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Hydraulic Cylinder Unit

Unit, HCU
HCU.

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H d
Hydraulic
li Cylinder
C li d Unit.
U it

1)) Distribution Block

2) Components:
FIVA
Accumulators
Cylinder Lubricator

3) Highpressure Pipes

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H d
Hydraulic
li Cylinder
C li d Unit,
U it HCU.
HCU
Accumulator
Exhaust Valve
Actuator

Fuel Oil
Pressure
booster
FIVA valve
Ball Valve
Distribution Block
Cylinder Lubricator
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Hydraulic Cylinder Unit,

HCU Di
Distribution
t ib ti
Block.
Bl k
Seen from Exhaust Side

Seen from Man. Side

MAN Diesel & Turbo

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Hydraulic Cylinder Unit, HCU

L70ME

Distribution block
Double wall pipe
Double wall pipe

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Hydraulic Cylinder Unit,

HCU Hydraulic Diagram.

Inlet Valves
MAN Diesel & Turbo

Drain Valves
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Hydraulic Cylinder Unit,

HCU Valve
Val e Operation.
Operation
405 : Drain valve for FIVA valve
406 : Drain valve for FIVA valve
420 : Main supply valve of high pressure
oilil tto FIVA valve
l
421 : Drain valve for distribution block
430 : Valve for double wall pipe leakage
detection
431 : Drain valve for outer pipe oil
455 : Mini-mess
Mini mess coupling for measurement
of the oil pressure (high pressure side)
560 : Supply valve of high pressure oil to
ME llubricator
bi t

560
406
421 455
405
420
430

431

Valve position during normal operation

405

406

420

421

430

431

560

Closed

Closed

Open

Closed

Open

Closed

Open

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Hydraulic Cylinder Unit,

Hydraulic Diagram 300 bar
bar.

MAN Diesel & Turbo

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Hydraulic Cylinder Unit,

HCU Valves.
Valves

I t ti
Instructions
Valve No.

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Hydraulic Cylinder Unit,

HCU Cautions

CAUTION

CAUTION

HCU OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 420, 531
2. OPEN VALVE NO. 421, 405, 406
3.CHECK PRESSURE AT MEASURING
POINT 455.
455
WARNING NEVER OPEN VALVE
420 WHEN SYSTEM PRESSURE IS
ON

LUBRICATION OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 560
2. CHECK PRESSURE AT MEASURING
POINT 565
3 IF PRESSURE IS PRESENT,
3.
PRESENT PRESS
THE PRE-LUB BOTTON AT THE HMI
PANEL.

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FIVA Valves

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FIVA
Fuel Injection Valve Actuation
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
g
the timing
g of injection
j
is variable and this is jjust an example.
p

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MAN Diesel FIVA.

Pilot Valve

Feed Back Sensor

Control
Piston

Main Spool
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FIVA Spool Positions.

Positions

Main Spool Position

Feedback from
LVDT Sensor

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Accumulator
Diaphrame Working Principle.
Diaphrame,
Principle

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Accumulator
Nit
Nitrogen
Ch
Check,
k SL06
SL06-469.
469
The accumulator
Th
l t charge
h
pressure should
h ld b
be
checked within the first week of service.
Next check should be made around 4
months
th llater,
t ffollowed
ll
db
by checking
h ki every 6
months.
A minor leakage from the accumulators is
unavoidable and service experience shows
unavoidable,
that a pressure drop in the range of 2-5
bar/month is to be expected.
The charge pressure is dependent on
working servo oil pressure as well as the
accumulator temperature.
For the 200 bar HPS accumulator charging
pressures are:
95 bar +0/-5 @ 20C
105 bar +0/-5 @ 50C

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Cylinder Lubrication System.

System

MAN Diesel & Turbo

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Cylinder Liners.
Liners
Injection nozzle

Injection nozzle
with non-return
valve

MAN Diesel & Turbo

3331050/20031212

(CBO/4100)

Cylinder liner

Author

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ME Cylinder Lubricator.
Lubricator
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
lub.
injectors

Injection plunger

Spacer for
basic setting of
pump
stroke
Non-return valve

Stroke
adjusting
screw

Drain
oil
outlet

200 bar system oil supply

Actuator
piston

Sealingring

MAN Diesel & Turbo

3331377/20041021

(2200/OZS)

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Cylinder Lubricator
Lubricator.

Distribution Block

Cylinder Lubricator

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Cylinder Lubrication Demands.

Demands

The purposes of cylinder lubrication are as follows:

1
1.

To create a hydrodynamic oil film separating the piston rings from the liner
The optimum is kept safely down to a feedrate of 0.60 g/kWh.

2.

To clean the piston rings, lands and ring grooves

All approved cylinder oils fullfils the requirements, even at a feed rate as low as 0.60 g/kWh.

3.

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

According to latest Service Letter (SL2013-571) Feedrate Factor and Minimum Feedrate have to be
adjusted to 0.20
0 20 0.34
0 34 g/kWhxS% x S% and 0.60
0 60 g/kWh

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Liner wear rate as a function of lube oil dosage

Highweardueto
ooilstarvation
(boundarylub
brication)

0,9

0,8

Lin er Wear (mm

m/1000h)

Forr training
oses only
purpo

Optimising the Cylinder Condition.

Lubrication versus Maintenance
Maintenance.

