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    31290030

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    PETRONAS TECHNICAL STANDARDS DESIGN AND ENGINEERING PRACTICE TECHNICAL SPECIFICATION OIL MIST LUBRICATION SYSTEMS PTS 31.29.00.30 JULY 2011 PETRONAS 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) _Attighsresorved, No prof thie document ray be eoroducea led in a etieval stom or warsmtid in any fxm or by ary moan {Glectoni, mechaniea, photocopying, recoraing o ethrwis) without he pormsion of the copyright owner, PTS 31.29.00.30 ‘August 2011 Page 2 'S Circular ad PETRONAS 2011-01 PTS No: 31.29.00.30. PTS Title: Oil Mist Lubrication Systems This revision of PTS 31.29.00.30 — Oil Mist Lubrication Systems has been updated to incorporate PETRONAS Lessons Leamt, Best Practice and new information issued by relevant industry code and standards. The previous version of this PTS 31.29.00.30 (December 2000) will be removed from PTS binder/ e- repository from herein onwards. Document naa Prepared Staff Engineer, valor . Retowes | Suffan Sahadan | RE EN lea (ne ‘Approved | Zaharudin Arifin a. ot fel Ck I ' , Senior Manager, 5 Verified | Zuraimi M Idris 7 ngineering, GTS 124/08 Jou A . ; General Manager, x Saifol Mualim Ahmad | General Verified Engineering, las/e/u Af Yahaya Eno i ; Senior General Endorsed | Pau Kiew Huai ees 26.9.1 AN. Revision Histor 1__| Azmi Md Lasin M Suffian Sahadan July 2011 I | PTS 31.29.00.30 ‘August 2011 Page 3 PREFACE PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUsiDivisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, It is expected of them to follow those design and engineering Practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the ‘owner. ‘The right to use PTS rests with three categories of users: 1) PETRONAS and its affiliates. 2) Other parties who are authorized to use PTS subject to appropriate contractual arrangements. 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards, Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this, disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be retumed after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. ‘The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement. PTS 31.29.00.30 ‘August 2011 Page 4 ‘TABLE OF CONTENTS 4. INTRODUCTION 4.4 SCOPE. 5 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS.. 5 1.3 DEFINITIONS. 5 1.4 CROSS-REFERENCES... 5 1.5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION. 6 2. GENERAL. 2.1 APPLICATION. 2.2 PERFORMANCE, 2.3 CONFLICTING REQUIREMENTS. 2.4 SYSTEM DESCRIPTIONS. 2.5 SYSTEM SELECTION. 2.6 SYSTEM DESIGN DATA. weeny 3. BASIC DESIGN 3.1 GENERAL, - - eet 3.2 SYSTEM DESIGN... 10 3.3 DISTRIBUTION PIPING. evnstsannensnntnsnenrsesansenrinaneen sen ene 3.4 COMPONENTS, ACCESSORIES AND UTILITIES, - 12 4, INSTRUMENTATION AND CONTROL 4.1 INSTRUMENTATION, - - 14 42 CONTROLS......... . seoesennennineaniveuneneev sve 15 4.3 ALARMS, : . 215; 5. INSPECTION, TESTING AND PROTECTION 5.1 INSPECTION, 5.2 CERTIFICATION. 5.3 TESTING......... 5.4 PREPARATION FOR SHIPMENT. 6. ROTATING EQUIPMENT ADAPTATION 6.1 GENERAL, 6.2 'PURE MIST’ APPLICATIONS. 6.3 PURGE MIST’ APPLICATIONS, 6.4 CLOSED LOOP APPLICATIONS......sc.:ess ceseseetnnenenseetsnsnsnvescnseess 20 7. VENDOR'S DATA 7.1 PROPOSALS, 7.2 CONTRACT DATA. 8, REFERENCES, . . 23 APPENDICES APPENDIX1 FIGURES.......... APPENDIX 2 CLEANING, TESTING AND COMMISSIONING OIL MIST SYSTEMS... 58 14 12 13 14 PTS 31.29.00.30 ‘August 2011 Page 5 INTRODUCTION SCOPE This PTS specifies requirements and gives recommendations for the design of oil mist lubrication systems which serve pumps, side entry mixers, centrifugal fans and their Totally Enclosed Fan Cooled (TEFC) electric motor or general purpose steam turbine drivers, located in close proximity to each other. Lubrication systems for internal combustion engines and gas turbine drivers are excluded from the scope of this PTS ‘This PTS shall be used in conjunction with datalrequisition sheet PTS 31.29.00.93. This PTS is a revision of the PTS of the same number dated December 2000; a summary of the main changes since the previous edition is given in (1.5). DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by PETRONAS, the distribution of this document is confined to companies forming part of PETRONAS group and to Contractors nominated by them. This PTS is intended for use in oil refineries, gas plants, chemical plants and, where applicable, in exploration and production facilities and supply/marketing installations, IF national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to safely, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this PTS Which is considered to be necessary in order to comply with national andor local regulations. The Principal may then negotiate with the authorities concerned with the objective of obtaining agreement to follow this PTS as closely as possible. DEFINITIONS ‘The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. ‘The Manufacturer/Supplier/Vendor is the party which manufactures or supplies ‘equipment and services to perform the duties specified by the Contractor. ‘The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements, The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. CROSS-REFERENCES Where cross-references to other parts of this PTS are made, the referenced section number is shown in brackets. Other documents referenced by this PTS are listed in (8). PTS 31.29.00.30 ‘August 2011 Page 6 1.5 SUMMARY OF CHANGES SINCE PREVIOUS EDITION The previous edition ofthis PTS was dated December 2000. Other than editorial changes, the following are the main changes since that edition: Od New section | section _| Change 25 25 ‘Addition of System Types description - 253 ‘Addition of Directed Mist Lubrication system 32 32 ‘Addition/amendment of system design specification 33) 33. ‘Amendment in distribution piping specification - 3.49 | Addition of ‘Integral air/oil heater (mist generator reservoir)” section 34.12 3.4.13 | Revision of oi fiter requirements 43 43 ‘Addition of alarm signals = 624 ‘Addition of “Pure mist bearing housings” section = 6.3.1 ‘Addition of Purge mist bearing housings” section 64 64 ‘Addition of new subsections 7A 7A