MWH ReliaValve

with Sentry Rotator

An Innovative and Patented Mechanical Valve Rotator for 2-Stroke Engines.

MARKISCHES WERK
Your Engine. Our Ingenuity.
MWH ReliaValve with Sentry Rotator

INTRODUCTION DESIGN OF CURRENT EXHAUST

Two-stroke engine exhaust valves operate under VALVES AND WEAR MECHANISMS
extremely harsh thermal and environmental
conditions that typically result in a 6,000 - 8,000 hr. A large fraction of the worlds marine 2-stroke
service interval for these components [1]. engines are designed by three manufacturers:
Exposure to high temperatures and heavy fuel oil MAN-B&W (MC-Series), Wrtsile-Sulzer (RTA-
(HFO) combustion products can lead to severe series) and Mitsubishi (UEC-series). Each engine
chemical attack on the valve head and other parts design has unique features, but many general
of the exhaust system. Eco-speed and low characteristics of the exhaust system are common
steaming can reduce engine speeds down to 10% to all three manufacturers. Figure 1 shows a
load. Combined with the additional low sulphur typical 2-stroke exhaust valve assembly, including
requirements, these conditions can promote rapid the valve drive (hydraulic actuator), pneumatic
wear of the valve spindle seat surface. MWH has spring (air cylinder), valve housing, valve guide,
seen by-products of the combustion with ashes of valve spindle (with vane rotator), and bottom piece
non-burning constituents coming from the HFO as or valve seat.
well as from the lubeoil.
Wear Mechanisms in 2-stroke Engine Exhaust
This paper describes the design, testing and serial Valves
operation of a novel mechanical valve rotator for
increasing the service life of 2-stroke engine The most prevalent wear mechanisms in 2-stroke
exhaust valves. engine valves have been described in [2] and
include:
Adhesion and abrasive wear
Macro particles and dent marks
Build up of glassy-deposits
Low temperature corrosion
High temperature corrosion
Low-cycle fatigue

The first two of these wear mechanisms

(adhesion/abrasive wear and macro particles/dent
marks) are of particular interest to this project, and
are described in further detail.

Adhesion and abrasive wear refers to a

mechanism in which deposit particles can become
entrapped between the valve guide and valve
spindle stem. These particles adhere to the valve
spindle guide and cause abrasive wear on guide
and stem. This mechanismen causes a sticking
effect which can prevent rotation of the valve
spindle. Lack of rotation causes un-symmetric
heating and distortion of the valve spindle head,
which can subsequently lead to combustion gas
leaks and erosion. Figure 2 shows a photograph
of a valve guide with considerable deposit particle
adhesion.

Figure 1: Typical 2-stroke engine exhaust valve

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MWH ReliaValve with Sentry Rotator

Engines operating with eco-speed or extreme low-

steaming down to 10% load experience high valve
spindle temperatures caused by the lower cooling
effect of the scavange air (low scavange air
pressure follows low load). In addition, the specific
lubrication quantity under low-load conditions is
high. The low sulphur content of the fuel (HFO)
results in an over-abundance of calcium from the
lubeoil. Under these conditions, the possibility of
creating glassy-deposits on the seat area of the
valve-spindle becomes high when the correct seat
contact pressure is present. Build-up of glassy-
deposits on the seat of the bottom piece has not
been observed.
These glassy-deposits (see Figure 4) have a
Figure 2: Valve guide with evidence of hardness of approximately 800 HV with high
adhesion and abrasive wear [6]. adhesion to the valve seat material. During
inspection, it is only possible to remove the glassy-
Macro particles and dent marks refers to a deposits from the valve spindle seat with hard
mechanism in which particles and deposits formed metal scrapers. Different coefficients of thermal
as a by-product of the combustion of fuel (HFO) expansion between the valve spindle seat and the
become trapped between the valve spindle and glassy-deposits lead to radial cracks in the deposit
seat ring. When the valve spindle closes on the layer. These cracks are the initation of exhaust gas
seat ring, these particles generate a dent in each channels. After a channel is formed, and a blow
of the paired surfaces. Repeated denting of the through begins to develop, the local temperature
seating surfaces can eventually create a path for increases, accelerating the local corrosion and
leakage of combustion gases. Once this occurs, causing rapid removal of the metal surface itself
the hot combustion gases lead to the rapid erosion [3]. Typical so called cobblestone corrosion [4],
and corrosion of these metal surfaces. Figure 3 characteristic of high-temperature corrosion is
shows a photograph of a valve spindle with documented in Figure 4 as type of valve spindle
extensive evidence of dent marks. wear. Subsequent valve spindle failure usually
results.

