Description

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Engineered for massive industrial complexes, the Dual Line Lubrication System uses alternating pressure headers and a heavy-duty pump to deliver precise grease or oil. Ideal for harsh environments, it ensures continuous operation despite blockages.

Technical Specifications

Manufactured in accordance with ISO 9001 standards, with CE compliance and optional ATEX/IECEx certifications for explosive-risk environments.

Technical Parameter	Specification Range & Details
Flow Rate	1.0 to 30 kg/h (depending on pump displacement and motor speed)
Max. Operating Pressure	Up to 400 bar (approx. 5,800 psi)
Lubricant Viscosity	Oils (from ISO VG 68) and Greases up to NLGI Grade 3
Operating Temperature	-30°C to +80°C (Special low/high-temperature element options available)
Main Line Pipe Size	Typically OD 18mm to 25mm heavy-wall seamless steel tubing
Electrical Supply	380V/415V AC 3-Phase (Standard), custom voltages upon request

System Configurations & Variations

Electric Motor-Driven Packages: Standard for fixed industrial facilities requiring automated, scheduled lubrication intervals via plant PLCs.

Pneumatic & Hydraulic-Driven Units: Ideal for mobile applications or remote sites lacking stable electrical infrastructure.

Multi-Pump Skids: Redundancy setups featuring dual pumps (one active, one standby) coupled with automated switchover valves for critical 24/7 continuous-production plants.

System Functions

Automated Cycle Management: Programmable logic controllers handle adjustable pause and run intervals, protecting pumps from dry-running.

Pressure Reversal Logic: Monitors end-of-line pressure switches to ensure complete system pressurization before initiating line-switching sequences.

Fault Detection & Alarms: Instantly flags pipeline blockages, low reservoir levels, or low-pressure faults, sending warning alerts to plant SCADA interfaces.

Applications

Steel & Metal Processing: Blast furnaces, continuous casting strands, rolling mills, sintering plants, and heavy material handling cranes.

Mining & Mineral Processing: Large-scale Jaw and Cone crushers, grinding mills, ore classifiers, and heavy conveyor belt systems.

Cement & Power Generation: Kiln support rollers, raw mills, coal pulverizers, and heavy turbine auxiliary setups.

Marine & Port Facilities: Container crane slewing rings, ship loaders, unloader booms, and massive winch mechanisms operating in corrosive saline air.

Customization Options

Custom Reservoir Sizes: Heavy-duty fabricated steel tanks ranging from 50L to 400L with pneumatic stirring paddles for heavy greases that tend to separate or channel.

Material Selection: Full stainless steel (SS304 / SS316) construction for corrosive marine environments or harsh chemical processing washdowns.

Advanced Monitoring Panels: Integrated explosion-proof (Ex-proof) control enclosures, ATEX certifications, and customized fieldbus communication (ProfiNet, Modbus RTU) for centralized control room oversight.

Pump Materials & Construction

Reservoir & Skid Frame: Heavy gauge structural steel, epoxy-coated or hot-dip galvanized to withstand corrosive industrial environments.

Valve Bodies & Spools: Forged carbon steel or nickel-plated brass with hardened, precision-lapped internal spools to eliminate internal fluid bypass under extreme pressures.

Seals & Gaskets: High-grade polyurethane, Viton (FKM), and NBR elastomers engineered to withstand continuous high-pressure cyclic stress.

FAQ

Q: What is a dual line lubrication system?

A: It is a centralized heavy-duty lubrication network that uses two alternating main supply headers and positive displacement metering valves to pump grease or oil to hundreds of friction points across large industrial machinery.

Q: How does a dual line system differ from a single line progressive system?

A: While progressive systems use a single line and sequential piston blocks (where one blockage stops the whole system), dual line systems use parallel lines and alternating pressure, meaning a single blocked feed point does not disrupt the rest of the machine.

Q: What happens if one lubrication point gets blocked in a dual line setup?

A: The specific metering valve feeding that blocked point will simply stop cycling, but the directional reversing valve will still switch pressures between the main headers, allowing all other connected bearings to continue receiving grease normally.

Q: What is the maximum distance a dual line system can cover?

A: Because it operates at higher pressures (up to 400 bar) and utilizes large main headers, a dual line system can easily feed points located over 100 to 200 meters away from the central pump station.

Q: What types of lubricants are compatible with dual line systems?

A: They are designed to handle heavy-duty mineral and synthetic oils, as well as greases ranging from NLGI Grade 0 up to Grade 3, even in sub-zero outdoor operating environments.

Q: How is the system reversal triggered?

A: Reversal is typically controlled by an electrical end-of-line pressure switch. Once the pressure at the farthest point of the active main line reaches a set threshold, it signals the reversing valve to switch flow to the secondary line.

Q: Can dual line systems be integrated into a plant's main PLC network?

A: Yes. Our pump packages come with configurable control cabinets that support standard industrial communication protocols, allowing operators to monitor system cycles, pressures, and tank levels directly from a central control room.

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