Revision of the Proposal section 7.22 722 ‘Addition of equipment listing in operating instruction manual ‘Appendix | Appendix | Combined typical design arrangements into one appendix with 1to5 1 additional configurations . ‘Appendix | Appendix addition on Cleaning, Testing and Commissioning Oi C 2 Mist Systems 24 22 23 24 244 242 243 244 PTS 31.29.00.30 ‘August 2011 Page7 GENERAL APPLICATION Oil mist lubrication systems may be considered in areas and/or applications where the environmental conditions will adversely affect bearing lifetime due to ingress of contaminants in the bearing housing. The maximum benefits of oll mist lubrication (enhanced bearing reliability resulting from high standards of lubrication quality control; prevention of ingress of water and other contaminants into the bearing housing; reduced maintenance cost and reduced exposure to hazardous chemicals) can be achieved by either a ‘pure mist’ dry sump lubrication system or a ‘purge mist’ wet sump lubrication system. The ‘purge mist’ system retains the conventional constant-level oiler arrangement and uses ‘purge mist’ to pressurize the housing and compensate for any cil loss from the constant-level oiler. PERFORMANCE Compliance with this PTS does not relieve the Vendor of the responsibility for ensuring that the system and equipment furnished are properly designed and constructed and suitable for the service intended. The required lifetime, reliability and availability of the system shall be specified by the Principal and agreed with the Vendor. CONFLICTING REQUIREMENTS. In the event of conflict between documents relating to the enquiry or order, the following hierarchy of documents shall apply: First level: purchase order and variations thereto Second level: data / requisition sheets and drawings Third level: this PTS SYSTEM DESCRIPTIONS il mist lubrication system ‘An oll mist lubrication system is a means of distributing atomized oil drops (between 2 um and 10 um in diameter) from a central mist generator to a number of lubrication points using a dry, low-pressure [nominally 50 mbar (ga)) air stream. The normal concentration of oil mist in the transport air is approximately 6 mlim3 (6 ppm). Pure oil mist systems Pure oil mist systems, also referred to as ‘pure mist’ or ‘dry sump’ systems, utilize a continuous oil mist flow through the bearing housing to deliver clean oil directly to the bearings and to maintain an outward flow of air from the housing to prevent the ingress of moisture and other corrosive contaminants. An oil sump is not needed. Purge oll mist systems Purge oil mist systems (also called ‘purge mist’ or ‘wet sump* systems) use rectassified oil to maintain a constant level of oil in the sump to lubricate the bearings. The air purges the bearing housing and prevents the ingress of moisture and other corrosive contaminants. Closed loop systems Closed loop systems are either pure or purge mist systems that include an oil mist recovery and return system. Such systems may require modification of the bearing house seals to achieve positive sealing in order to prevent exposure of oil vapors to the atmosphere. 25 2.54 25.4.4 252 2.5.24 253 PTS 31.29.00.30 ‘August 2011 Page 8 SYSTEM TYPES Purge oil mist Purge oll mist lubrication (wet sump) is an arrangement in which the oll mist purges the bearing housing to exclude moisture and contamination from the external environment. Normal bearing housing oil levels are maintained by the use of a constant level oiler in combination with an overflow device and conventional oil bath, finger or ol rings. Equipment with sleeve or journal bearings shall be lubricated by purge oil mist. For product temperatures above 300 °C (572 °F), bearing housings with ‘purge mist’ systems may require special features to protect the bearing from being overheated by heat transfer from the product Equipment receiving purge mist lubrication shall have an enclosed bearing housing. Purge oil mist lubrication shall be used: ‘a. _ when equipment contains sleeve type bearings, gears, or other sliding surfaces; b. when equipment speeds are less than 600 r/min; ©. when specified by the Principal. Purge oil mist can be applied on bearing housings with rolling element bearings or hydrodynamic bearings. Pure oil mist Pure oil mist lubrication (dry sump) is an arrangement in which no oil Ievel is maintained in the bearing housing. Lubrication is effected by coalescence of oil mist on rolling elements within the bearing housing Unless otherwise specified, equipment with anti-tiction or rolling element bearings shall be lubricated with pure oil mist or directed mist lubrication Equipment receiving pure mist lubrication shall have an enclosed bearing housing, Radial and thrust bearings shall be roller or ball bearings with no more than two consecutive rows, ie. double row thrust bearing. Ball bearings shall be an open (unshielded) design. Bearings shall have a minimum speed of 600 r/min. Pure oil mist shall be used wherever possible Directed mist lubrication Equipment with anti-friction bearings that are subject to high thrust loads shall be considered for directed mist lubrication. Equipment operating under any of the following conditions shall be evaluated: = pump speed is in excess of 3800 r/min; = equipment driver power is in excess of 150 kW (200 hp); = pumps susceptible to cavitation or recirculation or having an operating range of +1- 40 % of best efficiency point (BEP), Equipment with a bearing housing having large oil drain back ports that allow the mist flow to go around rather than through the bearing shall use directed mist. 26 PTS 31.29.00.30 ‘August 2011 Page 9 IF directed mist lubrication cannot be provided to an existing bearing housing, that housing shall be modified accordingly, or purge mist lubrication shall be provided. See (6.2.1.9) for a description on making bearing housings suitable for directed mist lubrication, The use of directed mist shall be subject to the mutual agreement between the Supplier and the Principal Closed loop systems may have to be selected to meet local environmental requirements or standards, Closed loop systems are preferred in order to minimize contamination by lube oil in the vicinity of the equipment. Closed loop systems shall be selected when rotating equipment is operated in a building. Alternative designs shall be considered ifa closed loop system is not practical ‘SYSTEM DESIGN DATA The Purchaser shall provide the Vendor of the oil mist lubrication system with sufficient data relating to the equipment to be lubricated to enable him to design the system required. For each consumer in the system, this information should include the item number of the equipment, its Manufacturer's type!model identification and the serial number. The Purchaser shall also indicate which equipment is subjected to frequent stops/starts and/or shock loading, The Vendor shall also be provided with a plot plan of the facility. 