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ME Engine Training Course

The document provides a history of MAN B&W Diesel and describes the development of diesel engines from 1904 to present. It details key milestones like the first ocean-going diesel vessel in 1912, the first turbocharged engine in 1952, and the introduction of new engine models. The document also outlines the company's global presence and licensees.

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100% found this document useful (5 votes)

2K views

ME Engine Training Course

Uploaded by

Venkatarama Krishnan

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 142

ME ENGINE

TRAINING COURSE

MAN B&W Diesel

1. General description
of ME engine

ME - Engines

MAN B&W Diesel, Company Presentation

MAN B&W Diesel

by
Preben Noeies

MAN B&W Diesel

06.01

4140/PWN

<1>

MAN B&W Diesel

06.01

4140/PWN

<2>

History

The Founding of the Company

MAN B&W Diesel

In 1843 Hans Heinrich Baumgarten establishes

a mechanical workshop in Copenhagen
In 1846 a partnership is established
with Carl Christian Burmeister and
they establish a company named
Baumgarten & Burmeister
The activities include a mechanical
workshop and a foundry
In 1854 a shipyard is established
In 1861 Hans Heinrich Baumgarten
retires from the company
William Wain joins the company in 1865,
and the name of the company is changed to
Burmeister & Wain (B&W)
MAN B&W Diesel

06.01

4140/PWN

W. Wain
<3>

MAN B&W Diesel

Rudolf Diesel 1858 1913

The First Diesel Engine and the Patent Certificate

06.01

C. C. Burmeister

4140/PWN

<4>

The First B&W Diesel Engine

MAN B&W Diesel

The first B&W fourstroke diesel engine

was delivered in 1904

Engine No. 1
Type: 140
Customer: N. Larsen,
Carriage Manufacturer,
Frederiksberg,
Denmark

MAN B&W Diesel

06.01

4140/PWN

<5>

MAN B&W Diesel

06.01

4140/PWN

<6>

The First Diesel Engine

for Ocean-going Ship Propulsion

Engine Development 1912 - 1952

MAN B&W Diesel

1912:

MAN B&W Diesel

Single-acting crosshead four-stroke direct reversible

Type: 8150-X Power: 1,250 IHP
(Introduced on M/S Selandia)

M/S Selandia, delivered to the Danish East Asiatic Company in

1912, is the worlds first ocean-going diesel motor ship.

1922:

Supercharging by electrically driven blower

1924:

Double-acting four-stroke Type: 6840D Power: 6,750 BHP

(Twin engine installation introduced on M/S Gripsholm)

Type: DM 8150-X (2 x 8 cylinder engines)

1929:

Double-acting two-stroke engine Type: 662-WF-140

Power: 7,000 IHP (Introduced on M/S Amerika)

Ships speed: 11 knots

1932:

Single-acting two-stroke engine with exhaust valves

Type: 50-VF-90

1938:

Tests with heavy fuel on M/S Transilvania

1952:

The worlds first turbocharged two-stroke engine

Type: 674VTBF-160 Power: 7,500 BHP
(Introduced on M/S Dorthe Mrsk)

MAN B&W Diesel

06.01

4140/PWN

Power: 2,500 IHP total

<7>

MAN B&W Diesel

First Ocean Going Vessel

with Fully Reversible Diesel Engines
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

<8>

The Worlds First Turbocharged

Two-stroke Diesel Engine

M/S Selandia
M/S Dorthe Mrsk, delivered
to the Danish company A. P.
Mller by Odense Steel
Shipyard in 1952, is the first
ship to be powered by a
turbocharged two-stroke
diesel engine

Main engines: 2 x 1250 IHK

B&W engines type DM8150X

Engine type: 674VTBF-160

Power: 7,500 BHP @ 115 r/min

MAN B&W Diesel

06.01

4140/PWN

<9>

MAN B&W Diesel

< 10 >

MAN B&W Diesel

In 1758 Eisenhtte St. Antony is established in Oberhausen

The worlds first turbocharged two-stroke engine

Type: 674VTBF-160 Power: 7,500 BHP
(Introduced on M/S Dorthe Mrsk)

1967:

Introduction of the K-EF range of engines, as well as the

large K98FF type (3,800 BHP/cyl. @ 103 RPM)

1973:

Delivery of the first K-GF engine

1976:

The first to introduce modern long stroke diesel engines

Type: L-GF, with a stroke-bore ratio of 2.5:1

1978:

The first with constant pressure turbo charging of modern

uniflow scavenged diesel engines

1979:

The first to test a rotating air-spring on exhaust valves in

service

1980:

The first to introduce layout flexibility, as well as a specific

fuel oil consumption below 140 g/BHPh Type: L-GFCA

MAN B&W Diesel

4140/PWN

The History of MAN B&W Diesel

Engine Development 1952 - 1980

MAN B&W Diesel

1952:

06.01

4140/PWN

In 1840 Sander'sche Maschinen Fabrik is established in Augsburg

In 1843 Baumgarten establishes a workshop in
Copenhagen
Gutehoffnungshtte
Actienverein (GHH)
is established in
1873

Burmeister & Wain

(1865)
B&W Motor A/S
(1974)

M.A.N.
Maschinenfabrik
Augsburg-Nrnberg
(1908)

In 1921 GHH
acquired a majority
in M.A.N.

In 1979/80 B&W Motor A/S is taken over

by M.A.N., and M.A.N. B&W Diesel A/S is
established

In 1986 M.A.N. was merged into GHH and renamed MAN AG

The divisions were hived off to form individual public limited companies
< 11 >

MAN B&W Diesel

06.01

4140/PWN

< 12 >

MAN B&W Diesel A/S

A Historical Overview Since 1843

Diesel Chronicle
MAN B&W Diesel

MAN B&W Diesel

1933 The first to introduce uniflow on a two-stroke engine

1952 The first to introduce turbocharging on two-stroke slow speed
diesel engines
1978 The first with constant pressure turbocharging of modern
uniflow engines
1981 The first to demonstrate engine efficiency of more than 50%
corresponding to specific fuel oil consumption figures below
125 g/BHPh
1994 The first to introduce an engine with power above 90,000 bhp
1996 The first to introduce a new generation of compact engines
1998 The first to introduce the Environmentally Friendly prop. system
2000 The first to put an electronically controlled engine into service

MAN B&W Diesel

06.01

4140/PWN

< 13 >

MAN B&W Diesel

The MAN Group - 2005

06.01

4140/PWN

< 14 >

MAN B&W Diesel Group

MAN B&W Diesel

61,259 employees
Turnover 14,9 billion
PBT 453 million

Services

Industrial
Commercial
Vehicles

Printing Machines

Diesel Engines

Turbo Machines

Further Industrial
Holding*

Industrial Services Financial Services

MAN
Nutzfahrzeuge AG

MAN Roland
Druckmaschinen
AG

MAN
B&W Diesel AG

MAN
Turbomaschinen AG

RENK
Aktiengesellshaft
MAN
Technologie AG
MAN DWE GmbH
Schwbische
Httenwerke GmbH

MAN Ferrostaal AG

Turnover 7,4 billion

MAN B&W Diesel

Turnover 1,6 billion

06.01

Turnover 1,4 billion

Turnover 0,7 billion

MAN Aktiengesellschaft Mnchen

100%

MAN Financial
Services GmbH

67%
S.E.M.T. Pielstick
France

MAN B&W Diesel AG

Germany

MAN B&W Diesel A/S

Denmark

Turnover 3,2 billion

4140/PWN

< 15 >

MAN B&W Diesel

Locations of MAN B&W Diesel

06.01

4140/PWN

< 16 >

Worldwide Service Network

MAN B&W Diesel

Great Britain
Paxman
Ruston
Mirrlees Blackstone
678 employees
Four-stroke engines

Frederikshavn

Copenhagen

Marine propulsion
Military marine
Power generation
Rail traction

Marine propulsion
Military marine
Power generation
Rail traction
Service
Licensor

Holeby
Rostock
Hamburg

Stockport

Paris
Augsburg
Saint-Nazaire

Denmark
MAN B&W Diesel A/S
2173 employees
Two-stroke engines
Research and development
Marine propulsion
Power generation
Service
Spare parts
Licensor
Four-stroke engines
Complete propulsion package
GenSets
Power generation
Licensor

Colchester

France
Pielstick
709 employees
Four-stroke engines

Jouet

Germany
MAN B&W Diesel AG
2474 employees
Four-stroke engines
Research & development
Marine propulsion
Power generation
Service
Licensor

Service Centres

06.01

4140/PWN

AuthorisednRepair Shops 55
Licensees

Total 6 034
MAN B&W Diesel

100%

100%
MAN B&W Diesel Ltd
England

< 17 >

MAN B&W Diesel

06.01

4140/PWN

< 18 >

Two-Stroke Licensees

Two-stroke Licensees

MAN B&W Diesel

China
HHM
DMD
YMD

1980
1980
1989

Korea
Hyundai
Doosan
STX

1976
1983
1984

Spain
IZAR Manises

Croatia
Uljanik
Split

1954
1984

Poland
Cegielski

1959

1941

Vietnam
Vinashin

Japan
Mitsui
Makita
Hitachi
Kawasaki

Russia
Bryansk

1926
1981
1951
1981

1959

2004

As at August 2004
MAN B&W Diesel

06.01

4140/PWN

< 19 >

MAN B&W Diesel

06.01

4140/PWN

< 20 >

MAN B&W Diesel A/S, Copenhagen

MAN B&W Diesel

Main Office
Warehouse

Production of
Key Components

Factory
Administration
R&D Centre

MAN B&W Diesel

06.01

4140/PWN

< 21 >

MAN B&W Diesel

4140/PWN

< 22 >

MAN B&W Diesel A/S,

Research Centre

MAN B&W Diesel A/S, Copenhagen

MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 23 >

MAN B&W Diesel

06.01

4140/PWN

< 24 >

Research engine 4T50ME4T50ME-X

MAN B&W Diesel A/S, Holeby

MAN B&W Diesel

Engine type

4T50MX

Initial engine output 10,200 BHP

Engine speed

123 r/min

Cylinder diameter

500 mm

Piston stroke

2200 mm

Stroke to bore ratio 4.4 : 1

Firing pressure

180 bar

Mean effective pressure

Mean piston speed

MAN B&W Diesel

06.01

4140/PWN

9 m/s

< 25 >

MAN B&W Diesel

06.01

MAN B&W Diesel A/S,

Frederikshavn (ALPHA)

4140/PWN

< 26 >

Designations

MAN B&W Diesel

Cross Section
S90 MC-C

MAN B&W Diesel

06.01

4140/PWN

< 27 >

MAN B&W Diesel

06.01

4140/PWN

< 28 >

Development of the MEME-engine

Designations
MAN B&W Diesel

MAN B&W Diesel

1991

Start of Intelligent Engine Project

1993

4T50MX equipped with Electronic

Engine Control equipment

1997

4T50MX with 2nd generation control

equipment

1997/98

Design - Production - Installation of

mechanical/hydraulic components for
service test on M/T "Bow Cecil"

1997/98

Design and implementation of governor

functionality, and service test onboard
Shanghai Express

1998/2000 Design - Production - Test - Installation of

Engine Control System on
M/T Bow Cecil
2000
2003
MAN B&W Diesel

2005.05.01

(4140/PWN)

< 29 >

MAN B&W Diesel

Start of service test on M/T Bow Cecil

First production engine
2005.05.01

4140/PWN

< 30 >

Reference List
Two-stroke Marine Engines
MAN B&W Diesel

MAN B&W Diesel

ME Programme
Vessels with ME engines lined up awaiting delivery.
On order/delivered

Type

Stena Arctica

( 7S60ME-C)

Captain Kostichev

( 7S60ME-C)

Pavel Chernysh

( 7S60ME-C)

Cape Brindisi

( 6S70ME-C)

MAN B&W Diesel

In service

K98ME/ME-C

S90ME-C
K90ME-C
K80ME-C
L70ME-C
S70ME-C
S65ME-C

2
8
17
16
72
3

7
3

S60ME-C
S50ME-C
Total

40
10
210

1
7
20

As at 2004.08.26

As at 2005.11.01
< 31 >

MAN B&W Diesel

Hydraulic Cylinder Unit

Total:
2005.05.01

5,860,589 kW
4140/PWN

Engine Room of M/T Bow Cecil

MAN B&W Diesel

ME systems connected for service test

Fuel Booster pump

MAN B&W Diesel

06.01

4140/PWN

< 33 >

MAN B&W Diesel

Engine Room at Bow Cecil

06.01

4140/PWN

< 34 >

7S50ME-C in M/V Bow Firda

MAN B&W Diesel

Inspection
onboard
Bow Cecil
after 4137
running
hours as
ME engine

MAN B&W Diesel

06.01

4140/PWN

< 35 >

MAN B&W Diesel

06.01

4140/PWN

< 36 >

The ME Engine
Hydraulic Power Supply (HPS)

7S50ME-C in M/V Bow Firda

MAN B&W Diesel

Generates the power

necessary for fuel oil
injection and exhaust
valve opening

Hydraulic Power Supply

MC
MAN B&W Diesel

06.01

4140/PWN

< 37 >

MAN B&W Diesel

ME
06.01

The ME Engine
Hydraulic Power Supply (HPS)

4140/PWN

< 38 >

HPS Hydraulic Power Supply

MAN B&W Diesel

Before engine start, the hydraulic oil pressure used in the mechanical/hydraulic
mechanical/hydraulic system for
controlling the actuators is generated by electrical driven start
start-up
t-up pumps. After start, the engine
star
driven pumps will take over the supply.

