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This standard is developed in accordance with the rules given in GB/T 1.1-2009.
This standard was proposed by and is under the jurisdiction of the National Technical Committee on Metallurgical Equipment of the Standardization Administration of China (SAC/TC 409).
Lubrication system - Inspection specification
1 Scope
This standard specifies the technical requirements, test methods, inspection rules, marking inspection and packaging inspection of lubrication system.
This standard is applicable to inspection of lubrication system.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
GB/T 191 Packaging - Pictorial marking for handling of goods
GB/T 3287 Malleable cast iron pipe fittings
GB/T 5277 Fasteners - Clearance holes for bolts and screws
GB/T 9969 General principles for preparation of instructions for use of industrial products
GB/T 13306 Plates
GB/T 14436 General principles of industrial product guarantee documents
GB 18613 Minimum allowable values of energy efficiency and energy efficiency grades for small and medium three-phase asynchronous motors
GB/T 19052 Acoustics - Noise emitted by machinery and equipment - Rules for the drafting and presentation of a noise test code
GB/T 37400.3 Heavy mechanical general technical specification - Part 3: Welding parts
GB/T 37400.10 Heavy mechanical general technical specification - Part 10: Assembling
GB/T 37400.11 Heavy mechanical general technical specification - Part 11: Piping
GB/T 37400.12 Heavy mechanical general technical specification - Part 12: Painting
GB/T 37400.13 Heavy mechanical general technical specification - Part 13: Packaging
GB 50093 Code for construction and quality acceptance of automation instrumentation engineering
GB 50171 Code for construction and acceptance of switchboard outfit complete cubicle and secondary circuit electric equipment installation engineering
NB/T 47004.1 Plate heat exchangers - Part 1: Plate-and-frame heat exchangers
NB/T 47007 Air-cooled heat exchangers
NB/T 47045 Brazed plate heat exchangers
3 Technical requirements
3.1 General requirements
3.1.1 The lubrication system shall be manufactured and inspected according to the drawing and technical document approved by prescribed procedures. The flow requirements and pressure design criteria for lubrication system shall be specified or agreed by the Buyer.
3.1.2 The lubrication system shall be free from penetration and leakage.
3.1.3 The lubrication system shall be able to keep the oil supply temperature at 40±3℃.
3.1.4 The sealing material in the lubrication system shall be compatible with the lubricating medium. Seal parts containing asbestos materials shall not be used.
3.1.5 All elements and accessories of the lubrication system shall be provided with qualification certificates.
3.1.6 Each external interface of the lubrication system shall be provided with companion flange or pipe joint.
3.1.7 Noise measurement shall meet the requirements of GB/T 19052. Under the nominal pressure and flow, the noise of lubrication system is less than or equal to 85dB(A).
3.1.8 The lubrication system shall be equipped with oil collecting facilities such as oil collecting tray, and the oil collecting facilities shall be provided with oil discharge outlets.
3.1.9 The lubrication system shall be installed on a horizontal plane, and anchor bolt installation holes shall be provided for fixing when necessary.
3.1.10 The lubrication system shall be provided with grounding bolts with clear grounding marks.
3.1.11 The lubrication system shall be provided with an electrical junction box, each end terminal inside shall be marked with line number printed by machine, and the junction box shall be arranged at a place convenient for maintenance. Shielded cables shall be adopted for control cables. In order to connect the cables into the junction box orderly, the oil tank shall be provided with line slots or threading pipes.
3.1.12 The welding parts shall meet the requirements of GB/T 37400.3.
3.1.13 The assembling shall meet the requirements of GB/T 37400.10.
3.1.14 The piping shall meet the requirements of GB/T 37400.11.
3.1.15 The painting shall meet the requirements of GB/T 37400.12.
3.1.16 The automation instrumentation shall meet the requirements of GB 50093.
3.1.17 Installation and wiring of electric control cabinet elements shall meet the requirements of GB 50171.
3.1.18 See Annex A for guidelines on reliability of lubrication system.
3.1.19 See Annex B and Annex C for the schematic diagram and outline drawing of oil lubrication system respectively.
3.1.20 See Annex D for the schematic diagram of single-line grease lubrication system of manual lubrication pump; see Annex E for the schematic diagram of ring-type double-line grease lubrication system of electric lubrication pump.
