HPS)

4140/PWN

< 38 >

HPS Hydraulic Power Supply

MAN B&W Diesel

MAN B&W Diesel

Before engine start, the hydraulic oil pressure used in the mechanical/hydraulic mechanical/hydraulic system for controlling the actuators is generated by electrical driven start start-up t-up pumps. After start, the engine star driven pumps will take over the supply.

Main components: • Self-cleaning filter with 10-micron filter mesh • Redundancy filter with 25-micron filter mesh

Accumulators

Self cleaning filter 10μ Start-up pumps

• Start up pumps:

Safety and accumulators block

x Start-up pumps

High pressure pumps with supply pressure of 175 bar Engine driven axial piston pumps

Low pressure pumps for filling the exhaust valve push rod with supply pressure of 4 bar • Engine driven axial piston pumps supplying high pressure oil to

The hydraulic power supply uses the engine system oil

the Hydraulic Cylinder Unit with oil pressure up to 250 bar Redundancy filter 25μ © MAN B&W Diesel

06.01

4140/PWN

< 39 >

© MAN B&W Diesel

06.01

4140/PWN

< 40 >

HPS 7S60ME-C

The ME Engine Hydraulic Oil Loop MAN B&W Diesel

MAN B&W Diesel

Fuel oil pressure Exhaust valve actuator booster

Redundancy Filter 25μ Hydraulic cylinder unit

Fuel 10 bar ELFI

ELVA

Self Cleaning Filter 10μ

200 bar

Alpha lubricator

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU

Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU Safety and Accumulator block

Fine aut. filter Main lube pump Piston cooling + bearings Servo oil return to sump

Servo oil

Engine Driven Axial Piston Pumps Chain Wheel and Step-up Gear Shielding with Drain

From sump Engine driven hydraulic pumps © MAN B&W Diesel

06.01

4140/PWN

EL. driven hydraulic pumps < 41 >

Safety and Accumulators Block

and Alarm Functions © MAN B&W Diesel

06.01

Electrically Driven Start-up Pumps 4140/PWN

< 42 >

7

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

MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 43 >

© MAN B&W Diesel

Large Bore ME - Aft end mounted HPS. 5-8K/L/S60-90MC-C & 7K98ME(-C)

06.01

4140/PWN

< 44 >

60-98ME-C HPS

MAN B&W Diesel

MAN B&W Diesel

Engines with moment compensator

Engines without moment compensator

Filter station

Identical HPS units Hydraulic pumps Identical chain tightening arrangement

Step-up gear

Chain tightener wheel

© MAN B&W Diesel

06.01

4140/PWN

< 45 >

© MAN B&W Diesel

Hydraulic Power Supply 6S70ME6S70ME-C

06.01

4140/PWN

< 46 >

Step-up gear

MAN B&W Diesel

MAN B&W Diesel

Redundancy Filter 25μ 25μ Self Cleaning Filter 10μ 10μ

Gear wheels: •Case hardened •Simple spur wheels •DIN standard

Shielding with Drain

Engine Driven Axial Piston Pumps

and Alarm Functions

Chain Wheel and StepStep-up Gear

© MAN B&W Diesel

06.01

(2510/JRL)

4140/PWN

< 47 >

© MAN B&W Diesel

06.01

4140/PWN

< 48 >

8

Filter unit

Engine driven high pressure pumps MAN B&W Diesel

MAN B&W Diesel

Self cleaning filter with 10-micron filter mesh

Redundancy filter with 25-micron filter mesh

Supplied by Bosch Rexroth Supplied by Boll&Kirscher

© MAN B&W Diesel

06.01

4140/PWN

< 49 >

© MAN B&W Diesel

Safety block

06.01

4140/PWN

< 50 >

Start-up pumps

MAN B&W Diesel

MAN B&W Diesel

•Safety and control valves

Three types: •2 x 15 kW for 50-60ME-C

•Line break valves

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

Basically the same block on all 6098ME/ME-C

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 51 >

© MAN B&W Diesel

06.01

4140/PWN

< 52 >

7S50ME-C Hydraulic Power Supply

7L70ME-C electrical HPS

MAN B&W Diesel

Accumulator Safety and accumulator block 3 engine driven axial piston pumps with flow controlled by ECS

Gearbox and chain drive is replaced by: •3 electrically driven pumps

Generates hydraulic oil pressure up to 250 bar

•230 kW each

Redundancy: Can operate on two pumps

Gear Box © MAN B&W Diesel

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

Engine Driven Pump (Viken 1436)

06.01

4140/PWN

< 56 >

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

Double Wall Pipe S70ME-C MAN B&W Diesel

MAN B&W Diesel

1.

Flange

2.

Outer Pipe

3.

Inner Pipe

4.

Sealing ring

5. Sealing ring 6. Sealing ring 7. Sealing ring 8. Screw

© MAN B&W Diesel

06.01

4140/PWN

< 59 >

© MAN B&W Diesel

06.01

4140/PWN

< 60 >

10

ME-C Engines Double Wall Pipe


MAN B&W Diesel

MAN B&W Diesel

Final Design of Double Wall Pipe Between HCU Blocks with Additional Sliding Rings Item 7 and Dirt Sealing Ring Item 8

6

9 7

6

Fuel oil Pressure Booster

7 10

1

Hydraulic Exhaust Valve Actuator

8 ELFI Proportional Valve

4 ELVA On/Off Valve

5 Distribution Block

© MAN B&W Diesel

06.01

4140/PWN

< 61 >

© MAN B&W Diesel

Oil Channel in the Distributor Block

06.01

4140/PWN

< 62 >

Hydraulic Cylinder Unit (HCU)

MAN B&W Diesel

MAN B&W Diesel

The oil channels connect the NC-valve, the Fuel Oil Pressure Booster, the Exhaust Valve Actuator and the Accumulator No risk of oil leakage as pipe connection is avoided

X-ray picture of the Distributor Block © MAN B&W Diesel

06.01

Manually operated valve for isolation of oil to the actuators in case of need for overhauling – running engine

4140/PWN

< 63 >

© MAN B&W Diesel

ME Control Valves MAN B&W Diesel

MAN B&W Diesel

MAN B&W FIVA

ELVA

06.01

ƒ

The HCU is found on the upper gallery

ƒ

One unit in front of each cylinder

4140/PWN

Hydraulic Cylinder Units 12K98ME12K98ME-C Fuel Oil Pressure Booster

ELFI

FIVA valve © MAN B&W Diesel

06.01

4140/PWN

< 65 >

© MAN B&W Diesel

< 64 >

06.01

4140/PWN

Exhaust Valve Actuator

Integrated Alpha Lubricator < 66 >

11

MAN B&W Diesel

© MAN B&W Diesel

K98ME(-C) Hydraulic Cylinder Unit

06.01

4140/PWN

MAN B&W Diesel

< 67 >

© MAN B&W Diesel

K98ME(-C) HCU Distributor Block

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 booster

Exhaust valve actuator Hydraulic cylinder unit

Fuel 10 bar FIVA

200 bar

Alpha lubricator

Cyl. 1 CCU

Cyl. 2 CCU

Cyl. 3 CCU

Cyl. 4 CCU

Cyl. 5 CCU

Cyl. 6 CCU

Fine aut. filter

Piston cooling + bearings Servo oil return to sump

Main lube pump

Safety and accumulator block Servo oil

From sump Engine-driven hydraulic pumps © MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 69 >

© MAN B&W Diesel

06.01

EL. driven hydraulic pumps

4140/PWN


S60ME-C

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 for control of piston movement

ME-C

Signal for lubrication from controller

Suction valve

Actuator piston

Outlets for cylinder liner lube oil injectors

Fuel plunger Fuel oil inlet pressure 8 bar

Injection plungers

Feed back position sensor

Hydraulic piston

Spacer for basic setting of pump stroke

Stroke adjusting screw

Drain oil outlet 200 bar servo Cylinder oil supply lube oil inlet Saves cylinder lube oil

© MAN B&W Diesel

06.01

4140/PWN

< 73 >

© MAN B&W Diesel

06.01

4140/PWN

< 74 >

Slide-type Fuel Valve

ME Fuel Injection System MAN B&W Diesel

MAN B&W Diesel

Suction valve

High pressure pipe

Slide fuel valve

Now used as standard

Fuel oil inlet 8 bar

Hydraulic piston

Possibility for retrofit

Membrane accumulator

ELFI Proportional valve

Conventional fuel valve Sac volume 1690 mm3

To drain

Slide-type fuel valve Sac volume 0 mm3

High pressure hydraulic oil – inlet © MAN B&W Diesel

06.01

4140/PWN

< 75 >

© MAN B&W Diesel

M E Exhaust Valve System

06.01

4140/PWN

< 76 >

ME Exhaust Valve

MAN B&W Diesel

MAN B&W Diesel

Self-adjusting damper piston

Hydraulic push rod

Hydraulic nut/measuring cone less sensor with integrated electronics

Exhaust valve

Outlet lube oil

Exhaust valve Actuator

Inlet lube oil Damper Membrane accumulator ELVA on-off valve

Air inlet

To drain © MAN B&W Diesel

High pressure hydraulic oil – inlet 06.01

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

MCMC-C design 80

MEME-C design Pilot air inlet

BlowBlow-off

70 60 Early closing Late closing Early opening Late opening Reference

mm

50 40 30

NCNC-valves

Connection for ECS

Starting air distributor

20 Starting valves

10

Starting valves

0 90

110

130

150

170

190

210

230

250

270

290

Dg. C. A.

The NC valve is mounted on the main starting pipe behind the cylinder cover © MAN B&W Diesel

06.01

4140/PWN

< 79 >

© MAN B&W Diesel

06.01

4140/PWN

Main Operating in ECR - HMI MAN B&W Diesel

MAN B&W Diesel

Interview with the daily operators - finger touch to trackball -

Inspection onboard Bow Cecil after 4137 running hours as ME engine © MAN B&W Diesel

06.01

Main Operating - HMI 4140/PWN

< 81 >

© MAN B&W Diesel

ME Tacho System

2005.05.01

(4140/PWN)

< 82 >

Service Experience

MAN B&W Diesel

MAN B&W Diesel

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

• 2 redundant set of sensors • Each set measure engine speed and crankshaft position for synchronisation of the control events •• Each set consist of four sensors. Two quadrature sensors measure on a trigger ring with 360 tooth and two marker sensors measures on one tooth – a semicircular ring Trigger segment with a sine-curved toothprofile The total trigger ring is build by 8 equal segments

© MAN B&W Diesel

2005.05.01

(4140/PWN)

< 83 >

© MAN B&W Diesel

2005.05.01

(4140/PWN)

< 84 >

14

Tacho System Angle Encoder MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2005.05.01

(4140/PWN)

< 85 >

© MAN B&W Diesel

06.01

4140/PWN

< 86 >

06.01

4140/PWN

< 88 >

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

Main Operating (MOP)

Angle Encoder – 12K98ME 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

Multi Purpose Controller (MPC)