34 32 33 PTS 31.29.00.30 ‘August 2011 Page 10 BASIC DESIGN GENERAL The design concepts discussed in this section apply to the lubrication of equipment with either rolling element bearings or sloeve bearings. ‘The Vendor of the oil mist lubrication system is in all cases responsible for co-ordination, and shall establish with the rotating equipment Manufacturers the oil mist lubrication requirements {for each item of equipment. SYSTEM DESIGN Each oil mist lubrication system shall consist essentially of an oil mist generator to produce and control the oil mist, a network of distribution lines to convey the oil mist to the points of lubrication (the consumers), and reclassifiers to control the flow of or coalesce the oll Provision shall be made for venting the oil mist from each bearing housing, and drains shall be provided to drain the coalesced oil from ‘pure mist’ systems or to collect any overfiow from ‘purge mist’ systems. Venting of oil mist into buildings shall not be allowed. Venting shall take place outside the building The oll mist generator shall be designed for a capacity of 125 % of the rated requirements of the system, and it shall be capable of operating satisfactorily at 50 % of its designed capacity. Distribution lines to the consumers shall be designed to ensure that coalescing of airborne Particles of oll is kept to an absolute minimum. ‘The design of the distribution system shall ensure that a homogeneous mixture of air and oll reaches all consumers, including the most remote, with sufficient pressure to impart a velocity to the mist adequate to generate turbulent fiow through the inlet fitings at the points of lubrication. Such turbulent conditions are needed for the satisfactory wetting of the surfaces to be lubricated. The Principal shall provide a dry air supply to the oil mist console at a pressure between 4 bar (ga) [60 psig] and 7 bar (ga) [100 psig] from an appropriate Instrument air header. This air supply shall be via piping installed solely for the oil mist lubrication system The reciassifiers shall be located at the ends of the branch lines in the mist manifold (see Appendix 1, Figure 1). The reclassified oil shall be fed to the individual bearing housings via feeder lines which shall not be more than 2.5 m long. The oll mist console (control cabinet) and all electrical equipment and components within the system shall be suitable for the area classification, gas grouping and temperature classes specified in the datalrequisition sheet DISTRIBUTION PIPING Atypical arrangement of the distribution pipework in an oil mist lubrication system is shown in Appendix 1, Figure 1 The oil mist generator shall be located in a position central to the system The length of pipe run from the oil mist generator to the most remote consumer shall not exceed 180 m (600 ft) PTS 31.29.00.30 ‘August 2011 Page 11 il mist supply headers shall not be horizontal. Headers shall be run to slope continuously downwards towards the oil mist generator at a slope of 1:240. Headers should be properly braced and secured according to bracing standards included in Appendix 1, Figure 2. Where elevation changes prevent continuous slope to the generator (e.g. where the header crosses the roadway), an automated drain leg shall be used. Drain legs should not vent to atmosphere or drain to sewer. See example in Appendix 1, Figure 3. ‘The riser from the oil mist generator shall enter the main header at the bottom Drop points shall be taken from the top of the main oil mist header. See Appendix 1, Figure 4. Feeder lines to individual bearing housings shall be run to slope continuously and downwards towards the equipment. See Appendix 1, Figure 5. Feeder lines shall be run direct to the point of lubrication with a minimum number of bends. ‘The mist supply manifold shall be accessible by the operator and located no higher than 1.8 m (6 ft) above grade. Location of the mist supply and drain lines on the equipment shall be subject to the mutual agreement between the Supplier and the Principal. Al distribution piping shall be smooth internally and free from all projections. Before the piping is made up, care shall be taken to ensure that its clean throughout the system. Cut lengths of pipe and tubing shall be reamed and de-burred at each end and then blown clean. All fitings shall be blown clean. If piping or tubing is to be stored before installation, then all open ends shall be capped and plugged. Care shall be taken to ensure that no damage occurs in storage. Al threaded connections shall be coated with a pipe sealantlubricant before the connections are made. SealanVlubricant paste with PTFE should be used. PTFE tape shall not be applied as it may block the opening if applied carelessly. There shall be no valves in oil mist headers or in any of the drops. The system shall be cleaned, tested and commissioned in accordance with Appendix 2. Construction materials for oll mist distribution piping shall be as follows: Table 1 Materials of construction of distribution piping [Main header/ return | DN 50 (NPS 2) Schedule 40 galvanised carbon steel pipe, threaded lheader NPT. Drop tines DN 20 (NPS 3/4) Schedule 40 galvanised carbon steel pipe, threaded NPT. _ - [Return drop ines BN 25 (NPS 1) Schedule 40 galvanised carbon sos ibe, Treaded ‘6 mm (1/4 in) OD, austenitic stainless steel tubing with 0.9 mm [Feeder lines (0.04 in) minimum wall thickness, or armoured flexible hose of similar bore and material, if approved by the Principal 40 mm (3/8 in) OD, austentic stainless steel tubing with 0.9 ran (0.04 in) minimum wal thickness. —— 25 mm (1 in) OD austenitic stainioss Steal tubing with 0.9 mm Return tubing lines | (0.04 in) minimum wall thickness. _ Rocessories ‘All reclassfiers and tube fitings shall be stainless steel or other [Drain tines. 