Study of Mill HydraulicLubrication System

By:Al jon M. A l t iche

Mentors :Engr. Ange l BathanSi r Mark Empredo

The PROJECT:

Mill STOPS = production of GOLD STOPS

Hydraulic Lube System

so that you can Extract Gold

We GRIND!!!

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.

I. GENERAL STUDY

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.

Surface B

Surface A

lubricant filmlubricant film

How does Lubrication occurs:

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

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.

II. SAG MILL / BALL MILLHydraulic Lubrication System

Motor BearingsGearbox

Pinion Bearings

Trunion Bearing(feed end) Trunion Bearing

(dis. end)

Fig.1 : SAG mill Diagram

Parts of SAG Mill to be lubricated:

Lubricant Data:

SAG Mill Components Type Characteristic

Motor Bearings Omala 150Gear 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 320Gear oil. 320 viscosity at 40˚C and 25 viscosity at 100˚C.

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.

Pres. Gauge(before)Pres. Gauge

(after)

Pres. Regulator

Temp. Gauge

FILTER(disposable)

HEAT EXCHANGER

Oil Tank

Breather

Flow sight glass

Relief valve

MOTOR PUMP12gpm

Motor Drive Lubrication System Diagram:

Motor Lube. System Schematic Diagram:

check valve

relief valve

HEAT EXCHANGER

wat

er in

out

pressure gauge (before filter)

ball valve

FILTER

temp. gauge

pressureregulator

pressure gauge (after filter)

to M

OTO

R B

EARI

NG

S

return to oil tank

retu

rn to

oil

tank

retu

rn to

oil

tank

from oil tank

MOTORPUMP

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

Relief valve

MOTOR(4 HP at 850rpm)

HEAT EXCHANGER

Pres. Gauge

Pres. Gauge

FILTER(scrap type)

Oil Tank

Flow Switch Control

Gearbox Lubrication System Diagram:

Gearbox Lube. System Schematic Diagram:

From

oil

Tank

MOTOR PUMP

relief valve

Return Oil

pressure gaugew/ transmitterFILTER

HE

AT

E

XC

HA

NG

ER

Flow Switch Control

pressure gaugew/ transmitter

to Bearings and Gears(spray type)

water in

water out retu

rn to

oil

tank

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

MOTOR(cleaning,15 KW) Trunnion Motor

(clean,37 KW)

HEAT EXCHANGER

Temp. Gauge

Temp. Gauge

FILTER (main)(duty/standby)

FILTER (trunnion)(duty/standby)

Heater

Relief valve

Breather

Oil Return

CLEANING CLEANRETURN

OIL TANK 3500 liters

Pinion Motors(clean, 2.2 KW)

Trunnion / Pinion Bearing Lube System Dia.:

FILTER (pinion)(duty/standby)

Trunnion / Pinion Bearing Lube System Schem. Dia.:

MOTOR PUMPduty

MOTOR PUMPStandby

CLEANINGRETURN CLEAN

relief valve

FILTERduty

FILTERstandby

check valve check valve

HEAT EXCHANGER

HEAT EXCHANGER

in out

MOTOR PUMPFeed End

MOTOR PUMPstandby

MOTOR PUMPDis. End

FILTERduty

FILTERstandby

check valve check valve check valvecheck valve

FILTERduty

FILTERstandby

r.v

to Trunnion Bearing(Feed end)

to Trunnion Bearing(Dis. end)

CLEANto Trunnion Bearing

(Feed end)

Flow Divider

FSC

Trunnion

Trunnion Bearing Lube System Schem. Dia.:

Pinion Lube. System Schematic Diagram:

FILTERduty

check valvecheck valve

FILTERstandby

MOTOR PUMPduty

MOTOR PUMPstandby

to Pinion Bearing

CLEAN

Flow Divider

Flow Divider Flow Divider

INBOARD INBOARDOUT BOARD OUT BOARD

to Pinion Bearing

FEED ENDBEARING

DIS. ENDBEARING

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

FIT572 Pinion Bearing No.1 Feed End Oil Flow, (L/min)

1.00 1.20 2.35 2.54 2.67 2.68

FIT573 Pinion Bearing No.1 Dis. End Oil Flow, (L/min) 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

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

PT554 Dis. End Trunnion Bearing Lift 0.15 0.20 0.36 0.58 0.31 0.35

Motor

Gearbox

Trunnion bearingFeed end

Trunnion bearingDis. end

Fig.2 : Ball Mill diagram.

Parts of Ball Mill to be lubricated:

Pinion

III. PROBLEM and

RECOMMENDATION

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

Gathered Data: This were the alarm gathered during my stay in the Mill.

CONTAMINATED OIL

Filter easily clogged up

Oil low flow

Contaminated Oil

Pressure build up

Differential Pres. high

Lubrication shortage

Alarm sent to the contol

panel

Mill shutdown

Temp. high

2,148,247 Php

Clean and Organize Oil Storage Wide Oil Storage Room

Proper Lube System Room

Proper Oil Storage Room

ventilation

Rugged, sealablePlastic Top –up Container that are clearly marked

Funnels StoredIn clean sealablePlastic containers

Store ShopRags in sealable container

Closable LockerProper Lube Cabinet

for housekeeping

Trainee:Aljon Altiche

Safety Awareness Clean and Enclosed Lube System Room

Mill Current Oil Storage Room

Small and Unorganized

Lubricants/instruments not properly stored

Top up containers(no lube cabinet)

Grease Gun

Mill Current Lube System Room

Prone to Contaminants(Unclean)

water

dirt

dust

Improper Draining system

Stagnant water

Leakage

Pile of mud

Lube System Room is widely OPEN

Nesting birds

dirt

Recommendation:

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.

Proper Drainage System - by having permanent submersible pump.

Enclose the Lube. System room - to prevent external contaminant to enter the system.

For Oil Storage Room:

For Lube. System Room:

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…..

because, The Hydraulic Lubrication System is the main reason why the mill is still running…

Thoughts about the Study:

The Lubeman

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