ME Engine Control System

MAN B&W Diesel

Bridge

MAN B&W Diesel

Bridge

Plug for ID key

MultiMulti-Purpose Controller

Main Operatingg

BACK-UP FOR MOP Control Room

PC

Engine Control Room

DIP Switches

EICU B

EICU A

Engine Interface Control Unit A and B Local Operation

Engine Control Unit A and B ECU B

ECU A

Control Network

Cylinders Control Unit 1 per cylinder ACU

CCU

Auxiliaries Control Unit 1, 2 and 3 © MAN B&W Diesel

06.01

Fuses in use are monitored by the alarm system

Engine Room/On Engine

4140/PWN

< 91 >

© MAN B&W Diesel

06.01

4140/PWN

< 92 >

Engine Control System MPC

MPC - configuration MAN B&W Diesel

MAN B&W Diesel

The MPC’s are software wise configured to 4 different controller functions: 1) Engine Interface Control Unit – EICU • 2 complete redundant units • Handles the interface to external systems 2) Engine Control Unit – ECU • 2 complete redundant units • Handles the engine specific control functions (the governor) 3) Cylinder Control Unit – CCU • 1 for each cylinder unit, redundancy by multiplicity • Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and starting air valves) 4) Auxiliary Control Unit – ACU • 3 units, redundancy by multiplicity • Handles the auxiliary systems (hydraulic power supply, aux blowers) © MAN B&W Diesel

06.01

4140/PWN

< 93 >

© MAN B&W Diesel

06.01

4140/PWN

< 94 >

06.01

4140/PWN

< 96 >

S70ME-C Engine Control System MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 95 >

© MAN B&W Diesel

16

The ME Engine Local Operating (LOP)

M E SIMULATOR in Copenhagen

MAN B&W Diesel

MAN B&W Diesel

Local Operating

Local Instrument

The The Local Local Operation Operation is is located located on on the the middle middle gallery gallery on on the the manoeuvring manoeuvring side side of of the the engine. engine. © MAN B&W Diesel

06.01

Local Operation

4140/PWN

< 97 >

© MAN B&W Diesel

06.01

4140/PWN

< 98 >

Normal Transport Conditions MAN B&W Diesel

MAN B&W Diesel

Tank top in a New building

© MAN B&W Diesel

06.01

4140/PWN

< 99 >

© MAN B&W Diesel

06.01

4140/PWN

< 100 >

Floating Crane Collapsed MAN B&W Diesel

MAN B&W Diesel

L60ME-C Bedplate © MAN B&W Diesel

06.01

4140/PWN

< 101 >

© MAN B&W Diesel

06.01

4140/PWN

< 102 >

17

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 103 >

© MAN B&W Diesel

Holding Down Bolts

06.01

4140/PWN

< 104 >

Installation Aspects

MAN B&W Diesel

MAN B&W Diesel

Side chocks, modified design

Previous design

© MAN B&W Diesel

06.01

4140/PWN

< 105 >

© MAN B&W Diesel

06.01

New design

4140/PWN

< 106 >

Installation Aspects MAN B&W Diesel

MAN B&W Diesel

End chocks Cast iron end chock liner

© MAN B&W Diesel

06.01

4140/PWN

< 107 >

© MAN B&W Diesel

06.01

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

© MAN B&W Diesel

06.01

4140/PWN

< 110 >

06.01

4140/PWN

< 112 >

06.01

4140/PWN

< 114 >

MAN B&W Diesel

06.01

4140/PWN

< 111 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 113 >

© MAN B&W Diesel

19

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

MAN B&W Diesel

2800 kW per cylinder © MAN B&W Diesel

06.01

4140/PWN

< 115 >

MAN B&W Diesel

© MAN B&W Diesel

06.01

5720 kW per cylinder

4140/PWN

< 116 >

MAN B&W Diesel

L60MC-C Landing Crankshaft in Bedplate © MAN B&W Diesel

06.01

4140/PWN

< 117 >

MAN B&W Diesel

06.01

4140/PWN

< 118 >

06.01

4140/PWN

< 120 >

MAN B&W Diesel

L60MC-C © MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

Crankshaft in Bedplate < 119 >

© MAN B&W Diesel

20

Bearings MAN B&W Diesel

MAN B&W Diesel

Crosshead

Crankpin

AlSn40

© MAN B&W Diesel

06.01

4140/PWN

Main

White metal

< 121 >

© MAN B&W Diesel

06.01

4140/PWN

< 122 >

Bearings Service Experience MAN B&W Diesel

MAN B&W Diesel

S50MC-C Main bearing lower shell - 18,000 hours

No remarks – excellent condition Thickness measurement of shell did not reveal indication of significant wear rate – less than 0.01 mm

© MAN B&W Diesel

06.01

4140/PWN

< 123 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 124 >

06.01

4140/PWN

< 126 >

MAN B&W Diesel

06.01

4140/PWN

< 125 >

© MAN B&W Diesel

21

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 127 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 128 >

06.01

4140/PWN

< 130 >

MAN B&W Diesel

06.01

4140/PWN

< 129 >

© MAN B&W Diesel

Earthing Device MAN B&W Diesel

MAN B&W Diesel

Spark erosion in main bearings Bronze: Propeller = + Potential difference < 50 mV V Main bearing

Current

Earthing device

Steel: Hull Intermediate shaft =÷ Propeller shaft © MAN B&W Diesel

06.01

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

© MAN B&W Diesel

06.01

4140/PWN

< 134 >

06.01

4140/PWN

< 136 >

06.01

4140/PWN

< 138 >

MAN B&W Diesel

06.01

4140/PWN

< 135 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 137 >

© MAN B&W Diesel

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

Crosshead bearings

4140/PWN

< 140 >

Crosshead bearings

MAN B&W Diesel

© MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 141 >

© MAN B&W Diesel

06.01

4140/PWN

< 142 >

06.01

4140/PWN

< 144 >

Crosshead bearings MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 143 >

© MAN B&W Diesel

24

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 145 >

MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 146 >

06.01

4140/PWN

< 148 >

06.01

4140/PWN

< 150 >

MAN B&W Diesel

06.01

4140/PWN

< 147 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 149 >

© MAN B&W Diesel

25

MAN B&W Diesel

MAN B&W Diesel

Test equipment for Relief Valves

ONLY Hoerbiger type EVN and Mt Halla type HCSG-N

Approved by MAN B&W

© MAN B&W Diesel

06.01

4140/PWN

< 151 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 152 >

06.01

4140/PWN

< 154 >

MAN B&W Diesel

06.01

4140/PWN

< 153 >

© MAN B&W Diesel

Crankcase relief valve MAN B&W Diesel

MAN B&W Diesel

In case of a crankcase explosion, the pressure wave will send a large amount of oil mist to the engine room. The oil mist will be moved around by the ventilation. If oil mist meets a hot spot it can be ignited. Maintenance of the insulation is important! Relief valve to prevent flames to the engine room.

© MAN B&W Diesel

06.01

4140/PWN

< 155 >

© MAN B&W Diesel

06.01

4140/PWN

< 156 >

26

Deformed Flame Arrester

Crankcase Explosion MAN B&W Diesel

MAN B&W Diesel

Cases of explosions where the cause is known Year

Cause of Explosion

1995

Bearing in PTO gearbox

1996

Inlet pipe for piston cooling oil falling off

Incorrect tightening

1997

Incorrect spring mounted in piston rod stuffing box

Unauthorised spare part

1997

Piston rod interference with cylinder frame

1999

Weight on chain tightener falling off

1999

Fire outside the engine

2000

Main bearing

2000

Camshaft bearing

2000

Incorrect shaft in camshaft drive

2001

Crankcase failure

2001

Piston crown failure

2001

Main bearing

2001

Crankpin bearing

2002

© MAN B&W Diesel

Inlet pipe for piston cooling oil falling off

06.01

4140/PWN

Cause of Failure


Unauthorised spare part


< 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: ƒ Low position of mating surface cylinder cover/cylinder liner ƒ Slim cylinder liner ƒ Straightforward cooling jacket Cylinder frame:

ƒ Smaller and lighter ƒ Uncooled and straightforward design

© MAN B&W Diesel

06.01

4140/PWN

< 159 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 160 >

06.01

4140/PWN

< 162 >

MAN B&W Diesel

06.01

4140/PWN

< 161 >

© MAN B&W Diesel

27


MAN B&W Diesel

Filter station

Step-up gear Hydraulic pumps

2. Order Moment Compensator shaft Chain drive for 4” Duplex chain Pump drive can be arranged on fore or aft end of the engine S70MES70ME-C © MAN B&W Diesel

06.01

4140/PWN

< 163 >

© MAN B&W Diesel

06.01

4140/PWN

< 164 >

06.01

4140/PWN

< 166 >

06.01

4140/PWN

< 168 >

Vibration Aspects MAN B&W Diesel

MAN B&W Diesel

General Internal forces

Piston

Crosshead

S

α

T N

P S

© MAN B&W Diesel

06.01

4140/PWN

S

< 165 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 167 >

© MAN B&W Diesel

28

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 169 >

MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 170 >

MAN B&W Diesel

Be sure that the counter weights are hanging downwards before mounting the tools for retightening of chains.

© MAN B&W Diesel

06.01

4140/PWN

< 171 >

© MAN B&W Diesel

06.01

4140/PWN

< 172 >

ME-C Engines Doubble Wall Pipe

Hydraulic Cylinder Units (HCU) MAN B&W Diesel

MAN B&W Diesel

HCUs mounted on common base plate

1.

Flange

2.

Outer Pipe

3.

Inner Pipe

4.

Sealing ring

5. Sealing ring 6. Sealing ring

Double walled high pressure pipe

7. Sealing ring High pressure oil inlet from the HPS

© MAN B&W Diesel

06.01

4140/PWN

8. Screw

< 173 >

© MAN B&W Diesel

06.01

4140/PWN

< 174 >

29

ME Fuel Oil Pressure Booster

K98ME(-C) Baseplate

MAN B&W Diesel

MAN B&W Diesel

MC-C

ME-C

Suction valve

Feed back position sensor

Fuel plunger Fuel oil inlet pressure 8 bar

Hydraulic piston

01-10-2003

(2500/KNB)

© MAN B&W Diesel

< 175 >

© MAN B&W Diesel


4140/PWN

< 176 >


MAN B&W Diesel

© MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 177 >

© MAN B&W Diesel

06.01

4140/PWN

< 178 >

06.01

4140/PWN

< 180 >

Hydraulic Cylinder Unit MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 179 >

© MAN B&W Diesel

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 MAN B&W Diesel

MAN B&W Diesel

Fuel oil Pressure Booster

Accumulators pressurized with nitrogen of 105 bar

Hydraulic Exhaust Valve Actuator ELFI Proportional Valve

ELVA On/Off Valve Distribution Block

© MAN B&W Diesel

06.01

4140/PWN

< 183 >

© MAN B&W Diesel


06.01

4140/PWN

< 184 >

ME Fuel Injection System

MAN B&W Diesel

MAN B&W Diesel

Fuel injection

Valve actuation High pressure pipe Suction valve

ELFI Proportional Valve

Slide fuel valve

ELVA On/Off Valve Fuel Pump

Fuel oil inlet 8 bar

Exhaust Valve Actuator Hydraulic piston


ELFI Proportional valve

To drain Accumulator © MAN B&W Diesel

06.01

4140/PWN

High pressure hydraulic oil – inlet

Distribution Block

< 185 >

© MAN B&W Diesel

06.01

4140/PWN

< 186 >

31

MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 187 >

© MAN B&W Diesel

06.01

4140/PWN

< 188 >

6S90MC-C

Service Experience MAN B&W Diesel

MAN B&W Diesel

1150 running hours Dosage 1.1 g/bhph Mobilgard 570 Liner No. 4

12K90MC, one year’s operation with Alpha ACC = S% * 0.25 g/bhph

© MAN B&W Diesel

06.01

4140/PWN

Maria A. Angelicoussis DW5127 Pascagoula 00.09.15

< 189 >

© MAN B&W Diesel

06.01

The ME Engine Alpha Cylinder Lubricator

4140/PWN

< 190 >

Cylinder Condition

MAN B&W Diesel

MAN B&W Diesel

Save 0.3 g/bhp cylinder oil

Inductive proximity switch for feed-back signal for control of piston movement

Timing of cylinder oil injection Pressure 25 bar


Injection pressure Alpha lubricator

Actuator piston

20 Outlets for cylinder liner lube oil injectors

Injection plungers

15

10 Spacer for basic setting of pump stroke


Drain oil outlet 200 bar servo Cylinder oil supply lube oil inlet Saves cylinder lube oil

