Oil Mist Lubrication Design and Installation | Rotating Equipment Engineering - PDFYAR

1 General …………………………………………………………………………………………..1.1 Scope ………………………………………………………………………………………….1.2 References …………………………………………………………………………………..1.3 Definitions ……………………………………………………………………………………1.4 Documentation ……………………………………………………………………………..2 Design ……………………………………………………………………………………………2.1 Applications ………………………………………………………………………………….2.2 Types of Mist ………………………………………………………………………………..2.3 System Sizing Requirements ……………………………………………………….2.4 System Requirements ……………………………………………………………………2.5 Oil Make-up System ………………………………………………………………………2.6 Distribution System ……………………………………………………………………..2.7 Equipment Inlets, Vents and Drains ……………………………………………….3 Installation ……………………………………………………………………………………3.1 Pipe Connections ………………………………………………………………………..3.2 Tubing Connections …………………………………………………………………….3.3 Equipment Lubrication Ports ……………………………………………………….4 Oil Compatibility ……………………………………………………………………………..5 Operating Manuals and Documentation …………………………………………….Figure A – Sample switching and troubleshooting instructions ……………………..6 Commissioning ………………………………………………………………………………6.1 General ……………………………………………………………………………………6.2 Reservoir ……………………………………………………………………………………6.3 Mist Distribution System ……………………………………………………………….6.4 Air, Oil and Mist Alarms ………………………………………………………………..Revision History………………………………………………………………………2Figure 1A – Oil Mist Lubrication Summary Sheet 1 of 2 ………………………………FIGURE 1B – Partially Completed Oil Mist Lubrication Summary Sheet 2 of 2Figure 2A – Sketch of Flow Diagram for Oil Mist Console …………………………..Figure 2B – Sketch of Flow Diagram For Oil Mist Console …………………………..FIGURE 3 – Oil Mist Piping System ……………………………………………………….FIGURE 4 – Oil Mist Drop Point Design ……………………………………………………FIGURE 5 – Oil Mist Drain Leg Details ……………………………………………………..FIGURE 6 – Drop Point Terminations ………………………………………………………FIGURE 7 – Oil Mist Connections for Most Common Equipment ………………….FIGURE 8 – Pure Mist Drain System ……………………………………………………….FIGURE 9 – Purge Mist Vent …………………………………………………………………..Figure 10 – Purge Mist Drain …………………………………………………………………..FIGURE 11 – Pumps With Side or Bottom Drain ………………………………………..Figure 12 – Mist Collection Container ……………………………………………………….

1 General

1.1 Scope
This specification covers requirements for materials, design, documentation,
installation, commissioning, training and supervision of oil mist lubrication systems.
1.1.1 Unless otherwise specified, all tasks detailed in this specification are to be
executed by the Oil Mist System Vendor.
The Vendor must be able to provide under a separate agreement and at a
later date, a service representative for technical assistance.
1.1.2 The Contractor shall be responsible to develop a comprehensive operator
and maintenance personnel-training program covering the fundamentals of
oil mist technology and the specific requirements of the oil mist system being
supplied. This training will encompass both classrooms, and walk through
the installed system, with hands on demonstration of the oil mist console
controls and monitoring devices.

1.2 References
The following publications from a part of this Specification. the references cited in
this Specification were used in its development. The latest edition of these
references shall be used with this Specification. In event of conflict the most stringent
requirement shall apply.
API RECOMMENDED PRACTICE 686, PIP REIE 686.
Chapter 1 – Introduction
Chapter 6 – Piping
Chapter 8 – Lubrication Systems
Chapter 9 – Commissioning –Paragraphs 4.6 and 4.12 on page 9-3

1.3 Definitions
For the purpos of understanding the standard, the following definitions apply:
Oil Mist System. Centralised lubrication system designed to produce, transport and
deliver oil mist from a central location to remote equipment bearing housings to
provide adequate lubrication.
Console. That portion of the system that generates the oil mist and provides the
controls of the system.
Back up Unit. Spare oil mist generating unit used for emergencies. It contains only
essentials for producing oil mist.

