MAN B&W Diesel A/S

Service Letter SL03-417/HRJ

January 2003

Cylinder Oil Dosage Optimisation

S/L/K-MC/MC-C/ME, Mk 6 engines
with Alpha Lubricator System
Action Code: WHEN CONVENIENT

Dear Sirs

Standard Guidelines

As informed in our Service Letter SL02-398/HRJ, January 2002, we have reduced our
guiding feed rates for K/L-MC/MC-C engines equipped with the Alpha Lubricator
system.

Service experience has now demonstrated that it is also possible to reduce the feed
rate for the super-long-stroke S-MC/MC-C engines fitted with Alpha Lubricators, even
down to the same low level as for the K/L engines, i.e. to a basic feed rate of 0.8
g/bhph and a minimum of 0.6 g/bhph, see the enclosure.

Alpha ACC (Adaptive Cylinder oil Control)

The actual need for cylinder oil quantity varies with the operational conditions such as
load and fuel oil quality. Consequently, in order to obtain the optimal lubrication, the
cylinder oil dosage should be adapted to such operational variations.

With the introduction of the electronically controlled Alpha Lubricator system, featuring
the easy-to-operate “HMI” panel, such adaptive lubrication has become feasible. The
Alpha Lubricator system offers the possibility of saving a considerable amount of
cylinder oil per year and, at the same time, to obtain a safer and more predictable
cylinder condition.

HEAD OFFICE (& Postal address) DIESEL SERVICE PRODUCTION FORWARDING MAN B&W Diesel A/S
Teglholmsgade 41 Teglholmsgade 41 Teglholmsgade 35 Teglholmsgade 35 Denmark
DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV DK-2450 Copenhagen SV CVR.No.: 39 66 13 14
Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00 Telephone: +45 33 85 11 00
Telex: 16592 manbw dk Telex: 31197 manbw dk Telex: 19023 manfw dk Telex: 19023 manfw dk
Telefax: +45 33 85 10 30 Telefax: +45 33 85 10 49 Telex: 19042 manfw dk Telex: 19042 manfw dk
E-mail: [email protected] E-mail: [email protected] Telefax: +45 33 85 10 17 Telefax: +45 33 85 10 16
http://www.manbw.dk E-mail: manufacturing/[email protected]
 2

Intensive studies of the relation between wear and lube oil dosage have revealed that
the actual need for cylinder lubrication follows the amount of fuel being burnt and the
fuel quality.

This calls for part-load lube oil control which is proportional to the engine output, as
load and oil consumption in this connection are practically proportional. This is, at the
same time, the most economical control mode, compared to the previous practice
where part-load dosages were controlled proportionally with either engine speed or
cylinder mean pressure.

The basic feed rate control should be adjusted in relation to the actual fuel quality
being burnt at a given time. Of course, fuel quality is rather complex. However, studies
have also shown that the sulphur percentage is a good indicator in relation to wear,
and an oil dosage proportional to the sulphur level will give the best overall cylinder
condition.

This new cylinder oil control principle is called the “Alpha Adaptive Cylinder oil
Control”, or abbreviated “Alpha ACC”.

Tests with Alpha ACC on K and S engines of various engine sizes have shown that a
safe and optimum lube-economical control is obtained with a basic setting according
to the below formula:

Basic lube oil setting = 0.25 g/bhph x S%,

with a minimum setting of 0.5 g/bhph, i.e. the setting should be kept constant from 2%
sulphur and down.

Alpha ACC
Cylinder oil Dosages (g/bhph)

1.25

0.75

0.5

0.25

0
0 1 2 3 4 5
Fuel Oil Sulphur %
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How to adjust the dosage according to the Alpha ACC principle

First of all, knowledge of the sulphur percentage of the fuel oil being burnt at any time
is a condition for obtaining the savings with Alpha ACC. Therefore, we recommend
that the ships in question join one of the well-known fuel analysis programmes on the
market, and that burning of the oil is not started until the analysis result is known. This
will normally take two to four days after bunkering.

One of the key parameters in Alpha ACC lubrication is part-load control proportional to
engine load. This is important in order to prevent over-lubrication at low loads, and it is
one of the main parameters to save oil, compared with conventional lubrication.