Injection pressure mechanical lubricator

Oil quill pressure

5

0 0 © MAN B&W Diesel

06.01

4140/PWN

< 191 >

© MAN B&W Diesel

10 06.01

20 4140/PWN

30

40

50

60

70

80

90 ms Time < 192 >

32

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

MAN B&W Diesel

Piston with high top land

S-MC-C

Piston ring further away from combustion space

S-MC

Mating surface Top land

Lower mating surface between cylinder cover and cylinder liner

First piston ring special patented R 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 R 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 (R) gaps

© MAN B&W Diesel

06.01

4140/PWN

< 195 >

© MAN B&W Diesel

06.01

4140/PWN

< 196 >

MAN B&W Diesel Service Alu-Coated Piston Ring

MAN B&W Diesel

MAN B&W Diesel

Genuine spare parts

Genuine spare parts A-A

Developed at our Research Centre •

Reduced running-in time by more than 50%

•

Thus saving cylinder oil

•

Thickness: about 0.3 mm

Alu-Coat

Piston ring with controlled pressure relief (R piston ring) A

© MAN B&W Diesel

06.01

4140/PWN

A

< 197 >

•

Reduced differential pressure on piston ring No. 2

•

Reduced temperature on piston ring No. 2

© MAN B&W Diesel

06.01

4140/PWN

< 198 >

33

Cylinder Condition MAN B&W Diesel

MAN B&W Diesel

Controlled pressure relief piston ring (R)

Large bore MC-S engines

90 and 98 bore engines A

F

1st ring: Type: R, RM14 High 2nd ring: Type: RM5, oblique cut with Alu-Coat Low 3rd ring: Type: RM5, oblique cut with Alu-Coat Low 4th ring: Type: RM5, oblique cut with Alu-Coat Low

F

F F

F A 3 mm © MAN B&W Diesel

06.01

4140/PWN

< 199 >

© MAN B&W Diesel

06.01

4140/PWN

< 200 >

Combustion Chamber Layout

Production MAN B&W Diesel

MAN B&W Diesel

Piston – high top land

Piston and piston rings

Cylinder cover Piston – high top land

Oros Piston

Liner diameter: 700 mm Liner wear:

Install:

Measuring point 5 =

ALU Coated

Piston Skirt Position in TDC

Piston Rings

0 – 0.70 mm

Standard PC-ring

0,70 – 1,4 mm Oversize PC-ring > 1,4 mm

No PC- ring

Cylinder liner

Piston cleaning ring

© MAN B&W Diesel

06.01

4140/PWN

< 201 >

© MAN B&W Diesel

“Bore polish” from topland deposits.

4140/PWN

< 202 >

“Bore polish” from topland deposits.

MAN B&W Diesel

MAN B&W Diesel

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

© MAN B&W Diesel

06.01

06.01

4140/PWN

< 203 >

•

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

© MAN B&W Diesel

06.01

4140/PWN

< 204 >

34

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 205 >

MAN B&W Diesel

© MAN B&W Diesel

06.01

4140/PWN

< 206 >

06.01

4140/PWN

< 208 >

06.01

4140/PWN

< 210 >

MAN B&W Diesel

06.01

4140/PWN

< 207 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 209 >

© MAN B&W Diesel

35

Exh. Valve (Viken 1436) MAN B&W Diesel

MAN B&W Diesel

Feed back sensor

Oil inlet to damper

Drain pipes

© MAN B&W Diesel

06.01

4140/PWN

< 211 >

© MAN B&W Diesel

06.01

4140/PWN

< 212 >

Slide-type Fuel Valve MAN B&W Diesel

MAN B&W Diesel

Now used as standard

Possibility for retrofit


© MAN B&W Diesel

06.01

4140/PWN

< 213 >

© MAN B&W Diesel

Slide Fuel Valve

06.01

Slide-type fuel valve Sac volume 0 mm3

4140/PWN

< 214 >

Slide-type Fuel Valve

MAN B&W Diesel

MAN B&W Diesel

In order to optimise combustion and to achieve a cleaner engine, we have developed a new generation of fuel valves, the so-called ”slide fuel valve”. The main benefits of this design, compared with the conventional design, are : • Reduced fouling of gas ways • Reduced fouling of piston top land and exhaust gas boiler

Further benefits : • Less smoke formation • Lower NOx emission levels • Lower fuel consumption

The difference between the slide fuel valve and the conventional type is the reduced (actually non-existent) sac volume.


SL 02-403 © MAN B&W Diesel

06.01

4140/PWN

< 215 >

© MAN B&W Diesel

06.01

4140/PWN

Slide-type fuel valve Sac volume 0 mm3 < 216 >

36

Slide-type Fuel Valve MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 217 >

© MAN B&W Diesel

06.01

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

© MAN B&W Diesel

For large bore above 70MC = 65Nm

06.01

4140/PWN

< 219 >

© MAN B&W Diesel

6L80MC MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 220 >

Marks and Stamps on Fuel Valve Nozzle MC and MC-C Type

Marking must, as a minimum, consist of: Name, IMO id No. and nozzle size. Name: Manufacturer’s name/ trade mark IMO id No.: A unique identification No. which links the component with the design specification that was used at the time of manufacture, eg. MAN B&W part No. or licensee’s drawing No. Nozzle size: Diameter of nozzle hole.

Damaged Piston Crown Reason: Fuel valves in bad condition

Example of marking: The example shows how to mark a nozzle with hole diameter Ø 1.5 mm. with Part No. 1261573-1

© MAN B&W Diesel

06.01

4140/PWN

< 221 >

© MAN B&W Diesel

06.01

4140/PWN

< 222 >

37

ME Starting Air System

Starting Air valve (Viken 1436)

MAN B&W Diesel

MAN B&W Diesel

MCMC-C design


BlowBlow-off

NCNC-valves

Starting valves

Starting air valve

Connection for ECS

Starting air distributor

Pilot valve for starting air valve

Starting valves

The NC valve is mounted on the main starting pipe behind the cylinder cover

© MAN B&W Diesel

06.01

4140/PWN

< 223 >

© MAN B&W Diesel

06.01

4140/PWN

< 224 >

06.01

4140/PWN

< 226 >

Auxiliary Systems MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 225 >

© MAN B&W Diesel

7S60ME-C

MAN B&W Diesel A/S MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

06.01

Thank you for

Thank you for

your attention

your attention

4140/PWN

< 227 >

© MAN B&W Diesel

< 228 >

38

The ME Engine MAN B&W Diesel

You and

together

Simple & Safe

Thank you for your attention Preben Noeies © MAN B&W Diesel

06.01

4140/PWN

< 229 >

39

2. ME Concept

MAN B&W Diesel

1) Control system: - Multi Purpose Controller. - Main Operating . - Local Operating . 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 Hydraulic cylinder unit

Fuel 10 bar ELFI

ELVA

200 bar

Alpha lubricator

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU Safety and Accumulator blok

Fine aut. filter Main lube pump

Servo oil

Piston cooling + bearings

Servo oil return to sump

From sump Engine driven hydraulic pumps © MAN B&W Diesel

L/73273-7.1/0403

EL. driven hydraulic pumps <2>

(2600/RØL)

Engine Control System MPC & Network MAN B&W Diesel

• The Multi Purpose Controllers are identical hardware wise. • They have different soft ware configurations. • 2 redundant control networks are connecting all Multi Purpose Controllers and both Main Operating s. • A backup of the application- and setup- soft ware are stored on both Main Operation s. • At replacement, the new controller are automatically configured with correct soft ware via the control networks. © MAN B&W Diesel


2006-01-06

<3>

1

L/73273-7.1/0403

Piston cooling + bearings

Servo oil return to sump

© MAN B&W Diesel

ELFI

(2600/RØL)

From sump

Main lube pump

Fine aut. filter

Cyl. 4 CCU

ELVA

Servo oil

EL. driven hydraulic pumps <2>

Safety and Accumulator blok

Hydraulic cylinder unit 200 bar

Engine driven hydraulic pumps

Cyl. 5 CCU Cyl. 6 CCU

Fuel oil pressure Exhaust valve actuator booster

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU

Alpha lubricator

Fuel 10 bar

MAN B&W Diesel

ME engine Hydraulic Loop

Engine Control System Diagram

Plate 70317

On Bridge BRIDGE

In Engine Control Room Backup Operation MOP B

MAIN OPERATION MOP A

EICU A

EICU B

In Engine Room/On Engine

LOCAL OPERATION - LOP

Actuators

Exhaust Fuel valve booster position position Cylinder 1 Cylinder 1

FIVA AL SAV Valve Cylinder 1 Cylinder 1 Cylinder 1

CCU Cylinder n

Sensors

CCU Cylinder 1

ACU 3

Sensors

ACU 2

ECU B

Fuel Exhaust booster valve position position Cylinder n Cylinder n

Act uat ors

ECU A

ACU 1

ECR

FIVA Valve SAV AL Cylinder n Cylinder n Cylinder n

M PUMP 5

M PUMP 4

M PUMP 3

M PUMP 2

M PUMP 1

M PUMP 2

M PUMP 1

AUXILIARY AUXILIARY BLOWER 1 BLOWER 2

Marker Sensor

AUXILIARY BLOWER 3

AUXILIARY BLOWER 4 Angle Encoders

AUXILIARY BLOWER 5

When referring to this page, please quote Operation Plate 70317, Edition 0003 MAN B&W Diesel A/S

Multi Purpose Controller - MPC MAN B&W Diesel

Battery for internal clock LED indicator Plug for ID key

DIP Switches

Fuses in use are monitored by the alarm system Power plug © MAN B&W Diesel


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


2006-01-06

<5>

2006-01-06

<6>

LED indication code MAN B&W Diesel

© MAN B&W Diesel


2

Multi Purpose Controller (MPC) MAN B&W Diesel

© MAN B&W Diesel


2006-01-06

<7>

Multi Purpose Controller (MPC) MAN B&W Diesel

Multi Purpose Controller

ing bracket for cables Amplifier

© MAN B&W Diesel


2006-01-06

<8>

2006-01-06

<9>

MPC’s Nordic Brasilia – 6S70ME-C MAN B&W Diesel

© MAN B&W Diesel


3

MPC – configuration MAN B&W Diesel

The MPC’s are software wise configured to 4 different controller functions: 1) Engine Interface Conrol Unit – EICU • 2 complete redundant units • Handles the interface to external systems 2) Engine Control Unit – ECU • 2 complete redundant units (except with 4 or more engine driven pumps) • Handles the engine specific control functions (the govenor) 3) Cylinder Control Unit – CCU • 1 for each cylinder unit, redundancy by multiplicity • Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and starting air valves) 4) Auxilliary Control Unit – ACU • 3 units, redundancy by multiplicity • Handles the auxilliary systems (hydraulic power supply, aux blowers) © MAN B&W Diesel


2006-01-06

< 10 >

2006-01-06

< 11 >

2006-01-06

< 12 >

Engine Interface Control Unit – EICU MAN B&W Diesel

Interface to remote control systems: • Safety system • Alarm system • Telegraph system • Power management system

Operator inputs: • Control station selection - Bridge, Engine control room or Local control • Standby / Finished with engine

Speed set point – Filter between handle and govenor: • Slow down • Shaft generator • Controlling accelaration • Load control • Barred speed range

© MAN B&W Diesel


Speed Setpoint MAN B&W Diesel

© MAN B&W Diesel


4

Engine Control Unit – ECU MAN B&W Diesel

Start / stop logic • Prepare start (MOP or handle) • Repeated start, (total 3 attempts, reset by setting the handle in ’STOP’) • Start blocking • Slow turning • Manual air run

Engine speed control and limiters • Calculations of fuel index

The gov enor

• Limiters (start, max fuel all and individual, torque, scav.air, hydraulic press.) • Feed forward (pitch, PTO power)

Engine running mode control • Emission mode • Economy mode

© MAN B&W Diesel


2006-01-06

< 13 >

2006-01-06

< 14 >

2006-01-06

< 15 >

Fuel Limiters MAN B&W Diesel

© MAN B&W Diesel


Cylinder Control Unit – CCU MAN B&W Diesel

Fuel injection control • Proportional valve • of plunger position only used for monitoring

Exhaust valve control • ON / OFF valve

FIVA VALVE

• 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


5

Engine Control System CCU MAN B&W Diesel

ƒ Fiva valve, Fuel & exhaust ƒ Fuel plunger pos. ƒ Exh. Spindle pos.