3.1.21 See Annex F for the schematic diagram of oil-mist lubrication system.
3.1.22 See Annex G for the schematic diagram of oil-air lubrication system.
3.1.23 See Annex H for the end-of-manufacturing inspection record sheet of oil lubrication device.
3.2 Technical requirements for oil lubrication system
3.2.1 Technical requirements for oil tank are as follows:
——The oil tank shall have a reserved space to avoid oil overflow when the oil in lubrication circuit returns to the oil tank.
——The opening of oil tank top plate shall be provided with a subplate with a thickness of at least 10mm and a seal washer.
——The oil tank shall have sufficient rigidity to avoid vibration or deformation after load bearing. For assemblies connected to the oil tank with bolts, the screw holes shall not extend into the oil tank.
——The oil tank shall be equipped with hoisting device for easy lifting and handling.
——Baffle plate shall be arranged inside the oil tank to separate the oil absorption area from the oil return area, so as to facilitate the oil to separate bubbles and precipitate impurities. Baffle plate shall not hinder the cleaning of oil tank.
——If it is required to enter the oil tank for cleaning, each manhole shall be at least 600mm×600mm in size or at least 450mm in diameter.
——Permissible deviation of levelness and verticality of oil tank is 1.5/1,000.
——The bottom plate of oil tank shall have a continuous inclination of not less than 1:50, so as to facilitate the evacuation of oil.
——Oil drain valve shall be provided at the lowest point of oil tank to ensure the complete discharge of oil.
——The bottom plate of oil tank is not less than 100mm away from the installation surface, so as to facilitate oil discharge and auxiliary heat dissipation.
——The oil tank shall be provided with ventilation device or air filter, liquid level meter, thermometer, liquid level message-sending device and oil return magnetic filter.
——Liquid level alarm sign shall be provided near the liquid level meter of oil tank.
——When the height of oil tank exceeds 1.8m, escalator shall be provided and guardrails shall be arranged around the top plate of oil tank.
3.2.2 When the lubrication system is equipped with electric heater:
——The maximum power density of electric heater surface shall not exceed 0.7W/cm2.
——The electric heater shall be capable of heating the oil in oil tank from the specified minimum on-site ambient temperature to the minimum starting temperature required by the lubrication pump within less than 12h.
3.2.3 Requirements for lubrication pump device are as follows:
——The motor energy efficiency shall meet the requirements of GB 18613.
——Except for single pump working and special requirements, the lubrication system shall be provided with a main lubrication pump and an emergency lubrication pump suitable for continuous operation.
——The lubrication pump shall be able to be overhauled and replaced online.
——The outlet line of each lubrication pump shall be provided with check valve to prevent oil from flowing back.
——The outlet line of lubrication pump shall be provided with safety valve. Under its setting pressure, the safety valve shall be able to pass the maximum flow of the protected lubrication pump.
——The oil suction pipe orifice of lubrication pump shall be inserted below the minimum liquid level to avoid air suction. The oil suction pipe orifice of lubrication pump shall be made at an inclination angle of 45°, and the lower end of the oil suction pipe orifice shall be at least 50mm higher than the bottom of oil tank.
——The suction line of lubrication pump shall be reliably sealed, and air shall not be sucked in.
——Lubrication pump shall be provided with product nameplate and clear marks of medium inlet and outlet.
——The rotating direction of pump shall be clearly marked on the lubrication pump; for immersed lubrication pump device or lubrication pump, the rotating direction shall be marked at the tail end of its driving motor when the rotating direction is difficult to be seen.
——After the coupling is assembled, the coaxiality error between the pump shaft extension and the motor shaft extension is not greater than 0.1mm.
——The exposed rotating shaft and coupling shall be equipped with detachable shield, of which the design shall meet the safety protection requirements.
3.2.4 Requirements for filter are as follows:
——The filtration accuracy of filter element shall meet the design requirements.
——Double switchable full-flow filters should be adopted to realize online replacement of filter element.
——The filter shall be equipped with pollution indicator or pollution alarm device.
