RT-flex Control Elements

RT-flex Training

Function of the different

Hydraulic- and Pneumatic
Components

Chapter 30

© Wärtsilä Land & Sea Academy Page 1 Chapter 30 30-Apr-09

RT-flex Control Elements Overview

Main Functions
Exhaust Valve Control Injection Control Starting Valve Control

Auxiliary Functions
Fuel pressure control
Servo oil pressure control

Control oil pumps control

Valve stroke measurement
ICU stroke measurement

Crank angle detection

© Wärtsilä Land & Sea Academy Page 2 Chapter 30 30-Apr-09

RT-flex Control Elements Injection Control Unit (ICU)

The ICU controls the timing and volume

of the injection.
Each ICU has 3 (or 2) “rail valves” to pre-
control its own “injection control valve”.
The injection control valves control the
movement of the “fuel quantity piston”.

© Wärtsilä Land & Sea Academy Page 3 Chapter 30 30-Apr-09

RT-flex Control Elements ICU

WECS-9520
Servo (control) oil control
supply 200 bar

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RT-flex Control Elements ICU

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RT-flex Control Elements ICU Cross-Section

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RT-flex Control Elements ICU

Fuel quantity piston

Servo rail
Fuel quantity
(Size 4: sensor
Control rail)

Fuel nozzles
Rail valves

Injection control
valves

Fuel rail

© Wärtsilä Land & Sea Academy Page 7 Chapter 30 30-Apr-09

RT-flex Control Elements ICU, new leak drain (96C-B)

New piping layout separates

leak drain from injection pipes
and from ICU internals.
Inspection plug for visual
check of leak.

© Wärtsilä Land & Sea Academy Page 9 Chapter 30 30-Apr-09

RT-flex Control Elements Fuel Overpressure Regulating Valve
Fuel overpressure regulating valve:

In case of the fuel pressure in intermediate

accumulator pipe or fuel rail pipe rises to
~1’050 bar, the overpressure regulating valve
releases fuel to the fuel return line.
The opening pressure is pre-adjusted by valve
manufacturer. Shims are used to give the right
position to the knurled screw, means if the screw
is fully screwed down to shims, 1’050 bar are set
Ö for new building RT-flex84T-D and 96C-B
engines’ opening pressure is 950 bar
Ö for in-service RT-flex84T-D and 96C-B
see Service Letter RT-flex-07/07

The min. opening pressure, means when knurled

screw is screwed fully out, is around 500 bar
(engine still operational).
During normal operation, main bearing oil
pressure keeps the valve closed. When the
opening fuel pressure is reached, main bearing
oil is released, pressure above piston drops and
fuel is released.

© Wärtsilä Land & Sea Academy Page 10 Chapter 30 30-Apr-09

RT-flex Control Elements Shutdown Valve
Solenoid valve leak
Engine shutdown function: Oil filter drain
Shutdown
A shutdown is initiated by energizing the Solenoid
solenoid valve (energized from safety valve
system, not WECS). In this way, main MB-oil
bearing oil pressure above piston is supply
released, resulting in fuel pressure drop
down ¾ engine stops Piston
Lever for
manual de-
pressurising
for mainte-
nance work

© Wärtsilä Land & Sea Academy Page 11 Chapter 30 30-Apr-09

RT-flex Control Elements (exhaust) Valve Control Unit (VCU)

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RT-flex Control Elements VCU

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RT-flex Control Elements VCU (general working principle)
The valve control unit is pre-controlled by the rail valve.
At a certain crank angle, it gets an „exhaust valve open“
impulse signal from WECS. Servo oil flows via rail valve Actuator pipe with
to the lower side of the 3/2 way valve spindle and moves main bearing oil
it up. Thus, servo oil flow to the VCU-cylinder is enabled.
Via bores in the VCU-piston, oil flows into the lower side
of the piston and moves it towards the upper end.
¾ the exhaust valve opens
At another calculated angle, WECS-9520 transmits an
„exhaust valve close“ signal to the rail valve. The 3/2
way valve spindle moves down, releasing the oil from
the VCU-piston underside allowing the oil volume in the
exhaust valve to return to the VCU. The servo oil
underneath the VCU piston is drained to the servo oil
return pipe. Rail valve
¾ the exhaust valve is closing
Due to certain control bores or chamfers, the VCU- 3/2 way valve
spindle
piston has a progressive movement. Means, it starts to
move fast and slows down, as it gets closer to the end
stop. The losses of servo oil through the orifice on the The servo oil return pipe has a back
exhaust valve side is compensated in the VCU with VCU piston pressure of ~2-3 bar, in order to
servo- or main bearing oil. dampen pressure peaks.