Main components:
Self-cleaning filter with 10-micron filter mesh
Redundancy filter with 25-micron filter mesh

Accumulators

Self cleaning
filter 10
Start-up
pumps

Start up pumps:

Safety and
accumulators block

x
Start-up
pumps

High pressure pumps with supply pressure of 175 bar

Engine driven
axial piston
pumps

Low pressure pumps for filling the exhaust valve push rod
with supply pressure of 4 bar
Engine driven axial piston pumps supplying high pressure oil to

The hydraulic power

supply uses the
engine system oil

the Hydraulic Cylinder Unit with oil pressure up to 250 bar

Redundancy filter 25
MAN B&W Diesel

06.01

4140/PWN

< 39 >

MAN B&W Diesel

06.01

4140/PWN

< 40 >

HPS 7S60ME-C

The ME Engine Hydraulic Oil Loop

MAN B&W Diesel

Fuel oil pressure

Exhaust valve actuator
booster

Redundancy Filter 25
Hydraulic
cylinder unit

Fuel 10 bar
ELFI

ELVA

Self Cleaning Filter 10

200 bar

Alpha lubricator

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU

Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU

Safety and
Accumulator
block

Fine aut. filter

Main lube
pump
Piston cooling
+ bearings
Servo oil
return to sump

Servo oil

Engine Driven Axial Piston Pumps

Chain Wheel and Step-up Gear
Shielding with Drain

From sump
Engine driven
hydraulic pumps
MAN B&W Diesel

06.01

4140/PWN

EL. driven
hydraulic pumps
< 41 >

Safety and Accumulators Block

and Alarm Functions

MAN B&W Diesel

06.01

Electrically Driven Start-up Pumps

4140/PWN

< 42 >

ME Engine, Pump Drive

and Moment Compensator
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 43 >

MAN B&W Diesel

Large Bore ME - Aft end mounted HPS.

5-8K/L/S60-90MC-C & 7K98ME(-C)

06.01

4140/PWN

< 44 >

60-98ME-C HPS

MAN B&W Diesel

Engines with moment

compensator

Engines without
moment compensator

Filter station

Identical
HPS units
Hydraulic pumps
Identical
chain
tightening
arrangement

Step-up gear

Chain tightener
wheel

MAN B&W Diesel

06.01

4140/PWN

< 45 >

MAN B&W Diesel

Hydraulic Power Supply

6S70ME6S70ME-C

06.01

4140/PWN

< 46 >

Step-up gear

MAN B&W Diesel

Redundancy Filter 25
25
Self Cleaning Filter 10
10

Gear wheels:
Case hardened
Simple spur wheels
DIN standard

Shielding with Drain

Engine Driven Axial Piston

Pumps

and Alarm Functions

Chain Wheel and StepStep-up Gear

MAN B&W Diesel

06.01

(2510/JRL)

4140/PWN

< 47 >

MAN B&W Diesel

06.01

4140/PWN

< 48 >

Filter unit

Engine driven high pressure pumps

MAN B&W Diesel

Self cleaning filter

with 10-micron filter
mesh

Redundancy filter
with 25-micron
filter mesh

Supplied by Bosch Rexroth

Supplied by Boll&Kirscher

MAN B&W Diesel

06.01

4140/PWN

< 49 >

MAN B&W Diesel

Safety block

06.01

4140/PWN

< 50 >

Start-up pumps

MAN B&W Diesel

Safety and control

valves

Three types:
2 x 15 kW for 50-60ME-C

Line break valves

2 x 25 kW for 70-80ME-C
2 x 38 kW for 90-98ME-C

Basically the same

block on all 6098ME/ME-C

MAN B&W Diesel

06.01

4140/PWN

< 51 >

MAN B&W Diesel

06.01

4140/PWN

< 52 >

7S50ME-C
Hydraulic Power Supply

7L70ME-C electrical HPS

MAN B&W Diesel

Accumulator
Safety and
accumulator block
3 engine driven axial
piston pumps with
flow controlled by
ECS

Gearbox and chain drive is

replaced by:
3 electrically driven pumps

Generates hydraulic
oil pressure up to
250 bar

230 kW each

Redundancy: Can
operate on two
pumps

Gear Box
MAN B&W Diesel

06.01

4140/PWN

< 53 >

MAN B&W Diesel

06.01

4140/PWN

< 54 >

El-driven Pumps (Viken 1436)

Engine Driven Pumps (Viken 1436)

MAN B&W Diesel

Pump

Suction line

MAN B&W Diesel

06.01

4140/PWN

< 55 >

MAN B&W Diesel

Engine Driven Pump (Viken 1436)

06.01

4140/PWN

< 56 >

Hydraulic Cylinder Units (HCU)

MAN B&W Diesel

HCUs mounted on common base plate

Feed back,
swash plate

Feed back,
pilot valve

Pilot valve for

swash plate
control

Double walled high

pressure pipe

High pressure oil inlet

from the HPS

MAN B&W Diesel

06.01

4140/PWN

< 57 >

MAN B&W Diesel

06.01

4140/PWN

< 58 >

ME-C Engines
Double Wall Pipe

Double Wall Pipe S70ME-C

MAN B&W Diesel

Flange

Outer Pipe

Inner Pipe

Sealing ring

5. Sealing ring
6. Sealing ring
7. Sealing ring
8. Screw

MAN B&W Diesel

06.01

4140/PWN

< 59 >

MAN B&W Diesel

06.01

4140/PWN

< 60 >

ME-C Engines
Double Wall Pipe

Hydraulic Cylinder Unit

MAN B&W Diesel

Final Design of Double Wall Pipe Between HCU Blocks with

Additional Sliding Rings Item 7 and Dirt Sealing Ring Item 8

9
7

Fuel oil
Pressure Booster

7
10

Hydraulic Exhaust
Valve Actuator

8
ELFI
Proportional Valve

4
ELVA
On/Off Valve

5
Distribution Block

MAN B&W Diesel

06.01

4140/PWN

< 61 >

MAN B&W Diesel

Oil Channel in the Distributor Block

06.01

4140/PWN

< 62 >

Hydraulic Cylinder Unit (HCU)

MAN B&W Diesel

X-ray picture of the Distributor Block

MAN B&W Diesel

06.01

Manually operated
valve for isolation of
oil to the actuators in
case of need for
overhauling
running engine

4140/PWN

< 63 >

MAN B&W Diesel

ME Control Valves
MAN B&W Diesel

MAN B&W Diesel

MAN B&W
FIVA

ELVA

06.01

The HCU is found on the upper gallery

One unit in front of each cylinder

4140/PWN

Hydraulic Cylinder Units

12K98ME12K98ME-C
Fuel Oil
Pressure Booster

ELFI

FIVA valve
MAN B&W Diesel

06.01

4140/PWN

< 65 >

MAN B&W Diesel

< 64 >

06.01

4140/PWN

Exhaust Valve Actuator

Integrated Alpha Lubricator

< 66 >

MAN B&W Diesel

K98ME(-C) Hydraulic Cylinder Unit

06.01

4140/PWN

MAN B&W Diesel

< 67 >

MAN B&W Diesel

K98ME(-C) HCU Distributor Block

06.01

4140/PWN

< 68 >

ME(-C) HCU Distributor Block

MAN B&W Diesel

The ME Engine Hydraulic Oil Loop

Fuel oil pressure

booster

Exhaust valve actuator

Hydraulic
cylinder unit

Fuel 10 bar
FIVA

200 bar

Alpha lubricator

Cyl. 1 CCU

Cyl. 2 CCU

Cyl. 3 CCU

Cyl. 4 CCU

Cyl. 5 CCU

Cyl. 6 CCU

Fine aut. filter

Piston cooling
+ bearings
Servo oil
return to sump

Main lube
pump

Safety and
accumulator
block
Servo oil

From sump
Engine-driven
hydraulic pumps
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 69 >

MAN B&W Diesel

06.01

EL. driven
hydraulic pumps

4140/PWN

Hydraulic Cylinder Unit (HCU)

S60ME-C

MAN B&W Diesel

Fuel Oil Pressure Booster

Exhaust Valve Actuator

FIVA Proportional Valve

Distribution Block

Alpha Lubricator

MAN B&W Diesel

06.01

4140/PWN

< 71 >

MAN B&W Diesel

06.01

4140/PWN

< 72 >

The ME Engine
Alpha Cylinder Lubricator

ME Fuel Oil Pressure Booster

MAN B&W Diesel

Save 0.3 g/bhp cylinder oil

MC-C

Inductive proximity switch

for feed-back signal
for control of
piston movement

ME-C

Signal for lubrication

from controller

Suction valve

Actuator piston

Outlets
for cylinder liner
lube oil injectors

Fuel plunger
Fuel oil inlet
pressure 8 bar

Injection plungers

Feed back
position sensor

Hydraulic piston

Spacer
for basic
setting of
pump
stroke

Stroke adjusting screw

Drain oil
outlet 200 bar servo
Cylinder
oil supply
lube oil inlet
Saves cylinder lube oil

MAN B&W Diesel

06.01

4140/PWN

< 73 >

MAN B&W Diesel

06.01

4140/PWN

< 74 >

Slide-type Fuel Valve

ME Fuel Injection System

MAN B&W Diesel

Suction valve

High pressure pipe

Slide fuel
valve

Now used
as standard

Fuel oil inlet

8 bar

Hydraulic
piston

Possibility for
retrofit

Membrane
accumulator

ELFI
Proportional
valve

Conventional fuel valve

Sac volume 1690 mm3

To
drain

Slide-type fuel valve

Sac volume 0 mm3

High pressure hydraulic oil inlet

MAN B&W Diesel

06.01

4140/PWN

< 75 >

MAN B&W Diesel

M E Exhaust Valve System

06.01

4140/PWN

< 76 >

ME Exhaust Valve

MAN B&W Diesel

Self-adjusting damper piston

Hydraulic
push rod

Hydraulic nut/measuring cone

Contact less sensor with
integrated electronics

Exhaust valve

Outlet lube oil

Exhaust valve
Actuator

Inlet lube oil

Damper
Membrane
accumulator
ELVA on-off valve

Air inlet

To drain
MAN B&W Diesel

High pressure hydraulic oil inlet

06.01

4140/PWN

< 77 >

MAN B&W Diesel

06.01

4140/PWN

< 78 >

The ME Engine
Exhaust Valve Timing

ME Starting Air System

MAN B&W Diesel

MCMC-C design
80

MEME-C design
Pilot air inlet

BlowBlow-off

70
60
Early closing
Late closing
Early opening
Late opening
Reference

50
40
30

NCNC-valves

Connection
for
ECS

Starting air
distributor

20
Starting valves

Starting valves

0
90

110

130

150

170

190

210

230

250

270

290

Dg. C. A.

The NC valve is mounted on the main

starting pipe behind the cylinder cover
MAN B&W Diesel

06.01

4140/PWN

< 79 >

MAN B&W Diesel

06.01

4140/PWN

Main Operating Panel in ECR - HMI

MAN B&W Diesel

Interview with the daily operators

- finger touch to trackball -

Inspection onboard
Bow Cecil after 4137
running hours as
ME engine
MAN B&W Diesel

06.01

Main Operating Panel - HMI

4140/PWN

< 81 >

MAN B&W Diesel

ME Tacho System

2005.05.01

(4140/PWN)

< 82 >

Service Experience

MAN B&W Diesel

A shaft encoder solution has been prepared as an alternative

to the standard mounted tacho ring

2 redundant set of sensors

Each set measure engine speed
and crankshaft position for
synchronisation of the control
events
Each set consist of four sensors.
Two quadrature sensors measure on
a trigger ring with 360 tooth and two
marker sensors measures on one
tooth a semicircular ring
Trigger segment with a sine-curved toothprofile The total trigger ring is build by 8
equal segments

MAN B&W Diesel

2005.05.01

(4140/PWN)

< 83 >

MAN B&W Diesel

2005.05.01

(4140/PWN)

< 84 >

Tacho System
Angle Encoder
MAN B&W Diesel

MAN B&W Diesel

2005.05.01

(4140/PWN)

< 85 >

MAN B&W Diesel

06.01

4140/PWN

< 86 >

06.01

4140/PWN

< 88 >

Tacho System
Angle Encoder
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 87 >

MAN B&W Diesel

Main Operating Panel (MOP)

Angle Encoder 12K98ME

MAN B&W Diesel

06.01

4140/PWN

< 89 >

MAN B&W Diesel

06.01

4140/PWN

< 90 >

Multi Purpose Controller (MPC)

ME Engine Control System

MAN B&W Diesel

Bridge
Panel

MAN B&W Diesel

Bridge

Plug for ID key

MultiMulti-Purpose
Controller

Main
Operatingg
Panel

BACK-UP FOR MOP

Control Room
Panel

Engine Control Room

DIP Switches

EICU B

EICU A

Engine Interface Control Unit A and B

Local
Operation
Panel

Engine Control Unit A and B

ECU B

ECU A

Control Network

Cylinders Control Unit 1 per cylinder

ACU

CCU

Auxiliaries Control Unit 1, 2 and 3

MAN B&W Diesel

06.01

Fuses in use are monitored by the alarm system

Engine Room/On Engine

4140/PWN

< 91 >

MAN B&W Diesel

06.01

4140/PWN

< 92 >

Engine Control System

MPC

MPC - configuration
MAN B&W Diesel

MAN B&W Diesel

The MPCs are software wise configured to

4 different controller functions:
1) Engine Interface Control Unit EICU
2 complete redundant units
Handles the interface to external systems
2) Engine Control Unit ECU
2 complete redundant units
Handles the engine specific control functions (the governor)
3) Cylinder Control Unit CCU
1 for each cylinder unit, redundancy by multiplicity
Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and
starting air valves)
4) Auxiliary Control Unit ACU
3 units, redundancy by multiplicity
Handles the auxiliary systems (hydraulic power supply, aux blowers)
MAN B&W Diesel

06.01

4140/PWN

< 93 >

MAN B&W Diesel

06.01

4140/PWN

< 94 >

06.01

4140/PWN

< 96 >

S70ME-C Engine Control System

MAN B&W Diesel

06.01

4140/PWN

< 95 >

MAN B&W Diesel

The ME Engine
Local Operating Panel (LOP)

M E SIMULATOR in Copenhagen

MAN B&W Diesel

Local Operating Panel

Local Instrument Panel

The
The Local
Local Operation
Operation Panel
Panel is
is located
located on
on the
the
middle
middle gallery
gallery on
on the
the manoeuvring
manoeuvring side
side of
of
the
the engine.
engine.
MAN B&W Diesel

