The document discusses the hydraulic lubrication system of a SAG mill. It provides definitions and discusses the importance of lubrication in reducing friction and wear between moving parts. It describes the various components of the lubrication system including the motor, gearbox, trunnion bearings and pinion bearings. It also summarizes data collected from the lubrication system from April 9-12, 2013 including temperatures, pressures, and oil flows. The document concludes with recommendations to improve the oil storage room and lubrication system room such as widening the areas, improving cleanliness, drainage, and enclosing rooms.

3. OBJECTIVES:
 To identify the definition and importance of a hydraulic lubrication system.
 To be familiarized with the lubricant and equipment used in the system.
 To understand the process and various design of Mill lubrication system.
 To identify some problems encountered by the system, and formulate
some recommendation to help fix the problems.

5. Hydraulic Lubrication System
A mechanical system of lubricating engines in which a pump forces
oil to flow into their gears and bearings. This system is composed of
various parameters, and instruments to maintain efficient lubrication to
ensure the machine is in good condition.
Definition of Lubricant…
A substance applied to the bearing and contact surfaces of machinery
to reduce friction and heat between moving parts.
Lubricants are usually divided into four basic classes namely Oil,
Grease, Dry lubricants and Gases.
Lubrication…
Lubrication is the process or technique of applying the lubricant to
reduce friction and wear of the material.

6. How does Lubrication occurs:
Surface A
lubricant film
Surface B

7. Gear Oil:
- is a fluid lubricant used in gear drives and industrial bearing
system. Commonly has a flash point of 415 ˚C and above.
Types of Gear Oil:
 Compounded gear oils
 Extreme Pressure (EP) gear oils
 Synthetic gear oils

8. Importance of Lube System:
 Reduces friction and wear between moving parts.
 Helps transfer heat and cools the surface.
 Cleans the inside of the machine by removing contaminants.
 Prevents rust and corrosion.
 Absorbs load and helps in sealing purposes.

10. Parts of SAG Mill to be lubricated:
Trunion Bearing
(feed end)
Motor Bearings
Gearbox
Pinion Bearings
Fig.1 : SAG mill Diagram
Trunion Bearing
(dis. end)

11. Lubricant Data:
Masbate Gold Project’s SAG mill uses Compounded Gear Oil as their main lubricant. But a
different class of Gear oil is use in every operating system of the SAG mill.
SAG Mill Components
Type
Characteristic
Motor Bearings
Omala 150
Gear oil. 150 viscosity at 40 C and 15 viscosity
at 100˚C
Gearbox
Omala 320
Gear oil. 320 viscosity at 40˚C and 25 viscosity
at 100˚C.
Trunnion/Pinion Bearings
Omala 320
Gear oil. 320 viscosity at 40˚C and 25 viscosity
at 100˚C.

12. Motor Drive Lubrication System Diagram:
Pres. Gauge
(before)
Pres. Gauge
(after)
Pres. Regulator
Temp. Gauge
FILTER
(disposable)
HEAT EXCHANGER
Relief valve
MOTOR PUMP
12gpm
Breather
Oil Tank
Flow sight glass

13. out
water in
Motor Lube. System Schematic Diagram:
pressure gauge
(before filter)
relief valve
to MOTOR
BEARINGS
return to oil tank
HEAT EXCHANGER
ball valve
FILTER
pressure gauge
(after filter)
check valve
MOTOR
PUMP
return to oil tank
return to oil tank
pressure
regulator
temp. gauge
from oil tank

14. Gathered Data: This were the data gathered from April 9 to April 12 of 2013.
MOTOR
(Feed End)
Mon.
Tues.
Wed.
Thurs.
Temperature
30˚C
35˚C
32 ˚C
35 ˚C
Pressure (bef. Filtration)
15 psi
13 psi
15 psi
17 psi
Pressure (after filtration)
35 psi
36 psi
37 psi
35 psi
(Dis. End)
Mon.
Tues.
Wed.
Thurs.
Temperature
31
32
35
34
Pressure (bef. Filtration)
16
15
17
15
Pressure (after filtration)
35
34
37
32