0,7

0,6

0,5

0,4

0,3
0.10 mm/1000h
0,2
0 05 mm/1000h
0.05
0,1

0.02 mm/1000h

0
03
0,3

04
0,4

05
0,5

06
0,6

07
0,7

08
0,8

09
0,9

11
1,1

12
1,2

13
1,3

14
1,4

15
1,5

16
1,6

Lube Oil Dosage (g/kWh)

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H
How
tto d
determine
t
i ACC ffactor.
t

Prerequisite for correct determination of

ACC factor = Feed Rate factor

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Sulphur % in relation to BN number.

SL2013 571
SL2013-571

Fuel type
yp
BN
Distillate and LNG
<= 40
Low Sulphur residual fuel
40 - 60
High Sulphur residual fuel Mk 6 - 8
55 - 100
High Sulphur residual fuel Mk 9 or newer 70 - 100

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Scaling the ACC factor

factor.

3 % S
S. BN 70

A A
A

A
A

3
3%S
S. BN 40

A
A

A
A

0.6
0 6 g/kWh

A
A

A
A

A
A

A
A

A
A
0.6 g/kWh

F = 70/40 =1.75
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ACC Dosages calculated from different Feedrate

Factors (SL2013-571,
(SL2013 571 Min Feedrate =0
=0.6
6 g/kWh)

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Lubricator part load break point

point.

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Two ways to ACC factor

factor.

1: ACC familiarsation.
Adjust according to piston ring and liner wear.
wear
Use oil analysis to evaluate.
.
2: Adjust according to Feed Rate sweep.
Adj
Adjust
according
di to oilil analysis.
l i

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Piston ring and liner wear

wear.

CPR-POP

Liner wear

CPR-CL
CPR CL
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Piston ring wear.

SL2013 571
SL2013-571.

CPR-CL

CPR-POP

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Analysis Safe Area.

SL 2013-571.
2013 571

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Graph to find the perfect Feed Rate

g
setting.
SL 2013-571

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Running in SL2013-571.
Breaking in.
in

MAN Diesel & Turbo

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Forr training
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ACC Running in schedule.

SL 2013-571.
2013 571

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ACC Cylinder Lubrication.

Lubrication

Minimum feed rate

Sulphur %
Feed rate factor F
F

Fixed Feed rate

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Correction Tables
Tables.

When operating the

Lubrication from MOP
without updated software,
the system will not allow
the Feed Rate Factor to be
adjusted below
0.25g/kWhxS%.

Running
g with Feed Rate Factor
0.20g/kWhxS% (Normal Running)
[Correction factor: 0.20/0.26=0.77]

Running
g with Feed Rate Factor
0.23g/kWhxS% (Running In)
[Correction factor: 0.23/0.26=0.88]

To ensure correct lubrication

oil dossage correspondig
to Feed Rate Factor
g 0,20
, or
settings
0,23g/kWhxS, the factor
has to be adjusted to
g
in the
0.26g/kWhxS%
MOP and correction on the
sulphur content in the fuel
oil (S%) has to be done
according to the
Correction Tables.
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Cylinder Lubrication Back-up.

Back up

MAN Diesel & Turbo

Author

In case of CCU failure, where the

CCU cannot be changed
immediately the cylinder lubrication
immediately,
can be achieved by a temporary
cable from one of the ECU units,
plug 52
52, to the solenoid valve on
the lubricator on the unit in
question.
Th lubrication
The
l b i ti will
ill b
be with
ith random
d
timing.

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Cylinder Lubrication Back-up.

Back up

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HCUs Mounted on a Common Base Plate.

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

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purpo

Hydraulic Cylinder Units

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HCU Line,
Line 300 Bar
Bar.

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Double Wall Piping,

Piping Sealings.
Sealings

Sealingrings
Screws

Flange
Fl
Outerpipe
InnerPipe

Sealing
rings
SlideBearings

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Double Wall Pipe.

Pipe

MAN Diesel & Turbo

2500/KNB

April 2003.

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Leak Detection

1.
2.
3.
4.
5
5.
6.

MAN Diesel & Turbo

CLOSE the valve 430 at the last but one Hydraulic Cylinder Unit.
OPEN the valve 431 at the last HCU to decrease the p
pressure in the space
p
between the inner and outer pipe.
CLOSE the valve 431 at the last HCU again.
Check the pressure increase in the space between at pos. 435, at the last HCU
If the pressure increases to system pressure level
level, the leakage has been found
found.
When the leakage has been eliminated, bring all the valves to their normal
position.

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Disclaimer
All data provided in these training materials is non-binding.
This data serves informational purposes only and is especially not
guaranteed in any way
way.
Depending on the subsequent specific individual projects, the relevant
data may be subject to changes and will be assessed and determined
i di id ll ffor each
individually
h project.
j t Thi
This will
ill d
depend
d on th
the particular
ti l
characteristics of each individual project, especially specific site and
operational conditions.

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Learning Objectives
The learning objective(s) of this training unit is (are) as follows:

Objective 1
Objective 2
Objective
j
3
.
.

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Qualification
The qualification of our trainees is
realised

Qualification 1
Qualification 2
Qualification 3
...
...

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MAN PrimeServ Academy

The PrimeServ Academy offers a
wide range of

Item 1
Item 2
Item 3
.

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Source Information
Release History
Module Topic changed

Changed
by

Change
Date

Approved
by

Approval
Date

Template updated

Michael
Johns

10042012

Name

Date

Template updated, SL2013-571

Michael
Johns

19062013

Name

Date

Name

Date

Name

Date

Name

Date

Name

Date

Topic 3
Topic 4
Related docs:
Handout (to be included via Hyperlink)

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