06.01

Local Operation Panel

4140/PWN

< 97 >

MAN B&W Diesel

06.01

4140/PWN

< 98 >

Normal Transport Conditions

MAN B&W Diesel

Tank top in a
New building

MAN B&W Diesel

06.01

4140/PWN

< 99 >

MAN B&W Diesel

06.01

4140/PWN

< 100 >

Floating Crane Collapsed

MAN B&W Diesel

L60ME-C
Bedplate
MAN B&W Diesel

06.01

4140/PWN

< 101 >

MAN B&W Diesel

06.01

4140/PWN

< 102 >

MAN B&W Diesel

06.01

4140/PWN

< 103 >

MAN B&W Diesel

Holding Down Bolts

06.01

4140/PWN

< 104 >

Installation Aspects

MAN B&W Diesel

Side chocks, modified design

Previous design

MAN B&W Diesel

06.01

4140/PWN

< 105 >

MAN B&W Diesel

06.01

New design

4140/PWN

< 106 >

Installation Aspects
MAN B&W Diesel

MAN B&W Diesel

End chocks
Cast iron
end chock liner

MAN B&W Diesel

06.01

4140/PWN

< 107 >

MAN B&W Diesel

06.01

4140/PWN

< 108 >

MAN B&W Diesel

06.01

4140/PWN

< 109 >

MAN B&W Diesel

06.01

4140/PWN

< 110 >

06.01

4140/PWN

< 112 >

06.01

4140/PWN

< 114 >

MAN B&W Diesel

06.01

4140/PWN

< 111 >

MAN B&W Diesel

06.01

4140/PWN

< 113 >

MAN B&W Diesel

K98FF (1966) Versus K98MC (1999)

MAN B&W Diesel

2800 kW per cylinder

MAN B&W Diesel

06.01

4140/PWN

< 115 >

MAN B&W Diesel

06.01

5720 kW per cylinder

4140/PWN

< 116 >

MAN B&W Diesel

L60MC-C Landing Crankshaft in Bedplate

MAN B&W Diesel

06.01

4140/PWN

< 117 >

MAN B&W Diesel

06.01

4140/PWN

< 118 >

06.01

4140/PWN

< 120 >

MAN B&W Diesel

L60MC-C
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

Crankshaft in Bedplate
< 119 >

MAN B&W Diesel

Bearings
MAN B&W Diesel

MAN B&W Diesel

Crosshead

Crankpin

AlSn40

MAN B&W Diesel

06.01

4140/PWN

Main

White metal

< 121 >

MAN B&W Diesel

06.01

4140/PWN

< 122 >

Bearings Service Experience

MAN B&W Diesel

S50MC-C Main bearing lower shell - 18,000 hours

No remarks excellent condition

Thickness measurement of shell did not reveal indication of significant wear rate
less than 0.01 mm

MAN B&W Diesel

06.01

4140/PWN

< 123 >

MAN B&W Diesel

06.01

4140/PWN

< 124 >

06.01

4140/PWN

< 126 >

MAN B&W Diesel

06.01

4140/PWN

< 125 >

MAN B&W Diesel

06.01

4140/PWN

< 127 >

MAN B&W Diesel

06.01

4140/PWN

< 128 >

06.01

4140/PWN

< 130 >

MAN B&W Diesel

06.01

4140/PWN

< 129 >

MAN B&W Diesel

Earthing Device
MAN B&W Diesel

MAN B&W Diesel

Spark erosion in main bearings

Bronze: Propeller = +
Potential difference
< 50 mV
V
Main bearing

Current

Earthing device

Steel: Hull
Intermediate shaft
=
Propeller shaft
MAN B&W Diesel

06.01

4140/PWN

< 131 >

MAN B&W Diesel

06.01

4140/PWN

< 132 >

MAN B&W Diesel

L60ME-C
A-Frame
Mounted on
Bedplate.
MAN B&W Diesel

06.01

4140/PWN

< 133 >

MAN B&W Diesel

06.01

4140/PWN

< 134 >

06.01

4140/PWN

< 136 >

06.01

4140/PWN

< 138 >

MAN B&W Diesel

06.01

4140/PWN

< 135 >

MAN B&W Diesel

06.01

4140/PWN

< 137 >

MAN B&W Diesel

Crosshead bearings

MAN B&W Diesel

06.01

4140/PWN

< 139 >

MAN B&W Diesel

Crosshead bearings

4140/PWN

< 140 >

Crosshead bearings

MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 141 >

MAN B&W Diesel

06.01

4140/PWN

< 142 >

06.01

4140/PWN

< 144 >

Crosshead bearings
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 143 >

MAN B&W Diesel

06.01

4140/PWN

< 145 >

MAN B&W Diesel

06.01

4140/PWN

< 146 >

06.01

4140/PWN

< 148 >

06.01

4140/PWN

< 150 >

MAN B&W Diesel

06.01

4140/PWN

< 147 >

MAN B&W Diesel

06.01

4140/PWN

< 149 >

MAN B&W Diesel

Test equipment
for Relief Valves

ONLY
Hoerbiger type EVN
and
Mt Halla type HCSG-N

Approved by MAN B&W

MAN B&W Diesel

06.01

4140/PWN

< 151 >

MAN B&W Diesel

06.01

4140/PWN

< 152 >

06.01

4140/PWN

< 154 >

MAN B&W Diesel

06.01

4140/PWN

< 153 >

MAN B&W Diesel

Crankcase relief valve

MAN B&W Diesel

In case of a crankcase
explosion, the pressure
wave will send a large
amount of oil mist to the
engine room.
The oil mist will be moved
around by the ventilation.
If oil mist meets a hot
spot it can be ignited.
Maintenance of the insulation
is important!
Relief valve to prevent flames
to the engine room.

MAN B&W Diesel

06.01

4140/PWN

< 155 >

MAN B&W Diesel

06.01

4140/PWN

< 156 >

Deformed Flame Arrester

Crankcase Explosion
MAN B&W Diesel

MAN B&W Diesel

Cases of explosions where the cause is known

Year

Cause of Explosion

1995

Bearing in PTO gearbox

1996

Inlet pipe for piston cooling oil falling off

Incorrect tightening

1997

Incorrect spring mounted in piston rod stuffing box

Unauthorised spare part

1997

Piston rod interference with cylinder frame

1999

Weight on chain tightener falling off

1999

Fire outside the engine

2000

Main bearing

2000

Camshaft bearing

2000

Incorrect shaft in camshaft drive

2001

Crankcase failure

2001

Piston crown failure

2001

Main bearing

2001

Crankpin bearing

2002

MAN B&W Diesel

Inlet pipe for piston cooling oil falling off

06.01

4140/PWN

Cause of Failure

Incorrect tightening

Unauthorised spare part

Incorrect tightening

< 157 >

MAN B&W Diesel

06.01

4140/PWN

< 158 >

Cylinder Liner and Frame Configuration

MAN B&W Diesel

S-MC

S-MC-C

Cylinder liner:
Low position of mating surface
cylinder cover/cylinder liner
Slim cylinder liner
Straightforward cooling jacket
Cylinder frame:

Smaller and lighter

Uncooled and straightforward design

MAN B&W Diesel

06.01

4140/PWN

< 159 >

MAN B&W Diesel

06.01

4140/PWN

< 160 >

06.01

4140/PWN

< 162 >

MAN B&W Diesel

06.01

4140/PWN

< 161 >

MAN B&W Diesel

ME Engine, Pump Drive

and Moment Compensator
MAN B&W Diesel

MAN B&W Diesel

Filter station

Step-up gear
Hydraulic pumps

2. Order Moment
Compensator shaft
Chain drive for
4 Duplex chain
Pump drive can be arranged on
fore or aft end of the engine
S70MES70ME-C
MAN B&W Diesel

06.01

4140/PWN

< 163 >

MAN B&W Diesel

06.01

4140/PWN

< 164 >

06.01

4140/PWN

< 166 >

06.01

4140/PWN

< 168 >

Vibration Aspects
MAN B&W Diesel

MAN B&W Diesel

General terms
Internal forces

Piston

Crosshead

T
N

P
S

MAN B&W Diesel

06.01

4140/PWN

< 165 >

MAN B&W Diesel

06.01

4140/PWN

< 167 >

MAN B&W Diesel

06.01

4140/PWN

< 169 >

MAN B&W Diesel

06.01

4140/PWN

< 170 >

MAN B&W Diesel

Be sure that the counter

weights are hanging
downwards before
mounting the tools
for retightening of chains.

MAN B&W Diesel

06.01

4140/PWN

< 171 >

MAN B&W Diesel

06.01

4140/PWN

< 172 >

ME-C Engines
Doubble Wall Pipe

Hydraulic Cylinder Units (HCU)

MAN B&W Diesel

HCUs mounted on common base plate

Flange

Outer Pipe

Inner Pipe

Sealing ring

5. Sealing ring
6. Sealing ring

Double walled high

pressure pipe

7. Sealing ring
High pressure oil inlet
from the HPS

MAN B&W Diesel

06.01

4140/PWN

8. Screw

< 173 >

MAN B&W Diesel

06.01

4140/PWN

< 174 >

ME Fuel Oil Pressure Booster

K98ME(-C) Baseplate

MAN B&W Diesel

MC-C

ME-C

Suction valve

Feed back
position sensor

Fuel plunger
Fuel oil inlet
pressure 8 bar

Hydraulic piston

01-10-2003

(2500/KNB)

MAN B&W Diesel

< 175 >

MAN B&W Diesel

Hydraulic Cylinder Unit

4140/PWN

< 176 >

Hydraulic Cylinder Unit

MAN B&W Diesel

06.01

MAN B&W Diesel

06.01

4140/PWN

< 177 >

MAN B&W Diesel

06.01

4140/PWN

< 178 >

06.01

4140/PWN

< 180 >

Hydraulic Cylinder Unit

MAN B&W Diesel

06.01

4140/PWN

< 179 >

MAN B&W Diesel

06.01

4140/PWN

< 181 >

MAN B&W Diesel

06.01

4140/PWN

< 182 >

Hydraulic Cylinder Unit (HCU)

Hydraulic Cylinder Unit

MAN B&W Diesel

Fuel oil
Pressure Booster

Accumulators
pressurized with
nitrogen of 105 bar

Hydraulic Exhaust
Valve Actuator
ELFI
Proportional Valve

ELVA
On/Off Valve
Distribution Block

MAN B&W Diesel

06.01

4140/PWN

< 183 >

MAN B&W Diesel

Hydraulic Cylinder Unit (HCU)

06.01

4140/PWN

< 184 >

ME Fuel Injection System

MAN B&W Diesel

Fuel injection

Valve actuation
High pressure pipe
Suction valve

ELFI Proportional Valve

Slide fuel
valve

ELVA On/Off Valve

Fuel Pump

Fuel oil inlet

8 bar

Exhaust Valve Actuator

Hydraulic
piston

Membrane
accumulator

ELFI
Proportional
valve

To
drain
Accumulator
MAN B&W Diesel

06.01

4140/PWN

High pressure hydraulic oil inlet

Distribution Block

< 185 >

MAN B&W Diesel

06.01

4140/PWN

< 186 >

MAN B&W Diesel

06.01

4140/PWN

< 187 >

MAN B&W Diesel

06.01

4140/PWN

< 188 >

6S90MC-C

Service Experience
MAN B&W Diesel

MAN B&W Diesel

1150 running hours

Dosage 1.1 g/bhph
Mobilgard 570
Liner No. 4

12K90MC,
one years operation with Alpha ACC = S% * 0.25 g/bhph

MAN B&W Diesel

06.01

4140/PWN

Maria A. Angelicoussis DW5127 Pascagoula 00.09.15

< 189 >

MAN B&W Diesel

06.01

The ME Engine
Alpha Cylinder Lubricator

4140/PWN

< 190 >

Cylinder Condition

MAN B&W Diesel

Save 0.3 g/bhp cylinder oil

Inductive proximity switch

for feed-back signal
for control of
piston movement

Timing of cylinder oil injection

Pressure
25 bar

Signal for lubrication

from controller

Injection pressure
Alpha lubricator

Actuator piston

20
Outlets
for cylinder liner
lube oil injectors

Injection plungers

10
Spacer
for basic
setting of
pump
stroke

Stroke adjusting screw

Drain oil
outlet 200 bar servo
Cylinder
oil supply
lube oil inlet
Saves cylinder lube oil

Injection pressure
mechanical lubricator

Oil quill pressure

0
0
MAN B&W Diesel

06.01

4140/PWN

< 191 >

MAN B&W Diesel

10
06.01

20
4140/PWN

90 ms Time
< 192 >

Combustion Chamber Design S-MC-C

MAN B&W Diesel

Piston with high

top land

S-MC-C

Piston ring further

away from
combustion space

S-MC

Mating
surface
Top land

Lower mating
surface between
cylinder cover and
cylinder liner

First piston ring special

patented CPR ring

MAN B&W Diesel

06.01

4140/PWN

< 193 >

MAN B&W Diesel

06.01

4140/PWN

< 194 >

Combustion Chamber Layout

MAN B&W Diesel

Combustion chamber engines Piston rings

High 1st piston ring to accommodate CPR
design
Optimal pressure drop over the upper piston
ring reduces the heat load on the second
piston ring significantly
All piston rings Alu-coat
Good performance of the piston
ring pack means high reliability of
the combustion chamber
components and the cylinder
condition

Controlled Pressure Relief (CPR) gaps

MAN B&W Diesel

06.01

4140/PWN

< 195 >

MAN B&W Diesel

06.01

4140/PWN

< 196 >

MAN B&W Diesel Service

Alu-Coated Piston Ring

MAN B&W Diesel

Genuine spare parts

A-A

Developed at our
Research Centre

Reduced running-in
time by more than 50%

Thus saving cylinder oil

Thickness: about 0.3 mm

Alu-Coat

Piston ring with controlled pressure

relief (CPR piston ring)
A

MAN B&W Diesel

06.01

4140/PWN

< 197 >

Reduced differential pressure on

piston ring No. 2

Reduced temperature on
piston ring No. 2

MAN B&W Diesel

06.01

4140/PWN

< 198 >

Cylinder Condition
MAN B&W Diesel

MAN B&W Diesel

Controlled pressure relief piston ring (CPR)

Large bore MC-S engines

90 and 98 bore engines

1st ring: Type: CPR, RM14

High
2nd ring: Type: RM5, oblique cut
with Alu-Coat
Low
3rd ring: Type: RM5, oblique cut
with Alu-Coat
Low
4th ring: Type: RM5, oblique cut
with Alu-Coat
Low

F
F

F
A
3 mm
MAN B&W Diesel

06.01

4140/PWN

< 199 >

MAN B&W Diesel

06.01

4140/PWN

< 200 >

Combustion Chamber Layout

Production
MAN B&W Diesel

MAN B&W Diesel

Piston high top land

Piston and piston rings

Cylinder cover
Piston high top land

Oros Piston

Liner diameter: 700 mm

Liner wear:

Install:

Measuring point 5 =

ALU Coated

Piston Skirt Position in TDC

Piston Rings

0 0.70 mm

Standard PC-ring

0,70 1,4 mm Oversize PC-ring

> 1,4 mm

No PC- ring

Cylinder liner

Piston cleaning ring

MAN B&W Diesel

06.01

4140/PWN

< 201 >

MAN B&W Diesel

Bore polish from topland deposits.