ƒ Cylinder lubrication ƒ Starting air valve ƒ One CCU for every cylinder unit

© MAN B&W Diesel


2006-01-06

< 16 >

2006-01-06

< 17 >

Auxiliary Control Unit - ACU MAN B&W Diesel

Control of Hydraulic Power Supply: • Engine driven pumps • Start-up pumps • Valves and pressure gauges

Individual control of aux blower: • Sequential start by different start delays • Engine contol blower / stop is decided in ECU

© MAN B&W Diesel


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


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


2006-01-06

< 19 >

ME Starting Air System MAN B&W Diesel

MCMC-C design


BlowBlow-off

NCNC-valves

Connection Connection for ECS

Starting Starting air distributor

Starting valves

Starting valves

© MAN B&W Diesel

< 20 >

Starting airand pilot air valve MAN B&W Diesel

Starting air valve

Pilot air valve

© MAN B&W Diesel


2006-01-06

< 21 >

7

Engine Control System Control s MAN B&W Diesel

ƒ Bridge Control system is connected to EICU

ƒ Engine Control Room is connected to EICU

ƒ Local Operating LOP is connected to ECU

© MAN B&W Diesel


2006-01-06

< 22 >

2006-01-06

< 23 >

2006-01-06

< 24 >

Main Operation (MOP) MAN B&W Diesel

© MAN B&W Diesel


Main Operating MOP MAN B&W Diesel

© MAN B&W Diesel


8

Main Operating MOP MAN B&W Diesel

© MAN B&W Diesel


2006-01-06

< 25 >

2006-01-06

< 26 >

2006-01-06

< 27 >

Local Operating (LOP) with telegraph MAN B&W Diesel

© MAN B&W Diesel


Local Operating (LOP) Without telegraph MAN B&W Diesel

© MAN B&W Diesel


9

Engine Control System Tacho System MAN B&W Diesel

There are 2 redundant tacho systems.

ƒ System A ƒ 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


2006-01-06

< 28 >

Tacho system MAN B&W Diesel MMA Q2A

Q1A

MMB

Q1B

System A (powered from ECU A)

Q2B

MMA = Marker Master A MSA = Marker Slave A Q1A = Quadratur 1A Q2A = Quadratur 2A MSA

System B (powered from ECU B) MMB = Marker Master B MSB = Marker Slave B Q1B = Quadratur 1B Q2B = Quadratur 2B Trigger ring pos. 1

MSB

Semi-circular marking ring pos. 2

© MAN B&W Diesel


2006-01-06

< 29 >

2006-01-06

< 30 >

ME Tacho-system MAN B&W Diesel

© MAN B&W Diesel

041104-ME 11-2003 Concept - 2500/KNB Tom Ballegaard/4140

10


© MAN B&W Diesel

04-1104ME 11-2003 Concept

2500/KNB - Tom Ballegaard/4140

2006-01-06

< 31 >

2006-01-06

< 32 >

Angle encoder – 12K98ME MAN B&W Diesel

© MAN B&W Diesel



• 2 redundant set of sensors. • Each set measure engine speed and crankshaft position for synkronisation of the control events. •• Each set consist of four sensors. Two quadrature sensors measure on a trigger ring with 360 tooth and two marker sensors measures on one tooth – a semicircular ring. Triggersegment with a sine-curved toothprofile The total trigger ring is build by 8 equal segments.

© MAN B&W Diesel

2200/OZS/030212 ME Concept -

Tom Ballegaard/4140

2006-01-06

< 33 >

11

Tacho sensors Nordic Brasilia – 6S70ME-C MAN B&W Diesel

© MAN B&W Diesel


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


2006-01-06

< 35 >

2006-01-06

< 36 >

Quadratur sensor MAN B&W Diesel

Status LED

Ahead turning towards the dot

© MAN B&W Diesel


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


2006-01-06

< 37 >

Exhaust valve timing MAN B&W Diesel

Exhaust valve movement 80 70 60 Early closing

mm

50

Late closing

40

Early opening Late opening

30

Reference

20 10 0 90

110

130

150

170

190

210

230

250

270

290

Dg. C. A. © MAN B&W Diesel

< 38 >

Pneumatic system MAN B&W Diesel

2 valves for redundancy No. 30 connected to ECU A No. 32 connected to ECU B

© MAN B&W Diesel


2006-01-06

< 39 >

13

MAN B&W Diesel A/S

S70ME-C Project Guide

100

r/min

90 bar 80

20

70

18

16

MEP

Engine speed

14 bar(abs) Mean effective pressure

150

12

130

Maximum pressure

120

Cyl. Pressure

140

110

bar(abs)

4

100

90

3

P-scav

Compression pressure

deg.C 450

400 Exhaust gas temperature inlet to turbocharger

350

300 Exhaust gas temperature outlet from turbocharger

2

Exh. Gas Temp.

Scavenge air pressure

1

250 g/kWh

170 Specific fuel oil consumption

SFOC

180

160

150 50%

75%

100%

Load

1555

2333

3110

kW/cyl

178 25 61-7.0

Fig. 1.04: Performance curves

430 100 500

198 34 48

1.06

3. Hydraulic Power Supply

MAN B&W Diesel

1) System 2) Filter unit 3) Startup pumps

4) Engine driven pumps Drive system Pump principle

5) Valve block © MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

<1>

The ME Engine Hydraulic Oil Loop MAN B&W Diesel

Fuel oil pressure Exhaust valve actuator booster Hydraulic cylinder unit

Fuel 10 bar ELFI

ELVA

200 bar

Alpha lubricator Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU

Safety and Accumulator blok

Fine aut. filter Main lube pump

Servo oil

Piston cooling + bearings Servo oil return to sump From sump

ISO 4406: 13/16 NAS Code: 7

© MAN B&W Diesel

L/73273-7.1/0403

(2600/RØL)

Engine driven hydraulic pumps

EL. driven hydraulic pumps 2006-01-23

<2>

2006-01-23

<3>

Separat hydraulic system MAN B&W Diesel

© MAN B&W Diesel


1

Filter Unit, Schematic MAN B&W Diesel

Old plants = 10 µ New plants = 6 µ

© MAN B&W Diesel

¾ Older plants are equipped with a by25 µ

valve which opens at 0.8 bar after the filter


2006-01-23

<4>

2006-01-23

<5>

2006-01-23

<6>

Filter unit MAN B&W Diesel

Single filter unit

© MAN B&W Diesel


Filter unit MAN B&W Diesel

Filtering process © MAN B&W Diesel


Back flushing process

2

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

¾ The purifier suction pipes have the same diameters but a different lenght. ¾ The purifier will suck primarily from the sump tank. ¾ The oil level in the 2 tanks will remain more or less equal due to the interconnection. ¾ When servo oil is back-flushed from the filter, the oil level in the servo oil tank will increase, and the purifier will suck from this tank until the level in the 2 tanks are equalized again. Then the suction will take place from the sump tank again.

© MAN B&W Diesel


2006-01-23

<7>

2006-01-23

<8>

2006-01-23

<9>

Start up pumps, fixed MAN B&W Diesel

P2

P1

© MAN B&W Diesel


Start up pumps, fixed MAN B&W Diesel

Automatic mode: ¾ Stopped at Finish With Engine. ¾ Master pump running at engine standby. (both pumps are running during pressure build up). ¾ Stopped via a timer at a specified engine RPM

Manual mode: ¾ Controlled by the operator via the Main Operating

© MAN B&W Diesel


3

El-driven pumps MAN B&W Diesel

© MAN B&W Diesel


2006-01-23

< 10 >

2006-01-23

< 11 >

Engine driven pumps MAN B&W Diesel

P2

P1

Sensors for suction pressure. Low pressure = shut down © MAN B&W Diesel



Automatic mode: ¾ The pressure set point is depending on the engine load. ¾ The pumps have two running modes, 1 in pressure control mode [Ctrl] (selected via the MOP screen), 2 in follow mode [Folw]. ¾ The [Ctrl] pump is running 50% and compensates immediately for deviations between actual pressure and set point. Over time the [Folw] pumps will take over the compensation while the [Ctrl] pump goes back to 50 %. ¾ In case the pressure controlling pump faces a failure, one of the other pumps will take over pressure control.

Manual mode: ¾ The pressure set point is set by the operator

© MAN B&W Diesel


2006-01-23

< 12 >

4


¾In case of control failure of a pump, the swash plate will be forced to maximum capacity in AHEAD direction. ¾Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3. ¾Pump Nos. 1, 2, and 3 have their own sensor for system pressure, connected to their controlling ACU ¾Pump Nos. 4 and 5 are controlled by a binary signal, either max capacity AHEAD or ASTERN. No. 4 is controlled from ECU A, and No. 5 from ECU B. ¾All pumps have sensors for suction pressure. If the pressure is to low, or all sensors are failing, a SHUT DOWN will be activated. © MAN B&W Diesel


2006-01-23

< 13 >

2006-01-23

< 14 >

Leak detection MAN B&W Diesel

Shut down level Alarm level © MAN B&W Diesel


Leak detection MAN B&W Diesel

Box for hydraulic pumps

Drainpipe

Sensor LS 1235 & JS 1236, ”vibrating fork” type. LS 1235 = Alarm

© MAN B&W Diesel


LS 1236 = Cancelable Shut Down

2006-01-23

< 15 >

5

© MAN B&W Diesel

Alarm level

MAN B&W Diesel

2006-01-23

Sensors for suction pressure. Low pressure = shut down


Shut down level

Engine driven pumps

< 13 >


Alarm level

Shut down level

© MAN B&W Diesel

Sensors for suction pressure. Low pressure = shut down


2006-01-23

< 16 >

2006-01-23

< 17 >

2006-01-23

< 18 >

7S50ME-C Gear Box for HPS MAN B&W Diesel

ƒ Output wheel ……………… ƒ Intermediate wheel………………. ƒ Connections wheel…………… ƒ Gearwheel on crankshaft… ƒ Two rows of gears, one is spare. Spacer………..

