Alpha Lubricator System Presentation For Korean Yards

MAN B&W Diesel A/S
Alpha Lubricator System

Presentations for Korean Yards
September 2003
OZS/2200/030830
Alpha Lubricator prototype for 7S35MC
The Alpha Lube princip was invented by Per Bak, Alpha Diesel in 1996 and testet
for the first time on a 7S35MC engine.
2200
2200/OZS/010423
• List of reference
• Design of the Alpha Lubricator System
• Service experience/updates
• Alpha ACC
• Retrofit of Alpha Lubricator System
• Alpha Lubricator for ME
OZS/2200/090203
Reference List.
As build:
In service: 121 engines with Alpha Lubricator
Engine types: S35MC to K98MC/MC-C
Total on order/in service: 180 engines with Alpha Lubricator
Maximum operating hours: 27,000 hours
Retrofit:
As build and retrofit:

OZS/2200/030902
• Design of the Alpha Lubricator System
OZS/2200/090203
R e a s o n fo r d e ve lo p m e n t o f o u r n e w
A lp h a L u b ric a tio n s y s te m .
• R e d u c tio n o f th e L u b e o il c o n s u m p tio n
• R e d u c tio n o f th e E m is s io n le v e l
2200
• E le m e n t fo r o u r In te llig e n t E n g in e C o n c e p t
2200/OZS/2000/0404
Spec. consump. g/Bhph at MCR
0
0,2
0,4
0,6
0,8
1
1,2
1,4
2200/OZS/2000/0404
84VT2BF180 8.5 bar
0,26
42VT2BF90 8.5 bar
0,39
K84EF 9.5 bar
0,24
K98FF 10 bar
0,21
L90GF 11.6 bar

0,35
K/L45GF 12 bar
0,45
K/L90GFCA 12.9 bar
Engine type
0,35
K/L45GFCA 13 bar
0,45
K/L-GB 15 bar
0,5
K/L/S-MC MK I-III 17 bar

0,6
1
K/L-MC MK V-VI 18 bar
S-MC MK V-VI 18 bar

1,2
Cylinder oil feed rate in the period 1965 to 2000
2200
Lubrication principle
• The lubrication principle is intermittent lubrication where an engine

cycle with lube oil injection is followed by one or more (normally 4
cycles without oil injection.
• The injection is timed in relation to the position of the piston ring.
• The specific feed rate is controlled by variation of the injection

frequency.
2200
• Adjusting of the feed rate in relation to engine power and to sulpher %
in the fuel. LCD lubrication is standard.
• Pre-lubrication of the cylinder can be done just before start of the

engine.
2200/OZS/2000/0803
Function of injection pattern
Design
L/9505-7.00299
2200
2200/OZS/2000/0803
MAN B&W Diesel A/S

L/70720-3.0/0301 (2200/OZS)
Alpha lubricator
Solenoid valve deactivated
Inductive feedback
sensor for control of
piston movement
Outlets
for cylinder liner Injection plungers
lube oil points
Solenoid
valve
Alpha Lubricator
Cylinder lube Cylinder
Spacer Adjusting screw Actuator piston oil outlet lube oil inlet
for basic setting
of pump stroke
L/ 71602- 3.1/ 0102 (2200/ OZS)

Alpha lubricator Signal for lubrication
Solenoid valve activated from control unit
Inductive feedback
sensor for control of
piston movement
Outlets
lube oil points
Solenoid valve
Alpha Lubricator
Cylinder lube Cylinder lube
Spacer Adjusting screw Actuator piston oil outlet oil inlet
for basic setting
of pump stroke
L/71601-1.1/0102 (2200/OZS)
Design
L/9491-1.0/0299
Starter 1 Starter 2 1 2
Power supply Console
24 VDC MCU HMI Pre
LCD Alarm Safety
B A input lub system system
SBU
Power supply 440V/380 VAC
BCU
11
1. Alpha Lubricator Control Unit 4
2. HMI panel
8
3. Pump station Intermediate
box
4. Transmitter box for Alpha Lubricator
7
Pick up 1
Pick up 2
5. BCU Pick-up´s
6. Encoder 5 6
7. Lubricator intermediate box

