vsp-6.3-gs-m-02 manual

7/27/2019 VSP-6.3-GS-M-02 manual

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RASHTRIYA ISPAT NIGAM L IMITED

VISAK HAPATNAM STEEL PLANTVISAKHAPATNAM

GENERAL SPECIFICATION NO. VSP-6.3/GS-M-02

FOR

LUBRICATION SYSTEMS

MARCH 2006

M.N. DASTUR & COMPANY (P) LTD

Consul t ing EngineersP-17 Miss i on Row Ex tens ionKolkata 700 013

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RASHTRIYA ISPAT NIGAM LIMITED

VISAKHAPATNAM STEEL PLANTVISAKHAPATNAM

GENERAL SPECIFICATION

FOR

LUBRICATION SYSTEMS

1.0 SCOPE

1.1 This general specification covers the lubrication systems

required for various units. The term 'lubrication systems'

referred herein covers all types of lubrication systems

including but not limited to centralised oil, centralised

grease, oil-mist, grease spray and Air-oil lubrication

systems, including interconnecting piping and electrical

control panel, positive force-feed lubricators, pad and waste

type devices, various types of oilers, drop feed devices and

manual devices. The term also covers components of

centralised circulating systems for indicating, recording andintegration of various parameters such as pressure,

temperature, velocity etc; control devices for manual and

automatic operation of the systems, safety devices and

alarms for abnormal operating conditions; interlocks for

sequencing and safe operation; hand-guns and other

appliances for manual lubrication; mobile grease guns on

wheels; spraying equipment and lubricating media.

1.2 The selection, design and construction of the systems shall

be suitable in every way for the service intended and shall be

oriented towards maximising interchangeability of

components and minimising maintenance. Each system shallbe complete in all respects including all accessories essential

for proper installation, operation and maintenance,

irrespective of whether such items are specifically mentioned

in the Technical and General Specifications.

1.3 In the interest of standardisation, the Purchaser reserves the

right of selecting a particular manufacturer of lubrication

system equipment and/or components and the contractor

shall supply equipment/components of the particular make,

if so required.

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2.0 STANDARDS

2.1 The lubrication systems shall be designed, manufactured,

erected, tested and commissioned as per the standards laiddown in this specification. Detailed instruction on such

aspects as are not indicated herein shall be as per the codes

and practices adopted by the Indian Standards (IS) wherever

available or American Society of Lubrication Engineers or as

per the standards of the national standards institution of the

country of origin or the codes of practices followed by the

manufacturer. These shall be clearly indicated by the

contractor and Purchaser’s prior approval shall be obtained.

Wherever standards other than IS are used/referred, the

contractor shall indicate the equivalent IS.

2.2 Wherever applicable, the Interplant Standards for Steel

Industry (IPSS) shall be followed.

2.3 The norms indicated in this specification shall be adhered to

unless adoption of these norms would vitiate the function

and/or safety of the systems offered. In such cases and

where different norms are adopted by the Contractor, the

same shall be clearly indicated with reasons and Purchaser's

approval obtained.

3.0 DESIGN BASIS

3.1 General

3.1.1 The design should ensure that the components of the

lubrication systems are compatible with the lubricant

selected, at the operating conditions in the plant and under

climatic conditions prevalent at site. In selecting the

lubricant, the operating temperature of system shall be given

careful consideration; and oil viscosities and grease

penetration numbers shall always be related to operating

temperature.

3.1.2 Details concerning each lubricant shall be furnished in the

form of a chart, indicating system reference, consuming point

references, location of system, type of lubricant, ISO viscosity

grade, manufacturer's code number for fluid type & grade

and quantity for first fill of system including interconnecting

piping. Wherever possible, equivalents with due regard to

local availability shall be mentioned.

3.2 Lubrication Circuits

3.2.1 Each circuit shall be designed so as to ensure adequate

supply of lubricant at the specified temperatures and

pressures for the relevant application. Each system shall be

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designed taking into account the maximum pressures

encountered in operation.

3.2.2 Each circuit shall incorporate a reservoir of adequatecapacity for lubricant with accessories, pumping equipment,

filters to eliminate undesirable particulate contaminants,

adequate cooling system to cool the return lubricant where

required, pressure tanks where necessary , adequate heating

system to adjust the viscosity of supply lubricant, generously

sized pipework, accessories and hoses, and all necessary

audio-visual alarms such as those for lubricant temperature

in reservoir, levels of lubricant in reservoirs, pump discharge

pressure, low lubricant flow, filter clogging, return lubricant

temperatures etc. Unless otherwise specified, lubrication

equipment for centralised systems located in unattended

areas, basements etc. shall have remote control facilities to

ensure safety of the main equipment served by such

lubrication systems.

3.2.3 The circuits shall incorporate necessary stand-by units, by -

passes, isolation devices etc. to ensure continuous operation

of the systems even when some components are under

maintenance, cleaning or repair.

3.2.4 The circuit design shall incorporate necessary connections,

valves and appurtenances to facilitate testing, pickling,

flushing, draining and recommissioning the systems.

3.2.5 Design of each circuit shall be such as to achieve quick

response to functional needs, economic operation of the

system and minimum maintenance. The circuit design shall

also ensure safety of the staff and of the equipment served by

the lubrication system, in case of emergencies such as power

failure, bursting of hose or pipe connections, opening of

safety valve or other devices.

3.2.6 Oil sampling outlets with isolating valves shall be provided at

suitable locations in the system.

3.3 Centralised Oil Lubrication System

3.3.1 Oil lubrication system shall be used when it is necessary :

i) To remove heat from the friction surfaces and to ensure

fluid film condition.

ii) To create a high hydro-dynamic pressure which ensures

separation of the sliding surfaces in fluid film condition.

iii) To lubricate rolling contact bearings which work for long

periods at high speeds.

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iv) To have, besides lubrication, intensive cooling of the

friction surfaces.

v) To lubricate gears and worms (with the exception of

very slow running and briefly operating mechanism).

3.3.2 Centralised oil lubrication systems shall be provided for

applications where lubrication is needed for a large number

of use points which are located reasonably close and needing

the same grade of oil lubricant.

3.3.3 Each centralised oil lubrication system shall incorporate oil

reservoir of adequate capacity , pump with electric motor,

stand-by pump with motor, duplex pressure filters (one

working, one standby), oil cooler, pressure tank, valves,

pipes, hoses, tubes and all necessary instruments and

controls and suitably designed dust and moisture proof

control panel.

3.3.4 In systems where contamination collected by the lubricating

oil is expected to be high and systems where ingress of water

in oil is high (e.g. Morgoil Systems & no-twist mill systems),

two identical reservoirs shall be provided so that while one

tank shall be in operation, the oil in the other tank shall be

centrifuged/cleaned. Centrifuge shall be permanently

connected to the tanks of such systems. The number of centrifuges for each system shall be as described in clause

no. 4.9.2 below.

