RETROFIT for

ALPHA LUBRICATOR
Index
What’s Alpha Lubricator ?

Lay out of Alpha Lubricator

Reference List of Alpha for Doosan Engine

How Retrofit

Cost & Payback

◆ What’s Alpha Lubricator ?

■ High pressure injection directly into the piston

ring pack

■ Precise Injection Timing ( Electronically )

■ Optimal Utilization of the Oil with minimum

of loss

■ Easy and Precise control of the feed rate

◆ Mechanical Type VS Alpha Lubricator

Description Mechanical Type Alpha Lubricator

Feed Rate 0.9 g / bhph (K/L) S % x 0.25 g / bhph
1.1 g / bhph (S) (Standard :0.80 g / bhp)
Oil Consumption RPM dependent LOAD dependent

Adjustment of Pump Stroke Injection Frequency

Feed Rate (Adjusting Bolt) (In HMI)

Pump Stroke Adjustable Fixed

Injection Frequency 1/1 revolution (fixed) Adjustable

Injection Pump
4 – 5 bar 40 – 50 bar
Pressure

Oil Actuating Power Camshaft Rotation Booster Oil Pressure

Operating Method Mechanic Electronic

◆ Lay - Out of Alpha System
PUMP ALCU HMI
PUMP STATION STATION

Build up oil pressure(40-50 bar) TANK

LUBRICATOR UNIT
Oil Injection
ALCU
(Alpha Lubricator Cont. Unit)
24V DC
Master Control Unit
Back Up Control Unit 220 V
440 V,
HMI PANEL 3 ph

(Human Machine Interface)

Remote Control & Display
LOAD
- TRANSMITTER
ANGLE ENCODER
BACK UP TRIGGER LUBRICATOR
LOAD ANGLE BACK UP
TRANSMITTER ENCODER TRIGGER
Piping System SYSTEM
CYLINDER
Electrical Connection
◆ PUMP STATION & 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 40-50 Normal Service

30-60 ˚C
Value bar Value

Alarm min. 35 bar Alarm max 70˚C

Alarm max. 60 bar

◆ 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 )
◆ TIMING OF CYLINDER OIL INJECTION

Pressure
25 bar Injection pressure
Alpha Lubricator

20

15
1. 2. 3. 4. Piston Ring
Injection pressure
10
mechanical lubricator

5 Oil quill pressure

0
0 10 20 30 40 50 60 70 80 90 ms
Time
◆ VIEW OF ALPHA LUBRICATOR RETROFIT

8K80MC-C
◆ ALCU & LOAD TRANSMITTER

ALCU
- Master Control Unit (MCU)
- Switching Board Unit (SBU)
- Backup Control Unit (BCU)

LOAD
TRANSMITTER
(4.5 mA ~ 19.5 mA)
FUEL INDEX -> MCU
◆ ANGLE ENCODER & BACK UP TRIGGER

Injection Timing Signal

- Installed at Crankshaft Fore End
- TDC signal & RPM -> MCU

Back up for Angle

Encoder
- Installed at Turning Wheel
- Consist of two pick-up sensors
◆ HMI PANEL

Control &
Display Interface
-Adjustment of Feed Rate
-Display of Engine Speed,
Fuel Index Oil Pressure,
Oil Temperature and
Alarm
◆ Reference Lists of Alpha Lubricator Retrofit
As of September, 2007

RETROFIT WORK
ENG.TYPE MATERIAL SUPPLY TOTAL
(INCLUDING MATERIAL)

50MC/MC-C - 15 15

60MC/MC-C 12 17 29

70MC/MC-C 1 1 2

80MC/MC-C 11 11

90MC/MC-C 12 12

98MC/MC-C 3 3

TOTAL 39 33 72
 HOW RETROFIT

◆ MODIFICATION PARTS FOR ALPHA

1. CYLINDER LINER
※ in case of only 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
◆ Modification of Cylinder Liner

Oil Quill Hole

Modification Drilling (9 Ø) / Oil
Groove Grinding

Liner
Liner oil
oil quill
quill hole
hole had
had drilled
drilled 99 mm
mm and
and made
made oil
oil groove
groove to
to spread
spread the
the oil
oil
horizontally
horizontally ..
Non
NonReturn
ReturnValve
Valve

INSTALLATION OF NEW
OLD NEW
NON RETURN VALVE
TYPE TYPE
◆ MODIFICATION TIME CHART
WORKING DAY
PROCEDURE
1 2 3 4 5 6 7 8 9

Cyl. Cover Dismounting & Assembly

Liner
Cyl. Liner Modified Lub. Oil Pocket Modification
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

◆ SAVING COST
◆ CYLINDER LINER WEAR DOWN (12K90MC-C)

Average Wear down rate of Mech. Lubricator

: 0.10 mm / 1000 Hours

Average Wear down rate of Alpha Lubricator

: 0.05 mm / 1000 Hours

901,40

901,20
M ax Liner D iameter (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
Thank You