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1
MAN Diesel A/S 32006.02.01 (4140 / PWN)
MAN Diesel A/S 42006.02.01 (4140 / PWN)
MAN Diesel A/S 222006.02.01 (4140 / PWN)
2
MAN Diesel A/S 23
Actuator Piston
Main Piston
Damper Piston
Distance Disc
Exhaust Valve Spindle
R0.1 max (sharp edged)
L
Crossbar (Distance: 47-51.2mm)
Orifice (0.7mm)
Piston Rings
2006.02.01 (4140 / PWN)
MAN Diesel A/S 242006.02.01 (4140 / PWN)
MAN Diesel A/S 252006.02.01 (4140 / PWN)
3
MAN Diesel A/S 26
Actuator Piston New Standard
Damper Piston
Positioning element
Main Piston
Compression pressure will beunaffected:
By grinding of the exhaust valve seating throughout the lifetime of the engine.
During cold-running of the engine.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 272006.02.01 (4140 / PWN)
MAN Diesel A/S 282006.02.01 (4140 / PWN)
4
MAN Diesel A/S 292006.02.01 (4140 / PWN)
MAN Diesel A/S 302006.02.01 (4140 / PWN)
MAN Diesel A/S 322006.02.01 (4140 / PWN)
5
MAN Diesel A/S 34
Shut off and release the air spring on the valve
Next to the engine side manoeuvring stand.
If Drop-down time within 30 minutes
Then check and overhaul.
If Drop-down time within 30 min and 1 hours
Keep under observation.
If Drop-down time more than 1 hours
OK.
Check of spindle drop-down time.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 35
Check the air spring tightness.
Connect compressed air to the air cylinder A
Disconnect return drain pipe from the oil cylinder C
Check if air is coming out from:
Oil bore B
Leakage coming from spindle stem sealing.
Hole for drain oil C
Leakage coming either from safety valve D
or
Leakage coming from air piston.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 362006.02.01 (4140 / PWN)
6
MAN Diesel A/S 38
MC EXHAUST VALVE
For new Plant Specification after April 2002
Sealing oil system - PrincipleSealing oildosage unit Consumption ~ 1l/day/cylinder
Supply fromLeak oil chamber
New air cylinder
New spindle guide
Single sealing ring
Sealing oil
2006.02.01 (4140 / PWN)
MAN Diesel A/S 392006.02.01 (4140 / PWN)
MAN Diesel A/S 40
Exhaust Valve Sealing Oil Dosage Unit
1. Vertical cross section, pressure low
2006.02.01 (4140 / PWN)
7
MAN Diesel A/S 41
2. Horizontal cross section, pressure low. Needle connected to output.
Exhaust Valve Sealing Oil Dosage Unit
Spring tension 4 5 bar
2006.02.01 (4140 / PWN)
MAN Diesel A/S 42
3. Pressure high. Needle connected to input and charged with oil.
Exhaust Valve Sealing Oil Dosage Unit
10 15 bar oil pressure.
Spring tension 4 5 bar
2006.02.01 (4140 / PWN)
MAN Diesel A/S 43
4. Pressure decreasing. Needle charge not released yet.
Exhaust Valve Sealing Oil Dosage Unit
Spring tension 4 5 bar
10 15 bar oil pressure.
2006.02.01 (4140 / PWN)
8
MAN Diesel A/S 44
5. Pressure low. Needle connected to output, charge delivered.
Exhaust Valve Sealing Oil Dosage Unit
2006.02.01 (4140 / PWN)
MAN Diesel A/S 452006.02.01 (4140 / PWN)
Exhaust Valve Sealing Oil Dosage Unit
MAN Diesel A/S 46
Sealing oil / stem lubrication by controlled oil level inside the air spring housing
A minimum oil level inside the air cylinder is secured by a stand pipe to the safety valve. This ensures a controlled oil level,high enough, to have oil on top of the sealing ring.
Furthermore, a new safety valve adjustment corresponds to this high oil level (23 bar).
