RASHTRIYA ISPAT NIGAM LIMITED VISAKHAPATNAM STEEL PLANT VISAKHAPATNAM

GENERAL SPECIFICATION NO. VSP-6.3/GS-M-02 FOR LUBRICATION SYSTEMS

MARCH 2006

M.N. DASTUR & COMPANY (P) LTD Consulting Engineers

P-17 Mission Row Extension Kolkata 700 013

VSP-6.3/GS-M-02

RASHTRIYA ISPAT NIGAM LIMITED VISAKHAPATNAM STEEL PLANT VISAKHAPATNAM GENERAL SPECIFICATION
FOR

LUBRICATION SYSTEMS
1.0 1.1 SCOPE This general specification covers the lubrication systems required for various units . The term 'lubrication systems' referred herein covers all types of lubrication systems including but not limited to centralised oil , centralised grease , oil-mist, grease spray and Air-oil lubrication systems , including interconnecting piping and electrical control panel , positive force - feed lubricators , pad and waste type devices , various types of oilers , drop feed devices and manual devices . The term also covers components of centralised circulating systems for indicating , recording and integration of various parameters such as pressure , temperature , velocity etc ; control devices for manual and automatic operation of the systems , safety devices and alarms for abnormal operating conditions ; interlocks for sequencing and safe operation ; hand - guns and other appliances for manual lubrication ; mobile grease guns on wheels ; spraying equipment and lubricating media . The selection, design and construction of the systems shall be suitable in every way for the service intended and shall be oriented towards maximising interchangeability of components and minimising maintenance. Each system shall be complete in all respects including all accessories essential for proper installation , operation and maintenance , irrespective of whether such items are specifically mentioned in the Technical and General Specifications . In the interest of standardisation , the Purchaser reserves the right of selecting a particular manufacturer of lubrication system equipment and/or components and the contractor shall supply equipment/components of the particular make , if so required .

1.2

1.3

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2.0 2.1

STANDARDS The lubrication systems shall be designed , manufactured , erected , tested and commissioned as per the standards laid down in this specification . Detailed instruction on such aspects as are not indicated herein shall be as per the codes and practices adopted by the Indian Standards (IS) wherever available or American Society of Lubrication Engineers or as per the standards of the national standards institution of the country of origin or the codes of practices followed by the manufacturer. These shall be clearly indicated by the contractor and Purchasers prior approval shall be obtained. Wherever standards other than IS are used/referred, the contractor shall indicate the equivalent IS. Wherever applicable , the Interplant Industry (IPSS) shall be followed . Standards for Steel

2.2 2.3

The norms indicated in this specification shall be adhered to unless adoption of these norms would vitiate the function and/or safety of the systems offered . In such cases and where different norms are adopted by the Contractor , the same shall be clearly indicated with reasons and Purchaser's approval obtained . DESIGN BASIS General The design should ensure that the components of the lubrication systems are compatible with the lubricant selected , at the operating conditions in the plant and under climatic conditions prevalent at site . In selecting the lubricant , the operating temperature of system shall be given careful consideration ; and oil viscosities and grease penetration numbers shall always be related to operating temperature. Details concerning each lubricant shall be furnished in the form of a chart , indicating system reference , consuming point references , location of system , type of lubricant, ISO viscosity grade , manufacturer's code number for fluid type & grade and quantity for first fill of system including interconnecting piping . Wherever possible, equivalents with due regard to local availability shall be mentioned . Lubrication Circuits Each circuit shall be designed so as to ensure adequate supply of lubricant at the specified temperatures and pressures for the relevant application . Each system shall be 2 of 29

3.0 3.1 3.1.1

3.1.2

3.2 3.2.1

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designed taking into account encountered in operation . 3.2.2

the

maximum

pressures

Each circuit shall incorporate a reservoir of adequate capacity for lubricant with accessories, pumping equipment , filters to eliminate undesirable particulate contaminants , adequate cooling system to cool the return lubricant where required , pressure tanks where necessary , adequate heating system to adjust the viscosity of supply lubricant , generously sized pipework , accessories and hoses , and all necessary audio - visual alarms such as those for lubricant temperature in reservoir , levels of lubricant in reservoirs , pump discharge pressure, low lubricant flow , filter clogging , return lubricant temperatures etc . Unless otherwise specified, lubrication equipment for centralised systems located in unattended areas , basements etc . shall have remote control facilities to ensure safety of the main equipment served by such lubrication systems . The circuits shall incorporate necessary stand - by units , by passes , isolation devices etc. to ensure continuous operation of the systems even when some components are under maintenance , cleaning or repair . The circuit design shall incorporate necessary connections , valves and appurtenances to facilitate testing , pickling , flushing , draining and recommissioning the systems . Design of each circuit shall be such as to achieve quick response to functional needs , economic operation of the system and minimum maintenance . The circuit design shall also ensure safety of the staff and of the equipment served by the lubrication system , in case of emergencies such as power failure , bursting of hose or pipe connections , opening of safety valve or other devices . Oil sampling outlets with isolating valves shall be provided at suitable locations in the system . Centralised Oil Lubrication System Oil lubrication system shall be used when it is necessary : i) ii) iii) To remove heat from the friction surfaces and to ensure fluid film condition . To create a high hydro - dynamic pressure which ensures separation of the sliding surfaces in fluid film condition . To lubricate rolling contact bearings which work for long periods at high speeds . 3 of 29

3.2.3

3.2.4

3.2.5

3.2.6 3.3 3.3.1

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iv) v) 3.3.2

To have, besides lubrication, intensive cooling of the friction surfaces. To lubricate gears and worms (with the exception of very slow running and briefly operating mechanism) .

Centralised oil lubrication systems shall be provided for applications where lubrication is needed for a large number of use points which are located reasonably close and needing the same grade of oil lubricant . Each centralised oil lubrication system shall incorporate oil reservoir of adequate capacity , pump with electric motor , stand - by pump with motor , duplex pressure filters (one working , one standby) , oil cooler , pressure tank, valves , pipes , hoses , tubes and all necessary instruments and controls and suitably designed dust and moisture proof control panel . In systems where contamination collected by the lubricating oil is expected to be high and systems where ingress of water in oil is high (e . g . Morgoil Systems & no - twist mill systems) , two identical reservoirs shall be provided so that while one tank shall be in operation, the oil in the other tank shall be centrifuged/cleaned . Centrifuge shall be permanently connected to the tanks of such systems . The number of centrifuges for each system shall be as described in clause no. 4.9.2 below. Centralised Oil Mist Lubrication System Centralised oil - mist lubrication system shall be used to serve a number of points , consistent with system economy : i) ii) To lubricate pneumatically operated devices such as air tools , cylinders and valves . To lubricate machinery components such as bearings , gears and slides which require fine film lubricant .