Cyl. liner
8. Lubricator
9. Pipes and non return valves 10
10. Index transmitter 9
11. Operation manual
L/74343-8.0/0502 (3210/GT)
Installation in Engine Room

L/71638-3.0/0401 (2200/OZS)
Pump Station
2200
2200/OZS/2001/12/05
Alpha Lubricator Control Unit
2200
2200/OZS/2000/1101
Alpha Lubricator system
Master Control Unit, MCU

Alpha Lubricator system
Electronic Control Units:

Master Control Unit, MCU.
• Exact timing of lube oil injection, calculation of oil-rate.
• Handles: LCD, Prelubrication, individual cylinder lubrication setup etc.
• Pump station control.
Backup Control Unit, BCU.

• Supervision of MCU and lubricators.
• Automatic takeover of lubricator control through SBU in failure situation.
• Simple pseudo random lubrication algorithm.
Switch Board Unit, SBU

• Switches the control of the lubricators from MCU to BCU.
• Switching is controlled either by BCU or by manual switch.
Display Unit, HMI panel.

• Display of different operating conditions: RPM, Fuel Index, alarms
• Setup of individual cylinder lubrication.
HMI Panel
2200
2200/OZS/2001/12/05
• Service experience/updates
OZS/2200/090203
Service Experience
Alpha Lubricator Service experience
In general the system has proven to be very reliable:
In a few cases on test-bed we have seen solenoid valve sticking

due to insufficient flushing of the oil system
On early installations, loose connections in the cylinder

intermediate boxes have been seen. Therefore, the intermediate
box has been redesigned with integrated PCB
(printed circuit board) instead of terminal blocks
The feedback sensor in the first design of the lubricators was

damaged from time to time. The sensor has been replaced with a
new reinforced type which has proved to be reliable
Software version 1.28 had problems with false alarms during

manoeuvring. This problem was solved from version 1.45
Version 1.67 is running on 70 installations in service without any

problems
3330496/20030829 (2300)
Service Experience
Alpha Lubricator Service back-up
Spare parts including ALCU-boards can

normally be delivered on a weekly basis.
ALCU-boards are normally on stock and
can, in case of an emergency, be
programmed and delivered in a few days
MAN B&W Copenhagen, Singapore and

Korea engineers available to support the
Alpha Lubricating system
3330497/20030829 (2300)
Alpha Lubricator
Mounting of Computer Panels
• Mounting of computer panel changed from 3 separate boxes
to one single cabinet – the so-called ALCU unit
(Alpha Lubricator control unit)
• Standard mounting position of computer panels are changed
from engine side to ECR
3 boxes mounted engine side ALCU unit mounted in ECR
3330472/20030828 (2300)
Alpha Lubricator
Other updates 1
• Software for MCU and BCU has been updated – changes include:
– Elimination of false alarms
– Total stroke counter logs the total number of injections, which
when multiplied by the lubricator volume can be used as a
precise flow meter
– Introduction of ACC mode (Alpha adaptive cylinder oil control)
– Display of actual injection angles in the HMI panel
– Improved menu system for easy adjustment
• Manual
– Manual has been updated including introduction of trouble
shooting guide and function diagrams
3330474/20030828 (2300)
Guiding Overhaul Intervals and
Expected Service Life
Component Overhauling Expected service life Remarks
interval in hours based on average wear
figures in hours
Starting valve, 12,000 Total engine lifetime
safety valve
and indicator
cock
Cylinder HJ Total engine lifetime *Cleaning of oil reservoir,
lubricator 16,000 filter and pumps.
Checking timing and
adjustment
Alpha Lubricator Total engine lifetime Actuators to be refilled
16,000
Crosshead 6-8,000 (every 64,000 crosshead bearing Bearings should only be

bearings year) 96,000 main bearings opened up if bearing
Main bearings check of clearances 96,000 crank bearings material fragments fall
Crank bearings and crankshaft 96,000 thrust bearing out. Inspections
Thrust bearing deflection according to classification
requirements
Page 4 (7)
L/1788-8.3/1002 (2300/PXN)
Alpha ACC
OZS/2200/090203
Cyl. lub. optimisation with Alpha system
•What means Alpha ACC ?
Electronically
timed, high Adaptive Cylinder
pressure oil dosage Control
lubrication
…or, with other words, the more fuel oil being

burnt, the more lube oil is required, and the
higher sulphur content in the fuel, the higher
quantum of additives is required. Or……….
•Presentation of Alpha ACC ?
…… Or, we like to turn it around:

With the old cylinder lubrication
systems, we had to recommend a
dosages high enough to cope with the
highest loads and the poorest fuels.
With Alpha ACC we can lubricate
optimal at any load and at any fuel
sulphur level, saving large quantities of
cylinder oil during average conditions.
Alpha ACC
From detailed wear-study of 12K90MC engine equipped with mechanical lubricator
1.6 Liner wear (mm)
0.00 mm/1000h
1.4 0.04 mm/1000h 0.06 mm/1000h 0.00 mm/1000h
1.2
1 0.48 mm/1000h 0.13 mm/1000h
0.8
0.6
0.21 mm/1000h
0.4
0.2
0
1 Liner wear (mm/1000h) *
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
*: Judgement made based on fe-content in drain oil samples
L/74407-5.0/0802 (2410 /SBJ)

Alpha ACC
The following two criteria determine the control:
1) Cylinder oil dosages proportional with the fuel oil sulpher

according to formula: Dosage= S%*0,25 g/bhph, with a minimum at
0,50 g/bhph (below 2% sulphur)
2) The cylinder oil dosage shall be proportional to the engine load (i.e.
amount of fuel entering the cylinder).
Combination of the above criteria results in:

Cylinder oil dosage proportional to the amount of sulpher entering
the cylinders.
2200/OZS/020903
Alpha ACC
Cylinder oil dosage (g/bhph)

1.25
0,25 g/bhph*S%
1.00
Optimised (reduced) side and
top-clearances introduced
based on good experience
0.75
with the MC-Compact
engines
Optimal ‘lemon-shape’
0.50
will give a minimum oil film
thickness increase of 30-40%
0.25
Sulphur %
0
0 1 2 3 4 5
L/74401-4.0/0802 (2410 /SBJ)

Alpha ACC
Cylinder oil reduction program, 10K98MC-C
Sulphur Specific dosage HMI
setting
% g/bhph g/kWh

1
1.1
0.50
0.50
0.68
0.68
59
59
1.2 0.50 0.68 59
1.3 0.50 0.68 59
1.4 0.50 0.68 59
1.5 0.50 0.68 59
Adaptive Cylinder oil 1.6 0.50 0.68 59
1.7 0.50 0.68 59
Control, easy to operate. 1.8
1.9
0.50
0.50
0.68
0.68
59
59
2 0.50 0.68 59
2.1 0.53 0.71 62
2.2 0.55 0.75 65
2.3 0.58 0.78 68
2.4 0.60 0.82 71
2.5 0.63 0.85 74
2.6 0.65 0.88 76
2.7 0.68 0.92 79
2.8 0.70 0.95 82
2.9 0.73 0.99 85
3 0.75 1.02 88
3.1 0.78 1.05 91
3.2 0.80 1.09 94
3.3 0.83 1.12 97
3.4 0.85 1.16 100
3.5 0.88 1.19 103
3.6 0.90 1.22 106
3.7 0.93 1.26 109
3.8 0.95 1.29 112
3.9 0.98 1.33 115
4 1.00 1.36 118
4.1 1.03 1.39 121
4.2 1.05 1.43 124
4.3 1.08 1.46 126
4.4 1.10 1.50 129
4.5 1.13 1.53 132
4.6 1.15 1.56 135
4.7 1.18 1.60 138
4.8 1.20 1.63 141
4.9 1.23 1.67 144
5 1.25 1.70 147
Cylinder lubrication
•Experience with Alpha ACC, new SL
•Newest optimisation test with ACC
Alpha ACC
Large scale test with Alpha ACC is in progress for various owners,
to explore the followings:
1) Savings in cylinder oil consumption.
2) Reduction of particle emissions.
3) Uniform and optimal cylinder liner wear rate.
Test involves large bore engines for both container vessels and for VLCC
propulsion, as well as small and medium bore engines.
2200/OZS/020903
Alpha ACC in service:
•Caroline Mærsk, 12K90MC, since December 2001
•Astro Cygnus, 6S90MCC, since February 2002
•Astro Carina, 6S90MCC, since April 2003
•Astipalia 6S90MCC, since January 2003
•Kos 6S90MCC, since January 2003
•Poros 6S90MCC, since February 2003
•Maria A. Angelicoussis 6S90MCC, since February 2003
•Laura Mærsk 10K90MC, since May 2002
•Mærsk Rotterdam 7S50MCC, since July 2002
•Undine 8S60MC, since March 2003
•Maersk Kolkata 10K98MCC, since March 2003
•Hamburg Express 12K98MC, since September 2002
•CMA CGM Verlaine 12K98MCC, since October 2002
•Hong Kong Express 12K98MC, since 27th November 2002
•Shanghai Express 12K98MC, since Januar 2003
•Kobe Express (retrofit) 9K90MC, since January 2003
!Dosages = 0.21 g/bhph x S%
Alpha ACC planned:
•Berlin Express 12K98MC, ultimo April 03
•Eagle Express 6S90MCC
•Samho Newbuildings 152, 153, 171 6S90MCC
”Alpha ACC VLCC 6S90MC-C:

