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Codeofchina.com is in charge of this English translation. In case of any doubt about the English translation, the Chinese original shall be considered authoritative. 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 润滑系统 检验规范 1 范围 本标准规定了润滑系统的技术要求、试验方法及检验规则、标志检验和包装检验。 本标准适用于润滑系统的检验。 2 规范性引用文件 下列文件对于本文件的应用是必不可少的。凡是注日期的引用文件，仅注日期的版本适用于本文件。凡是不注日期的引用文件，其最新版本(包括所有的修改单)适用于本文件。 GB/T 191 包装储运图示标志 GB/T 3287 可锻铸铁管路连接件 GB/T 5277 紧固件 螺栓和螺钉通孔 GB/T 9969 工业产品使用说明书 总则 GB/T 13306 标牌 GB/T 14436 工业产品保证文件 总则 GB 18613 中小型三相异步电动机能效限定值及能效等级 GB/T 19052 声学 机器和设备发射的噪声 噪声测试规范起草和表述的准则 GB/T 37400.3 重型机械通用技术条件 第3部分：焊接件 GB/T 37400.10 重型机械通用技术条件 第10部分：装配 GB/T 37400.11 重型机械通用技术条件 第11部分：配管 GB/T 37400.12 重型机械通用技术条件 第12部分：涂装 GB/T 37400.13 重型机械通用技术条件 第13部分：包装 GB 50093 自动化仪表工程施工及质量验收规范 GB 50171 电气装置安装工程 盘、柜及二次回路接线施工及验收规范 NB/T 47004.1 板式热交换器 第1部分：可拆卸板式热交换器 NB/T 47007 空冷式热交换器 NB/T 47045 钎焊板式热交换器 3 技术要求 3.1 一般要求 3.1.1 润滑系统的制造、检验应按规定程序批准的图样和技术文件执行。润滑系统的流量要求和压力设计准则应由买方规定或经买方同意。 3.1.2 润滑系统不应有渗透、泄漏现象。 3.1.3 润滑系统应能保持供油温度为40℃±3℃。 3.1.4 润滑系统中的密封材料应与润滑介质相兼容。不应使用含石棉材料的密封件。 3.1.5 润滑系统所有元辅件应具有合格证明文件。 3.1.6 润滑系统各外部接口应提供配对法兰或管接头。 3.1.7 噪声测量应符合GB/T 19052的规定。在公称压力和公称流量情况下，润滑系统的噪声≤85dB(A)。 3.1.8 润滑系统应有集油盘等集油设施，集油设施应设油液排放口。 3.1.9 润滑系统放置于水平面安装，应设有地脚螺栓安装孔以备需要时固定。 3.1.10 润滑系统应有接地螺栓，且有明确的接地标识。 3.1.11 润滑系统应设置电气接线盒，盒内各线端应采用机器打印的线号标识，接线盒应设置在方便检修的地方。控制电缆应采用屏蔽电缆，为使电缆有序连接进接线盒，油箱上应设置行线槽或穿线管。 3.1.12 焊接件应符合GB/T 37400.3的规定。 3.1.13 装配应符合GB/T 37400.10的规定。 3.1.14 配管应符合GB/T 37400.11的规定。 3.1.15 涂装应符合GB/T 37400.12的规定。 3.1.16 自动化仪表应符合GB 50093的规定。 3.1.17 电控柜元件安装及接线应符合GB 50171的规定。 3.1.18 润滑系统可靠性导则参见附录A。 3.1.19 稀油润滑系统原理图和外形图参见附录B和附录C。 