fuel inj # 1

2006/09/09 MAN Diesel A/S

FUEL OIL SYSTEM


Performance Fuel Valve Design

L/9902-3.1/0202 (2410/SBJ)


Performance


K98MC-C Atomizer.

Transparent view Outside view Inside view


Marks and Stamps on Fuel Valve NozzleMC 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 componentwith 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.

Example of marking:

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


Spindle Guide for Slide Valve


Compound Fuel Valve Nozzle.


CFD Calculated Temperatures

Boundary conditionfor FEM analysis


L/74071-7.0/0302 (2410/SBJ)

K90MC Nozzle

Steel nozzle BWPS1 nozzle

CFD calculatedtemperature field

Measuredtemperature field


Vacuum Brazingof Compound Fuel Valve Nozzle

Brazing preparation Vacuum brazing Nozzle blank

Inconelpowder

Brazingalloypowder

Brazing alloy powderInfiltrating Inconel powder

H13 tool steel H13 tool steel


Compound Fuel Valve Nozzle

25000 blanks are produced

Approximately 50 % are in service

Not a single fracture has been experienced

Standard on all new engines

All slide valve atomizer Compound in the future


Fuel system development

Twin row slide valve


Slide Valve Pressure Testing

Risk of seizure

3-5

4

1-2

Avoid atomisation test because of:

1. Small lift

2. Large pressure drop

3. High contact pressure

4. High frequency

5. Thin oil

L/74231-2.0/0402 (2300/MCJ)


Obel P. adapter


Fuel Valve Comparison K90MC

L/73504-0.0/1002 (2000/CEE)

Conventional Fuel Valve Slide Fuel Valve

6334 hours6334 hours


Fuel Valve Comparison K90MC

Conventional Fuel Valve Slide Fuel Valve

6334 hours 6334 hours

L/73503-9.0/1002 (2000/CEE)


Fuel Valve Comparaison K90MC

Mini Sac Fuel Valve Slide Fuel Valve

Liner wear: 0.06 mm/1000h

6334 hours

Liner wear: 0.03 mm/1000h

6334 hours

L/72950-2.0/0202 (2400/ALO)


Service ExperienceK90MC after 6,334 Hours

L/70568-2.0/0100 (2430/DT)

Exhaust gas ductMini-sac

Slide Valve


SLIDE VERSUS CONVENTIONAL

L/72517-8.0/0102 (3001/UM)

Slide fuel valves Conventional fuel valves


Performance of Fuel Valve

L/71261-8.1/0100 (3210/PYJ)

Slide-type fuel valve (890 h after installation)

Conventional valve


Performance

L/71173-2.1/1000 (3210/PYJ)

Fuel oil valve, conventional nozzle

M/V Don Juan Exhaust valve cylinder 2Before installation of slide valve


7S50MC-C Slide Fuel Valves

350370390410430450470490510530550

SeatBottom

Conventional MiniSac SlideC

Combustion chamber temperaturesLiner

L/73093-9.0/0602 (2430/NK)

BottomSeal



150

200

250

300

350

400

3 h=55 mm 5 h=123 mm


Combustion chamber temperaturesLiner

L/73092-7.0/0602 (2430/NK)

3 5



240

260

280

300

320

340

360

380

400

Middle 3 R= 84 5 R=137 7 R=180 9 R=232


Combustion chamber temperaturesPiston

L/73091-5.0/0602 (2430/NK)

Middle3

57 9


7S50MC-C Slide Fuel ValvesComparison of hydrocarbons (HC)

0

200

400

600

800

1000

100755025

Conventional MiniSac SlideHC (dry 15% O2)

Load [%]

L/73090-3.0/0602 (2430/NK)


7S50MC-C Slide Fuel ValvesComparison of CO

0

10

20

30

40

50

60

70

100755025

Conventional MiniSac SlideCO (dry 15% O2) [ppm]

Load [%]

L/73089-3.0/0602 (2430/NK)


