Quick guide

for

Alpha Cylinder Lubricator

Alpha ACC

from

MAN B&W Diesel A/S

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Preface:

This guide is intended as a brief introduction to the engineers running the engine
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with the newly retrofitted Alpha Lubricator System.

This guide cannot replace the main manual also supplied with the Alpha Lubricator
System.

Content:

1. Why Cylinder Lubrication?..................................................................................3

2. Alpha ACC System Layout4
3. How to get started...5
4. Daily use.9

CD-rom Content:

1. Pdf of main manual

2. ACC cyl oil log_extended.XLS
3. Sparepart Plates
4. Maintenance Procedures
5. Maintenance of Pump Station

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 1. Why Cylinder Lubrication?
The main purpose of Cylinder Lubrication is to keep the liner walls and the piston rings
lubricated at all times during engine operation.

Proper lubrication will reduce cylinder wear and ensure proper gas-tight sealing of the
clearance between piston rings and cylinder liner wall.

Large-scale testing programmes of the Alpha Lubricator System (on engines in

operation) have proved that considerable savings for the engine owners can be
achieved in respect to:

Savings on cylinder oil

Reduced particle emissions
Reduced combustion chamber wear

The principle of the Alpha ACC

The cylinder oil amount is controlled according to the amount of sulphur entering the
cylinder with the fuel. Two criteria determine the control:

The cylinder oil dosage shall be proportional to the sulphur percentage in the fuel.

The cylinder oil dosage shall be proportional to the engine load i.e. the amount of
fuel entering the cylinders.

Implementation of the above two criteria leads to an optimal cylinder oil dosage.

All this, as well as other operational aspects, is explained in details in the Instruction
Book, operation, Volume 1, sections 707-01 and 707-02. (see below)

Volume 1 Operation book, Chapter

707:
Sections:
Cylinder Condition 707-01 and
Cylinder Lubrication 707-02

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 2. Alpha ACC System Layout
The Alpha ACC System Layout is shown in a simple schematic diagram below.

Where:

1. Pump Station
2. Alpha Lubricator
3. Existing Lubricator
4. T-piece
5. ALCU (Alpha Lubricator Control Unit)
6. Non-return valves

The system is described in more detail (load transmitter, trigger system, back-up trigger
system, and etcetera) in the following chapter.

The main manual is delivered to you, together with this quick guide and the mechanical
parts from MAN B&W Diesel A/S.

NOTE: The photos and drawings used in this manual are only intended for
guidance and may differ from your engine layout.

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 3. How to get started
The Alpha Lubricator system is now commissioned and tested by the attending
superintendent.

As illustrated by the drawing on page 11, the system consists of an electronic system
coupled with a mechanical system to inject the lubrication oil into the cylinder.

The electronic system uses a series of sensors in order to establish the load and
running condition of the engine.

Encoder: Used by the MCU (Master Control Unit) to calculate the correct injection
timing of the cylinder oil.

Encoder

Index transmitter: Used by the MCU to calculate the engine load.

Index transmitter

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 BCU pickup box: The BCU (Backup Control Unit) has a set of pickups installed near
the flywheel for triggering the backup unit in case the MCU fails.

BCU pickup box

Pump station: The pump station boosts the cylinder oil up to a pressure of app. 45
bar, thereby enabling the mechanical lubricators to inject the oil at high pressure.

The pump station is controlled by the Alpha Lubricator Control Unit (see next page).

Pump station

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 The HMI (Human Machine Interface) panel: Is normally placed in the ECR (Engine
Control Room) console and gives information about possible alarms and adjustment of
feed rates, etc. Normal control and checks before start of the engine is performed from
this panel.

HMI panel

Alarm list

ALCU (Alpha Lubricator Control Unit): This cabinet contains 3 units. The Master
Control Unit (MCU), the Backup Control Unit (BCU) and the Switch Board Unit (SBU).
Normal running is carried out from the MCU. In case there is a serious electrical
malfunction in the MCU, the system will automatically switch to the BCU and an alarm
will sound. The function of the SBU is to physically switch all the electrical signals from
the MCU to the BCU.