Figure 3: Valve spindle with extensive evidence

of dent marks [6].
Recently, we have begun to see a new type of
wear mechanism on the valve spindle seat, the so
called glassing or glassy-deposits. As opposed Figure 4: Valve spindle with extensive "glassy-
to the well known wear mechanism from macro- deposits" and beginning of blow-byes.
particle indentation (see Figure 3), these glassy-
deposits form a thin, hard layer only on the valve Analysis of Glassy-Deposits
spindle seat surface. The mechanism of the glassy
deposit formation is very complex and appears to MWH analysis of the glassy-deposits showed the
be related to a combination of the following presence of compounds of calcium, vanadium,
conditions: sulphur and sodium. Under pressure and
temperature, the salts crystallize to form a thin
Fuel (HFO) quality glassy layer. Kingston-Jones, et al. have described
Lubeoil quality and quantity the formation of low melting point salts in detail [5].
Engine operation condition Sulphur oxides (SO2 and SO3), vanadium oxides
Temperature (V2O5) and sodium oxides (NA2O) from the
Seating pressure combustion process react with each other and with
calcium from the lubeoil to form these low melting

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MWH ReliaValve with Sentry Rotator

point salts. These salts include sodium sulphate

(NaSO4), calcium sulphate (CaSO4) and sodium
vanadyl vanadates of varying compositions
(usually referred to as NaVV). Table 1 shows a list
of sodium vanadyl vanadates and their respective
melting points.

Table 1: Melting points of some vanadates [5].

Compound Temperature C
NaVV* (5:12) 570
NaVV (1:6) 625
NaVO3 630
V2 O5 650-680
MgV2O6 680-700
CaV2O6, BaV2O6 700-705
Figure 5: Valve spindle with extensive
NiV2O6 720 dentmarks and beginning of blow-byes (W-type
CaV2O6 778 geometrie of bottom piece).
CrVO4 810
FeVO4 816
Ca2V2O7 820 Conventional Valve Rotation Mechanisms
Ba2V2O7 863
Ni2V2O7 880 Rotation of the valve spindle within the exhaust
Ca2V2O7 1015 valve assembly is beneficial for several reasons,
*NaVV = sodium vanadyl vanadate 5:12 = 5Na2O.V2O4. and it generally reduces the wear rate of the
11V2O5 exhaust valve assembly. Today, most 2-stroke
1:6 = Na2O.V2O4.5V2O5 exhaust valves rely on aerodynamic vanes (wing
bushes) for passive spindle rotation (see Figure 1).
Exhaust gases flow over the vanes and rotate the
Seat Ring Geometry spindle as it opens, creating an axi-symmetric
temperature distribution, and reducing thermal
The three different designs of the seat of the gradients within the valve spindle. This decreases
bottom piece of 2-stroke exhaust valves were distortion and thermal stresses within the spindle,
described extensively in [6]. The standard-type and reduces low and high cycle fatigue. However,
design features flat valve spindle and seat ring in some types of engines, vanes fail to provide
surfaces, while the W-type and Chamber-type seat additional important benefits, namely the polishing
rings employ a more complex geometry with the and removal of residuals on the valve spindle
aim of addressing the dent mark wear mechanism. sealings surface and overcoming the stiction
These seat ring designs generate higher interfacial caused by deposits within the valve guide. As
contact loads, and provide a pocket where cool, discussed previously, these phenomena lead to
un-combusted gases can reside next to the seating wear of the exhaust spindle, guide and seat ring,
surface. If a passage for gas leakage is created by and ultimately force most operators to service their
dent marks, the cool gases can escape without exhaust valves after 6,000 to 8,000 hours of
eroding the metal surfaces of the valve spindle and service. The rotation rate of the spindles is not
seat ring. controlled with the use of aerodynamic vanes. As
Seat ring geometry modifications can be used to a result, inadequate rotation is achieved at low
alleviate the dent wear mechanism, but the engine speeds and loads, and insufficient
adhesion and abrasive mechanism (sticking of rotational torque is generated to overcome stiction
valve spindle stem) and blow-byes (glassy- within the valve guide once adhesion and abrasive
deposits) must be addressed by other means, see wear are initiated. Positive mechanical rotation
also Figure 4 (chamber-type) and Figure 5 (W- addresses the shortcomings of traditional valve
type). rotators.

