the ultimate lubrication systemmaytau.ut.edu.vn/userfiles/files/alpha-lubricator.pdf · 1. what is...
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◆ADAPTIVE CYLINDER OIL CONTROL SYSTEM
The Ultimate Lubrication System
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Contents
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
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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
Pre-lubrication of the cylinder before start of the engine
Very Easy and Precise control of the feed rate
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1. 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
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2. Layout
1)System layout
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2. 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 Connection
Piping System
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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 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
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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 ALPHAMODIFICATION 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 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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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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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 L
iner
Dia
mete
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
Cyl No. 1A Cyl No. 9A Cyl No. 10A Cyl No. 1A
Cyl No. 6A Cyl No. 7A Cyl No. 10A Cyl No. 12A
5. Benefits of Alpha Lubricator
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-C
3398MC/MC-C
131380MC/MC-C
15135116TOTAL
41192260MC/MC-C
60164450MC/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
E-mail : [email protected]
Jung, jae ho
Tel : 82-55-260-8404
E-mail : [email protected]
Part Sales & Technical Service Team
www.doosanengine.com
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Your Choice! Your Success!
Your success partner
Doosan Engine
- Thank you -