3.4 3.44 3.4.2 3.4.3 344 34.5 PTS 31.29.00.30 ‘August 2011 Page 12 ‘corrosion-resistant material. The size of the reclassifiers shall be ‘stamped on the hexagonal portion of the fitting at a place where it will be visible when in service. COMPONENTS, ACCESSORIES AND UTILITIES Oil mist generator The oil mist shall be generated by means of a vortex chamber. Oil mist console/generator The Oil Mist Generator (OMG) shall be enclosed in a stainless steel cabinet, which shall be {freestanding and provided with a hinged door with robust closures. The cabinet shall be weatherproofed and vented, and mounted at ground level. For oil mist generators located in colder climates, sufficient insulation and heat shall be provided to maintain an internal cabinet temperature of 10 °C (50°F). The oil mist generator shall be accessible in order to permit its on-stream inspection. All exposed steel surfaces shall be primed and finished in accordance with the Manufacturer's standards. All electrical ‘components shall be suitable for the electrical area classification where the cabinet is installed, ‘See Appendix 1, Figure 6A and Figure 6B. Reclassifiers For ‘pure mist’ applications, mist reclassifiers shall be used. ‘The mist issuing from the feeder lines shall be directed through the rolling element bearing, For ‘purge mis applications, reclassifiers shall be of the mist type. Each lubrication point shall have its own rectassifier. Bearing housings For ‘pure mist’ systems, an oil sight bottle incorporating a drain valve shall be fitted to the drain connection of the housing in order to monitor, and subsequently drain, any accumulation of oil, Existing constant-tevel oiler connections in the housing shall be plugged. In ‘purge mist’ systems, an oil level sight assembly with overflow level control shall be provided to maintain a maximum oil level in the bearing housing. In ‘closed loop’ systems the seals in the bearing housing covers shall provide positive sealing to avoid exposure of oil vapors to the atmosphere. The oil seals selected shall be designed for a service lifetime of at least 40,000 h. Air The air supplied to the mist generator shall be clean and dry; instrument air shall be used for this since plant air is normally not suitable for long-term trouble-free operation. The air supplied to the oil mist system shall meet the following requirements: = Itshall be free from liquids and toxic, corrosive and flammable gases; 3.46 347 3.48 3.49 3.4.10 3.441 PTS 31.29.00.30 ‘August 2011 Page 13 ~The solids content shall be less than 0.1 glm® (0.1 ppm) and the particle diameter shall not exceed 3 um; = The dew point at the supply pressure shall always be 5 °C (9F) lower than the lowest annual ambient temperature. Air filter An air flterhwater separator shall be provided for the inlet air supply. It shall be capable of removing 100 % of particles of size 40 jum and larger, and shall be suitable for a normal working pressure of 7 bar (ga) [100 psig}. Air regulator ‘An air regulator shall be provided to control the pressure of the ait supply within the oil mist distribution system. The regulator shall be capable of accepting inlet air supplied at pressures within the range of 4 bar (ga) {60 psig] to 7 bar (ga) [100 psig]. Air pre-heater A thermostatically controlled electric heater shall be provided to maintain the inlet air at operating temperature, and to limit the air temperature to a maximum of 65 °C (150 *F). If the oil mist generator is equipped with the air preheating system at the factory, no additional User connections or installation are required. Integral air/oil heater (mist generator reservoir) Air shall be supplied at 60 °C (140 °F) to the mist generator through the air heating element, Which is immersed in the oil. In this way, a reservoir oil temperature of 44 °C (110 °F) shall be achieved. Oil selection Suitable oil shall be selected and approved by the Principal in consultation with the oil mist Vendor to ensure compatiblity with the oil mist generator. As a minimum, the following factors shall be evaluated in selecting the oil for mist lubrication’ = Viscosity of the oil at the temperature in the mist head; = Surface tension of the oil; = Compliance of the properties of the selected oil with the lubricant requirements specified by the Supplier of the system and by the Manufacturers of the connected equipment; = Wax formation tendency of the oil at low ambient temperature, to prevent blockage of the reclassifiers; = Pour point relative to the ambient temperature. NOTE: In cold climates (temperatures below ~25 °C (13 °F), synthetic ol shall be used in order to avoid having tohheattrace the oll mst headers. Main/auxiliary oil mist reservoir Main/auxiliary oll mist reservoirs shall be provided and each sized for at least 72h of continuous operation at the rated oil mist production capacity. The reservoirs shall be located within the oil mist console and shall each have a valved drain 3.4.42 3.4.13 44 444 412 414 PTS 31.29.0030 ‘August 2011 Page 14 ‘supply reservoir ‘An oil supply reservoir including oil transport pump shall be provided permanently connected to. the oil mist reservoir. The reservoir should be sized for at least 31 days capacity. The oil mist reservoir floor shall be sloped to a valved drain, to ensure all oil and contaminants can be drained from the reservoir. Oil filter For pumped refiling of the oil reservoir, an inlet oil fiter shall be provided and installed upstream of the ail reservoir. It shall be capable of removing 100 % of particles of size 10 um and larger. Connections to the oil make-up reservoir shall be such as to prevent sand or dust entering the system. Demisting apparatus (see 6.4.2) Demisting apparatus must be designed for sufficient capacity and to maintain sufficient pressure at all points in the system to prevent oil mist from escaping to atmosphere. For oil mist generators installed indoors, a separate bulk oil supply tank with demisting apparatus shall be supplied. INSTRUMENTATION AND CONTROL INSTRUMENTATION General ‘The Vendor shall make provisions for monitoring the following systems, and shall supply the necessary instrumentation unless otherwise specified in the data/requisition sheet. All instrumentation and connections for instruments shall comply with the requirements of PTS 32,31.09.31 and PTS 32.31.00.32 Air system Provision shall be made to monitor the following: = Inlet supply pressure; - Outlet supply pressure downstream of the air regulator; = Air heater outlet temperature. Ol system Provision shall be made to monitor the following: ~ Reservoir oil level; - Oil supply pressure; Oil mist generator outlet pressure to main header; = Oil mist density. Isolating valves Isolating valves shall be provided for all level indicators and for all pressure indicators. 