The oil, to the top of the sealing ring, is passing through 3 bores in flange. As a safety precaution, in case of a sealing ringleakage, an orifice is placed in each bore.
NEW Exhaust Valve Sealing Oil.
2006.02.01 (4140 / PWN)
9
MAN Diesel A/S 47
Controlled Oil Level (COL)
Safety valve adjustment 23 bar
Min. level controlled by stand pipe
Spring air/non-return valve
Sealing ring
Oil reservoir above stem sealing ring
Simplification, replaces sealing oil system
MAN Diesel A/S 48
Modification of exhaust valve with Low Spindle Guide to controlled oil level
NEW Exhaust Valve Sealing Oil.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 49
ELVA on-off valveELVA on-off valve
Exhaust valve ActuatorExhaust valve Actuator
Exhaust valve spindleExhaust valve spindle
High pressurehydraulic oil inlet
High pressurehydraulic oil inlet
MembraneaccumulatorMembraneaccumulator
Hydraulicpush rodHydraulicpush rod
To drainTo drain
2006.02.01 (4140 / PWN)
10
MAN Diesel A/S 50
ME Exhaust Valve
S50MC-CS50MC-C S50ME-CS50ME-C
Hydraulic damper for fixed valve stroke introduced
Hydraulic damper for fixed valve stroke introduced
Air spring size for closing the exhaust valve reduced
Air spring size for closing the exhaust valve reduced
New valve spindle design introducedNew valve spindle design introduced
2006.02.01 (4140 / PWN)
MAN Diesel A/S 522006.02.01 (4140 / PWN)
Exhaust Valve Sealing Oil Dosage Unit
MAN Diesel A/S 532006.02.01 (4140 / PWN)
Exhaust Valve Sealing Oil Dosage Unit
11
MAN Diesel A/S 54
ME Exhaust Valve & Actuator
2006.02.01 (4140 / PWN)
MAN Diesel A/S 55
The ME EngineExhaust Valve Timing
0
10
20
30
40
50
60
70
80
90 110 130 150 170 190 210 230 250 270 290Dg. C. A.
Early closingLate closing
Early openingLate opening
Referencemm
2006.02.01 (4140 / PWN)
MAN Diesel A/S 56
ME Exhaust Valve System
ELVA on-off valveELVA on-off valve
Exhaust valve ActuatorExhaust valve Actuator
Exhaust valve spindleExhaust valve spindle
To drainTo drainHigh pressure hydraulic oil inletHigh pressure hydraulic oil inlet
MembraneaccumulatorMembraneaccumulator
Hydraulicpush rodHydraulicpush rod
2006.02.01 (4140 / PWN)
12
MAN Diesel A/S 57
Hydraulic Cylinder Units (HCU)
HCUs mounted on an common base plate.HCUs mounted on an common base plate.
High pressure oil inletfrom the HPSHigh pressure oil inletfrom the HPS
Double wall high pressure pipeDouble wall high pressure pipe
2006.02.01 (4140 / PWN)
MAN Diesel A/S 58
Actuator for Exhaust Valve
The ELVA valve which drives the actuatoron the exhaust side has two positions,open or shut.
When it is opened with a binary signal from theengine control system, the hydraulic oil is forced in and pushes the pistons upwards,thusopening the engines exhaust valve via thehydraulic push rod.
The pressure is permanently maintaineduntil the ELVA valve is activated to blockthe pressure when the required exhaust phaseis completed.
The exhaust valve is returned to its closed position by the force from the air spring.
Unpressurised hydraulic oilPressurised hydraulic oil
ELVA
Actuator
2006.02.01 (4140 / PWN)
MAN Diesel A/S 59
Exhaust Valve Actuator
Mounted on top of the distributor block.
Hydraulic push rod for opening/closing the exhaust valve
Two-stage piston.Second stage
First stage
High pressure oil inlet
Mounted on top of the distributor block.