ƒ Gear ratio - 12:1

© MAN B&W Diesel


© MAN B&W Diesel

L/73898-1.0/0303

(2600/RØL)

6

Chain tightener MAN B&W Diesel

Pressure: 70ME: 1500 bar 98ME: 2200 bar

© MAN B&W Diesel


2006-01-23

< 19 >

2006-01-23

< 20 >

ME – Engine, Pump Drive MAN B&W Diesel

Hydraulic Pump

Step Up Gear

Chain wheel for 4” Duplex chain

© MAN B&W Diesel

Pump shaft principle MAN B&W Diesel

Gear end

High friction disc Pump end

© MAN B&W Diesel

2006-01-23

< 21 >

7

12K98ME(-C) HPS MAN B&W Diesel

Design of Hydraulic Power Supply (HPS)

• Mounting of HPS • Structure of HPS and Framebox • Design of components

© MAN B&W Diesel

2500/KNB

November 2003.

2006-01-23

< 22 >

2006-01-23

< 23 >

K98ME(-C) Pump drive MAN B&W Diesel

© MAN B&W Diesel

2510/ERA

Nov. 2003.

ME(-C) Hydraulic Power Supply MAN B&W Diesel

© MAN B&W Diesel

05-02-2004

(2500/KNB)

< 24 >

8

K98ME(-C) HPS MAN B&W Diesel

8-12K98ME/C

© MAN B&W Diesel

2510/ERA

< 25 >

Nov. 2003.

10-12K98ME/ME-C new design MAN B&W Diesel

ƒ 5 x 500 ccm pumps ƒ Fore side

ƒ Aft side

© MAN B&W Diesel

2006-01-23

< 26 >

2006-01-23

< 27 >

8-9K98ME/ME-C new design MAN B&W Diesel

ƒ 4 x 500 ccm pumps ƒ Fore side

© MAN B&W Diesel

ƒ Aft side

9

Axial piston pumps, principals MAN B&W Diesel

© MAN B&W Diesel


2006-01-23

< 28 >

Axial piston pumps, principals MAN B&W Diesel

A: Swash plate

D: Pressure side

B: Cylinder block

R: Suction side

C: Distibutor valve

h: Stroke α: Swash plate angle Animation.lnk

© MAN B&W Diesel


2006-01-23

< 29 >

2006-01-23

< 30 >

Axial piston pump MAN B&W Diesel

© MAN B&W Diesel


10

Axial piston pump MAN B&W Diesel

© MAN B&W Diesel


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


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


2006-01-23

< 33 >

11

Engine driven pump, mechanical indication MAN B&W Diesel

© MAN B&W Diesel


2006-01-23

< 34 >

2006-01-23

< 35 >

2006-01-23

< 36 >

Engine driven pump – 750 ccm MAN B&W Diesel

© MAN B&W Diesel


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


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


2006-01-23

< 37 >

2006-01-23

< 38 >

2006-01-23

< 39 >

K98ME/-C new design MAN B&W Diesel

ƒ Modulated Accumulator block ƒ Divided into fore and aft section ƒ Double wall substituted by flexible hoses ƒ Pump mounted N2_Accumulator (Pump depent)

© MAN B&W Diesel

K98ME/-C new design MAN B&W Diesel

ƒ Modulated Accumulator block ƒ Top mounted Fore section

ƒ Top mounted Aft section

© MAN B&W Diesel

13

Valve block, Fore, new design MAN B&W Diesel

ƒ Fore section ƒ Adaption flange (Engine depent)

ƒ Primary block, (Basic for all engines 60-98ME/-C)

ƒ Inlet block (Pump-depent: 2 or 3 ports)

© MAN B&W Diesel

2006-01-23

< 40 >

2006-01-23

< 41 >

Valve block, Aft, new design MAN B&W Diesel

ƒ Aft section ƒ Adaption flange (Engine depent)

ƒ Slave block, (Basic for all engines with middle chain drive 80-98ME/-C)

ƒ Inlet block (Pump-depent: 2 or 3 ports)

© MAN B&W Diesel

14

4. Hydraulic Cylinder Unit

MAN B&W Diesel

1) Distributor block 2) Komponents: FIVA Accumulators Cylinder lubricator 3) Highpressure pipes

© MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

<1>

2006-01-19

<2>

2006-01-19

<3>

Hydraulic Cylinder Unit HCU MAN B&W Diesel

© MAN B&W Diesel


Hydraulic Cylinder Unit HCU MAN B&W Diesel

© MAN B&W Diesel


1

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

© MAN B&W Diesel

05-02-2004

(2500/KNB)

ME(-C) Hydraulic cylinder Unit (FIVA)

MAN B&W Diesel

© MAN B&W Diesel

03-11-2003

(2500/KNB)

FIVA MAN B&W Diesel

FIVA Degree Crank angle

-20

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360

Injection start (0) Injection End (20) Exhaust valve open (110) Exhaust valve Close (270)

Approximate timing of events to be carried out by the FIVA valve On an ME- engine the timing of injection is variable and this is just an example.

© MAN B&W Diesel


2006-01-19

<6>

2

Accumulator MAN B&W Diesel

1. Assemble without the diaphragm. Make the mark 1.

2.

© MAN B&W Diesel

2. Assemble with the diaphragm. Tighten until the ofset D06-216 is achieved


2006-01-19

<7>

2006-01-19

<8>

2006-01-19

<9>

Accumulator Nitrogen check MAN B&W Diesel

© MAN B&W Diesel


Cylinder lubricator system MAN B&W Diesel

© MAN B&W Diesel


3

Cylinder lubricator system MAN B&W Diesel

© MAN B&W Diesel


2006-01-19

< 10 >

Alpha Lubricator for MEME-Engine MAN B&W Diesel

Cylinder lub. oil inlet

Inductive proximity sensor for feed-back signal to control of piston movement


Level sensor for cylinder oil in lubricator

Outlets for cylinder liner lub. oil injectors

Injection plunger

Spacer for basic setting of pump stroke Non-return valve

Drain oil outlet


200 bar system oil supply Actuator piston

Sealingring © MAN B&W Diesel

3331377/20041021 Hydraulic Cylinder

Unit (2200/OZS) - Tom Ballegard/4140

2006-01-19

< 11 >

Cylinder Lubricator MAN B&W Diesel

HCU Distributorblock

Cylinder lubricator

© MAN B&W Diesel


2006-01-19

< 12 >

4

Cylinder Liners MAN B&W Diesel

Injection nozzle

Injection nozzle with non-return valve

© MAN B&W Diesel

3331050/20031212

Cylinder liner

(CBO/4100)

Cylinder Lubrication Demands MAN B&W Diesel

The purpose of the cylinder lubrication is as follows: (SL 05-455/HRJ) 1.

To create a hydrodynamic oil film seperating the piston rings from the liner, The oil amount needed to create an oil film is more or less independent of the fuel oil being used. The optimum is kept safely down to a feedrate of 0.55 g/kWh.

2.

To clean the piston rings, lands and ring grooves, This relies on the detergency properties of the cylinder oil. All approved cylinder oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh.

3.

To control corrosion, i.e. control the neutralisation af sulphuric acid. The combustion process creates highly corrosive sulphuric acids depending on the sulphur in the fuel. It has therefore been of paramount importance to design the combustion chamber and the cylinder oil so as to create the optimum balance of corrosion.

© MAN B&W Diesel


2006-01-19

< 14 >

Adaptive Cylinder oil Control ACC (Service Letter SL05-455) MAN B&W Diesel

ƒ 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.

ƒ 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.

ƒ 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.

ƒ 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


2006-01-19

< 15 >

5

Adaptive Cylinder oil Control ACC (Service Letter SL05-455) MAN B&W Diesel

© MAN B&W Diesel


2006-01-19

< 16 >

2006-01-19

< 17 >

2006-01-19

< 18 >

Auxiliaries: Cylinder Lubricators MAN B&W Diesel

Minimum feed rate

Sulphur % (0 – 5 %)

Feed rate factor ”F”

(0.5 – 2.0 g/kWh)

(0.25 – 1.5)

© MAN B&W Diesel


Adjustment of cylinder oil lubrication MAN B&W Diesel

© MAN B&W Diesel


6

© MAN B&W Diesel

MAN B&W Diesel


Adjustment of cylinder oil lubrication

2006-01-19

< 18 >

ME Lubrication Back Up Signal

S903-0031

In case of CCU failure (and the CCU can not be changed immediately), activation of the ME lubricator can be achieved as follows. Note: In case of CCU failure, the engine is running at “Slow Down” mode. A temporary cable from ECU A or B plug J52 is connected to solenoid valve on the lubricator of the failing CCU. See figure 1. The activation signal from J52 on ECUA/B is random.

LUBRICATOR ACTIVATION BACK UP

Fig. 1

OVDC GND IN/OUT v_IN 24VDC

SOLENOID VALVE LUBRICATOR

0

1

2

3

4

5

6

7

8

9

+ECU A/B

A B C D C

+ECU A/B

J52

ME lubricator

/

A1

1

2

/

A2

=SOLENOID VALVE

S9030031C01

1x2x0,75 mm² WLUB_BACK UP

SOLENOID VALVE LUBRICATOR

When referring to this page, please quote S-Instruction S903 Edition 0031 MAN B&W Diesel A/S

Page 1

Emergency cylinder lubrication MAN B&W Diesel

© MAN B&W Diesel

9

In case of CCU failure, where the CCU cannot be changed immediately, the cylinder lubrication can be achieved by a temporary cable from one of the ECU units, plug 52, to the solenoid valve on the lubricator on the unit in question.

9

The lubrication will be with random timing.


2006-01-19

< 19 >

2006-01-19

< 20 >

Emergency cylinder lubrication MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel


Hydraulic Cylinder Unit L70ME

HCU Distributer block Double wall pipe Double wall pipe

© MAN B&W Diesel


2006-01-19

< 21 >

7

HCU - Valves MAN B&W Diesel

Instructions Valve No.

© MAN B&W Diesel


2006-01-19

< 22 >


HCU’s mounted on an common base plate.

Double wall high pressure pipe High pressure oil inlet from the HPS

© MAN B&W Diesel

Hydraulic Cylinder Units MAN B&W Diesel

© MAN B&W Diesel


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


2006-01-19

< 25 >

2006-01-19

< 27 >

ME-C Engines Doubble Wall Pipe MAN B&W Diesel

1.

Flange

2.

Outer Pipe

3.

Inner Pipe

4.

Sealing ring

5. Sealing ring 6. Sealing ring 7. Sealing ring 8. Screw

© MAN B&W Diesel

0902

(2600/RØL)

Tool for high pressure doublepipe MAN B&W Diesel

© MAN B&W Diesel


9

Two-Stroke Diesel Engines. MAN B&W Diesel

© MAN B&W Diesel

2500/KNB

April 2003.


© MAN B&W Diesel

2500/KNB

April 2003.


© MAN B&W Diesel

2500/KNB Hydraulic

April 2003. Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 30 >

10

Hydraulic Cylinder Unit (HCU) Leakage MAN B&W Diesel

Fuel oil pressure booster

Exhaust valve actuator Hydraulic cylinder unit

Unit 1

© MAN B&W Diesel

Unit 2

Safety and Accumulator Block

ELVA

ELFI

Unit 3

Unit 4

Unit 5

Unit 6


Valve 315

2006-01-19

< 31 >

Hydraulic Cylinder Unit (HCU) Leakage MAN B&W Diesel

HCU

Leakage check between 2 HCUs: • Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block. • Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between. • Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining. • Mount a pressure gauge on minimesh coupling 435. • Close valve 315, and build up pressure in the inner pipe with the start-up pumps. • If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If not, try the next pipe! © MAN B&W Diesel


2006-01-19

< 32 >

1

HCU

© MAN B&W Diesel


2006-01-19

• If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If not, try the next pipe!

