loading
| Availability: | |
|---|---|
| Quantity: | |
Customized
MDP Hydraulics
The high-speed motor/compressor bearing lubrication system station is an intelligent lubrication solution specifically designed for high-speed rotating equipment. It adopts advanced oil circulation lubrication technology to ensure the safe and stable operation of the equipment under extreme conditions. Our system strictly follows the API 614 international standard and provides reliable lubrication guarantees for key equipment such as steam turbines, compressors, and high-speed motors.
• Highly integrated design: Integrates high-speed motor, frequency converter and intelligent oil lubrication system into one unit, enabling one-button operation for driving.
• In-plant load testing: Simulate harsh operating conditions to conduct load coordination tests for the variable frequency drive system, thereby reducing the difficulty of on-site debugging.
• Fully digital control: Automatically adjust the parameters of the motor, oil station and frequency converter to achieve energy-saving mode.
• Oil and gas lubrication system: Suitable for high-speed operating conditions above 15,000 - 20,000 rpm. Compared to traditional grease lubrication, it can increase the maximum rotational speed limit.
• Precise oil quantity control: The oil quantity at each lubrication point can be precisely allocated. Compared to oil lubrication, this method saves nearly 90% of lubricant consumption.
Positive pressure protection: Prevents foreign objects or dust from entering the bearing, thereby extending the service life of the bearing.
• Dual-pump redundant design: The main and auxiliary oil pumps automatically switch, ensuring continuous oil supply without interruption.
• High-level fuel tank protection: In the event of failure of the main or auxiliary fuel pumps, it can maintain emergency fuel supply for more than 5 minutes.
• Intelligent Monitoring System: Real-time monitoring of key parameters such as temperature, pressure, and liquid level, enabling 24-hour unmanned operation.
Parameter Item | Technical Specification | Notes |
|---|---|---|
Nominal supply pressure | 0.63 MPa | Adjustable range: 0.1 - 0.4 MPa |
Filter accuracy | 0.08 - 0.12mm | Double-barrel mesh filter |
Cooling water temperature | ≤ 28℃ | Tube-type oil cooler |
Oil supply temperature | 40 ± 3℃ | Temperature control accuracy: ± 1℃ |
Working medium | N22-N460 lubricating oil | ISO VG22-VG460 grade |
Motor power | 0.55 - 22 kW | configured according to flow rate |
Bearings type | Power range (kW) | Speed range (RPM) | Motor efficiency | Bearing loss (kW) |
|---|---|---|---|---|
Rolling bearing | 70-2000 | 3600-24000 | 97.2%-97.5% | 1.5-5 |
Sliding bearing | 54-1600 | 3600 - 31000 | 97.2%-97.5% | 12 - 23 |
• Volume design: Customized according to the equipment's lubrication requirements, equipped with a heater and a liquid level indicator
• Oil quality management: Built-in filter baffle to remove impurities and release gases, ensuring the quality of the oil product.
• Temperature control: The electric heater ensures that the oil temperature is between 35 and 45 degrees Celsius when it is started.
• Dual pump configuration: Flow rate 200 - 350 L/min, Outlet pressure ≥ 0.5 MPa
• Pressure regulation: The operating pressure is adjusted by the safety valve. Overpressure is automatically protected.
• Pressure reduction oil supply: Enters the bearing lubrication point at a pressure of 0.08 - 0.15 MPa
• Dual-filter design: Run one filter while keeping the other in standby, allowing for seamless switching and cleaning without stopping the operation.
• Dual cooling system configuration: plate type or tube type. The oil temperature should be controlled within the optimal range of 35-45℃.
• Temperature control accuracy: ±1℃, ensuring stable lubrication effect
• PLC intelligent control: Fully digital system, automatically adjusting operating parameters
• Multiple protections: Low oil pressure protection, excessive bearing temperature protection, power failure protection
• Remote Monitoring: Supports access via computer and mobile terminal, enabling remote control.