If “load-proportional control” is not already preset from delivery of your Alpha

Lubricator system, we suggest that you contact MAN B&W Diesel A/S in order to get
instructions on how to change the software from either speed-proportional control or
cylinder-mean-pressure proportional control.

When starting to burn new bunker oil, the HMI setting of the Alpha ACC should be
adjusted according to the bunker analysis results. For reference, the below table
should be used:

Sulphur Dosage HMI

% g/bhph g/kWh Setting
0.0-2.0 0.50 0.68 63
2.2 0.55 0.75 69
2.4 0.60 0.82 75
2.6 0.65 0.88 81
2.8 0.70 0.95 88
3.0 0.75 1.02 94
3.2 0.80 1.09 100
3.4 0.85 1.16 106
3.6 0.90 1.22 113
3.8 0.95 1.29 119
4.0 1.00 1.36 125
4.2 1.05 1.43 131
4.4 1.10 1.50 138
4.6 1.15 1.56 144
4.8 1.20 1.63 150
5.0 1.25 1.70 156
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Some of the early Alpha Lubricator systems have deviating relations between the
delivery dosage and the HMI setting. Please check with your instruction manual that
the HMI setting is 100% at 0.8 g/bhph. If not, please contact MAN B&W Diesel A/S.

Our ‘basic setting’ is traditionally chosen to obtain a dosage which, in average

conditions, results in a safe and lube-oil-economical cylinder condition. This leaves
possibilities for further individually based reductions, towards the recommended
minimum setting.

In the case of the Alpha ACC, the basic factor of 0.25 g/bhph x S% may, of course,
also be lowered. Currently, we have experienced down to a factor of 0.21 g/bhph x
S%.

Regarding running-in, part load and load change situations and lubrication in the event
of abnormal cylinder condition, please refer to the attached “Guiding Cylinder Oil Feed
Rates”.

Questions or comments regarding this SL should be directed to our Dept. 2300.

Yours faithfully
MAN B&W Diesel A/S

Carl-Erik Egeberg Mikael C. Jensen

Encl.
MAN B&W Diesel A/S

Guiding Cylinder Oil Feed Rates

S/L/K-MC/MC-C/ME/ME-C engines with Alpha Lubricators, based on a BN 70 cylinder oil

Standard guidelines Alpha Adaptive Cylinder oil

(ref. to MCR load) Control (Alpha ACC)

0.8 g/bhph 0.25 g/bhph x S%

Basic setting
1.1 g/kWh 0.34 g/kWh x S%

0.6 g/bhph 0.5 g/bhph

Minimum feed rate
0.8 g/kWh 0.7 g/kWh

Maximum feed rate 1.25 g/bhph 1.25 g/bhph

during normal service 1.7 g/kWh 1.7 g/kWh

Proportional to mean cylinder

Proportional to engine load
pressure
Part-load control
Below 25% load, proportional to engine speed.

First 5 hours: 1.6 g/bhph = 200%

Feed rate: From 5 to 250 hours: Basic setting +50%
Alu-coat From 250 to 500 hours: Basic setting +25%
Running- piston rings:
in new Engine load: Stepwise increase to max. load over 5 hours
liners
and
piston First 15 hours: 1.6 g/bhph
rings Non-coated Feed rate: From 15 to 250 hours: Basic setting +50%
or From 250 to 500 hours: Basic setting +25%
hard-coated
rings:
Engine load: Stepwise increase to max. load over 15 hours

Feed rate: Basic setting +25% for 24 hrs.

Running-in new rings in Alu-coat piston rings: No load restrictions
already run-in liners: Non-coated or hard-coated rings: Stepwise load increase to max.
load over 5 hours.

During starting, manoeuvring and load changes, regulation

Load change depen-
proportional to load or mean effective pressure should be replaced
dent lubrication (LCD)
by rpm proportional control, and the dosage increased by 25%.

Frequent scavenge port inspections of piston rings and cylinder

liners are very important for maintaining a good cylinder condition.
Lubrication of cylinders
If irregularities are seen, adjustments of the lube oil rate should be
that show abnormal
considered.
conditions:
In case of scuffing, sticking piston rings or high liner temperature
fluctuations, the feed rate should be raised by 25–50%.

2003-01-20
HRJ/ATJ