ALCU unit:
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MCU

SBU

BCU

Setup files (pocket)

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 Checks before start (first time)

Start with checking for failures on the HMI panel. Correct any failures by consulting the
manual.

Pressure check
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Start one pump by pressing the [pump 1] or [pump 2] button on the HMI panel.
Observe that the bar graph [Oil Pressure] on the HMI panel rises to app. 45 Bar. This
can also be verified by using the arrows [], [] to read the oil pressure in the HMI
panel.

Stop the pump again when the pressure has been verified.

Prelubricating
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Next: press the [prelub] button. The pump station will start up, and the lubricators will
inject lubrication oil 12 times for each unit. In this way, system failures are tested for,
and the cylinder liners lubricated before engine start. If no alarms appear in the HMI
panel, the system is ready for start.

Please note that when the auxiliary blowers are started before normal engine start,
prelubrication will be activated automatically. Once the blowers are running the button
[prelub] is disabled and will not work if pressed.

Adjusting the feed rate

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The feed rate is adjusted on the HMI panel by pressing the [] button until the display
reads [F.rate].

Press the [enter] button, and choose individual cylinders or choose [Set.al] (for setting
the same feed rate on all cylinders) with the [] button.

Press [enter] when the desired cylinder(s) has been chosen. Adjust the feed rate with
the [, ] buttons and press [enter].

For adjustment reference see the feed rate adjustment sheet handed over by the
attending superintendent engineer.

Reading the alarms

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Any alarm detected in the system will be indicated on the HMI panel with a
corresponding alarm number. The alarm number can be decoded by means of the
alarm list which is usually placed next to the HMI panel (see HMI picture on page 7).
Detailed explanations can be found in the main manual.

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 4. Daily Use

The Alpha Lubricator System requires only a minimum of maintenance during its daily
use; however, we recommend that you observe the following items when the engine is
running.

Pump station
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During engine running, the differential pressure in the suction filter for the pump-
station must be checked for excessive pressure build-up. This is done by checking the
local manometer near the filter.

In case the filter indicator enters the red area, switch to the pump on standby and
exchange or clean the filter. Switching the pumps is done on the HMI panel by pressing
either button [pump 1] or [pump 2].

If the pump continues running with a high differential pressure, the system will
automatically start the standby pump and release an alarm, but otherwise the system
will function as normal. In worst case e.g. both filters clogged a slowdown of the engine
will be released.

Intermediate box
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The green flashing diode on the feedback intermediate box, located near the
lubricators, indicates that lubrication oil is being injected.

If no flashing can be observed, the HMI panel must be checked for any failures.
If there are no failures on the panel, the error is located to the green light diode itself,
which must be changed at the first opportunity.

Alarms
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If the panel indicates any alarms, check the user manual for corrections.

Any failures of the system, either critical or non-critical, will be indicated on the HMI
alarm panel according to the alarm list placed next to the panel, and a signal will be
sounded in the engine room.

Detailed information on possible alarms and how to respond can be found in the
manual.

Any extensive oil leaks observed must be corrected immediately.

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 Cylinder oil consumption
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With the Excel sheet ACC cyl oil log_extended XLS (see the CD-rom enclosed) it is
possible to calculate the cylinder oil consumption for a specific period of time, e.g.
daily.

Fill in the lubricator piston strokes in the log table.

The values (Str.hi and Str.lo) to be inserted in the log table can be read on the HMI.
Reading of the values is described in detail on page 14 15 in the main manual.

The value Lubricator hydraulic volume can be found on page 2 (two) of the setup
document, which the superintendent has enclosed in the ALCU unit cabinet door.

The ACC cyl oil log_extended XLS is

used to calculate the cylinder oil
consumption.

Fill in date and time and the values

(Str.hi) and (Str.lo) on the log table
shown here

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