15. Gearbox Lubrication System Diagram:
Pres. Gauge
Relief valve
Pres. Gauge
MOTOR
(4 HP at 850rpm)
FILTER
(scrap type)
Flow Switch Control
HEAT EXCHANGER
Oil Tank

16. Gearbox Lube. System Schematic Diagram:
pressure gauge
w/ transmitter
FILTER
relief valve
to Bearings and Gears
(spray type)
water out
pressure gauge
w/ transmitter
Flow Switch Control
From oil Tank
water in
return to oil tank
HEAT EXCHANGER
Return Oil
MOTOR PUMP

17. Gathered Data: This were the data gathered from April 9 to April 12 of 2013.
GEAR BOX DATA
High Warn.
High Trip
Mon.
Tues.
Wed.
Thurs.
TT506A Gearbox No.1 Dis. End High
Speed Bearing Temp.
79
81
73
70
65
63
TT506B Gearbox No.1 Dis. End Low
speed bearing Temp.
79
81
61
58
51
50
TT506C Gearbox No.1 Dis. End High
Speed Bearing Temp.
79
81
65
62
54
52
TT506D Gearbox No.1 Feed End Low
Speed Bearing Temp.
79
81
70
67
65
64
TT507A Gearbox No.2 Dis. End High
Speed Bearing Temp.
79
81
51
48
47
46
TT507B Gearbox No.2 Dis. End Low
Speed Bearing Temp.
79
81
72
67
62
60
TT507C Gearbox No.2 Feed End Low
Speed Bearing Temp.
79
81
66
59
56
55
TT507D Gearbox No.2 Feed End
High Speed Bearing Temp.
79
81
71
67
61
58

18. Trunnion / Pinion Bearing Lube System Dia.:
MOTOR
(cleaning,15 KW)
Relief valve
Trunnion Motor
(clean,37 KW)
Oil Return
Breather
Temp. Gauge
Pinion Motors
(clean, 2.2 KW)
OIL TANK
3500 liters
RETURN
CLEANING
CLEAN
Temp. Gauge
Heater
FILTER (main)
(duty/standby)
HEAT EXCHANGER
FILTER (trunnion)
(duty/standby)
FILTER (pinion)
(duty/standby)

19. Trunnion / Pinion Bearing Lube System Schem. Dia.:
in
out
HEAT EXCHANGER
HEAT EXCHANGER
check valve
check valve
FILTER
duty
FILTER
standby
relief valve
MOTOR PUMP
duty
RETURN
MOTOR PUMP
Standby
CLEANING
CLEAN

20. to Trunnion Bearing
(Feed end)
check valve
FILTER
duty
to Trunnion Bearing
(Dis. end)
check valve
check valve
FILTER
standby
FILTER
duty
Trunnion Bearing Lube System Schem. Dia.:
check valve
FILTER
standby
Trunnion
FSC
r.v
Flow Divider
MOTOR PUMP
Feed End
MOTOR PUMP
standby
MOTOR PUMP
Dis. End
CLEAN
to Trunnion Bearing
(Feed end)

21. Pinion Lube. System Schematic Diagram:
to Pinion Bearing
FEED END
BEARING
check valve
FILTER
duty
check valve
INBOARD
DIS. END
BEARING
OUT BOARD
INBOARD
FILTER
standby
Flow Divider
Flow Divider
Flow Divider
MOTOR PUMP
duty
MOTOR PUMP
standby
to Pinion Bearing
CLEAN
OUT BOARD

22. Gathered Data: This were the data gathered from April 9 to April 12 of 2013.
Pinion Lube System
Low Trip
Low Warn.
Mon.
Tues.
Wed.
Thurs.
PT547 Pinion Bearing Oil Pressure
12
15
20
20
20
21
1.00
1.20
2.35
2.54
2.67
2.68
0.50
0.60
3.14
3.28
3.32
3.32
FIT574 Pinion Bearing No.2 Feed
End Oil Flow, (L/min)
0.70
0.80
3.37
3.47
3.48
3.49
FIT575 Pinion Bearing No.2 Feed
End Oil Flow, (L/min)
0.50
0.60
1.94
1.98
2.0
2.0
FIT572 Pinion Bearing No.1 Feed
End Oil Flow, (L/min)
FIT573 Pinion Bearing No.1 Dis.
End Oil Flow, (L/min)