Hydraulic push rod for opening/closing the exhaust valve
Two-stage piston.Second stage
First stage
High pressure oil inlet
2006.02.01 (4140 / PWN)
13
MAN Diesel A/S 60
S70me-c
Exhaust ActuatorTop cover
Minimesh
Actuator house
Actuator Piston
1. Step
2.Step
2006.02.01 (4140 / PWN)
MAN Diesel A/S 61
Exh. Valve
Oil inlet to damper
Drain pipes
Feed back sensor
2006.02.01 (4140 / PWN)
MAN Diesel A/S 62
Self-adjusting damper pistonSelf-adjusting damper piston
Hydraulic nut/measuring coneHydraulic nut/measuring cone
Outlet lube oilOutlet lube oil
DamperDamper
Air inletAir inlet
Inlet lube oilInlet lube oil
Contact less sensor with integrated electronicsContact less sensor with integrated electronics
ME Exhaust Valve
2006.02.01 (4140 / PWN)
14
MAN Diesel A/S 632006.02.01 (4140 / PWN)
MAN Diesel A/S 64
Tightening of Damper on Exhaust Valve Spindle
Hydraulic Jack& Support
Damper
Air Piston
Spindle
2006.02.01 (4140 / PWN)
MAN Diesel A/S 652006.02.01 (4140 / PWN)
15
MAN Diesel A/S 662006.02.01 (4140 / PWN)
MAN Diesel A/S 672006.02.01 (4140 / PWN)
MAN Diesel A/S 682006.02.01 (4140 / PWN)
16
MAN Diesel A/S 692006.02.01 (4140 / PWN)
MAN Diesel A/S 70
Safety Valve
Safety Valve:Adjustment of openingpressure: 21 bar
2006.02.01 (4140 / PWN)
MAN Diesel A/S 712006.02.01 (4140 / PWN)
17
MAN Diesel A/S 722006.02.01 (4140 / PWN)
MAN Diesel A/S 73
Exh. Valve
2006.02.01 (4140 / PWN)
MAN Diesel A/S 752006.02.01 (4140 / PWN)
18
MAN Diesel A/S 762006.02.01 (4140 / PWN)
MAN Diesel A/S 77
421
If running with an open exhaust valve
THEN.
1. Close valve 420
2. Open valve 421Mount pressure gauge at
minimess point 455
Check that the HCU is
pressure free.
SPECIAL RUNNING CONDITIONS
2006.02.01 (4140 / PWN)
MAN Diesel A/S 78
SPECIAL RUNNING CONDITIONS
Connect the mini-mesh hose between top flange on actuator
point 540 and point 425at the hydraulic block
2006.02.01 (4140 / PWN)
19
MAN Diesel A/S 79
421
2. Close valve 421
1. Open valve 420
SPECIAL RUNNING CONDITIONS
2006.02.01 (4140 / PWN)
MAN Diesel A/S 80
98ME Special Running
Mount pressure gauge at minimess point 455
Check that the HCU is pressure free.
