6 Hydraulic Cylinder Unit PDF

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Hydraulic Cylinder Unit

Unit, HCU
HCU.
MAN Diesel & Turbo Author Current topic 00.00.2012 < 1 >
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H d
Hydraulic
li Cylinder
C li d Unit.
U it
1)) Distribution Block
2) Components:
FIVA
Accumulators
Cylinder Lubricator
3) Highpressure Pipes
purposes only
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H d
Hydraulic
li Cylinder
C li d Unit,
U it HCU.
HCU
Accumulator
Exhaust Valve
Actuator
Fuel Oil
Pressure
booster
FIVA valve
Ball Valve
Distribution Block
Cylinder Lubricator
purposes only
Forr training Hydraulic Cylinder Unit,
HCU Di
Distribution
t ib ti Block.
Bl k
Seen from Man. Side Seen from Exhaust Side
purposes only
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Hydraulic Cylinder Unit, HCU
L70ME
Distribution block
Double wall pipe

Double wall pipe
purposes only
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Hydraulic Cylinder Unit,
HCU Hydraulic Diagram.
Inlet Valves Drain Valves

purposes only
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HCU Valve
Val e Operation.
Operation
405 : Drain valve for FIVA valve

406 : Drain valve for FIVA valve
420 : Main supply valve of high pressure
oilil tto FIVA valve
l
421 : Drain valve for distribution block
430 : Valve for double wall pipe leakage
detection
431 : Drain valve for outer pipe oil
560 455 : Mini-mess
Mini mess coupling for measurement
406 of the oil pressure (high pressure side)
421 455 560 : Supply valve of high pressure oil to
405 ME llubricator
bi t
420
430 431
Valve position during normal operation
405 406 420 421 430 431 560
Closed Closed Open Closed Open Closed Open
purposes only
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Hydraulic Diagram 300 bar
bar.
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HCU Valves.
Valves
I t ti
Instructions
Valve No.
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HCU Cautions
CAUTION CAUTION
HCU OVERHAULING LUBRICATION OVERHAULING
0. CHECK GAUGE WORKS! 0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 420, 531 1. CLOSE VALVE NO. 560
2. OPEN VALVE NO. 421, 405, 406 2. CHECK PRESSURE AT MEASURING
3.CHECK PRESSURE AT MEASURING POINT 565
POINT 455.
455 3 IF PRESSURE IS PRESENT,
3. PRESENT PRESS
WARNING NEVER OPEN VALVE THE PRE-LUB BOTTON AT THE HMI
420 WHEN SYSTEM PRESSURE IS PANEL.
ON
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FIVA Valves
MAN Diesel & Turbo Author Current topic 2007-01-03

00.00.2012 < 11 >
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FIVA
Fuel Injection Valve Actuation
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
g the timing
g of injection
j is variable and this is jjust an example.
p
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MAN Diesel FIVA.
Pilot Valve
Feed Back Sensor
Control
Piston
Main Spool
purposes only
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FIVA Spool Positions.

Positions
Main Spool Position

Feedback from
LVDT Sensor
purposes only
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Accumulator
Diaphrame Working Principle.
Diaphrame, Principle
purposes only
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Accumulator
Nit
Nitrogen Ch
Check,
k SL06
SL06-469.
469
The accumulator
Th l t charge
h pressure should
h ld bbe
checked within the first week of service.
Next check should be made around 4
months
th llater,
t ffollowed
ll db
by checking
h ki every 6
months.
A minor leakage from the accumulators is
unavoidable and service experience shows
unavoidable,
that a pressure drop in the range of 2-5
bar/month is to be expected.
The charge pressure is dependent on
working servo oil pressure as well as the
accumulator temperature.
For the 200 bar HPS accumulator charging
pressures are:
95 bar +0/-5 @ 20C
105 bar +0/-5 @ 50C
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Cylinder Lubrication System.

System
purposes only
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Cylinder Liners.
Liners
Injection nozzle
Injection nozzle
with non-return Cylinder liner
valve
MAN Diesel & Turbo 3331050/20031212 (CBO/4100) Author Current topic 00.00.2012 < 18 >
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ME Cylinder Lubricator.
Lubricator
Cylinder lub. Inductive proximity sensor
oil inlet for feed-back signal to
control of piston movement
Signal for
lubrication from
controller
Level sensor for
cylinder oil in lubricator
Outlets for
cylinder liner Injection plunger
lub oil
lub.
injectors
Spacer for
basic setting of
pump
stroke
Drain 200 bar system oil supply
Non-return valve Stroke oil
adjusting outlet Actuator
screw piston
Sealingring
MAN Diesel & Turbo 3331377/20041021 (2200/OZS) Author Current topic 00.00.2012 < 19 >
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Cylinder Lubricator
Lubricator.
Distribution Block
Cylinder Lubricator
purposes only
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Cylinder Lubrication Demands.