Generator Head. Device that actually makes the oil mist. It is located inside the
reservoir in the console. Air accelerates through a venturi or vortex head causing oil
to be lifted from the reservoir and atomized into a fine mist (about 1 to 5 microns).
Distribution System. Piping/tubing network through which the mist is transported
from the console where it is made to the bearing housings where it is used.
Header Pressure. Pressure of the oil mist inside the header (mist pressure). Normal
design pressure is 508 – 1016 mm water or 5-10 kpa.
Regulated Air. Air pressure required by the generator to produce a header pressure
as stated in paragraph 6 above.
Drain Leg. Vertical section of pipe the same diameter as the main header. Drain
leg collects oil that coalesces in the header but cannot be drained back to the
generator. This oil must be manually drained on a periodic basis.
Drop Point. Vertical section of pipe that is usually smaller in diameter than the main
header. This pipe rises out of a tee in the main header, turns horizontally and
extends downward to the equipment being lubricated.
Main-fold Block. Small rectangular block that has either 4 or 6 holes drilled and
tapped in opposite faces to divert the oil-mist to individual supply lines to equipment
lubrication points.
Reclassifiers. Long path orifices that clause the small particle size “dry” mist in the
header to be converted into larger particle size “wet” mist that can lubricate bearings.
Reclassifiers are screwed into the faces of the manifold blocks. Each lubrication
point must be supplied through a reclassifier. “Dry” mist will not lubricate.
Snap Drain. Device for draining coalesced oil from a drop point, a drain leg, or a
sight glass.
Sight Glass. Small clear plastic device used under a pump to collect oil that has
passed through the pump. Some have small holes for weeping away excess oil while
others do not.
Purge Mist. Method for lubricating bearings in which the oil mist (wet sump) provides
a positive pressure in the bearing housing. Normal oil level, constant level oiler and
slinger (or flinger) are left intact. Oil mist system Vendor shall provide an alternate
vent/orifice and method of maintaining a constant oil sump level.
Pure Mist. Method for lubricating bearings in which all oil is (dry sump) drained from
the bearing housing and the mist alone provides lubrication. The drain plug is left out.
Drain System. Means for removing oil that coalesces in a bearing housing that is
operating on pure mist. The drain system can be as simple as a bottle under the
bearing housing or as elaborate as a solid piped system.

1.4 Documentation
2 Design

For record purpose, the oil-mist system Vendor shall provide tabulations per Figures
1A and 1B with equipment listed and designated as to pure or purge mist and listing
reclassified, air consumption, and related data as shown.
The Contractor is required to update equipment data sheets to show oil mist
required on each piece or equipment to be supplied with oil mist lubrication.

2.1 Applications
Use of oil mist lubrication systems shall be considered for new machinery or for
retrofitting of existing machinery if any of the following conditions exist:
2.1.1 A single oil mist generator can service eight or more pieces of machinery.

2.1.2 Machinery is exposed to hostile plant environments, including H2S, chlorine,
rapidly changing temperatures, high humidity, airborne dust and dirt, etc.
2.1.3 Machinery experiences a higher than expected bearing failure rate and all
possible causes except lubrication have been eliminated.
2.1.4 Conditions are such that periodic inspection and lubrication get overlooked.

2.2 Types of Mist
2.2.1 Unless otherwise specified, Rotating equipment with anti-friction or rolling
element bearings shall be lubricated with pure oil mist.
2.2.2 Open bearings shall be used in pumps and bearings that are shielded on one
side (shield to windings) shall be used in electric motors.
2.2.3 Equipment with sleeve or journal bearings shall be lubricated by purge oil
mist.
2.2.4 All general purpose gear boxes cavities shall be lubricated by purge oil mist.
2.2.5 Metering pumps, vertical sump pumps, submersible pumps, and sanitary lift
pumps will not be lubricated with oil mist as well as their motors.
2.2.6 All motors 0.75 kW and under will not be lubricated by oil mist.
2.3 System Sizing Requirements
2.3.1 General
The Oil mist system shall be specifically sized for the total items of
equipment that use oil mist. The total equipment need shall be blocked into