42 43 PTS 31.29.00.30 ‘August 2011 Page 15 CONTROLS ‘The Vendor shall include the following controls within the scope of supply: = an air pressure regulator to control the pressure within the oil mist distribution system. The regulator shall be capable of accepting inlet air supplied at pressures within the range 4 bar (ga) [60 psig] to 7 bar (ga) [100 psig]; = anil flow valve to control the density ofthe oll mist; = an air by-pass valve to control the oil mist pressure without increasing the oll output; - automatic control ofthe oll level in the reservoir of the oll mist generator. ALARMS Individual alarm lights shall be installed for the following functions: = Low oil mist outlet pressure; - High oil mist outlet pressure; ~ Low reservoir oil level (main generator reservoir); ~ High reservoir oil level (main generator reservoir); - Low air supply temperature (air heater outlet); - High air supply temperature (air heater outlet); ~ Low oil temperature (oil supply reservoir); - High oil temperature (oil supply reservoir); - Low oil level (oil supply reservoir); = High oil level (oil supply reservoir); = High oil supply pressure; - Low oil supply pressure; - Low regulated air supply pressure; = High oll mist density; = Low oil mist density ‘Alarm lights for each malfunction shall be panel-mounted and located within the oll mist console, The first alarm can be determined by scrolling the event log. ‘A common mist generator alarm shall be connected to the Principal's Distributed Control ‘System (DCS). The oil mist generator shall have the ability to communicate individual alarms to the Principal's Dcs. ‘The actuation of the remote alarm in the plant control room shall also be indicated locally by a red light mounted on the top of the oil mist cabinet. Normal operation of the oil mist lubrication ‘system shall be indicated by a green light mounted on the top of the cabinet. The alarm and normal operation lights shall be clearly visible in all horizontal directions. ‘The area classification and the supply voltage for the alarm/indicator system shall be specified in the data/requisition sheet. 64 52 53 54 PTS 31.29.00.30 ‘August 2011 Page 16 INSPECTION, TESTING AND PROTECTION OF OIL MIST CABINET INSPECTION ‘The Manufacturer shall state in the proposal the inspection methods that will be applied and shall give details of the quality control procedures set up in the manufacturing facility. ‘The Principal shall indicate whether, and to what extent, he will witness the Manufacturer's inspections and functional testing CERTIFICATION ‘The Manufacturer shall provide certificates of compliance (ISO 10474, type 2.1) in which it is confirmed that the materials of construction used for all equipment, piping and ‘components are in accordance with the requirements of the purchase order. For electrical equipment, the Manufacturer shall provide certificates of conformity stating that the electrical apparatus complies with the relevant standards for apparatus for potentially explosive atmospheres, with respect to the area classification, gas grouping and temperature classes specified in the datalrequisition sheet. TESTING ‘The oil mist generator shall be tested in accordance with the Manufacturer's standard shop test. On-site functional testing of the oil mist system shall be performed in accordance with a test procedure agreed by the Principal and Vendor. All instrumentation including end devices shall be functionally tested. PREPARATION FOR SHIPMENT Preparation for shipment and the procedures to be followed shall be as specified by the Purchaser. Generally, machined surfaces shall be coated with a suitable rust preventative, ends of piping and tubing shall be sealed and protected, and all pipes and tubes shall be braced and secured to prevent damage during shipment. 61 62 6.2.4 PTS 31.29.00.30 ‘August 2011 Page 17 ROTATING EQUIPMENT ADAPTATION GENERAL It will be necessary to carry out certain modifications to the standard bearing housing arrangements of rotating equipment in order to allow operation of an oil mist lubrication system. Centrifugal pumps may already have provisions for oil mist lubrication if so specified when purchased. The Vendor of the oil mist lubrication system shall verify the details of necessary modifications with the Principal. Shielded or sealed bearings shall not be used. The rotating equipment Supplier shall inform the Principal about the modifications required. il mist inlet connections to bearing housings shall be at least 6 mm (1/4 in) threaded NPT. "PURE MIST’ APPLICATIONS Pure mist bearing housings a. Reclassifier fitings shall be located in the mist manifold block. For directed mist applications that require the reclassifier to be located at the bearing housing, see (62.1.h) b. Reclassifier selection for pure mist applications shall be based on calculations by the Vendor's engineering department as part of the design and engineering package. ¢. Pure mist bearing housing shall be vented so that the oll mist flow is through the bearing. Large oil drain ports around the bearings shall be plugged to ensure proper mist flow. 4. Pure mist bearing housings shall have a clear plastic sight bottle with a 10 mm (318 in) stainless stee! tubing vent. The sight bottle shall be installed at the bearing housing low point so that all