3.4 Centralised Oil Mist Lubrication System

3.4.1 Centralised oil-mist lubrication system shall be used to serve

a number of points, consistent with system economy :

i) To lubricate pneumatically operated devices such as air

tools, cylinders and valves.

ii) To lubricate machinery components such as bearings,

gears and slides which require fine film lubricant.

3.4.2 Centralised oil-mist lubrication system shall incorporate mist

lubricator unit (oil atomiser) with reservoir, air line filters,

regulator with pressure gauge, lubricator, isolation valves,

heater and controls, pipes & fittings, electrical control panel,

make-up reservoir unit with pump and provision for

automatic charging. Individual element/equipment of the

system will be installed keeping in mind accessibility and

ease of maintenance.

3.5 Centralised Air-oil Lubrication System

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3.5.1 Centralised air-oil lubrication system shall be used for

lubrication of following equipment :

i) To lubricate intermediate mill RE and RTD guides, No-

twist mill RE guides, loopers, stelmor chain etc.

ii) To lubricate machinery components such as bearings,

sliding surfaces which require fine film lubricant.

3.5.2 Centralised air-oil lubrication system shall include oil

reservoir with all accessories, pumps with standby pump,

electric motor, duplex filters (one working + one standby),

pressure gauge, pressure switch, relief valve on downstream

side of each pump, progressive distributor blocks, air line

isolation valve, filter, regulator with pressure gauge, pressure

switch, solenoid valve, flow control valve, pipes & fittings,

electrical control panel etc.

3.6 Dual Line Centralised Grease Lubrication System

3.6.1 Hand operated dual line centralised grease lubrication

system shall be used for separate machines and mechanism

which have a small number of lubrication points and require

an infrequent supply of lubricant. However, for Rolling Mills,

hand operated dual-line centralised grease lubrication system

shall not be provided. For Rolling Mills, all isolated pointsrequiring less frequent greasing, shall be lubricated by mobile

greasing unit.

3.6.2 Automatic dual line centralised grease lubrication system

shall be used for lubricating large number of bearing points

in a large machine or group of machines requiring frequent

supply of lubricant for long and uninterrupted operation.

3.6.3 An automatic dual line centralised grease lubrication system

shall incorporate grease reservoir of adequate capacity with

motorised plunger type grease pump and motor, stand-by pump with motor and grease reservoir, check valves, relief

valves, pressure gauge, pressure switch, grease filters,

isolation valves with limit switches on discharge lines & tank

return lines between pumps and change over valve,

motorised/ hydraulic reversing valve, lubrication dose feeders

(metering feeders), end-of-line pressure switches with

pressure gauges, high pressure dual line pipes complete with

pipe fittings, high pressure tubing complete with end fittings

for connection to lubrication points, manifold blocks, grease

filling pump with lifting device for automatic filling of

reservoirs, solenoid valves on grease filling lines, instruments

and controls, suitably designed dust and moisture proof

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control panel, necessary interconnecting sensing and relay

lines etc.

As far as possible, separate grease systems shall be providedfor the hot zone and cold zone.

3.6.4 Each hand operated dual line centralised grease lubrication

system shall incorporate a grease reservoir of adequate

capacity , hand operated plunger type grease pump, check

valve, relief valve, pressure gauge, grease filters, manual

reversing valve, lubrication dose feeders (metering feeders),

high pressure pipes and fittings, manifold blocks etc.

3.7 Other Lubrication Facilities

3.7.1 Lubrication points which are not served by centralised

lubrication systems shall be provided with lubrication grease

nipple of standard make and type, with threads preferably as

per British Standards/ as per thread of the lubrication

points.

3.7.2 In case the space available for manual lubrication of the

point does not permit the use of the standard nipple, `button-

head' fitting or `tat head' shall be employed.

3.7.3 The connector for the hand lubrication device shall suit the

connections provided at the lubrication points.

3.7.4 Isolated lubrication points, needing oil lubrication

continuously , shall be provided with sight feed lubricators.

3.7.5 Isolated lubricating points which are not easily accessible

and are not included under centralised grease lubrication

system, shall be suitably grouped and connected to a

common distributor or distributors located conveniently for

greasing from a single point by a hand operated grease gun.

4.0 EQUIPMENT

4.1 Reservoir for Centralised Oil Lubrication System

4.1.1 For gear oil lubrication systems for rolling mills etc. where

contamination and muck is expected to be high, the useful

capacity of reservoir shall be equal to 30 minutes total pump

flow. In case of Morgoil bearings & no-twist mill bearings of

rolling mills, the useful capacity of reservoir shall be equal

to 50 minutes total pump flow. For bearings of electric

motor, steam turbine and gas turbine, the useful reservoir

capacity shall be equal to 5 to 10 minutes pump flow. The

total volume of reservoir shall be 15 per cent to 20 per cent

more than the useful volume, which will remain as free air

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space. The reservoir shall be rectangular type and shall be

proportioned as length : width : height = 2:1:1, unless

economics or standardisation dictates other proportions.

4.1.2 The reservoir shall be designed and constructed to prevent

entry of foreign matter including water. Reservoirs shall be

separate and removable from the equipment base. Cast iron

reservoirs shall not be used.

4.1.3 A 3-compartment arrangement shall preferably be used in

reservoir construction. While one compartment shall be used

for sucking of oil, the other two compartments shall be used

for return oil and for settling of water and other solid

contaminants from the oil. The volume of return chamber,

settling chamber and suction chamber shall have a ratio of

1:2:1. Suitable skimmer shall be used to separate foam

specially for large oil water emulsion systems. The suction

chamber containing clean oil for circulation shall be provided

with a float suction in addition to deep suction.

4.1.4 The reservoir shall be sub-divided into compartments by

providing baffle plates inside the reservoir across the width of

the reservoir. Necessary coarse strainers shall be provided

inside the reservoir along the baffle plate so that when the

return oil flows from return chamber to middle chamber of

the reservoir, coarse particles are removed. Necessary

magnetic rods shall also be provided on the baffle plate sothat while lubricant flows from return chamber to middle

chamber, the iron particles are arrested in the magnets.

4.1.5 All reservoirs shall have provision for lubricant filling and air

breathing, separately . The filler hole shall have a filter for

filtering the lubricant during filling and shall be fixed with

fasteners requiring hand tools for opening. Filler holes shall

be provided with caps or covers permanently attached to

the reservoir by suitable means. Combination breather and

filler assemblies shall not be used. Breather hole(s) shall be

provided and protected by air cleaner(s) containing indicativetype silica-gel for moisture trapping. The air cleaner(s) shall

be of sufficient capacity to maintain approximate atmospheric

pressure inside reservoir even at maximum demand of the

lubrication system. The number of air breathers shall

depend on the capacity of the reservoir and the capacity of

the pumps.

