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ADAPTIVE CYLINDER OIL CONTROL SYSTEM

The Ultimate Lubrication System

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Contents

1.
1.What
WhatisisAlpha
AlphaLubricator
Lubricator??

2.
2.Layout
Layout

3.
3.Main
Maincomponents
components

4.
4.How
Howto
toretrofit
retrofit??

5.
5.Benefits
Benefitsof
ofAlpha
AlphaLubricator
Lubricator

6.
6.Reference
Referencelist
list

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1. 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

Very Easy and Precise control of the feed rate

Pre-lubrication of the cylinder before start of the engine

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1. What is Alpha Lubricator ?

 Mechanical Type VS Alpha Lubricator

Description Mechanical Type Alpha Lubricator

0.9 g/bhp.h (K/L) S % x 0.25 g/bhph


Feed Rate
1.1 g/bhp.h (S) (Standard :0.75 g/bhph)
Oil Consumption RPM dependent LOAD dependent
Pump Stroke Injection Frequency
Adjustment of Feed Rate
(Adjusting Bolt) (in HMI)
Pump Stroke Adjustable Fixed
Injection Frequency 1 / 1 revolution ( fixed ) Adjustable
Injection Pump Pressure 4 – 5 bar 40 – 50 bar
Oil Actuating Power Camshaft Rotation Booster Oil Pressure
Operating Method Mechanic Electronic

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2. Layout
1) System layout

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2. Layout
2) System connection PUMP ALCU HMI
STATION

• PUMP STATION TANK

Build up oil pressure(40-50 bar)

• LUBRICATOR UNIT
Oil Injection

24V DC
• ALCU
(Alpha Lubricator Cont. Unit) 220 V
Master Control Unit 440 V,
3 ph
Back Up Control Unit

• HMI PANEL
(Human Machine Interface)
Remote Control & Display

• LOAD TRANSMITTER
• ANGLE ENCODER LUBRICATOR
LOAD ANGLE BACK UP
• BACK UP TRIGGER TRANSMITTER ENCODER TRIGGER
SYSTEM
Piping System
CYLINDER
Electrical Connection 5
3. 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 Pressure Cylinder Lube Oil Temperature

Normal service Value 40-50 bar Normal Service Value 30-60 ˚C

Alarm min. 35 bar Alarm max 70˚C

Alarm max. 60 bar

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3. 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 )

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3. 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

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3. 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 ALPHA

1) CYLINDER LINER
※ in case of previous design
- Drilling of Oil Hole ( Φ 4 -> Φ 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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4. How to retrofit ?

1) CYLINDER LINER

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4. How to retrofit ?

1) CYLINDER LINER

Modification of Lub. Quill


- Drilling and Grinding

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4. How to retrofit ?

2) NON RETURN VALVE


ø9

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4. How to retrofit ?

◆ MODIFICATION TIME CHART


WORKING DAY
PROCEDURE
1 2 3 4 5 6 7

Cyl. Cover Dismounting & Assembly

Cyl. Liner Modified Lub. Oil Pocket

Replaced Non-return Valve

Electric Cabling

Booster Pump Unit

Piping & Lub. Unit

Control Unit
Installation of
Alpha HMI Panel
Component
Angle Encoder

Back up Trigger

Flushing & Cleaning

Supervision Commisioning of System

REMARK 8 WORKING PEOPLE

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5. Benefits of Alpha Lubricator

1) Saving Cost
Specification 6S 50MC-C 7S60MC 7S80MC 12K90MC

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


Lay out SMCR
BHP 12,900 19,460 34,650 74,640

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


Load point
(=85% S MCR)
BHP 10,965 16,541 29,453 63,444

Fuel oil sulphur content % 3.00 3.00 3.00 3.00

g/Kwh 1.50 1.50 1.50 1.50


Mech. Lubricator
g/BHPh 1.10 1.10 1.10 1.10
Feed rate
g/Kwh 0.82 0.82 0.82 0.82
Alpha with ACC
g/BHPh 0.60 0.60 0.60 0.60

Running Hours/Y ear Hour 7,500 7,500 7,500 7,500

Cy linder Lub. O il price $ /ton 1,700 1,700 1,700 1,700

S av ing for Y ear $ /y ear 69,902 105,449 187,760 404,456

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5. Benefits of Alpha Lubricator

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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5. Benefits of Alpha Lubricator

3) Cylinder Liner Wear Down – 12K90MC-C


901,40

901,20
Max Liner Diameter (mm)

901,00

900,80

900,60

900,40

900,20

900,00

899,80
0 5000 10000 15000 20000 25000

0.05 / 1000 Hours (mm) Cyl No. 1A Cyl No. 2A Cyl No. 3A Engine Hours
Cyl No. 4A Cyl No. 6A Cyl No. 8A Cyl No. 9A
Cyl No. 1A Cyl No. 9A Cyl No. 10A Cyl No. 1A
Cyl No. 6A Cyl No. 7A Cyl No. 10A Cyl No. 12A

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

Reference List of Alpha for Doosan Engine As of MARCH 2010


RETROFIT WORK
ENG.TYPE (INCLUDING MATERIAL SUPPLY TOTAL
MATERIAL)
46MC/MC-C 3 3
50MC/MC-C 44 16 60
60MC/MC-C 22 19 41

70MC/MC-C 15 15

80MC/MC-C 13 13
90MC/MC-C 16 16
98MC/MC-C 3 3
TOTAL 116 35 151

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Contact Point

Part Sales & Technical Service Team

Lee, dong jin


General manager
Tel: 82-55-260-6260
E-mail: dongjin1.lee@doosan.com

Park, dong gyu


Tel : 82-55-260-6137
E-mail : donggyu1.park@doosan.com

Cho, doo hyeong


Tel : 82-55-260-6138
E-mail : doohyeong.cho@doosan.com

Jung, jae ho
Tel : 82-55-260-8404
www.doosanengine.com
E-mail : jaeho4.jung@doosan.com

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Your Choice! Your Success!
Your success partner
Doosan Engine

- Thank you - 21