•Cylinder oil dosages proportional with the fuel oil sulphur
according to formula: Dosages = S% * 0.25 g/bhph, with a
minimum at 0.55 g/bhph (below 2.4% sulphur), i.e. similar
dosage as the test on K90MC
•Part load control proportional with the engine load.
•Test started 8th February 2002
One years operation with ”Alpha ACC”

12K90MC, one
years operation
with Alpha ACC
= S% * 0.25
g/bhph
7,200 TEU / 12K98MC

to be operated with a
Cylinder Oil Consumption at
267 tons per year using Alpha ACC.
Specific Specific
A large Time
Oil
consumption
Engine
Engine load consump. at consump. at
speed
part load MCR
Container vessel, Date hours /
Kg Kg/24h rpm mW Load % mep% g/kWh g/bhph g/kWh g/bhph
12K98MC, day
10-Aug-02 18 936 1248 93.8 57.62 84 89 0.90 0.66 0.85 0.63
before 11-Aug-02 36 1901 1267 94 60.42 88 92 0.87 0.64 0.84 0.62
conversion to 13-Aug-02
14-Aug-02
24
24
1270
1270
1270
1270
94
94
58.39
58.39
85
85
90
90
0.91
0.91
0.67
0.67
0.86
0.86
0.63
0.63
Alpha ACC 15-Aug-02 25 1013 972 85 43.58 63 74 0.93 0.68 0.80 0.59
16-Aug-02 25 1116 1071 88.2 47.16 69 78 0.95 0.70 0.84 0.61
17-Aug-02 24 1102 1102 89.4 50.42 73 81 0.91 0.67 0.82 0.60
18-Aug-02 25 1148 1102 87.2 47.72 69 78 0.96 0.71 0.85 0.63
19-Aug-02 25 956 918 84 42.18 61 72 0.91 0.67 0.77 0.57
20-Aug-02 24 752 752 80 34.09 50 63 0.92 0.68 0.73 0.54
21-Aug-02 25 727 698 77.5 31.41 46 59 0.93 0.68 0.71 0.52
23-Aug-02 18 769 1025 88 46.45 68 77 0.92 0.68 0.81 0.59
24-Aug-02 24 974 974 86.8 43.5 63 74 0.93 0.69 0.80 0.59
25-Aug-02 24 972 972 87.8 45.61 66 76 0.89 0.65 0.77 0.57
26-Aug-02 24 1015 1015 88 47.69 69 78 0.89 0.65 0.79 0.58
27-Aug-02 24 972 972 83 41.85 61 72 0.97 0.71 0.82 0.60
5-Sep-02 18.5 992 1287 93.7 59.11 86 90 0.91 0.67 0.86 0.63
6-Sep-02 24 1230 1230 93.6 57.77 84 89 0.89 0.65 0.84 0.62
7-Sep-02 24 1234 1234 98.8 57.26 83 89 0.90 0.66 0.85 0.62
8-Sep-02 30.5 1435 1129 92 53.46 78 85 0.88 0.65 0.81 0.60
10-Sep-02 23 1138 1187 93.1 57.11 83 88 0.87 0.64 0.81 0.60
12-Sep-02 19 801 1012 90 48.95 71 80 0.86 0.63 0.77 0.57
13-Sep-02 23 895 934 87.9 45.22 66 76 0.86 0.63 0.75 0.55
14-Sep-02 23 919 959 87.9 45.77 67 76 0.87 0.64 0.76 0.56
15-Sep-02 24 979 979 88 47.38 69 78 0.86 0.63 0.76 0.56
16-Sep-02 23 923 963 88 46.14 67 77 0.87 0.64 0.76 0.56
17-Sep-02 23 895 934 88.1 46.1 67 77 0.84 0.62 0.74 0.54
18-Sep-02 24 877 877 86.3 42.91 62 73 0.85 0.63 0.73 0.54
19-Sep-02 23 854 891 86.6 42.9 62 73 0.87 0.64 0.74 0.54
Average 1043 89 48.50 71 79 0.90 0.66 0.80 0.59
1.4 Alpha ACC
1.3
1.2
1.1 World Wide average sulphur
content
1
Specific dosages (g/bhph)
0.9
0.8
0.7
0.66 g/bhph
0.6
0.5
0.4
0.3 0.25 g/bhph x S%
0.2
0.1
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Sulphur %
Consequently,
Hapag Lloyd runs there 4x12K98MC
engines with
Alpha ACC
according to:
Dosage = 0.21 g/bhph x S%
1.4 Alpha ACC
1.3
1.2
1.1 World Wide average sulphur
content
1
Specific dosages (g/bhph)
0.9
0.8
0.7
0.6
0.25 g/bhph x S%
0.5 0.24 g/bhph x S%
0.4 0.23 g/bhph x S%
0.3 0.22 g/bhph x S%
0.2 0.21 g/bhph x S%
0.1 0.20 g/bhph x S%
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Sulphur %
Cylinder Condition K98
Max. Liner Diameter Analysis

