FUEL OIL SYSTEM

MAN Diesel A/S

2006/09/09

Performance Fuel Valve Design

L/9902-3.1/0202

(2410/SBJ)

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Performance

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

K98MC-C Atomizer.

Transparent view

Outside view

Inside view
MAN Diesel A/S

2006/09/09

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.

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

MAN Diesel A/S

2006/09/09

Spindle Guide for Slide Valve

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Compound Fuel Valve Nozzle.

MAN Diesel A/S

2006/09/09

CFD Calculated Temperatures

Boundary condition
for FEM analysis

MAN Diesel A/S

2006/09/09

K90MC Nozzle

CFD calculated
temperature field

Measured
temperature field

Steel nozzle
L/74071-7.0/0302

BWPS1 nozzle

(2410/SBJ)

MAN Diesel A/S

2006/09/09

Vacuum Brazing
of Compound Fuel Valve Nozzle

Brazing
alloy
powder

Brazing alloy powder

Infiltrating Inconel powder

Inconel
powder

H13 tool steel

Brazing preparation

H13 tool steel

Vacuum brazing

Nozzle blank

MAN Diesel A/S

2006/09/09

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

MAN Diesel A/S

2006/09/09

Fuel system development

Twin row slide valve

MAN Diesel A/S

2006/09/09

Slide Valve Pressure Testing

Risk of seizure
Avoid atomisation test because of:
1. Small lift
2. Large pressure drop
3. High contact pressure

4. High frequency
3-5

5. Thin oil
1-2

L/74231-2.0/0402

(2300/MCJ)

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Obel P. adapter

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Fuel Valve Comparison K90MC

Conventional Fuel Valve

Slide Fuel Valve

6334 hours

6334 hours

L/73504-0.0/1002

(2000/CEE)

MAN Diesel A/S

2006/09/09

Fuel Valve Comparison K90MC

L/73503-9.0/1002

Conventional Fuel Valve

Slide Fuel Valve

6334 hours

6334 hours

(2000/CEE)

MAN Diesel A/S

2006/09/09

Fuel Valve Comparaison K90MC

L/72950-2.0/0202

Mini Sac Fuel Valve

Slide Fuel Valve

Liner wear: 0.06 mm/1000h

Liner wear: 0.03 mm/1000h

6334 hours

6334 hours

(2400/ALO)

MAN Diesel A/S

2006/09/09

Service Experience
K90MC after 6,334 Hours
Exhaust gas duct
Mini-sac

Slide Valve

L/70568-2.0/0100

(2430/DT)

MAN Diesel A/S

2006/09/09

SLIDE VERSUS CONVENTIONAL

Slide fuel valves

L/72517-8.0/0102

(3001/UM)

Conventional fuel valves

MAN Diesel A/S

2006/09/09

Performance of Fuel Valve

Conventional valve

Slide-type fuel valve

(890 h after installation)

L/71261-8.1/0100

(3210/PYJ)

MAN Diesel A/S

2006/09/09

Performance
Fuel oil valve, conventional nozzle
M/V Don Juan
Exhaust valve cylinder 2
Before installation of slide valve

L/71173-2.1/1000

(3210/PYJ)

MAN Diesel A/S

2006/09/09

7S50MC-C Slide Fuel Valves

Combustion chamber temperatures
Liner

Conventional

MiniSac

Slide

550
530

Bottom
Seal

510
490
470
450
430
410
390
370
350
Bottom

L/73093-9.0/0602

Seat

(2430/NK)

MAN Diesel A/S

2006/09/09

7S50MC-C Slide Fuel Valves

Combustion chamber temperatures
Liner
Conventional

MiniSac

Slide

400
350
300
250
200
150
3 h=55 mm

L/73092-7.0/0602

5 h=123 mm

(2430/NK)

MAN Diesel A/S

2006/09/09

7S50MC-C Slide Fuel Valves

Combustion chamber temperatures
Piston
7
5
3
Middle

9
Conventional

MiniSac

Slide

C
400
380
360
340
320
300
280
260
240
Middle

L/73091-5.0/0602

3 R= 84

5 R=137

7 R=180

9 R=232

(2430/NK)

MAN Diesel A/S

2006/09/09

7S50MC-C Slide Fuel Valves

Comparison of hydrocarbons (HC)
HC (dry 15% O2)

Conventional

MiniSac

Slide

1000
800
600
400
200
0
25

50

75

100
Load [%]

L/73090-3.0/0602

(2430/NK)

MAN Diesel A/S

2006/09/09

7S50MC-C Slide Fuel Valves

Comparison of CO
CO (dry 15% O2) [ppm]

Conventional

MiniSac

Slide

70
60
50
40
30
20
10
0
25

50

75

100
Load [%]

L/73089-3.0/0602

(2430/NK)

MAN Diesel A/S

2006/09/09

Fuel Valve Comparison

Bosch smoke numbers
Engine: 6L60MC/ME Bow Cecil

Bosch number
0.7
0.6
0.5
0.4
0.3
0.2
0.1

6L60MC Conventional valves

6L60ME Slide valves

0
0

25

50

75

100

Engine power [%]

L/72818-6.1/0309

(2430/NK)

MAN Diesel A/S

2006/09/09

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)

MAN Diesel A/S

2006/09/09

Clean after 3,900 hours.

MAN Diesel A/S

2006/09/09

Tightening torque for engines up to 70MC = 60Nm

For large bore above 70MC = 65Nm

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

8S60MC

8S60MC total 43,000 h

Slide fuel valves 13,000 h
Max. 2mm burning

MAN Diesel A/S

2006/09/09

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
MAN Diesel A/S

2006/09/09

8S60MC total 43,000 h

Slide fuel valves 13,000 h
Max. 2mm burning

MAN Diesel A/S

2006/09/09

8S60MC total 43,000 h

Slide fuel valves 13,000 h
Max. 2mm burning

MAN Diesel A/S

2006/09/09

CAT FINES

MAN Diesel A/S

2006/09/09

Cat fines in 50 automatic filter

MAN Diesel A/S

2006/09/09

Abrasive wear

MAN Diesel A/S

2006/09/09

Over Heating.
Wrong Nozzel.

MAN Diesel A/S

2006/09/09

Banana Burnings.

Wrong Nozzel.

MAN Diesel A/S

2006/09/09

Heat Cracks in Ring Land.

MAN Diesel A/S

2006/09/09

Overheated Ringpack due to

wrong nozzels.

MAN Diesel A/S

2006/09/09

Typical

Blow-By
Crack.

MAN Diesel A/S

2006/09/09

Conventional valve.

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

FUEL PUMP SHOCK ABSORBER

In a few cases cracks have appeared in
the sealing ring groove of the housing
In certain cases the guide ring acts
as a tight sealing ring because the
high running temperature reduces
the ring gap to almost nothing
A pressure of approx. ten times the
normal working pressure is then
Built up, hence causing the cracks
The problem was solved by exchanging
the guide ring with a new ring with
larger gap

MAN Diesel A/S

2006/09/09

MODIFICATIONS OF SHOCK ABSORBER

MAN Diesel A/S

2006/09/09

WILL CONTINUE

MAN Diesel A/S

2006/09/09

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%.
MAN Diesel A/S

2006/09/09