Bulk Fill Grease System for R.O.M

We were asked to design, manufacture, install & commission a fully functional bulk fill grease system to provide clean & measured flow of grease to the Stamler Feeder Breaker machine.

The design incorporated a refillable 500kg stainless steel tank on ground level with over 30M of hard piping & hydraulic hoses up to the grease pump reservoir that supplies grease to the required lubrication points.

Grease from the bulk fill tank travels upstream to the current pump reservoir that supplies grease to the bearings & seals by using injectors that are mounted in 2 separate cabinets on either side of the machine.

The 500kg capacity tank was fitted out with a 50:1 pump controlled by a 24v DC Solenoid Valve. Next to the tank is a control cabinet that communicates between the grease system & the control room. A pressure switch was fitted at the Stamler reservoir fill line, set at approx. 1500 PSI. The old system used an analogue level sensor, which reported reservoir grease level back to the PLC.

Upon commissioning of the system, the tank will be filled on a fortnightly basis to keep it topped up with grease as a routine service.

The control sequence is as follows;

When the Stamler reports a low level to the PLC, the PLC energises the pump solenoid & grease transfer commences.

When the Stamler reports a high level (100% full) or when the pressure switch operates, the PLC de-energises the Stamler pump solenoid valve, pumps stops & grease vent valve opens to vent residual pressure from the delivery lines.

We designed & fitted 2 stainless-steel grease injector cabinets to be mounted to the Stamler Crusher. The cabinets consisted of 6 grease injectors mounted to manifold blocks & connected via tubing & hydraulic hoses to the bearings & seals.

The main purpose of the grease cabinets is to protect the injectors & associated parts from the harsh environment ensuring optimum cleanliness & longevity.