3.3.3

3.3.4

3.4 3.4.1

3.4.2

Centralised oil-mist lubrication system shall incorporate mist lubricator unit (oil atomiser) with reservoir, air line filters, regulator with pressure gauge, lubricator, isolation valves, heater and controls, pipes & fittings, electrical control panel, make-up reservoir unit with pump and provision for automatic charging. Individual element/equipment of the system will be installed keeping in mind accessibility and ease of maintenance. Centralised Air-oil Lubrication System 4 of 29

3.5

VSP-6.3/GS-M-02

3.5.1

Centralised air-oil lubrication system shall be used for lubrication of following equipment : i) To lubricate intermediate mill RE and RTD guides, Notwist mill RE guides, loopers, stelmor chain etc.

ii) To lubricate machinery components such as bearings, sliding surfaces which require fine film lubricant. 3.5.2 Centralised air-oil lubrication system shall include oil reservoir with all accessories, pumps with standby pump, electric motor, duplex filters (one working + one standby), pressure gauge, pressure switch, relief valve on downstream side of each pump, progressive distributor blocks, air line isolation valve, filter, regulator with pressure gauge, pressure switch, solenoid valve, flow control valve, pipes & fittings, electrical control panel etc. Dual Line Centralised Grease Lubrication System Hand operated dual line centralised grease lubrication system shall be used for separate machines and mechanism which have a small number of lubrication points and require an infrequent supply of lubricant . However, for Rolling Mills, hand operated dual-line centralised grease lubrication system shall not be provided. For Rolling Mills, all isolated points requiring less frequent greasing, shall be lubricated by mobile greasing unit. Automatic dual line centralised grease lubrication system shall be used for lubricating large number of bearing points in a large machine or group of machines requiring frequent supply of lubricant for long and uninterrupted operation . An automatic dual line centralised grease lubrication system shall incorporate grease reservoir of adequate capacity with motorised plunger type grease pump and motor , stand - by pump with motor and grease reservoir, check valves , relief valves , pressure gauge, pressure switch, grease filters, isolation valves with limit switches on discharge lines & tank return lines between pumps and change over valve, motorised/ hydraulic reversing valve, lubrication dose feeders (metering feeders) , end-of-line pressure switches with pressure gauges, high pressure dual line pipes complete with pipe fittings , high pressure tubing complete with end fittings for connection to lubrication points , manifold blocks , grease filling pump with lifting device for automatic filling of reservoirs, solenoid valves on grease filling lines , instruments and controls , suitably designed dust and moisture proof 5 of 29

3.6 3.6.1

3.6.2

3.6.3

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control panel , necessary interconnecting sensing and relay lines etc . As far as possible, separate grease systems shall be provided for the hot zone and cold zone. 3.6.4 Each hand operated dual line centralised grease lubrication system shall incorporate a grease reservoir of adequate capacity , hand operated plunger type grease pump , check valve , relief valve , pressure gauge , grease filters, manual reversing valve, lubrication dose feeders (metering feeders) , high pressure pipes and fittings , manifold blocks etc . Other Lubrication Facilities Lubrication points which are not served by centralised lubrication systems shall be provided with lubrication grease nipple of standard make and type , with threads preferably as per British Standards/ as per thread of the lubrication points . In case the space available for manual lubrication of the point does not permit the use of the standard nipple , `button head' fitting or `tat head' shall be employed . The connector for the hand lubrication device shall suit the connections provided at the lubrication points . Isolated lubrication points , needing oil lubrication continuously , shall be provided with sight feed lubricators . Isolated and are system, common greasing lubricating points which are not easily accessible not included under centralised grease lubrication shall be suitably grouped and connected to a distributor or distributors located conveniently for from a single point by a hand operated grease gun.

3.7 3.7.1

3.7.2

3.7.3 3.7.4 3.7.5

4.0 4.1 4.1.1

EQUIPMENT Reservoir for Centralised Oil Lubrication System For gear oil lubrication systems for rolling mills etc . where contamination and muck is expected to be high, the useful capacity of reservoir shall be equal to 30 minutes total pump flow . In case of Morgoil bearings & no - twist mill bearings of rolling mills , the useful capacity of reservoir shall be equal to 50 minutes total pump flow . For bearings of electric motor, steam turbine and gas turbine, the useful reservoir capacity shall be equal to 5 to 10 minutes pump flow. The total volume of reservoir shall be 15 per cent to 20 per cent more than the useful volume , which will remain as free air 6 of 29

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space . The reservoir shall be rectangular type and shall be proportioned as length : width : height = 2 : 1 : 1, unless economics or standardisation dictates other proportions . 4.1.2 The reservoir shall be designed and constructed to prevent entry of foreign matter including water . Reservoirs shall be separate and removable from the equipment base . Cast iron reservoirs shall not be used . A 3 - compartment arrangement shall preferably be used in reservoir construction . While one compartment shall be used for sucking of oil , the other two compartments shall be used for return oil and for settling of water and other solid contaminants from the oil . The volume of return chamber, settling chamber and suction chamber shall have a ratio of 1 : 2:1 . Suitable skimmer shall be used to separate foam specially for large oil water emulsion systems . The suction chamber containing clean oil for circulation shall be provided with a float suction in addition to deep suction . The reservoir shall be sub-divided into compartments by providing baffle plates inside the reservoir across the width of the reservoir. Necessary coarse strainers shall be provided inside the reservoir along the baffle plate so that when the return oil flows from return chamber to middle chamber of the reservoir, coarse particles are removed. Necessary magnetic rods shall also be provided on the baffle plate so that while lubricant flows from return chamber to middle chamber, the iron particles are arrested in the magnets. All reservoirs shall have provision for lubricant filling and air breathing, separately . The filler hole shall have a filter for filtering the lubricant during filling and shall be fixed with fasteners requiring hand tools for opening . Filler holes shall be provided with caps or covers permanently attached to the reservoir by suitable means . Combination breather and filler assemblies shall not be used . Breather hole(s) shall be provided and protected by air cleaner(s) containing indicative type silica - gel for moisture trapping . The air cleaner(s) shall be of sufficient capacity to maintain approximate atmospheric pressure inside reservoir even at maximum demand of the lubrication system . The number of air breathers shall depend on the capacity of the reservoir and the capacity of the pumps . An additional nozzle connection of suitable size shall be provided in the reservoir for external filling line , but plugged for shipping . For Rolling Mills, fresh oil shall be filled to the system tank from central oil storage. For other shops/areas, fresh oil shall be filled to the system tank by a mobile filling pump. Reservoirs shall be designed for adequate heat 7 of 29