coalesced oil drains from the bearing housing. ©. Pure Mist Application Method 1 Mist is introduced at two locations, one on the outboard side of the thrust and one on. the outboard side of the radial bearing. The mist flow is through each bearing towards the centre of the bearing housing. The mist and coalesced oil vents and drains from the bearing housing through the drain connection. This configuration is typical for ‘overhung type API/ISO OH2 pumps and for some ANSI pumps, FD or ID fan spindle type bearing housings, or other specialized equipment. See Appendix 1, Figure 7. f. Pure Mist Application Method 2 Mist is introduced at one location between the thrust and radial bearings. The mist flow is through each bearing toward each bearing end cap where it vents to ‘atmosphere through the labyrinth seal. if the bearing end caps do not have labyrinth type seals the end caps must be modified to allow the mist to vent out of the bearing housing. Coalesced oil vents and drains from the bearing housing through the drain connection. This configuration is typical for overhung type pumps and FD or ID fan spindle type bearing housings, or other specialized equipment. See Appendix 1, Figure 8. PTS 31.29.00.30 ‘August 2011 Page 18 Pure Mist Application Method 3 Mist is introduced onto one side of the bearing, traverses through the bearing and vents through the shaft seal directly on the opposite side of the bearing. Coalesced oil vents and drains from the bearing housing through the drain connection. Typical applications are bearing housings of between bearing type pumps, vertical ANSI pumps and pillow block bearing housings. See Appendix 1, Figure 9 and Figure 10. Pure Mist Application Method 4 This type of pure mist application is described as Directed Mist. The equipment bearing housings may require modification to provide drilled and tapped holes in the bearing housing or bearing end caps for mounting the rectassifiers. Reclassifiers are located so that the mist flow is directed at the centreline of the rolling elements. See (2.5.3) for determining when directed mist is required. See Appendix 1, Figure 11 Pure Mist Application Method 5 Mist is introduced at one location between the thrust and radial bearings. The mist flow is into the radial bearing from one side and through the thrust bearing toward the bearing end cap where it vents through an opening on the bottom of the end cap to the collection container. See Appendix 1, Figure 12. Pure Mist Application Method 6 Mist is introduced at two locations, one each above the thrust and the radial bearing. ‘The mist flow is through each bearing toward the bottom of the bearing housing. The mist and coalesced oil vents and drains from the bearing housing through the drain connection. This configuration is typical for vertical type APV/ISO pumps and for some: ANSI pumps. See Appendix 1, Figure 13. Horizontal Electric Motors - Method 7 - Horizontal electric motors shall be frame size 254 and larger [11 KW (15 hp)] with ball bearings that have a re-greaseable construction, or are designed for oil mist, service, = The re-lubrication (mist) inlet shall be in the upper bracket quadrant. - The venvidrain outlet shall be near the 6 o'clock position. This maintains a “dry-sump” system and minimizes accumulation and churning of ol - Positive isolation shall be supplied between bearing and motor winding to prevent oil ingress. - Bearings shall be open, not shielded or sealed, and be enclosed with bearings caps. = Drain tubing shall be tubed away from the fan, into an oil collection container. = Inlet and vent / drain hole threads shall accommodate standard pipe thread connections. - The insulation materials shall be compatible with the oil mist. Nomex insulation, ‘epoxy varnish and Tefion lead cable systems offer the best protection. Silicon rubber should be avoided due to potential swelling. ~The bearing cavities shall be free of grease for the oil mist to pass into and exit the bearing housing. Any small amount of residue grease will plug the vent / drain ‘opening and prevent proper lubrication. The bearing should be installed with a preservative oil coating after tear down to remove grease from the bearings. = The conduit box mounted on the motor shall be sealed around the wires to prevent stray mist from travelling through the conduit from the motor to the motor control centre. See Appendix 1, Figure 14 PTS 31.29.00.30 ‘August 2011 Page 19 Vertical Electric Motors - Method 8 = Vertical electric motors shall be frame size 180 and larger [2.2 kW (3 hp)] with ball bearings that have a re-greaseable construction, or are designed for oil mist service. = Vertical motors shall have the same features as described for horizontal motors in (62.1.4). - Positive isolation shall be supplied between the bearing and motor winding to prevent oil ingress. = The re-lubrication (mist) inlet shall be located above the upper and lower bearings to allow the oil mist to enter without trapping and pass down through the rolling elements of the bearings ~The vent/drain outlet should be below the upper and lower bearings to maintain a “dry sump" system and minimize accumulation and churning of oil. However on. some motors a vent can only be installed on the upper bearing and the coalesced cit drains out ofthe lower bearing ventidrain, which can be lower than the bearing, See Appendix 1, Figure 15. 