——The filter shall have sufficient oil passing capacity. Under normal working conditions of lubrication system, the pressure drop of clean filter assembly shall not exceed 0.1MPa.
——The filter shall be installed in an accessible place, and enough space shall be reserved to replace the filter element.
——The dirty oil discharge outlet of filter shall be located at the lower part of housing to facilitate the complete discharge of dirty oil.
——The filter shall be provided with product nameplate and marks of medium inlet and outlet, and shall be fixed at the obvious position of product.
3.2.5 Requirements for cooler are as follows:
——The cooler shall be equipped with bypass and overhaul valve to realize online overhaul and replacement.
——Under normal working conditions of lubrication system, the pressure drop of hot side of the cooler shall not exceed 0.1MPa.
——The cooler shall be provided with product nameplate and clear marks of medium inlet and outlet.
——Brazing cooler shall meet the requirements of NB/T 47045.
——Plate cooler shall meet the requirements of NB/T 47004.1.
——Air cooler shall meet the requirements of NB/T 47007.
3.2.6 Requirements for lube oil line are as follows:
——Steel pipes below with diameter less than DN40 shall be bent at room temperature, and the bent parts of pipes shall be free from defects such as wrinkles and peeling.
——The steel pipe of lube oil line shall be cut mechanically; after cutting, sharp edges shall be blunted and scrap irons shall be removed.
——Where lubrication equipment needs to be transported in sections, the dismantled lines and their joints shall be marked with identification marks, and all exposed ports shall be blocked.
——The line of lubrication system shall be marked with oil flow.
——The size of through-holes for bolts and screws shall meet the requirements of GB/T 5277.
——Line connectors should comply with GB/T 3287.
3.2.7 Requirements for instrument, control and electrical system are as follows:
——The pressure instrument and temperature instrument installed on the lubrication line shall be capable of being replaced online.
——Electric contact control instruments shall not be adopted for the lubrication system.
——10%~20% spare terminals shall be reserved for junction box and electric control cabinet.
——The electric control cabinet of lubrication system shall be capable of operating manually or automatically.
——See Table 1 for alarm and mainframe rundown conditions of lubrication system.
Table 1 Alarm and mainframe rundown conditions
Condition Alarm Mainframe rundown
Low oil supply pressure — ×
High differential pressure of filter × —
Low oil level of oil tanka × —
Too low oil level of oil tank — ×
Low oil level of lube-oil rundown oil tankb × —
High oil supply temperature × —
Low oil supply temperaturec × —
Low oil supply flowd — ×
a High oil level of oil tank alarm may be provided.
b If the system is provided with lube-oil rundown tank.
c Low oil supply temperature may be used as a condition that the mainframe is not allowed to start.
d The independent oil supply system of constant displacement pump may not be equipped with flow detection instrument, but the compliance of flow shall be tested before the lubrication system leaves the factory.
3.2.8 Requirements for lube-oil rundown tank
——When the lubrication system is equipped with rundown oil tank, the volume of rundown oil tank shall not be less than the lube oil volume within 3min.
——Sight glass shall be installed at the place where the overflow line of rundown oil tank is easy to observe.
——Three valve groups or two valve groups shall be set in the line of rundown oil tank, as shown in Figure 1.
——When the liquid level of rundown oil tank is low, an alarm signal shall be given to prompt filling. Only when the liquid level is normal may the mainframe be allowed to start.
——Pressurized oil tanks such as pressure tanks shall comply with the design specifications of pressure vessels.
Keys:
1——Ball valve;
2——Restriction orifice;
3——Check valve;
4——Ball valve;
5——Check valve with holes.
Figure 1 Three valve groups and two valve groups of rundown oil tank
3.3 Technical requirements for grease lubrication system
3.3.1 The nominal pressure and flow of grease lubrication system shall meet the design requirements.
3.3.2 Where the amount of grease in the oil tank changes beyond the specified value, the oil level monitoring device shall immediately give an alarm signal or realize chain actions such as starting and stopping the filling pump.
3.3.3 The motor energy efficiency of electric lubrication pump shall meet the requirements of GB 18613.
3.3.4 The rotating direction of motor shall conform to the rotating direction mark on the lubrication pump, and shall not be reversed. It is not allowed to start the motor in case of no grease in the oil tank.
