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