This article discusses exhaust valves used in the marine diesel, properties of

materials, new design features, causes for exhaust valve burning, indication
of exhaust valve leakage, stress on the exhaust valve, stress failures, and
exhaust valve problems.

Introduction

The exhaust valve consists of a valve housing and a valve spindle. The valve
housing is of cast iron and arranged for water cooling. The housing is
provided with a bottom piece of steel with stellite welded onto the seat. The
spindle or valve stem is made of heat resistant steel with stellite welded on to
the seat. The housing is provided with spindle guide or valve guide. The
exhaust valve housing is connected to the cover with studs and nuts
tightened by a hydraulic jack. The exhaust valve is opened hydraulically and
closed by a set of helical springs. The hydraulic system consists of a piston
pump mounted on the roller guide housing, a high pressure pipe, and a
working cylinder on the exhaust valve. The piston pump is activated by the
cam on the shaft.

The exhaust valve is subjected to hot gases, and the temperature resistance
of its seat and body is therefore crucial. In new designs, Nimonic valves
combined with proper seat cooling have yielded excellent service behavior
and long life times. When exhaust valves are not centered in the combustion
chamber, heating will not be symmetrical on the valve lid. For this reason, an
automatic rotating device may be fitted causing the valve to rotate slowly,
thereby avoiding localized heating.

Material Properties:

High tensile strength and creep resistance properties.

Resistance at high temperature properties.

Resistance to high temperature corrosion.

Exhaust Valve Improved Design

Bore cooling for efficient cooling systems (as low as 327oC at full load).

Valve rotational mechanism.

Heat and corrosion resistance material used.

Hydraulic push rod with controlled valve landing speed.

Air spring (or increasing number of springs with improved material) to reduce
valve bouncing.

Guide bush is sealed by pressurized air.

For less obstruction of gases, use valve seat angle 30o instead of 45o.

Cause of Exhaust Valve Burning

Continuous overloading of engine or particular unit causing high exhaust

temperature.

Poor combustion (or after burning) of fuel due to dirty fuel injectors, incorrect
fuel injection pressure, incorrect fuel temperature, late fuel injection timing,
air starvation, water or impurities in fuel.

Valve not closing properly due to incorrect tappet clearance or starvation of

closing air supply.

Insufficient cooling water supply may cause the valve to overheat.

Hot corrosion due to bad quality fuel, which contains high vanadium sodium
etc.

Unstable material used.

Indication of Exhaust Leaking

Indicates high exhaust temperature in that unit.

Indicates low compression pressure and low peak pressure in the indicator
diagram. Low compression pressure and low peak pressure can be caused of
shortage of air supply also, but in that case scavenge air or turbocharger air
pressure will increase abnormally.

Exhaust Valve Failure

Exhaust Valve Failure

Stress on Exhaust Valve

Thermal stress 3 times greater than mechanical stress.

Thermal stress in radial direction greater than axial direction.

Largest mechanical stress at the flame face center.

Highest thermal hoop stress in lid.

Largest mechanical stress in the radial direction along the bend radius
circumferentially.

Maximum combined stress at the valve neck points.

Stress Failures

Circumferential and radial cracks around head radius.

Breaking at the neck.

Radial crack at the seat.

Dishing in the head.

Cracking at the frame face.

Exhaust Valve Problems

1. Burning due to high temperature use bore cooling.

Use valve rotational mechanism.

Use Nimonic material.

2. Seat trumping and wear.

3. Valve bouncing

Use air and hydraulic actuator.

Or increase number of spring with improved material.

4. Hot corrosion and erosion at the valve seat and its underside.

5. Possibility of scaling due to poor water treatment.

6. Thermal stress due to heating and cooling.

7. Cracking at the seat and center of the flame face.

8. Breaking at the valve neck.