HAMBURG EXPRESS HYUNDA-AA1434
Alpha ACC factor = 0.21 g/bhph

981.00
0.05 / 1000 Hours (mm)

980.90
Cyl No. 1A
980.80
Cyl No. 2A
M ax Liner Diameter (mm)
Cyl No. 3A Alpha ACC introduced

980.70
Dosages = 0.21 g/bhph x S%
Cyl No. 5A
980.60 0.05 mm/1000h
Cyl No. 10A
980.50 Cyl No. 11A
Cyl No. 12A

980.40
980.30
980.20
980.10
980.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Engine Hours
Alpha ACC, M/S Caroline Mærsk, 12K90MC:

•Cylinder oil dosages proportional with the fuel oil sulphur
according to formula: Dosages = S% * 0.25 g/bhph, with a
minimum at 0.50 g/bhph (below 2% sulphur)
•Part load control proportional with the engine load.
•Test started 8th December 2001 at 8390h
Caroline Mærsk, 12K90MC, Alpha ACC, Cylinder liner wear
0.05 mm/1000h
0.50
0.45
Cyl 1
0.40
Cyl 2
Cyl 3 "Sulphur handle" control
Cyl 6 introduced
0.35
Cyl 7
absolute max wear (mm)
Cyl 10
0.30 Cyl 11
Cyl 12
0.25
0.20
0.15
0.10
0.05
0.00
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000
Running hours
VLCC, 6S90MC-C on Alpha ACC, Cylinder wear
0,3
0.05 mm/1000h
0,25
Test piston crown mounted. New

0,2 Alu-coat rings fitted
liner wear (mm)
0,15
Introduction of sulphur
0,1 dependent lubrication Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 6
0,05
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000
engine hours
Alpha Lubricated
MAERSK ROTTERDAM BWFRHV-052016 S50MC-C
500.30 4
0.05 / 1000 Hours (mm) ACC conversion

