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Exhaust valve system MAN Diesel & Turbo Author Current topic  00.00.2012 < 1 >
Exhaust valve system
MAN Diesel & Turbo
Author
Current topic

00.00.2012
<
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For training
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Exhaust Valve System. 1) Exhaust valve actuator 2) Exhaust valves High Force 1st Low Force
Exhaust Valve System.
1) Exhaust valve actuator
2) Exhaust valves
High Force
1st Low Force
2nd Low Force
3) Special running
conditions
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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2
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For training
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Exhaust Valve Actuation, MC versus ME. Hydraulic Hydraulic push rod push rod Exhaust valve Exhaust
Exhaust Valve Actuation,
MC versus ME.
Hydraulic
Hydraulic
push rod
push rod
Exhaust valve
Exhaust valve
Actuator
Actuator
Exhaust valve
Exhaust valve
spindle
spindle
High pressure
High pressure
hydraulic oil –
hydraulic oil –
inlet
inlet
FIVAFIVA ValveValve
AccumulatorAccumulator
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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3
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For training
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Exhaust Valve, Pipe Connections. MAN Diesel & Turbo AAA-CPH Exhaust valve system 22.05.2015 < 4
Exhaust Valve,
Pipe Connections.
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
4
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For training
purposes
only

only

For training

purposes

only F o r t r a i n i n g purposes Exhaust Valve Actuator.

Exhaust Valve Actuator.

t r a i n i n g purposes Exhaust Valve Actuator. Top Cover Minimesh Actuator
t r a i n i n g purposes Exhaust Valve Actuator. Top Cover Minimesh Actuator
t r a i n i n g purposes Exhaust Valve Actuator. Top Cover Minimesh Actuator
t r a i n i n g purposes Exhaust Valve Actuator. Top Cover Minimesh Actuator

Top Cover

Minimesh

Actuator Housing

Actuator Pistons

 

MAN Diesel & Turbo

  MAN Diesel & Turbo   AAA-CPH Exhaust valve system   22.05.2015 < 5 >
 

AAA-CPH

Exhaust valve system

 

22.05.2015

< 5

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only

   

For training

purposes

Exhaust Valve Actuator,

Working Principle.

 
F o r t r a i n i n g purposes Exhaust Valve Actuator, Working
 
 
Actuator FIVA

Actuator

FIVA

Actuator FIVA
   
 
  Unpressurised hydraulic oil Pressurised hydraulic oil

Unpressurised hydraulic oil

Pressurised hydraulic oil

 

MAN Diesel & Turbo

  MAN Diesel & Turbo   AAA-CPH Exhaust valve system   22.05.2015 < 6 >
 

AAA-CPH

Exhaust valve system

 

22.05.2015

< 6

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Exhaust Valve Actuation. Initial Position Step 1 Step 2 MAN Diesel & Turbo AAA-CPH Exhaust
Exhaust Valve Actuation.
Initial Position
Step 1
Step 2
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
7
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For training
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Exhaust Valve System. 1) Exhaust valve actuator 2) Exhaust valves High Force 1st Low Force
Exhaust Valve System.
1) Exhaust valve actuator
2) Exhaust valves
High Force
1st Low Force
2nd Low Force
3) Special running
conditions
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
8
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For training
purposes
only

only

     

For training

purposes

Design Features,

MC versus ME high force exh. valve

F o r t r a i n i n g purposes Design Features, MC versus
 
 

S50MC-CS50MC-C

 

S50ME-CS50ME-C

 

Air spring size

Air spring size

   

for closing the

for closing the

exhaust valve

exhaust valve

reduced

reduced

Hydraulic damper for fixed

Hydraulic damper for fixed

 
valve stroke valve stroke Different valve spindle Different valve spindle design design
valve stroke valve stroke Different valve spindle Different valve spindle design design
valve stroke valve stroke Different valve spindle Different valve spindle design design
valve stroke valve stroke Different valve spindle Different valve spindle design design

valve stroke

valve stroke

Different valve spindle

Different valve spindle

design

design

 

MAN Diesel & Turbo

  MAN Diesel & Turbo AAA-CPH Exhaust valve system   22.05.2015 < 9 >

AAA-CPH

Exhaust valve system

 