serviceable areas that allow proper installation of the oil mist system. Area to
be within 100 m distance from the oil mist cabinet.
2.3.2 Pure Mist
Volume requirements for pure mist shall take into consideration shaft size, in
millimeters and the number of rows of elements in each bearing housing. The
following equation shall be used to determine the minimum air flow (SCMH)
input for pure mist:
SCMH = C1 x D x N
Where:
C1 = Service Factor
For moderate service C1 = 0.00147
For heavy service C1 = 0.00301
D = Shaft Diameter in mm
N = Number of rows of ball or rollers
Service factors are as follows:
Use moderate service factor when equipment speed is 3600 rpm or less and
equipment horsepower is less than 149 kW.
Use heavy service factor when equipment speed is more than 3600 rpm and
equipment horse power is 149 kW or more.
Use heavy service for equipment in hot service
Use heavy service factors for all directed mist applications
2.3.3 Purge Mist
2.3.3.1 Calculations to determine airflow are not required for purge mist
applications.
2.3.3.2 A size 501 (Lubrimist) reclassifier, or equivalent, shall be used for
small bearing housings such as general-purpose turbines and small
pumps.
2.3.3.3 Size 502 (Lubrimist) reclassifier, or equivalent, shall be used for
bearing housings and gear boxes with an air space of more than
0.085 m
.
2.3.4 Generator Head
3
a. Size of generator head shall provide 125% of the required airflow
without exceeding the maximum capacity of the head. They shall
also be capable of proper misting operating down to 50% of rated
flow.
b. Generator head shall be sized such that minimum required regulated
air pressure exceeds 70 Kpa.
2.3.5 Oil Mist Generator.
2.3.5.1 Mist generator shall meet the requirements of : Area Classification 1,
Division 2, Group B, C, D and Area Classification 2, Division 2,
Group G. The Auto Ignition Temp. of 225
°
C. (437
°
F).

2.3.5.2 The oil mist console shall incorporate a microprocessor controller
that in addition to monitoring operating variables also experts direct
control over oil/air temperature and oil level in the mist-generating
chamber.
2.3.5.3 The oil mist generator shall not have any heating elements that come
in direct contact with the lubricating oil.
2.3.5.4 The oil mist console shall be protected via a stainless steel
sunscreen roof.

2.4 System Requirements
2.4.1 General
a. Typical flow diagram for an oil mist console is shown on drawing
Sketch in Figure 2A and 2B.
b. Consoles shall be made of stainless steel.
c. All piping tubing, fittings and mounting brackets shall be of stainless
steel.
2.4.2 Generator Head
a. Generator head shall have an oil flow regulator to control mist
density.
b. Size or generator head shall be based on the number and size of
reclassifiers in the system.
c. The design of the mist head shall be such that its capacity can be
changed without complete removal of the mist head from the
console. Capacity changes shall be effected by removal and
insertion of mist head components only.
2.4.3 Oil Filter.
a. Oil filter shall be rated for 10 microns (Hilco Safeguard or equal).
b. Oil filter shall be easily accessible to maintenance personal.
2.4.4 Oil Reservoir
a. Oil reservoir shall be constructed of stainless steel and shall allow
system to operate for a minimum of 72 hours without refill.
b. Oil reservoir shall have:
1. Level sight glass
2. Pressure relief valve set at 35 Kpa.
3. Opening for clean out with removable cover
4. Low point drain with valve
5. Level controller and switch that automatically maintain oil
level in the reservoir, includes low and high level alarms
6. Temperature gauge

7. Heater with a maximum capacity of 1.55 Watts/cm2
and with
automatic cutout for over-temperature protection.
8. Temperature sensor and controls to automatically maintain
constant oil temperature.
9. Header pressure gauge 0-1525 mm of water.
10. Mist inspection valve.
2.4.5 Air System
a. Unless otherwise specified, air to the console shall be supplied from
the instrument air system. Connection point shall be via a 1/2 in, 150
pound, stainless steel raised face flange.
b. Air system shall have:
(i) Shut-off valve.
(ii) Line pressure gauge that reads from 0 to 1100 Kpa.
(iii) Filter/moisture separator with auto-drain piped to sewer.
(iv) Pressure regulator with gauge and locking device.
(v) Air header, air temperature gauge, automatic temperature
controls and cutouts for protection against high temperature
or loss of air.
2.4.6 Instrumentation
Console shall have the following instrumentation:
a. Sensors and individual low and high alarms for air temperature, oil
temperature, mist density, mist header pressure and oil reservoir
level.
b. Red warning light and green normal operating light. Lights shall be
mounted on top of console and shall be visible from all directions.
c. Separate alarm lights in the console to indicate malfunctions.
d. Contacts for a remote alarm to indicate power failure or local alarm
condition.
2.4.7 Back-up Unit
2.4.7.1 Console shall have a back-up unit with the following characteristics:
a. Oil mist-generating capacity equal to that of the main unit.
b. Enclosed in a cabinet of the same material as and attached
to the main unit.
c. Have its own Air pressure regulator
d. Shall be capable of operating independently from the main
generating system.
2.4.7.2 Oil reservoir with
(i) 24 hour reserve
(ii) Mist generating head
(iii) Relief valve set at 35 Kpa.

