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Lubrication Management System for Petrochemical Equipment 1 Scope 1.1 Lubrication is a necessary condition to ensure the proper operation of equipment. This system is established to reduce equipment wear and power consumption, extend the service life of the equipment, and ensure its safe, stable, long-lasting, efficient, and optimal operation. 1.2 This system covers the responsibilities for equipment lubrication management, the storage and preservation of oils, the management and use of lubrication tools, the use of lubricating oils, the standards for lubricating oils (greases), and the recycling of used oils. 1.3 This system applies to the lubrication management of petrochemical equipment. 1.4 Each unit shall formulate its own lubrication management system in accordance with this regulation. 1.5 Definition: “Five fixes” refer to fixing the location, the person in charge, the quality standards, the time, and the quantity. ——Designated points: Specify the lubrication areas and oil filling points for each piece of equipment ； ——Designate a person: Specify the person in charge for each oil addition and change point ； ——Qualification: Specify the lubricant brand code for each filling station ； ——Timing: Specify the time for adding and changing oil ； ——Quantification: Specify the amount of oil to be added or replaced each time. “In the “three-stage filtration” process, the first stage of filtration is from the large oil container to the oil storage tank; the second stage is from the oil storage tank to the oil pot; and the third stage is from the oil pot to the lubrication points. 2 Normative reference documents The provisions in the following documents become provisions of this standard through reference to it. For any referenced documents dated, all subsequent amendment sheets (excluding corrections) or revised versions shall not be applicable to this specification; however, the parties reaching an agreement under this specification are encouraged to consider whether the latest versions of such documents can be used. For reference documents without a date, the latest version applies to these specifications. API 614 – Lubrication, shaft sealing, and control oil systems as well as auxiliary equipment; Q/SHCG 0100-2014-SPTS-RE01-T001 – General technical specifications for the procurement of lubrication stations for centrifugal compressors. 3 Responsibilities for equipment lubrication management: 3.1 Responsibilities of the equipment management department: 3.1.1 The equipment management department is the department responsible for lubrication management; it is tasked with implementing relevant laws and regulations, as well as Sinopec’s rules and standards regarding equipment lubrication management, and it assigns specialized personnel to handle daily management tasks. 3.1.2 Responsible for formulating the unit’s equipment lubrication management system, the lubrication guidelines, and the consumption quotas for lubricants (greases). The Five-Determination Instruction Form is shown in Appendix B. 3.1.3 Responsible for reviewing the plans related to lubricants in the unit, overseeing the use of these lubricants as well as the management of lubrication equipment, and organizing regular inspections; any issues identified are addressed promptly. 3.1.4 Responsible for organizing the promotion of advanced lubrication technologies and lubrication management practices, ensuring rational and economical use of oil, and continuously improving the level of equipment lubrication management. 3.1.5 Responsible for establishing maintenance standards for the oil mist lubrication system, and regularly checking the system’s daily maintenance and usage. 3.1.6 Responsible for the localization of lubricating oils. 3.2 Responsibilities of the Supply Department 3.2.1 Responsible for formulating the annual oil procurement plan and organizing purchases. 3.2.2 Based on the certificate of conformity, carry out thorough inspection of newly arrived oil products upon receipt. 3.2.3 Responsible for the storage and distribution of lubricants and lubrication equipment. 3.2.4 Be responsible for submitting requests for quality inspection of inventory oil products at the prescribed times, and keep the test analysis reports and relevant documents. 3.2.5 Responsible for organizing the recycling and regeneration of used oil. 3.3 Responsibilities of the inspection department: As assigned, it is responsible for analyzing and testing the lubricants in use and in stock within the organization, and providing inspection reports. 3.4 Responsibilities of the using unit (workshop) 3.4.1 Responsible for the lubrication management of the equipment in its own unit, formulating operating procedures for the oil mist lubrication system there, checking and evaluating the implementation of the equipment lubrication management regulations, and ensuring proper storage, maintenance, inspection, and distribution of lubricants. 3.4.2 Be responsible for organizing the employees of the unit to study the equipment lubrication manual carefully, and carrying out training on lubrication management for those employees. 3.4.3 Responsible for establishing the lubricant consumption quotas for the unit, and submitting the lubricant usage plans on time. 3.4.4 Carefully fill out the equipment lubrication records and the five-fixed assignment forms; be responsible for proposing plans for the localization and substitution of lubricants, and organize their implementation after approval by the equipment management department. 3.4.5 Responsible for the management and use of lubricants and related equipment in the unit. 3.4.6 Responsible for checking the lubrication status of equipment and addressing any issues promptly. 3.4.7 Assist in and supervise the recycling of obsolete oil products. 