4.1.6 An additional nozzle connection of suitable size shall be

provided in the reservoir for external filling line, but plugged

for shipping. For Rolling Mills, fresh oil shall be filled to the

system tank from central oil storage. For other shops/areas,

fresh oil shall be filled to the system tank by a mobile filling

pump. Reservoirs shall be designed for adequate heat

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dissipation by generously proportioning the reservoir wall

surface and shall be installed as to allow unhindered air flow

over all surfaces - sides, top and bottom. Return fluid

shall have peripheral flow along reservoir side wall fromsuitably bevelled cut pipe.

4.1.7 Suitable dial thermometers protected and mounted in a

bulbwell shall be installed in the suction and return

chambers of the reservoir with at least 150 mm immersion

length. Thermostats shall be provided in the reservoir for

high temperature alarm in case temperature of oil in reservoir

exceeds the set value and for controlling tank heaters.

Wherever required, temperature transmitter shall be provided

in the reservoir with signal accessible to main control room

for on-line temperature measurement.

4.1.8 Where reservoirs are not mounted on equipment, the bottom

of the reservoir shall have a minimum clearance of 150 mm

from the floor. The legs shall have appropriate mounting

holes.

4.1.9 The reservoir shall be provided with tube type protected

level indicator. Acrylic Borosilicate glass shall be used for

level indicator. The level indicator shall be provided with

isolation valves with limit switches and drain valve. The level

indicator shall be provided with calibrated scale with

markings to show ‘high’ and ‘low’ levels with pump runningand, where necessary , ‘high’ level with pump stoppage. The

tube type or flush type level indicators shall cover the entire

height of the reservoir. For very small oil reservoirs flush

mounted type level indicators shall be provided. The flush

mounted type level indicators shall be fixed in a staggered

way to cover the entire height of the reservoir.

4.1.10 Tube type level indicators shall be provided with necessary

switches for high level alarm and filling pump cut-off, low

level alarm and low-low level alarm & main pump cut-off.

The level switches shall be mounted externally to thereservoir. Wherever required, level transmitter shall be

provided in the reservoir for signal transmission to control

room, for on-line monitoring of level.

4.1.11 The suction pipe shall be below the low-low level of fluid in

the reservoir, to avoid cavitation. The return oil pipe, the

relief return pipe and the fresh oil filling line shall be brought

down below the low-low level of fluid in the reservoir to avoid

aeration. The return oil pipe and relief return pipe shall be

located in the return chamber of the reservoir and shall be

provided with bevelled cut pipe for smooth flow. The return

oil pipe and relief return pipe shall always be located away

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from suction pipe (preferably in different compartments of the

reservoir) for efficient and smooth operation.

4.1.12 The return oil from gear boxes and bearings shall drain by gravity to the reservoir. Return lines shall slope down to the

reservoir at about 3 to 4 per cent to the horizontal depending

on specification of oil used in the system.

4.1.13 Provision shall be made for efficient cleaning of reservoir.

Suitable square or rectangular openings with hinged covers

shall be provided on top of tank. Similarly , suitable square

or rectangular openings with oil tight covers shall be provided

in each compartment of the reservoir, at the side walls ,

flushing with tank bottom plate to facilitate tank cleaning.

The top openings shall be suitably located for entry to each

compartment of the reservoir for cleaning. Openings shall be

suitable for man entry. Suitable opening with cover shall

also be provided on top of tank, along the width, for taking

out tank strainers, and magnets for cleaning.

4.1.14 The reservoir bottom shall have about 4 per cent slope

towards drain. The drain shall be piped out for further

disposal. The drain connections of the reservoir shall be

provided with isolating valves. For each compartment of the

reservoir, at least one drain connection shall be considered.

4.1.15 Reservoirs shall be fabricated from steel of suitable grade,having thickness depending on capacity of reservoirs. The

thickness of plate for reservoirs shall generally be as follows:

Capacity of

Reservoir in m3

Thickness of

side plates

Thickness of

bottom plate

Upto 3 m3 5 mm 5mm

5 to 10 m3 6 mm 6 mm

10 to 35 m3 8 mm 10 mm

35 to 90 m3 10 mm 12 mm

Necessary stiffening plates/ channels shall be provided onthe external surface of the reservoir. Interior surface of the

reservoir shall be sand blasted, cleaned and coated with

copaphen aluminium or shall be coated with the lubricating

oil to be used for circulation.

4.1.16 Lubricant return to the reservoir shall preferably be through

horizontal lines directed over a combination of trays and

screens of suitable mesh size to eliminate turbulence and

help defoaming of the lubricant. Spill from relief valve and

other pressure regulators which are free of air and

contaminants shall be discharged 150 mm or more below

lubricant level and away from pump suction to avoid

splashing. The return flow from separate lubricant

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purification systems shall also be discharged 150 mm or

more below lubricant level.

4.1.17 Pump suction opening shall be placed such that bottom of suction pipe is at least 150 mm to 200 mm above the tank

bottom to prevent dirt or water pick up. The suction opening

must be kept well below the low-low level of lubricant

(minimum 100 to 150 mm) to avoid air entry and cavitation.

When lubricant level varies widely , a floating suction shall be

used to meet the requirement.

4.1.18 Necessary sampling connection with valves shall be provided

in each compartment of the reservoir. Necessary water

detecting units shall be provided in the reservoir for Morgoil

and No-Twist Mill Oil lubrication systems.

4.1.19 The filling of fresh lubrication in the reservoir shall be either

from the central oil storage or locally by a mobile pump filter

unit from ± 0.00 level. The spent lubricant from the reservoir

shall be dumped either to the spent oil tank in the central oil

storage or shall be disposed locally in drums/oil tanker at ±

0.00 level. For small lubrication systems, the system pumps

shall be used for unloading the spent lubricant from the

reservoir. For large gear oil/morgoil/ No-Twist Mill

lubrication systems a separate pump shall be provided for

unloading the lubricant from the reservoir. Necessary nozzles

shall be provided in the reservoir for connecting spent oilpump.

4.1.20 Necessary nozzles shall be provided in the reservoir for

connecting centrifuge/vacuum dehydrator.

4.1.21 The level of low-low level switch in the reservoir shall be at

least 100 mm above the top most level of suction nozzle or

100 mm above the top most level of pump casing, whichever

is higher, to avoid cavitation of the pumps.

4.1.22 Necessary ladders shall be provided outside as well as insidethe reservoir for climbing on top of the reservoir and for

going inside the reservoir respectively, during maintenance.

4.1.23 Reservoir shall be provided with electrical junction box and

shall be prewired upto junction box.

4.2 Reservoir for Centralised Grease Lubrication system

4.2.1 Reservoir for grease lubrication systems shall be of adequate

capacity to feed grease for reasonable hours of operation. It

shall be made from general purpose structural steel fitted

with accessories to achieve specific purposes. It shall be of

cylindrical shape and mounted on top of pumping equipment

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for efficient priming. The interior shall be oiled but not be

painted. External surface shall be painted as per

General Specification for Painting (VSP-6.3/GS-P-01).