3.1.20 手动润滑泵单线式干油润滑系统原理图可参见附录D；电动润滑泵环式双线干油润滑系统原理图可参见附录E。 3.1.21 油雾润滑系统原理图可参见附录F。 3.1.22 油气润滑系统原理图可参见附录G。 3.1.23 稀油润滑装置出厂检验试验记录表可参见附录H。 3.2 稀油润滑系统技术要求 3.2.1 油箱的技术要求如下： ——油箱应具备当润滑回路中的油回到油箱时不致溢出的预备空间。 ——油箱顶板开口处应加垫板，且垫板厚度至少10mm并加密封垫。 ——油箱应有足够的刚度以免发生振动或在承重后发生变形。用螺栓连接到油箱上的组件，螺孔不应伸至油箱内。 ——油箱应设置吊装装置，便于起吊和搬运。 ——油箱内部应设置隔板将吸油区和回油区分隔开，以利于油液分离气泡，沉淀杂质。隔板不应防碍油箱的清理。 ——如果要求进入油箱内部作清理，每个检修孔尺寸至少为600mm×600mm或至少为直径450mm。 ——油箱水平度、垂直度允许偏差1.5/1000。 ——油箱底板应有不小于1：50的连续倾斜度，以利于油液排空。 ——在油箱最低点应配备排油阀，以保证油液完全排放。 ——油箱底板离安装面不少于100mm，以利于放油和辅助散热。 ——油箱上应设有通风装置或空气滤清器、液位计、温度计、液位发讯器和回油磁过滤器。 ——油箱液位计附近应有液位报警标识。 ——油箱高度超过1.8m时，应设置扶梯并在油箱顶板四周设置护栏。 3.2.2 润滑系统设置电加热器时： ——电加热器表面最大功率密度不应超过0.7W/cm2。 ——电加热器应能将油箱内的油在少于12h内，从规定的最低现场环境温度加热到润滑油泵所需的最低启动温度。 3.2.3 润滑泵装置要求如下： ——电动机能效应符合GB 18613的规定。 ——单泵工作及特殊要求除外，润滑系统应有适合于连续运行的一台主润滑泵和一台备用润滑泵。 ——润滑泵应能实现在线检修、更换。 ——每台润滑泵的出口管路应设置单向阀，以防止油液回流。 ——润滑泵出口管路应设置安全阀，在其设定压力下，安全阀应能通过被保护润滑泵的最大流量。 ——润滑泵吸油管口应插入最低液面之下，以免发生吸空。润滑泵吸油管口应制成45°斜角，吸油管口下端应高于油箱底部至少50mm。 ——润滑泵的吸油管路应可靠密封，不应吸入空气。 ——润滑泵应有产品铭牌和介质进出口明显标志。 ——润滑泵上应明显标示泵的旋转方向，浸没式润滑泵装置或润滑泵上旋转方向不易被看见时应在其驱动电动机尾端标示旋转方向。 ——联轴器组装后，泵轴伸与电动机轴伸同轴度误差不大于0.1mm。 ——外露的旋转轴和联轴器应装有可拆卸的护罩，护罩的设计应符合安全防护的规定。 3.2.4 过滤器要求如下： ——滤芯过滤精度应符合设计要求。 ——过滤器宜采用双联可切换的全流量过滤器，以便实现滤芯在线更换。 ——过滤器应装有污染指示器或污染报警装置。 ——过滤器应有足够的通油能力。润滑系统在正常工作条件下，洁净过滤器总成压降不应超过0.1MPa。 ——过滤器应安装在易于接近的地方，并留出足够的空间更换滤芯。 ——过滤器污油排放口应位于壳体下部，以便于污油的完全排放。 ——过滤器应有产品铭牌和介质进、出口标志，且固定于产品明显位置。 3.2.5 冷却器要求如下： ——冷却器应设置旁路及检修阀，以实现冷却器的在线检修、更换。 ——润滑系统在正常工作条件下，冷却器热侧压降不应超过0.1MPa。 ——冷却器应有产品铭牌和介质进、出口标志。 ——钎焊式冷却器应符合NB/T 47045的规定。 ——板式冷却器应符合NB/T 47004.1的规定。 ——空气冷却器应符合NB/T 47007的规定。 3.2.6 润滑油管路要求如下： ——DN40通径以下的钢管应在常温下进行弯曲，管子弯曲部位不应有皱纹、起皮等缺陷。 ——润滑油路钢管应采用机械方法切割，切割后需将锐边倒钝，并清除铁屑。 ——润滑设备需分段运输时，对已拆管路及其相连接处应做好识别标记，并封堵所有外露口。 ——润滑系统管路应有油流标识。 ——螺栓和螺钉用通孔尺寸应符合GB/T 5277的规定。 ——管路连接件宜采用GB/T 3287。 3.2.7 仪表、控制及电气系统要求如下： ——润滑管路上安装的压力仪表、温度仪表应能在线更换。 ——润滑系统不应采用电接点控制仪表。 ——接线盒、电控柜应留有10％～20％的备用端子。 ——润滑系统电控柜应具有手动和自动两种运行方式。 ——润滑系统报警和停主机条件见表1。 表1 要求报警和停主机的条件 条件 报警 停主机 供油压力低 — × 过滤器压差高 × — 油箱油位低a × — 油箱油位过低 — × 润滑油停机油箱油位低b × — 供油温度高 × — 供油温度低c × — 供油流量低d — × a 可增设油箱油位高报警。 b 如果系统设置有停机润滑油箱。 c 供油温度低可作为不准许主机启动的条件。 d 定量泵独立供油系统可不安装流量检测仪表，但润滑系统出厂前应测试流量的符合性。 3.2.8 停机润滑油箱要求如下： ——当润滑系统带有停机油箱时，停机油箱容积应不少于3min的润滑油量。 ——在停机油箱的溢流管路易于观察的地方应装有视镜。 ——停机油箱的管路应设置三阀组或二阀组，见图1。 ——停机油箱液位低时应发出报警信号，提示充液。当液位正常时才能允许主机启动。 ——压力罐等加压油箱应符合压力容器设计规范。 连接停机油箱 a)三阀组 连接停机油箱 b)二阀组 说明： 1——球阀； 2——限流孔板； 3——单向阀； 4——球阀； 5——开孔单向阀。 图1 停机油箱三阀组、二阀组 3.3 干油润滑系统技术要求 3.3.1 干油润滑系统的公称压力和流量应符合设计要求。 3.3.2 油箱内润滑脂量变动超过规定时，油位监控装置应立即发出报警信号或实现启动和停止加油泵等连锁动作。 3.3.3 电动润滑泵电动机能效应符合GB 18613的规定。 3.3.4 电动机旋向应符合润滑泵上旋向标示，不应反转。油箱内无润滑脂时不准许启动电动机。 3.3.5 干油润滑泵流量值为其公称流量值的95％～105％。 3.3.6 润滑泵应有产品铭牌和介质进出口明显标志。 3.3.7 联轴器组装后，泵轴伸与电动机轴伸同轴度误差不大于0.1mm。 3.3.8 干油润滑泵在公称压力下运行，停泵1min内，其压力降不应大于公称压力的25％。 3.3.9 干油过滤器的过滤精度依据介质流程工艺要求而定。 3.3.10 干油过滤器应定期检查清洗过滤网。 3.3.11 双线式润滑脂系统的主管与给油器及压力操纵阀连接后，应使系统中所有给油器的指示杆及压力操纵阀的触杆在同一润滑周期内同时伸出或同时缩入。 3.3.12 双线给油器或分配器应尽可能靠近润滑点安装，且不妨碍其他机械的运动。 3.3.13 双线给油器或分配器安装后应便于观察、调整和检修，且尽可能避免高温、灰尘和水汽的侵蚀。 3.4 油雾润滑系统技术要求 3.4.1 在油箱最低点应配备排油阀，以保证油液完全排放。 3.4.2 油箱上一般应设有液位计、温度计、液位发讯器和空气滤清器。 3.4.3 油雾润滑系统的油雾发生能力需大于或等于系统总耗油量。 3.4.4 油雾装置工作时，应能显示出工作状态下的油温、空气温度和油雾压力。 3.4.5 油雾润滑系统的油雾发生器与润滑点间的管道宜短。凝缩嘴安装后与润滑点的距离和角度应符合设计规定。 3.4.6 油雾润滑系统应设油雾净化装置以防止压缩空气中的浮悬油粒污染环境。 3.5 油气润滑系统技术要求 3.5.1 油气润滑系统油气管道的长度不应小于0.5m。 3.5.2 在油箱最低点应配备排油阀，以保证油液完全排放。 3.5.3 油箱上一般应设有液位计、温度计、液位发讯器和空气滤清器。 3.5.4 电动式油气润滑系统用电动机旋向应符合润滑泵旋向标示，不应反转。 3.5.5 电动式油气润滑系统用电动机能效应符合GB 18613的规定。 