4140/PWN

< 202 >

Bore polish from topland deposits.

MAN B&W Diesel

Example of,
polished
liner
surface,
from heavy
deposits on
the piston
topland,
rubbing
against the
liner
surface.

MAN B&W Diesel

06.01

4140/PWN

< 203 >

Example of heavy deposits

on the piston topland, being
polished from rubbing
against the liner running
surface

MAN B&W Diesel

06.01

4140/PWN

< 204 >

MAN B&W Diesel

06.01

4140/PWN

< 205 >

MAN B&W Diesel

06.01

4140/PWN

< 206 >

06.01

4140/PWN

< 208 >

06.01

4140/PWN

< 210 >

MAN B&W Diesel

06.01

4140/PWN

< 207 >

MAN B&W Diesel

06.01

4140/PWN

< 209 >

MAN B&W Diesel

Exh. Valve (Viken 1436)

MAN B&W Diesel

Feed back sensor

Oil inlet to damper

Drain pipes

MAN B&W Diesel

06.01

4140/PWN

< 211 >

MAN B&W Diesel

06.01

4140/PWN

< 212 >

Slide-type Fuel Valve

MAN B&W Diesel

Now used
as standard

Possibility for
retrofit

Conventional fuel valve

Sac volume 1690 mm3

MAN B&W Diesel

06.01

4140/PWN

< 213 >

MAN B&W Diesel

Slide Fuel Valve

06.01

Slide-type fuel valve

Sac volume 0 mm3

4140/PWN

< 214 >

Slide-type Fuel Valve

MAN B&W Diesel

In order to optimise combustion and to achieve a cleaner engine,

we have developed a new generation of fuel valves, the so-called
slide fuel valve.
The main benefits of this design, compared with
the conventional design, are :
Reduced fouling of gas ways
Reduced fouling of piston top land and exhaust gas boiler

Further benefits :
Less smoke formation
Lower NOx emission levels
Lower fuel consumption

The difference between the slide fuel valve and the

conventional type is the reduced (actually non-existent) sac
volume.

Conventional fuel valve

Sac volume 1690 mm3

SL 02-403
MAN B&W Diesel

06.01

4140/PWN

< 215 >

MAN B&W Diesel

06.01

4140/PWN

Slide-type fuel valve

Sac volume 0 mm3
< 216 >

Slide-type Fuel Valve

MAN B&W Diesel

06.01

4140/PWN

< 217 >

MAN B&W Diesel

06.01

4140/PWN

< 218 >

Fuel Valve, Spring Housing

MAN B&W Diesel

Malfunction due to incorrect tightening

Fuel Valve

Tightening torque for engines up to 70MC = 60Nm

SL 94-316

MAN B&W Diesel

For large bore above 70MC = 65Nm

06.01

4140/PWN

< 219 >

MAN B&W Diesel

6L80MC
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 220 >

Marks and Stamps on Fuel Valve Nozzle

MC and MC-C Type

Marking must, as a minimum, consist of: Name, IMO id No. and nozzle size.
Name:
Manufacturers name/ trade mark
IMO id No.: A unique identification No. which links the component
with the design specification that was used at the time of
manufacture, eg. MAN B&W part No. or licensees drawing
No.
Nozzle size: Diameter of nozzle hole.

Damaged Piston Crown

Reason: Fuel valves in bad
condition

Example of marking:
The example shows how to mark a nozzle with hole
diameter 1.5 mm. with Part No. 1261573-1

MAN B&W Diesel

06.01

4140/PWN

< 221 >

MAN B&W Diesel

06.01

4140/PWN

< 222 >

ME Starting Air System

Starting Air valve (Viken 1436)

MAN B&W Diesel

MCMC-C design

MEME-C design
Pilot air inlet

BlowBlow-off

NCNC-valves

Starting valves

Starting air valve

Connection
for
ECS

Starting air
distributor

Pilot valve for

starting air valve

Starting valves

The NC valve is mounted on the main starting

pipe behind the cylinder cover

MAN B&W Diesel

06.01

4140/PWN

< 223 >

MAN B&W Diesel

06.01

4140/PWN

< 224 >

06.01

4140/PWN

< 226 >

Auxiliary Systems
MAN B&W Diesel

MAN B&W Diesel

06.01

4140/PWN

< 225 >

MAN B&W Diesel

7S60ME-C

MAN B&W Diesel A/S

MAN B&W Diesel

06.01

Thank you for

your attention

4140/PWN

< 227 >

MAN B&W Diesel

< 228 >

The ME Engine
MAN B&W Diesel

You and

together

Simple & Safe

Thank you for your attention

Preben Noeies
MAN B&W Diesel

06.01

4140/PWN

< 229 >

2. ME Concept

MAN B&W Diesel

1) Control system:
- Multi Purpose Controller.
- Main Operating Panel.
- Local Operating Panel.
2) Tacho system.
3) Performance
4) Manoeuvring System
MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<1>

ME engine
Hydraulic Loop
MAN B&W Diesel

Fuel oil pressure

Exhaust valve actuator
booster
Hydraulic
cylinder unit

Fuel 10 bar
ELFI

ELVA

200 bar

Alpha lubricator

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU

Safety and
Accumulator
blok

Fine aut. filter

Main lube
pump

Servo oil

Piston cooling
+ bearings

Servo oil
return to sump

From sump
Engine driven
hydraulic pumps
MAN B&W Diesel

L/73273-7.1/0403

EL. driven
hydraulic pumps
<2>

(2600/RL)

Engine Control System

MPC & Network
MAN B&W Diesel

The Multi Purpose Controllers are

identical hardware wise.
They have different soft ware
configurations.
2 redundant control networks are
connecting all Multi Purpose Controllers
and both Main Operating Panels.
A backup of the application- and
setup- soft ware are stored on both
Main Operation Panels.
At replacement, the new controller
are automatically configured with
correct soft ware via the control
networks.
MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<3>

L/73273-7.1/0403

Piston cooling
+ bearings

Servo oil
return to sump

MAN B&W Diesel

ELFI

(2600/RL)

From sump

Main lube
pump

Fine aut. filter

Cyl. 4 CCU

ELVA

Servo oil

EL. driven
hydraulic pumps
<2>

Safety and
Accumulator
blok

Hydraulic
cylinder unit
200 bar

Engine driven
hydraulic pumps

Cyl. 5 CCU Cyl. 6 CCU

Fuel oil pressure

Exhaust valve actuator
booster

Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU

Alpha lubricator

Fuel 10 bar

MAN B&W Diesel

ME engine
Hydraulic Loop

Engine Control System Diagram

Plate 70317

On Bridge
BRIDGE PANEL

In Engine Control Room

Backup Operation Panel
MOP B

MAIN OPERATION PANEL

MOP A

EICU A

EICU B

In Engine Room/On Engine

LOCAL OPERATION
PANEL - LOP

Actuators

Exhaust
Fuel
valve
booster
position position
Cylinder 1 Cylinder 1

FIVA
AL
SAV
Valve
Cylinder 1 Cylinder 1 Cylinder 1

CCU
Cylinder n

Sensors

CCU
Cylinder 1

ACU 3

Sensors

ACU 2

ECU B

Fuel
Exhaust
booster
valve
position position
Cylinder n Cylinder n

Act uat ors

ECU A

ACU 1

ECR PANEL

FIVA
Valve
SAV
AL
Cylinder n Cylinder n Cylinder n

M PUMP 5

M PUMP 4

M PUMP 3

M PUMP 2

M PUMP 1

M PUMP 2

M PUMP 1

AUXILIARY AUXILIARY
BLOWER 1 BLOWER 2

Marker Sensor

AUXILIARY
BLOWER 3

AUXILIARY
BLOWER 4
Angle Encoders

AUXILIARY
BLOWER 5

When referring to this page, please quote Operation Plate 70317, Edition 0003
MAN B&W Diesel A/S

Multi Purpose Controller - MPC

MAN B&W Diesel

Battery for internal clock

LED indicator
Plug for ID key

DIP Switches

Fuses in use are monitored by the alarm system

Power plug
MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<4>

LED information Code

MAN B&W Diesel

The LED gives information, either as constant light of flashing.

A flashing LED is a coded message from the controller.The code consists of 2 digits:
1. digit are given by red flashes on yellow background
2. digit are given by green flashes on yellow background
The 2 digits are seperated by a 1 sec. yellow pulse.

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<5>

2006-01-06

<6>

LED indication code

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Multi Purpose Controller (MPC)

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<7>

Multi Purpose Controller (MPC)

MAN B&W Diesel

Multi Purpose Controller

Supporting bracket for cables

Amplifier

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

<8>

2006-01-06

<9>

MPCs Nordic Brasilia 6S70ME-C

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

MPC configuration
MAN B&W Diesel

The MPCs are software wise configured to

4 different controller functions:
1) Engine Interface Conrol Unit EICU
2 complete redundant units
Handles the interface to external systems
2) Engine Control Unit ECU
2 complete redundant units (except with 4 or more engine driven pumps)
Handles the engine specific control functions (the govenor)
3) Cylinder Control Unit CCU
1 for each cylinder unit, redundancy by multiplicity
Handles the cylinder specific functions (fuel injection, exh. Valve, cylinder lubrication and
starting air valves)
4) Auxilliary Control Unit ACU
3 units, redundancy by multiplicity
Handles the auxilliary systems (hydraulic power supply, aux blowers)
MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 10 >

2006-01-06

< 11 >

2006-01-06

< 12 >

Engine Interface Control Unit EICU

MAN B&W Diesel

Interface to remote control systems:

Safety system
Alarm system
Telegraph system
Power management system

Operator inputs:
Control station selection - Bridge, Engine control room or Local control
Standby / Finished with engine

Speed set point Filter between handle and govenor:

Slow down
Shaft generator
Controlling accelaration
Load control
Barred speed range

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Speed Setpoint
MAN B&W Diesel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Engine Control Unit ECU

MAN B&W Diesel

Start / stop logic

Prepare start (MOP or handle)
Repeated start, (total 3 attempts, reset by setting the handle in STOP)
Start blocking
Slow turning
Manual air run

Engine speed control and limiters

Calculations of fuel index

The gov
enor

Limiters (start, max fuel all and individual, torque, scav.air, hydraulic press.)
Feed forward (pitch, PTO power)

Engine running mode control

Emission mode
Economy mode

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 13 >

2006-01-06

< 14 >

2006-01-06

< 15 >

Fuel Limiters
MAN B&W Diesel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Cylinder Control Unit CCU

MAN B&W Diesel

Fuel injection control

Proportional valve
Feedback of plunger position only used for monitoring

Exhaust valve control

ON / OFF valve

FIVA
VALVE

Feedback signal for exh. Valve position, used in determination of valve timing

Cylinder lubrication
ON / OFF valve controling the alpha lubricator
Feedrate controlled in the ECU

Starting air valve control (timing of solenoid valve)

ON / OFF valve

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Engine Control System

CCU
MAN B&W Diesel

Fiva valve, Fuel & exhaust

Fuel plunger pos. feedback
Exh. Spindle pos. feedback

Cylinder lubrication
Starting air valve
One CCU for every cylinder
unit

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 16 >

2006-01-06

< 17 >

Auxiliary Control Unit - ACU

MAN B&W Diesel

Control of Hydraulic Power Supply:

Engine driven pumps
Start-up pumps
Valves and pressure gauges

Individual control of aux blower:

Sequential start by different start delays
Engine contol blower / stop is decided in ECU

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Engine Control System

Auxiliary Blowers
MAN B&W Diesel

Aux blower No. 1 is controlled by ACU 1

Aux blower No. 2 is controlled by ACU 2
Aux blower No. 3 is controlled by ACU 3
Aux blower No. 4 is controlled by ACU 1
Aux blower No. 5 is controlled by ACU 2

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 18 >

Engine Control System

Hydraulic Pumps
MAN B&W Diesel

El-pump 1 controlled by ACU 1

El-pump 2 controlled by ACU 2
Eng.driven pump 1 controlled by ACU 1,
- Pressure controlled / follow mode

Eng.driven pump 2 controlled by ACU 2,

- Pressure controlled / follow mode

Eng.driven pump 3 controlled by ACU 3,

- Pressure controlled / follow mode

Eng.driven pump 4 controlled by ECU 1,

- On-OFF

Eng.driven pump 5 controlled by ECU 2,

- On-OFF
MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 19 >

ME Starting Air System

MAN B&W Diesel

MCMC-C design

MEME-C design
Pilot air inlet

BlowBlow-off

NCNC-valves

Connection
Connection
for
ECS

Starting
Starting air
distributor

Starting valves

MAN B&W Diesel

< 20 >

Starting airand pilot air valve

MAN B&W Diesel

Starting air valve

Pilot air valve

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 21 >

Engine Control System

Control Panels
MAN B&W Diesel

Bridge Control system is

connected to EICU

Engine Control Room Panel is

connected to EICU

Local Operating Panel LOP is

connected to ECU

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 22 >

2006-01-06

< 23 >

2006-01-06

< 24 >

Main Operation Panel (MOP)

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Main Operating Panel MOP

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Main Operating Panel MOP

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 25 >

2006-01-06

< 26 >

2006-01-06

< 27 >

Local Operating Panel (LOP)

with telegraph
MAN B&W Diesel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Local Operating Panel (LOP)

Without telegraph
MAN B&W Diesel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Engine Control System

Tacho System
MAN B&W Diesel

There are 2 redundant tacho systems.