4.2.2 The useful capacity of the reservoir shall be such that it will

contain minimum 7 days and preferably 15 days grease

required by the lubrication points of the respective system.

4.2.3 The reservoir shall be complete with a heavy inertia follower

plate or churning mechanism for efficient purging of grease to

pump suction, tell-tale rod for indication of grease content,

filling connection with strainers and reservoir cover. Tell-tale

rod shall be equipped with electrical contact limit switches

for audio-visual alarms for low level, low-low level & high

level. At low level of the reservoir the grease filling pump

shall start automatically and at high level of the reservoir the

grease filling pump shall stop automatically. At low-low level

of the reservoir the main grease pump shall stop

automatically.

4.3 Pumps for Oil Lubrication System

4.3.1 Pumps for each system shall be designed to meet at least 125

per cent of system flow rates and 125 per cent of system

operating pressure. For small systems, higher pump capacity

may be selected to meet the minimum standard rating

available. Pumps for the lubrication system shall preferably be of positive displacement triple screw type. The pump

speed shall be 1500 rpm. Pump motors shall be adequate

to operate the pump continuously at 125 percent of the

system operating pressure without being overloaded.

4.3.2 In general, for each self-contained or centralised oil

lubrication system, one (1) operating and one (1) stand by

pump units shall be provided. For very large gear oil/No-

Twist Mill/Morg oil lubrication systems, two (2) nos. working

pumps may be provided with a prior approval from

Purchaser. In such system a minimum of 50% stand-by pump shall be provided. Stand-by units shall be piped to the

system. Instruments and controls for the system shall

ensure that the stand-by pump shall automatically start in

sequence in case of failure of any one of the operating pumps.

The failure of any one of the pumps shall be indicated by

audio-visual alarms, located on the control panel.

4.3.3 Pumps shall preferably be floor mounted on base frames with

flooded suction and shall not be mounted inside reservoir or

on top of reservoir without specific approval of purchaser.

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4.3.4 Flexible shaft couplings complete with coupling guards shall

be provided between the pump and motor. The type of

coupling shall be suitable for the application.

4.3.5 Direct coupled pumps shall be securely mounted in a manner

to assure alignment under normal operating conditions. The

coupling shall have adequate capacity to transmit the power

required.

4.3.6 Pumps shall be provided with stainless steel compensator

and isolation valve with limit switch on the suction side and

relief valve, check valve, isolation valve on the discharge side.

Necessary pressure gauge shall be provided on the

downstream side of each pump and pressure switches shall

be provided on the common header on the discharge side

of pumps for low pressure alarm and for automatic

starting of stand by pump in case of failure of working

pump. Necessary pressure transmitter shall be provided with

signal accessible to main control room for online pressure

measurement.

4.3.7 On the down stream side of pumps, a by-pass line with a

globe valve shall be provided, for closed circulation during

cold starting in peak winter season.

4.3.8 The mounting surface provided for a separate pump and

motor shall be rigid and shall prevent coupling misalignmentdue to work load and temperature variations. Flexible

couplings shall be used between the motor and pump, and be

of a type suitable for the application. An approved

detachable safety guard shall be fastened over the coupling

and equipped with a hinged section to facilitate lubrication.

4.3.9 The pump-motor unit shall be provided with drip tray and

drain valve. Each pump-motor unit shall be provided with

electrical junction box and shall be prewired upto junction

box.

4.3.10 The following information shall be shown on metallic name

plates on each pump:

i) Manufacturers’ name and address

ii) Manufacturer’s part, model and /or serial number

iii) Delivery, pressure, power required

The direction of rotation of each pump shall be clearly

indicated on the pump where it can be readily seen.

4.4 Pumps for Grease Lubrication System

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4.4.1 Pumps for grease lubrication system shall be of adequate

pressure rating to overcome the tremendous pressure loss in

pipelines and in metering feeders and to introduce grease in

bearing through restriction. Suitable check valve and relief valve shall be provided with the pump to protect the internal

parts from being damaged. Internal operating parts shall be

well lubricated to ensure smooth operation.

4.4.2 Grease pumps shall be positive displacement plunger type

with robust construction consistent with high pressure

service. Care shall be taken while selecting the pressure

rating of the pump for high pressure loss through pipes and

fittings, particularly in case of long piping.

4.4.3 The grease reservoir shall be mounted on top of the pump for

efficient pumping.

4.4.4 Main grease pumps shall be driven by electric motors for

automatic systems. Hand operated pumps shall be used for

manual systems. Grease filling pumps shall preferably be

pneumatically driven with dry compressed air. For

compressed air drive, the actuating mechanism shall operate

successfully with the dry air pressure available at the shop.

If the available air pressure is not adequate, separate

booster shall be provided.

4.4.5 For each centralised grease lubrication system having one (1)motor driven operating main pump to meet the system

requirement, one (1) identical motor driven additional main

pump shall be provided as a stand-by unit. Stand-by unit

shall be permanently piped to the system. Instruments and

controls shall indicate the need for starting the standby

pump in the event of failure of working main pump. The

standby main pump unit shall be started manually. The

pumping unit shall be provided with electrical junction box

and shall be prewired upto junction box. Each grease system

shall be provided with a PLC based electrical control panel.

4.5 Filters for Oil Lubrication System

4.5.1 Filters shall be provided for continuous removal of

contaminants from the lubricant which are likely to cause

damage to the equipment to be lubricated as well as the

equipment of the oil lubrication system. All systems shall be

equipped with pressure filters having specified filtration

capacity. Necessary strainers shall also be provided on the

tank return line for oil lubrication system for No-Twist Mill.

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4.5.2 Filters shall be of pressure filtration type unless specified.

The filters shall be suitable for filtering particle sizes of 50

microns for gear oil lubrication systems. For Morgoil

lubrication systems, 50 micron duplex filters shall beprovided in the system and 50 micron duplex filters shall be

provided near each stand. For No-Twist Mill bearing

lubrication system, 3-stage duplex filters of 50 micron, 25

micron and 7 micron shall be provided. Filters for large

centralised oil lubrication systems for Rolling Mills, handling

lubricants which may be contaminated by ferrous particles,

shall be provided with magnets. The pressure drop across

filters shall not exceed 0.20 kg per sq cm in clean condition

and with 125% of total pump flow. Provision shall be made

for manual changeover of the filter unit in case the pressure

drop across the working filter is more than 0.8 kg/cm2 with

rated system capacity i.e. when filter is clogged. To facilitate

this, necessary built-in changeover valves shall be provided

at the inlet and outlet of each filter.

4.5.3 Filters shall be provided with differential pressure switch

for audio visual alarm for filter clogging. Pressure check

minimess couplings shall be provided on upstream and

downstream side of filters.

