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Mill Lubrication System

This presentation has a high sentimental value to me..

Mill Lubrication System

  1. 1. 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.
  2. 2. 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.
  3. 3. How does Lubrication occurs: Surface A lubricant film Surface B
  4. 4. 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
  5. 5. 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.
  6. 6. 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)
  7. 7. 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.
  8. 8. 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
  9. 9. 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
  10. 10. 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
  11. 11. 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
  12. 12. 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
  13. 13. 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
  14. 14. 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)
  15. 15. 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
  16. 16. 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)
  17. 17. 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
  18. 18. 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)
  19. 19. 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
  20. 20. Parts of Ball Mill to be lubricated: Trunnion bearing Feed end Gearbox Trunnion bearing Dis. end Pinion Fig.2 : Ball Mill diagram. Motor
  21. 21. 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
  22. 22. 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
  23. 23. Proper Oil Storage Room Proper Lube System Room Clean and Organize Oil Storage Wide Oil Storage Room
  24. 24. 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
  25. 25. Safety Awareness Clean and Enclosed Lube System Room
  26. 26. Mill Current Oil Storage Room Small and Unorganized
  27. 27. Top up containers (no lube cabinet) Grease Gun Lubricants/instruments not properly stored
  28. 28. dust Mill Current Lube System Room water dirt Prone to Contaminants (Unclean)
  29. 29. Pile of mud Leakage Stagnant water Improper Draining system
  30. 30. Nesting birds dirt Lube System Room is widely OPEN
  31. 31. 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.
  32. 32. 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…..
  33. 33. Leader Engr. Angel Bathan Co – Leader Sir. Mark Empredo Side Kick Mr. Aljon M. Altiche Side Kick Ex - GF Anne Curtis Side Kick GF Angel Locsin Side Kick Future GF Jennifer Lawrence Side Kick Uncle # 1 Robert Downey Jr. Side Kick Uncle # 2 Johnny Depp Side Kick Uncle # 3 Robin Padilla

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