Close valve 420
Open valve 421
2006.02.01 (4140 / PWN)
MAN Diesel A/S 81
Close valve 531
Shut off oil to damper
98ME Special Running
2006.02.01 (4140 / PWN)
20
MAN Diesel A/S 82
Disconnect air supply to air cylinder
Drain off air pressure from
air cylinder with a mandrel
98ME Special Running
2006.02.01 (4140 / PWN)
MAN Diesel A/S 83
Remove plug screw and mount
tools to keep exhaust valve open
98ME Special Running
2006.02.01 (4140 / PWN)
MAN Diesel A/S 84
Reconnect air supply under air piston
Open damper oil supply
98ME Special Running
2006.02.01 (4140 / PWN)
21
MAN Diesel A/S 85
98ME Special Running
Mount pressure gauge at minimess point 455
Check that the HCU is pressure free.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 86
98ME Special Running
Disconnect air supply to air cylinder
Drain off air pressure from
air cylinder with a mandrel
Remove the tools which kept the
exhaust valve open and mount
the plug screw.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 87
Open valve 420
98ME Special Running
Close valve 421
Open damper oil supply, valve 531
Reconnect air supply under air piston
2006.02.01 (4140 / PWN)
22
MAN Diesel A/S 88
ME-B Engine
3333553.2006.05.11 (2200/OZS)
Hydraulicdual-Cylinder Unit
Hydraulic oil linein containment
Reduced camshaft diameter Bearings only near cams
Cam-activated exhaust valves
Fuel cams omitted
MAN Diesel A/S 89
ME-B Exhaust Valve
Dura SpindleW-seat
Exhaust valve for S35/40ME-Breused from S35MC and S42MC
MAN Diesel A/S 90
Small Bore Electronic InjectionME-B System Layout
Injection valvesInjection valves
Pressure Pressure boostersboosters
ELFIELFIValvesValves
Hydraulic oilHydraulic oilrailrail
Camshaft drivenCamshaft drivenexhaust exhaust
actuatorsactuators
Light camshaftLight camshaft
Dual cylinderDual cylinderHCUHCU
23
MAN Diesel A/S 91
ME-B Camshaft
Gear wheel for starting air distributor
Exhaust cam
Chain wheel
MAN Diesel A/S 92
ME-B Camshaft
OZS/2200/20061006
Bearing supports only at the exhaust cams
MAN Diesel A/S 93
ME-B Camshaft
OZS/2200/20061006
Axial bearings
OverhangingChainwheel
24
MAN Diesel A/S 122
Areas for possible improvements on the MC Exhaust Valve1983 - 2005
K90MCK98MC
Self-adjusting damper
Cast iron/high spindle g.
HVOF
Modified cooling
Controlled oil level
Cr sealing ring
U-seal
DuraSpindle
Hardened steel W-seat
Closing damper
Spindle guide
Spindle stem
Water cooling
Sealing system
Sealing ring
Viton sealing
Spindle seat
Bottom piece seat
Improved ItemsItems
MC EXHAUST VALVE
2006.02.01 (4140 / PWN)
MAN Diesel A/S 1232006.02.01 (4140 / PWN)
MAN Diesel A/S 127
MC EXHAUST VALVE
Chamber seat W-seat
2006.02.01 (4140 / PWN)
25
MAN Diesel A/S 128
The longer lifetime on the seat area is achievedwith the new geometry of the W-seat, whichretains the temperature reducing features of thechamber seat and combines them with the benefit of the two narrow concentric contact areas.
The effect is that all carbon particles which aretrapped between the spindle and bottom pieceare crushed and squeezed out and thereforeeliminated without giving rise to any appreciablerisk dents.
The spindle and seat are fit for further use provided that :
There is contact along the entire inner circumference of the seat.
There are no blow-by tracks across the inner part of the seats.
Exhaust Valve Spindle & Bottom Piece 98MC/MC-C 26MC
16,000 h between overhauls60-100,000 h lifetime for spindle> 30,000 h lifetime for bottom piece
2006.02.01 (4140 / PWN)
MAN Diesel A/S 1292006.02.01 (4140 / PWN)
MAN Diesel A/S 1312006.02.01 (4140 / PWN)
26
MAN Diesel A/S 1322006.02.01 (4140 / PWN)
MAN Diesel A/S 1332006.02.01 (4140 / PWN)
MAN Diesel A/S 137
MC EXHAUST VALVE
Valve spindle for engine types: K/L/S-MC/-C/-S1983 - 1992: 26 - 50 MC Alloy 5060 - 90 MC Stellite 6
1992 2002:26 - 50 MC Alloy 50S50MC / 60 - 98 MC Nimonic
2002 - :26 - 50 MC DuraSpindle S50MC / 60 - 98 MC Nimonic
1983 1996: Cr stem coating
1996 - : HVOF stem coating
(INCO 625 on request)
Cr (0.25 mm) HVOF (0.15 mm)
Stellite 6
SNCrW
Nimonic
Alloy 50
2006.02.01 (4140 / PWN)
27
MAN Diesel A/S 1392006.02.01 (4140 / PWN)
MAN Diesel A/S 1422006.02.01 (4140 / PWN)
MAN Diesel A/S 1482006.02.01 (4140 / PWN)
MC EXHAUST VALVE Sealing Rings
28
MAN Diesel A/S 154
Design
Features:Damped valve closing by means of oil cushion
New sealing air chamber suitable for air as well as oil sealing medium
Hardened steel chamber-type bottom piece
HVOF coating on Nimonic spindles
Improvements:Mechanical stop for spindle movement combined with safety valve in actuator
Smaller bottom piece
Cooling water connection between cylinder cover and valve housing through bores in valve housing
Strengthened design of damper piston
Cast iron liner in hydraulic cylinders
Cast iron single bush for valve stem
Verification:Calculation and service tests
Exhaust valve K90MC-C K98MC-C
2006.02.01 (4140 / PWN)
MAN Diesel A/S 155
Exhaust Valve Bottom Piece
K98MC, K98MC-C
Original design Modified design
New tool for handling(instead of bolt assembly)2 pcs.