22.05.2015

<

9

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Design details. Self-adjustingSelf-adjusting damperdamper pistonpiston HydraulicHydraulic nut/measuringnut/measuring
Design details.
Self-adjustingSelf-adjusting damperdamper pistonpiston
HydraulicHydraulic nut/measuringnut/measuring conecone
Contact less sensor with
Contact less sensor with
integrated electronics
integrated electronics
OutletOutlet lubelube oiloil
InletInlet lubelube oiloil
DamDam erer
pp
AirAir inletinlet
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
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Sealing Oil Control Unit. Sealing oil MAN Diesel & Turbo AAA-CPH Exhaust valve system 22.05.2015
Sealing Oil Control Unit.
Sealing oil
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
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Spindle Guide Sealing System - Sealing Oil MAN Diesel & Turbo AAA-CPH Exhaust valve system
Spindle Guide Sealing System
- Sealing Oil
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
purposes
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Exhaust Valve. Sealing Oil Control Unit Feed back sensor Oil inlet to damper Drain pipes
Exhaust Valve.
Sealing Oil Control Unit
Feed back sensor
Oil inlet to damper
Drain pipes
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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13
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For training
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Low Force Exhaust Valve MAN Diesel & Turbo AAA-CPH Exhaust valve system 22.05.2015 < 14
Low Force Exhaust Valve
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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14
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For training
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only

   

For training

purposes

LowLowForceForceExhaustExhaustValveValve

 
F o r t r a i n i n g purposes Low Low Force Force
 
 

Cost reduction

Less force and cavitation in hydraulic

pipe and actuator

Standard MC exhaust valve design

can be used on ME engines

Dura Spindle design applied

and actuator • Standard MC exhaust valve design can be used on ME engines • Dura
and actuator • Standard MC exhaust valve design can be used on ME engines • Dura
and actuator • Standard MC exhaust valve design can be used on ME engines • Dura
 

Longer Time Between Overhaul (TBO)

Controlled Oil Level (COL)

In some cases down sizing of HPS can

also be possible

 

Step 1 stroke and step 2 diameter

reduced in actuator

 
 

MAN Diesel & Turbo

  MAN Diesel & Turbo AAA-CPH Exhaust valve system   22.05.2015 < 15 >

AAA-CPH

Exhaust valve system

 

22.05.2015

<

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only

 
only      
   

For training

purposes

1 st

and 2

nd

generation Low Force.

 

Reduced diameter on Oil Cylinder, Air

Cylinder and Air Piston (reducing weight)

2

nd

generation

 

Added cone on Exhaust Valve Spindle

 Added cone on Exhaust Valve Spindle  
 

(for direct measurement of valve stroke)

Added inductive sensor for direct

measurement of valve stroke (removing

pressure transmitter)

Simplifying air spring, by increasing air

1

1

st

generation

 

pressure from 3bar to 7bar (removing

 

reduction station)

 
 

MAN Diesel & Turbo

 
  MAN Diesel & Turbo   AAA-CPH Exhaust valve system   22.05.2015 < 16 >

AAA-CPH

Exhaust valve system

 

22.05.2015

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For training

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Differences in Low Force.

 
F o r t r a i n i n g purposes Differences in Low Force.
 
 

2nd generation Low Force

1st generation Low Force

   

Studs changed from

 

moment tightened to

hydraulic tightened.

Number of studs reduced

Rod.lift-Rotation

check removed

 
Inductive Sensor

Inductive

Sensor

  Inductive Sensor  
 
   

Pressure-

 

transducer

 

MAN Diesel & Turbo

  MAN Diesel & Turbo AAA-CPH Exhaust valve system   22.05.2015 < 17 >

AAA-CPH

Exhaust valve system

 

22.05.2015

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2’nd generation Low Force. Shorter Piston, Actuator Cone on Exhaust Valve Spindle Inductive sensor Direct
2’nd generation Low Force.
Shorter Piston, Actuator
Cone on
Exhaust Valve Spindle
Inductive sensor
Direct measurement
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
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For training
purposes
only
2’nd generation Low Force. Low Force, 2nd Volume reduced generation Diameter reduced Rough weight reduction
2’nd generation Low Force.
Low Force, 2nd
Volume reduced
generation
Diameter reduced
Rough weight reduction
98ME ~249 kg (~8,3 %)
Inlet
90ME ~156 kg (~6,5 %)
pressure
7 bar
New Safety Valve
setting
25 bar
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
purposes
only

only

For training

purposes

only only F o r t r a i n i n g purposes Controlled Oil

Controlled Oil Level (COL)