Lubrication system of steam turbines and gas turbines
Generator bearing lubrication
Wind turbine gearbox lubrication
Centrifugal compressor lubrication system
Reciprocating compressor lubrication
Lubrication guarantee for large pump sets
Rolling mill lubrication system
Lubrication of blast furnace blowers
Continuous casting machine lubrication system
High-speed motor bearing lubrication
Turboexpander lubrication
Machine tool spindle lubrication system
• API STD 614-2022: Lubrication, Shaft Seals, and Oil-Control Systems and Auxiliary Equipment, 6th Edition
• ISO 10434: Industrial Valves Standard
• ASME B31.3: Process Pipeline Standard
• IEC 60079: Standard for Explosion-proof Electrical Equipment
Factory Acceptance Test (FAT) Procedure
On-site Acceptance Test (SAT) standards
Life-cycle quality management system
Automatically adjust operating parameters to achieve the optimal energy-saving mode
Direct drive with high-speed permanent magnet motor, eliminating the need for speed-up gears, resulting in an increase in system efficiency.
• The power factor is greater than 0.95, and the motor's maximum efficiency is above 98%.
One-hour on-site bearing replacement design
Modular design, with simple and quick maintenance.
Remote diagnosis function, reducing downtime
Precisely protect complex components such as high-speed motors
• Capable of withstanding large axial and radial loads, and has strong anti-shudder performance
The bearing can operate across the critical point and is capable of adapting to various working conditions.
The oil pipeline is welded using argon arc welding, which reduces the generation of welding slag.
Pipe plasma cutting, and promptly remove iron filings
A 4% return oil gradient design is adopted to ensure smooth return oil flow.
1. Initial flushing: Use the same specification of waste mechanical oil for the oil circuit flushing.
2. Secondary flushing: Use new lubricating oil for a 24-hour circulation flushing.
3. Cleanliness test: Reach cleanliness standards below NAS 9 level.
4. Performance test: Conduct a comprehensive test of all functional indicators of the system.
Daily checks should be conducted for the oil level, oil quality and the condition of the filters.
Monitor the pressure, temperature and vibration parameters of the system
Record the operation data and establish a device health record.
Monthly oil sample analysis is conducted to test for moisture and acidity.
Clean the filters every quarter and check the operating condition of the pump unit.
Annual comprehensive maintenance and replacement of worn-out parts
Choose the same brand and the same specification of lubricating oil.
Conduct regular oil quality tests to ensure the effectiveness of lubrication.
Professional waste oil recycling, in line with environmental protection requirements
Customer requirement: Lubrication for high-speed motor bearings operating at 15,000 - 20,000 rpm
Solution: Customized oil and gas lubrication system
Implementation effect: The bearing temperature remained stable at 32℃, and the vibration significantly decreased, meeting the requirements for high-speed operation.
Customer requirement: Enhance the reliability of the lubrication system and reduce unplanned downtime
Solution: Retrofitting of lubrication station in accordance with API 614 standard
Implementation effect: System operation stability has been improved by 40%, and maintenance costs have been reduced by 25%
Customer requirement: Continuous and stable lubrication under heavy-load conditions
Solution: High-pressure lubrication station configuration
Implementation effect: Equipment failure rate reduced by 60%, production efficiency increased by 15%
20 years of experience in designing lubrication systems for high-speed equipment
Self-developed intelligent control system
Strictly follow the international standard API 614
All components are made of 304 stainless steel.
Complete 72-hour continuous operation test before leaving the factory.
Provide an 18-month quality guarantee period
24-hour technical response
On-site installation and commissioning guidance
Lifetime maintenance service
Our engineering team can provide you with a full-service ranging from scheme design, equipment manufacturing to installation and commissioning, according to your specific needs. Whether it's a new project or an upgrade, we can offer the most suitable lubrication solutions.
Contact us immediately to obtain our customized technical solution and quotation!
A1: This is a core safety consideration in our design. In addition to the control cabinet being equipped with an UPS power supply, the system relies on a crucial mechanical protection device - the "high-level oil tank" (or called the emergency oil tank). It is physically installed at a higher position above the equipment. When the entire factory experiences a power outage and all oil pumps stop, the lubricating oil stored in the high-level oil tank will continue to supply oil to the equipment bearings through gravity, ensuring that the equipment is fully lubricated during the few minutes of inert run (safe sliding shutdown), fundamentally avoiding the catastrophic damage of "dry grinding".