4.1.3

4.1.4

4.1.5

4.1.6

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dissipation by generously proportioning the reservoir wall surface and shall be installed as to allow unhindered air flow over all surfaces - sides , top and bottom . Return fluid shall have peripheral flow along reservoir side wall from suitably bevelled cut pipe . 4.1.7 Suitable dial thermometers protected and mounted in a bulbwell shall be installed in the suction and return chambers of the reservoir with at least 150 mm immersion length . Thermostats shall be provided in the reservoir for high temperature alarm in case temperature of oil in reservoir exceeds the set value and for controlling tank heaters. Wherever required, temperature transmitter shall be provided in the reservoir with signal accessible to main control room for on-line temperature measurement. Where reservoirs are not mounted on equipment , the bottom of the reservoir shall have a minimum clearance of 150 mm from the floor . The legs shall have appropriate mounting holes . The reservoir shall be provided with tube type protected level indicator. Acrylic Borosilicate glass shall be used for level indicator. The level indicator shall be provided with isolation valves with limit switches and drain valve. The level indicator shall be provided with calibrated scale with markings to show high and low levels with pump running and, where necessary , high level with pump stoppage . The tube type or flush type level indicators shall cover the entire height of the reservoir . For very small oil reservoirs flush mounted type level indicators shall be provided. The flush mounted type level indicators shall be fixed in a staggered way to cover the entire height of the reservoir. Tube type level indicators shall be provided with necessary switches for high level alarm and filling pump cut-off, low level alarm and low-low level alarm & main pump cut-off. The level switches shall be mounted externally to the reservoir. Wherever required, level transmitter shall be provided in the reservoir for signal transmission to control room, for on-line monitoring of level. The suction pipe shall be below the low-low level of fluid in the reservoir, to avoid cavitation. The return oil pipe, the relief return pipe and the fresh oil filling line shall be brought down below the low-low level of fluid in the reservoir to avoid aeration. The return oil pipe and relief return pipe shall be located in the return chamber of the reservoir and shall be provided with bevelled cut pipe for smooth flow. The return oil pipe and relief return pipe shall always be located away 8 of 29

4.1.8

4.1.9

4.1.10

4.1.11

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from suction pipe (preferably in different compartments of the reservoir) for efficient and smooth operation. 4 . 1 . 12 The return oil from gear boxes and bearings shall drain by gravity to the reservoir . Return lines shall slope down to the reservoir at about 3 to 4 per cent to the horizontal depending on specification of oil used in the system . Provision shall be made for efficient cleaning of reservoir . Suitable square or rectangular openings with hinged covers shall be provided on top of tank . Similarly , suitable square or rectangular openings with oil tight covers shall be provided in each compartment of the reservoir, at the side walls , flushing with tank bottom plate to facilitate tank cleaning . The top openings shall be suitably located for entry to each compartment of the reservoir for cleaning. Openings shall be suitable for man entry. Suitable opening with cover shall also be provided on top of tank, along the width, for taking out tank strainers, and magnets for cleaning. The reservoir bottom shall have about 4 per cent slope towards drain . The drain shall be piped out for further disposal . The drain connections of the reservoir shall be provided with isolating valves . For each compartment of the reservoir, at least one drain connection shall be considered . Reservoirs shall be fabricated from steel of suitable grade , having thickness depending on capacity of reservoirs . The thickness of plate for reservoirs shall generally be as follows : Capacity of Reservoir in m 3 Upto 3 m 3 5 to 10 m 3 10 to 35 m 3 35 to 90 m 3 Thickness of side plates 5 mm 6 mm 8 mm 10 mm Thickness of bottom plate 5mm 6 mm 10 mm 12 mm

4 . 1 . 13

4 . 1 . 14

4 . 1 . 15

Necessary stiffening plates/ channels shall be provided on the external surface of the reservoir. Interior surface of the reservoir shall be sand blasted , cleaned and coated with copaphen aluminium or shall be coated with the lubricating oil to be used for circulation . 4 . 1 . 16 Lubricant return to the reservoir shall preferably be through horizontal lines directed over a combination of trays and screens of suitable mesh size to eliminate turbulence and help defoaming of the lubricant . Spill from relief valve and other pressure regulators which are free of air and contaminants shall be discharged 150 mm or more below lubricant level and away from pump suction to avoid splashing . The return flow from separate lubricant 9 of 29

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purification systems shall also be discharged more below lubricant level. 4 . 1 . 17

150 mm or

Pump suction opening shall be placed such that bottom of suction pipe is at least 150 mm to 200 mm above the tank bottom to prevent dirt or water pick up . The suction opening must be kept well below the low-low level of lubricant (minimum 100 to 150 mm) to avoid air entry and cavitation. When lubricant level varies widely , a floating suction shall be used to meet the requirement . Necessary sampling connection with valves shall be provided in each compartment of the reservoir. Necessary water detecting units shall be provided in the reservoir for Morgoil and No-Twist Mill Oil lubrication systems. The filling of fresh lubrication in the reservoir shall be either from the central oil storage or locally by a mobile pump filter unit from 0.00 level. The spent lubricant from the reservoir shall be dumped either to the spent oil tank in the central oil storage or shall be disposed locally in drums/oil tanker at 0.00 level. For small lubrication systems, the system pumps shall be used for unloading the spent lubricant from the reservoir. For large gear oil/morgoil/ No-Twist Mill lubrication systems a separate pump shall be provided for unloading the lubricant from the reservoir. Necessary nozzles shall be provided in the reservoir for connecting spent oil pump. Necessary nozzles shall be provided in the reservoir for connecting centrifuge/vacuum dehydrator. The level of low-low level switch in the reservoir shall be at least 100 mm above the top most level of suction nozzle or 100 mm above the top most level of pump casing, whichever is higher, to avoid cavitation of the pumps. Necessary ladders shall be provided outside as well as inside the reservoir for climbing on top of the reservoir and for going inside the reservoir respectively, during maintenance. Reservoir shall be provided with electrical junction box and shall be prewired upto junction box. Reservoir for Centralised Grease Lubrication system Reservoir for grease lubrication systems shall be of adequate capacity to feed grease for reasonable hours of operation . It shall be made from general purpose structural steel fitted with accessories to achieve specific purposes . It shall be of cylindrical shape and mounted on top of pumping equipment 10 of 29