Exhaust valve stem lubrication: Controlled Oil Level (COL)

Oil reservoir

Spring air/ above stem sealing ring non-return valve Safety valve adjustment 23 bar Min. level
Spring air/
above stem sealing
ring
non-return valve
Safety valve
adjustment 23 bar
Min. level
Sealing ring

controlled by stand pipe

Simplification, replaces sealing oil system

MAN Diesel & Turbo

replaces sealing oil system MAN Diesel & Turbo AAA-CPH Exhaust valve system 22.05.2015 < 20 >

AAA-CPH

Exhaust valve system

22.05.2015

< 20

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Modifications MAN Diesel & Turbo AAA-CPH Exhaust valve system 22.05.2015 < 21 > For training
Modifications
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
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For training
purposes
only
DuraSpindle. Production steps of DuraSpindle Austenitic valve stainless steel Rolling process, 10 t load Inconel
DuraSpindle.
Production steps of DuraSpindle
Austenitic
valve stainless steel
Rolling
process, 10 t
load
Inconel 718
Hardening heat
treatment
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
purposes
only

only

   

For training

purposes

Dura Spindle in service.

 
F o r t r a i n i n g purposes Dura Spindle in service.
 
 

Nimonic spindle & W-seat,

  Nimonic spindle & W-seat,    
   

S60MC, 25.500 service hrs

Dura Spindle & W-seat,

S60MC,33.900 service

S60MC,33.900 service

hrs

 

MAN Diesel & Turbo

  MAN Diesel & Turbo AAA-CPH Exhaust valve system   22.05.2015 < 23 >

AAA-CPH

Exhaust valve system

 

