purposes only

For training

Exhaust valve system

MAN Diesel & Turbo Author Current topic 00.00.2012 < 1 >
purposes only
For training

Exhaust Valve System.

HPS, Sp/pilot
Hydraulic connection
Filter (6 micron)
2-3 bar
pump 1) Exhaust valve actuator
Accumulator/S
afety block
Start-up
pump
2) Exhaust valves
- High Force
Hydraulic
system - 1st Low Force
Roughly 10%
- 2nd Low Force
Lubrication,
Engin Cooling
3) Special running
e roughly 90% HCU, Fuel booster, conditions
Exhaust valve actuator

Ship Main Tank

filter and pumps

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 3 >
purposes only
For training

Exhaust Valve,
Pipe Connections.

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 4 >
purposes only
For training

Exhaust Valve Actuator.

Top Cover
Minimesh
Actuator Housing

Actuator Pistons

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 5 >
purposes only
For training

Exhaust Valve Actuator,

Working Principle.

Actuator

FIVA

Unpressurised hydraulic oil

Pressurised hydraulic oil

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 6 >
purposes only
For training

Exhaust Valve Actuation.

Initial Position Step 1 Step 2

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 7 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 8 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 9 >
purposes only
For training

Sealing Oil Control Unit.

Sealing oil

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 10 >
purposes only
For training

Spindle Guide Sealing System

- Sealing Oil

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 11 >
purposes only
For training

Exhaust Valve.

Sealing Oil Control Unit

Feed back sensor

Oil inlet to damper

Drain pipes

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 12 >
purposes only
For training

Low Force Exhaust Valve

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 13 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 14 >
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)

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 15 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 16 >
Differences
purposes only
For training

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 29.04.2014 < 17 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 18 >
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
MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 19 >
purposes only
For training

Modifications

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 20 >
purposes only
For training

DuraSpindle.

Production steps of DuraSpindle

Austenitic
stainless
valve steel

Rolling
process, 10 t
load

Inconel 718

Hardening heat
treatment

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 21 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 22 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 23 >
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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 24 >
purposes only
For training

MOP Exhaust Valve Adjustments.

Adjustment of exhaust
valve closing time

Adjustment of exhaust
valve opening time

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 25 >
purposes only
For training

Special running conditions, open exh-valve

Small Bore Program (50 ME).

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 29.04.2014 < 26 >
purposes only
For training

Special running conditions, open exh-valve

Large Bore Program (From 60 and up).

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

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 27 >
purposes only
For training

Special running conditions, open exh-valve

Large Bore Program (From 60 and up).

Remove plug screw and mount tools to

keep exhaust valve spindle open

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 28 >
purposes only
For training

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 29.04.2014 < 29 >
<
purposes only
For training

Special running conditions,

Open exh-valve, Low force valve.

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 30 >
purposes only
For training

Special running conditions,

Open exh-valve, Low force valve.

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 31 >
purposes only
For training

Special running conditions,

Open exh-valve, Low force valve.

MAN Diesel & Turbo AAA-CPH Exhaust valve system 29.04.2014 < 32 >