500.25 Cyl No. 1A 3.5
Cyl No. 2A
C ylinde r oil dos age (g/bhph a t ac tua l load) a nd

Cyl No. 3A
500.20 3
Cyl No. 4A
Max Liner D iameter (mm )
Cyl No. 5A
500.15 Cyl No. 6A 2.5
Cyl No. 7A
Sulphur %
Sulphur %
500.10 2
Feed rate
500.05 1.5
500.00 1
499.95 0.5
499.90 0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Engine Hours
Conclusion after one years Alpha ACC test on 6S90MC-C

and 6S50MCC:
Astro Cygnus has been operated on ”Alpha-Sulphur handle-control”
since 8th Feb 2002, i.e for about 6000 hours.
•Daily average cylinder oil consumption has been 460 kg against
720 kg with standard lubrication.
•Frequent inspections of the cylinder condition, latest 26th August
2002, has proven a stable and very good cylinder condition.
•Tests on ”S” engines has proved no need for differentiated guide
lines between K/L and S engines. Therefore the equation ”Dosage
= S% x 0.25 g/bhph and a minimum at 0.50 g/bhph may be used
on all Mk VI engines with the newest combustion chamber.
MAN B&W, August 2003
Guiding Cylinder Oil Feed rates

S/L/K-MC/MC-C engines with Alpha Lubricators, based on a BN 70 cylinder oil
Standard guidelines Alpha Adaptive Cylinder oil

(ref. to MCR load) Control (Alpha ACC)
0.8 g/bhph 0.25 g/bhph x S%

Basic setting
1.1 g/kWh 0.34 g/kWh x S%
0.6 g/bhph 0.5 g/bhph

Minimum feed rate
0.8 g/kWh 0.7 g/kWh
Maximum feed rate 1.25 g/bhph 1.25 g/bhph

during normal service 1.7 g/kWh 1.7 g/kWh
Proportional to mean cylinder

Proportional to engine load
pressure
Part-load control
Below 25% load, proportional to engine speed.
Service Experience
with Alpha Lubricated S90MC-C
Alpha Adaptive Cylinder Oil Control (Alpha ACC)
Standard Alpha Lubrication versus Alpha ACC
800 722
700
Daily Cylinder oil dosages (kg/24h)
600
500 464
400
300 258
200
100
0
Standard lubrication, 1.1 Actual Alpha ACC Saving by Alpha ACC
g/bhph, mep control
L/73120-4.0/0702 (3001/UM)
Service Experience
with Alpha Lubricated S90MC-C
Alpha Adaptive Cylinder Oil Control (Alpha ACC)
Standard Alpha Lubrication versus (Alpha ACC)

250.000
$210.602
Yearly Cylinder oil expence ($)
200.000
$135.222
150.000
100.000
$75.380
50.000
0
Standard lubrication, 1.1 Actual Alpha ACC Saving by Alpha ACC
g/bhph, mep control
L/73122-8.0/0702 (3001/UM)
New standard for Lubrication method.
MC/MC-C engines:
Alpha Lubricator: Alpha ACC
Mechanical Lubricator: RPM or MEP
ME engines:
Alpha Lubricator: Alpha ACC
OZS/2200/090203
• Retrofit of Alpha Lubricator System
OZS/2200/090203
Retrofit Alpha
1. Pump station
2. Alpha Lubricator
3. Conventional lubricator
4. T-piece
5. ALCU (Computer)
6. Non-return valves
L/73614-2.1/0403 (4100/PYJ)
Alpha Lubricator Retrofit
7S80MC for VLCC
L/73240-2.0/0802 (3001/UM)
Retrofit
Alpha ACC Lubricator "Cost and savings"
Engine type: 6S70MC
Layout point: 22.920 BHP
Load point: 20.628 BHP 90%
Lub. oil consumption with conventional H.J. Lubricator: 1,00 g/BHPh
Lub. oil consumption with Alpha ACC Lubricator: 0,60 g/BHPh
Fuel oil sulphur content: 2,40 %
Running hours per year: 7.000 Hours
Lub. Oil Price: 720 USD
Lub. Oil Consumption with conventional H.J. Lubricator: 154.985 kg / Year
Lub. Oil Consumption with Alpha ACC Lubricator: 86.638 kg / Year
Saving in Cyl. Lub. Oil consumption: 68.347 kg / Year
Savings per year: 49.209 USD
Budget price for Alpha Lubricator System: 87.700 USD
Estimated supervision during installation: 11.800 USD
Estimated fitter assistance: 17.000 USD
Total budget price: 116.500 USD
Pay back time: 2,37 Years
CBO/4100/20020923
ME-Engine

for
ME Engines.
OZS/2200/030312
Alpha Lubricator System for ME
Cylinder oil
Cylinder Cylinder
service tank
liner liner
Feedback Feedback
Lubricator
Lubricator
sensor sensor
Solenoid Solenoid
valve valve
200 bar To other
system oil cylinders
Hydraulic Hydraulic
cylinder unit cylinder unit
Lube oil pipes

