1d - Mde 2 - Cylinder Head

Marine Diesel Engine 2
LMB 40303
(Engine Components)
Malaysian Institute of Marine Engineering Technology (MIMET) Marine Diesel Engine 2 / WEY / Jan 2017
Course Learning Outcomes (CLO)

On completion of this course, the students will be able to:
1. Explain the components from which engines are made:
foundation and accessories
2. Describe engine lubrication process, possible causes of wear and
tear and lube oil analysis
3. Describe the process of starting and reversing the engines and
be able to run, operate and trouble-shoot problems
4. Explain multi-engine propulsion arrangement, reversing,
coupling and describe the means by which main propulsion
plant is coupled by gear, pumping and generation of electrical
power.
1
Cylinder Head
Large-Bore
Two-Stroke Entablature
Diesel Engine
Frame
Bedplate
(Source of Animation: MAN B&W)
Cylinder Head
2
• Cylinder heads form the top of the combustion
chambers.
• Their primary function is to close the end of the cylinder
and seal in the gasses as they pass through a cycle
involving extreme pressure and temperature.
• The cylinder head is fitted with a number of valves and
other components for the running of the engine.
3
EXHAUST VALVE IN WATER INLET VALVE WITH RENEWABLE CAST IRON
COOLED CAGE SEAT
TO EXHAUST FROM SCAVENGE

MANIFOLD MANIFOLD
STRONGBACK LINE OF AIR STARTING

VALVE
FLAME OR
COMBUSTION
PLATE/BELT
FUEL INJECTOR
JACKET
CYLINDER LINER
4- STROKE CYLINDER COVER

4- STROKE CYLINDER COVER

• Cylinder head cast due to intricate shape
• Flat instead of conical seats for valve cages
• Reasonable size hand holes for water spaces.
• Guidance of water flow (by means of internal tubes

or baffles) towards hot centre part of lower plate.
• Improved quality cast iron, higher tensile strength
and resist creeping properties.
4
FUEL INJECTOR
RELIEF VALVE STARTING AIR
VALVE
CYLINDER HEAD
STUDS
CYLINDER HEAD
WATER GUIDE
JACKET
PISTON
CYLINDER LINER
SOFT IRON
JOINT
CYLINDER
JACKET
2- STROKE CYLINDER COVER WITH BORE COOLING

BORE COOLING COVER

• Normally for loop or cross scavenging scavenge engine
• Advantages
• Heat stress low
• Mechanical strength high
• Cover can be cast or forged (steel) – adv for forging gain and reduces
or eliminates casting defects
• Risk of notch effects due to cutting apertures reduced
• Fitting can be removed individually as complete unit
5
EXHAUST VALVE
VALVE SPINDLE HOUSING
RADIAL BORES
SOLID STEEL
PLATE
FORGED STEEL
RING PISTON @ TDC BEVELLED
BORES
2- STROKE CYLINDER TWO PARTS COVER (B&W K90GF)
TWO PARTS COVER (B&W K90GF)

• Upper part – solid steel plate with radial cooling water
bores
• Lower part – forged steel ring with bevelled cooling
water bores
• Advantages
• Short and light valves
• Low temperature level
• Small varying and low tensile stresses
• Simple mounting of valves and easy dismantling
• Disadvantages
• More joints
6
FUEL INJECTOR
RELIEF VALVE STARTING AIR VALVE
CAST IRON INSERT
CAST IRON COVER
PISTON @ TDC
2- STROKE COVER USING INSERT (RND SULZER)

USING INSERT
• Advantages
• Head shallow
• Studs evenly spaced on a pitch circle close to liner
• Studs smaller and in large numbers
• Allow large cooling water space in cylinder head
• Easier to overhaul cylinder head valve
7
VALVE SPINDLE EXHAUST VALVE
HOUSING
FUEL INJECTOR
CAST IRON COVER
PISTON @ TDC
2- STROKE COVER USING EXHAUST V/V HOUSING (B&W)
USING EXHAUST V/V HOUSING

(B&W)
• Easier valve overhauling without disturbing cylinder
head
• Position of fuel injectors problem rectified by used

three number with relatively angle
• Less exhaust gas passage restriction (for

turbocharger)
8
FUEL INJECTOR
INTERMEDIATE PLATE
CAST IRON
STRONGBACK PISTON @ TDC
(UNCOOLED)
CAST IRON COVER
(COOLED)
2- STROKE COVER USING STRONGBACK (K.Z. MAN)