(iv) Level sight glass
(v) Header pressure gauge
(vi) Oil heater and oil temperature gauge if system is installed in
climate that can have sustained temperatures at or below 12 °C.
(vii) Removable cover plate for inspection and clean out
(viii) Low point drain with valve
2.4.7.3 The start-up of the auxiliary/back-up unit shall be semi-automated
and essential fail-safe.
Manual switching of valves in the header system is not an
acceptable procedure
To switch from the main unit to the auxiliary shall be accomplished
through the use of pneumatically driven air slide valves controlled at
the operator panel
2.4.8 Mist outlet and header connection:
2.4.8.1 The mist outlet pipe from the console shall be 2” stainless steel.
2.4.8.2 The mist outlet shall terminate with a 2-inch, 150-pound, stainless
steel, raised face flanged.

2.5 Oil Make-up System
2.5.1 Oil mist systems shall have an automatic oil make-up system. The bulk
supply whether external or internal shall contain at least sixty days (60)
supply of oil.
2.5.2 Oil make-up system shall consist of:
a. A skid mounted reservoir with a capacity of 1.0m3

b. An air operated oil pump. A level gauge and a low level alarm switch.
c. Reservoir shall:
(i) Be Stainless Steel
(ii) Be mounted on legs such that accumulated water drains
away from the oil suction lines.
(iii) Have a vent and a low-point drain connection with a valve
(iv) Be purged with oil mist
(v) Fill connection equipped with spin oil filter
d. Oil pump shall have a 1:1 ratio of inlet to discharge pressure
e. Supply line from the oil pump to the reservoir shall have a pressure
relief valve to prevent over-pressuring the gasket in the oil filter.
f. Include secondary containment.
2.5.3 The bulk oil supply shall be integral to the central oil mist console. A separate
vessel and interconnecting pipe are not required.

2.5.3.1 An air driven oil transfer pump shall automatically deliver oil from the
internal bulk tank to the oil mist-generating chamber.
2.5.3.2 The internal oil reservoir shall be constructed of stainless steel and
shall be purged with oil mist.
2.5.3.3 The level of the internal oil reservoir shall be continuously monitored
through the console microprocessor and alarm if a low level is
reached.
2.5.3.4 The internal reservoir shall also be affixed with a level gauge, lowlevel
drain
port
with
valve
and
removable
access
panel.

2.6 Distribution System
2.6.1 General
Unless otherwise specified, pipe shall be screwed; galvanized steel,
schedule 40 and tubing shall be 300 series stainless steel (See Figure 3).
2.6.2 Main Headers
Time required for oil mist to reach the most distant lubrication point(s) on a
header shall not exceed 5 minutes.
a. Main headers shall be 2” pipe and shall not exceed 100 m in length.
b. Main headers shall be sloped continuously downward to the console
at a rate of 25 mm per 3 meters for a distance of 15m from the
generator and 25 mm per 250 mm thereafter wherever possible.
Portion of headers that cannot be sloped to the console due to
obstructions shall be sloped to drain legs at the rate of 10 mm per 5
m. Drain legs to be installed at the end of the header.
c. Unless otherwise specified, main headers shall be supported on top
of horizontal beams or pipe racks with structural angle, or equal.
d. Unsupported spans of main headers shall not be greater than the
distance between adjacent beams.
e. If supports cannot be placed on top of beams, main headers may be
suspended below beams or other appurtenances, with approval of
SABIC.
f. Horizontal bracing shall not be used to support horizontal headers.
g. Main headers shall be run as close to the outside of the pipe rack as
possible and in such a manner as to leave space for future additions
of process piping in the pipe rack.
h. Large oil mist systems that have back-up generating units shall not
have block valves in the main headers downstream of the switching
valves.
i. Main headers shall be leak free and not allow oil-mist to escape to
the atmosphere.