• Close valve 315, and build up pressure in the inner pipe with the start-up pumps.

• Mount a pressure gauge on minimesh coupling 435.

• Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining.

• Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between.

• Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block.

Leakage check between 2 HCUs:

MAN B&W Diesel

Hydraulic Cylinder Unit (HCU) Leakage

< 32 >

2

Therefore, we have revised our Guiding Cylinder Oil Feed Rates (see enclosures 1-3) for the purpose of optimising the cylinder lube oil consumption (CLOC). Cylinder lubrication demands The purpose of cylinder lubrication is as follows: 1. to create a hydrodynamic oil film separating the piston rings from the liner, 2. to clean the piston rings, ring lands and ring grooves, 3. to control corrosion, i.e. control the neutralisation of sulphuric acid. Re 1: The oil amount needed to create an oil film is more or less independent of the fuel oil being used. Measurements of the oil film have also revealed that when the feed rate for optimum oil film is reached, no further increase of the oil film is obtained from an increase of the feed rate. This optimum is kept safely down to a feed rate of 0.55 g/kWh. Re 2: Cleaning of piston rings, ring lands and grooves is essential, and relies on the detergency properties of the cylinder oil. All approved cylinder oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh. Re 3: The combustion process creates highly corrosive sulphuric acids depending on the sulphur in the fuel. It has therefore been of paramount importance to design the combustion chamber and the cylinder lube oil so as to create the optimum balance of corrosion. Cylinder lubrication dosage The optimal corrosion control is achieved by a combination of the cooling water design of the cylinder liner, the sulphur content in the fuel, the cylinder lube oil alkalinity, and our new lubrication principle, the ACC algorithm system (Adaptive Cylinder oil Control). The ACC system feeds the oil proportionately to the load (which is proportional to the fuel oil amount being burnt) and to the sulphur content in the fuel. By dosing the amount of oil and, thereby, the amount of alkaline additives proportionately to the total sulphur amount being burnt in the combustion chamber, a constant and controlled low corrosion level can be achieved. The experience gained so far from a large number of vessels operating at a feed rate factor of 0.34 g/kWh x S% has been very positive. However, long term tests with, first 0.29 g/kWh x S% and later 0.26 g/kWh x S% have been successful, indicating that an optimum lubrication level is within the below algorithm: F x S%, where “F” is in the range of 0.26 to 0.34 g/kWh

3

ACC algorithm with a BN 70 cylinder oil: 1.70 1.60 1.50 1.30 1.20 1.10 1.00 0.90 0.80

, 70 BN

Average dosage: 0.8 g/kWh

Fx

he ,w % S

r

= eF

[0.

/k W 4]g 3 . 0 26-

h

0.70 0.60

Average sulphur worldwide

Absolute dosage (g/kWh)

1.40

0.50 0.40 0.30 0.20 0.10 0.00 0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Sulphur %

On the world market, the average sulphur content in fuels for large two-stroke engines is 2.7%. This would result in an average cylinder oil dosage of around 0.8 g/kWh. The 0.8 g/kWh multiplied with the yearly production of kWh can be directly used in the calculation of the yearly cylinder oil consumption. The ACC principle, with the algorithm F x S% where “F” is in the range of 0.26-0.34 g/kWh, satisfies the need for neutralising additives. However, due to the physical need for a certain amount of oil to create a hydrodynamic oil film, the present lower limit is set in the range of 0.60-0.70 g/kWh, which according to the above diagram will be reached with around 2% sulphur. Running on fuels with a varying sulphur content Although fuel sulphur levels above 4% are rather rare, running on high-sulphur fuels has ed for a major part of cylinder wear in the past. Therefore, increasing the oil dosage according to the ACC algorithm is necessary, and very beneficial economically, to prevent the excessive wear associated with such fuels. However, on low-sulphur fuels, below 2% sulphur content, the engine will, according to the above diagram, be overdosed with alkaline additives. This may lead to cylinder condition problems and, in severe cases, to scuffing.

4

Overdosing with alkaline additives has two negative effects, which may both lead to the so-called “bore-polish” phenomenon: •

A surplus of alkaline additives has a strong tendency to accumulate on the piston top land, and may grow in thickness to an extent where it interferes with the cylinder liner running surface, in spite of the PC ring (piston cleaning ring). This is most pronounced in the middle and lower part of the liner (where the liner is exposed the least to heat) and in the exhaust side (where the PC-ring is less effective). The result of this negative effect is called mechanical bore-polish.

•

The other negative effect of overdosing with alkaline additives may be that corrosion (so-called cold-corrosion) is suppressed completely, thereby, limiting the necessary “refreshment” (open graphite structure) of the liner surface. The result of this is called chemical bore-polish. In other words, corrosion should be controlled rather than prevented.

The occurrence of the above negative effects is time-dependent. This means that a surplus of alkaline additives can be accepted for a certain period, depending on the severity of the overdosing. For example: when running on a fuel with 1% sulphur and using a normal BN 70 cylinder oil, theoretically, a dosage in the range of 0.26 to 0.34 g/kWh is called for according to the ACC algorithm. However, in order to fulfil the lower limit set at 0.600.70 g/kWh for hydrodynamic reasons, the amount of additives applied is consequently higher than needed. Such overdosing of alkaline additives should be limited to one or two weeks, and to temporary running on low-sulphur fuels in restricted areas. If low-sulphur fuels are used predominantly, we advise using a low-BN cylinder oil, either a BN 40 or BN 50 oil. The diagram overleaf shows the algorithm using a BN 40 cylinder oil versus a “normal” BN 70 cylinder oil.

5

ACC algorithm with BN 40 versus BN 70 cylinder oils 1,70 1,60 1,50

Absolute dosages (g/kWh)

1,40 1,30 1,20 1,10 1,00 0,90 0,80

BN

0,70

,F 40

x

h ,w % S

e er

F

=

0 /4 70

x

[

34 0. 26 0.

,F 70 N B

x

W /k ]g

h

F ere h ,w S%

=[

h kW ]g/ 4 .3 6 -0 0.2

0,60 0,50 0,40 0,30 0,20 0,10 0,00 0

1

2

3

4

5

Sulphur %

Experience has shown that satisfactory running on fuels containing almost no sulphur (gas oil, kerosene, etc.) can be obtained using a low-BN cylinder oil. If a BN 40 cylinder oil is used, the ACC algorithm should be: F x 70/40 x S%, where “F” is in the range of 0.26-0.34 g/kWh If low-sulphur fuels are bunkered regularly, in-between normal or high-sulphur fuels, a two-tank system should be considered, offering the possibility of changing between lowBN and normal-BN cylinder oils. Questions or comments regarding this SL should be directed to our Dept. 2300. Yours faithfully MAN B&W Diesel A/S

Carl-Erik Egeberg Encl.

Ole Grøne

Encl. 1 for SL05-455/HRJ

Guiding Cylinder Oil Feed Rates S/L/K-MC/MC-C/ME/ME-C, Mk 6 and higher, with Alpha ACC lubrication system

Basic setting

Standard BN 70 cylinder oil

BN 40 cylinder oil

0.26-0.34 g/kWh x S% 0.19-0.25 g/bhph x S%

0.26-0.34 g/kWh x 70/40 x S% 0.19-0.25 g/bhph x 70/40 x S%

Minimum feed rate

0.60-0.70 g/kWh 0.45-0.50 g/bhph

Maximum feed rate during normal service

1.7 g/kWh 1.25 g/bhph

Part-load control

Running-in new or reconditioned liners and new piston rings

Feed rate:

Proportional to engine load Below 25% load, proportional to MEP (Mean Effective Pressure) Alu-coated or hard-coated piston rings: Non-coated:

Engine load:

First 5 hours: From 5 to 250 hours: From 250 to 500 hours: First 15 hours: From 15 to 250 hours: From 250 to 500 hours:

1.7 g/kWh 1.5 g/kWh 1.2 g/kWh 1.7 g/kWh 1.5 g/kWh 1.2 g/kWh

Alu-coated or hard-coated piston rings:

Stepwise increase to max. load over 5 hours

Non-coated:

Stepwise increase to max. load over 15 hours

Running-in new rings in already run-in and well running liners:

Alu-coated or hardcoated piston rings Non-coated rings Feed rate

Manoeuvring and load change situations.

During starting, manoeuvring and load changes, the feed rate should be increased by 25% and kept at this level for ½ hour after the load has stabilised.

Lubrication of cylinders that show abnormal conditions:

Frequent scavenge port inspections of piston rings and cylinder liners are very important for maintaining a safe cylinder condition. If irregularities are seen, adjustments of the lube oil rate should be considered. In case of scuffing, sticking piston rings or high liner temperature fluctuations, the feed rate should be raised by 25-50%.

HRJ/JCB September 2005

: No load restrictions : Stepwise increase to max. load over 5 hours : Basic setting +25% for 24 hrs.


Adjusting Alpha Lub. using ACC, BN 40 Cylinder Oil ACC factor g/kWh x S% 0,26

0,27

0,29

0,30

0,31

0,33

0,34

g/kWh

HMI setting

0 1,1 1,1 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0

0 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,9 2,9

0,61 0,61 0,65 0,71 0,77 0,83 0,89 0,95 1,01 1,07 1,13 1,19 1,25 1,31 1,37 1,43 1,49 1,55 1,61 1,73 1,70

56 56 60 66 71 77 82 88 93 98 104 109 115 120 126 131 137 142 148 160 156

Sulphur content % 0 1,4 1,5 1,6 1,7 1,8 2,0 2,1 2,2 2,4 2,5 2,6 2,8 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8


0 1,3 1,4 1,5 1,6 1,8 1,9 2,0 2,1 2,3 2,4 2,5 2,6 2,8 2,9 3,0 3,1 3,3 3,4 3,5 3,6

0 1,2 1,3 1,4 1,5 1,7 1,8 1,9 2,0 2,1 2,3 2,4 2,5 2,6 2,7 2,9 3,0 3,1 3,2 3,3 3,4

0 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,2 2,3 2,4 2,5 2,6 2,7 2,8 3,0 3,1 3,2 3,2

0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1


Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil ACC factor g/kWh x S% 0,26

0,27

0,29

0,30

0,31

0,33

0,34

g/kWh

HMI setting

0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5

0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5

0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,65 0,68 0,71 0,75 0,78 0,82 0,85 0,88 0,92 0,95 0,99 1,02 1,05 1,10 1,12 1,16 1,19 1,22 1,26 1,29 1,33 1,36 1,39 1,43 1,46 1,50 1,53

56 56 56 56 56 56 56 56 56 56 56 59 63 66 69 72 75 78 81 84 88 91 94 97 100 103 106 109 113 116 119 122 125 128 131 134 138 141

Sulphur content % 0,0 0,5 1,0 1,1 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,5 2,6 2,8 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8 3,9 4,1 4,2 4,3 4,5


0,0 0,5 1,0 1,1 1,2 1,4 1,6 1,8 2,0 2,2 2,3 2,4 2,5 2,6 2,8 2,9 3,0 3,1 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,3 4,4 4,5

0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,6 1,8 2,0 2,1 2,3 2,4 2,5 2,6 2,7 2,9 3,0 3,1 3,2 3,3 3,5 3,6 3,7 3,8 3,9 4,0 4,2 4,3 4,4 4,5

0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,6 1,8 1,9 2,0 2,2 2,3 2,4 2,5 2,6 2,7 2,8 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5

0,0 0,5 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,8 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,5

5. Fuel System

MAN B&W Diesel

1) Fuel oil pressure booster 2) Adjustments

© MAN B&W Diesel

2006-01-26

<1>

ME Fuel Oil Pressure Booster MAN B&W Diesel

S50MCS50MC-C

S50MES50ME-C

Fuel Plunger

Suction Valve

Fuel oil oil inlet pressure 8 bar

Feed back Position sensor

Hydraulic actuator

7S50ME7S50ME-C

© MAN B&W Diesel

2006-01-26

<2>

2006-01-26

<3>

98ME(-C) Fuel Oil Pressure Booster MAN B&W Diesel

© MAN B&W Diesel

01-10-2003

(2500/KNB)

1

Fuel Injection System MAN B&W Diesel

High pressure pipe Suction valve

Slide Fuel valve

Fuel plunger Fuel oil inlet 8 bar Hydraulic piston Membrane accumulator

ELFI / FIVA Proportional Valve

7S50ME7S50ME-C To drain

High pressure hydraulic oil - inlet

© MAN B&W Diesel

2006-01-26

<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 chamber via the ELFI valve.