4.5.4 Pressure and return line filters shall be so constructed and

installed that the filter element can be changed for cleaning

or replacement without disturbing the piping or equipmentoperation. For this purpose, duplex filters (one working +

one stand-by) shall be provided. All filters shall be provided

with isolation valves across it and drain valves/drain plugs

to facilitate maintenance of filters/filter elements. Necessary

vent valves shall also be provided for filters.

4.5.5 The filters shall be basket type/cartridge type. The material

of filter element shall be stainless steel wire mesh upto 25

micron. Finer filter elements of 10 micron & 7 micron shall

be of glass wool/paper.

4.5.6 Suitable reinforcing perforated sheet shall be provided with

the basket type/cartridge type pressure filter element to

avoid tearing of the filter element due to flow impulse.

4.5.7 Filter unit shall be provided with drip tray and drain valve.

Electrical junction box shall be provided for filter unit. The

filter unit shall be prewired upto electrical junction box.

4.6 Filters and Strainers for Grease Lubrication Systems

4.6.1 Filters used in grease lubrication system shall be of l ine

mounted type. The filter element shall be so located that

dismantling of filter is not necessary while taking out the

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element for cleaning. Body of filter shall be `Y' type made

from steel bar stock to withstand high pressure duty . Filter

element shall be of stainless steel and of 250 micron

fineness (approx).

4.6.2 Necessary filter shall be provided in the reservoir filling port

to filter the grease during filling. The filter element shall be

easily removable for cleaning.

4.6.3 Necessary line mounted filter of 250 micron fineness shall

also be provided on downstream side of grease filling pump to

filter the grease while filling the reservoirs of main pumps.

4.7 Coolers and Heaters for Oil Lubrication System

4.7.1 Coolers shall be provided in the oil lubrication systems

where normal operation of the lubrication systems will raise

the fluid temperature to over 40°C during any time of the

year and will affect the fluid viscosity. Coolers shall be plate

type of gasketted design. The plate type coolers shall be

designed such that all the four (4) ports shall be on one (1)

side of the cooler. Cooler shall be generously designed

considering high ambient temperature and water inlet

temperature of 35°C and shall have 20% spare capacity.

Cooling medium shall preferably be water. Where water line

connection is not available, air may be used as cooling

medium with prior approval from Purchaser. Plate type heatexchangers and finned tube heat exchangers shall be

designed as per manufacturer's standards.

4.7.2 Heaters shall be used in the reservoir of the lubrication

systems if the viscosity of the lubricant under ambient

conditions would affect the system operation adversely .

Heaters shall preferably be of the electrical type, having

heating intensity of not more than 0.8 watt per sq. cm.

4.7.3 Electrical heaters shall preferably be of the cartridge type,

suitable for mounting in reservoir and thermostatically controlled.

4.7.4 Each cooler shall be provided with the following :

a) Isolation valves on cooler water inlet and outlet lines

b) Isolation valves on oil inlet and outlet lines from cooler

and on the bypass line across cooler.

c) Pressure gauge and temperature indicators on cooler

water inlet & outlet lines.

d) Temperature indicators on oil inlet and outlet lines from

cooler

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e) Pressure check minimess couplings on oil inlet and

outlet lines from cooler, for checking pressure drop

across cooler.

f) Basket type filter of 250 micron fineness on cooler water

inlet line.

g) Necessary control valve with controller on cooler water

inlet line for automatic control of water flow.

4.7.5 Cooler shall be fitted external to the reservoir and shall

be mounted on a frame with drip tray and drain valve. The

cooler unit shall be provided with electrical junction box and

shall be pre-wired upto junction box.

4.7.6 The pressure drop across cooler on oil circuit shall be less

than one (1) bar and on water circuit shall be less than 0.5

bar.

4.8 Pressure Tanks for Oil Lubrication Systems

4.8.1 Pressure tank shall be provided in the oil lubrication system

to supply oil to the gear boxes/bearings of the main

equipment in case of power failure or failure of working and

stand by pumps of the oil lubrication system. The capacity of

the pressure tank shall be such that the useful workingvolume of oil in pressure tank shall be equal to 2 to 3

minutes system rated flow or shall be adequate to supply oil

to the gear boxes/bearings of the main equipment till the

transfer bar comes out of the equipment, whichever is

larger, in case of power failure or failure of both working

& standby pumps. Pressure tanks shall be designed

conforming to ASME Code for Pressure Vessels or equivalent.

4.8.2 Pressure tank shall be provided with relief valve for

protection against over pressure, pressure gauge, pressure

switches, tube type level gauge to cover entire height of pressure tank, level switch, drain valve, flow gauge glass,

man-hole with Davit, air line connection with filter, regulator

with pressure gauge, lubricator, isolation valve etc. Each

pressure tank shall be provided with isolation valve on oil

line.

4.8.3 The following information shall be permanently indicated on

each pressure tank:

a) Manufacturer's name and address.

b) Manufacturer's model number

c) Manufacturer's serial number, if any

d) Rated maximum operating pressure

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e) Charging medium

f) Total liquid capacity

g) Pre-charge pressure

h) ‘Caution - Pressurised Vessel’

4.8.4 Pressure tank shall be charged with plant compressed air.

4.8.5 The pressure tank unit shall be provided with a drip tray and

drain valve. Necessary electrical junction box shall be

provided for each pressure tank unit and the pressure tank

unit shall be prewired upto the electrical junction box.

4.9 Separator (Centrifuge) for oil lubrication systems

4.9.1 Separator shall be used with oil lubrication systems to

remove contaminants of lubricant which are picked up by the

lubricant while in operation. Contaminants which shall be

removed by separator from lubricant are as follows:

a) Water which may ingress into the system from the

equipment being lubricated, due to seal failure of plate

type cooler or due to condensation etc.

b) Dirt, dust and solid contaminants which find their way

from surrounding atmosphere into the system as well as

rust and wear products from bearings and gears.

c) Oxidation products which form sludge specially if oil is

operating at higher temperature.

4.9.2 The separator shall suck oil from the dirty oil chambers of

the reservoir, clean the oil and deliver the cleaned oil to the

clean oil chamber of the reservoir. Each gear oil lubrication

system shall have one dedicated separator unit. Each

Morgoil lubrication system shall be provided with one (1) no.

centrifuge and the centrifuge of the gear oil lubrication

system shall be connected to the tanks of Morgoil system

also. For each NTM bearing lubrication system 1 working + 1stand by centrifuge shall be provided. The capacity of the

separator shall depend on the system tank capacity . In

general, the capacity of separator shall be equal to capacity of

tank divided by 15 to 20 hours, approximately .

4.9.3 Each separator unit shall be complete with electrical control

panel and prewired upto control panel. The separator unit

shall be mounted on a base frame with drip tray and drain

valve.

4.10 Vacuum Dehydrator

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4.10.1 Higher capacity vacuum Dehydrator with a standard filter

shall be included for each No-Twist Mill bearing lubrication

system and for Finishing block lubrication system, to remove

water from oil.