j. Low spots or pockets are not permitted unless unavoidable and
accepted by SABIC.
k. Unavoidable low points shall be provided with Auto drains.
Purchaser must approve the type and location of drain.
2.6.3 Branch Headers
a. Branch Headers shall be 2” pipes.
b. Branch headers shall be sloped continuously downward to the main
header at a rate of 10 mm per 2.5 m wherever possible. Portion of
branch headers that cannot be sloped to the main header due to
obstructions shall be sloped to drain legs at the rate of 10 mm per 5
m.
c. Branch headers shall come off the top of the main headers (refer to
the Sketch in Figure 4)
d. Branch headers shall be connected to the main-header with tees.
Upward legs of tees that are not used shall be plugged.
e. Requirements for support of branch headers shall be the same as
those for main headers.
f. Branch headers shall not have block valves.
2.6.4 Drain Legs
a. Drain legs shall be avoided in all cases if possible. When used they
shall be in accordance with Sketch in Figure 5. Other proven designs
are acceptable with SABIC‟s approval.
b. Drain legs shall be the same diameter as the pipe to which they are
connected.
c. Drain legs shall terminate between 460 mm and 610 mm above the
ground.
d. Drain legs shall have:
(i) reclassifier vent overflow
(ii) A drain valve
(iii) A pressure gauge that reads from 0-1524 mm of water
(iv) A block valve that permits pressure gauge to be changed
e. Tubing shall be connected to drain leg reclassifier to carry the
discharge to an oil mist collection container with a minimum capacity
4 liters. Reclassifier shall not discharge to open pads or to the
ground.
2.6.5 Drop Points
1. General
a. Drop points shall be ¾” pipe and shall come off the top of the
headers (refer to the sketch in Figure 4).
b. Drop points shall be sloped continuously downward toward the
main or branch headers at the rate of 10 mm per 5 m

c. Drop points shall terminate between 60 cm and 120 cm above
the equipment that is to be lubricated
d. Drop points shall be located such that they do not interfere with
access, installation, or removal of equipment
e. Unless otherwise specified, using branched headers to lubricate
multiple pumping train units with one-drop point is prohibited.
There shall be one drop point per pump / driver set receiving oil
mist.
f. Horizontal bracing shall not be used to support horizontal piping
runs but may be used to support vertical piping runs
g. Horizontal piping runs shall be a maximum of 10 m
h. Drop points shall not have block valves.
2. Termination
a. Termination of drop points shall conform to Sketch in Figure 6.
Other proven designs are acceptable with SABIC‟s approval.
b. Drop points shall terminate in a manifold or in a tee. Manifold
should be located at eye level for routine inspection and easy
draining.
c. Manifold shall be rectangular brass, aluminum, or steel block.
d. Termination shall have a sight glass and a valve to permit
draining of oil to the mist collection container via
3
/8
in stainless
steel tubing.
e. Valve shall be snap acting, petcock, or some other type that
does not open due to vibration.
f. Drop points shall not terminate directly over hot surfaces such as
steam turbine and hot piping.
2.6.6 Reclassifiers
a. Reclassifiers shall be 300 series stainless steel or cadmium plated
steel.
b. Reclassifiers shall be sized using the severity factor for moderate
duty.
c. Reclassifiers shall not be oversized such that they cause excessive
stray mist, increased oil and air consumption, and increased
housekeeping problems.
d. Reclassifiers shall be screwed into the manifold block or tee instead
of into the bearing housing.
2.6.7 Feed Lines
a. Feed lines from the manifold block/tee to the equipment shall be ¼”
stainless steel tubing.
b. Feed lines shall be sloped continuously downward to the equipment.
Right angle turns or bends shall be minimized.

c. Feed lines shall be installed so that they do not need to be removed
when routine inspection and maintenance is performed on the
equipment.

