QSV Diesel Engines

Module 3 - Systems
Air, Exhaust and Starting

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 System Module - Air, Exhaust and Starting

Learning Objectives
At the end of this section of the module you will be able to describe
the operation of the pneumatic starting system and trace the flow
paths of the Combustion Air, Starting Air and Exhaust Gas.

Agenda
Air Intake (Combustion Air) and Exhaust
• Pneumatic System Schematic
• Pneumatic Starter
• Engine Turning Mechanism

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 Air / Exhaust / Starting Systems

• Turbochargers (May vary dependant on application):

Diesel ‘L’ - 1 x ABB TPS48, boost at 1500 - approx.2.8 Bar, no water cooling.
Diesel ‘V’ - 4 x Holset HX82, boost at 1500 - approx.3.5 Bar, water cooled bearing
housing only.

• Exhaust:
Diesel - Constant Pressure Exhaust Manifold (Single chamber feeding all turbo’s).

(Exhaust temperature nominally 450 - 470ºC at full load dependant on rating, overall
variations exceeding 50ºC must be investigated)

• Barring Device:
QSV Diesel - No mechanical air starter interlock, electrical micro-switch system
only.

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 Combustion Air

Atmospheric
Air in
Through
Multi-duct

Air Cooled to
approx. 45 - 60º C
Output Air (113 - 140º F)
pressurised up to
3.5 Bar (51PSI ),
Temperature can
rise up to to around
149º C (300º F).

Into
Cylinder

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 Exhaust Gas System ‘V’ Engines

E - Main Manifold Section Constant Pressure Exhaust system

D - End Manifold Section
J
F - Bellows
H - 4 x Turbocharger H H

J - 2 x Exhaust ‘T’
F F

D D
E E

M U L T I-D U C T S

SUPPORTS SUPPORTS
RETURN FEED ‘T’ RETURN
TURBO OIL

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 Intake and Exhaust Connections

AIR

Water MULTI - DUCT

3421685

Sealing Rings
Multi-duct to Block Gasket
Flow
Water

EXHAUST
Rivet
EXH AIR Locations

Exhaust Manifold to Multi-duct Bellows

Multi-duct to Cylinder Head Gasket

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 Pneumatic System

Barring Device
micro-switch

Starter control
Valve
Main Starting
Pneumatic Stop
Valve Starter Motor
Cylinders

Safety Valve

Main Stop
Valve
Pressure
Regulator
10 Bar

Air Receiver
40 Bar Non return
Valve

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 Engine Mounted Air Receiver

Pressure
Switch Three-way Valve
2 (Pressure switch calibration / test)
90 deg Test
1

Supply

Control Solenoid
with test button

Air Exhaust Port

Receiver supplies air

to emergency stop
solenoids even in
event of air supply
failure Receiver Drain Valve

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 Air-Start Safety Valve

• The Air-Start Safety Valve is installed in a

vertical position in order that any foreign matter
will fall out of the valve.

• If replacing, ensure the correct spanner is used

to install. A pipe wrench will deform the valve
and consequently the valve will not function. Air-Start Safety Valve
• New valves are delivered with the lifting device
set at “check” (open). When put into service, the Operating Pressure: 15 Bar
red knob must be turned fully clockwise to the
“service” position. If an installation is to be taken
out of service for a long period, then the lifting Range of Application:
device must be opened by turning the red knob
Compressed air and non-poisonous, non-
counter-clockwise until an audible “click” is
combustible gases. Gases allowed to
heard.
escape freely, up to 180° C (356° F).
• Valve operation pressure IS NOT adjustable. Not suitable for water steam.

• Replace valve if valve seat is damaged.

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 Pneumatic Starter

• No lubrication
• No filtration
• Low noise level
• Pre-engaged drive
• Low pressure
• Easy maintenance
• No mechanical wear

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 Starter Performance
45MB - 10, Compressed Air, 15.95:1

225
200 40
175 150 psi
120 psi
Torque (lb.ft.)

150 30
90 psi

Power ( HP )
125
100 20
75
50 10
25
0 0
0 500 100 1500 2000 2500 3000 3500 4000 4500 5000
Pinion Speed (rpm)

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 TDI - 45M Cross Section

Single Stage Precision Ball Electronic Control

Solenoid Valve Bearing
Turbine Bearings Module 9 - 40V dc.

8 Deflection Double Planetary Pre - engage

Relay Valve Exhaust Port
Nozzles Gearbox 16:1 Piston

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 Starter at Rest

Inlet Housing

3 - Way Solenoid Valve

Closed, Exhaust Position

Air at 10Bar (150psi)

Supply from Tank

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 Starter - Engaging

Relay Valve
Closed

3 - Way Solenoid
Valve Open

Supply from Tank

Air at 10Bar (150psi)

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 Starter Cranking

Exhaust Relay Valve

Open

3 - Way Solenoid
Valve Open
Exhaust

Air at 10Bar (150psi)

Supply from Tank

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 Starter Disengaging

Relay Valve
Closing

3 - Way Solenoid Valve

Closed, Exhaust Position

Supply from Tank Air at 10Bar (150psi)

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 Engine Turning Mechanism

Micro-switch
Electrical
System
Interlock
2

1
1 3

Engaged Disengaged

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 Module 3 - Air, Exhaust and Starting
On Completion of all Module 3 sections

Team Task
- End -
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