4.10.2 Each vacuum Dehydrator unit shall be complete with

electrical control panel and prewired upto control panel. The

vacuum Dehydrator unit shall be mounted on a base frame

with drip tray and drain valve.

4.11 Pipework and Hose Assemblies

4.11.1 Components of pipework for oil/grease lubrication systems

shall conform to the General Specification for Pipework (VSP-

6.3/GS-M-01). All pipes for oil lubrication and grease

lubrication systems shall be seamless pipes.

4.11.2 The pipes and fittings for gear oil and normal bearing oil

lubrication systems shall be of carbon steel. The piping in

wet area for oil lubrication systems shall be of stainless steel.

For oil lubrication systems for No-Twist Mill and Finishing

block, the pipes and fittings for oil supply line on

downstream side of fine filters shall be of stainless steel. The

piping for air-oil system shall be of stainless steel.

4.11.3 Oil feed lines shall be designed for a velocity of not more than

1.2 metres per second and preferably not more than 1.0metre per second for oil with medium viscosity . For return

lines, the velocity shall be limited to 0.25 to 0.30 metres per

second, with a slope of 3 to 4 per cent. Suction lines to

pumps shall be sized for fluid velocity less than 0.5 metres

per second to avoid turbulence and pump cavitation.

4.11.4 For Morgoil and No-Twist Mill bearing lubrication systems,

where ingress of water to oil is more, drip legs shall be

provided on the return line from each stand/bearing.

4.11.5 The main headers and subheaders for grease lubricationsystems shall be of carbon steel with carbon steel

fittings. The feed pipes from metering feeders to lubrication

points shall be of stainless steel with carbon steel cadmium

plated fittings. The headers and subheaders in wet area

shall be of stainless steel with stainless steel fittings.

4.11.6 For Grease System, the main dual-line headers shall be of 30

mm OD x 5 mm thk or 25 mm OD x 4 mm thk or 20 mm OD x

3 mm thk depending on the length of main headers. The sub-

headers shall be 20 mm x OD x 3 mm thk or 16 mm OD x 2.5

mm thk or 10 mm OD x 1.5 mm thk depending on the length

of subheaders. The feed lines from metering feeders to

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lubrication points shall be 10 mm OD x 1 mm thk stainless

steel.

4.11.7 For hose, the bursting pressure shall be at least 5 times themaximum working pressure of the system. Pipework and

hoses shall be suitable for operating temperature from + 10

deg C to + 90 deg C. All the hoses in hot area shall be with

stainless steel braided cover and silica cloth cover.

4.11.8 Lubricant flow to different sections of the equipment shall be

metered out preferably by use of knife edged orifices or globe

valves.

4.11.9 The material of all isolation valves, check valves, relief valves

and control valves shall be cast steel / forged steel. All

isolation valves on oil lines shall be plug/ball type valves.

The isolation valves on cooler water inlet/outlet lines shall be

gate valves of cast steel/forged steel.

4.12 Sealing Devices

4.12.1 Material of all sealing devices shall be compatible to the

lubricant. Wherever possible, sealing devices shall be of the

pressure sealing type.

4.12.2 Sealing devices shall be suitable for system operating

temperature and pressure.

4.13 Devices for Circuit Control, Protection and Safety

4.13.1 Over-pressure Protection

4.13.1.1 Suitable relief valves shall be provided on the discharge sideof all positive displacement pumps and over-pressure

protection shall be provided else-where in circuits where

damage to the equipment or hazards to personnel may result

if design pressures are exceeded. Check valves shall be

provided on the discharge side of all pumps to prevent any

back flow.

4.13.1.2 Sequence control shall be primarily governed by

mechanically actuated limit switches, electronic timers,

sequence valve or any other position sensing device.

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4.13.1.3 A pressure gauge with shut-off valve shall be provided with

each pressure control valve. All relief valve drains shall be

piped directly to the reservoir.

4.13.2 Interlocks

4.13.2.1 The machinery and all connected equipment shall be brought

to a safe stop upon failure of electric power, control power or

control components. The system shall remain inoperative

after restoration of electric power until the controls are

reset. If an unscheduled stop would result in an unsafe

condition, then the failure shall be announced by audio-

visual alarms and stand-by or stored power shall be provided

that will permit a delayed or gradual stop under manual or

automatic control.

4.13.2.2 In the event of failure in the controls, manual controls shall

be provided that would permit bringing the system to a safe

state of operation or to a stop.

4.13.2.3 For oil lubrication systems, necessary controls shall be

provided so that the standby pump shall start automatically,

in the event of failure of the working pump, with an alarm

indicating that the working pump has failed.

4.13.2.4 Where there is more than one pump operating, interlocks

shall be provided so that the stoppage of one pump in thecircuit will not damage the equipment.

4.13.2.5 Where pumps are operating in parallel, manual valving

which will permit disconnection of one pump while the others

are still in operation shall be provided downstream of the

relief valve.

4.13.2.6 Where loss of working pressure on the discharge side of a

pump or pumps may result in damage to the equipment, in

loss of accuracy , or in danger of injury to personnel, means

shall be provided to prevent operation under these conditionsincluding automatic shut-off of pressure control by -pass

valve.

4.13.2.7 Electrically and pneumatically controlled lubrication devices

shall be applied in such a manner that in the event of

electrical or pneumatic circuit failure, there will be no

damage to the equipment or danger to personnel.

4.13.2.8 All main equipment served by lubrication systems shall be

suitably interlocked with the lubrication control circuit with a

suitable time delay relay to ensure positive lubrication before

starting.

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4.13.2.9 Lubrication systems shall be provided with local control panel

for start, stop and audio-visual alarms for faults. Lubrication

systems shall be suitably interlocked with shop PLC.

4.13.3 Other Instruments, Controls and accessories

4.13.3.1 Necessary devices shall be provided on the reservoir to

assure proper lubricant level. Reservoirs shall have sight

glasses to indicate maximum, normal and minimum lubricant

level in reservoir. Reservoirs shall have high level, low level

and low-low level switches for audio-visual alarm for high

level (with filling pump cut off), low level and low-low level

(with main pumps cut off).

4.13.3.2 Pump delivery controls shall assure correct flow of lubricant

and system pressure. With positive displacement pumps, a

pressure relief valve shall be provided to allow lubricant to

come back to reservoir in case the system pressure increases

above normal and thus protecting the pumps from being

overloaded. Unless otherwise approved by Purchaser, an air-

loaded surge tank shall be used to keep smooth supply of

lubricant during pump failure or power failure in each

system. Instrumentation on such an air tank shall normally

include an air safety valve set to operate at a pressure of 1 kg

per sq cm (g) higher than relief valve setting. Other items

are as described under Clause 4.8.2 above.

4.13.3.3 The main motor control circuit of the lubrication circulation

system shall be interlocked with that of the parent equipment

motor with suitable time delay relay to ensure positive

lubrication on start-up.