2.7 Equipment Inlets, Vents and Drains
2.7.1 General
Typical arrangements of oil mist connections, vents and drains at pumps (or
other equipment) shall agree with Sketch in Figure 7.
2.7.2 Inlets
Unless otherwise specified, oil mist inlets shall be on top of the bearing
housings and shall be located such that oil mist can completely fill the
housings (refer to Figure 7).
2.7.3 Vents
a. Bearings that are lubricated with purge mist shall have a vent in their
housing to ensure adequate supply of fresh mist.
b. Unless otherwise specified vent shall conform to Sketch in Figure 9.
2.7.4 Drains
a. Bearing housings shall have a drain system that is environmentally
3 Installation

friendly and consist of a metal container with a minimum capacity of
3.785 liters or 30 days that is tied to the drain point to receive and
store coalesced oil.
b. Drain tubing shall be stainless steel tubing with a minimum 9.5 mm
(
3
/8
inch).
c. Design of drain systems for housings with pure mist shall conform to

Sketch in Figure 8.
d. Design of drain systems for housings with purge mist shall conform
to Sketch in Figure 10.
e. All drain lines shall be sloped continuously downward to the oil
collection container.(See Figure 11)
f. Drain lines shall not terminate on base plates or drip legs.
g. The collection container shall have an overflow drain and valve
connection for draining (See Figure 12).

3.1 Pipe Connections
a. Use of Teflon tape on pipe connections is prohibited

b. Pipe connections may be sealed with Liquid-O-Ring Lubon # 404 sealant
shall be applied lightly and no closer than three threads from the end of the
pipe.

3.2 Tubing Connections
a. Tubing fittings and oil-mist fittings between drop point/distribution manifolds
and equipment lubrication ports shall be installed as follows:
(i) Install oil-mist fittings only after cleaning and blowing has been
completed. Caps, plugs, or block valves shall be installed
temporarily to allow cleaning one branch at a time.
(ii) Remove temporary block fittings and install oil-mist fittings.
Distribution manifolds shall be furnished with a snap drain or similar
quick-acting valve.
(iii) Make connections to equipment lubrication ports after blowing is
completed and approved by owner.
(iv) The application fittings shall be connected to the equipment by
tubing arranged so that normal maintenance may be performed
without requiring the application fitting and/lateral to be removed.

3.3 Equipment Lubrication Ports
Equipment Lubrication Ports shall remain plugged until the oil mist lubrication system
is certified clean and final connections are being made.

4 Oil Compatibility

The lubricant type and grade shall be fully compatible with conventional non-detergent
petroleum oils. Neither separation nor undesirable reactions occur when the products are
mixed. It shall be compatible with seal materials, paints, and metals that are commonly found
in industrial systems.
5 Operating Manuals and Documentation

5.1 The oil-mist systems Vendor shall supply five operation manuals. These manuals
shall be written specifically for the oil-mist equipment being furnished and shall
contain as a minimum the following information:
a. List of all distribution manifolds and application fittings by size and model and
description of equipment to be served by each manifold and corresponding
fittings.

b. Drawings and details necessary for the installation, commissioning, operation
and shutdown of the system without the need for assistance from the
Vendor.
c. Settings and operating ranges of all controls and instrumentation.
d. Complete parts list, bills of material and set of final “ as-built” drawings.
e. Switching and troubleshooting instructions shall be posted inside the console
cabinet doors. These instructions shall be executed in a fashion similar to
Figure A below:
Figure A – Sample switching and troubleshooting instructions

NOTICE:

REPORT ALL OIL MIST PROBLEMS IMMEDIATELY

If main generator malfunctions or fails to produce oil mist, turn on
back-up generator as follows:

 Check Oil level in back-up generator. Fill if required.

 Close air supply valve to main generator.

 Close 2” ball valve on mist outlet of main generator.

 Turn off electrical power to main generator.

 Open 2” ball valve on mist outlet of back-up generator.

 Open-air supply valve to back-up generator.

 Turn on electrical power to back-up generator.

Figure A-1 (Sample switching and troubleshooting instructions).

6 Commissioning

6.1 General
6.1.1 This procedure outlines the steps required to properly commission a newly
installed oil mist system. It requires a nitrogen supply and that the air and oil
supply lines to the generator have been commissioned and 110-volt power is
connected.

6.1.2 The procedure has separate sections for flushing the generator reservoir and
distribution system and for checking and adjusting controls and alarms.
6.1.3 All steps of this procedure can and should normally be performed by the oil
mist system vendor with final inspection and verification by a SABIC
inspector or engineer, or authorized representative.