23. Trunnion Lube System
Low Trip
Low Warn.
Mon.
Tues.
Wed.
Thurs.
PT566 Dis. End Trunnion Bearing Line
1 Oil Pressure, (psi)
20
22
48
48
48
49
PT567 Dis. End Trunnion Bearing Line
2 Oil Pressure, (psi)
20
22
48
48
47
48
PT561 Feed End Trunnion Bearing
Line 1 Oil Pressure, (psi)
20
22
48
48
52
48
PT562 Feed End Trunnion Bearing
Line 2 Oil Pressure, (psi)
20
22
48
49
49
49
FIT533 Thrust Bearing Line 1 Oil
Pressure, (psi)
3
4
14
15
15
15
FIT534 Thrust Bearing Line 1 Oil
Pressure, (psi)
1
2
7
7
7
7
FIT531 Thrust Bearing Dis. End Oil
Flow, (psi)
87
92
129
132
132
135
FIT557 Thrust Bearing Feed End Oil
Flow, (psi)
90
95
99
102
100
104
PT553 Dis. End Thrust Bearing Oil
Pressure, (psi)
35
38
56
58
58
59
PT554 Feed End Thrust Bearing Oil
Pressure, (psi)
30
32
58
60
60
60
0.15
0.20
0.36
0.58
0.31
0.35
PT554 Dis. End Trunnion Bearing Lift

24. Parts of Ball Mill to be lubricated:
Trunnion bearing
Feed end
Gearbox
Trunnion bearing
Dis. end
Pinion
Fig.2 : Ball Mill diagram.
Motor

26. Gathered Data: This were the alarm gathered during my stay in the Mill.
MILL ALARM
DATE
Diff. High Pressure Trunnion Feed
End
April 20, 2013
SAG Bearing Recirculation Oil Inlet
Temp. High
April 28, 2013
Dis. End Trunnion Bearing Temp.
No.2
April 30, 2013
Recirculation Oil Heat Exchanger
Inlet Temp. High
May 7, 2013
Gearbox No.1 Feed End High Speed
Bearing Temp.
May 8, 2013

28. Mill shutdown
Alarm sent to
the contol
panel
Temp. high
Differential
Pres. high
Lubrication
shortage
Oil low flow
Filter easily clogged up
Contaminated Oil
Pressure
build up

29. Proper Oil Storage Room
Proper Lube System Room
Clean and Organize Oil Storage
Wide Oil Storage Room

30. ventilation
Rugged, sealable
Plastic Top –up
Container that are
clearly marked
Funnels Stored
In clean sealable
Plastic containers
Store Shop
Rags in sealable
container
Closable Locker
Proper Lube Cabinet
for housekeeping

31. Safety Awareness
Clean and Enclosed Lube System Room

32. Mill Current Oil Storage Room
Small and Unorganized

33. Top up containers
(no lube cabinet)
Grease Gun
Lubricants/instruments not properly stored

34. dust
Mill Current Lube System Room
water
dirt
Prone to Contaminants
(Unclean)

35. Pile of mud
Leakage
Stagnant water
Improper Draining system

36. Nesting birds
dirt
Lube System Room is widely OPEN

37. Recommendation:
For Oil Storage Room:
 Widening of Oil Storage Room - for maximum storage capacity of different types
of oil used.
 Safety awareness – by having fire extinguisher installed inside and proper room
ventilation
 Cleanliness of Oil Storage Room - by having lube. cabinet for Top-Up Container and
Grease Guns.
For Lube. System Room:
 Proper Drainage System - by having permanent submersible pump.
 Enclose the Lube. System room - to prevent external contaminant to enter the system.

38. Thoughts about the Study:
Hydraulic Lubrication system is very important in the Mill. It
reduce friction and absorbs heat from gears and bearings, it cleans
the machine. It is also equipped with different instruments and follows
important parameters just to maintain efficient lubrication, because
even lubrication system is not the main reason why the mill starts to
run, it is still very important…..

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