Demands
The purposes of cylinder lubrication are as follows:
1
1. To create a hydrodynamic oil film separating the piston rings from the liner
The optimum is kept safely down to a feedrate of 0.60 g/kWh.
2. To clean the piston rings, lands and ring grooves
All approved cylinder oils fullfils the requirements, even at a feed rate as low as 0.60 g/kWh.
3. To control corrosion, i.e. control the neutralisation af sulphuric acid

According to latest Service Letter (SL2013-571) Feedrate Factor and Minimum Feedrate have to be
adjusted to 0.20
0 20 0.34
0 34 g/kWhxS% x S% and 0.60
0 60 g/kWh
oses only
Forr training
Optimising the Cylinder Condition.
Lubrication versus Maintenance
Maintenance.
purpo
Liner wear rate as a function of lube oil dosage

1
ooilstarvation
0,9
brication)
0,8
(boundarylub
Highweardueto
0,7
m/1000h)
0,6
Lin er Wear (mm

0,5
0,4
0,3
0.10 mm/1000h
0,2
0 05 mm/1000h
0.05
0,1 0.02 mm/1000h
0
03
0,3 04
0,4 05
0,5 06
0,6 07
0,7 08
0,8 09
0,9 1 11
1,1 12
1,2 13
1,3 14
1,4 15
1,5 16
1,6
Lube Oil Dosage (g/kWh)
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Forr training
H
How tto d
determine
t i ACC ffactor.
t
Prerequisite for correct determination of

ACC factor = Feed Rate factor
purposes only
Forr training
Sulphur % in relation to BN number.
SL2013 571
SL2013-571
Fuel type
yp BN
Distillate and LNG <= 40
Low Sulphur residual fuel 40 - 60
High Sulphur residual fuel Mk 6 - 8 55 - 100
High Sulphur residual fuel Mk 9 or newer 70 - 100
purposes only
Forr training
Scaling the ACC factor

factor.
3 % S
S. BN 70 3
3%S
S. BN 40
A A
A A
A
A
A
A
A
A A
A A A
A A A
A
0.6
0 6 g/kWh A A A
0.6 g/kWh
F = 70/40 =1.75
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Forr training
ACC Dosages calculated from different Feedrate
Factors (SL2013-571,
(SL2013 571 Min Feedrate =0
=0.6
6 g/kWh)
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Lubricator part load break point

point.
purposes only
Forr training
Two ways to ACC factor

factor.
1: ACC familiarsation.
Adjust according to piston ring and liner wear.
wear
Use oil analysis to evaluate.
.
2: Adjust according to Feed Rate sweep.

Adj
Adjust according
di to oilil analysis.
l i
purposes only
Forr training
Piston ring and liner wear

wear.
CPR-POP Liner wear
CPR-CL
CPR CL
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Forr training
Piston ring wear.
SL2013 571
SL2013-571.
CPR-POP CPR-CL
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Analysis Safe Area.
SL 2013-571.
2013 571
Graph to find the perfect Feed Rate
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g
setting.
SL 2013-571
purposes only
Forr training
Running in SL2013-571.
Breaking in.
in
purposes only
Forr training
ACC Running in schedule.
SL 2013-571.
2013 571
purposes only
Forr training
ACC Cylinder Lubrication.

Lubrication
Sulphur % Minimum feed rate

Feed rate factor F
F
Fixed Feed rate
purposes only
Forr training
Correction Tables
Tables.
Runningg with Feed Rate Factor Runningg with Feed Rate Factor
0.20g/kWhxS% (Normal Running) 0.23g/kWhxS% (Running In)
[Correction factor: 0.20/0.26=0.77] [Correction factor: 0.23/0.26=0.88]
When operating the
Lubrication from MOP
without updated software,
the system will not allow
the Feed Rate Factor to be
adjusted below
0.25g/kWhxS%.
To ensure correct lubrication
oil dossage correspondig
to Feed Rate Factor
g 0,20
settings , or
0,23g/kWhxS, the factor
has to be adjusted to
g
0.26g/kWhxS% in the
MOP and correction on the
sulphur content in the fuel
oil (S%) has to be done
according to the
Correction Tables.
purposes only
Forr training
Cylinder Lubrication Back-up.