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MWH ReliaValve with Sentry Rotator

DESIGN FEATURES OF THE An innovative and patented mechanical valve

MECHANICAL VALVE ROTATOR rotator (Sentry Rotator) for 2-stroke engines has
been developed by Mrkisches Werk GmbH
Various approaches for controlling wear in exhaust (MWH). This valve rotator mechanism can be
valves have been employed with various degrees incorporated into an existing exhaust valve
of success. This paper describes the design of a assembly with only minor modification, as shown in
mechanical valve rotator that addresses both of Figure 6 and Figure 7. The rotator features an
the aforementioned wear mechanisms to extend inner and outer drive element. The helical rotating
the service interval of 2-stroke exhaust valves. gear is linked to the inner drive element via a free-
wheel device that transmits a rotation to the valve
The main benefit of mechanical rotation is
stem during the valve closing movement. The
achieved when a certain wiping or grinding effect is
helical gear rotator and free-wheel mechanism are
produced on the valve spindle and seat ring
shown in Figure 8.
surfaces. This seating surface polishing effect is
produced by the valve spindles rotational motion
as it contacts the bottom piece or seat ring [5].

Figure 7: Detail view of mechanical valve

rotator mechanism.

Figure 6: Exhaust valve assembly with Figure 8: Helical gear rotator and free-wheel
mechanical valve rotator. mechanism.

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MWH ReliaValve with Sentry Rotator

surfaces on the valve spindle and bottom piece

Advantages of Mechanical Rotation
were performed. In 2007, the inspection showed
The mechanical valve rotator essentially forces a that the continuous rotation described above was
controlled rotation of the valve spindle during the effective in maintaining clean, polished seating
valve closing movement. This continuous rotation surfaces. Moreover, no dent marks were visible on
speed can be tuned from 3 20 rpm, and is a either the valve spindle or bottom piece surfaces.
linear function of the engine speed. In addition, this Even after 16,647 hours of operation, there was no
valve rotation is achieved even under conditions evidence of excessive wear on the seating
where sticking in the valve guide would prevent surfaces.
rotation with an aerodynamic vane.
Based on the postive results seen in 2007, the
The Sentry Rotator provides all the traditional
target of 30,000 hours service-free operation was
benefits of valve rotation, including an axi-
deemed as possible. Additional to the on-going
symmetrical temperature distribution in the valve
field test on six MAN-B&W engines in the range
spindle to reduce thermal stresses and improve
from MC60 to MC90 type, there are also nine
low and high cycle fatigue life. However, by
MAN-B&W engines completely equipped with
rotating the valve spindle during the closing
converted ReliaValves . With this wide range of
movement, a continuous polishing effect is
experience, the MWH ReliaValves have been
achieved on the seating surfaces of the valve
approved for 30,000 hours or more. The only
spindle and bottom piece. This seat polishing
scheduled maintenance item for the ReliaValve
effect prevents deterioration by dent marks and
with Sentry Rotator consists of the replacing the
dramatically reduces the possibility of combustion
valve spindle stem seals after 15,000 to 18,000
gas leaks. In essence, continuously polishing the
hours. This work can be performed on board
seating surfaces ensures that all functions of the
without removing the complete ReliaValve from
seat (gas sealing, heat transfer, etc.) remain at
the engine. Only disassembly of the valve drive
peak efficiency throughout the life of the engine.
and air cylinder is necessary to change the stem
An additional possible benefit is that, by removing sealings. It is recommended that the free-wheel

the aerodynamic vane (wing bush) from the valve mechanism and axial bearings of the Sentry
spindle stem, an improvement in scavenging Rotator be inspected every 30,000 hours and
efficiency may be achieved. This could result in replaced, if necessary.
improved thermodynamic efficiency of the engine
and reduced fuel consumption. However, this
effect has not yet been quantified.
Mechanical valve rotation addresses two of the
major mechanisms for exhaust valve wear
(adhesion and abrasive wear and build up of
deposits and dent marks) which enables an
increase in time between overhauls of exhaust
valve assemblies.

FIELD TESTS AND SERIES OPERATION

First MWH ReliaValve reached 37,505 hours
operating experience
Figure 9: Cylinder #1 of the MAN-B&W 7L70MC
Various engine field tests have been in progress engine on the "MV Libra Buenos Aires / CMA
since 2003, on several engine types and sizes. CGM Bahia" [6].
The results of the first four years were documented
in [6]. One such field test was performed on the Figure 10 through Figure 17 show the inspection

MV Libra Buenos Aires / CMA CGM Bahia, which results and the reliability of the first ReliaValve on
is powered with a MAN-B&W 7L70MC engine (see the MV Libra Buenos Aires / CMA CGM Bahia.
Figure 9). A new Nimonic exhaust valve and Thes pictures document the operation up to the

Sentry Rotator were installed in 2003 in cylinder # 37,505 hour inspection performed in January 2010.
1 of this engine. As reported in 2007 [6], the The helix gear and the ratchet system were last

ReliaValve had succesfully reached 16,647 hours inspected at 31,882 hours. Thes components
of operation. Periodic inspections at 1,000, 4,200, appeared in as-new condition with no visible wear.
9,100, and 16,647 hours of the general function of

the ReliaValve and, in particular, the seating

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MWH ReliaValve with Sentry Rotator

Figure 12: Photograph of the valve spindle and

seat ring surfaces after 16,647 hours [6].
Figure 10: Photographs of the valve spindle
and seat ring surfaces after 1,000 hours [6].

