Description

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The Industrial Dual Line Lubrication System is a high-pressure centralized system designed for heavy-duty machinery with multiple distributed lubrication points. Operating through two alternating main supply lines, the system provides automated, controlled lubricant delivery across large-scale industrial equipment.

Technical Parameters

Technical Parameter	Engineering Standard
System Type	Dual Line Centralized Automatic Lubrication
Operating Pressure	Up to 400 bar (40 MPa)
Lubricant Compatibility	NLGI 000# – 3# Grease / Industrial Oil (Viscosity > 68 cSt)
Reservoir Capacity	10L / 30L / 60L / 100L (Reservoir options: Steel or AISI 304 Stainless Steel)
Pump Drive Options	Electric (3-Phase 380V/415V/460V, 50/60 Hz) / Pneumatic / Hydraulic / Bare Shaft
Discharge Volume	0.5 to 5.0 cc/stroke (Adjustable per outlet port)
Main Line Connections	G3/8" / G1/2" BSPP, NPT, or M22×1.5 (DIN 2353 heavy series option)
Operating Temperature	-25°C to +80°C (-13°F to +176°F)
IP / Protection Rating	IP65 (Standard) / ATEX Zone 21 & 22 Explosion-Proof (Optional)

Core System Architecture

High-Pressure Pump Unit: Supplies fluid displacement with integrated pressure relief valves and low-level sensors.

Hydraulic / Motorized Change-Over Valve: Alternates system pressure between Line A and Line B to actuate the metering cycle.

Dual-Line Metering Distributors: Direct-acting metering valves equipped with visual indicator pins and optional electronic stroke sensors.

Dual Main Line Network: Alternating high-pressure lines connecting the pump unit to distribution blocks.

Control & Monitoring Module: Pressure switches, end-of-line pressure transmitters, and control panels for system fault signals.

Customization

Hydraulic Adaptation: Custom displacement per stroke, pressure switch threshold tuning, and multi-outlet manifold setups.

Environmental Resistance: Stainless steel AISI 304/316 options for corrosive or offshore environments; severe cold/high-temperature seals.

System Integration: Pre-wired terminal boxes, custom mounting brackets, and PLC signal matching for factory automation.

Industry Applications

Steel & Metallurgy: Continuous casters, hot/cold rolling mills, and transfer cars.

Mining & Minerals: Primary jaw/cone crushers, vibrating screens, grinding mills, and stacker-reclaimers.

Cement & Material Processing: Kiln drives, roller presses, and bucket elevators.

Port & Heavy Handling: Ship unloaders, gantry cranes, and bulk material conveyors.

Engineering Support

Engineering support is provided based on the number and location of lubrication points, lubricant requirements and equipment layout.

Lubrication-point assessment and system sizing

Pump, distributor and metering device selection

Dual-line piping layout and line sizing

Pressure and lubricant delivery calculations

PLC, alarm and monitoring interface design

System drawings, component lists and installation documentation

Quality Control & Inspection Workflow

Incoming & Dimensional Inspection
Verification of housing tolerances, thread integrity, and material quality for critical components.

Sub-Assembly & Precision Fit
Piston clearance checks, seal seat verification, and fastener torque compliance.

High-Pressure Leakage Testing
Static and dynamic pressure hold tests up to 400+ bar across ports, lines, and valve seals.

Change-Over & Signal Calibration
Repetitive line switching tests and exact signal threshold calibration for pressure switches and sensors.

Final Load & Metering Verification
Operational test run with standard lubricant to measure precise displacement per outlet and test low-level alarm triggers.

FAQ

Q: What happens to the system if a single lubrication point becomes blocked?

A: Unlike progressive systems, dual-line distributors operate independently in parallel. A blockage at one point does not halt the rest of the system; all other outlets continue delivering metered lubricant normally.

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

A: Operating at up to 400 bar with alternating pressure relief, the system can pump grease over main line distances exceeding 100 meters, depending on pipe diameter, ambient temperature, and grease grade.

Q: Are your distributors interchangeable with standard third-party brands?

A: Yes. Distributors use standard mounting dimensions and port threads (BSPP, NPT, Metric), allowing direct drop-in replacement on existing machinery without pipe modification.

Q: How are main line pressure leaks or valve failures detected?

A: End-of-line pressure switches monitor pressure at the furthest point. If the required threshold is not reached within a set time, the system triggers a fault alert for pressure loss, line leaks, or valve failure.

Q: Can output volume be adjusted at individual outlets after installation?

A: Yes. Each distributor segment includes an adjustment screw or stroke pin to fine-tune discharge volume per outlet directly on site.

Q: How does the system handle low ambient temperatures and stiff grease?

A: For severe cold, options include reservoir heaters, larger main line diameters, or switching to lower-viscosity synthetic greases (NLGI 00#/0#) to prevent pump cavitation and flow resistance.

Q: Which spare parts are recommended for a 2-year maintenance kit?

A: Essential spares include pump seals, filter cartridges, change-over valve seal kits, indicator pin assemblies, and pressure switch contact modules.

Q: What engineering documentation is provided for installation?

A: Systems ship with General Arrangement (GA) drawings, hydraulic schematics, PLC wiring diagrams, calibration manuals, and an itemized spare parts list.

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