4.

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

ELFI Valve

Unpressurised fuel oil Pressurised fuel oil Unpressurised hydraulic oil Pressurised hydraulic oil

© MAN B&W Diesel

2006-01-26

<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 es through the ELFI valve and fills the hydraulic chamber.

6.

The high pressure forces the pistons upwards.

7.

The fuel oil inlet is closed.

8.

The pressure on the fuel oil rises and exceeds the force of the spring in the cylinder’s fuel injection valve.

ELFI Valve

Unpressurised fuel oil Pressurised fuel oil Unpressurised hydraulic oil Pressurised hydraulic oil

© MAN B&W Diesel

2006-01-26

<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


2006-01-26

< 10 >

2006-01-26

< 11 >

2006-01-26

< 12 >

Suction Valve, S70ME MAN B&W Diesel

© MAN B&W Diesel


Fuel Oil Pressure Booster Maintenance manual, S70ME MAN B&W Diesel

Fuel pump: • Pump housing nuts, tightening torque:

1000 Nm

• Pump housing, weight:

160 kg

• Top cover studs, screwing in torque:

270 Nm

• Fuel pump complete, weight:

322 kg

• Hydraulic plunger, weight:

38 kg

Top cover: • Top cover nuts, tightening torque:

410 Nm

• Outlet seat, max grinding diameter:

26 mm

• Top cover, weight:

124 kg

Suction valve: • Suction valve, tightening torque:

© MAN B&W Diesel


460 Nm

4

Fuel Oil Pressure Booster, K98ME MAN B&W Diesel

© MAN B&W Diesel


2006-01-26

< 13 >

2006-01-26

< 14 >

2006-01-26

< 15 >

Suction Valve, K98ME MAN B&W Diesel

© MAN B&W Diesel

Fuel Oil Pressure Booster Maintenance manual, K98ME MAN B&W Diesel

Fuel pump: • Hydraulic pressure mounting:

2200 bar

• Hydraulic pressure dismantling:

2000 – 2400 bar

• Booster housing, weight:

260 kg

• Booster complete, weight:

700 kg

• Hydraulic plunger, weight:

70 kg

Top cover: • Fuel plunger weight:

35 kg

• Top cover, weight:

260 kg

Suction valve: • Suction valve, tightening torque:

© MAN B&W Diesel

1165 Nm

5

6. Exhaust System

B&W MAIN OFFICE COPENHAGEN

ME EXHAUST VALVE

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<1>

MAN B&W Diesel

© MAN B&W Diesel

<2>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<3>

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

<4>

2006.01.16

(4140 / PWN)

<6>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<5>

© MAN B&W Diesel

1

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<7>

MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

<8>

MAN B&W Diesel

Hydraulic push rod

Exhaust valve Actuator

Exhaust valve spindle

High pressure hydraulic oil – inlet ELVA on-off valve


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 Exhaust Valve Timing

ME Exhaust Valve & Actuator MAN B&W Diesel

MAN B&W Diesel

mm 80

Early opening Late opening

Reference

Early closing Late closing

70 60 50 40 30 20 10 0 90 110 130 150 170 190 210 230 250 270 290 Dg. C. A. © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 11 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 12 >

2



MAN B&W Diesel

HCU’s mounted on an common base plate. Fuel oil Pressure Booster Hydraulic Exhaust Valve Actuator


ELVA On/Off Valve

Double wall high pressure pipe

Distribution Block

High pressure oil inlet from the HPS © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 13 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 14 >

Two-Stroke Medium Bore ME – Engine, Design Concept

HCU MAN B&W Diesel

MAN B&W Diesel

HCU Unit – 60ME-C. Hydraulic pushrod

Fuel Pump

Exhaust Valve Actuator Exh. Valve actuator

Elva Elfi

ELVA valve

Alpha Lubricator

Double wall pipe

Plug Valve

Common supply of HP Oil © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 15 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 16 >

Exhaust Valve Actuator

Actuator for Exhaust Valve MAN B&W Diesel

MAN B&W Diesel

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

When it is opened with a binary signal from the engine control system, the hydraulic oil is forced in and pushes the pistons upwards,thus opening the engine’s exhaust valve via the hydraulic push rod.

ELVA

•

Mounted on top of the distributor block.

•

Hydraulic push rod for opening/closing the exhaust valve

•

Two-stage piston. Second stage

The pressure is permanently maintained until the ELVA valve is activated to block the pressure when the required exhaust phase is completed.

First stage

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

•

High pressure oil inlet

Unpressurised hydraulic oil Pressurised hydraulic oil © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 17 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 18 >

3

S70me-c

ME Exhaust Valve

MAN B&W Diesel

MAN B&W Diesel

S50MC-C

Exhaust Actuator

S50ME-C Air spring size for closing the exhaust valve reduced

Top cover Minimesh Actuator house

Hydraulic damper for fixed valve stroke introduced

Actuator Piston New valve spindle design introduced

1. Step

2.Step

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 19 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 20 >

Exh. Valve MAN B&W Diesel

MAN B&W Diesel

Feed back sensor

Oil inlet to damper

Drain pipes

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 21 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 22 >

2006.01.16

(4140 / PWN)

< 24 >

ME Exhaust Valve MAN B&W Diesel

MAN B&W Diesel

Self-adjusting damper piston

Hydraulic nut/measuring cone less sensor with integrated electronics

Outlet lube oil

Inlet lube oil Damper

Air inlet

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 23 >

© MAN B&W Diesel

4

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 25 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 26 >

Safety Valve MAN B&W Diesel

MAN B&W Diesel

Safety Valve: Adjustment of opening pressure: 21 bar

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 27 >

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 28 >

ME Exhaust valve S50MC-C

S50ME-C Air spring size for closing the exhaust valve reduced.

Hydraulic damper for fixed valve stroke introduced.

New valve spindle introduced.

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 29 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 30 >

5

Exhaust Valve Top

Exh. Valve MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 31 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 32 >

2006.01.16

(4140 / PWN)

< 34 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 33 >

© MAN B&W Diesel

Spindle Rotation Check MAN B&W Diesel

MAN B&W Diesel

Rod for checking spindle rotation Reaches with the air piston by activation.

Note! The rod must only be activated for shorter periods

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 35 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 36 >

6

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 37 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 38 >

2006.01.16

(4140 / PWN)

< 40 >

2006.01.16

(4140 / PWN)

< 42 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 39 >

© MAN B&W Diesel

Tightening of Damper on Exhaust Valve Spindle MAN B&W Diesel

MAN B&W Diesel

Hydraulic Jack & Damper Air Piston

Spindle

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 41 >

© MAN B&W Diesel

7

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 43 >

© MAN B&W Diesel

Dismantling of High Pressure Pipe

2006.01.16

(4140 / PWN)

< 44 >


MAN B&W Diesel

MAN B&W Diesel

Valve actuation Be sure that the area around the working space is completely clean before and during dismantling of the hydraulic system.

ELVA On/Off Valve Exhaust Valve Actuator

Shut off the oil supply.

Close valve 420 and open valve 421 Distribution Block © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 45 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 46 >


Hydraulic Cylinder Unit (HCU) MAN B&W Diesel

MAN B&W Diesel

Fuel injection

Valve actuation


Close the valve 531 for

Fuel Pump

the actuator oil supply

ELVA On/Off Valve Exhaust Valve Actuator

and the valve 536 for damper oil supply.

Accumulator © MAN B&W Diesel

2006.01.16

Distribution Block

(4140 / PWN)

< 47 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 48 >

8


Overhaul of High Pressure Pipe

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 49 >

© MAN B&W Diesel

Overhaul of High Pressure Pipe

2006.01.16

(4140 / PWN)

< 50 >

Mounting of High Pressure Pipe

MAN B&W Diesel

MAN B&W Diesel

Open the valve 531 for the actuator oil supply and the valve 536 for damper oil supply.

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 51 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 52 >

Exh. Valve Sealing Air / Oil Dosage Unit

Mounting of High Pressure Pipe MAN B&W Diesel

MAN B&W Diesel

Close valve 421 and open valve 420

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 53 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 54 >

9

Sealing Oil system. MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 55 >

MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 56 >

2006.01.16

(4140 / PWN)

< 58 >

MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 57 >

© MAN B&W Diesel

Exhaust Valve Sealing Oil Dosage Unit


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



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.



10 – 15 bar oil pressure. © MAN B&W Diesel

2006.01.16

10 – 15 bar oil pressure.

(4140 / PWN)

< 61 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 62 >

2006.01.16

(4140 / PWN)

< 64 >

2006.01.16

(4140 / PWN)

< 66 >

Exhaust Valve Sealing Oil Dosage Unit MAN B&W Diesel

MAN B&W Diesel

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


© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 63 >

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

Grinding set-up for exhaust spindle.

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 65 >

© MAN B&W Diesel

11

MAN B&W Diesel

MAN B&W Diesel

Small dent marks on the seating are acceptable and need NOT to be ground away if they don’t make blow-by.

K98MC/ME

Small dent marks on the spindle seating are acceptable and need NOT to be ground away if they don’t make blow-by. © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 67 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 68 >

2006.01.16

(4140 / PWN)

< 70 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 69 >

© MAN B&W Diesel

MC EXHAUST VALVE MAN B&W Diesel

MAN B&W Diesel

Bottom piece for engine types: K/L/S-MC/-C/-S 1983 - 1992: 26 - 50 MC 60 - 90 MC

Cooled Alloy 50 Cooled Stellite 6

1992 – 1997: 26 - 50 MC Cooled Alloy 50 60 - 90 MC Semi-cooled hard. steel

1997 - 2000: 26 - 42 MC Cooled hard.steel 46 - 98 MC Semi-cooled hard. steel

2000 – : 26 - 42 MC 46 - 98 MC

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 71 >

© MAN B&W Diesel

2005.05.25

4140/PWN

Cooled W-seat Semi-cooled W-seat

< 72 >

12

MAN B&W Diesel

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

MC EXHAUST VALVE Chamber seat

MAN B&W Diesel

The longer lifetime on the seat area is achieved with the new geometry of the W-seat, which retains the temperature reducing features of the chamber seat and combines them with the benefit of the two narrow concentric areas.

W-seat

The effect is that all carbon particles which are trapped between the spindle and bottom piece are crushed and squeezed out and therefore eliminated without giving rise to any appreciable risk dents.

The spindle and seat are fit for further use provided that : • There is along the entire inner circumference of the seat. • There are no blow-by tracks across the inner part of the seats.

