How Dual Line System can reduce maintenance cost upto 75%

In the realm of heavy machinery plants, bearing failure is a persistent challenge that not only leads to increased downtime but also escalates maintenance costs.

Customer Problem - 1. Bearing failure in Heavy Machinery Plants 2. Escalating Downtime 3. High maintenance cost

ANSWRS- Dual-Line lubrication system, addresses the root causes of bearing failures and downtime. This technology not only promises longevity for industrial equipment but also significantly reduces the financial burden associated with maintenance.

Dual-Line lubrication system also known as a two-line lubrication system, is a type of centralized lubrication system used to distribute lubricants (such as oil or grease) to various points within a machine or system. The Dual-Line system employs two main lubricant supply lines that alternate between pressurization and depressurization, allowing for controlled and precise delivery of lubricants to different lubrication points.

Key Components of Dual Line Systems - (1) High Pressure Pump, (2) Inline Filter, (3) Reversing Valve (Hydraulic changeover valve, Motorized changeover valve, Solenoid operated changeover valve) for ensuring lubricant supply to each line, (4) Two Main Lines- Line A and Line B (5) End Pressure Relay (end of line pressure switch) and (6) Control Panel.

Dual Line Lubrication Systems are designed for medium-sized or large machines and mills with a large number of lubrication points, long lines and tough operating conditions.

Applications include Steel Plants, Rolling Mills, Power Plants, Pulp and Paper Plant, Mining Machinery, Cement Plants, Sugar Mills, Mineral Processing, Crushers, Cranes, Bulk Material Handling Equipment etc.

Dual Line Systems are very reliable when the distance of lubrication points to the pumping station is long. They can supply more than 1000 lubrication points from a single pump station, resulting in high lubricating reliability with pressures of up to 400 bar. Dual Line Systems can be designed so that different sections of the system may operate at different frequencies. If provisioned in the system design, a particular section can be isolated from the rest of the plant if it is under maintenance or breakdown. The system can also be easily extended for future expansion.

Dual Line Systems offer great flexibility when it comes to adjustment of metered quantity as per specific lubrication point. Dosage of each set of point can also individually set and monitored with help of indicator pins in dose feeders!

Advantages-

• Large number of points and long distances from single pump station.
• Adjustable Dose for each lubrication point.
• Metered quantity independent of back pressure.
• Easy Extension and Reduction of System.
• Can operate fully automatically with variable intervals!
• Standby Pump (optional) ensures that the system is up all the time even if one of the pump fails, low level signal when the lubricant level in reservoir is low.
• Monitoring devices raise an alarm in case of pump- Failure/malfunctioning, Burst/Leakage main line , Crushed/Clogged main line

By adopting ANSWRS- Dual Line system technology can result in up to a 75% reduction in maintenance expenditures, making it a financially prudent choice for industrial plants.