4.1.18

4.1.19

4.1.20 4.1.21

4.1.22

4.1.23 4.2 4.2.1

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for efficient priming . The interior shall be oiled but not be painted . External surface shall be painted as per General Specification for Painting (VSP-6.3/GS-P-01) . 4.2.2 The useful capacity of the reservoir shall be such that it will contain minimum 7 days and preferably 15 days grease required by the lubrication points of the respective system. The reservoir shall be complete with a heavy inertia follower plate or churning mechanism for efficient purging of grease to pump suction , tell - tale rod for indication of grease content , filling connection with strainers and reservoir cover . Tell - tale rod shall be equipped with electrical contact limit switches for audio - visual alarms for low level , low - low level & high level. At low level of the reservoir the grease filling pump shall start automatically and at high level of the reservoir the grease filling pump shall stop automatically. At low-low level of the reservoir the main grease pump shall stop automatically. Pumps for Oil Lubrication System Pumps for each system shall be designed to meet at least 125 per cent of system flow rates and 125 per cent of system operating pressure . For small systems , higher pump capacity may be selected to meet the minimum standard rating available . Pumps for the lubrication system shall preferably be of positive displacement triple screw type . The pump speed shall be 1500 rpm . Pump motors shall be adequate to operate the pump continuously at 125 percent of the system operating pressure without being overloaded. In general, for each self-contained or centralised oil lubrication system, one (1) operating and one (1) stand by pump units shall be provided. For very large gear oil/NoTwist Mill/Morg oil lubrication systems, two (2) nos. working pumps may be provided with a prior approval from Purchaser. In such system a minimum of 50% stand-by pump shall be provided. Stand-by units shall be piped to the system. Instruments and controls for the system shall ensure that the stand-by pump shall automatically start in sequence in case of failure of any one of the operating pumps. The failure of any one of the pumps shall be indicated by audio-visual alarms, located on the control panel. Pumps shall preferably be floor mounted on base frames with flooded suction and shall not be mounted inside reservoir or on top of reservoir without specific approval of purchaser.

4.2.3

4.3 4.3.1

4.3.2

4.3.3

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4.3.4

Flexible shaft couplings complete with coupling guards shall be provided between the pump and motor . The type of coupling shall be suitable for the application. Direct coupled pumps shall be securely mounted in a manner to assure alignment under normal operating conditions . The coupling shall have adequate capacity to transmit the power required . Pumps shall be provided with stainless steel compensator and isolation valve with limit switch on the suction side and relief valve, check valve, isolation valve on the discharge side. Necessary pressure gauge shall be provided on the downstream side of each pump and pressure switches shall be provided on the common header on the discharge side of pumps for low pressure alarm and for automatic starting of stand by pump in case of failure of working pump. Necessary pressure transmitter shall be provided with signal accessible to main control room for online pressure measurement. On the down stream side of pumps, a by-pass line with a globe valve shall be provided, for closed circulation during cold starting in peak winter season. The mounting surface provided for a separate pump and motor shall be rigid and shall prevent coupling misalignment due to work load and temperature variations. Flexible couplings shall be used between the motor and pump, and be of a type suitable for the application. An approved detachable safety guard shall be fastened over the coupling and equipped with a hinged section to facilitate lubrication. The pump-motor unit shall be provided with drip tray and drain valve. Each pump-motor unit shall be provided with electrical junction box and shall be prewired upto junction box. The following information shall be shown on metallic name plates on each pump: i) ii) iii) Manufacturers name and address Manufacturers part, model and /or serial number Delivery, pressure, power required

4.3.5

4.3.6

4.3.7

4.3.8

4.3.9

4.3.10

The direction of rotation of each pump shall be clearly indicated on the pump where it can be readily seen. 4.4 Pumps for Grease Lubrication System

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4.4.1

Pumps for grease lubrication system shall be of adequate pressure rating to overcome the tremendous pressure loss in pipelines and in metering feeders and to introduce grease in bearing through restriction. Suitable check valve and relief valve shall be provided with the pump to protect the internal parts from being damaged. Internal operating parts shall be well lubricated to ensure smooth operation. Grease pumps shall be positive displacement plunger type with robust construction consistent with high pressure service . Care shall be taken while selecting the pressure rating of the pump for high pressure loss through pipes and fittings , particularly in case of long piping . The grease reservoir shall be mounted on top of the pump for efficient pumping . Main grease pumps shall be driven by electric motors for automatic systems. Hand operated pumps shall be used for manual systems. Grease filling pumps shall preferably be pneumatically driven with dry compressed air. For compressed air drive, the actuating mechanism shall operate successfully with the dry air pressure available at the shop . If the available air pressure is not adequate , separate booster shall be provided . For each centralised grease lubrication system having one (1) motor driven operating main pump to meet the system requirement , one (1) identical motor driven additional main pump shall be provided as a stand - by unit . Stand - by unit shall be permanently piped to the system . Instruments and controls shall indicate the need for starting the standby pump in the event of failure of working main pump . The standby main pump unit shall be started manually. The pumping unit shall be provided with electrical junction box and shall be prewired upto junction box. Each grease system shall be provided with a PLC based electrical control panel.

4.4.2

4.4.3 4 . 4.4

4.4.5

4.5 4.5.1

Filters for Oil Lubrication System Filters shall be provided for continuous removal of contaminants from the lubricant which are likely to cause damage to the equipment to be lubricated as well as the equipment of the oil lubrication system . All systems shall be equipped with pressure filters having specified filtration capacity. Necessary strainers shall also be provided on the tank return line for oil lubrication system for No-Twist Mill. 13 of 29

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4.5.2

Filters shall be of pressure filtration type unless specified . The filters shall be suitable for filtering particle sizes of 50 microns for gear oil lubrication systems. For Morgoil lubrication systems, 50 micron duplex filters shall be provided in the system and 50 micron duplex filters shall be provided near each stand. For No-Twist Mill bearing lubrication system, 3-stage duplex filters of 50 micron, 25 micron and 7 micron shall be provided. Filters for large centralised oil lubrication systems for Rolling Mills, handling lubricants which may be contaminated by ferrous particles, shall be provided with magnets . The pressure drop across filters shall not exceed 0 . 20 kg per sq cm in clean condition and with 125% of total pump flow . Provision shall be made for manual changeover of the filter unit in case the pressure drop across the working filter is more than 0 . 8 kg/cm 2 with rated system capacity i . e . when filter is clogged . To facilitate this, necessary built-in changeover valves shall be provided at the inlet and outlet of each filter. Filters shall be provided with differential pressure switch for audio visual alarm for filter clogging. Pressure check minimess couplings shall be provided on upstream and downstream side of filters. Pressure and return line filters shall be so constructed and installed that the filter element can be changed for cleaning or replacement without disturbing the piping or equipment operation . For this purpose , duplex filters (one working + one stand-by) shall be provided . All filters shall be provided with isolation valves across it and drain valves/drain plugs to facilitate maintenance of filters/filter elements . Necessary vent valves shall also be provided for filters. The filters shall be basket type/cartridge type. The material of filter element shall be stainless steel wire mesh upto 25 micron. Finer filter elements of 10 micron & 7 micron shall be of glass wool/paper. Suitable reinforcing perforated sheet shall be provided with the basket type/cartridge type pressure filter element to avoid tearing of the filter element due to flow impulse . Filter unit shall be provided with drip tray and drain valve. Electrical junction box shall be provided for filter unit. The filter unit shall be prewired upto electrical junction box. Filters and Strainers for Grease Lubrication Systems Filters used in grease lubrication system shall be of line mounted type . The filter element shall be so located that dismantling of filter is not necessary while taking out the 14 of 29