4.13.3.4 Each circulating oil lubrication system shall have globe type

by -pass valve on the downstream side of the pumps and the

line shall be connected to the tank. This is required for

closed circulation during cold start-up.

4.13.3.5 Filters shall have devices to signal need for cleaning orreplacement when they become too much loaded with dirt.

4.13.3.6 Lubricant cooler instrumentation shall assure that lubricant

is delivered at the correct temperature. Instrumentation

shall include all the items as described under Clause 4.7.4

above.

4.13.3.7 Each circulating oil lubrication system shall have automatic

pressure control valve with pressure controllers, to maintain

constant pressure on the downstream side of the system.

The pressure control/over pressure valve shall be located on

the downstream side of filters. Necessary pressure control

with controller/pressure reducing valves shall also be

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provided near gear boxes/bearings. Each system shall have

automatic temperature control valve with temperature

controller, mounted on the cooler water inlet line to maintain

constant set temperature at the outlet of the system.Necessary temperature switch shall be provided on

downstream side of heat exchanger for high temperature

alarm.

4.13.3.8 Necessary pressure gauge, pressure switch and flow switch

shall be provided on pressure feed line to each gear box and

temperature indicator & temperature switch on the return oil

line from each gear box. Pressure gauge, pressure switch

and temperature indicator shall be provided on the pressure

feed line to each bearing. Globe valve shall be provided on

the pressure feed line near each gear box/bearing.

Necessary sampling valve shall be provided on the return line

from each gear box.

4.13.3.9 Pressure, flow and temperature of lubricant delivered shall

be measured near gear boxes/bearings and shall be relayed

back to the control console for ‘low pressure’ , ‘low-flow’ and

‘high temperature’ alarms. If the pressure and temperature of

lubricating oil cross preset levels, the machine served by the

system shall be cut off by a suitable control.

4.13.3.10 Water detecting units shall be provided in the reservoir as well

as in the pipelines for systems for Morgoil bearings, no-twistmill bearings etc.

4.13.3.11Instrumentation and Control systems shall conform to

General Specification for Instrumentation and Control

Systems (VSP-6.3/GS-I-01).

4.13.4 Fault Alarms

4.13.4.1 Audio visual alarms shall be provided in the local control

panel for each oil lubrication system for the following faults:

a) Low Pressure in the systemb) Excessive temperature of oil in the reservoir

c) High level of oil in the reservoir

d) Low level of oil in the reservoir

e) Low-low level of oil in reservoir and pump cut-off

f) Clogging of filters

g) Low oil flow

h) Motor overload

4.13.4.2 For any of the above faults, necessary audio-visual alarms

shall be provided in the control room/control pulpit for

‘FAULT IN OIL LUBRICATION SYSTEM”.

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4.13.4.3 Audio-visual alarms shall be provided in the local control

panel for each grease lubrication system for following faults:

a) High level of grease in reservoir and grease filling pump

cut-off

b) Low level of grease in reservoir

c) Low-low level of grease in reservoir and main-pump cut-

off

d) Low pressure in the system

e) Motor overload

4.13.4.4 For any of the faults mentioned above, necessary audio-visual

alarms shall be provided in control pulpit/control desk for

‘FAULT IN GREASE LUBRICATION SYSTEM’.

4.14 Accessories for Grease Systems

4.14.1 In centralised grease lubrication systems, spool and plunger

type dose feeders (metering feeders) with adjustment knob

shall be provided near lubrication points. The adjustment

knob shall be graduated in cubic centimetres, to indicate

metering of grease at each setting of knob. The glands and

packing of the spool and plunger shall be designed to with-

stand high grease pressure.

4.14.2 Necessary isolation valves with limit switches shall be

provided on the P&T lines between each main grease pump

and line changeover valve for positive selection of the greasepumps.

4.14.3 End pressure switches shall be provided in dual line grease

system to ensure pressure attainment at the farthest end of

the circuit, during the cycle of operation and to alter the path

of grease flow by reversing the motorised changeover valve by

electrical impulses. The end pressure switches shall be

mounted at the upstream side of farthest dose feeder

(metering feeder).

4.14.4 Necessary isolation valves shall be included on the main

branch lines. The piping in wet area shall be of stainless

steel.

4.14.5 Grease filling device

Automatic grease filling device shall consist of grease filling

pump driven by dry compressed air, grease drum cover,

necessary starter and controls, follower plate, limit switch

for low level alarm (grease drum empty), pressure gauge,

relief valve, line filter of 250 micron on the discharge side of

pump and pump lifting device. Necessary air line filter,

regulator with pressure gauge and lubricator, isolation valveand solenoid valve shall be provided on air line to grease

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filling pump. The limit switches fitted to grease reservoir of

main pumps shall relay electrical impulse initiated by tell-

tale rod to the motor control or solenoid operated pneumatic

valve, indicating the need for filling. The filling system shallautomatically stop when the reservoir is full, on getting

similar electrical impulse from another limit switch.

4.15 Oil Mist Lubrication System

4.15.1 Oil mist lubrication system shall be complete with mist

lubricating unit, accessories, electrical controls, piping and

fittings.

4.15.2 The system shall be designed in such a way that the spray fog

that escapes from the lubricated elements shall be kept to a

minimum.

4.15.3 Oil mist lubrication unit shall include a reservoir with

accessories, automatic filter and moisture separator,

pressure regulator, air inlet valve, pressure switch to monitor

the inlet air, suitably sized mist generator and necessary

alarms and controls.

4.15.4 The system shall have suitable provisions for collecting,

draining and purging out the oil that will condense in the

pipeline.

4.15.5 Pipework and hose assemblies, sealing devices, circuit

control, protection, safety and interlock devices shall be

generally as laid out in Clause 4.11 through 4.13 above.

4.16 Other Lubrication Devices

4.16.1 These devices shall be selected to suit the lubrication

requirements for components of various equipment

accessories, valves etc. for which centralised lubrication

systems have not been provided for technical or economic

reasons. Where necessary , the reasons for selection of thedevice adopted shall be described clearly . The devices

selected shall be compatible with the lubricant recommended.

4.16.2 Manual devices such as containers with suitable outlet and

manually controlled valve shall be used only for inexpensive

or rough machinery such as wire rope, chains, open gear,

valves etc. Oil squirt cans, pump valve squirt can, screw

type grease cup, grease hand gun etc. may be classified

under this category of device.

4.16.3 Drop feed devices, which are gravity flow devices, shall be

considered for applications for isolated equipment/

components such as journal and roller bearings, gears,

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chains, engine guides, pumps, compressors pillow blocks,

etc.

4.16.4 Splash or bath lubrication method may be adopted forinternal combustion engines, chain drives, closed gear sets

etc.

4.16.5 Ring, chain and roller type lubrication methods may be

adopted for smaller electric motors, fans, blowers,

compressors, in-line shaft bearings etc. in instances where

proper bearing lubricant reservoir level can be easily

maintained.

