08 Exhaust Valve System (Sep 2015) PDF

purposes only
For training
Exhaust valve system
MAN Diesel & Turbo Author Current topic  00.00.2012 < 1 >
purposes only
For training
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 < 2 >
purposes only
For training
Exhaust Valve Actuation,
MC versus ME.
Hydraulic
push rod
Exhaust valve
Actuator Exhaust valve
spindle
High pressure
hydraulic oil –
inlet
FIVA Valve
Accumulator
purposes only
For training
Exhaust Valve,
Pipe Connections.
purposes only
For training
Exhaust Valve Actuator.
Top Cover
Minimesh
Actuator Housing
Actuator Pistons
purposes only
For training
Exhaust Valve Actuator,

Working Principle.
Actuator
FIVA
Unpressurised hydraulic oil

Pressurised hydraulic oil
purposes only
For training
Exhaust Valve Actuation.
Initial Position Step 1 Step 2
purposes only
For training
2) Exhaust valves
High Force
1st Low Force
2nd Low Force
3) Special running
conditions
purposes only
For training Design Features,
MC versus ME high force exh. valve
S50MC-C S50ME-C
Air spring size

for closing the
exhaust valve
reduced
Hydraulic damper for fixed
valve stroke
Different valve spindle

design
purposes only
For training
Design details.
Self-adjusting damper piston
Hydraulic nut/measuring cone
Contact less sensor with

integrated electronics
Outlet lube oil
Inlet lube oil

Damper
Air inlet
purposes only
For training
Sealing Oil Control Unit.
Sealing oil
purposes only
For training
Spindle Guide Sealing System

- Sealing Oil
purposes only
For training
Exhaust Valve.
Sealing Oil Control Unit
Feed back sensor
Oil inlet to damper
Drain pipes
purposes only
For training
Low Force Exhaust Valve
purposes only
For training
Low Force
Low Exhaust
Force Valve
Exhaust Valve
• 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
• 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
purposes only
For training
1st and 2nd generation Low Force.
2nd generation
 Reduced diameter on Oil Cylinder, Air
Cylinder and Air Piston (reducing weight)
 Added cone on Exhaust Valve Spindle

(for direct measurement of valve stroke)
 Added inductive sensor for direct

measurement of valve stroke (removing
pressure transmitter)
1st generation
 Simplifying air spring, by increasing air
pressure from 3bar to 7bar (removing
reduction station)
purposes only
For training
Differences in Low Force.
2nd generation Low Force 1st generation Low Force
Studs changed from

moment tightened to Rod.lift-Rotation
hydraulic tightened. check removed
Number of studs reduced
Inductive
Sensor
Pressure-
transducer
Differences
purposes only
For training
2’nd generation Low Force.
Shorter Piston, Actuator
Cone on
Exhaust Valve Spindle
Inductive sensor
Direct measurement
purposes only
For training
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
purposes only
For training
Controlled Oil Level (COL)
Exhaust valve stem lubrication: Controlled Oil Level (COL)

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

controlled by stand pipe
Simplification, replaces sealing oil system
purposes only
For training
Modifications
purposes only
For training
DuraSpindle.
Production steps of DuraSpindle
Austenitic
stainless
valve steel
Rolling
process, 10 t
load
Inconel 718
Hardening heat
treatment
purposes only
For training
Dura Spindle in service.
Nimonic spindle & W-seat,

S60MC, 25.500 service hrs
Dura Spindle & W-seat,

S60MC,33.900 service
hrs
purposes only
For training
Specification of DURA Spindles
New spindles: New spindles:

DURA seat technologi used without Extent of DURA seat technologi
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
purposes only
For training
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
purposes only
For training
MOP Exhaust Valve Adjustments.
Adjustment of exhaust
valve closing time
Adjustment of exhaust
valve opening time
purposes only
For training
2) Exhaust valves
High Force
1st Low Force
2nd Low Force
3) Special running
conditions
purposes only
For training
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
purposes only
For training

540
Connect the mini-mesh hose

between top flange on
actuator point 540 and point
425 at the hydraulic block
purposes only
For training


Open
Close
purposes only
For training
Large Bore Program (From 60 and up).

Close
Open
Check pressure free at “minimess” point 455
purposes only
For training


Close valve 531 to

shut off oil to damper
purposes only
For training
Disconnect air
supply to air spring
Check that the exh. valve spindle has

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
purposes only
For training


Remove plug screw and mount tools to

keep exhaust valve spindle open
purposes only
For training
Open damper oil supply

Valve 531
Reconnect air supply

under air piston
purposes only
For training
Special running conditions, open

exh-valve, Low force valve.

purposes only
For training

purposes only
For training

purposes only
For training Special running conditions, open exh
valve, Low force valve.

purposes only
For training
Special running conditions,

Open exh-valve, Low force valve.
purposes only
For training
purposes only
For training
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.

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purposes only

Exhaust valve system

Exhaust Valve System.

1) Exhaust valve actuator

Exhaust Valve Actuator.

Exhaust Valve Actuator,

Unpressurised hydraulic oil

Exhaust Valve Actuation.

Initial Position Step 1 Step 2

Exhaust Valve System.

1) Exhaust valve actuator

Air spring size

Different valve spindle

Self-adjusting damper piston

Hydraulic nut/measuring cone

Contact less sensor with

Inlet lube oil

Sealing Oil Control Unit.

Spindle Guide Sealing System

Sealing Oil Control Unit

Feed back sensor

Oil inlet to damper

Low Force Exhaust Valve

1st and 2nd generation Low Force.

 Added cone on Exhaust Valve Spindle

 Added inductive sensor for direct

Differences in Low Force.

2nd generation Low Force 1st generation Low Force

Studs changed from

2’nd generation Low Force.

Shorter Piston, Actuator

2’nd generation Low Force.

Rough weight reduction

New Safety Valve

Controlled Oil Level (COL)

Exhaust valve stem lubrication: Controlled Oil Level (COL)

Min. level Sealing ring

Production steps of DuraSpindle

Dura Spindle in service.

Nimonic spindle & W-seat,

Dura Spindle & W-seat,

Specification of DURA Spindles

New spindles: New spindles:

Base material is either Nimonic

Recap of Exhaust valve designs

MOP Exhaust Valve Adjustments.

Exhaust Valve System.

1) Exhaust valve actuator

Special running conditions, open exh-valve

Look at chapter 704-04

Check pressure free at “minimess” point 455

Look at chapter 704-04

Connect the mini-mesh hose

Special running conditions, open exh-valve

Look at chapter 704-04

Look at chapter 704-04

Check pressure free at “minimess” point 455

Special running conditions, open exh-valve

Look at chapter 704-04

Close valve 531 to

Check that the exh. valve spindle has

Drain off air pressure from

Special running conditions, open exh-valve