4.5.3

4.5.4

4.5.5

4.5.6

4.5.7

4.6 4.6.1

VSP-6.3/GS-M-02

element for cleaning . Body of filter shall be `Y' type made from steel bar stock to withstand high pressure duty . Filter element shall be of stainless steel and of 250 micron fineness (approx) . 4.6.2 Necessary filter shall be provided in the reservoir filling port to filter the grease during filling . The filter element shall be easily removable for cleaning . Necessary line mounted filter of 250 micron fineness shall also be provided on downstream side of grease filling pump to filter the grease while filling the reservoirs of main pumps. Coolers and Heaters for Oil Lubrication System Coolers shall be provided in the oil lubrication systems where normal operation of the lubrication systems will raise the fluid temperature to over 40C during any time of the year and will affect the fluid viscosity. Coolers shall be plate type of gasketted design. The plate type coolers shall be designed such that all the four (4) ports shall be on one (1) side of the cooler. Cooler shall be generously designed considering high ambient temperature and water inlet temperature of 35C and shall have 20% spare capacity. Cooling medium shall preferably be water . Where water line connection is not available , air may be used as cooling medium with prior approval from Purchaser . Plate type heat exchangers and finned tube heat exchangers shall be designed as per manufacturer's standards . Heaters shall be used in the reservoir of the lubrication systems if the viscosity of the lubricant under ambient conditions would affect the system operation adversely . Heaters shall preferably be of the electrical type , having heating intensity of not more than 0 . 8 watt per sq. cm . Electrical heaters shall preferably be of the cartridge type , suitable for mounting in reservoir and thermostatically controlled . Each cooler shall be provided with the following : a) b) c) d) Isolation valves on cooler water inlet and outlet lines Isolation valves on oil inlet and outlet lines from cooler and on the bypass line across cooler. Pressure gauge and temperature indicators on cooler water inlet & outlet lines. Temperature indicators on oil inlet and outlet lines from cooler 15 of 29

4.6.3

4.7 4.7.1

4.7.2

4.7.3

4.7.4

VSP-6.3/GS-M-02

e)

Pressure check minimess couplings on oil inlet and outlet lines from cooler, for checking pressure drop across cooler. Basket type filter of 250 micron fineness on cooler water inlet line. Necessary control valve with controller on cooler water inlet line for automatic control of water flow.

f) g) 4.7.5

Cooler shall be fitted external to the reservoir and shall be mounted on a frame with drip tray and drain valve. The cooler unit shall be provided with electrical junction box and shall be pre-wired upto junction box. The pressure drop across cooler on oil circuit shall be less than one (1) bar and on water circuit shall be less than 0.5 bar. Pressure Tanks for Oil Lubrication Systems Pressure tank shall be provided in the oil lubrication system to supply oil to the gear boxes/bearings of the main equipment in case of power failure or failure of working and stand by pumps of the oil lubrication system. The capacity of the pressure tank shall be such that the useful working volume of oil in pressure tank shall be equal to 2 to 3 minutes system rated flow or shall be adequate to supply oil to the gear boxes/bearings of the main equipment till the transfer bar comes out of the equipment, whichever is larger, in case of power failure or failure of both working & standby pumps. Pressure tanks shall be designed conforming to ASME Code for Pressure Vessels or equivalent. Pressure tank shall be provided with relief valve for protection against over pressure , pressure gauge , pressure switches , tube type level gauge to cover entire height of pressure tank , level switch , drain valve , flow gauge glass , man-hole with Davit, air line connection with filter , regulator with pressure gauge , lubricator, isolation valve etc . Each pressure tank shall be provided with isolation valve on oil line. The following information shall be permanently indicated on each pressure tank : a) b) c) d) Manufacturer's name and address . Manufacturer's model number Manufacturer's serial number , if any Rated maximum operating pressure 16 of 29

4.7.6

4.8 4.8.1

4.8.2

4.8.3

VSP-6.3/GS-M-02

e) f) g) h) 4.8.4 4.8.5

Charging medium Total liquid capacity Pre - charge pressure Caution - Pressurised Vessel

Pressure tank shall be charged with plant compressed air . The pressure tank unit shall be provided with a drip tray and drain valve. Necessary electrical junction box shall be provided for each pressure tank unit and the pressure tank unit shall be prewired upto the electrical junction box. Separator (Centrifuge) for oil lubrication systems Separator shall be used with oil lubrication systems to remove contaminants of lubricant which are picked up by the lubricant while in operation . Contaminants which shall be removed by separator from lubricant are as follows : a) Water which may ingress into the system from the equipment being lubricated , due to seal failure of plate type cooler or due to condensation etc . Dirt , dust and solid contaminants which find their way from surrounding atmosphere into the system as well as rust and wear products from bearings and gears . Oxidation products which form sludge specially if oil is operating at higher temperature .

4.9 4.9.1

b)

c) 4.9.2

The separator shall suck oil from the dirty oil chambers of the reservoir , clean the oil and deliver the cleaned oil to the clean oil chamber of the reservoir . Each gear oil lubrication system shall have one dedicated separator unit . Each Morgoil lubrication system shall be provided with one (1) no. centrifuge and the centrifuge of the gear oil lubrication system shall be connected to the tanks of Morgoil system also. For each NTM bearing lubrication system 1 working + 1 stand by centrifuge shall be provided. The capacity of the separator shall depend on the system tank capacity . In general, the capacity of separator shall be equal to capacity of tank divided by 15 to 20 hours , approximately . Each separator unit shall be complete with electrical control panel and prewired upto control panel. The separator unit shall be mounted on a base frame with drip tray and drain valve. Vacuum Dehydrator