3.3.5 The flow value of grease lubrication pump is 95%~105% of its nominal flow value.
3.3.6 Lubrication pump shall be provided with product nameplate and clear marks of medium inlet and outlet.
3.3.7 After the coupling is assembled, the coaxiality error between the pump shaft extension and the motor shaft extension is not greater than 0.1mm.
3.3.8 The grease lubricating pump operates under nominal pressure, and its pressure drop shall not be greater than 25% of nominal pressure within 1min after stopping the pump.
3.3.9 The filtration accuracy of grease filter depends on the process requirements for medium flow.
3.3.10 Grease filter shall be inspected and the filter screen shall be cleaned regularly.
3.3.11 After the main pipe of double-line grease system is connected with the oil feeder and the pressure operating valve, the indicating arms of all oil feeders and the feeler levers of the pressure operating valve in the system shall be extended or retracted at the same time in the same lubrication cycle.
3.3.12 Double-line oil feeder or distributor shall be installed as close to lubrication point as possible, and shall not hinder the movement of other machinery.
3.3.13 After installation, the double-line oil feeder or distributor shall be convenient for observation, adjustment and overhaul, and the erosion of high temperature, dust and water vapor shall be avoided as possible.
3.4 Technical requirements for oil-mist lubrication system
3.4.1 Oil drain valve shall be provided at the lowest point of oil tank to ensure the complete discharge of oil.
3.4.2 The oil tank shall be generally provided with liquid level meter, thermometer, liquid level message-sending device and air filter.
3.4.3 The oil mist generating capacity of the oil-mist lubrication system shall be greater than or equal to the total oil consumption of the system.
3.4.4 During working, the oil mist device shall be able to display the oil temperature, air temperature and oil mist pressure under working conditions.
3.4.5 The line between oil mist generator and lubrication point of oil-mist lubrication system should be short. After installation, the distance and angle between the condensing nozzle and the lubrication point shall meet the design requirements.
3.4.6 The oil-mist lubrication system shall be equipped with oil mist purification device to prevent the floating oil particles in compressed air from polluting the environment.
3.5 Technical requirements for oil-air lubrication system
3.5.1 For oil-air lubrication system, the length of oil-air line shall not be less than 0.5m.
3.5.2 Oil drain valve shall be provided at the lowest point of oil tank to ensure the complete discharge of oil.
3.5.3 The oil tank shall be generally provided with liquid level meter, thermometer, liquid level message-sending device and air filter.
3.5.4 For electric oil-air lubrication system, the rotating direction of motor shall conform to the rotating direction mark on the lubrication pump, and shall not be reversed.
3.5.5 The motor energy efficiency of electric oil-air lubrication system shall meet the requirements of GB 18613.
Foreword i
1 Scope
2 Normative references
3 Technical requirements
3.1 General requirements
3.2 Technical requirements for oil lubrication system
3.3 Technical requirements for grease lubrication system
3.4 Technical requirements for oil-mist lubrication system
3.5 Technical requirements for oil-air lubrication system
4 Test methods and inspection rules
4.1 General rules
4.2 Test methods and inspection rules of oil lubrication system
4.3 Test methods and inspection rules of grease lubrication system
4.4 Test methods and inspection rules of oil-mist lubrication system
4.5 Test methods and inspection rules of oil-air lubrication system
5 Marking inspection and packaging inspection
5.1 Marking inspection
5.2 Packaging inspection
Annex A (Informative) Guidelines on reliability of lubrication system
Annex B (Informative) Schematic diagram of oil lubrication system
Annex C (Informative) Outline drawing of oil lubrication system
Annex D (Informative) Schematic diagram of single-line grease lubrication system of manual lubrication pump
Annex E (Informative) Schematic diagram of ring-type double-line grease lubrication system of electric lubrication pump
Annex F (Informative) Schematic diagram of oil-mist lubrication system
Annex G (Informative) Schematic diagram of oil-air lubrication system
Annex H (Informative) End-of-manufacturing inspection record sheet of oil lubrication device
