02 Prime Customized HPS-HCU Basics

Hydraulic Power Supply &
Hudraulic Cylinder Unit
Customized Course
PrimeServ Piraeus
Period : June 30 – July 02
Public | Academy Piraeus – Customized – ©2021 June, 2021 2

Period : July 13 – July 15

Agenda
Hydraulic Power Supply (HPS)
1 System
2 Filter unit
3 Startup pumps
4 Engine driven pumps
5 Valve block
6 Electric driven pumps

ME engine introduction
Hydraulic system
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Auxiliary Control Unit (ACU) – Blower control
The blowers are started one by one in order to prevent

overload of the electrical system.
In AUTO mode:
The blowers are started at ‘Prepare Start’
At engine running they are controlled by the scavenge
air pressure. They stop at 0,7 bar (time delay), they
start at 0,4 bar.
At engine stop they continue to run for a default 15-20
min.
In MANUAL mode:
Operation is controlled by the operator via the MOP.
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Auxiliary Control Unit (ACU) – Pump control
Electrically driven start-up pumps 1 & 2 are controlled

ECU A
ECU AB
by ACU 1 & 2
Engine driven pumps 1, 2, & 3 are controlled by ACU 1,

2 & 3 respectively. The control is modulated, based on
the pressure set point and the actual hydraulic
pressure.
Engine driven pumps 4 and 5 are the same type as 1, 2

and 3, but they are controlled digitally by ECU A & B,
either max ahead or max astern.
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System – Lubricating and cooling oil system

System – Integrated hydraulic system (standard)
Contamination of hydraulic oil must not

exceed:
 ISO 4406: 16 / 13
 NAS Code: 7 or 8

System – Separate hydraulic system (option)

System - Engine driven hydraulic pumps; Three different setups
Aft with chain drive in case of a Aft with gear box in case of a Between cylinder 6 and 7 for
bore size more than 50 bore size of 50 and less engines with a bore size of 90 or
98 and with more than 9 cylinders

Agenda
1 System
2 Filter unit
3 Startup pumps
5 Valve block

Filter unit
Automatic backflush filter

and startup pumps

Filter unit – Boll & Kirch ver. 6.64

Filter unit - Cartridges
6 µm filter cartridge:
09 / 06 = production month / year
1341146 = filter cartridge ID
Sintered filter material

Filter unit – Layout and principle

Filter unit – Back flush line to sump tank

Agenda
1 System
2 Filter unit
3 Startup pumps
5 Valve block

Startup pumps – Pump designs

Startup pumps – Layout
Inlet
Electric motor
Pressure relief
valve set point
175 / 225 bar
Pump
Outlet
Valve
Pump drain

Startup pumps – Control
Automatic mode
 Master pump running at engine standby (both pumps

are running during pressure build up)
 Stopped at finish with engine
 Stopped via timer at a specified engine RPM (default
15% MCR)

Agenda
1 System
2 Filter unit
3 Startup pumps
5 Valve block

Engine driven pumps – Axial piston pumps
Axial Piston Pump – A4VSO xxx

HS3xxx… (Bosch - Rexroth)

Engine driven pumps – Pilot valves either Parker or MOOG

Engine driven pumps – Sizes
Pump sizes
125 cm3/rev - three pumps

180 cm3 /rev - three pumps
500 cm3 /rev - three to five pumps
(750 cm3 /rev - three to five pumps)

Engine driven pumps – Gear box
Hydraulic pump
Step up gear
Chain wheel for

4” duplex chain

Engine driven pumps – Gear box

Engine driven pumps – Safety shaft principle
Gear end
Pump end
High friction - disc

Engine driven pumps – Complete HPS 12K98ME Mark 4
HPS high pressure hoses five years date

of manufactory!

Engine driven pumps – 200 / 300 bars system
210 Bar → 300 Bar

Working pressure increased from 210 bar to 300 bar resulting in:
HPS:
Necessary pump size reduced from 355 cc. to 250 cc.
Only three pumps needed
Same pipe and hose dimensions
This is because of the relation between Q’ (flow) and pressure (p) shown by the equation:
P= Q’x p, where P is the power generated by the pump, the power consumption is the same; therefore a
higher pressure will result in a lower flow.