4.9.3

4.10

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4.10.1

Higher capacity vacuum Dehydrator with a standard filter shall be included for each No-Twist Mill bearing lubrication system and for Finishing block lubrication system, to remove water from oil. Each vacuum Dehydrator unit shall be complete with electrical control panel and prewired upto control panel. The vacuum Dehydrator unit shall be mounted on a base frame with drip tray and drain valve. Pipework and Hose Assemblies Components of pipework for oil/grease lubrication systems shall conform to the General Specification for Pipework (VSP6.3/GS-M-01). All pipes for oil lubrication and grease lubrication systems shall be seamless pipes. The pipes and fittings for gear oil and normal bearing oil lubrication systems shall be of carbon steel. The piping in wet area for oil lubrication systems shall be of stainless steel. For oil lubrication systems for No-Twist Mill and Finishing block, the pipes and fittings for oil supply line on downstream side of fine filters shall be of stainless steel. The piping for air-oil system shall be of stainless steel. Oil feed lines shall be designed for a velocity of not more than 1 . 2 metres per second and preferably not more than 1.0 metre per second for oil with medium viscosity . For return lines , the velocity shall be limited to 0 . 25 to 0 . 30 metres per second , with a slope of 3 to 4 per cent . Suction lines to pumps shall be sized for fluid velocity less than 0.5 metres per second to avoid turbulence and pump cavitation. For Morgoil and No-Twist Mill bearing lubrication systems , where ingress of water to oil is more , drip legs shall be provided on the return line from each stand/bearing . The main headers and subheaders for grease lubrication systems shall be of carbon steel with carbon steel fittings. The feed pipes from metering feeders to lubrication points shall be of stainless steel with carbon steel cadmium plated fittings. The headers and subheaders in wet area shall be of stainless steel with stainless steel fittings. For Grease System, the main dual-line headers shall be of 30 mm OD x 5 mm thk or 25 mm OD x 4 mm thk or 20 mm OD x 3 mm thk depending on the length of main headers. The subheaders shall be 20 mm x OD x 3 mm thk or 16 mm OD x 2.5 mm thk or 10 mm OD x 1.5 mm thk depending on the length of subheaders. The feed lines from metering feeders to 18 of 29

4.10.2

4 . 11 4.11.1

4.11.2

4 . 11 . 3

4 . 11 . 4

4.11.5

4.11.6

VSP-6.3/GS-M-02

lubrication points shall be 10 mm OD x 1 mm thk stainless steel. 4 . 11 . 7 For hose , the bursting pressure shall be at least 5 times the maximum working pressure of the system . Pipework and hoses shall be suitable for operating temperature from + 10 deg C to + 90 deg C . All the hoses in hot area shall be with stainless steel braided cover and silica cloth cover. Lubricant flow to different sections of the equipment shall be metered out preferably by use of knife edged orifices or globe valves . The material of all isolation valves, check valves, relief valves and control valves shall be cast steel / forged steel. All isolation valves on oil lines shall be plug/ball type valves. The isolation valves on cooler water inlet/outlet lines shall be gate valves of cast steel/forged steel. Sealing Devices Material of all sealing devices shall be compatible to the lubricant. Wherever possible, sealing devices shall be of the pressure sealing type. Sealing devices shall be temperature and pressure. suitable for system operating

4 . 11 . 8

4.11.9

4 . 12 4 . 12 . 1

4 . 12 . 2

4 . 13 4 . 13 . 1

Devices for Circuit Control, Protection and Safety Over-pressure Protection

4 . 13 . 1 . 1 Suitable relief valves shall be provided on the discharge side of all positive displacement pumps and over - pressure protection shall be provided else - where in circuits where damage to the equipment or hazards to personnel may result if design pressures are exceeded . Check valves shall be provided on the discharge side of all pumps to prevent any back flow . 4 . 13 . 1 . 2 Sequence control shall be primarily governed by mechanically actuated limit switches , electronic timers , sequence valve or any other position sensing device .

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4 . 13 . 1 . 3 A pressure gauge with shut - off valve shall be provided with each pressure control valve . All relief valve drains shall be piped directly to the reservoir. 4 . 13 . 2 Interlocks

4 . 13 . 2 . 1 The machinery and all connected equipment shall be brought to a safe stop upon failure of electric power , control power or control components . The system shall remain inoperative after restoration of electric power until the controls are reset . If an unscheduled stop would result in an unsafe condition , then the failure shall be announced by audio visual alarms and stand - by or stored power shall be provided that will permit a delayed or gradual stop under manual or automatic control . 4 . 13 . 2 . 2 In the event of failure in the controls , manual controls shall be provided that would permit bringing the system to a safe state of operation or to a stop . 4.13.2.3 For oil lubrication systems, necessary controls shall be provided so that the standby pump shall start automatically, in the event of failure of the working pump, with an alarm indicating that the working pump has failed. 4 . 13 . 2 . 4 Where there is more than one pump operating , interlocks shall be provided so that the stoppage of one pump in the circuit will not damage the equipment . 4 . 13 . 2 . 5 Where pumps are operating in parallel , manual valving which will permit disconnection of one pump while the others are still in operation shall be provided downstream of the relief valve . 4 . 13 . 2 . 6 Where loss of working pressure on the discharge side of a pump or pumps may result in damage to the equipment , in loss of accuracy , or in danger of injury to personnel , means shall be provided to prevent operation under these conditions including automatic shut - off of pressure control by - pass valve . 4 . 13 . 2 . 7 Electrically and pneumatically controlled lubrication devices shall be applied in such a manner that in the event of electrical or pneumatic circuit failure , there will be no damage to the equipment or danger to personnel. 4 . 13 . 2 . 8 All main equipment served by lubrication systems shall be suitably interlocked with the lubrication control circuit with a suitable time delay relay to ensure positive lubrication before starting . 20 of 29

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4.13.2.9 Lubrication systems shall be provided with local control panel for start, stop and audio-visual alarms for faults. Lubrication systems shall be suitably interlocked with shop PLC. 4 . 13 . 3 Other Instruments, Controls and accessories

4 . 13 . 3 . 1 Necessary devices shall be provided on the reservoir to assure proper lubricant level . Reservoirs shall have sight glasses to indicate maximum , normal and minimum lubricant level in reservoir . Reservoirs shall have high level, low level and low-low level switches for audio-visual alarm for high level (with filling pump cut off), low level and low-low level (with main pumps cut off). 4 . 13 . 3 . 2 Pump delivery controls shall assure correct flow of lubricant and system pressure . With positive displacement pumps , a pressure relief valve shall be provided to allow lubricant to come back to reservoir in case the system pressure increases above normal and thus protecting the pumps from being overloaded . Unless otherwise approved by Purchaser , an air loaded surge tank shall be used to keep smooth supply of lubricant during pump failure or power failure in each system . Instrumentation on such an air tank shall normally include an air safety valve set to operate at a pressure of 1 kg per sq cm (g) higher than relief valve setting . Other items are as described under Clause 4 . 8 . 2 above . 4 . 13 . 3 . 3 The main motor control circuit of the lubrication circulation system shall be interlocked with that of the parent equipment motor with suitable time delay relay to ensure positive lubrication on start - up . 4 . 13 . 3 . 4 Each circulating oil lubrication system shall have globe type by - pass valve on the downstream side of the pumps and the line shall be connected to the tank . This is required for closed circulation during cold start - up . 4 . 13 . 3 . 5 Filters shall have devices to signal need for cleaning or replacement when they become too much loaded with dirt . 4 . 13 . 3 . 6 Lubricant cooler instrumentation shall assure that lubricant is delivered at the correct temperature . Instrumentation shall include all the items as described under Clause 4 . 7.4 above . 4 . 13 . 3 . 7 Each circulating oil lubrication system shall have automatic pressure control valve with pressure controllers , to maintain constant pressure on the downstream side of the system . The pressure control/over pressure valve shall be located on the downstream side of filters . Necessary pressure control with controller/pressure reducing valves shall also be 21 of 29

