MAN B&W Diesel A/S

Service Letter

SL02-403/UM June 2002

Introduction of Slide Fuel Valve Action Code: WHEN CONVENIENT 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. This design has been introduced on all the latest versions of large bore engines, i.e. 80 cm bore and upward, and it will be the future standard on all our new engine types. The slide fuel valve is also available as a retrofit option for engines in service. The main benefits of this design, compared with the conventional design, are: = Reduced fouling of gasways = Reduced fouling of piston topland and exhaust gas boiler Further benefits: = Less smoke formation = Lower NOx emission levels. The difference between the slide fuel valve and the previous fuel valve types is the reduced (actually non-existent) sac volume, as shown in Fig.1.

HEAD OFFICE (& Postal address) Teglholmsgade 41 DK-2450 Copenhagen SV Telephone: +45 33 85 11 00 Telex: 16592 manbw dk Telefax: +45 33 85 10 30 E-mail: manbw@manbw.dk http://www.manbw.dk

DIESEL SERVICE Teglholmsgade 41 DK-2450 Copenhagen SV Telephone: +45 33 85 11 00 Telex: 31197 manbw dk Telefax: +45 33 85 10 49 E-mail: diesel-service@manbw.dk

PRODUCTION Teglholmsgade 35 DK-2450 Copenhagen SV Telephone: +45 33 85 11 00 Telex: 19023 manfw dk Telex: 19042 manfw dk Telefax: +45 33 85 10 17 E-mail: manufacturing/copenhagen@manbw.dk

FORWARDING Teglholmsgade 35 DK-2450 Copenhagen SV Telephone: +45 33 85 11 00 Telex: 19023 manfw dk Telex: 19042 manfw dk Telefax: +45 33 85 10 16

MAN B&W Diesel A/S Denmark CVR.No.: 39 66 13 14

Now used as standard

Conventional fuel valve 3 3 Sac volume 1690 mm

Slide fuel valve Sac volume 0 mm3

Fig. 1: Fuel injection valves, slide type compared with conventional type, illustrating the elimination of sac volume

The spray pattern layout for the slide fuel valves for each individual engine type is based on computational fluid dynamic calculations. This ensures an optimal combination of heat load, combustion efficiency and emission level. Furthermore, the performance of the slide fuel valves will be confirmed by service tests on all relevant engine types. During the scavenging period, the contents of fuel oil in the sac volume will, for the conventional fuel valve, to some extent be blown out by the air swirl and the fuel vapour pressure. This means that a certain amount of fuel will enter the combustion chamber at a time when the temperature level is too low for complete combustion, and the fuel therefore contributes to fouling of the engine, to smoke formation, and increased hydrocarbon and particulate emissions. With the incomplete combustion of fuel being practically reduced to zero with the slide fuel valves, combustion chamber fouling is considerably reduced. The fuel consumption is also reduced thanks to the eliminated waste of oil. Downstream from the engine, the exhaust gas system becomes cleaner, and the economiser is exposed to less carbon accumulation. Fig. 2 shows an example of the measured effect on HC emission when comparing the fuel valves on a 7S50MC-C engine. Generally, a reduction of around 75% of the HC emission is obtained at all loads by changing to slide fuel valves. Furthermore, the positive effect on smoke emission (in this case the Bosch number) is illustrated by measurements taken on a 7S60MC engine, as shown in Fig. 3.

Reduction of exhaust gas emissions on a 7S50MC-C with slide fuel valves

HC (as CH4) g/kWh 5
Bosch Number (10 strokes) 1.0

Reduction of smoke on a 7S60MC with slide fuel valve

0.8

3 2

Conventional fuel valve

0.6

0.4

Conventional fuel valve

0.2

Slide fuel valve

0.0

Slide fuel valve

0 0 25 50 Engine Power -%

75

100

25

50 Engine Power - %

75

100

Figure 2: HC emission measured with and without slide fuel valves

Figure 3: Smoke level measurement with and without slide fuel valves

Fig. 4 shows the effect of the fuel valve design on the emission of particulates from an S60MC engine and a K90MC. The particulate matter (PM) is a more complex exhaust component and, therefore, its reduction is not the same as for HC. However, a reduction of up to 50% is achieved, depending on the engine load.

7S60MC fuel nozzle comparison Measured particulates

PM - g/kWh 2 PM - g/kWh 2

12K90MC fuel nozzle comparison Measured particulates

1.6

1.6

1.2 Conventional fuel valve 0.8 0.4 Slide fuel valve 0 0 25 50 Engine power - % 75 100

1.2 0.8 0.4

Conventional fuel valve

Slide fuel valve

0 0 25 50 Engine load - % 75 100

Figure 4: Influence of fuel valve design on deposits in gasways

The positive effect on emissions and smoke has been confirmed on all engine types tested.

Fig. 5 shows the excellent condition of the exhaust valve duct on an S60MC engine when using slide fuel valves.

Slide fuel valve (890 h after installation) Figure 5: Influence of fuel valve design on deposits in gasways

It should be mentioned that the fuel valve, including the fuel valve nozzle, are components that are covered by IMOs NOx regulation. As NOx emissions with slide fuel valves are generally lower than or equal to NOx emissions with conventional fuel valves, IMOs rules on NOx emissions are met with the slide fuel valves. As, on some engine types, the nozzle tip on the slide fuel valve has a slightly larger diameter than that of the original fuel valve nozzle, it may become necessary to increase the diameter of the fuel valve bore in the cylinder cover. This can usually be done by removing only the exhaust valve and leaving the cover in position. MAN B&W Diesel can provide the necessary instructions and tools for machining the cylinder cover, or you can order the job from MAN B&W Diesel A/S in Copenhagen. On some engines, the spring housings for securing the fuel valves to the cylinder cover must be replaced by stronger spring housings. Replacing conventional fuel valves with slide valves on engines in service is very advantageous to the shipowner. The slide fuel valves should be introduced on all cylinders at the same time, including spares. When slide fuel valves are introduced, the relationship between the engine load and fuel pump index will change slightly, and the limiters in the governor must therefore be readjusted. Furthermore, careful performance readings and pmax adjustments should be carried out. We recommend that a service engineer from MAN B&W Diesel carry out the governor adjustments, the pmax adjustments and the performance readings. As mentioned above, the slide fuel valves will be introduced as standard on all new MAN B&W engine types and are also available for retrofit purposes.

The following engine types can at present be retrofitted with slide fuel valves: = K90MC-C with 3 fuel valves per cylinder = K90MC-C with 2 fuel valves per cylinder = K90MC with 3 fuel valves per cylinder = K90MC with 2 fuel valves per cylinder = K90MC-S = K80MC-C with 3 fuel valves per cylinder = S80MC = K80MC-S = S70MC-C = S60MC-C = S60MC Slide fuel valves will successively be released for other engine types. If you want to replace your existing fuel valves with the slide fuel valves, please contact our Diesel Service department in Copenhagen, or the engine builder. Questions or comments regarding this SL should be directed to our Dept. 4100.

Yours faithfully MAN B&W Diesel A/S

Ole Grne

Otto Winkel