RETROFIT for

ALPHA LUBRICATOR

Index
Whats Alpha Lubricator ?
Lay out of Alpha Lubricator
Reference List of Alpha for Doosan Engine
How Retrofit
Cost & Payback

 Whats 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
Feed Rate

Mechanical Type

Alpha Lubricator

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)

Pump Stroke

Adjustable

(In HMI)
Fixed

Injection Frequency

1/1 revolution (fixed)

Adjustable

Injection Pump
Pressure

4 5 bar

40 50 bar

Oil Actuating Power

Camshaft Rotation

Booster Oil Pressure

Operating Method

Mechanic

Electronic

 Lay - Out of Alpha System

PUMP STATION

PUMP
STATION

ALCU

HMI

TANK

Build up oil pressure(40-50 bar)

LUBRICATOR UNIT
Oil Injection

ALCU
(Alpha Lubricator Cont. Unit)
Master Control Unit
Back Up Control Unit

HMI PANEL

24V DC
440 V,
3 ph

220 V

(Human Machine Interface)

Remote Control & Display

LOAD
- TRANSMITTER
ANGLE ENCODER
BACK UP TRIGGER

LUBRICATOR

CYLINDER

LOAD
ANGLE
TRANSMITTER ENCODER

Piping System
Electrical Connection

BACK UP
TRIGGER
SYSTEM

 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
Value

40-50
bar

Normal Service
Value

30-60 C

Alarm min.

35 bar

Alarm max

70C

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
mechanical lubricator

10

Oil quill pressure

0
10
Time

20

30

40

50

60

70

80

90 ms

 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

ENG.TYPE

RETROFIT WORK
(INCLUDING MATERIAL)

MATERIAL SUPPLY

TOTAL

50MC/MC-C

15

15

60MC/MC-C

12

17

29

70MC/MC-C

80MC/MC-C

11

11

90MC/MC-C

12

12

98MC/MC-C

TOTAL

39

33

72

HOW RETROFIT
MODIFICATION PARTS FOR ALPHA
1. CYLINDER LINER
in case of only previous design
- Drilling of Oil Hole ( 4 -> 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

Modification

Oil Quill Hole

Drilling (9 ) / 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

OLD
TYPE

NEW
TYPE

INSTALLATION OF NEW
NON RETURN VALVE

 MODIFICATION TIME CHART

WORKING DAY
PROCEDURE
1

Cyl. Cover

Dismounting & Assembly

Cyl. Liner

Modified Lub. Oil Pocket

Electric Cabling
Booster Pump Unit
Piping & Lub. Unit
Control Unit
HMI Panel
Angle Encoder
Back up Trigger
Flushing & Cleaning
Supervision

Commisioning of System
REMARK

Liner
Modification

Replaced Non-return Valve

Installation of
Alpha
Component

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

M ax Liner D iameter (mm)

901,20
901,00
900,80

900,60
900,40
900,20
900,00
899,80
0

5000

10000

15000

20000

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

25000

Engine Hours

Thank You