63 'PURGE MIST’ APPLICATIONS 6.3.1 Purge mist bearing housings a b Reclassifier fittings shall be located in the mist manifold block. Where possible, purge mist bearing housings shall be equipped with oil level control devices designed to maintain the proper operating oil level in the bearing housing. The devices shail be installed in such a way that coalesced oil can be drained into an «il collection container. The devices shall have a field adjustable ol level setting that can be adjusted to limit the oil level in the bearing housing. Drilled drain plugs and automatic oilers which drain coalesced oil directly onto the equipment base plate shall not be used. Purge mist bearing housings shall be equipped with purge mist vent fill assemblies which allow easy filing and maintaining of ol levels without disconnecting the oil mist supply. Purge mist bearing housings shall have a clear plastic sight bottle, equipped with a valve. The sight bottle shall be installed at the bearing housing low point. Purge Mist Application Method 1 For machinery identified as suitable for installation of adjustable oil level sight assemblies where anticipated oil loss is minimal. This configuration does not provide a local liquid oil reserve for oil loss. Oil make up is provided by coalesced oil from the mist supply. Oil level is maintained by setting a field adjustable overflow tube to the proper operating level. A balanced reference pressure line between the air space in the bearing housing and the air space in the oil level sight assembly eliminates false oll level readings in the bearing housing. Coalesced oil and oil mist is vented from the oil level sight assembly through the oil over flow tube. Examples are small to medium HP steam turbines, between bearing pumps, and oil lubricated electric motors. Purge mist applications for gear boxes should be provided with adjustable oil level sight assemblies if possible. See Appendix 1, Figure 16 64 6.44 64.2 6.4.3 PTS 31.29.00.30 ‘August 2011 Page 20 Q. Purge Mist Application Method 2 For machinery where anticipated oil usage may be more than what the oll mist system will normally add to the bearing housing. This configuration provides a local liquid oil reservoir for oil make-up into the bearing housing. Oil make-up level is field adjustable to maintain the proper operating oil level. A separate overfiow tube adjustment is field set to ensure that the bearing housing does not overfil. A balanced reference pressure line between the air space in the bearing housing and the air space in the constant level sight assembly eliminates false oil level readings. Coalesced oll and oil mist is vented from the oil level sight assembly through the oil overflow tube. Examples are large steam turbines, between-bearing pumps and oil lubricated electric motors. See Appendix 1, Figure 17. h. Purge Mist Application Method 3 Sultable for large machinery bearing housings where oil addition from the mist system does not significantly raise the operating oil level between scheduled oil changes. This configuration is used where there is no bearing housing connection that would allow the use of an oil level sight assembly or a constant level sight assembly. This configuration does not utilize any oil level control device, but the advantages of purge mist are gained. In some cases, a purge mist ventifll assembly may be used. Examples are large gearboxes. See Appendix 1, Figure 18. CLOSED LOOP APPLICATIONS General When specified by the Principal, the oil mist system shall include the necessary equipment, piping and accessories to recover the coalesced oil and vented mist to a central location. Bracing standards are the same as indicated in (3.3). Return oil system 1. The oil mist generator shall be equipped with an elect ‘apparatus for stripping the return mist from the carrier air. 2. Carrier air shall be vented to atmosphere. 3. The demisting apparatus shall be designed so that the return oil mist header operates at atmospheric pressure. powered demisting Oil mist return header 1, The return oil mist header piping material shall be the same as the oil mist distribution, header and equipment drop piping. 2. The return oil mist header shall follow the same general routing and slope and use the same bracing standards as the oil mist distribution header. 3. The retum oll mist header shall slope toward the demisting apparatus. Return oil mist headers shall be DN 50 (NPS 2) pipe size. ‘See Appendix 1, Figure 19, 64.4 Return 1 6 6.4.5 Api The oil PTS 31.29.00.30 ‘August 2011 Page 21 oil mist drop piping The return oil mist drop piping materials shall be the same type as the oil mist supply drop piping. The nominal return oil mist drop pipe size shall be DN 25 (NPS 1). Equipment drop piping shall be connected to the top of the main return oil mist header. Equipment drop piping shall slope toward the return oil mist header from which it originates. Return drop piping shall be located so that it a. terminates between 60 cm (2 ft) and 180 om (6 ft) above the equipment to be serviced b. is located off centre so that equipment can be serviced without the need to remove the oil mist drop piping c. does not impede access to equipment 4d. does not interfere with installation or removal of equipment, Return drop piping shall be as shown in Appendix 1, Figure 20. Return drop piping shall terminate with a return mist manifold block. Mist manifold blocks shall 8. provide a means to vent all mist from the oil collection containers to the return oll mist headers; b. provide a means to allow liquid oil to be manually pumped from the oil collection containers into the return oil mist header without obstructing mist venting; . provide a means to connect the drain connection of the supply mist manifold to drain collected oil directly into the oil collection container. Al collection containers shall be equipped with manual operated pumps to pump the coalesced oil from the bearing housings into the mist return header. tion to equipment mist shall be applied to the equipment in the same manner as indicated in (6.2). The drains shall be routed differently and according to the drawings associated with each method. a b. c cl e. f 9 h Pure Mist Method 4 — Appendix 1, Figure 21. Pure Mist Method 2 ~ Appendix 1, Figure 22. Pure Mist Method 3~ Appendix 1, Figure 23 and Figure 24 Pure Mist Method 4— Appendix 1, Figure 25. Pure Mist Method 5 - Appendix 1, Figure 26. Pure Mist Method 6 ~ Appendix 1, Figure 27. Horizontal Electric Motors ~ Method 7 — Appendix 1, Figure 28. Vertical Electric Motors — Method 8 - Appendix 1, Figure 29, Purge Mist Application Method 1 — Appendix 1, Figure 30. Purge Mist Application Method 2 — Appendix 1, Figure 31 Purge Mist Application Method 3 - Appendix 1, Figure 32. 