4 试验方法及检验规则 4.1 一般规则 4.1.1 每台(套)润滑产品均应由制造企业质量检验部门按本标准逐台进行检验，检验合格才能出厂。 4.1.2 各项检查验收均应编制检查(试验)记录，由制造企业质量检验部门填报与汇总，并建立产品质量档案。 4.1.3 出厂试验应由制造企业负责，属供需双方联合验收的产品，应在需方代表在场的情况下进行。 4.2 稀油润滑系统试验方法及检验规则 4.2.1 润滑系统的出厂试验应按本标准规定的技术要求和试验方法，逐项进行检验。 4.2.2 润滑系统试验条件如下： ——润滑油的运动黏度、试验油温、油液清洁度等级应符合技术文件要求； ——润滑系统内各阀门的开闭状态应符合技术文件要求，供油管路和回油管路应畅通； ——试验电压和试验频率应与润滑系统用电保持一致； ——电控柜与润滑系统上的接线盒、仪表盘或仪表箱的线路连接应符合电气要求且完整。 4.2.3 耐压和密封试验的试验压力应符合表2的规定，流量允差应符合表3的规定。 表2 试验压力 公称压力 ρ＜25MPa ρ≥25MPa 试验压力 1.25ρ 1.15ρ 试验压力应逐步升高，不可一次达到峰值，达到试验压力后，保压时间不少于10min。 表3 流量允差 流量范围/(L/min) 流量允差/％ 4.2.4 试验方法及检验规则应符合表4的规定。 表4 润滑系统的试验方法及检验规则 序号 检验项目 试验方法及检验规则 测试仪表 名称 精度 1 电动机启/停试验 通过点动方式确认电动机旋向是否和润滑泵的旋转方向一致，若旋向相反，则调整电动机接线，重新点动测试。电动机能正常启动和停止且其旋向符合润滑泵的旋转方向为合格 — — 2 空载试验 将安全阀调至最大开口状态，启动润滑泵，空载运行时间≥10min，安全阀畅通，润滑系统平稳无异常噪声为合格 — — 3 密封(耐压)试验 按表2要求，将系统压力升至试验压力保压10min，再降至公称压力进行全面检查，润滑系统无任何泄漏或渗透为合格 (1)压力表 (2)压力变送器 (1)：1.6级 (2)：0.5级 4 备用泵启/停试验 在正常工作状态下逐渐升高或降低润滑系统的出口压力(可模拟)，备用泵在启/停压力设定值能正常启动或停止为合格 (1)压力表 (2)压力控制器 (3)压力变送器 (1)：1.6级 (2)：1.5级 (3)：0.5级 5 供油压力低报警 供油压力低于设定报警值时，报警信号正确为合格 (1)压力控制器 (2)压力变送器 (1)：1.5级 (2)：0.5级 6 液位报警 当油箱液位(或模拟油箱液位)达到液位报警设定值时，液位报警信号正确为合格 (1)液位控制器 (2)液位变送器 — 7 加热器启/停试验 通过油箱温度(或模拟油箱温度)控制，加热器在启/停温度点能正常启动和停止为合格 (1)双金属温度计 (2)铂热电阻 (3)温度变送器 (1)：1.5级 (2)：B级 (3)：0.5级 8 供油温度报警 润滑系统正常运行条件下，供油温度(或模拟供油温度)达到设定值时，报警信号正确为合格 (1)双金属温度计 (2)铂热电阻 (3)温度变送器 (1)：1.5级 (2)：B级 (3)：0.5级 9 润滑泵流量试验 润滑系统在系统公称压力下运行，测量供油流量(测三个值，取平均值)，流量允差符合表3的规定为合格 (1)椭圆齿轮流量变送器 (2)涡轮流量变送器 (3)孔板＋差压流量变送器 (1)：0.5级 (2)：0.5级 (3)：1.5级 10 供油流量低报警a 供油流量低于设定报警值时，报警信号正确为合格 (1)椭圆齿轮流量变送器 (2)涡轮流量变送器 (3)孔板＋差压流量变送器 (4)技术协议要求的其他流量检测仪表 (1)：0.5级 (2)：0.5级 (3)：1.5级 (4)：— 11 油液污染报警 当过滤器进出口压差达到或超过设定值时(可模拟)，报警信号正确为合格 (1)压力表 (2)压差表 (3)压差控制器 (4)压差变送器 (1)：1.6级 (2)：1.6级 (3)：— (4)：0.5级 