VSP-6.3/GS-M-02

provided near gear boxes/bearings . Each system shall have automatic temperature control valve with temperature controller , mounted on the cooler water inlet line to maintain constant set temperature at the outlet of the system . Necessary temperature switch shall be provided on downstream side of heat exchanger for high temperature alarm . 4 . 13 . 3 . 8 Necessary pressure gauge , pressure switch and flow switch shall be provided on pressure feed line to each gear box and temperature indicator & temperature switch on the return oil line from each gear box . Pressure gauge , pressure switch and temperature indicator shall be provided on the pressure feed line to each bearing . Globe valve shall be provided on the pressure feed line near each gear box/bearing . Necessary sampling valve shall be provided on the return line from each gear box. 4 . 13 . 3 . 9 Pressure , flow and temperature of lubricant delivered shall be measured near gear boxes/bearings and shall be relayed back to the control console for low pressure , low - flow and high temperature alarms . If the pressure and temperature of lubricating oil cross preset levels , the machine served by the system shall be cut off by a suitable control . 4.13.3.10 Water detecting units shall be provided in the reservoir as well as in the pipelines for systems for Morgoil bearings , no - twist mill bearings etc . 4.13.3.11 Instrumentation and Control systems shall conform to General Specification for Instrumentation and Control Systems (VSP-6.3/GS-I-01). 4.13.4 Fault Alarms

4.13.4.1 Audio visual alarms shall be provided in the local control panel for each oil lubrication system for the following faults: a) b) c) d) e) f) g) h) Low Pressure in the system Excessive temperature of oil in the reservoir High level of oil in the reservoir Low level of oil in the reservoir Low-low level of oil in reservoir and pump cut-off Clogging of filters Low oil flow Motor overload

4.13.4.2 For any of the above faults, necessary audio-visual alarms shall be provided in the control room/control pulpit for FAULT IN OIL LUBRICATION SYSTEM.

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4.13.4.3 Audio-visual alarms shall be provided in the local control panel for each grease lubrication system for following faults: a) High level of grease in reservoir and grease filling pump cut-off b) Low level of grease in reservoir c) Low-low level of grease in reservoir and main-pump cutoff d) Low pressure in the system e) Motor overload 4.13.4.4 For any of the faults mentioned above, necessary audio-visual alarms shall be provided in control pulpit/control desk for FAULT IN GREASE LUBRICATION SYSTEM. 4 . 14 4 . 14 . 1 Accessories for Grease Systems In centralised grease lubrication systems , spool and plunger type dose feeders (metering feeders) with adjustment knob shall be provided near lubrication points . The adjustment knob shall be graduated in cubic centimetres , to indicate metering of grease at each setting of knob . The glands and packing of the spool and plunger shall be designed to with stand high grease pressure . Necessary isolation valves with limit switches shall be provided on the P&T lines between each main grease pump and line changeover valve for positive selection of the grease pumps . End pressure switches shall be provided in dual line grease system to ensure pressure attainment at the farthest end of the circuit, during the cycle of operation and to alter the path of grease flow by reversing the motorised changeover valve by electrical impulses . The end pressure switches shall be mounted at the upstream side of farthest dose feeder (metering feeder) . Necessary isolation valves shall be included on the main branch lines . The piping in wet area shall be of stainless steel . Grease filling device Automatic grease filling device shall consist of grease filling pump driven by dry compressed air , grease drum cover , necessary starter and controls , follower plate, limit switch for low level alarm (grease drum empty), pressure gauge, relief valve, line filter of 250 micron on the discharge side of pump and pump lifting device. Necessary air line filter, regulator with pressure gauge and lubricator, isolation valve and solenoid valve shall be provided on air line to grease 23 of 29

4 . 14 . 2

4 . 14 . 3

4 . 14 . 4

4 . 14 . 5

VSP-6.3/GS-M-02

filling pump. The limit switches fitted to grease reservoir of main pumps shall relay electrical impulse initiated by tell tale rod to the motor control or solenoid operated pneumatic valve , indicating the need for filling . The filling system shall automatically stop when the reservoir is full , on getting similar electrical impulse from another limit switch . 4 . 15 4 . 15 . 1 Oil Mist Lubrication System Oil mist lubrication system shall be complete with mist lubricating unit , accessories , electrical controls , piping and fittings . The system shall be designed in such a way that the spray fog that escapes from the lubricated elements shall be kept to a minimum . Oil mist lubrication unit shall include a reservoir with accessories , automatic filter and moisture separator , pressure regulator , air inlet valve , pressure switch to monitor the inlet air , suitably sized mist generator and necessary alarms and controls . The system shall have suitable provisions for collecting , draining and purging out the oil that will condense in the pipeline . Pipework and hose assemblies , sealing devices , circuit control , protection , safety and interlock devices shall be generally as laid out in Clause 4.11 through 4.13 above. Other Lubrication Devices These devices shall be selected to suit the lubrication requirements for components of various equipment accessories , valves etc. for which centralised lubrication systems have not been provided for technical or economic reasons . Where necessary , the reasons for selection of the device adopted shall be described clearly . The devices selected shall be compatible with the lubricant recommended . Manual devices such as containers with suitable outlet and manually controlled valve shall be used only for inexpensive or rough machinery such as wire rope , chains , open gear , valves etc . Oil squirt cans , pump valve squirt can , screw type grease cup , grease hand gun etc. may be classified under this category of device . Drop feed devices , which are gravity flow devices , shall be considered for applications for isolated equipment/ components such as journal and roller bearings , gears , 24 of 29