4 Work Procedures 4.1 Planning and Procurement of Lubricants 4.1.1 The using unit shall submit a plan for the next period’s procurement of lubricants, based on its own consumption and inventory levels of such lubricants. After approval by the equipment management department, the procurement will be carried out by the supply department. 4.1.2 The using unit shall formulate the monthly lubricant requisition plan for month F based on its own consumption and inventory levels of lubricants. 4.2 Storage and handling of oils 4.2. 1 The oil storage area must be protected from rain, sunlight, dust, and freezing; it should be dry, clean, and well-ventilated, with adequate fire-fighting facilities. Large oil drums that have been opened and used, as well as lubrication equipment, must be stored in the oil storage facility. 4.2.2 The oil storage containers should be cleaned regularly to maintain cleanliness, and all accessories should be complete and in good condition. The container should indicate the name and grade of the oil it contains. 4.2.3 Oil stored in inventory must come with a certificate of conformity; oil that has been in storage for more than 1 year should be sampled and analyzed according to standards, and substandard oil should be disposed of promptly. 4.2.4 Before changing the type of container or using oils of different grades, it is necessary to thoroughly clean it in accordance with the regulations before switching to another type of oil. 4.2.5 For the storage of sludge oil products, the following documents shall be available ； a) Quality specifications for various types of lubricants: b) Equipment lubrication management system: c) Standard consumption rates for equipment lubricants: d) Certificates of conformity for lubricants and laboratory analysis reports. 4:3 Management and Use of Lubrication Equipment 4.3.1 Lubrication equipment C (excluding large oil tanks) should be made of stainless steel, purchased or manufactured in accordance with unified specifications and standards, and distributed as required by the specific tasks. Basic tools include: fixed oil tanks, oil pumps, oil lifting tanks, oil pots, oil collection trays, filtering funnels, grease tanks, grease shovels, grease guns, etc. 4.3.2 All lubrication tools should be clearly labeled, used only for their designated oils, and cleaned regularly. Under normal circumstances, fixed oil drums (tanks) should be cleaned every 3 months ； The remaining items should be washed once a week. After using or cleaning each utensil. It should be placed neatly at the designated location. 4.3.3 The oil used for equipment lubrication should be managed under a “three-stage filtration” system, with the third stage of filtration particularly requiring strict implementation. The schematic diagram of the three-stage filtration is shown in Figure 1. file:///C:\Users\BlackFox\AppData\Local\Temp\ksohtml\wps2A72.tmp.jpg 4.3.4 The filters used in the three-stage filtration must meet the following requirements: 4.3.4.1 For filters used with hydraulic oil, turbine oil, refrigeration oil, compressor oil, motor oil, or other oils with similar viscosity: 60-mesh for the first stage ； Secondary grade, 80 mesh ； Grade 3, 100 mesh. 4.3.4.2 The number of filters for other oils with high viscosity should be reduced accordingly; in case of special requirements, the relevant special provisions shall apply. 4.4 Use of Lubricants 4.4.1 Equipment must be lubricated with oils that meet the specified requirements; arbitrary misuse or mixing of oils is not allowed, and substandard oils shall not be used. The selection of lubricating oil for equipment should take into account three factors: the grade of lubricating oil recommended in the equipment manual, the recommended lubricating oils for equipment listed in Appendix A, and any optimizations implemented under the unified management of the organization. 4.4.2 When a change in oil type is required, approval from the equipment management department must be obtained; the oil-using units shall not make any changes at will. 4,4.3 The substitution of lubricating oils must adhere to the principle of equal quality or using a superior alternative; substitution should cease once the specified oil is supplied. 4.4.4 When it is necessary to replace lubricants of different types, or when the existing lubricant fails inspection and needs to be replaced, the old lubricant should generally be completely removed first, before the new one is added. If online oil replacement is required due to certain constraints, a replacement plan must be developed and approved by the equipment management department before it can be carried out. 4.4.5 For equipment that is newly installed and put into operation for the first time (during the running-in period), it is generally necessary to change the oil once every 15 to 30 days ； Under normal operation, the oil change interval should be determined according to the five-fixed schedule or the lubricant inspection report. For equipment that operates intermittently or is not in use for extended periods, the quality of the lubricating oil should be checked regularly and replaced as needed. 4.4.6 The lubricating oil of key units in operation should be inspected at least once a month; under harsh conditions or towards the end of the operation period, the frequency of inspections as well as the checks related to the film index should be increased accordingly. Any deficiencies found should be addressed promptly, and it is recommended to use online oil purification devices that can remove water and oil films. The inspection report for the lubricating oil must be kept properly. 4.5 Equipment Lubrication and Oil/Fatty Fluid Application Standards 4.5.1 Oil lubrication: The amount of oil to be applied should be determined based on the scale markings. When there are no scale lines, the following provisions shall apply: 4.5.1.1 Recirculating lubrication. During normal operation, the oil level in the tank should be kept above 2/3. 