Alpha Lubricator

0ADAPTIVE CYLINDER OIL CONTROL SYSTEM

The Ultimate Lubrication System

1Contents

1. What is Alpha Lubricator ?1. What is Alpha Lubricator ?

2. Layout2. Layout

3. Main components3. Main components

4. How to retrofit ?4. How to retrofit ?

5. Benefits of Alpha Lubricator5. Benefits of Alpha Lubricator

6. Reference list6. Reference list

21. What is Alpha Lubricator ?

High pressure injection directly into the piston ring pack

Very Precise Injection Timing ( Electronically )

Optimal Utilization of the Oil with minimum of loss

Pre-lubrication of the cylinder before start of the engine

Very Easy and Precise control of the feed rate

31. What is Alpha Lubricator ?

Booster Oil PressureCamshaft RotationOil Actuating Power

FixedAdjustablePump Stroke

Adjustable 1 / 1 revolution ( fixed )Injection Frequency

40 50 bar4 5 barInjection Pump Pressure

Injection Frequency

(in HMI)

Pump Stroke

(Adjusting Bolt)Adjustment of Feed Rate

ElectronicMechanicOperating Method

LOAD dependentRPM dependentOil Consumption

S % x 0.25 g/bhph

(Standard :0.75 g/bhph)

0.9 g/bhp.h (K/L)

1.1 g/bhp.h (S)Feed Rate

Alpha LubricatorMechanical TypeDescription

Mechanical Type VS Alpha Lubricator

42. Layout

1)System layout

52. Layout

2) System connection PUMP STATION ALCU

PUMP STATION

Build up oil pressure(40-50 bar)

LUBRICATOR UNITOil Injection

ALCU

(Alpha Lubricator Cont. Unit)

Master Control Unit

Back Up Control Unit

HMI PANEL(Human Machine Interface)

Remote Control & Display

LOAD TRANSMITTER

ANGLE ENCODER

BACK UP TRIGGER

TANK

HMI

CYLINDER

LUBRICATORLOAD

TRANSMITTERANGLE

ENCODERBACK UP TRIGGER SYSTEM

24V DC

440 V, 3 ph

220 V

Electrical ConnectionPiping System

63. Main components

1) PUMP STATION AND STARTER PANEL

Build up oil pressure (40-50 bar)

Consist of two pumps, Heater, Filters, Suction

Tank and Pressure/Temperature sensor.

One pump is for Stand-by

Cylinder Lube Oil TemperatureCylinder Lube Oil Pressure

Alarm max

Normal Service Value

Alarm max.

Alarm min.

Normal service Value

70C35 bar60 bar

30-60 C40-50 bar

73. Main components

2) LUBRICATOR UNITS

Oil Injection

- One Lubricator for below 60 bore Engines, Two Lubricator for 98 70 bore

Engines

- Consist of inlet nitrogen accumulator ( 25-30 bar ) and outlet

accumulator (1.5bar )

83. Main components

3) ALCU & LOAD TRANSMITTER

ALCU - Master Control Unit (MCU)- Switch Board Unit (SBU)

- Backup Control Unit (BCU)

LOAD TRANSMITTER- Calibration with Engine load - FUEL INDEX MCU

93. Main components

4) ANGLE ENCODER & PICK UP UNIT

ANGLE ENCODER

- Installed at Crankshaft Fore End

- TDC signal & RPM MCU

PICK UP UNIT

- Installed at Turning Wheel

- Consist of two pick-up sensors

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3. Main components

5) HMI & UPS PANEL

Control & Display Interface - Adjustment of Feed Rate

- Display of Engine Speed,

Fuel Index Oil Pressure,

Oil Temperature and Alarm

UPS Panel

-. Uninterruptible Power

Supply for Alpha System

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4. How to retrofit ?