© Wärtsilä Land & Sea Academy Page 14 Chapter 30 30-Apr-09

RT-flex Control Elements VCU
3/2 way valve To exhaust valve drive
Valid for flex 58T (MKI),
60C (MKI), 96C-B

The servo oil supply from the servo oil rail is

Main bearing oil done via connecting element.
supply, (non return
valve at inlet) To compensate the intended oil loss through the
constant orifice in the exhaust valve drive upper
Rail valve
housing, there is a main bearing oil inlet via a
non-return valve.

VCU cylinder

Servo oil return/

Filter insert outlet

Connecting element

© Wärtsilä Land & Sea Academy Page 15 Chapter 30 30-Apr-09

RT-flex Control Elements VCU
Rail Valve

Valid for flex 50B, 58T (MKII),

To exhaust
valve drive 60C (MKII), 68B, 84T-D
3/2 way valve

The VCU sits directly on the servo rail.

In order to refill the intended oil loss through
the constant orifice in the exhaust valve drive
upper housing, there is an internal orifice to
the upper part of the VCU/actuator pipe.

Servo oil return

VCU piston

HP-hoses to/
Servo oil supply from ICU

© Wärtsilä Land & Sea Academy Page 16 Chapter 30 30-Apr-09

RT-flex Control Elements VCU

Rail valve Slide rod Piston Exhaust valve

Oil supply *)

*) internal from servo rail or

external from lube oil
Servo rail

Position sensor

Spring air

© Wärtsilä Land & Sea Academy Page 17 Chapter 30 30-Apr-09

RT-flex Control Elements Automatic Filter

Servo oil and control oil is fine filtered before it enters the pumps and hydraulics. The automatic filter
has cartridges of nominal 6 µm. There is an bypass filter of 36 µm mesh size.
The reason for filtering is to increase the lifetime and safety margin of all hydraulic components.

Control box with indications

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RT-flex Control Elements Automatic Filter

The back flushing is automatically initiated by the control box either

A) standard: Time controlled (after 1 hour)
B) or: if the differential pressure across the filter becomes too high (0.35 bar)

The filter "sludge" goes back to the crankcase. It is filtered system oil which is clean enough for normal
use.
In the filter control box the back flushing is initiated either by time or differential pressure. Flushing
cycles are counted. Failure messages are generated if necessary (Over current, differential pressure
high etc…)
Inside the box there are switches/buttons to switch from “Operation” to “Adjust”. For detailed information
please consult filter maker’s manuals.

© Wärtsilä Land & Sea Academy Page 20 Chapter 30 30-Apr-09

RT-flex Control Elements Air system

Air is used for:

ƒ Actuation of automatic start valve
ƒ Starting of engine
ƒ Spring air supply
ƒ (Oil mist detector)
ƒ Flushing of automatic filter for servo
and control oil

@ (OMD)
@ (SHD valve)

© Wärtsilä Land & Sea Academy Page 21 Chapter 30 30-Apr-09

RT-flex Control Elements Air supply

From starting air bottles (30 bar)

To air springs To automatic main
starting valve
From control air
through turning gear
supply (7-9 bar)

@ (OMD)
@ (SHD valve)

© Wärtsilä Land & Sea Academy Page 22 Chapter 30 30-Apr-09

RT-flex Control Elements Control air supply unit

© Wärtsilä Land & Sea Academy Page 23 Chapter 30 30-Apr-09

RT-flex Control Elements Air system (size 0)

Air is used for:

ƒ Actuation of automatic start valve
ƒ Starting of engine
ƒ Spring air supply
ƒ (Oil mist detector)
ƒ Flushing of automatic filter for servo
and control oil

© Wärtsilä Land & Sea Academy Page 24 Chapter 30 30-Apr-09

RT-flex Control Elements Air supply (size 0)

From control air To air springs

supply (7-9 bar) and automatic
main starting
valve through
turning gear

© Wärtsilä Land & Sea Academy Page 25 Chapter 30 30-Apr-09

RT-flex Control Elements Main starting valve

© Wärtsilä Land & Sea Academy Page 26 Chapter 30 30-Apr-09

RT-flex Control Elements Starting air

© Wärtsilä Land & Sea Academy Page 27 Chapter 30 30-Apr-09