Figure 13: Photograph of valve spindle seat

surfaces after 31,882 hours.

Figure 11: Photographs of the valve spindle

and seat ring surfaces after 9,100 hours [6].

Figure 14: Photograph of valve spindle seat

surfaces after 37,505 hours.

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MWH ReliaValve with Sentry Rotator

DESIGN REFINEMENTS
Hydraulic oil drains and air spring chamber
Field tests on an MC90 engine have lead to

refinements of the Sentry Rotator design.
Specifically, improvements have been made to the
hydraulic oil drains and air-spring chamber. This
refinement was done in 2006 and reported also in
[6].
The need for increasing the capacity of the
hydraulic oil drains was necessitated by the large
oil flow requirement of large engine valve
actuators. The addition of longitudinal grooves on
the helical gear has increased the oil drain
capacity to handle flow rates in excess of 500 l/hr.
The air-spring chamber design has also been
Figure 15: Photograph of the rotator gear and modified. This was done in order to limit the
free-wheel after 31,882 hours. maximum air pressure within the system and
match the characteristic of the original air-spring,
as shown in Figure 18 and Figure 19.

Figure 18: Comparison of the air-spring

Figure 16: Photograph of the outer helix gear chamber pressure for original valve assembly
inside the valvedrive after 31,882 hours. (no rotator), initial rotator (Evolution I), and
refined rotator design (Evolution II) [6].

Figure 19: Comparison of the hydraulic drive

pressure for original valve assembly (no
rotator), initial rotator (Evolution I), and refined
rotator design (Evolution II) [6].
Figure 17: Photograph of the inner helix gear
after 31,882 hours.

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MWH ReliaValve with Sentry Rotator

Effect of seating pressure on the removal of

glassy-deposits from the valve spindle seat
The mechanism of the glassy-deposits was
discussed in the beginning of this paper (see also
Figure 4, Table 1, and Figure 5). To remove these
hard deposits during engine operation, the
necessary and sufficient conditions are:
Seating pressure of more than 400 MPa
Rotation of the valve spindle during closing

On most of the 2- and 4-stroke engines the seating

pressure of the exhaust valve spindles operate
below 100 MPa, see also [7]. The geometry of the
W-type bottom piece reaches seating pressures of A
400 MPa or more. Similarly, after modifying the
interference angle of the seat (changing the seat
angle of the valve spindle or changing the seat
angle of the bottom piece), the necessary seating B
pressure with a minimum of 400MPa can be
achieved for exhaust valves with the common
bottom piece geometries. To limit the valve spindle
wear on the seat area, the seating pressure should
not exceed 800 MPa.
Figure 5 shows the seat area of a valve spindle Figure 20: Valve spindle seat with removed
(W-type geometry of bottom piece) with removed glassy-deposits (chamber type geometrie of
glassy-deposits at the contact area. In the majority bottom piece with modified seat angle for
of cases, MWH has seen that vane-driven valve higher seating pressure).
spindles do not rotate after the valve spindle seat
initiates contact with the bottom piece during
closing. With seating pressures above 400 MPa,
the glassy-deposit layer is effectively destroyed in
the seat contact area, but lacking rotation of the
valve spindle seat against the bottom piece, the
particles of the glassy-deposits are pressed into
the valve spindle seat, forming dentmarks and the
beginning of blow-byes.
To solve the newly observed problem with glassy-

deposits, the MWH ReliaValve Evolution III was
developed. This improved design combines the

proven ReliaValve Evolution II with a new seat
interference angle for higher seating pressure
(more than 400 MPa). The end result is a very
effective solution to combat the newly discovered
and dangerous problem of glassy-deposits. These
results can be seen in Figure 20, where the hard
particles of the glassy-deposits do not create
dentmarks during the closing process. Note that
region A is the seat mating surface area that is
both free of glassy-deposits and dents. Region B
is the remainder of the seating area which,
although covered by glassy-deposits, does not
negatively influence the operation of the valve (i.e.
does not create blow-byes).