Bosch smoke numbersEngine: 6L60MC/ME Bow Cecil

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 25 50 75 100

Engine power [%]

Bosch number

6L60MC Conventional valves6L60ME Slide valves

Fuel Valve Comparison

L/72818-6.1/0309 (2430/NK)


Slide-type Fuel Valves versus Conventional Fuel Valves

Lower emissions- Reduced Bosch number (BSN10)- HC and CO emissions reduced by 30%

and 40%, respectively- Nox reduction- Co2 reduction

Cleaner combustion- Improved cylinder condition and TBO- Reduced LOC - Reduced deposits

L/72858-1.0/0202 (3001/DT)


Clean after 3,900 hours.


Tightening torque for engines up to 70MC = 60Nm

For large bore above 70MC = 65Nm


8S60MC

8S60MC total 43,000 hSlide fuel valves 13,000 hMax. 2mm burning


Slide Fuel Valve

Condition after 36,811 hours on 12K90MC-C.

At 25,360 hours, change to slide fuel valves, at that time

max. burned area 130 x 80 x 4,5 mm

After 11,451 hours with slide fuel valves,

max. burned area 145 x 100 x 4.7 mm


8S60MC total 43,000 hSlide fuel valves 13,000 hMax. 2mm burning


CAT FINES


Cat fines in 50 automatic filter


Abrasive wear


Wrong Nozzel.

Over Heating.


Wrong Nozzel.

Banana Burnings.


Heat Cracks in Ring Land.


Overheated Ringpack due to

wrong nozzels.


Typical

Blow-ByCrack.


Conventional valve.


FUEL PUMP SHOCK ABSORBER

In a few cases cracks have appeared inthe sealing ring groove of the housing

In certain cases the guide ring actsas a tight sealing ring because thehigh running temperature reducesthe ring gap to almost nothing

A pressure of approx. ten times thenormal working pressure is thenBuilt up, hence causing the cracks

The problem was solved by exchangingthe guide ring with a new ring withlarger gap


MODIFICATIONS OF SHOCK ABSORBER


WILL CONTINUE


Function of Super Vit.

When the compression pressure is of a value corrosponding to

app 45% of load, the Super-Vit start to change the Lead Angel so

the injection starts earlier. This change in lead angel to earlier

injection continues until the pressure differense between combustion pressure

and compression pressure is max 35bar at app. 85% of Engine load..

At 85% of Engine load, the max pressure is now 100%.

When increasing to 100% Engine load, the Super-Vit retard the injection

again, so the combustion pressure during the increase is kept at 100%,

even due to the delaied injection, wich should lower the combustion pressure.

The increase in compression pressure compensates for the later injection

and keeps the combustion pressure constant at 100%.

FUEL OIL SYSTEMPerformance Fuel Valve DesignK98MC-C Atomizer. Marks and Stamps on Fuel Valve Nozzle MC and MC-C TypeSpindle Guide for Slide ValveCompound Fuel Valve Nozzle.CFD Calculated TemperaturesK90MC NozzleVacuum Brazing of Compound Fuel Valve NozzleCompound Fuel Valve NozzleFuel system developmentSlide Valve Pressure TestingObel P. adapterFuel Valve Comparison K90MCFuel Valve Comparison K90MCFuel Valve Comparaison K90MCService ExperienceK90MC after 6,334 HoursSLIDE VERSUS CONVENTIONALPerformance of Fuel ValvePerformance7S50MC-C Slide Fuel Valves7S50MC-C Slide Fuel Valves7S50MC-C Slide Fuel Valves7S50MC-C Slide Fuel Valves7S50MC-C Slide Fuel ValvesFuel Valve ComparisonSlide-type Fuel Valves versus Conventional Fuel ValvesClean after 3,900 hours.8S60MCSlide Fuel ValveCAT FINES Cat fines in 50 automatic filterAbrasive wearConventional valve.FUEL PUMP SHOCK ABSORBERFunction of Super Vit.

fuel inj # 1

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