Back up
In case of CCU failure, where the

CCU cannot be changed
immediately the cylinder lubrication
immediately,
can be achieved by a temporary
cable from one of the ECU units,
plug 52
52, to the solenoid valve on
the lubricator on the unit in
question.
Th lubrication
The l b i ti will ill b
be with
ith random
d
timing.
purposes only
Forr training
Cylinder Lubrication Back-up.

Back up
purposes only
Forr training
HCUs Mounted on a Common Base Plate.
Double wall
high pressure
pipe
High pressure oil inlet
from the HPS
oses only
Forr training
Hydraulic Cylinder Units

purpo
purposes only
Forr training
HCU Line,
Line 300 Bar
Bar.
purposes only
Forr training
Double Wall Piping,

Piping Sealings.
Sealings
Flange
Fl
Outerpipe
Sealingrings
Screws
InnerPipe
Sealing
rings
SlideBearings
purposes only
Forr training
Double Wall Pipe.

Pipe
MAN Diesel & Turbo 2500/KNB April 2003. Author Current topic 00.00.2012 < 43 >
purposes only
Forr training
Leak Detection
1. CLOSE the valve 430 at the last but one Hydraulic Cylinder Unit.
2. OPEN the valve 431 at the last HCU to decrease the p pressure in the space
p
between the inner and outer pipe.
3. CLOSE the valve 431 at the last HCU again.
4. Check the pressure increase in the space between at pos. 435, at the last HCU
5
5. If the pressure increases to system pressure level
level, the leakage has been found
found.
6. When the leakage has been eliminated, bring all the valves to their normal
position.
purposes only
Forr training
Disclaimer
All data provided in these training materials is non-binding.

This data serves informational purposes only and is especially not
guaranteed in any way
way.
Depending on the subsequent specific individual projects, the relevant
data may be subject to changes and will be assessed and determined
i di id ll ffor each
individually h project.
j t Thi
This will
ill d
depend
d on th
the particular
ti l
characteristics of each individual project, especially specific site and
operational conditions.
purposes only
Forr training
Learning Objectives
The learning objective(s) of this training unit is (are) as follows:
Objective 1
Objective 2
Objective
j 3
.
.
purposes only
Forr training
Qualification
The qualification of our trainees is

realised
Qualification 1
Qualification 2
Qualification 3
...
...
purposes only
Forr training
MAN PrimeServ Academy
The PrimeServ Academy offers a

wide range of
Item 1
Item 2
Item 3
.
purposes only
Forr training
Source Information
Release History
Module Topic changed Changed Change Approved Approval

by Date by Date
Template updated Michael 10042012 Name Date
Johns
Template updated, SL2013-571 Michael 19062013 Name Date
Johns
Topic 3 Name Date Name Date
Topic 4 Name Date Name Date

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purposes only

Hydraulic Cylinder Unit

1)) Distribution Block

Seen from Man. Side Seen from Exhaust Side

Double wall pipe

Inlet Valves Drain Valves

405 : Drain valve for FIVA valve

MAN Diesel & Turbo Author Current topic 2007-01-03

Degree Crank angle

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

MAN Diesel FIVA.

Feed Back Sensor

FIVA Spool Positions.

Main Spool Position

Cylinder Lubrication System.

Cylinder Lubrication Demands.

The purposes of cylinder lubrication are as follows:

2. To clean the piston rings, lands and ring grooves

3. To control corrosion, i.e. control the neutralisation af sulphuric acid

Liner wear rate as a function of lube oil dosage

Lin er Wear (mm

0,1 0.02 mm/1000h

Lube Oil Dosage (g/kWh)

Prerequisite for correct determination of

Scaling the ACC factor

Lubricator part load break point

Two ways to ACC factor

2: Adjust according to Feed Rate sweep.

Piston ring and liner wear

CPR-POP Liner wear

ACC Cylinder Lubrication.

Sulphur % Minimum feed rate

Fixed Feed rate

Cylinder Lubrication Back-up.

In case of CCU failure, where the

Cylinder Lubrication Back-up.

Hydraulic Cylinder Units

Double Wall Piping,

Double Wall Pipe.

All data provided in these training materials is non-binding.

The learning objective(s) of this training unit is (are) as follows:

The qualification of our trainees is

MAN PrimeServ Academy

The PrimeServ Academy offers a

Module Topic changed Changed Change Approved Approval

Topic 4 Name Date Name Date

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