Professional lubricating oil supply for large gas engines, diesel engines and large gas compressors

Why and what are professional lubricating oil supply systems for?

Krampitz has been building oil supply systems since 1994. Several hundred systems were produced during this period. Combustion engines and compressors are supplied with circulating oil lubrication from the oil pan of the respective machine. This oil, also known as lubricating oil, ensures lubrication of the crankshaft and the sliding between the piston and the cylinder wall.

The machine continuously consumes small amounts of lubricating oil during operation. A correct oil level in the machine's oil pan is a basic requirement for trouble-free operation of the engine. On small machines, the fill level of the oil pan is determined using an oil dipstick, which sits above or in the oil pan. The refilling is done manually by the respective service personnel. Large professional machines are usually supplied with independent lubricating oil supply systems.

General structure of lubricating oil supply systems

These lubricating oil supply systems have a fresh oil tank to store the required lubricating oil. Continuous-running machines such as combined heat and power plants or power stations usually have a quarterly volume for oil changes or for around 2200 operating hours. Of course, a corresponding used oil tank is also part of the system.

This used oil tank is required to hold the used oil (occurs when changing the machine's oil), which must be carried out regularly after 500 to 1000 operating hours, depending on the manufacturer's instructions.

The tanks are equipped with level switches, overfill protection and mechanical float content indicators. Optionally, a fully electronic content display based on ultrasound can also be installed. This shows the fill level of the tank in percent as well as in liters.
The tank is double-walled steel with vacuum leak monitoring.

Other equipment components include the fish oil pump or waste oil pumps and decentralized day tanks.

Waste oil delivery stations (called OSP) are installed directly next to the machine's oil pan if the line routes to the used oil tank are too long.

When fresh oil is delivered in drums, a drum station is used to accept the oil into the system and to dispose of used oil in drums.

The program also includes filling and disposal cabinets with tank truck connections for accepting or extracting fresh oils or used oils from or into tank trucks.

The level control of the lubricating oil in the oil pan

The oil pans of large machines have different level measurements and controls. Large professional systems are usually equipped with electronic level switches in an external float housing directly on the side of the machine. These level switches usually work with reed contacts which close the circuit when the level drops. This opens the inlet solenoid valve of the fresh oil line on the oil pan and fresh oil can flow in.

When the fill level increases, in the max position, the reed contact opens. The circuit is broken and the inlet solenoid valve closes (closed when de-energized).

Depending on the system structure, if no day tanks are installed, the fresh oil pump of the fresh oil tank can also be requested when the inlet solenoid valve is opened.

There are also mechanical oil pan intake controls. However, these do not work 100 percent trouble-free.

Investment philosophies

There are two essentially different philosophies in the design of lubricating oil supply systems.

The first relies on the use of decentralized day tanks with a static flow to the respective machine. These day tanks should be positioned approximately two meters above the inlet solenoid valve of the oil pan in order to achieve a proper static pressure of the oil level column in the fresh oil line. This guarantees a quiet and quick flow of fresh oil into the oil pan. Advantage: The day tank works completely independently of the rest of the fresh oil system. This variant does not build up high oil pressure in front of the inlet solenoid valve as with direct filling by an electric oil pump. The static pressure causes the oil to flow in smoothly. The level of lubricating oil in the oil pan is precisely dosed. A larger day tank (250 liters) can also supply two machines at the same time.

The second philosophy relies on the direct filling of the oil pans using the fresh oil pump of the lubricating oil supply system. The advantage here is a simple system structure and savings in investment costs.

Driving the oil change

For regular oil changes, the used lubricating oil (waste oil) is sucked out of the machine's oil pan and pumped into the used oil storage tank using the used oil pump installed on the lubricating oil supply system. To do this, the drain cock at the lowest point of the oil pan is opened manually immediately after switching off the warm engine. The warm engine oil is pumped through the used oil pump into the used oil tank of the lubricating oil supply system via the connected used oil suction line.

If the pipe routes are too long, we recommend installing waste oil extraction stations (OSP) directly on the oil pan to safely remove waste oil. This eliminates cavitation problems. Overfilling of the used oil tank is prevented by an overfill protection installed in the used oil tank. When the waste oil extraction is complete, the drain cock on the machine is closed manually.

Now the fresh oil filling can begin. To do this, the inlet solenoid valve on the engine oil pan is opened. The fresh oil pump can now be started. Attention: If day tanks are integrated into the fresh oil line system, they must be switched off beforehand using installed ball valves or solenoid valves. When the maximum fill level is reached, the activated inlet solenoid valve of the machine closes automatically. The machine is now properly filled.

Filling the fresh oil tank

The fresh oil tank is usually filled by tank trucks. There is a filling pipe in the fresh oil tank, which is connected to the filling and disposal cabinet by a pipeline. The filling and disposal cabinet is usually installed on the outside wall of the building. Filling and extraction ports are installed in this lockable cabinet in different configurations depending on the system standard.

The cabinet also contains the connection for the automatic shutdown of the tanker pump through the overfill protection in the tank. An alarm acknowledgment box is also installed, which triggers a visual and acoustic alarm via a flashing light and horn when the overfill protection in the tank is triggered. This alarm can be acknowledged using an acknowledgment button on the front of the box. This will turn off the horn. The flashing light continues to work until the overfill protection (ÜSI) is no longer wetted.

Suction off the used oil

To suck out the used oil, the tanker driver connects his suction hose to the used oil connection of the filling and disposal cabinet. A suction pipe is installed in the used oil tank and extends to the bottom of the tank. This suction pipe is connected to the suction nozzle in the filling and disposal cabinet by means of a pipe connection. The tanker driver opens the ball valve on the suction port and starts the suction.

When the minimum contact in the used oil tank is reached, the 2nd alarm acknowledgment box is triggered. This means the tanker driver knows immediately that the tank is empty. The extraction of the used oil is finished. The tanker driver acknowledges the alarm acknowledgment box and disconnects his suction hose.