System A
System B
Standard is:
angle encoders with one
reference sensor on the flywheel
(A-system)

Option is sensors at the flywheel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 28 >

Tacho system
MAN B&W Diesel
MMA
Q2A

Q1A

MMB

Q1B

System A (powered from ECU A)

Q2B

MMA = Marker Master A

MSA = Marker Slave A
Q1A = Quadratur 1A
Q2A = Quadratur 2A
MSA

System B (powered from ECU B)

MMB = Marker Master B
MSB = Marker Slave B
Q1B = Quadratur 1B
Q2B = Quadratur 2B
Trigger ring
pos. 1

MSB

Semi-circular
marking ring
pos. 2

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 29 >

2006-01-06

< 30 >

ME Tacho-system
MAN B&W Diesel

MAN B&W Diesel

041104-ME
11-2003
Concept - 2500/KNB
Tom Ballegaard/4140

ME Tacho-system
MAN B&W Diesel

MAN B&W Diesel

04-1104ME
11-2003
Concept

2500/KNB
- Tom
Ballegaard/4140

2006-01-06

< 31 >

2006-01-06

< 32 >

Angle encoder 12K98ME

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

ME Tacho-system
MAN B&W Diesel

2 redundant set of sensors.

Each set measure engine speed
and crankshaft position for
synkronisation of the control
events.
Each set consist of four sensors.
Two quadrature sensors measure on
a trigger ring with 360 tooth and two
marker sensors measures on one
tooth a semicircular ring.
Triggersegment with a sine-curved toothprofile The total trigger ring is build by 8
equal segments.

MAN B&W Diesel

2200/OZS/030212
ME Concept -

Tom Ballegaard/4140

2006-01-06

< 33 >

Tacho sensors
Nordic Brasilia 6S70ME-C
MAN B&W Diesel

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 34 >

Tacho sensors, replacement

MAN B&W Diesel

Sensing distance to the highest point on the trigger / marker ring:

1.0 mm

The highest point is marked [T]

Highest point

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 35 >

2006-01-06

< 36 >

Quadratur sensor
MAN B&W Diesel

Status LED

Ahead turning towards the dot

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

Performance curves
MAN B&W Diesel

By changing the exh. Valve timing, the Pcomp can be

adjusted, and then the Pmax can be kept constant in a
bigger range.

The maximum pressure jump is the same as for MC

engine because the combustion chambers are
identical.

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 37 >

Exhaust valve timing

MAN B&W Diesel

Exhaust valve movement

80
70
60
Early closing

Late closing

Early opening
Late opening

Reference

20
10
0
90

110

130

150

170

190

210

230

250

270

290

Dg. C. A.
MAN B&W Diesel

< 38 >

Pneumatic system
MAN B&W Diesel

2 valves for redundancy

No. 30 connected to ECU A
No. 32 connected to ECU B

MAN B&W Diesel

ME Concept - Tom Ballegaard/4140

2006-01-06

< 39 >

MAN B&W Diesel A/S

S70ME-C Project Guide

100

r/min

90
bar
80

MEP

Engine speed

14
bar(abs)
Mean effective pressure

150

130

Maximum pressure

120

Cyl. Pressure

140

110

bar(abs)

100

P-scav

Compression pressure

deg.C
450

400
Exhaust gas temperature
inlet to turbocharger

350

300
Exhaust gas temperature
outlet from turbocharger

Exh. Gas Temp.

Scavenge air pressure

250
g/kWh

170
Specific fuel oil
consumption

SFOC

180

160

150
50%

75%

100%

Load

1555

2333

3110

kW/cyl

178 25 61-7.0

Fig. 1.04: Performance curves

430 100 500

198 34 48

1.06

3. Hydraulic Power Supply

MAN B&W Diesel

1) System
2) Filter unit
3) Startup pumps

4) Engine driven pumps

Drive system
Pump principle

5) Valve block
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

<1>

The ME Engine
Hydraulic Oil Loop
MAN B&W Diesel

Fuel oil pressure

Exhaust valve actuator
booster
Hydraulic
cylinder unit

Fuel 10 bar
ELFI

ELVA

200 bar

Alpha lubricator
Cyl. 1 CCU Cyl. 2 CCU Cyl. 3 CCU Cyl. 4 CCU

Cyl. 5 CCU Cyl. 6 CCU

Safety and
Accumulator
blok

Fine aut. filter

Main lube
pump

Servo oil

Piston cooling
+ bearings
Servo oil
return to sump
From sump

ISO 4406: 13/16

NAS Code: 7

MAN B&W Diesel

L/73273-7.1/0403

(2600/RL)

Engine driven
hydraulic pumps

EL. driven
hydraulic pumps
2006-01-23

<2>

2006-01-23

<3>

Separat hydraulic system

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Filter Unit, Schematic

MAN B&W Diesel

Old plants = 10
New plants = 6

MAN B&W Diesel

Older plants are equipped with a by25

pass valve which opens at 0.8 bar

after the filter

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

<4>

2006-01-23

<5>

2006-01-23

<6>

Filter unit
MAN B&W Diesel

Single filter unit

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Filter unit
MAN B&W Diesel

Filtering process
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Back flushing process

Backflushing line to Lub. Oil tank

MAN B&W Diesel

The purifier suction pipes have the same

diameters but a different lenght.
The purifier will suck primarily from the sump
tank.
The oil level in the 2 tanks will remain more or
less equal due to the interconnection.
When servo oil is back-flushed from the filter,
the oil level in the servo oil tank will increase,
and the purifier will suck from this tank until the
level in the 2 tanks are equalized again. Then
the suction will take place from the sump tank
again.

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

<7>

2006-01-23

<8>

2006-01-23

<9>

Start up pumps, fixed

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Start up pumps, fixed

MAN B&W Diesel

Automatic mode:
Stopped at Finish With Engine.
Master pump running at engine
standby. (both pumps are running
during pressure build up).
Stopped via a timer at a specified
engine RPM

Manual mode:
Controlled by the operator via the
Main Operating Panel

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

El-driven pumps
MAN B&W Diesel

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 10 >

2006-01-23

< 11 >

Engine driven pumps

MAN B&W Diesel

Sensors for suction pressure.

Low pressure = shut down
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Engine driven pumps

MAN B&W Diesel

Automatic mode:
The pressure set point is depending on the engine load.
The pumps have two running modes, 1 in pressure control mode [Ctrl]
(selected via the MOP screen), 2 in follow mode [Folw].
The [Ctrl] pump is running 50% and compensates immediately for deviations
between actual pressure and set point. Over time the [Folw] pumps will take
over the compensation while the [Ctrl] pump goes back to 50 %.
In case the pressure controlling pump faces a failure, one of the other pumps
will take over pressure control.

Manual mode:
The pressure set point is set by the operator

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 12 >

Engine driven pumps

MAN B&W Diesel

In case of control failure of a pump, the swash plate will be forced to

maximum capacity in AHEAD direction.
Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.
Pump Nos. 1, 2, and 3 have their own sensor for system pressure,
connected to their controlling ACU
Pump Nos. 4 and 5 are controlled by a binary signal, either max capacity
AHEAD or ASTERN. No. 4 is controlled from ECU A, and No. 5 from
ECU B.
All pumps have sensors for suction pressure. If the pressure is to low,
or all sensors are failing, a SHUT DOWN will be activated.
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 13 >

2006-01-23

< 14 >

Leak detection
MAN B&W Diesel

Shut down level

Alarm level
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Leak detection
MAN B&W Diesel

Box for hydraulic pumps

Drainpipe

Sensor LS 1235 & JS 1236, vibrating fork type.

LS 1235 = Alarm

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

LS 1236 = Cancelable Shut Down

2006-01-23

< 15 >

MAN B&W Diesel

Alarm level

MAN B&W Diesel

2006-01-23

Sensors for suction pressure. Low pressure = shut down

Hydraulic power supply - Tom Ballegaard/4140

Shut down level

Engine driven pumps

< 13 >

Engine driven pumps

MAN B&W Diesel

Alarm level

Shut down level

MAN B&W Diesel

Sensors for suction pressure. Low pressure = shut down

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 16 >

2006-01-23

< 17 >

2006-01-23

< 18 >

7S50ME-C Gear Box for HPS

MAN B&W Diesel

Output wheel
Intermediate wheel.
Connections wheel
Gearwheel on crankshaft
Two rows of gears, one is spare.
Spacer..

Gear ratio - 12:1

MAN B&W Diesel

ME Engine, Pump Drive

and Moment Compensator
MAN B&W Diesel

MAN B&W Diesel

L/73898-1.0/0303

(2600/RL)

Chain tightener
MAN B&W Diesel

Pressure:
70ME: 1500 bar
98ME: 2200 bar

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 19 >

2006-01-23

< 20 >

ME Engine, Pump Drive

MAN B&W Diesel

Hydraulic Pump

Step Up Gear

Chain wheel for

4 Duplex chain

MAN B&W Diesel

Pump shaft principle

MAN B&W Diesel

Gear end

High friction disc

Pump end

MAN B&W Diesel

2006-01-23

< 21 >

12K98ME(-C) HPS
MAN B&W Diesel

Design of Hydraulic Power Supply (HPS)

Mounting of HPS
Structure of HPS and Framebox
Design of components

MAN B&W Diesel

2500/KNB

November 2003.

2006-01-23

< 22 >

2006-01-23

< 23 >

K98ME(-C) Pump drive

MAN B&W Diesel

2510/ERA

Nov. 2003.

ME(-C) Hydraulic Power Supply

MAN B&W Diesel

05-02-2004

(2500/KNB)

< 24 >

K98ME(-C) HPS
MAN B&W Diesel

8-12K98ME/C

MAN B&W Diesel

2510/ERA

< 25 >

Nov. 2003.

10-12K98ME/ME-C new design

MAN B&W Diesel

5 x 500 ccm pumps

Fore side

Aft side

MAN B&W Diesel

2006-01-23

< 26 >

2006-01-23

< 27 >

8-9K98ME/ME-C new design

MAN B&W Diesel

4 x 500 ccm pumps

Fore side

MAN B&W Diesel

Aft side

Axial piston pumps, principals

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 28 >

Axial piston pumps, principals

MAN B&W Diesel

A: Swash plate

D: Pressure side

B: Cylinder block

R: Suction side

C: Distibutor valve

h: Stroke
: Swash plate angle
Animation.lnk

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 29 >

2006-01-23

< 30 >

Axial piston pump

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Axial piston pump

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 31 >

Engine driven pumps,

Nordic Brasilia 6S70ME-C
MAN B&W Diesel

Pump

Sensor for suction pressure

Suction line

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 32 >

Engine driven pumps,

Nordic Brasilia 6S70ME-C
MAN B&W Diesel

Feed back, swash plate

Feed back, pilot valve

Pilot valve for swash

plate control

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 33 >

Engine driven pump,

mechanical indication
MAN B&W Diesel

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 34 >

2006-01-23

< 35 >

2006-01-23

< 36 >

Engine driven pump 750 ccm

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Engine driven pump

dismantling
MAN B&W Diesel

Weight:
500 ccm pump: 185 kg
750 ccm pump: 460 kg
MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

Valve block
MAN B&W Diesel

To hydraulic cylinder unit (HCU)

P2 pressure

311 Safety valve.

10 12 cyl. 90 98 bore
have 2 valves, one on
each valve block

Safety system for leaking

high pressure inner pipe

LPS From filter unit

MAN B&W Diesel

Hydraulic power supply - Tom Ballegaard/4140

2006-01-23

< 37 >

2006-01-23

< 38 >

2006-01-23

< 39 >

K98ME/-C new design

MAN B&W Diesel

Modulated Accumulator block

Divided into fore and aft section
Double wall substituted by flexible hoses
Pump mounted N2_Accumulator
(Pump depent)

MAN B&W Diesel

K98ME/-C new design

MAN B&W Diesel

Modulated Accumulator block

Top mounted Fore section

Top mounted Aft section

MAN B&W Diesel

Valve block, Fore, new design

MAN B&W Diesel

Fore section
Adaption flange
(Engine depent)

Primary block,
(Basic for all engines 60-98ME/-C)

Inlet block
(Pump-depent: 2 or 3 ports)

MAN B&W Diesel

2006-01-23

< 40 >

2006-01-23

< 41 >

Valve block, Aft, new design

MAN B&W Diesel

Aft section
Adaption flange
(Engine depent)

Slave block, (Basic for all engines with

middle chain drive 80-98ME/-C)

Inlet block
(Pump-depent: 2 or 3 ports)

MAN B&W Diesel

4. Hydraulic Cylinder Unit

MAN B&W Diesel

1) Distributor block
2) Komponents:
FIVA
Accumulators
Cylinder lubricator
3) Highpressure pipes

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

<1>

2006-01-19

<2>

2006-01-19

<3>

Hydraulic Cylinder Unit

HCU
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Hydraulic Cylinder Unit

HCU
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

ME(-C) Hydraulic Cylinder Unit

MAN B&W Diesel

05-02-2004

(2500/KNB)

ME(-C) Hydraulic cylinder Unit

(FIVA)

MAN B&W Diesel

03-11-2003

(2500/KNB)

FIVA
MAN B&W Diesel

FIVA
Degree Crank angle

-20

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360

Injection start (0)

Injection End (20)
Exhaust valve open (110)
Exhaust valve Close (270)

Approximate timing of events to be carried out by the FIVA valve

On an ME- engine the timing of injection is variable and this is just an example.

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

<6>

Accumulator
MAN B&W Diesel

1. Assemble without the

diaphragm. Make the mark
1.

MAN B&W Diesel

2. Assemble with the diaphragm.

Tighten until the ofset D06-216
is achieved

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

<7>

2006-01-19

<8>

2006-01-19

<9>

Accumulator
Nitrogen check
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Cylinder lubricator system

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Cylinder lubricator system

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 10 >

Alpha Lubricator for MEME-Engine

MAN B&W Diesel

Cylinder lub.
oil inlet

Inductive proximity sensor

for feed-back signal to
control of piston movement

Signal for
lubrication from
controller

Level sensor for

cylinder oil in lubricator

Outlets for
cylinder liner
lub. oil
injectors

Injection plunger

Spacer for
basic setting of
pump
stroke
Non-return valve

Drain
oil
outlet

Stroke
adjusting
screw

200 bar system oil supply

Actuator
piston

Sealingring
MAN B&W Diesel

3331377/20041021
Hydraulic Cylinder

Unit (2200/OZS)
- Tom Ballegard/4140

2006-01-19

< 11 >

Cylinder Lubricator
MAN B&W Diesel

HCU Distributorblock

Cylinder lubricator

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 12 >

Cylinder Liners
MAN B&W Diesel

Injection nozzle

Injection nozzle
with non-return
valve

MAN B&W Diesel

3331050/20031212

Cylinder liner

(CBO/4100)

Cylinder Lubrication Demands

MAN B&W Diesel

The purpose of the cylinder lubrication is as follows: (SL 05-455/HRJ)

To create a hydrodynamic oil film seperating the piston rings from the liner,
The oil amount needed to create an oil film is more or less independent of the fuel oil being used.
The optimum is kept safely down to a feedrate of 0.55 g/kWh.

