0602 Exhaust Valve + ME

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1 <1> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN) <2> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN) <3> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN) <4> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN) <5> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN) <6> MAN B&W Diesel © MAN B&W Diesel 2006.02.01 (4140 / PWN)

Transcript of 0602 Exhaust Valve + ME

Page 1: 0602 Exhaust Valve + ME

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MAN B&W Diesel

© MAN B&W Diesel 2006.02.01 (4140 / PWN) <2>

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <8>

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© MAN B&W Diesel

Piston, Air Spring

Air Piston

Conical Locking Ring

Flange

Relief holes

Teflon ring

Teflon ring withback-up O-ring

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

Spindle Rotation Check

Rod for checking spindle rotation

Reaches contact with the airpiston by activation.

Note!The rod must only be activatedfor shorter periods

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

Exhaust valve system

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© MAN B&W Diesel

Safety Valve

Safety Valve:Adjustment of openingpressure: 21 bar

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <18>

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© MAN B&W Diesel

Exhaust valve system

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

Non return valve

Tohydraulicsystem

Camshaft oil

Back pressure valve for air spring (17.5 or 21 bar)

Adjusting valve(for control of leakage)

Safety valve for hydraulic system (300 bar)

Valves in exhaust valve system

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© MAN B&W Diesel

Piston, Air Spring

Safety Valve

or

Relief holes

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MAN B&W Diesel

© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

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

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

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.

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <39>

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

MC EXHAUST VALVE

For new Plant Specification after April 2002

Sealing oil system - PrincipleSealing oildosage unit Consumption ~ 1l/day/cylinder

Supply from’Leak oil chamber’

New air cylinder

New spindle guide

Single sealing ring

Sealing oil

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© MAN B&W Diesel

Exhaust Valve Sealing Oil Dosage Unit

1. Vertical cross section, pressure low

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© MAN B&W Diesel

2. Horizontal cross section, pressure low. Needle connected to output.

Exhaust Valve Sealing Oil Dosage Unit

Spring tension 4 – 5 bar

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© MAN B&W Diesel

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

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© MAN B&W Diesel

4. Pressure decreasing. Needle charge not released yet.

Exhaust Valve Sealing Oil Dosage Unit

Spring tension 4 – 5 bar

10 – 15 bar oil pressure.

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© MAN B&W Diesel

5. Pressure low. Needle connected to output, charge delivered.

Exhaust Valve Sealing Oil Dosage Unit

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Small dent marks on the spindle seating are acceptable and need NOT to be ground away if they don’t make blow-by.

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© MAN B&W Diesel

Small dent marks on the seating are acceptable and need NOT to be ground away if they don’t make blow-by.

K98MC/ME

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© MAN B&W Diesel

Exhaust Valve Actuator

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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

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <110>

MAN B&W Diesel

© MAN B&W Diesel

MC EXHAUST VALVE

1983 - 1992: 26 - 50 MC Cooled Alloy 5060 - 90 MC Cooled Stellite 6

1992 – 1997:26 - 50 MC Cooled Alloy 5060 - 90 MC Semi-cooled hard. steel

1997 - 2000:26 - 42 MC Cooled hard.steel 46 - 98 MC Semi-cooled hard. steel

2000 – :26 - 42 MC Cooled W-seat 46 - 98 MC Semi-cooled W-seat

Bottom piece for engine types: K/L/S-MC/-C/-S

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MC EXHAUST VALVE

Chamber seat W-seat

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© MAN B&W Diesel

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

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <117>

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Bottom PieceW-Seat

U-Type Sealing Ring:

Heat the sealing ring in 100°C hotwater for at least five minutesbefore mounting

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© MAN B&W Diesel

Bottom Piece

References of W-seatsrunning for more than 36000hours without any grindingand only very small dent marks

U-type sealing ring(Teflon with a spring back-up)

Hole for indication of coolingwater leakage from thelowermost sealing ring or gas leakage from the combustion chamber

Connect compressed air to the air spring to keep the exhaust valve closed during mounting

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MAN B&W Diesel

© MAN B&W Diesel

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

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Exhaust Valve Nimonic Spindle

Base Material: Nimonic 80A

HVOF-coatingFormation of dent marks is aninevitable consequence of service onheavy fuel oil.

Dent marks may appear harmful, butwill in general have no influence onthe performance of the exhaust valveseat.

If indications of blow-by are found,then the seat must be ground.

Vane wheel for gasdriven spindle rotation

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <131>

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Exhaust Valve Spindle - Stem

HVOF spraying on valve stem

Ni-Cr-W valve steel

Ni-Cr + Cr3C2

150 µm

HVOF: High Velocity Oxy-Fuel Process

Coating applied on the exhaust valve stem onlyHighly wear-resistant mixtureof metalcarbide and superalloyThermally sprayed coatingThickness: about 0.25 mm

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© MAN B&W Diesel

MC EXHAUST VALVE

HVOF - ring

Cr - ring

Valve spindle stem sealing ring

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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© MAN B&W Diesel 2006.02.01 (4140 / PWN) <139>

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© MAN B&W Diesel

MC EXHAUST VALVE

K90MC W-seat in combination with Nimonic spindles, 36.000 hrs service

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© MAN B&W Diesel

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

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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)

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© MAN B&W Diesel

MAN B&W Diesel A/SRolled exhaust valve spindles

”DuraValve”

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© MAN B&W Diesel

MC EXHAUST VALVE

Welding and rolling preparation of DuraSpindle

Welded Ni-base alloy

Inconel 718 / Rene22010 t

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© MAN B&W Diesel

Exhaust Valve Spindle - Plate

Inconel 718/Rene 220

Ni-Cr-W valve steel

MIG/MAG welding on valve seat

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© MAN B&W Diesel

MC EXHAUST VALVE

Rolled seat area of 50MC DuraSpindle

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© MAN B&W Diesel

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.

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© MAN B&W Diesel

MC EXHAUST VALVE

Section of rolled and heat treated 35 MC DuraSpindle seat

Hardness distribution of section2006.02.01 (4140 / PWN)

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© MAN B&W Diesel

MC EXHAUST VALVE

Nimonic spindle & chamber seat, S60MC, 25.500 service hrs

DuraSpindle & chamber seat, S60MC, 33.900 service hrs

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© MAN B&W Diesel

MC EXHAUST VALVE

Nimonic spindle & W-seat, S60MC, 25.500 service hrs

DuraSpindle & W-seat, S60MC,33.900 service hrs

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© MAN B&W Diesel 2006.02.01 (4140 / PWN)

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MAN B&W Diesel

© MAN B&W Diesel

Thank you for

your attention

Thank you for

your attention

MAN B&W Diesel A/S

Preben Noeies

2006.02.01 (4140 / PWN)

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MAN B&W Diesel

© MAN B&W Diesel 2006.02.01 (4140 / PWN)