MODIFICATION PARTS FOR ALPHAMODIFICATION PARTS FOR ALPHA

1) CYLINDER LINER

in case of previous design- Drilling of Oil Hole ( 4 -> 9 ) and Grinding Oil Groove- Adoption of Piston Cleaning Ring ( Optional & Recommendable )

2) NON RETURN VALVE

- Adoption of New Non Return Valve

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1) CYLINDER LINER

13


1) CYLINDER LINER

Modification of Lub. Quill

- Drilling and Grinding

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2) NON RETURN VALVE

9

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MODIFICATION TIME CHART MODIFICATION TIME CHART 1 2 3 4 5 6 7

Cyl. Cover Dismounting & Assembly

Cyl. Liner Modified Lub. Oil Pocket

Booster Pump Unit

Piping & Lub. Unit

Control Unit

HMI Panel

Angle Encoder

Back up Trigger

Flushing & Cleaning

Supervision Commisioning of System

REMARK 8 WORKING PEOPLE

Replaced Non-return Valve

Electric Cabling

Installation of

Alpha

Component

PROCEDUREWORKING DAY

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5. Benefits of Alpha Lubricator

6S50MC-C 7S60MC 7S80MC 12K90MC

Kw 9,488 14,313 25,485 54,898

BHP 12,900 19,460 34,650 74,640

Kw 8,065 12,166 21,662 46,663

BHP 10,965 16,541 29,453 63,444

% 3.00 3.00 3.00 3.00

g/Kwh 1.50 1.50 1.50 1.50

g/BHPh 1.10 1.10 1.10 1.10

g/Kwh 0.82 0.82 0.82 0.82

g/BHPh 0.60 0.60 0.60 0.60

Hour 7,500 7,500 7,500 7,500

$ /ton 1,700 1,700 1,700 1,700

$ /year 69,902 105,449 187,760 404,456

Specification

Layout SMCR

Load point(=85% SMCR)

Mech. Lubricator

Feed rate

Cy linder Lub. O il price

Sav ing for Year

Running Hours/Year

Fuel oil sulphur content

Alpha with ACC

1) Saving Cost

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2) Cylinder Liner Condition

ENGINE : DOOSAN-MAN B&W 12K90MC OWNER : A.P.MOLLER

DEL. DATE : 2000.09.25

TEST DATE : 2001.12.08 ( at 8390 Running Hour )

12K90MC, 3th April 2002 at

10,543 engine hours and

2153 operating hours at

Alpha ACC = S% * 0.25 g/bhph

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899,80

900,00

900,20

900,40

900,60

900,80

901,00

901,20

901,40

0 5000 10000 15000 20000 25000

Engine Hours

M

a

x

L

i

n

e

r

D

i

a

m

e

t

e

r

(

m

m

)

0.05 / 1000 Hours (mm) Cyl No. 1A Cyl No. 2A Cyl No. 3A

Cyl No. 4A Cyl No. 6A Cyl No. 8A Cyl No. 9A




3) Cylinder Liner Wear Down 12K90MC-C

Average Wear down rate of Alpha Lubricator : 0.05 mm / 1000 Hours

Average Wear down rate of Mechanical Lubricator : 0.10 mm / 1000 Hours

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6. Reference List

As of MARCH 2010

3346MC/MC-C

161690MC/MC-C3398MC/MC-C

131380MC/MC-C

15135116TOTAL

41192260MC/MC-C60164450MC/MC-C

151570MC/MC-C

RETROFIT WORK

(INCLUDING

MATERIAL)ENG.TYPE TOTALMATERIAL SUPPLY

Reference List of Alpha for Doosan Engine

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Contact Point

Lee, dong jin

General manager

Tel: 82-55-260-6260

E-mail: [email protected]

Park, dong gyu

Tel : 82-55-260-6137

E-mail : [email protected]

Cho, doo hyeong

Tel : 82-55-260-6138


Jung, jae ho

Tel : 82-55-260-8404


Part Sales & Technical Service Team

www.doosanengine.com

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Your Choice! Your Success!

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Doosan Engine

- Thank you -

Documents

Alpha Lubricator