To clean the piston rings, lands and ring grooves,

This relies on the detergency properties of the cylinder oil.
All approved cylinder oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh.

To control corrosion, i.e. control the neutralisation af sulphuric acid.

The combustion process creates highly corrosive sulphuric acids depending on the sulphur in the fuel.
It has therefore been of paramount importance to design the combustion chamber and the cylinder oil
so as to create the optimum balance of corrosion.

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 14 >

Adaptive Cylinder oil Control

ACC (Service Letter SL05-455)
MAN B&W Diesel

The ACC system feeds the oil proportionately to the engine load (which is proportional
to the fuel oil being burnt), and to the sulphur content in the fuel.

By dosing the amount of cylinder oil and, thereby, the amount of alkaline additives
proportionately to the total sulphur amount beeing burnt in the combustion chamber, a
constant low corrosion level can be achieved.

The experience gained so far from a large number of vessels operating at a feed
rate factor of 0.34 g/kWh x S% has been very positive.

Long term tests with first 0.29 g/kWh x S%and later 0.26 g/kWh x S% have been
succesful, indicating that an optimum lubrication level is witin the following algoritm:

F x S%
where F is in the range of 0.26 to 0.34 g/kWh

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 15 >

Adaptive Cylinder oil Control

ACC (Service Letter SL05-455)
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 16 >

2006-01-19

< 17 >

2006-01-19

< 18 >

Auxiliaries:
Cylinder Lubricators
MAN B&W Diesel

Minimum feed rate

Sulphur %
(0 5 %)

Feed rate factor F

(0.5 2.0 g/kWh)

(0.25 1.5)

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Adjustment of cylinder oil

lubrication
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Adjustment of cylinder oil

lubrication

2006-01-19

< 18 >

ME Lubrication Back Up Signal

S903-0031

In case of CCU failure (and the CCU can not be changed immediately), activation of the ME lubricator
can be achieved as follows.
Note: In case of CCU failure, the engine is running at Slow Down mode.
A temporary cable from ECU A or B plug J52 is connected to solenoid valve on the lubricator of the failing CCU.
See figure 1. The activation signal from J52 on ECUA/B is random.

LUBRICATOR
ACTIVATION
BACK UP

Fig. 1

OVDC
GND
IN/OUT
v_IN
24VDC

SOLENOID
VALVE
LUBRICATOR

+ECU A/B

A
B
C
D
C

+ECU A/B

J52

ME lubricator

=SOLENOID VALVE

S9030031C01

1x2x0,75 mm
WLUB_BACK UP

SOLENOID
VALVE
LUBRICATOR

When referring to this page, please quote S-Instruction S903 Edition 0031
MAN B&W Diesel A/S

Page 1

Emergency cylinder lubrication

MAN B&W Diesel

In case of CCU failure, where the

CCU cannot be changed
immediately, the cylinder lubrication
can be achieved by a temporary
cable from one of the ECU units,
plug 52, to the solenoid valve on
the lubricator on the unit in
question.

The lubrication will be with random

timing.

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 19 >

2006-01-19

< 20 >

Emergency cylinder lubrication

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Hydraulic Cylinder Unit

L70ME

HCU Distributer block

Double wall pipe
Double wall pipe

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 21 >

HCU - Valves
MAN B&W Diesel

Instructions
Valve No.

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 22 >

Hydraulic Cylinder Units (HCU)

MAN B&W Diesel

HCUs mounted on an common base plate.

Double wall
high pressure
pipe
High pressure oil inlet
from the HPS

MAN B&W Diesel

Hydraulic Cylinder Units

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 24 >

HCU return oil pipes

MAN B&W Diesel

Double bottom
base plate for HCU.
Return oil from the
HCUs is collected
here and via the
vertical pipes led
back to the
crankcase.

Return pipes from

HCU

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 25 >

2006-01-19

< 27 >

ME-C Engines
Doubble Wall Pipe
MAN B&W Diesel

Flange

Outer Pipe

Inner Pipe

Sealing ring

5. Sealing ring
6. Sealing ring
7. Sealing ring
8. Screw

MAN B&W Diesel

0902

(2600/RL)

Tool for high pressure doublepipe

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

Two-Stroke Diesel Engines.

MAN B&W Diesel

2500/KNB

April 2003.

Two-Stroke Diesel Engines.

MAN B&W Diesel

2500/KNB

April 2003.

Two-Stroke Diesel Engines.

MAN B&W Diesel

2500/KNB
Hydraulic

April 2003.
Cylinder
Unit - Tom Ballegard/4140

2006-01-19

< 30 >

Hydraulic Cylinder Unit (HCU)

Leakage
MAN B&W Diesel

Fuel oil pressure

booster

Exhaust valve actuator

Hydraulic
cylinder unit

Unit 1

MAN B&W Diesel

Unit 2

Safety and
Accumulator
Block

ELVA

ELFI

Unit 3

Unit 4

Unit 5

Unit 6

Hydraulic Cylinder Unit - Tom Ballegard/4140

Valve 315

2006-01-19

< 31 >

Hydraulic Cylinder Unit (HCU)

Leakage
MAN B&W Diesel

HCU

Leakage check between 2 HCUs:

Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block.
Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between.
Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining.
Mount a pressure gauge on minimesh coupling 435.
Close valve 315, and build up pressure in the inner pipe with the start-up pumps.
If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If
not, try the next pipe!
MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

< 32 >

HCU

MAN B&W Diesel

Hydraulic Cylinder Unit - Tom Ballegard/4140

2006-01-19

If the gauge shows pressure, congratulations, you have found the leaking double wall pipe. If
not, try the next pipe!

Close valve 315, and build up pressure in the inner pipe with the start-up pumps.

Mount a pressure gauge on minimesh coupling 435.

Drain the pressure in the outer double wall pipe by opening valve 431. Close it again after draining.

Close valve 430 on the 2 HCUs to isolate the outer double wall pipe in between.

Relieve pressure from the double pipe system by opening valve 315 on the Safety and Accu block.

Leakage check between 2 HCUs:

MAN B&W Diesel

Hydraulic Cylinder Unit (HCU)

Leakage

< 32 >

Therefore, we have revised our Guiding Cylinder Oil Feed Rates (see enclosures 1-3)
for the purpose of optimising the cylinder lube oil consumption (CLOC).
Cylinder lubrication demands
The purpose of cylinder lubrication is as follows:
1. to create a hydrodynamic oil film separating the piston rings from the liner,
2. to clean the piston rings, ring lands and ring grooves,
3. to control corrosion, i.e. control the neutralisation of sulphuric acid.
Re 1: The oil amount needed to create an oil film is more or less independent of the fuel oil being used. Measurements of the oil film have also
revealed that when the feed rate for optimum oil film is reached, no
further increase of the oil film is obtained from an increase of the feed
rate. This optimum is kept safely down to a feed rate of 0.55 g/kWh.
Re 2: Cleaning of piston rings, ring lands and grooves is essential, and relies
on the detergency properties of the cylinder oil. All approved cylinder
oils fulfil the requirements, even at a feed rate as low as 0.55 g/kWh.
Re 3: The combustion process creates highly corrosive sulphuric acids
depending on the sulphur in the fuel. It has therefore been of
paramount importance to design the combustion chamber and the
cylinder lube oil so as to create the optimum balance of corrosion.
Cylinder lubrication dosage
The optimal corrosion control is achieved by a combination of the cooling water design
of the cylinder liner, the sulphur content in the fuel, the cylinder lube oil alkalinity, and
our new lubrication principle, the ACC algorithm system (Adaptive Cylinder oil Control).
The ACC system feeds the oil proportionately to the load (which is proportional to the
fuel oil amount being burnt) and to the sulphur content in the fuel. By dosing the amount
of oil and, thereby, the amount of alkaline additives proportionately to the total sulphur
amount being burnt in the combustion chamber, a constant and controlled low corrosion
level can be achieved.
The experience gained so far from a large number of vessels operating at a feed rate
factor of 0.34 g/kWh x S% has been very positive.
However, long term tests with, first 0.29 g/kWh x S% and later 0.26 g/kWh x S%
have been successful, indicating that an optimum lubrication level is within the below
algorithm:
F x S%, where F is in the range of 0.26 to 0.34 g/kWh

ACC algorithm with a BN 70 cylinder oil:

1.70
1.60
1.50
1.30
1.20
1.10
1.00
0.90
0.80

,
70
BN

Average dosage: 0.8 g/kWh

he
,w
%
S

=
eF

[0.

/k W
4]g
3
.
0
26-

0.70
0.60

Average sulphur worldwide

Absolute dosage (g/kWh)

1.40

0.50
0.40
0.30
0.20
0.10
0.00
0

0.5

1.5

2.5

3.5

4.5

Sulphur %

On the world market, the average sulphur content in fuels for large two-stroke engines
is 2.7%. This would result in an average cylinder oil dosage of around 0.8 g/kWh.
The 0.8 g/kWh multiplied with the yearly production of kWh can be directly used in the
calculation of the yearly cylinder oil consumption.
The ACC principle, with the algorithm F x S% where F is in the range of 0.26-0.34
g/kWh, satisfies the need for neutralising additives. However, due to the physical need
for a certain amount of oil to create a hydrodynamic oil film, the present lower limit is set
in the range of 0.60-0.70 g/kWh, which according to the above diagram will be reached
with around 2% sulphur.
Running on fuels with a varying sulphur content
Although fuel sulphur levels above 4% are rather rare, running on high-sulphur fuels has
accounted for a major part of cylinder wear in the past. Therefore, increasing the oil
dosage according to the ACC algorithm is necessary, and very beneficial economically,
to prevent the excessive wear associated with such fuels.
However, on low-sulphur fuels, below 2% sulphur content, the engine will, according to
the above diagram, be overdosed with alkaline additives. This may lead to cylinder
condition problems and, in severe cases, to scuffing.

Overdosing with alkaline additives has two negative effects, which may both lead to
the so-called bore-polish phenomenon:

A surplus of alkaline additives has a strong tendency to accumulate

on the piston top land, and may grow in thickness to an extent where
it interferes with the cylinder liner running surface, in spite of the PC
ring (piston cleaning ring). This is most pronounced in the middle and
lower part of the liner (where the liner is exposed the least to heat)
and in the exhaust side (where the PC-ring is less effective). The
result of this negative effect is called mechanical bore-polish.

The other negative effect of overdosing with alkaline additives may be

that corrosion (so-called cold-corrosion) is suppressed completely,
thereby, limiting the necessary refreshment (open graphite
structure) of the liner surface. The result of this is called chemical
bore-polish. In other words, corrosion should be controlled rather than
prevented.

The occurrence of the above negative effects is time-dependent. This means that a
surplus of alkaline additives can be accepted for a certain period, depending on the
severity of the overdosing.
For example: when running on a fuel with 1% sulphur and using a normal BN 70
cylinder oil, theoretically, a dosage in the range of 0.26 to 0.34 g/kWh is called for
according to the ACC algorithm. However, in order to fulfil the lower limit set at 0.600.70 g/kWh for hydrodynamic reasons, the amount of additives applied is consequently
higher than needed. Such overdosing of alkaline additives should be limited to one or
two weeks, and to temporary running on low-sulphur fuels in restricted areas.
If low-sulphur fuels are used predominantly, we advise using a low-BN cylinder oil,
either a BN 40 or BN 50 oil.
The diagram overleaf shows the algorithm using a BN 40 cylinder oil versus a normal
BN 70 cylinder oil.

ACC algorithm with BN 40 versus BN 70 cylinder oils

1,70
1,60
1,50

Absolute dosages (g/kWh)

1,40
1,30
1,20
1,10
1,00
0,90
0,80

0,70

,F
40

h
,w
%
S

e
er

0
/4
70

34
0.
26
0.

,F
70
N
B

W
/k
]g

F
ere
h
,w
S%

h
kW
]g/
4
.3
6 -0
0.2

0,60
0,50
0,40
0,30
0,20
0,10
0,00
0

Sulphur %

Experience has shown that satisfactory running on fuels containing almost no sulphur
(gas oil, kerosene, etc.) can be obtained using a low-BN cylinder oil.
If a BN 40 cylinder oil is used, the ACC algorithm should be:
F x 70/40 x S%, where F is in the range of 0.26-0.34 g/kWh
If low-sulphur fuels are bunkered regularly, in-between normal or high-sulphur fuels, a
two-tank system should be considered, offering the possibility of changing between lowBN and normal-BN cylinder oils.
Questions or comments regarding this SL should be directed to our Dept. 2300.
Yours faithfully
MAN B&W Diesel A/S

Carl-Erik Egeberg
Encl.

Ole Grne

Encl. 1 for SL05-455/HRJ

Guiding Cylinder Oil Feed Rates

S/L/K-MC/MC-C/ME/ME-C, Mk 6 and higher, with Alpha ACC lubrication system

Basic setting

Standard BN 70 cylinder oil

BN 40 cylinder oil

0.26-0.34 g/kWh x S%
0.19-0.25 g/bhph x S%

0.26-0.34 g/kWh x 70/40 x S%

0.19-0.25 g/bhph x 70/40 x S%

Minimum feed rate

0.60-0.70 g/kWh
0.45-0.50 g/bhph

Maximum feed rate

during normal service

1.7 g/kWh
1.25 g/bhph

Part-load control

Running-in
new or
reconditioned
liners and
new piston
rings

Feed
rate:

Proportional to engine load

Below 25% load, proportional to MEP (Mean Effective Pressure)
Alu-coated or
hard-coated
piston rings:
Non-coated:

Engine
load:

First 5 hours:
From 5 to 250 hours:
From 250 to 500 hours:
First 15 hours:
From 15 to 250 hours:
From 250 to 500 hours:

1.7 g/kWh
1.5 g/kWh
1.2 g/kWh
1.7 g/kWh
1.5 g/kWh
1.2 g/kWh

Alu-coated or
hard-coated
piston rings:

Stepwise increase to max. load over 5 hours

Non-coated:

Stepwise increase to max. load over 15 hours

Running-in new rings in

already run-in and well
running liners:

Alu-coated or hardcoated piston rings

Non-coated rings
Feed rate

Manoeuvring and load

change situations.

