Bearing Pre-lubrication System

Transcription

1 Bearing Pre-lubrication System

2 Benefits Reduced risk of personal injury LOTO will not be required Removal/replacement of guarding will not be required Climbing on equipment for pre-lube will not be required Slip hazards due to spills will be reduced Introduces no new hazard 24vdc power supply no shock Enhanced equipment cleanliness Eliminate effects of oil splash onto adjacent equipment Enhanced equipment reliability Proper amount, location and application of pre-lube every time Increased equipment availability Reduced downtime due to improved maintenance practice Reduced maintenance cost Fewer bearing issues due to consistently correct pre-lube practices Fewer motor/generator issues due to reduced effects of oil splash migration

3 Benefits Ensures adequate lubrication at each start Minimal human involvement required Oil flow to each bearing is monitored May be configured as a START permissive Ensures consistent application of lubrication A predetermined quantity of lubricant will be applied, every time Lubricant will be applied directly into the lubrication port in the top of the bearing. System integrity poses no additional risk Entire assembly is inside web of pedestal and will be covered by a metal plate Pump connection is above normal operating level in sightglass All plumbing fittings are rigid pipe, either iron or brass

4 Benefits Eliminates opportunity for overfill due to frequent starts Lubricant is pumped from pedestal reservoir Additional oil is not required Ensures cleanliness of lubricant supply Possibility of contamination from new oil source is reduced Oil is pumped from sight glass level, not from drain level Ensures equal application of oil to each bearing All pumps controlled by one timer

5 Benefits Increases likelihood that each bearing is lubricated at start Application of lubricant to all bearings occurs simultaneously Reduces opportunity for contamination of MG set equipment Lubrication contained within pedestal No external splash to attract contamination No migration from pedestal to brush paths

6 System Operation System begins to operate upon initiation of MG set start sequence, if AUTO mode is selected Motor start permissive may be blocked pending completion of lube cycle MG set synchronous motor start circuit provides an output to the controller Individual pedestal pumps start Flow is detected to each bearing A timer is started when oil flow is detected to all of the pedestals Upon completion of the set time, synch motor start permissive is set Motor may be started as desired automatically or manually Pumps may be operated manually and flow may be monitored at the TEST panel

7 System Operation Test and monitoring capabilities are installed in the control panel Test pushbutton starts and runs pumps Individual LEDs indicate flow from each pump Detailed drawings will be provided

8 Components 1. Filler cap 1. Modified standard cap 2. Custom applicator tube length 2. Flexible hose 1. Steel braid re-enforced 2. Swaged connections 3. Flow switch 1. Severe duty rated 4. Pump 1. 24VDC 1. Minimal shock hazard 2. Diaphragm operated 1. Positive displacement 2. Self-priming 3. Back flow blocking 4. Teflon diaphragm 5. Pipe union 1. ¼ union provides opportunity for quick removal/replacement 6. Shutoff valve 1. ¼ Brass ball valve Where practical, brass components will be incorporated to reduce environmental effects.

9 Supply Lube application Opposite sightglass port Clean oil Monitored in sightgalss Direction Quantity Reliability Application tube centered with oiling port in top of bearing Tube length adjusted to extend into oiling port of bearing Tube position fixed by position of filler cap and bearing position Thirty seconds of pump run time provides approximately six ounces of oil Easily adjustable via timer value change in PLC or independent device The pump in the test system has performed more than 4,000, thirty second cycles It has operated continuously for twenty-eight hours in addition to the intermittent cycling operations It has withstood the rough handling involved with installation and modification

10 Field Test The setup pictured was for testing only It was intended to provide Quick, temporary installation Sufficiently rigid mounting of the controller to allow a good test of the permanently installed components during equipment operation Personnel protection from exposed wiring or terminations Protection of the equipment from incidental contact by equipment, tools or personnel An indication of operating time, number of cycles performed, amount of lube applied, and time of failure, if applicable Satisfactory performance of the permanently installed components demonstrated the capability of the system to provide the service required, reliably.

11 Reliable, Effective & Economical Installed and commissioned March 2010 In continuous service from that time Issues encountered: One minor leak piping connection Two of sixteen pumps failed Benefits realized: Increased availability and reduced risk (Improved bottom line) Eliminated removal of guards to pre-lubricate bearings Eliminated temptation to defeat guarding for that purpose Eliminated requirement for LOTO for splashing as a separate task Eliminated pedestal oil leaks due to overfill Provides opportunity for increased production by eliminating time consuming tasks