Multi Purpose Multi Purpose
Electrical
Controller Controller
connections
L/73734-0.0/0203 (2200/OZS)
Alpha Lubricator for ME-Engine
Inductive proximity switch
for feed-back signal Signal for lubrication
for control of from controller
piston movement
Actuator piston
Outlets
lube oil injectors
Spacer
for basic setting
of pump stroke Drain oil
outlet 200 bar
Cylinder
system oil
Stroke adjusting screw lube oil supply
inlet
L/74176-1.0/0402 (2200/OZS)
ME, Alpha Lubricator
Hydraulic Cylinder Unit
ME, Alpha Lubricator
OZS/2200/030312

Alpha Lubricator System Presentation For Korean Yards

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Alpha Lubricator System Presentation For Korean Yards

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MAN B&W Diesel A/S

Alpha Lubricator System

As build and retrofit:

• Design of the Alpha Lubricator System

L90GF 11.6 bar

K/L90GFCA 12.9 bar

K/L/S-MC MK I-III 17 bar

K/L-MC MK V-VI 18 bar

S-MC MK V-VI 18 bar

• The lubrication principle is intermittent lubrication where an engine

• The injection is timed in relation to the position of the piston ring.

• The specific feed rate is controlled by variation of the injection

• Pre-lubrication of the cylinder can be done just before start of the

MAN B&W Diesel A/S

L/ 71602- 3.1/ 0102 (2200/ OZS)

7. Lubricator intermediate box

11. Operation manual

Alpha Lubricator System

Master Control Unit, MCU

Electronic Control Units:

Backup Control Unit, BCU.

Switch Board Unit, SBU

Display Unit, HMI panel.

In a few cases on test-bed we have seen solenoid valve sticking

On early installations, loose connections in the cylinder

The feedback sensor in the first design of the lubricators was

Software version 1.28 had problems with false alarms during

Version 1.67 is running on 70 installations in service without any

Spare parts including ALCU-boards can

MAN B&W Copenhagen, Singapore and

3 boxes mounted engine side ALCU unit mounted in ECR

Crosshead 6-8,000 (every 64,000 crosshead bearing Bearings should only be

•What means Alpha ACC ?

…or, with other words, the more fuel oil being

•Presentation of Alpha ACC ?

…… Or, we like to turn it around:

L/74407-5.0/0802 (2410 /SBJ)

1) Cylinder oil dosages proportional with the fuel oil sulpher

Combination of the above criteria results in:

Cylinder oil dosage (g/bhph)

L/74401-4.0/0802 (2410 /SBJ)

Cyl. lub. optimisation with Alpha system

”Alpha ACC VLCC 6S90MC-C:

One years operation with ”Alpha ACC”

7,200 TEU / 12K98MC

Max. Liner Diameter Analysis

Alpha ACC factor = 0.21 g/bhph

0.05 / 1000 Hours (mm)

Cyl No. 3A Alpha ACC introduced

Cyl No. 12A

Alpha ACC, M/S Caroline Mærsk, 12K90MC:

Caroline Mærsk, 12K90MC, Alpha ACC, Cylinder liner wear

VLCC, 6S90MC-C on Alpha ACC, Cylinder wear

Test piston crown mounted. New

0.05 / 1000 Hours (mm) ACC conversion

C ylinde r oil dos age (g/bhph a t ac tua l load) a nd

Conclusion after one years Alpha ACC test on 6S90MC-C

Guiding Cylinder Oil Feed rates

Standard guidelines Alpha Adaptive Cylinder oil

0.8 g/bhph 0.25 g/bhph x S%

0.6 g/bhph 0.5 g/bhph

Maximum feed rate 1.25 g/bhph 1.25 g/bhph

Proportional to mean cylinder