During starting, manoeuvring and load changes, the feed rate

should be increased by 25% and kept at this level for hour after
the load has stabilised.

Lubrication of cylinders
that show abnormal
conditions:

Frequent scavenge port inspections of piston rings and cylinder

liners are very important for maintaining a safe cylinder condition.
If irregularities are seen, adjustments of the lube oil rate should be
considered.
In case of scuffing, sticking piston rings or high liner temperature
fluctuations, the feed rate should be raised by 25-50%.

HRJ/JCB
September 2005

: No load restrictions
: Stepwise increase to max. load over 5 hours
: Basic setting +25% for 24 hrs.

Encl. 2 for SL05-455/HRJ

Adjusting Alpha Lub. using ACC, BN 40 Cylinder Oil

ACC factor g/kWh x S%
0,26

0,27

0,29

0,30

0,31

0,33

0,34

g/kWh

HMI
setting

0
1,1
1,1
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,8
2,9
3,0

0
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,9
2,9

0,61
0,61
0,65
0,71
0,77
0,83
0,89
0,95
1,01
1,07
1,13
1,19
1,25
1,31
1,37
1,43
1,49
1,55
1,61
1,73
1,70

56
56
60
66
71
77
82
88
93
98
104
109
115
120
126
131
137
142
148
160
156

Sulphur content %
0
1,4
1,5
1,6
1,7
1,8
2,0
2,1
2,2
2,4
2,5
2,6
2,8
2,9
3,0
3,2
3,3
3,4
3,6
3,7
3,8

HRJ/JCB
September 2005

0
1,3
1,4
1,5
1,6
1,8
1,9
2,0
2,1
2,3
2,4
2,5
2,6
2,8
2,9
3,0
3,1
3,3
3,4
3,5
3,6

0
1,2
1,3
1,4
1,5
1,7
1,8
1,9
2,0
2,1
2,3
2,4
2,5
2,6
2,7
2,9
3,0
3,1
3,2
3,3
3,4

0
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
2,2
2,3
2,4
2,5
2,6
2,7
2,8
3,0
3,1
3,2
3,2

0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,8
2,9
3,0
3,1

Encl. 3 for SL05-455/HRJ

Adjusting Alpha Lub. using ACC, BN 70 Cylinder Oil

ACC factor g/kWh x S%
0,26

0,27

0,29

0,30

0,31

0,33

0,34

g/kWh

HMI
setting

0,0
0,5
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,9
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,8
2,9
3,0
3,1
3,2
3,3
3,4
3,5
3,6
3,8
3,9
4,0
4,1
4,2
4,3
4,4
4,5

0,0
0,5
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,8
2,9
3,0
3,1
3,2
3,3
3,4
3,5
3,6
3,7
3,8
3,9
4,0
4,1
4,2
4,3
4,4
4,5

0,60
0,60
0,60
0,60
0,60
0,60
0,60
0,60
0,60
0,60
0,60
0,65
0,68
0,71
0,75
0,78
0,82
0,85
0,88
0,92
0,95
0,99
1,02
1,05
1,10
1,12
1,16
1,19
1,22
1,26
1,29
1,33
1,36
1,39
1,43
1,46
1,50
1,53

56
56
56
56
56
56
56
56
56
56
56
59
63
66
69
72
75
78
81
84
88
91
94
97
100
103
106
109
113
116
119
122
125
128
131
134
138
141

Sulphur content %
0,0
0,5
1,0
1,1
1,2
1,4
1,6
1,8
2,0
2,2
2,4
2,5
2,6
2,8
2,9
3,0
3,2
3,3
3,4
3,6
3,7
3,8
3,9
4,1
4,2
4,3
4,5

HRJ/JCB
September 2005

0,0
0,5
1,0
1,1
1,2
1,4
1,6
1,8
2,0
2,2
2,3
2,4
2,5
2,6
2,8
2,9
3,0
3,1
3,3
3,4
3,5
3,6
3,8
3,9
4,0
4,1
4,3
4,4
4,5

0,0
0,5
1,0
1,1
1,2
1,3
1,4
1,6
1,8
2,0
2,1
2,3
2,4
2,5
2,6
2,7
2,9
3,0
3,1
3,2
3,3
3,5
3,6
3,7
3,8
3,9
4,0
4,2
4,3
4,4
4,5

0,0
0,5
1,0
1,1
1,2
1,3
1,4
1,6
1,8
1,9
2,0
2,2
2,3
2,4
2,5
2,6
2,7
2,8
3,0
3,1
3,2
3,3
3,4
3,5
3,6
3,8
3,9
4,0
4,1
4,2
4,3
4,4
4,5

0,0
0,5
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,8
2,0
2,1
2,2
2,3
2,4
2,5
2,6
2,7
2,8
2,9
3,0
3,2
3,3
3,4
3,5
3,6
3,7
3,8
3,9
4,0
4,1
4,2
4,3
4,5

5. Fuel System

MAN B&W Diesel

1) Fuel oil pressure

booster
2) Adjustments

MAN B&W Diesel

2006-01-26

<1>

ME Fuel Oil Pressure Booster

MAN B&W Diesel

S50MCS50MC-C

S50MES50ME-C

Fuel Plunger

Suction Valve

Fuel oil
oil inlet
pressure 8 bar

Feed back
Position sensor

Hydraulic actuator

7S50ME7S50ME-C

MAN B&W Diesel

2006-01-26

<2>

2006-01-26

<3>

98ME(-C) Fuel Oil Pressure Booster

MAN B&W Diesel

01-10-2003

(2500/KNB)

Fuel Injection System

MAN B&W Diesel

High pressure pipe

Suction valve

Slide Fuel
valve

Fuel plunger
Fuel oil inlet
8 bar
Hydraulic piston
Membrane
accumulator

ELFI / FIVA
Proportional
Valve

7S50ME7S50ME-C
To drain

High pressure hydraulic oil - inlet

MAN B&W Diesel

2006-01-26

<4>

Fuel Oil Injection

MAN B&W Diesel

Phase 1
1.

The pistons move to the bottom position.

The fuel inlet is open.

Hydraulic oil leaves the hydraulic oil

chamber via the ELFI valve.

The accumulators are supplied by the

Hydraulic Power Supply. The pressurised
hydraulic oil is held back by the closed ELFI
valve.

ELFI
Valve

Unpressurised fuel oil

Pressurised fuel oil
Unpressurised hydraulic oil
Pressurised hydraulic oil

MAN B&W Diesel

2006-01-26

<5>

Fuel Oil Injection

MAN B&W Diesel

Phase 2
5.

The ELFI valve is activated upwards, closing

the return flow and opening for the flow of
pressurised hydraulic oil. The oil passes
through the ELFI valve and fills the hydraulic
chamber.

The high pressure forces the pistons

upwards.

The fuel oil inlet is closed.

The pressure on the fuel oil rises and

exceeds the force of the spring in the
cylinders fuel injection valve.

ELFI
Valve

Unpressurised fuel oil

Pressurised fuel oil
Unpressurised hydraulic oil
Pressurised hydraulic oil

MAN B&W Diesel

2006-01-26

<6>

Fuel index adjusment

MAN B&W Diesel

Index offset at 100 % load

Index offset at 0 % load

Individual Chief limiter

MAN B&W Diesel

2006-01-26

<7>

Adjustment of maximum pressure

MAN B&W Diesel

Timing of fuel injection

(corresponding to VIT
adjustment on the MC
engine)

MAN B&W Diesel

2006-01-26

<8>

Hydraulic Cylinder Unit

L70ME
MAN B&W Diesel

Hydraulic pushrod

Exh. Valve actuator

Fuel Oil Pressure Booster

Double wall pipe

MAN B&W Diesel

Fuel oil pressure booster - Tom Ballegaard/4140

2006-01-26

<9>

Fuel Oil Pressure Booster, S70ME

MAN B&W Diesel

Fuel oil pressure booster - Tom Ballegaard/4140

2006-01-26

< 10 >

2006-01-26

< 11 >

2006-01-26

< 12 >

Suction Valve, S70ME

MAN B&W Diesel

Fuel oil pressure booster - Tom Ballegaard/4140

Fuel Oil Pressure Booster

Maintenance manual, S70ME
MAN B&W Diesel

Fuel pump:
Pump housing nuts, tightening torque:

1000 Nm

Pump housing, weight:

160 kg

Top cover studs, screwing in torque:

270 Nm

Fuel pump complete, weight:

322 kg

Hydraulic plunger, weight:

38 kg

Top cover:
Top cover nuts, tightening torque:

410 Nm

Outlet seat, max grinding diameter:

26 mm

Top cover, weight:

124 kg

Suction valve:
Suction valve, tightening torque:

MAN B&W Diesel

Fuel oil pressure booster - Tom Ballegaard/4140

460 Nm

Fuel Oil Pressure Booster, K98ME

MAN B&W Diesel

Fuel oil pressure booster - Tom Ballegaard/4140

2006-01-26

< 13 >

2006-01-26

< 14 >

2006-01-26

< 15 >

Suction Valve, K98ME

MAN B&W Diesel

Fuel Oil Pressure Booster

Maintenance manual, K98ME
MAN B&W Diesel

Fuel pump:
Hydraulic pressure mounting:

2200 bar

Hydraulic pressure dismantling:

2000 2400 bar

Booster housing, weight:

260 kg

Booster complete, weight:

700 kg

Hydraulic plunger, weight:

70 kg

Top cover:
Fuel plunger weight:

35 kg

Top cover, weight:

260 kg

Suction valve:
Suction valve, tightening torque:

MAN B&W Diesel

1165 Nm

6. Exhaust System

B&W MAIN OFFICE COPENHAGEN

ME EXHAUST VALVE

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<1>

MAN B&W Diesel

<2>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<3>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<4>

2006.01.16

(4140 / PWN)

<6>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<5>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<7>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

<8>

MAN B&W Diesel

Hydraulic
push rod

Exhaust valve
Actuator

Exhaust valve
spindle

High pressure
hydraulic oil
inlet
ELVA on-off
valve

Membrane
accumulator

To drain
MAN B&W Diesel

2006.01.16

(4140 / PWN)

<9>

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 10 >

The ME Engine
Exhaust Valve Timing

ME Exhaust Valve & Actuator

MAN B&W Diesel

mm
80

Early opening
Late opening

Reference

Early closing
Late closing

70
60
50
40
30
20
10
0
90 110 130 150 170 190 210 230 250 270 290
Dg. C. A.
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 11 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 12 >

Hydraulic Cylinder Unit

Hydraulic Cylinder Units (HCU)

MAN B&W Diesel

HCUs mounted on an common base plate.

Fuel oil
Pressure Booster
Hydraulic Exhaust
Valve Actuator

ELFI
Proportional Valve

ELVA
On/Off Valve

Double wall high

pressure pipe

Distribution Block

High pressure oil inlet

from the HPS
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 13 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 14 >

Two-Stroke Medium Bore

ME Engine, Design Concept

HCU
MAN B&W Diesel

MAN B&W Diesel

HCU Unit 60ME-C.

Hydraulic pushrod

Fuel Pump

Exhaust Valve Actuator

Exh. Valve actuator

Elva
Elfi

ELVA valve

Alpha Lubricator

Double wall pipe

Plug Valve

Common supply of HP Oil

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 15 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 16 >

Exhaust Valve Actuator

Actuator for Exhaust Valve

MAN B&W Diesel

The ELVA valve which drives the actuator

on the exhaust side has two positions,
open or shut.
Actuator

When it is opened with a binary signal from the

engine control system, the hydraulic oil is
forced in and pushes the pistons upwards,thus
opening the engines exhaust valve via the
hydraulic push rod.

ELVA

Mounted on top of the distributor block.

Hydraulic push rod for opening/closing

the exhaust valve

Two-stage piston.
Second stage

The pressure is permanently maintained

until the ELVA valve is activated to block
the pressure when the required exhaust phase
is completed.

First stage

The exhaust valve is returned to its closed

position by the force from the air spring.

High pressure oil inlet

Unpressurised hydraulic oil

Pressurised hydraulic oil
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 17 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 18 >

S70me-c

ME Exhaust Valve

MAN B&W Diesel

S50MC-C

Exhaust Actuator

S50ME-C
Air spring size
for closing the
exhaust valve
reduced

Top cover
Minimesh
Actuator house

Hydraulic damper for

fixed valve stroke
introduced

Actuator Piston
New valve spindle
design introduced

1. Step

2.Step

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 19 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 20 >

Exh. Valve
MAN B&W Diesel

MAN B&W Diesel

Feed back sensor

Oil inlet to damper

Drain pipes

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 21 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 22 >

2006.01.16

(4140 / PWN)

< 24 >

ME Exhaust Valve
MAN B&W Diesel

MAN B&W Diesel

Self-adjusting damper piston

Hydraulic nut/measuring cone

Contact less sensor with
integrated electronics

Outlet lube oil

Inlet lube oil

Damper

Air inlet

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 23 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 25 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 26 >

Safety Valve
MAN B&W Diesel

MAN B&W Diesel

Safety Valve:
Adjustment of opening
pressure: 21 bar

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 27 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 28 >

ME Exhaust valve
S50MC-C

S50ME-C
Air spring
size for
closing the
exhaust valve
reduced.

Hydraulic damper for

fixed valve stroke
introduced.

New valve spindle

introduced.

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 29 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 30 >

Exhaust Valve Top

Exh. Valve
MAN B&W Diesel

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 31 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 32 >

2006.01.16

(4140 / PWN)

< 34 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 33 >

MAN B&W Diesel

Spindle Rotation Check

MAN B&W Diesel

Rod for checking spindle rotation

Reaches contact with the air
piston by activation.

Note!
The rod must only be activated
for shorter periods

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 35 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 36 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 37 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 38 >

2006.01.16

(4140 / PWN)

< 40 >

2006.01.16

(4140 / PWN)

< 42 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 39 >

MAN B&W Diesel

Tightening of Damper on
Exhaust Valve Spindle
MAN B&W Diesel

MAN B&W Diesel

Hydraulic Jack
& Support
Damper
Air Piston

Spindle

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 41 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 43 >

MAN B&W Diesel

Dismantling of High Pressure Pipe

2006.01.16

(4140 / PWN)

< 44 >

Hydraulic Cylinder Unit (HCU)

MAN B&W Diesel

Valve actuation
Be sure that the
area around the
working space is
completely clean
before and during
dismantling of the
hydraulic system.