6.2 Reservoir
6.2.1 Preliminary
6.2.1.1 Verify that correct oil and air filter elements are installed in external
filter housings and that oil filter inside console is properly installed.
6.2.1.2 Verify that oil reservoir is equipped with a clear plastic sight glass.
6.2.1.3 Verify that oil and air supply valves are closed and main power
switch is “OFF”.
6.2.2 Flushing Reservoir
6.2.2.1 Equipment required for this phase are a hand operated sprayer, a 5gallon

( 0.02 m
3
) can of Varsol solvent or approved equal, and
necessary safety equipment required by location safety rules or by
the solvent manufacturer. (Some items might be goggles,
respirator, rubber gloves, etc).
6.2.2.2 Remove mist generator head. Inspect screen for integrity and
cleanliness. Clean as required.
6.2.2.3 Remove oil level control/alarm switches.
6.2.2.4 Open drain valve on bottom of sight glass and leave it open. Allow
all oil to drain.
6.2.2.5 Remove reservoir inspection plate.
6.2.2.6 Thoroughly spray all internal surfaces and parts with solvent with
hand sprayer. Be certain all areas get flushed.
6.2.2.7 After spraying, allow to drain. Wipe dry with clean, lint-free cloth.
6.2.2.8 Replace inspection cover, oil level switch and generator head. Close
reservoir drain valve.
6.2.3 Checking Oil Level Switch
6.2.3.1 Open oil supply valve, Turn main power “ON”. Oil solenoid valve
should open and reservoir begin to fill. (At this point, the LOW oil
level, air temperature, oil temperature and mist pressure alarm lights
will be on. Heaters will not be energized since there is no air flow).
6.2.3.2 When Oil level reaches the low level alarm set point, the low oil level
light should go out. (It should be near the scribe mark near the
bottom of the sight glass). Record the level where solenoid closes
(normal level).

6.2.3.3 Remove manual fill plug and continue to fill reservoir manually until
high level alarm light comes on. Should be near scribe mark at the
top of the sight glass. Record this level.
6.2.3.4 If either alarm set-point is significantly off, drain reservoir, turn off
power, remove level switch and adjust as required. Repeat steps
2.3.1 through 2.3.4 until set points are correct.
6.2.3.5 When level switch settings are correct, drain reservoir to operating
level and turn off power.

6.3 Mist Distribution System
6.3.1 Preparation
6.3.1.1 Holes in manifold blocks for reclassifiers should be plugged. No
reclassifiers should be in place during cleaning steps. If any
reclassifiers have been installed, remove them and replace with pipe
plugs.
6.3.1.2 Remove snap drains from all manifold blocks and all drain legs.
Retain for installation after commissioning. Plug all manifold block
drains.
6.3.1.3 Disconnect main mist header where it exits the console and
spare/piggyback unit. Rotate vertical section of pipe away from
console far enough to provide room to work (0.6 or 0.9m) or ( 2 or 3
feet ).
6.3.1.4 Plug, cap or seal stub connections out of the main and spare
generators. Plug the piping connection from vertical pipe to spare
generator. System configuration should be main header open at
console; all drain legs, drop points and reclassifier locations plugged.
6.3.2 Cleaning System
[NOTE: Previous procedures have required steam blowing followed by air-
drying. While the procedure cleaned the system well, it had potential
problems if not done properly. Special precautions had to be taken to
prevent the header pipe from distorting. Traces of water could possibly get
trapped in the header system and personnel had to be warned against
touching a hot pipe during the steaming portion. To avoid these problems,
only dry nitrogen will be used in the current procedure. The intent is to
maintain high velocity in the system so small particles will be removed. It
should be recognized that nitrogen will not have the same cleansing ability as
high-pressure steam but cleaning should still be adequate].
6.3.2.1 Connect nitrogen supply through a regulator to the vertical oil mist
header pipe at console using NPS 1 ½ ( 38 mm) screwed pipe.
Experience has shown that pressure loss in a hose can be excessive
thereby preventing adequate cleaning.
6.3.2.2 Main and secondary headers.