A2: We do not recommend mixing lubricants of different brands or models because their additive formulations may not be compatible, and mixing them may result in sludge, sedimentation or a decline in lubrication performance. If an accidental mix occurs, although it may not immediately cause equipment damage, it must be regarded as an oil contamination incident. We suggest you: 1) Contact our service engineers immediately; 2) Arrange for a thorough flushing of the lubrication system as soon as possible and replace it with brand-new, unified lubricants. This can avoid long-term potential wear risks.
A3: During a quick inspection, several points should be noted: See: Check if the oil level in the oil tank is within the normal range, whether the oil flow in the return oil window is continuous (without bubbles), and if the pressure gauge reading is stable. Listen: Observe if the running sounds of the main oil pump and the motor are smooth and uniform, and if there are any abnormal knocking or sharp whistling sounds. Touch (ensure safety): Compare the temperatures of the pump casing, the inlet and outlet of the cooler, and the supply pipes for the bearings. The temperature difference should be within a reasonable and stable range. Any sudden or continuous changes warrant stopping the machine for a thorough inspection.
A4: The foams will seriously affect the lubrication effect. The specific hazards are as follows: 1) They cause the efficiency of the oil pump to decrease or even "air erosion", resulting in unstable oil supply pressure; 2) The foams have poor heat conductivity, which affects the system cooling; 3) The bearings come into contact with an unstable mixture of gas and liquid instead of a solid oil film, which aggravates wear. Our system prevents foams by selecting high-quality anti-foaming oil products, having sufficient "foam-breaking areas" in the oil tank to cause the foams to break, and controlling the position and flow rate of the return oil pipe. If severe foams occur, it is necessary to check the oil level, whether the oil has deteriorated or been contaminated.
A5: Yes. Our system usually adopts a pressure feedback regulation design. When the equipment load suddenly increases and the instantaneous oil demand rises, the system pipeline pressure will have a slight downward trend. This signal will be quickly captured by the pressure sensor and fed back to the control system, immediately adjusting the output of the variable oil pump or the regulating valve, and increasing the oil supply volume within a very short period of time (usually within seconds) to restore the pressure to the set value, thereby ensuring that the lubrication points receive a stable and sufficient supply of lubricating oil under any working conditions.
A6: We will develop a detailed construction plan, scheduling most of the installation and pipeline work to be carried out concurrently with the planned maintenance shutdown period of your equipment. For the core final commissioning and testing, there will indeed be a need for the equipment to be temporarily shut down. However, we will adopt modular prefabrication and advance installation of ancillary pipelines, etc., to minimize the downtime on the critical path. Generally, the impact on the main equipment's production can be reduced to within a few days.
A7: For renovation projects, compatibility is the top priority. Our service begins with on-site inspection of your existing equipment, including interface dimensions, original oil lines, space layout, and operating conditions. The system design will be customized based on these factors to ensure a seamless connection. Installing a professional lubrication system on an old device is to enhance its reliability, extend its lifespan, and is a protective investment, not a burden.
A8: Yes, we highly recommend and can assist you in establishing a regular "oil analysis" program. Just like taking blood tests, regularly extract oil samples from the system and send them to the laboratory for analysis. The report can accurately show the contamination degree, moisture content, acid value of the oil, and most importantly - the types and quantities of wear metal particles. This can scientifically evaluate the lubrication effect and can alert in advance about potential failures of bearings or gears before the equipment suffers severe wear.
A9: During the initial design phase, we usually reserve certain engineering margins for the tank capacity, the capacity of the oil pumps and the coolers. If you need to add more lubrication points in the future, simply provide the oil consumption and technical requirements for the new points. We can assess whether the existing system has sufficient margins and provide you with an expansion plan, which may include adding valves, expanding the control program or upgrading some components. The system itself has good scalability.
A10: We have taken noise control into consideration during the design process. Main noise sources such as oil pumps and electric motors will be equipped with low-noise models, and they will be installed through means like shock-absorbing pads and flexible joints. The overall operating noise of the system is usually controlled below 75 decibels (equivalent to a noisy office environment), and it will not cause significant additional noise interference to the workshop environment. The specific noise levels will be clearly indicated in the equipment specification book.