ELVA On/Off Valve

Exhaust Valve Actuator

Shut off the oil supply.

Close valve 420

and
open valve 421
Distribution Block
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 45 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 46 >

Dismantling of High Pressure Pipe

Hydraulic Cylinder Unit (HCU)

MAN B&W Diesel

Fuel injection

Valve actuation

ELFI Proportional Valve

Close the valve 531 for

Fuel Pump

the actuator oil supply

ELVA On/Off Valve

Exhaust Valve Actuator

and
the valve 536
for damper oil supply.

Accumulator
MAN B&W Diesel

2006.01.16

Distribution Block

(4140 / PWN)

< 47 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 48 >

Dismantling of High Pressure Pipe

Overhaul of High Pressure Pipe

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 49 >

MAN B&W Diesel

Overhaul of High Pressure Pipe

2006.01.16

(4140 / PWN)

< 50 >

Mounting of High Pressure Pipe

MAN B&W Diesel

Open the valve 531 for

the actuator oil supply
and
the valve 536 for
damper oil supply.

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 51 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 52 >

Exh. Valve Sealing Air / Oil Dosage Unit

Mounting of High Pressure Pipe

MAN B&W Diesel

Close valve 421

and
open valve 420

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 53 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 54 >

Sealing Oil system.

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 55 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 56 >

2006.01.16

(4140 / PWN)

< 58 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 57 >

MAN B&W Diesel

Exhaust Valve Sealing Oil Dosage Unit

MAN B&W Diesel

1. Vertical cross section, pressure low

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

Spring tension
4 5 bar

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 59 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 60 >

Exhaust Valve Sealing Oil Dosage Unit

MAN B&W Diesel

4. Pressure decreasing. Needle charge not released yet.

3. Pressure high. Needle connected to input and charged with oil.

Spring tension
4 5 bar

10 15 bar
oil pressure.
MAN B&W Diesel

2006.01.16

10 15 bar
oil pressure.

(4140 / PWN)

< 61 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 62 >

2006.01.16

(4140 / PWN)

< 64 >

2006.01.16

(4140 / PWN)

< 66 >

Exhaust Valve Sealing Oil Dosage Unit

MAN B&W Diesel

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

Spring tension
4 5 bar

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 63 >

MAN B&W Diesel

Grinding set-up
for
exhaust spindle.

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 65 >

MAN B&W Diesel

Small dent marks on the

seating are acceptable
and need NOT to be
ground away if they dont
make blow-by.

K98MC/ME

Small dent marks on the spindle seating are acceptable and

need NOT to be ground away if they dont make blow-by.
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 67 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 68 >

2006.01.16

(4140 / PWN)

< 70 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 69 >

MAN B&W Diesel

MC EXHAUST VALVE
MAN B&W Diesel

MAN B&W Diesel

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

1983 - 1992:
26 - 50 MC
60 - 90 MC

Cooled Alloy 50
Cooled Stellite 6

1992 1997:
26 - 50 MC
Cooled Alloy 50
60 - 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
46 - 98 MC

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 71 >

MAN B&W Diesel

2005.05.25

4140/PWN

Cooled W-seat
Semi-cooled W-seat

< 72 >

MAN B&W Diesel

Exhaust Valve Spindle &

Bottom Piece 98MC/MC-C 26MC

MC EXHAUST VALVE
Chamber seat

MAN B&W Diesel

The longer lifetime on the seat area is achieved

with the new geometry of the W-seat, which
retains the temperature reducing features of the
chamber seat and combines them with the
benefit of the two narrow concentric contact
areas.

W-seat

The effect is that all carbon particles which are

trapped between the spindle and bottom piece
are crushed and squeezed out and therefore
eliminated without giving rise to any appreciable
risk 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.

MAN B&W Diesel

2005.05.25

4140/PWN

< 73 >

MAN B&W Diesel

2005.05.25

4140/PWN

< 74 >

2005.05.25

4140/PWN

< 76 >

2005.05.25

4140/PWN

< 78 >

MAN B&W Diesel

2005.05.25

4140/PWN

< 75 >

MAN B&W Diesel

16,000 h between overhauls

60-100,000 h lifetime for spindle
> 30,000 h lifetime for bottom piece

MAN B&W Diesel

2005.05.25

4140/PWN

< 77 >

MAN B&W Diesel

If water leaks from

between valve seat
and cylinder cover
the upper sealing ring
must be changed.

If water leaks from

one or both holes
the lower sealing ring
must be changed.
MAN B&W Diesel

2005.05.25

4140/PWN

< 79 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 80 >

Bottom Piece
Design
MAN B&W Diesel

MAN B&W Diesel

Exhaust Valve Small/medium bore

References of W-seats
running for more than 36000
hours without any grinding
and only very small dent marks
New seal for
bottom piece
lower groove

Hole for indication of cooling

water leakage from the
lowermost sealing ring or gas
leakage from the combustion
chamber
U-type sealing ring
(Teflon with a spring
back-up)
Connect compressed air to the
air spring to keep the exhaust
valve closed during mounting

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 81 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 82 >

2006.01.16

(4140 / PWN)

< 84 >

Bottom Piece W-Seat

MAN B&W Diesel

U-Type Sealing Ring:

Heat the sealing ring in 100C hot
water for at least five minutes
before mounting

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 83 >

MAN B&W Diesel

MC EXHAUST VALVE

Valve spindle for engine types: K/L/S-MC/-C/-S

Cr
(0.25 mm)
HVOF (0.15 mm)

Nimonic

1983 - 1992:
26 - 50 MC
60 - 90 MC

Alloy 50
Stellite 6

1992 2002:
26 - 50 MC
S50MC / 60 - 98 MC

Alloy 50
Nimonic

2002 - :
26 - 50 MC
S50MC / 60 - 98 MC

DuraSpindle
Nimonic

SNCrW

Alloy 50

1983 1996:

Cr stem coating

Stellite 6
1996 - :

HVOF stem coating

(INCO 625 on request)

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 85 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 86 >

Exhaust Valve Nimonic Spindle

MAN B&W Diesel

Formation of dent marks is an

inevitable consequence of service on
heavy fuel oil.
Dent marks may appear harmful, but
will in general have no influence on
the performance of the exhaust valve
seat.

HVOF-coating

If indications of blow-by are found,

then the seat must be ground.
Vane wheel for gas
driven spindle rotation

Base Material: Nimonic 80A

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 87 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 88 >

2006.01.16

(4140 / PWN)

< 90 >

Design Features
MAN B&W Diesel

MAN B&W Diesel

HVOF: High Velocity Oxy-Fuel Process

Coating applied on the

exhaust valve stem only

Highly wear-resistant mixture

of metal carbide and super alloy

Thermally sprayed coating

Thickness: about 0.25 mm

This process is performed by:

MAN B&W Copenhagen

MAN B&W Singapore

MAN B&W Hamburg

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 89 >

MAN B&W Diesel

Exhaust Valve Nimonic Spindle

MAN B&W Diesel

Formation of dent marks is an

inevitable consequence of service
on
heavy fuel oil.
Dent marks may appear harmful, but
will in general have no influence on
the performance of the exhaust
valve
seat.

HVOF-coating

Vane wheel for gas

driven spindle rotation

If indications of blow-by are found,

then the seat must be ground.
Base Material: Nimonic 80A

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 91 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 92 >

2006.01.16

(4140 / PWN)

< 94 >

MC EXHAUST VALVE
MAN B&W Diesel

MAN B&W Diesel

Valve spindle stem sealing ring

HVOF - ring

Cr - ring

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 93 >

MAN B&W Diesel

MAN B&W Diesel A/S

Rolled exhaust valve spindles

MC EXHAUST VALVE

MAN B&W Diesel

DuraValve

Welding and rolling preparation of DuraSpindle

Welded Ni-base alloy

10 t

Inconel 718 / Rene220

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 95 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 96 >

Exhaust valve Rolling equipment

MC EXHAUST VALVE

MAN B&W Diesel

Rolled seat area of 50MC DuraSpindle

Background
The roller is pressed against a rotating spindle at a
pressure of 10 tons. The combination of the deformation
and the subsequent heating in the oven imparts a
hardness to the interial which has not been seen before.
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 97 >

MAN B&W Diesel

MC EXHAUST VALVE

2006.01.16

(4140 / PWN)

< 98 >

MC EXHAUST VALVE

MAN B&W Diesel

Section of rolled and heat treated 35 MC DuraSpindle seat

Nimonic spindle &

chamber seat, S60MC,
25.500 service hrs

DuraSpindle &
chamber seat, S60MC,
33.900 service hrs

Hardness distribution of section

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 99 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 100 >

2006.01.16

(4140 / PWN)

< 102 >

MC EXHAUST VALVE
MAN B&W Diesel

MAN B&W Diesel

Nimonic spindle & W-seat,

S60MC, 25.500 service hrs

DuraSpindle & W-seat,

S60MC,33.900 service hrs

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 101 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 103 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 104 >

2006.01.16

(4140 / PWN)

< 106 >

2006.01.16

(4140 / PWN)

< 108 >

Exhaust Valve Bottom Piece

MAN B&W Diesel

K98MC, K98MC-C
Original design

Modified design

New tool for handling

(instead of bolt assembly)
2 pcs.

Increased diameter
0.15 taper

Hardened
W-seat

MAN B&W Diesel

2006.01.16

(4140 / PWN)

Decreased
diameter

< 105 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 107 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 109 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 110 >

2006.01.16

(4140 / PWN)

< 112 >

2006.01.16

(4140 / PWN)

< 114 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 111 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 113 >

MAN B&W Diesel

Design Features
MAN B&W Diesel

MAN B&W Diesel

HVOF: High Velocity Oxy-Fuel Process

Coating applied on the

exhaust valve stem only

Highly wear-resistant
mixture of metal carbide
and super alloy

Thermally sprayed coating

Thickness: about 0.25 mm

This process is performed by:

MAN B&W Copenhagen

MAN B&W Singapore

MAN B&W Hamburg

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 115 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 116 >

SPECIAL RUNNING CONDITIONS

MAN B&W Diesel

IF
running with
an open
exhaust valve
THEN.
Mount pressure gauge at
minimess point 455
Check that the HCU is
pressure free.

421
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 117 >

MAN B&W Diesel

SPECIAL RUNNING CONDITIONS

2006.01.16

Close valve 420

Open valve 421

(4140 / PWN)

< 118 >

SPECIAL RUNNING CONDITIONS

MAN B&W Diesel

Connect the mini-mesh

hose between top
flange on actuator
point 540 and point 425
at the hydraulic block

1. Open valve 420

421
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 119 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

2. Close valve 421

< 120 >

98ME Special Running

MAN B&W Diesel

Close valve 531

Shut off oil to damper
Close valve 420

Open valve 421

Mount pressure gauge at minimess point 455
Check that the HCU is pressure free.
MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 121 >

MAN B&W Diesel

98ME Special Running

2006.01.16

(4140 / PWN)

< 122 >

98ME Special Running

MAN B&W Diesel

Disconnect air supply to air cylinder

Drain off air pressure from

air cylinder with a mandrel

Remove plug screw and mount

tools to keep exhaust valve open

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 123 >

MAN B&W Diesel

98ME Special Running

2006.01.16

(4140 / PWN)

< 124 >

98ME Special Running

MAN B&W Diesel

Open damper oil supply

Reconnect air supply

under air piston

Mount pressure gauge at minimess point 455

Check that the HCU is pressure free.

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 125 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 126 >

98ME Special Running

MAN B&W Diesel

Remove the tools which kept the

Disconnect air supply to air cylinder

Open damper oil supply, valve 531

exhaust valve open and mount

Reconnect air supply
under air piston

the plug screw.

Open valve 420

Drain off air pressure from
air cylinder with a mandrel

Close valve 421

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 127 >

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 128 >

MAN B&W Diesel A/S

MAN B&W Diesel

Thank you for

your attention
Preben Noeies

MAN B&W Diesel

2006.01.16

(4140 / PWN)

< 129 >

7. MOP Displays

MAN B&W Diesel

Going through all screens:

Alarms
Engine:
Auxiliaries
Maintenance
Admin
MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

<1>

2006-01-05

<2>

2006-01-05

<3>

Engine:
Operation
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Access Level
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Engine:
Status
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

<4>

2006-01-05

<5>

2006-01-05

<6>

Engine:
Process Information
Running Mode

MOP displays - Tom Ballegaard/4140

Engine:
Process Information
Speed Control

MOP displays - Tom Ballegaard/4140

Engine:
Cylinder Load
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

<7>

2006-01-05

<8>

2006-01-05

<9>

Engine:
Cylinder Pressure
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Auxiliaries:
Hydraulic System
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Auxiliaries:
Scavenge Air
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

< 10 >

2006-01-05

< 11 >

2006-01-05

< 12 >

Auxiliaries:
Cylinder Lubricators
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Maintenance:
System View, I/O Test
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

MAN B&W Diesel

Maintenance:
System View, I/O Test
ECU-A

MOP displays - Tom Ballegaard/4140

2006-01-05

< 13 >

2006-01-05

< 14 >

2006-01-05

< 15 >

Maintenance:
System View, I/O Test
ECU-A, Channel-35

MOP displays - Tom Ballegaard/4140

Maintenance
Invalidated Inputs
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Maintenance
Network Status
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

< 16 >

2006-01-05

< 17 >

2006-01-05

< 18 >

Admin.:
Version
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Admin.:
Set Time
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Alarms:
Alarm List
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

< 19 >

2006-01-05

< 20 >

2006-01-05

< 21 >

Alarms:
Alarm List
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Alarms:
Event Log
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

Alarms:
Manual Cut-Out List
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

2006-01-05

< 22 >

2006-01-05

< 23 >

Alarms:
Channel List
MAN B&W Diesel

MAN B&W Diesel

MOP displays - Tom Ballegaard/4140

8. PMI

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

2006-02-19

<1>

2006-02-19

<2>

2006-02-19

<3>

PMI system
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

PT diagram
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

PT diagram - zoomed
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

2006-02-19

<4>

2006-02-19

<5>

2006-02-19

<6>

PV diagram
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

Balanced plot, Pmax - Pcomp

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

Balanced plot, Pi
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

2006-02-19

<7>

2006-02-19

<8>

Calculated values
MAN B&W Diesel

MAN B&W Diesel

PMI system - Tom Ballegaard / 4140

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