7A 72 724 PTS 31.29.00.30 ‘August 2011 Page 22 VENDOR'S DATA PROPOSALS ‘The Vendor shall submit the proposal for the oil mist lubrication system(s) required, which shall Include the following: 1 ‘A comprehensive description of the oil mist lubrication system proposed and of the function of each component; preliminary outline drawing, fully dimensioned; ‘A summary of the oll, electrical and air requirements; An estimate of header pipe and number of oil mist cabinets; ‘A description of the Manufacturer's quality control procedures and standard shop tests; Recommendations for the type and grade of lubricating oi(s) to be used in the oil mist lubrication system(s). The Vendor shall include in the proposal the supply of the following items for each oll mist lubrication system required: 4. Oil mist generator; 2. Oil mist console, including provisions for venting and weatherproofing; 3, The required number of reclassifiers; 4. Airfilter/water separator, including drainage arrangement; 5. Airregulat 6. Integral airioll heater (mist generator); 7. Oilreservoir, including provision for draining to the outside of the cabinet; 8. Oil fier, including provisions for connection to main oll supply reservoir, 9. Distribution pipe work, including main oil mist header, branch lines and feeder tines; 10. The flow, pressure and level controls specified in (4.2); 11. The necessary instrumentation, unless otherwise specified, for the monitoring of the air and oil systems through the DCS or through manual means; 12. When specified, the alarm/indicator system, including tie-in to the Principal's remote alarm system; 13. All necessary support brackets and fixings for pipe work and components, and for instrumentation where applicable. CONTRACT DATA Drawings ‘The number of copies of drawings/schedules/forms required and the time within which these have to be submitted shall be specified in the purchase order. PTS 31.29.00.30 ‘August 2011 Page 23 7.2.2 Project coordination In addition to the information contained in the proposal, the Vendor shall provide further detailed information, which shall include the following: 1. Dimensional drawings of the oil mist lubrication system, including details of all ‘external connections. ‘Asschematic diagram of the oil mist generator system. The oil mist generator system-wiring diagram. The documents for controls and instrumentation as specified in PTS 92.31.09.31 Abill of materials forthe oil mist generator. A\list of recommended spares. ‘An operating instruction manual, which shall include: = Alldetails necessary for the installation and operation of the system; - The operating ranges of the instrumentation; - The settings for the alerms/indicators; = Equipment list_showing equipment number, Manufacturer, model number, horsepower, RPM, bearing number, reclassifier size, mist flow and reference drawing NOSEoN 8. REFERENCES In this PTS reference is made to the following publications: NoTE: Uni spectically designated by dat, the latest issue of each publication shall be used (together with smencments/supplements/revsionsthoreof), PETRONAS STANDARDS Index to PTS publications and standard specifications PTS 00.00.05.05, Data/requisition sheet for centralized oll mist lubrication PTS 31.29.00.93. systems Note: Requisiton shoots are contained in a bindar, PTS 30.10.01.10. Instruments for measurement and contro! PTS 32.31.00.32. Instrumentation for equipment packages PTS 32.31.09.31 INTERNATIONAL STANDARDS Stee! and steel products - Inspection documents Iso 10474 Issued by: Interntional Organisation for Standardization 4, Rue de Varembs GH 1241 Geneva 20 ‘Switzoriand Copies can also be obtained from national standrds organizations. APPENDIX 1 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6A Figure 6B Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 igure 22 igure 23, Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 PTS 31.29.00.30 ‘August 2011 Page 24 FIGURES Typical arrangement for oil mist distribution piping (open loop) Bracing standards Auto drain leg reservoir assembly (SS) Typical oil mist drop point Feeder lines PID oll mist generator (for outdoor installations) PID oil mist generator (for indoor installations) Typical pure mist (dry sump-open loop) — Detail for OH2 APV/ISO pumps Typical pure mist (dry sump-open loop) — Detail for OH2 ANS! pumps. Typical pure mist (dry sump-open loop) — Detail for BB1, BB2 API/ISO pumps ‘Typical Pure mist (dry sump-open loop) — Detail for ANSI vertical in-line pumps Typical pure mist (dry sump-open loop) directional reciassitier — Detail for between bearing pumps, non-API standard Pure mist method (open loop) for ALT, OH2 type ‘Typical pure mist (dry sump-open loop) — Det ‘Typical pure mist (dry sump-open loop) — Detail for electric motor (method 7) Typical pure mist (dry sump-open loop) — Detail for electric motor (method 8) Typical purge mist (wet sump-open loop) oil level sight assembly detail ‘Typical purge mist (wet sump-open loop) constant level oiler detail ‘Typical purge mist (wet sump-open loop) per gear box detail ‘Typical arrangement for oil mist distribution piping (closed loop) Typical oil mist closed loop drop piping detail ‘Typical pure mist (dry sump-closed loop) — Detail for OH2 API/ISO pumps ‘Typical pure mist (dry sump-closed loop) ~ Detail for OH ANSI pumps Typical pure mist (dry sump-closed loop) — Detail for BB1, BB2 API/ISO pumps Typical pure mist (dry sump-closed loop) ~ Detail for ANSI vertical in-line pumps Typical pure mist (dry sump-closed loop) directional reclassifier — Detail for BB1, BB2 - non-API standard Pure mist method (closed loop) — Alternative for OH2 pumps Typical pure mist (dry sump-closed loop) - Detail for OH3 pumps. Typical pure mist (dry sump-closed loop) — Detail for horizontal electric motor Typical pure mist (dry sump-closed loop) ~ Detail for vertical electric motor Typical purge mist (wet sump-closed loop) ol level sight assembly detail Typical purge mist (wet sump-closed loop) constant level oller detail Typical purge mist (wet sump-closed loop) per gear box detail for OH3 pumps PTS 31.29.00.30 ‘August 2011 Page 25 Figure1 Typical arrangement for oll mist distribution piping (open loop) PTS 31.29.00.30 ‘August 2011 Page 26 PTS 31.29.00.30 ‘August 2011 Page 27 Figure2 Bracing standards 26m (9) Nt shee (8 129 ten pene ss (09 e a reenyressnt 3.9mm (170) NOE vt nm (9/87 9 + te 76) He EL) /~ v0. ce o Bo eo “/ 1 ¢ a s12mm o0 ] Been GO | —

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