4.5.1.2 Lubrication by oil in the oil ring 4.5.1.2.1 When the inner diameter D of the oil ring is 25–40 mm, the oil level should be such that it covers D/4 of the oil ring. 4.5.1.2.2 When the inner diameter D of the oil ring is 45–60 mm, the oil level should be such that it submerges D/5 of the oil ring. 4.5.1.2.3 When the inner diameter D of the oil ring is 70～130 mm, the oil level should submerge D/6 of the oil ring. 4.5.1.3 Oil immersion lubrication a) Oil immersion lubrication of rolling bearings: (a) When n＜3000 r/min, the oil level should be below the center of the lowest rolling element in the bearing, but it must cover the lower edge of those rolling elements. (b) When n = 1500–3000 r/min, the oil level should be above the center of the lowest rolling element in the bearing, but it must not submerge the upper edge of the rolling elements. (c) When n＜1500 r/min, the oil level is at the upper edge of the lowest rolling element in the bearing or submerges the rolling elements. b) Oil immersion lubrication for gearboxes: (a) The oil level in the cylindrical gear gearbox should be 2–3 times higher than the tooth height of the lower gears in the gear pair. (b) The level of the bevel gear transmission oil should submerge the entire tooth width of one of the gears. (c) The oil level in the worm gear reducer should submerge 2–3 times the height of the worm gear teeth, or one tooth height of the worm. 4.5.2 Grease lubrication 4.5.2.1 When n > 3000 r/min, the amount of grease to be added is 1/3 of the volume of the bearing housing. 4.5.2.2 When n≤3000 r/min, the amount of grease to be added is 1/2 of the bearing housing volume. 4.6 Recovery of Used Oil 4.6.1 Oil is considered used oil if it meets one of the following conditions: a) It fails analytical tests, and it is not possible to bring it up to standard through measures such as heating, filtering, or dehydration ； b) Discharged during equipment maintenance ； D) Those that show significant color change after long-term use ； d) Mixing of different oil types with each other ； e) Severe lubricant emulsification ； f) The grease dries out and hardens. 4.6.2 Each unit shall, based on its own actual conditions, establish targets for the recycling of used oil as well as relevant management systems, in order to ensure the proper collection, regeneration, and disposal of such oil. 4.6.3 Used oil must not be discharged indiscriminately; used oil containers (tanks) should be collected. Used oil drums must be sealed, stored separately from other oil drums, and arranged neatly. 5 Management of Forced Lubrication Systems 5.1 For the procurement and configuration of lubrication systems, reference can be made to API 614 standard and Q/SHCG-0100-2014-SPTS-RE01-T001 \"General Technical Specifications for the Procurement of Lubrication Oil Stations for Centrifugal Compressors\". 5.2 After new installation or maintenance of the equipment, the oil system must be thoroughly cleaned before lubricating oil can be added. The lubricating oil should be circulated for a certain period of time; only after passing the inspection can it be used for testing or operation. 5.3 The lubrication system of the standby equipment must undergo regular static interlock tests, and the oil pump should be started up for testing on a regular basis. 5.4 After the maintenance of the lubrication system, static and dynamic tests of the auxiliary oil pump’s automatic start-up and interlock protection should be conducted. These tests must be carried out in the presence of both the maintenance unit and the user unit, who shall sign to confirm their participation. 5.5 After the installation or maintenance of the equipment lubrication accessories is completed, they can be put into use only after passing the inspection. Any work involving openings in lubrication equipment must be approved by the equipment management department. 6.1 Management of the oil mist lubrication system 6.1.1 The oil mist lubrication system should be maintained regularly on the main machine in accordance with the instructions, to ensure that the operating parameters remain within the normal range. 6.1.2 An oil mist recovery system shall be installed for oil mist lubrication, and the emission of oil mist shall meet the requirements of environmental protection standards. 6.1.3 The oil mist lubrication system should be regularly serviced by a designated person to add lubricating oil to the main oil tank. The lubricating oil added to the main and auxiliary fuel tanks must be filtered, with a precision of at least 10μm. 6.1.4 The primary and auxiliary systems should be switched regularly to check whether the auxiliary system can operate properly. The lubricating oil in the misting device and oil collection box should be drained regularly. 6.1.5 The design capacity of the oil mist lubrication system shall match the actual lubrication requirements on site, with a 20% margin left. 6.1.6 The purge air used for the oil mist generator shall meet the relevant process requirements. 6.1.7 During major overhauls of the equipment, the main pipelines of the oil mist lubrication system should be inspected, cleaned, and dried. 7 Inspection and Assessment 7.1 The equipment management department shall conduct inspections from time to time in accordance with the requirements of these management regulations, and include the results of those inspections in the internal assessments of the enterprise, thereby continuously improving the level of equipment lubrication management and operation. 7.2 The professional inspection contents and standards for equipment lubrication shall be in accordance with the \"Detailed Rules for Equipment Inspection in Sinopec Refining and Chemical Enterprises\".