Increased diameter0.15 taper
Decreased diameter
HardenedW-seat
2006.02.01 (4140 / PWN)
MAN Diesel A/S 1562006.02.01 (4140 / PWN)
29
MAN Diesel A/S 1572006.02.01 (4140 / PWN)
MAN Diesel A/S 168
MAN B&W Diesel A/SRolled exhaust valve spindles
DuraValve
2006.02.01 (4140 / PWN)
MAN Diesel A/S 169
Exhaust Valve Spindle - Plate
Inconel 718/Rene 220
Ni-Cr-W valve steel
MIG/MAG welding on valve seat
2006.02.01 (4140 / PWN)Inconel 625
Inconel 718
HVOF
SNCrW
30
MAN Diesel A/S 170
GMAW of Inconel 718, Rene 220
Austenitic stainless
valve steel
Rolling process, 10 t load
MC EXHAUST VALVE
Welding and rolling preparation of DuraSpindle
MAN Diesel A/S 172
Exhaust valve Rolling equipment
BackgroundThe roller is pressed against a rotating spindle at a pressure of 10 tons. The combination of the deformationand the subsequent heating in the oven imparts a hardness to the interial which has not been seen before.
2006.02.01 (4140 / PWN)
MAN Diesel A/S 173
MC EXHAUST VALVE
Rolled seat area of 50MC DuraSpindle
2006.02.01 (4140 / PWN)
31
MAN Diesel A/S 175
Hardness profile (as rolled)
Hardness profile(as rolled and heat treated)
Effect of rolling and heat-treatment on seat hardness
MC EXHAUST VALVE
MAN Diesel A/S 176
MC EXHAUST VALVE
Nimonic spindle & chamber seat, S60MC, 25.500 service hrs
DuraSpindle & chamber seat, S60MC, 33.900 service hrs
2006.02.01 (4140 / PWN)
MAN Diesel A/S 177
MC EXHAUST VALVE
Nimonic spindle & W-seat, S60MC, 25.500 service hrs
DuraSpindle & W-seat, S60MC,33.900 service hrs
2006.02.01 (4140 / PWN)
32
MAN Diesel A/S 178
DuraSpindle & Chamber-seat, S60MC, 44.122 service hrs
MC EXHAUST VALVE
MAN Diesel A/S 179
Nimonic spindle & W-seat, S60MC, 25.500 service hrs
DuraSpindle & W-seat,S60MC, 40.042 service hrs
MC EXHAUST VALVE
MAN Diesel A/S 185
06 May 2006
3333522.2006.04.05 (2160/CEJ)
E N G I N E E R I N G T H E F U T U R EE N G I N E E R I N G T H E F U T U R E
THANK YOU FOR YOUR ATTENTION
33
MAN Diesel A/S 2452006.02.01 (4140 / PWN)