12 噪声检查 噪声测量应符合GB/T 19052的规定，在公称压力和公称流量的情况下，润滑系统的噪声≤85dB(A)为合格 (1)压力表 (2)椭圆齿轮流量变送器 (3)声级计 (1)：1.6级 (2)：0.5级 (3)：— 13 电流检查 在公称压力和公称流量条件下，实测电动机电流小于或等于其额定电流为合格 (1)压力表 (2)椭圆齿轮流量变送器 (3)钳形电流表 (1)：1.6级 (2)：0.5级 (3)：1.0级 14 连续运转测试 在公称压力和公称流量条件下，润滑系统连续运行时间不低于2h无异常为合格 (1)压力表 (2)椭圆齿轮流量变送器 (3)钟表 (1)：1.6级 (2)：0.5级 (3)：— a 润滑系统如果没有设置供油流量检测元件，则不需要检查该项。 4.3 干油润滑系统试验方法及检验规则 4.3.1 压力试验按以下要求进行： ——双线式系统试验压力为系统工作压力的1.25倍，非双线式系统试验压力为系统工作压力。当试验压力达到规定的压力后，对系统进行全面检查，无外泄漏为合格。 ——双线式系统压力试验时，两条主管路应分别进行。 ——润滑泵在公称压力下运行，停泵1min内，其压力降不大于公称压力的25％为合格。 4.3.2 流量试验：工作压力下，试验润滑泵流量值在公称流量值的95％～105％范围为合格。 4.3.3 电动润滑泵用电动机电流检查：在公称压力和公称流量条件下，实测电动机电流小于或等于其额定电流为合格。 4.3.4 调整和试运转按以下要求进行： ——调试应在各相关工程确认具备试运转条件后进行。 ——油箱在加脂前应经检查，不应有任何肉眼可见污物。 ——用加油泵向油箱加脂时，应通过油箱上的加油口经过滤器过滤，不得打开油箱上盖直接添加润滑脂。 ——带有油位监控装置的油箱，应在充填润滑脂的同时，调试油位监控装置。油箱未加润滑脂时，油位监控装置应有低位报警，当油箱内润滑脂量超过规定低位时，停止报警；当润滑脂量继续增加，至高位时，油位监控装置应发出报警信号和停止加油泵等连锁动作。 ——润滑泵在连续试运转前，应点动检查旋向，其旋向应和泵壳上箭头所示方向一致。 ——润滑泵开始工作后，应将系统压力表导管及压力继电器导管灌满规定的润滑油。 ——润滑泵向压力管和主管充润滑脂时，应将主管与给油器或分配器的接口打开，当接口排出润滑脂后，方能将主管与给油器或分配器重新连接。 ——系统调试完毕后应符合下列要求： · 润滑泵工作应正常、无异常噪声； · 系统压力阀的调定值应符合设计要求； · 各连锁和报警装置应准确、灵敏； · 系统的工作程序应符合设计要求； · 所有润滑点的给脂量应符合设计要求； · 干油喷射润滑系统的空气压力以及润滑带的长度和宽度应符合设计要求； · 系统无漏脂现象。 ——系统调试过程中应作调试记录。 4.4 油雾润滑系统试验方法及检验规则 4.4.1 压力试验按以下要求进行： ——气动系统一般以压缩空气进行压力试验； ——油雾润滑系统中的压缩空气管道和油雾管道的试验压力按工作压力的1.15倍，当试验压力达到规定的压力后，对系统进行全面检查，无外泄漏为合格； ——压力试验时，压力应缓慢上升，达到试验压力后保持10min，再降至工作压力进行全面检查，以无漏气、目测无变形为合格。 4.4.2 调试和试运转按以下要求进行： ——调试前应向油雾器加入规定的润滑油，油雾化量应按设计要求进行调节。调试过程中应保持油雾化器有油，应及时将手动分水过滤器中的水排走。 ——油雾润滑系统的调试应符合下列规定： · 油箱的液位监控装置调试后，当油箱液位下降至规定高度时，应立即发出最低液位报警信号； · 系统进行喷雾试验前，应调整油温监控装置，将润滑油温控制在规定的范围内； · 油雾压力和含油量调整后应符合设计要求； · 连锁装置应正确、灵敏。 |
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