USING STRONGBACK (K.Z. MAN)

• Netter material can be used for bottom part
• Cooling space can be machined to get a smooth,
turbulent and cavitations – free space
• Gutter can be machined to give even thermal loading

• Cheaper to replace
9
Cylinder Head Defects
• Cracking
• Hairline crack between fuel valve and exhaust valve
apertures (holes)
• Thermal cracking occurs at edge of aperture reinforced by a
boss and progresses in a radial direction towards central
injector hole.
• Caused by overheating, casting strains or stress-raisers
• Repaired by metal-locking(semi-permanent repair) and
welding possible if material is suitable
• Burning
• Mainly due to flame impingement
• Repair by grinding and welding if material is suitable
10
• Distortion
• Improper, uneven tightening down of studs, overheating,
unrelieved casting strains
• Prevention: hydraulic tightening of bolts, proper corrosion-
inhibitor used
• Deposits and corrosion

• Excessive scaling take p[lace when cooling water is not
suitably treated or maintained properly
• Corrosion also takes place when the water is not treated
• Prevention: cooling water treatment proper repairing a
cracked
11
Cylinder Head Temporary Repair
• Locate ends of cracks
• Drill holes about 10mm
beyond visible ends of cracks
• Tapped holes and plugged
• Used heavy brackets and
fitted as shown
• Reduce loading of engine as
low as possible
Cylinder Head Fittings

• Relief valve
• Indicator cock
• Starting air valve
• Valve gear (if any)
• Fuel injector
12
Cylinder Head Relief Valve
• Each cylinder head equipped with relief valve in order to
protect the cylinder against excessive pressures and blow off
pressure should be adjusted 20 to 30% above the normal
working pressure.
• Th3e blow-off pressure can be adjusted by altering the

thickness of the spacer ring as shown or by adjusting screw
or nut.
• Relief valve normally operated when an engine is first

started, owing to injection of an excessive fuel charge or to
pre-ignition.
Spacer ring Guide
Cylinder
head
Gas release
Spindle
Spring
Valve
Seat
SULZER-AND CYLINDER COVER RELIEF VALVE
13
Indicator Cock
• Each cylinder is provided with a test cock or
indicator cock which is used to vent the cylinder
before starting (blow true).
• This valve is also used to relieve the cylinder of
compression when turning over the engine by hand
or turning gear.
• The same valve is used far taking compression and
firing pressure readings of the cylinder while the
engine is in operation.
14
• In case of blow off occurs, valves should reseat properly and be

perfectly gas-tight when normal conditions in the cylinders are
restored. When these valve open, a piece of grit sometimes
becomes jammed between the valve seat and lid and prevents it
reseating properly.
• In such an event the fuel should be shut off from cylinder

concerned, otherwise the valve face may be burnt, then rotated
the valve until leakage stops.
• If fail to do that, stop the engine and change valve with ready
spare which have been properly cleaned, lubricated and
grounded seat
15
Summary
• Functions
• Construction
• Manufacture
• Operation & Working
• Problems & Faults
16

1d - Mde 2 - Cylinder Head

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Marine Diesel Engine 2

Course Learning Outcomes (CLO)

(Source of Animation: MAN B&W)

TO EXHAUST FROM SCAVENGE

STRONGBACK LINE OF AIR STARTING

4- STROKE CYLINDER COVER

4- STROKE CYLINDER COVER

• Guidance of water flow (by means of internal tubes

2- STROKE CYLINDER COVER WITH BORE COOLING

BORE COOLING COVER

2- STROKE CYLINDER TWO PARTS COVER (B&W K90GF)

TWO PARTS COVER (B&W K90GF)

CAST IRON COVER

2- STROKE COVER USING INSERT (RND SULZER)

CAST IRON COVER

2- STROKE COVER USING EXHAUST V/V HOUSING (B&W)

USING EXHAUST V/V HOUSING

• Position of fuel injectors problem rectified by used

• Less exhaust gas passage restriction (for

2- STROKE COVER USING STRONGBACK (K.Z. MAN)

USING STRONGBACK (K.Z. MAN)

• Gutter can be machined to give even thermal loading

• Deposits and corrosion

Cylinder Head Fittings

• Starting air valve

• Valve gear (if any)

• Th3e blow-off pressure can be adjusted by altering the

• Relief valve normally operated when an engine is first

Spacer ring Guide

• In case of blow off occurs, valves should reseat properly and be

• In such an event the fuel should be shut off from cylinder

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