4 . 15 . 2

4 . 15 . 3

4 . 15 . 4

4 . 15 . 5

4 . 16 4 . 16 . 1

4 . 16 . 2

4 . 16 . 3

VSP-6.3/GS-M-02

chains , engine guides , pumps , compressors pillow blocks , etc . 4 . 16 . 4 Splash or bath lubrication method may be adopted for internal combustion engines , chain drives , closed gear sets etc . Ring , chain and roller type lubrication methods may be adopted for smaller electric motors , fans , blowers , compressors , in - line shaft bearings etc. in instances where proper bearing lubricant reservoir level can be easily maintained . Pad and waste type devices may be used for traction motor bearings , sleeve bearings etc . These devices shall preferably not be used in very dirty environments . Wick feed oiler , waste feed oiler , under feed pad oiler , saturated pad oiler etc may be considered under this category of devices . Force feed lubricators , comprising of one or more plunger type adjustable stroke pumps mounted on a reservoir , and driven by a mechanical linkage , may be used for equipment not requiring large quantity of lubricants . For application such as steam cylinders , bearings for diesel and gas engines , metal press bearings etc . these devices may be used . Air - oil devices comprising oil reservoir , compressed air supply device , piping and aspiration mechanism to draw oil through the action of air passing through a suitable control valve or orifice may be provided for high - speed bearings , enclosed gears , chains , slides , guides , table - ways etc . SAFETY AND ACCESSIBILITY Safety Flexible lines shall be restrained to prevent undesirable movements to reduce possibility of failure . Lubricating systems shall be suitably interlocked with operating machinery with some time delay relay (in case of motorised lubricating systems) to ensure positive lubrication before the equipment starts functioning . Lubrication equipment and piping shall be so located or protected as to prevent damage from material handling equipment . All controls , pumps etc. shall be located objects and operator's accidental movements . 25 of 29 against falling

4 . 16 . 5

4 . 16 . 6

4 . 16 . 7

4 . 16 . 8

5.0 5.1 5.1.1 5.1.2

5.1.3

5.1.4

VSP-6.3/GS-M-02

5.1.5

Lubrication equipment and piping shall be located or protected against excessive temperature or other detrimental effects such as water . Automatic control shall be located and protected to prevent accidental operation . Components which might be damaged by exposure to dirt , dust or other environmental conditions , or by moving equipment , shall be adequately protected and readily accessible . Piping shall not be used to support valves or other system components . Automatic air bleeds shall be installed on the discharge side of all pumps . Thermal insulation shall be provided for lubrication system for equipment operating in areas of high temperatures . For lubrication systems provided in the vicinity of open flames , high temperatures , molten metal etc . (such as those for furnaces , cranes , coilers etc.) , special protection shall be given to prevent breakout of fire in case of pressure break out of the lubricant . These shall include selection of suitable seal , packings and fittings . Use of non - inflammable lubricant shall be considered only with the approval of Purchaser . Accessibility Name plates shall be provided for all control station components and shall be located so that they can be easily read . Lubrication devices located at an elevated height shall be provided with proper access . An emergency stop shall be considered , and when provided shall be readily accessible from the operator's normal working position . This feature shall be engineered to suit the requirements . All lubrication equipment , controls and piping shall be accessible , have adequate working clearance and be mounted in a position that will not interfere with the equipment adjustments or maintenance and shall not require the use of portable platforms or ladders . Removal of equipment other than that being attended for maintenance shall not be necessary . 26 of 29

5.1.6 5.1.7

5.1.8 5.1.9 5 . 1 . 10 5 . 1 . 11

5.2 5.2.1

5.2.2 5.2.3

5.2.4

VSP-6.3/GS-M-02

5.2.5

All manual controls shall be mounted within easy reach of the operator when he is in normal operating position . Operator shall not be required to reach fast moving equipment to reach manual controls. ASSEMBLY, ERECTION AND COMMISSIONING All components and equipment of lubrication systems shall be cleaned , both externally and internally , as mentioned in the equipment suppliers' manuals for erection and maintenance . Lubrication pipework shall be assembled , tested , pickled , flushed and commissioned as given in the General Specification for Pipework VSP-6.3/GS-M-01 . Installation of electrical system shall conform to General Specification for Installation , Testing and Commissioning of Electrical Equipment . INSPECTION AND TESTING All components of the lubrication systems shall be inspected and tested at the manufacturers premises by the Purchaser/ authorised representative of Purchaser as per the General Specification for Inspection and Testing requirement for Plant & Equipment at manufacturers Premises(VSP-6.3/GS-IN-01). Each lubrication system/equipment shall be inspected at site for completeness and correctness of supply and erection as per the General Conditions of Contract and as specified in relevant clauses of the Technical Specification for the systems and equipment. Performance tests for lubrication systems/equipment shall be carried out at site along with the operation of the main equipment to which the lubrication systems shall be connected, to check the flow rate, pressure & temperature of lubricant, pressure drop across filters & cooler, power consumption by electric motors etc. as well as proper functioning of the main equipment as per the requirement of conditions of contract. PAINTING All components of the lubrication systems shall be painted as per General Specification for Painting VSP-6.3/GS-P-01 .

6.0 6.1

6.2

6.3

7.0 7.1

7.2

7.3

8.0

9.0 9.1

DRAWINGS AND OTHER DOCUMENTS Drawings and technical information shall be furnished in accordance with the General Condition of Contract and as 27 of 29

VSP-6.3/GS-M-02

specified in the relevant clauses of the equipment specification . The following types of drawings and technical information shall be provided for the lubrication systems : 9.1.1 Flow diagram for each lubrication system showing all components and pipelines by means of approved graphical symbols with parts list indicating complete specification, size, pressure rating, material, model no. make, quantity etc. of each item. General arrangement lubrication system. General arrangement cellars/rooms. drawings drawings for each the unit of the

9.1.2 9.1.3 9.1.4

for

lubrication

Interconnecting piping drawings for the piping from take over point of the shop upto lubrication cellars/rooms, piping within the lubrication cellars/rooms and piping between lubrication cellars/rooms and lubrication points etc., with Bill of Quantities. The piping drawings shall show detailed routing of pipes, details of supports, fittings, valves etc. with sufficient sections so that the erector can erect the pipes with the help of these drawings. For grease systems, grease spray systems, oil mist system and air-oil system, the interconnecting piping shall be from T.O.P of shop to pumping station and between pumping station and lubrication points. Isometric drawings for interconnecting piping in critical areas. Catalogue/technical literature including component details, sectional drawings, trouble shooting charts etc. Operation and instruments manuals for hydraulic system. Electrical ladder diagram When the lubrication system is supplied with electrical control , electrical diagram supplied shall be ladder type and include chart showing limit switch , relay and solenoid actuation .

9.1.5 9.1.6 9.1.7 9 . 1.8

9.1.9

Sequence-time chart A chart shall be supplied showing sequence of operation in relation to cycle time , and electrical actuation . This chart should also show pressure and flow for each portion of the cycle .

9 . 1 . 10

Detailed list of each component and equipment served by each lubrication system . 28 of 29

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9 . 1 . 11 9.1.12 9 . 1 . 13

Type, characteristics and trade name of lubricant for each equipment indicating Indian equivalent . Quantity of lubricant consumed for each system (hourly flow rates , annual consumptions) . Schedule for lubricant change for each system .

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