Engine driven pumps – 200 / 300 bars system

Engine driven pumps – Pressure sensors

Engine driven pumps – Leak detection
Hydraulic power supply
Drain pipe
Sensors “vibrating fork” type

LS 1235 = Alarm
LS 1236 = Cancelable shut down

Engine driven pumps – Summary
In case of control failure of a pump, the swash plate will be forced to +100% AHEAD direction cause of default
position of pilot valve.
Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2 and pump 3 by ACU 3.
Pump Nos. 1, 2, and 3 have their own sensor for system pressure, connected to their controlling ACU.
All pumps have sensors for suction pressure.
If the pressure is too low, or all sensors are failing, a SHUTDOWN will be activated.
High pressure shutdown: 145 bar / 175 bar Alarm:
0,7 bar low oil pressure
0,5 bar shut down
Deviation alarm:
Sensor value deviates more
than one bar from the other.

Agenda
1 System
2 Filter unit
3 Startup pumps
5 Valve block

Valve block – Standard HPS
High pressure
sensors
Control oil for pumps
Safety & shutdown valves

Valve block 310 and 311
Opening pressure:
310: 230 / 310 bar or by
ACU1 & 3 (shutdown)
311: 250 / 315 bar

Valve block – HPS between cylinder 6 and 7
Valve blocks
One valve 311 each
Accumulator block
One valve 310

Agenda
1 System
2 Filter unit
3 Startup pumps
5 Valve block

Electric driven pumps
Overhaul and maintenance
Disassembly for main

components

Agenda
Hydraulic Cylinder Unit (HCU)
1 High pressure pipes

2 Distribution block
3 Components:
 Accumulators
 Lubricator
4 Lubrication
Public | Academy Copenhagen – Hydraulic Cylinder Unit (HCU) – ©2020 June, 2021 44
High pressure pipes – 200 or 300 bars system
Double wall pipe,

200 bar system
Single pipe in casing

300 bar system

High pressure pipes – 200 or 300 bars system
Public | Academy Copenhagen – Hydraulic Cylinder Unit (HCU) – ©2020 June, 2021 46
High pressure pipes – 200 bars pipe
Outer pipe
Sealing rings Inner pipe Sealing rings
Screws
Slide bearings
Flange

High pressure pipes – Leak detection 200 bars system
1. CLOSE the valve 430 at the last, but one Hydraulic

Cylinder Unit (HCU).
2. OPEN the valve 431 at the last HCU to decrease
the pressure in the space between the inner and
outer pipe.
3. CLOSE the valve 431 at the last HCU again.
4. Check the pressure increase in the space between
at position 435, at the last HCU.
5. If the pressure increases to system pressure level,
the leakage has been found.
6. When the leakage has been eliminated, bring all the
valves to their normal position.

Agenda
1 High pressure pipes

2 Distribution block
3 Components:
 Accumulators
 Lubricator

Distribution block
Front side Back side

Distribution block
Fuel oil Exhaust valve

pressure booster actuator
Overflow pipe
(de - air rating)
Accumulator
Distribution
block
ME lubricator
FIVA valve
Ball valve

Distribution block – 200 bars system diagram

Distribution block – 300 bars system diagram

Distribution block – 200 bars system valves

Distribution block – Preparation for maintenance
CAUTION!
HCU OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO.: 420, 531
2. CHECK PRESSURE AT MEASURING POINT 455.
3. CHECK PRESSURE AT MEASURING POINT 455.
WARNING - NEVER ‘OPEN’ VALVE WHEN SYSTEM
PRESSURE IS ‘ON’
Valve No.
CAUTION!
HCU OVERHAULING
0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO.: 420, 531
2. CHECK PRESSURE AT MEASURING POINT
455.
3. CHECK PRESSURE AT MEASURING POINT
455

Agenda
1. High pressure pipes

2. Distribution block
3. Components:
– Accumulators
– Lubricator
4. Lubrication

Accumulators

Accumulators – Nitrogen check, SL2019 - 673
The accumulator charge pressure For the 300 bar HPS accumulator
should be checked within the first charging pressures are:
week of service. Next check should
be made minimum every month.
A minor leakage from the
accumulators is unavoidable and
service experience shows that a
pressure drop in the range of
2 - 5 bar / month is to be expected.
The charge pressure is dependent
on working servo oil pressure as
well as the accumulator
temperature.

Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteristics
of each individual project, especially specific site and operational conditions.

Intellectual property rights
The intellectual property rights of this work are owned and managed by MAN Energy Solutions and are protected
both nationally and internationally according to related laws such as copyright law.
This content is for personal learning and non-commercial use only.
You may not modify or reproduce it except for your personal use.
This content is for training purposes only.
This work is the proprietary intellectual property of MAN Energy Solutions.
MAN Energy Solutions owns all rights to this work and the lecture, and this work is only offered by the instructor
or via the MAN eAcademy through the MAN Energy Solutions.
Any use of this work at will, without the consent of MAN Energy Solutions, may cause legal problems.
This work is provided for the convenience of course participant, and it does not give intellectual property
rights to user.

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Hydraulic Power Supply &

Hudraulic Cylinder Unit

Public | Academy Piraeus – Customized – ©2021 June, 2021 2

Public | Academy Piraeus – Customized – ©2021 June, 2021 3

Public | Academy Piraeus – Customized – ©2021 June, 2021 4

Public | Academy Copenhagen – ME control system I – ©2020 April 29, 2020 5

Public | Academy Piraeus – Customized – ©2021 June, 2021 6

The blowers are started one by one in order to prevent

Public | Academy Piraeus – Customized – ©2021 April 29, 2020 7

Electrically driven start-up pumps 1 & 2 are controlled

Engine driven pumps 1, 2, & 3 are controlled by ACU 1,

Engine driven pumps 4 and 5 are the same type as 1, 2

Public | Academy Piraeus – Customized – ©2021 April 29, 2020 8

Public | Academy Piraeus – Customized – ©2021 June, 2021 9

Contamination of hydraulic oil must not

Public | Academy Piraeus – Customized – ©2021 June, 2021 10

Public | Academy Piraeus – Customized – ©2021 June, 2021 11

Public | Academy Piraeus – Customized – ©2021 June, 2021 12

Public | Academy Piraeus – Customized – ©2021 June, 2021 13

Automatic backflush filter

Hydraulic Power Supply (HPS)

Public | Academy Piraeus – Customized – ©2021 June, 2021 14

Public | Academy Piraeus – Customized – ©2021 June, 2021 15

09 / 06 = production month / year

1341146 = filter cartridge ID

Sintered filter material

Public | Academy Piraeus – Customized – ©2021 June, 2021 16

Public | Academy Piraeus – Customized – ©2021 June, 2021 17

Public | Academy Piraeus – Customized – ©2021 June, 2021 18

Public | Academy Piraeus – Customized – ©2021 June, 2021 19

Public | Academy Piraeus – Customized – ©2021 June, 2021 20

Public | Academy Piraeus – Customized – ©2021 June, 2021 21

 Master pump running at engine standby (both pumps

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Public | Academy Piraeus – Customized – ©2021 June, 2021 23

Axial Piston Pump – A4VSO xxx

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125 cm3/rev - three pumps

Public | Academy Piraeus – Customized – ©2021 June, 2021 28

Chain wheel for

Public | Academy Piraeus – Customized – ©2021 June, 2021 29

Public | Academy Piraeus – Customized – ©2021 June, 2021 30

Public | Academy Piraeus – Customized – ©2021 June, 2021 31

HPS high pressure hoses five years date

Public | Academy Piraeus – Customized – ©2021 June, 2021 32

210 Bar → 300 Bar

Public | Academy Piraeus – Customized – ©2021 June, 2021 33

Public | Academy Piraeus – Customized – ©2021 June, 2021 34

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Hydraulic power supply

Sensors “vibrating fork” type

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Public | Academy Piraeus – Customized – ©2021 June, 2021 37

Public | Academy Piraeus – Customized – ©2021 June, 2021 38

Control oil for pumps

Safety & shutdown valves

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Overhaul and maintenance

Disassembly for main

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