a. Remove cap from farthest end of main header.
b. Turn on nitrogen and adjust pressure to 690 kpa (100 psi).
c. Blow line 1 hour. After 1 hour, install a 100 mesh „witness‟
screen over end of pipe for 5 minutes. If not clean, blow for
additional ½-an-hour and recheck with witness screen.
When clean, move to opposite end of main header.
d. Remove end cap here and replace at clean end.
e. Repeat step c.
f. Continue blowing down and checking each secondary
header one at a time until all NPS 2 headers are cleaned.
6.3.2.3 Drop points and drain legs
a. After all headers are clean, remove 20 plugs from drop
points or drain legs. Replace all caps on header system.
b. Blow these 20 points for 1 hour. Check with witness screen
that all are clean.
c. when these are clean, open 20 more and close first 20.
Repeat step b.
d. continue cleaning drop point/drain legs in groups of 20 until
entire system is cleaned.
e. Turn off nitrogen. Disconnect temporary piping. Reconnect
main
header
to primary
and
spare
generators.

f. Reinstall all snap drains in system. Close them. Install all
reclassifiers.
g. as a final check, walk the entire system and verify that all
reclassifiers are installed and all snap drains are installed
and closed.
Mist system is now clean and dry and ready for instrument
and alarm check out.

6.4 Air, Oil and Mist Alarms
6.4.1 Normally, the oil mist vendor should be present when the system is first
started and provide check-out of controls and alarms. This should be
included in the purchase agreement. However, if SABIC or authorized
representative, elects to do it, the following procedure should be followed:
6.4.1.1 Starting Unit: During this phase, the generator must be operating
normally with mist being blown to atmosphere. This will provide a
check that all reclassifiers are clean and working. To start the
system:
a. Verify that ball valve to main header is open to main
generator.

b. Open lube oil supply valve. Verify oil level is at level set
during reservoir checkout.
c. Open air supply valve.
d. Adjust regulator to provide 20 in (500 mm) H2O on mist
pressure gauge. You should now be making oil mist.
e. Turn on main power switch.
6.4.1.2 Adjusting Alarms: When the power switch is turned on, the red light
on top of the console will light and the low air temperature and low oil
temperature lights inside the console will be on.
a. Normal set points are:
Air Temperature 100
0
F (38
0
C) low, 140
0
F (60
0
C) running,
180
0
F (82
°
C) high
Oil Temperature 80
0
F (27
0
C) low, 110
0
F (43
0
C) running,
140
0
F (60
°
C) high
Mist Pressure
Lubrimist 10” (250 mm) H
O low, 20” (500 mm) running, 30”
(760 mm) high
Alemite 8” (200 mm) H
2
2
O low 20” (500 mm) running, 55”
(1395 mm) high
b. As temperatures increase, the low air temperature light will
go off first. Record temperature on data sheet. It should
be just slightly below 100
°
F (38
°
C) because there is thermal
lag in the system between the sensing point and the
temperature gauge.
c. Oil temperature increases more slowly than air temperature.
While waiting for the oil temperature light to go off, check
settings of mist pressure alarms, but continue watching the
oil temperature light to verify when it goes out.
d. Increase regulated air pressure by adjusting regulator. Go
in 2 psi (14 Kpa) increments and allow to stabilize at each
point. Record header pressure where high-pressure alarm
light goes on.
e. Reduce regulated air pressure to original setting that
produced 20 inches (508 mm) header pressure.
f. Using regulator relief valve, slowly bleed off pressure until
low mist pressure light comes on. Record pressure.
g. At this point, all lights inside the console should be out and
you should have recorded the low air and oil temperature
alarm points and the low and high mist pressure alarm
points.
h. High air temperature alarm point can be found by removing
the cover on the air heater switch and adjusting the control in

¼ turn increments. Allow temperature to stabilize before
proceeding to next adjustment. Record temperature at
which high air temperature light in console comes on.
Return switch to original setting by reversing the control the
same number of turns.
i. High oil temperature alarm point is found the same way as
above except it will take longer because the reaction times
on the oil system are much slower.
j. All set points can be adjusted by removing the cover from
the appropriate controller and adjusting with a screwdriver or
Allen wrench as required. Mist pressure can be reset
quickly. Air temperature adjustments have longer response
times and oil temperature adjustments are very time
consuming.
k. Resetting the low oil temperature alarm point may take a
couple days unless the reservoir is drained and fresh, cool
oil is used. Low air temperature alarm can be reset by
turning off the power switch but letting air continue to flow.
Turn switch back on when temperature is lower than
expected set point. For resetting alarm points, the
procedures described above should be used.
Once alarm points have been set, commissioning is
complete. The system can be shut down and all final
connections (tubing, drains, sight glasses, etc.) to equipment
can be made.