© MAN B&W Diesel

2005.05.25

4140/PWN

< 73 >

MAN B&W Diesel

© MAN B&W Diesel

2005.05.25

4140/PWN

< 74 >

2005.05.25

4140/PWN

< 76 >

2005.05.25

4140/PWN

< 78 >

MAN B&W Diesel

2005.05.25

4140/PWN

< 75 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

16,000 h between overhauls 60-100,000 h lifetime for spindle > 30,000 h lifetime for bottom piece

© MAN B&W Diesel

MAN B&W Diesel

2005.05.25

4140/PWN

< 77 >

© MAN B&W Diesel

13

MAN B&W Diesel

MAN B&W Diesel

If water leaks from between valve seat and cylinder cover the upper sealing ring must be changed.

If water leaks from one or both holes the lower sealing ring must be changed. © MAN B&W Diesel

2005.05.25

4140/PWN

< 79 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 80 >

Bottom Piece Design MAN B&W Diesel

MAN B&W Diesel

Exhaust Valve Small/medium bore

References of W-seats running for more than 36000 hours without any grinding and only very small dent marks New seal for bottom piece lower groove

Hole for indication of cooling water leakage from the lowermost sealing ring or gas leakage from the combustion chamber U-type sealing ring (Teflon with a spring back-up) Connect compressed air to the air spring to keep the exhaust valve closed during mounting

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 81 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 82 >

2006.01.16

(4140 / PWN)

< 84 >

Bottom Piece W-Seat MAN B&W Diesel

MAN B&W Diesel

U-Type Sealing Ring: Heat the sealing ring in 100°C hot water for at least five minutes before mounting

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 83 >

© MAN B&W Diesel

14

MAN B&W Diesel

MAN B&W Diesel

MC EXHAUST VALVE

Valve spindle for engine types: K/L/S-MC/-C/-S

Cr (0.25 mm) HVOF (0.15 mm)

Nimonic

1983 - 1992: 26 - 50 MC 60 - 90 MC

Alloy 50 Stellite 6

1992 – 2002: 26 - 50 MC S50MC / 60 - 98 MC

Alloy 50 Nimonic

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

DuraSpindle Nimonic

SNCrW

Alloy 50

1983 – 1996:

Cr stem coating

Stellite 6 1996 - :

HVOF stem coating

(INCO 625 on request) © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 85 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 86 >

Exhaust Valve Nimonic Spindle MAN B&W Diesel

MAN B&W Diesel

Formation of dent marks is an inevitable consequence of service on heavy fuel oil. Dent marks may appear harmful, but will in general have no influence on the performance of the exhaust valve seat.

HVOF-coating

If indications of blow-by are found, then the seat must be ground. Vane wheel for gas driven spindle rotation

Base Material: Nimonic 80A

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 87 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 88 >

2006.01.16

(4140 / PWN)

< 90 >

Design Features MAN B&W Diesel

MAN B&W Diesel

HVOF: High Velocity Oxy-Fuel Process ƒ

Coating applied on the exhaust valve stem only

ƒ

Highly wear-resistant mixture of metal carbide and super alloy

ƒ

Thermally sprayed coating

ƒ


This process is performed by:

ƒ

MAN B&W Copenhagen

ƒ

MAN B&W Singapore

ƒ

MAN B&W Hamburg

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 89 >

© MAN B&W Diesel

15

Exhaust Valve Nimonic Spindle MAN B&W Diesel

MAN B&W Diesel

Formation of dent marks is an inevitable consequence of service on heavy fuel oil. Dent marks may appear harmful, but will in general have no influence on the performance of the exhaust valve seat.

HVOF-coating

Vane wheel for gas driven spindle rotation

If indications of blow-by are found, then the seat must be ground. Base Material: Nimonic 80A

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 91 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 92 >

2006.01.16

(4140 / PWN)

< 94 >


MAN B&W Diesel

Valve spindle stem sealing ring

HVOF - ring

Cr - ring

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 93 >

© MAN B&W Diesel

MAN B&W Diesel A/S Rolled exhaust valve spindles

MC EXHAUST VALVE

MAN B&W Diesel

MAN B&W Diesel

”DuraValve”

Welding and rolling preparation of DuraSpindle

Welded Ni-base alloy

10 t

Inconel 718 / Rene220

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 95 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 96 >

16

Exhaust valve – Rolling equipment

MC EXHAUST VALVE

MAN B&W Diesel

MAN B&W Diesel

Rolled seat area of 50MC DuraSpindle

• Background The roller is pressed against a rotating spindle at a pressure of 10 tons. The combination of the deformation and the subsequent heating in the oven imparts a hardness to the interial which has not been seen before. © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 97 >

© MAN B&W Diesel

MC EXHAUST VALVE

2006.01.16

(4140 / PWN)

< 98 >

MC EXHAUST VALVE

MAN B&W Diesel

MAN B&W Diesel

Section of rolled and heat treated 35 MC DuraSpindle seat

Nimonic spindle & chamber seat, S60MC, 25.500 service hrs

DuraSpindle & chamber seat, S60MC, 33.900 service hrs

Hardness distribution of section © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 99 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 100 >

2006.01.16

(4140 / PWN)

< 102 >


MAN B&W Diesel

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

DuraSpindle & W-seat, S60MC,33.900 service hrs

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 101 >

© MAN B&W Diesel

17

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 103 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 104 >

2006.01.16

(4140 / PWN)

< 106 >

2006.01.16

(4140 / PWN)

< 108 >

Exhaust Valve Bottom Piece MAN B&W Diesel

MAN B&W Diesel

K98MC, K98MC-C Original design

Modified design

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

Increased diameter 0.15° taper

Hardened W-seat

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

Decreased diameter

< 105 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 107 >

© MAN B&W Diesel

18

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 109 >

MAN B&W Diesel

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 110 >

2006.01.16

(4140 / PWN)

< 112 >

2006.01.16

(4140 / PWN)

< 114 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 111 >

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 113 >

© MAN B&W Diesel

19

Design Features MAN B&W Diesel

MAN B&W Diesel

HVOF: High Velocity Oxy-Fuel Process •

Coating applied on the exhaust valve stem only

•

Highly wear-resistant mixture of metal carbide and super alloy

•

Thermally sprayed coating

•


This process is performed by: •

MAN B&W Copenhagen

•

MAN B&W Singapore

•

MAN B&W Hamburg

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 115 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 116 >

SPECIAL RUNNING CONDITIONS MAN B&W Diesel

MAN B&W Diesel

IF running with an open exhaust valve THEN…. Mount pressure gauge at “minimess” point 455 Check that the HCU is pressure free.

421 © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 117 >

© MAN B&W Diesel

SPECIAL RUNNING CONDITIONS

2006.01.16

1.

Close valve 420

2.

Open valve 421

(4140 / PWN)

< 118 >

SPECIAL RUNNING CONDITIONS

MAN B&W Diesel

MAN B&W Diesel

Connect the mini-mesh hose between top flange on actuator point 540 and point 425 at the hydraulic block

1. Open valve 420 421 © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 119 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

2. Close valve 421 < 120 >

20

98ME Special Running


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 >


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 >


MAN B&W Diesel

MAN B&W Diesel

Open damper oil supply

Reconnect air supply under air piston

Mount pressure gauge at “minimess” point 455 Check that the HCU is pressure free.

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 125 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 126 >

21


98ME Special Running MAN B&W Diesel

MAN B&W Diesel

Remove the tools which kept the Disconnect air supply to air cylinder

Open damper oil supply, valve 531

exhaust valve open and mount Reconnect air supply under air piston

the plug screw.

Open valve 420 Drain off air pressure from air cylinder with a mandrel

Close valve 421 © MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 127 >

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 128 >

MAN B&W Diesel A/S MAN B&W Diesel

Thank you for your attention Preben Noeies

© MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 129 >

22

7. MOP Displays

MAN B&W Diesel

Going through all screens: ¾Alarms… ¾Engine: ¾Auxiliaries… ¾Maintenance… ¾… © MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

<1>

2006-01-05

<2>

2006-01-05

<3>

Engine: Operation MAN B&W Diesel

© MAN B&W Diesel


Access Level MAN B&W Diesel

© MAN B&W Diesel


1

Engine: Status MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel


2006-01-05

<4>

2006-01-05

<5>

2006-01-05

<6>

Engine: Process Information Running Mode


Engine: Process Information Speed Control


2

Engine: Cylinder Load MAN B&W Diesel

© MAN B&W Diesel


2006-01-05

<7>

2006-01-05

<8>

2006-01-05

<9>

Engine: Cylinder Pressure MAN B&W Diesel

© MAN B&W Diesel


Auxiliaries: Hydraulic System MAN B&W Diesel

© MAN B&W Diesel


3

Auxiliaries: Scavenge Air MAN B&W Diesel

© MAN B&W Diesel


2006-01-05

< 10 >

2006-01-05

< 11 >

2006-01-05

< 12 >

Auxiliaries: Cylinder Lubricators MAN B&W Diesel

© MAN B&W Diesel


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

© MAN B&W Diesel


4

MAN B&W Diesel

© MAN B&W Diesel

MAN B&W Diesel

© MAN B&W Diesel

Maintenance: System View, I/O Test ECU-A


2006-01-05

< 13 >

2006-01-05

< 14 >

2006-01-05

< 15 >

Maintenance: System View, I/O Test ECU-A, Channel-35


Maintenance Invalidated Inputs MAN B&W Diesel

© MAN B&W Diesel


5

Maintenance Network Status MAN B&W Diesel

© MAN B&W Diesel


2006-01-05

< 16 >

2006-01-05

< 17 >

2006-01-05

< 18 >

.: Version MAN B&W Diesel

© MAN B&W Diesel


.: Set Time MAN B&W Diesel

© MAN B&W Diesel


6

Alarms: Alarm List MAN B&W Diesel

© MAN B&W Diesel


2006-01-05

< 19 >

2006-01-05

< 20 >

2006-01-05

< 21 >

Alarms: Alarm List MAN B&W Diesel

© MAN B&W Diesel


Alarms: Event Log MAN B&W Diesel

© MAN B&W Diesel


7

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

© MAN B&W Diesel


2006-01-05

< 22 >

2006-01-05

< 23 >

Alarms: Channel List MAN B&W Diesel

© MAN B&W Diesel


8

8. PMI

MAN B&W Diesel

© MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

2006-02-19

<1>

2006-02-19

<2>

2006-02-19

<3>

PMI system MAN B&W Diesel

© MAN B&W Diesel


PT diagram MAN B&W Diesel

© MAN B&W Diesel


1

PT diagram - zoomed MAN B&W Diesel

© MAN B&W Diesel


2006-02-19

<4>

2006-02-19

<5>

2006-02-19

<6>

PV diagram MAN B&W Diesel

© MAN B&W Diesel


Balanced plot, Pmax - Pcomp MAN B&W Diesel

© MAN B&W Diesel


2

Balanced plot, Pi MAN B&W Diesel

© MAN B&W Diesel


2006-02-19

<7>

2006-02-19

<8>

Calculated values MAN B&W Diesel

© MAN B&W Diesel


3

Overview 4q3b3c

More details 26j3b

Related Documents 171j1w

Man Bw L27_38 5p366b

Tibco Bw Online Training 6o1n4e

Man Diesel Engine Manual 4d148

Man D20 Engine k5u6q

Engine Isuzu Training 436z3r

More Documents from "abcde" 663a3b

Tens Past 2x2f1

Sasaran Belajar 4 Whole Lung Lavage 4w1454