RETROFIT for RETROFIT for
ALPHA LUBRICATORALPHA LUBRICATOR
Lay out of Alpha LubricatorLay out of Alpha Lubricator
Reference List of Alpha for Reference List of Alpha for DoosanDoosan EngineEngine
How RetrofitHow Retrofit
Cost & PaybackCost & Payback
WhatWhat’’ss Alpha LubricatorAlpha Lubricator ??
Index
■ 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
◆◆ WhatWhat’’ss Alpha Lubricator ?Alpha Lubricator ?
◆◆ Mechanical Type VS Mechanical Type VS Alpha LubricatorAlpha Lubricator
ElectronicMechanicOperating Method
Booster Oil PressureCamshaft RotationOil Actuating Power
40 – 50 bar4 – 5 barInjection PumpPressure
Adjustable 1/1 revolution (fixed)Injection Frequency
FixedAdjustablePump Stroke
(In HMI)(Adjusting Bolt)Feed Rate
Injection FrequencyPump StrokeAdjustment of
LOAD dependentRPM dependentOil Consumption
(Standard :0.80 g / bhp)1.1 g / bhph (S)
S % x 0.25 g / bhph0.9 g / bhph (K/L)Feed Rate
Alpha LubricatorMechanical TypeDescription
PUMP STATIONBuild 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
PUMP STATION
ALCU HMI
CYLINDER
LUBRICATORLOAD
TRANSMITTERANGLE
ENCODERBACK UP TRIGGER SYSTEM
24V DC
440 V, 3 ph
220 V
Electrical Connection
Piping System
◆◆ Lay Lay -- Out of Out of Alpha SystemAlpha System
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
70˚C35 bar
60 bar
30-60 ˚C40-50 bar
◆◆ PUMP STATION & STARTER PANELPUMP STATION & STARTER PANEL
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 )
◆◆ LUBRICATOR UNITS LUBRICATOR UNITS
Pressure
25
20
15
10
5
00 10 20 30 40 50 60 70 80 90 ms
Time
bar Injection pressure
Alpha Lubricator
Oil quill pressure
1. 2. 3. 4. Piston Ring
Injection pressure
mechanical lubricator
◆◆ TIMING OF CYLINDER OIL INJECTIONTIMING OF CYLINDER OIL INJECTION
8K80MC-C
◆◆ VIEW OF ALPHA LUBRICATOR RETROFITVIEW OF ALPHA LUBRICATOR RETROFIT
ALCU - Master Control Unit (MCU)- Switching Board Unit (SBU)
- Backup Control Unit (BCU)
LOAD
TRANSMITTER(4.5 mA ~ 19.5 mA)
FUEL INDEX -> MCU
◆◆ ALCU & LOAD TRANSMITTERALCU & LOAD TRANSMITTER
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
◆◆ ANGLE ENCODER & BACK UP TRIGGERANGLE ENCODER & BACK UP TRIGGER
Control &
Display Interface
-Adjustment of Feed Rate
-Display of Engine Speed,
Fuel Index Oil Pressure,
Oil Temperature and
Alarm
◆◆ HMI PANELHMI PANEL
As of September, 2007
121290MC/MC-C
3398MC/MC-C
111180MC/MC-C
723339TOTAL
29171260MC/MC-C
1515-50MC/MC-C
21 170MC/MC-C
RETROFIT WORK
(INCLUDING MATERIAL)ENG.TYPE TOTALMATERIAL SUPPLY
◆◆ Reference Lists of Alpha Lubricator RetrofitReference Lists of Alpha Lubricator Retrofit
HOW RETROFITHOW RETROFIT
◆◆ MODIFICATION PARTS FOR ALPHAMODIFICATION 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
Oil Quill Hole Oil Quill Hole Drilling (9 Drilling (9 ØØ) / Oil ) / Oil Groove GrindingGroove Grinding
Liner oil quill hole had drilled 9 mm and made oil groove to spread the oil
horizontally .
Liner oil quill hole had drilled 9 mm and made oil groove to spread the oil
horizontally .
ModificationModification
◆◆ Modification of Cylinder Liner
Non Return ValveNon Return Valve
OLD OLD TYPETYPE
NEW NEW TYPETYPE
INSTALLATION OF NEW INSTALLATION OF NEW NON RETURN VALVE NON RETURN VALVE
1 2 3 4 5 6 7 8 9
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
Liner Modification
◆◆ MODIFICATION TIME CHARTMODIFICATION TIME CHART
◆◆ SAVING COSTSAVING COST
Average Wear down rate of Mech. Lubricator : 0.10 mm / 1000 Hours
Average Wear down rate of Alpha Lubricator : 0.05 mm / 1000 Hours
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
Max Liner Diameter (mm)
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
Cyl No. 1A Cyl No. 9A Cyl No. 10A Cyl No. 1A
Cyl No. 6A Cyl No. 7A Cyl No. 10A Cyl No. 12A
◆◆ CYLINDER LINER WEAR DOWN (12K90MCCYLINDER LINER WEAR DOWN (12K90MC--C)C)
Thank YouThank You