22.05.2015

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Specification of DURA Spindles New spindles: New spindles: Extent of DURA seat technologi DURA seat
Specification of DURA Spindles
New spindles:
New spindles:
Extent of DURA seat technologi
DURA seat technologi used without
necessary corrosion layer welded on spindle
used with necessary corrosion
disc underside can be applied on all engine
layer welded on spindle disc
types not mentioned in the tabel on right
underside, ref below tabel.
side.
NOTE:
S46MC-C
Reconditioning of all types of spindles
S50MC
(Mk. V 1992 & forward)
require a welding of seat and bottom
60 – 98MC/C
(Mk. V 1992 & forward)
underside with Inconel 625 & 718
S46ME – 98ME
Inconel 718
Inconel 718
Base material is either Nimonic
or Stainless steel (SNCrW)
Inconel 625
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
24
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For training
purposes
only
Recap of Exhaust valve designs ME High Force • High excess force being waisted in
Recap of Exhaust valve designs
ME High Force
• High excess force being waisted in opening damper. Mechanical stop.
• Cavitation in hydraulic push rod and actuator
• Nimonic spindle
• Hydraulic tensioned cone on spindle for feed back sensor
• Sealing Oil Control Unit
1st generation Low Force
• Opening damper removed. Floating piston
• MC valve mounted on ME
• Dura spindle introduced
• Hydraulic tensioned cone removed
• Spring air measured by pressure transducer
• Sealing Oil Control Unit exchanged with Controlled Oil Level
• Spring air 3 bar
2nd generation Low Force
• Spindle with cone shape for direct measurement
• Air cylinder and piston reduced for weight reduction
• New safety valve setting 25 bar
• Spring air 7
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
25
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For training
purposes
only
MOP Exhaust Valve Adjustments. Adjustment of exhaust valve closing time Adjustment of exhaust valve opening
MOP Exhaust Valve Adjustments.
Adjustment of exhaust
valve closing time
Adjustment of exhaust
valve opening time
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
26
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For training
purposes
only
Exhaust Valve System. 1) Exhaust valve actuator 2) Exhaust valves High Force 1st Low Force
Exhaust Valve System.
1) Exhaust valve actuator
2) Exhaust valves
High Force
1st Low Force
2nd Low Force
3) Special running
conditions
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
27
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For training
purposes
only
Special running conditions, open exh-valve Small Bore Program (50 ME). Look at chapter 704-04 in
Special running conditions, open exh-valve
Small Bore Program (50 ME).
Look at chapter 704-04
in the operation manual
Check pressure free at “minimess” point 455
Close
Open
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
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For training
purposes
only
Special running conditions, open exh-valve Small Bore Program (50 ME). Look at chapter 704-04 in
Special running conditions, open exh-valve
Small Bore Program (50 ME).
Look at chapter 704-04
in the operation manual
540
Connect the mini-mesh hose
between top flange on
actuator point 540 and point
425 at the hydraulic block
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
29
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For training
purposes
only
Special running conditions, open exh-valve Small Bore Program (50 ME). Look at chapter 704-04 in
Special running conditions, open exh-valve
Small Bore Program (50 ME).
Look at chapter 704-04
in the operation manual
Open
Close
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
30
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For training
purposes
only
Special running conditions, open exh-valve Large Bore Program (From 60 and up). Look at chapter
Special running conditions, open exh-valve
Large Bore Program (From 60 and up).
Look at chapter 704-04
in the operation manual
Close
Open
Check pressure free at “minimess” point 455
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
31
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For training
purposes
only
Special running conditions, open exh-valve Large Bore Program (From 60 and up). Look at chapter
Special running conditions, open exh-valve
Large Bore Program (From 60 and up).
Look at chapter 704-04
in the operation manual
Close valve 531 to
shut off oil to damper
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
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For training
purposes
only
Special running conditions, open exh-valve Large Bore Program (From 60 and up). Disconnect air supply
Special running conditions, open exh-valve
Large Bore Program (From 60 and up).
Disconnect air
supply to air spring
Ch
ec
k th
a
t th
e ex
h
. va ve sp n
l
i
dl
e
h
as
moved to open position on the
Main Operating Panel, ’Maintenance’ –
’System View I/O Test’ – CCU, Ch 34
Drain off air pressure from
air cylinder with a mandrel
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
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For training
purposes
only
Special running conditions, open exh-valve Large Bore Program (From 60 and up). Look at chapter
Special running conditions, open exh-valve
Large Bore Program (From 60 and up).
Look at chapter 704-04
in the operation manual
Remove plug screw and mount tools to
keep exhaust valve spindle open
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
34
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For training
purposes
only
Special running conditions, open exh-valve Large Bore Program (From 60 and up). Open damper oil
Special running conditions, open exh-valve
Large Bore Program (From 60 and up).
Open damper oil supply
Valve 531
Reconnect air supply
under air piston
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
35
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For training
purposes
only
Special running conditions, open exh-valve, Low force valve. Look at chapter 704-04 in the operation
Special running conditions, open
exh-valve, Low force valve.
Look at chapter 704-04
in the operation manual
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
36
>
For training
purposes
only
Special running conditions, open exh-valve, Low force valve. Look at chapter 704-04 in the operation
Special running conditions, open
exh-valve, Low force valve.
Look at chapter 704-04
in the operation manual
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
37
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For training
purposes
only
Special running conditions, open exh-valve, Low force valve. MAN Diesel & Turbo AAA-CPH Exhaust valve
Special running conditions, open
exh-valve, Low force valve.
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
38
>
For training
purposes
only
Special running conditions, open exh valve, Low force valve. Look at chapter 704-04 in the
Special running conditions, open exh
valve, Low force valve.
Look at chapter 704-04
in the operation manual
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
39
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For training
purposes
only
Special running conditions, Open exh-valve, Low force valve. MAN Diesel & Turbo AAA-CPH Exhaust valve
Special running conditions,
Open exh-valve, Low force valve.
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
<
40
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For training
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only
Special running conditions, open exh-valve, Low force valve. MAN Diesel & Turbo AAA-CPH Exhaust valve
Special running conditions, open
exh-valve, Low force valve.
MAN Diesel & Turbo
AAA-CPH
Exhaust valve system
22.05.2015
< 41
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For training
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only

   

For training

purposes

Disclaimer

 
F o r t r a i n i n g purposes Disclaimer    
 
 

All data provided in this document is non-binding.

   

This data serves informational purposes only and is especially

not guaranteed in any way. Depending on the subsequent

specific individual projects, the relevant data may be subject

to changes and will be assessed and determined individually

for each project. This will depend on the particular

characteristics of each individual project, especially specific

site and operational conditions.

 
 

MAN Diesel & Turbo

  MAN Diesel & Turbo AAA-CPH Exhaust valve system   22.05.2015 < 42 >

AAA-CPH

Exhaust valve system

 

22.05.2015

< 42

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