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 FORWARDING MAN B&W Diesel A/S
Teglholmsgade 35 Teglholmsgade 35 Denmark
DK-2450 Copenhagen SV DK-2450 Copenhagen SV CVR.No.: 39 66 13 14
Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00
Telex: 19023 manfw dk Telex: 19023 manfw dk
Telex: 19042 manfw dk Telex: 19042 manfw dk
Telefax: +45 33 85 10 17 Telefax: +45 33 85 10 16
E-mail: manufacturing/copenhagen@manbw.dk
 2

Now used
as standard

Conventional fuel valve Slide fuel valve

Sac volume 1690 mm 3
3 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 combina-
tion of heat load, combustion efficiency and emission level. Furthermore, the perfor-
mance 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.
 3

Reduction of exhaust gas emissions on a Reduction of smoke on a

7S50MC-C with slide fuel valves 7S60MC with slide fuel valve
HC (as CH4) Bosch Number
g/kWh (10 strokes)
5 1.0

4 0.8

3 0.6
Conventional fuel valve

2 0.4 Conventional fuel valve

1 0.2
Slide fuel valve Slide fuel valve

0 0.0
0 25 50 75 100 0 25 50 75 100
Engine Power -% Engine Power - %

Figure 2: HC emission measured with and without Figure 3: Smoke level measurement with and
slide fuel valves 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 12K90MC fuel nozzle comparison

Measured particulates Measured particulates
PM - g/kWh PM - g/kWh
2 2

1.6 1.6

1.2 1.2 Conventional fuel valve

Conventional fuel valve

0.8 0.8

0.4 0.4 Slide fuel valve

Slide fuel valve
0 0
0 25 50 75 100 0 25 50 75 100
Engine power - % Engine load - %

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.
 4

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.
 5

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