4.16.6 Pad and waste type devices may be used for traction motor

bearings, sleeve bearings etc. These devices shall preferably

not be used in very dirty environments. Wick feed oiler,

waste feed oiler, under feed pad oiler, saturated pad oiler etc

may be considered under this category of devices.

4.16.7 Force feed lubricators, comprising of one or more plunger

type adjustable stroke pumps mounted on a reservoir, and

driven by a mechanical linkage, may be used for equipment

not requiring large quantity of lubricants. For application

such as steam cylinders, bearings for diesel and gas engines,

metal press bearings etc. these devices may be used.

4.16.8 Air-oil devices comprising oil reservoir, compressed airsupply device, piping and aspiration mechanism to draw oil

through the action of air passing through a suitable control

valve or orifice may be provided for high-speed bearings,

enclosed gears, chains, slides, guides, table-ways etc.

5.0 SAFETY AND ACCESSIBILITY

5.1 Safety

5.1.1 Flexible lines shall be restrained to prevent undesirable

movements to reduce possibility of failure.

5.1.2 Lubricating systems shall be suitably interlocked with

operating machinery with some time delay relay (in case of

motorised lubricating systems) to ensure positive lubrication

before the equipment starts functioning.

5.1.3 Lubrication equipment and piping shall be so located or

protected as to prevent damage from material handling

equipment.

5.1.4 All controls, pumps etc. shall be located against falling

objects and operator's accidental movements.

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5.1.5 Lubrication equipment and piping shall be located or

protected against excessive temperature or other detrimental

effects such as water.

5.1.6 Automatic control shall be located and protected to prevent

accidental operation.

5.1.7 Components which might be damaged by exposure to dirt,

dust or other environmental conditions, or by moving

equipment, shall be adequately protected and readily

accessible.

5.1.8 Piping shall not be used to support valves or other system

components.

5.1.9 Automatic air bleeds shall be installed on the discharge side

of all pumps.

5.1.10 Thermal insulation shall be provided for lubrication system

for equipment operating in areas of high temperatures.

5.1.11 For lubrication systems provided in the vicinity of open

flames, high temperatures, molten metal etc. (such as those

for furnaces, cranes, coilers etc.), special protection shall be

given to prevent breakout of fire in case of pressure break out

of the lubricant. These shall include selection of suitable

seal, packings and fittings. Use of non-inflammable lubricantshall be considered only with the approval of Purchaser.

5.2 Accessibility

5.2.1 Name plates shall be provided for all control station

components and shall be located so that they can be easily

read.

5.2.2 Lubrication devices located at an elevated height shall be

provided with proper access.

5.2.3 An emergency stop shall be considered, and when provided

shall be readily accessible from the operator's normal working

position. This feature shall be engineered to suit the

requirements.

5.2.4 All lubrication equipment, controls and piping shall be

accessible, have adequate working clearance and be mounted

in a position that will not interfere with the equipment

adjustments or maintenance and shall not require the use of

portable platforms or ladders. Removal of equipment other

than that being attended for maintenance shall not be

necessary .

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5.2.5 All manual controls shall be mounted within easy reach of

the operator when he is in normal operating position .

Operator shall not be required to reach fast moving

equipment to reach manual controls.

6.0 ASSEMBLY, ERECTION AND COMMISSIONING

6.1 All components and equipment of lubrication systems shall

be cleaned, both externally and internally , as mentioned in

the equipment suppliers' manuals for erection and

maintenance.

6.2 Lubrication pipework shall be assembled, tested, pickled,

flushed and commissioned as given in the General

Specification for Pipework VSP-6.3/GS-M-01.

6.3 Installation of electrical system shall conform to General

Specification for Installation, Testing and Commissioning of

Electrical Equipment.

7.0 INSPECTION AND TESTING

7.1 All components of the lubrication systems shall be inspected

and tested at the manufacturer’s premises by the Purchaser/

authorised representative of Purchaser as per the General

Specification for Inspection and Testing requirement for Plant

& Equipment at manufacturer’s Premises(VSP-6.3/GS-IN-01).

7.2 Each lubrication system/equipment shall be inspected at site

for completeness and correctness of supply and erection as

per the General Conditions of Contract and as specified in

relevant clauses of the Technical Specification for the

systems and equipment.

7.3 Performance tests for lubrication systems/equipment shall be

carried out at site along with the operation of the main

equipment to which the lubrication systems shall be

connected, to check the flow rate, pressure & temperature of lubricant, pressure drop across filters & cooler, power

consumption by electric motors etc. as well as proper

functioning of the main equipment as per the requirement of

conditions of contract.

8.0 PAINTING

All components of the lubrication systems shall be painted as

per General Specification for Painting VSP-6.3/GS-P-01.

9.0 DRAWINGS AND OTHER DOCUMENTS

9.1 Drawings and technical information shall be furnished in

accordance with the General Condition of Contract and as

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specified in the relevant clauses of the equipment

specification. The following types of drawings and technical

information shall be provided for the lubrication systems:

9.1.1 Flow diagram for each lubrication system showing all

components and pipelines by means of approved graphical

symbols with parts list indicating complete specification, size,

pressure rating, material, model no. make, quantity etc. of

each item.

9.1.2 General arrangement drawings for each unit of the

lubrication system.

9.1.3 General arrangement drawings for the lubrication

cellars/rooms.

9.1.4 Interconnecting piping drawings for the piping from take over

point of the shop upto lubrication cellars/rooms, piping

within the lubrication cellars/rooms and piping between

lubrication cellars/rooms and lubrication points etc., with

Bill of Quantities. The piping drawings shall show detailed

routing of pipes, details of supports, fittings, valves etc. with

sufficient sections so that the erector can erect the pipes with

the help of these drawings. For grease systems, grease spray

systems, oil mist system and air-oil system, the

interconnecting piping shall be from T.O.P of shop to

pumping station and between pumping station and

lubrication points.

9.1.5 Isometric drawings for interconnecting piping in critical

areas.

9.1.6 Catalogue/technical literature including component details,

sectional drawings, trouble shooting charts etc.

9.1.7 Operation and instruments manuals for hydraulic system.

9.1.8 Electrical ladder diagram

When the lubrication system is supplied with electricalcontrol, electrical diagram supplied shall be ladder type and

include chart showing limit switch, relay and solenoid

actuation.

9.1.9 Sequence-time chart

A chart shall be supplied showing sequence of operation in

relation to cycle time, and electrical actuation. This chart

should also show pressure and flow for each portion of the

cycle.

9.1.10 Detailed list of each component and equipment served by

each lubrication system.

7/27/2019 VSP-6.3-GS-M-02 manual


VSP-6.3/GS-M-02

9.1.11 Type, characteristics and trade name of lubricant for each

equipment indicating Indian equivalent.

9.1.12 Quantity of lubricant consumed for each system (hourly flow

rates, annual consumptions).

9.1.13 Schedule for lubricant change for each system.

vsp-6.3-gs-m-02 manual

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