Mm9a0e 1

Project Dwg. No: G101-25-1723.
40-MM58
Turbine Main Oil Tank and

Auxiliary Oil Pumps (AOP, TOP & EOP)
MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP)
Maintenance Manual No. MM-M05.08
Revision 000
Note
This mechanical maintenance manual is intended to provide the Paiton Expansion Project
mechanical maintenance personnel with the basic understanding required to perform preventive,
routine, corrective and overhaul maintenance activities on the subject equipment.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and Paiton Expansion Project.
Turbine
Main Oil Tank
and Auxiliary
Oil Pumps
(AOP, TOP & EOP)
Maintenance
Be sure to read this manual.
Contents
Safety
General
Specifications
Preventive Maintenance
Disassembly and Reassembly
Corrective Maintenance
Recommended Lubrication
Appendixes
Revision Record
Description of Revision
Revision Issue
Date
Date Revised
Pages
Inserted
MM-M05.08
Rev.000
Page Number
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP)
Mitsubishi
Important Information
Purpose of the Plant Usage
This plant is designed to generate electric power of 815 MW by the steam turbine
generator.
The plant is only used for the electric power generation purpose that supports stable
and reliable electric power supply to the power grid and supplying steam for the
auxiliary equipment in the power station.
General
1.
To satisfy the purpose mentioned above the following points must be strictly
observed,
a)
The operation, maintenance and inspection of Equipment must be

performed by the persons who have basic technical knowledge and have
been trained concerning the hazard of the Equipment and the avoidance
of the hazard.
b)
The operators and maintainers must read and understand these manuals
before starting the operation, maintenance or inspection.
It is often experienced that serious damage to the equipment or personnel
have occurred by the unexpected action of operators or maintainers who
do not fully understand the equipment.
c)
The modification or change of operational specification must be performed

under MHI supervision or as per the written acceptances of MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The Customer is requested to contact MHI regarding any modification or
proposed changes before the work commences.
MM-M05.08
Rev.000
The address for MHI to be contacted is shown in this chapter.

2.
The operation and maintenance must be performed according to the applicable

laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local legal
regulations.
4.
The copyright of software, drawings and other documents provided by MHI at

all times, is still reserved by MHI.
Mitsubishi
ii
Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.
Important General Notice for Safety

1.
The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as a Safety and Health

management system and operate continuously.
The Safety and Health management system must include the following points,
a) Instruction for use and the maintenance of the personal protective
equipment issued to operators and maintainers
b) The establishment of a work management organization to make clear the
operation directives and work procedures
c) Implementation of training for operator and maintainer
4.
The Customer must train the operators and maintainers to act positively and
to prevent the occurrence of an accident by using their knowledge of the
power plant.
5.
The Customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to

observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operator, and to the maintainer.
MM-M05.08
Rev.000
7.
a)
Risk of a fatal accident
b)
Danger to lose his health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as danger
due to human error and/or dangers caused by the operating environment.
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.
Mitsubishi
iii
8.
MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.
Instruction of this Manual

This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.
MM-M05.08
Rev.000
1.
Mitsubishi
iv
Warranty
The provisions set forth in this section are in addition to all liability and warranty
disclaimers and limitations set forth in the Contract, whether arising under law
or from course of performance, course of dealing, or usage of trade.
Nothing in these provisions shall constitute or be deemed to constitute any

additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and

Commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing in
the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents, partial
or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and other
equipment), or any other liability (collectively, Accidents and Damages) in the
case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;
MM-M05.08
Rev.000
Mitsubishi
Accidents and Damages caused by the modification or re-installation of the

Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during

transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in accordance

with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing

performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other

equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of the

damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect

references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or

storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.
MM-M05.08
Rev.000
Mitsubishi
vi
Limitations of Liability
General
Nothing in this Limitation of Liability section or manual shall constitute or be

deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.
Use and Disposal
Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.
For Documents and Safety Training
MM-M05.08
Rev.000
The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety
training prior to the start of their work. Persons who have not received such
safety training are not permitted to work on the installed Plant. This initial
training, however, is merely the minimum requirements prior to allowing any
personnel to work on the installed Plant. The Customer must, on a continual
and regular schedule, give up-to-date training to its personnel on safety
requirements, provide testing or other methods to confirm their understanding
of the safety training, and confirm that they have the physical and mental
capability to perform their respective roles. The Customers obligation for
safety training and personnel supervision is an ongoing obligation and must be
continuously performed and kept current throughout the operation of the Plant.
Accidents, partial or total failure of the Plant, damage to personnel or property,
loss, injuries, and other liability (collectively, Liability) caused by inadequate
safety training or the Customers personnels failure to abide by the documents
provided by MHI are expressly excluded from the coverage of any warranty
provided by MHI and are the sole and exclusive responsibility of the Customer.
Mitsubishi
vii
MHI will NOT be liable for any Liability caused by modification or changes
made in Plant-related documents (including any Safety Manual) by anyone
other than MHI.
For Damage to the Plant

Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected by
MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault,
in material or Equipment that was used during a repair, even when such repair
was performed by or under an instruction given by MHI.
MM-M05.08
Rev.000
Mitsubishi
viii
Copyright
COPYRIGHT 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS
RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED.
All of the content contained in this manual is protected by Japanese,
International and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property
rights in the documents provided by Mitsubishi Heavy Industries, Ltd.(MHI)
(including safety-and-instruction manuals) are at all times owned and reserved
by MHI. Subject to your compliance with the restrictions set forth below, MHI
grants to you a limited, non-exclusive license in the copyright for the sole
purpose of allowing you to use, operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents

provided by MHI (including safety-and-instruction manuals) for any purpose
other than the purpose described above without MHIs prior written consent is
strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,

uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, estoppel or
otherwise, is being granted or otherwise transferred.
MM-M05.08
Rev.000
Mitsubishi
ix
Personnel to whom the

Manual is Directed
This Manual was prepared for all personnel who will participate in the operation and
maintenance of the plant, and the other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed to
perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge Engineer
are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to emergency stop devices following instructions
given by their superior when dangerous or hazardous situations are recognized.
Maintainer
MM-M05.08
Rev.000
Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work if
MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.
Mitsubishi
Contact Address
For any question or any clarification required, please do not hesitate to contact MHI
through the following address (es).
For Support before Operation:

MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
1-1, Akunoura Machi, Nagasaki 850-91
For Support after Commissioning and in an Emergency
MM-M05.08
Rev.000
(Later)
Mitsubishi
xi
Abbreviations
ABB.
EXPANDED FORM
ABB.
EXPANDED FORM
AOP
Auxiliary Oil Pump
NDE
Non-destructive Examination
CCW
Closed Cooling Water
NWL
Normal Working Level
EOP
Emergency Oil Pump
OJT
On Job Training
FL
Floor Level
P&ID
Process and Instrumentation

Diagram
I&C
Instrument and Control
PPE
Personal Protective Equipment
MOP
Main Oil Pump
PTW
Permit to Work
IP
Intermediate Pressure
RTD
Resistance Temperature Detector
MOT
Main Oil Tank
TOP
Turning
MSDS
Material Safety Data Sheet
MM-M05.08
Rev.000
Oil Pump
Mitsubishi
xii
List of Vendor Manuals
MM-M05.08
Rev.000
LATER
Mitsubishi
xiii
A rr a n g e m e n t o f t h e S y s t e m
Maintenance Manual
This manual is arranged as follows.
Chapter 1
Describes health and safety issues during maintenance, disassembly and reassembly
of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP).
Chapter 2
Describes the construction, purpose, and function of the Turbine Main Oil Tank and
Auxiliary Oil Pumps (AOP,TOP & EOP) and the associated parts.
Chapter 3
Describes the Turbine Main Oil Tank and the various Pumps using the relevant Data
Sheets.
Chapter 4
Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5
Describes the disassembly and reassembly procedures, necessary to obtain access
to internal parts for inspection and repair during the Main Oil Tank and the various
pumps overhaul.
Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.
Rev.000
Chapter 7
MM-M05.08
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents
Mitsubishi
xiv
Contents
Contents
Revision Record i
Important Information ii
Warranty v
Limitations of Liability vii
Copyright ix
Personnel to whom the Manual is Directed x
Contact Address xi
Abbreviations xii
List of Vendor Manuals xiii
Arrangement of the System Maintenance Manual xiv
Chapter1
Safety ____________________________
1.1
Features of Turbine Main Oil Tank and Auxiliary Oil Pumps

(AOP, TOP & EOP) Safety 1-1
1.2
Warnings Description1-2
1.2.1
Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property 1-3
1.2.2
Symbol1-4
1.2.3
Hazard Warning Label 1-5
1.2.4
Hazard Area1-7
1.3
Risk Assessment Standard 1-8
1.4
Safety Measures1-10
1.4.1
Work Permit System (Lockout/Tagout) 1-10
1.4.2
General Cautions on Personnel in Working Area 1-11
1.4.2.1
Caution against Rotating Equipment 1-11
1.4.2.2 Cautions against Electrical Equipment 1-11

1.4.2.3 Cautions against High Temperature Sections1-12
1.4.2.4 Cautions for Steam Leak in the Plant 1-13
1.4.2.5 Cautions against Oil Leak in the Plant1-13
1.4.2.6 Cautions against Chemicals1-14
MM-M05.08
Rev.000
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-14

1.4.2.8 Cautions against Lack of Oxygen1-15
1.4.2.9 Cautions against Lifting Heavy Object1-16
1.4.2.10 Caution against Sharp Objects1-16
1.4.2.11 Cautions using Fork Lift1-16
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP)
Mitsubishi
Contents
Chapter1
Safety (Continued from previous page)

1.4.2.12 Cautions using Crane1-17
1.4.2.13 Disposal1-18
1.5
Emergency Measure1-19
1.5.1 Evacuation on Emergency Case1-19
1.5.1.1 Evacuation Route1-19
1.5.1.2 Evacuation of disabled persons who cannot move by
themselves1-19
MM-M05.08
Rev.000
1.5.1.3 Evacuation from Power House1-20

1.5.2
Fire Accident 1-21
1.5.3
Earthquake 1-22
1.5.4
Explosion Accident1-22
1.6
Qualification and Training 1-23
Chapter2
General___________________________
2.1
Purpose 2-1
2.2
References 2-1
2.3
Overview of the Main Oil Tank and the AOP, TOP & EOP 2-3
2.4
Construction 2-10
2.4.1
Oil Pumps 2-11
2.4.2
Vapor Extractor Fan 2-12
2.4.3
Oil Mist Separator 2-13
2.4.4
Oil Ejectors 2-13
2.4.5
Oil Level Gauge 2-14
2.4.6
Oil Strainers 2-14
2.4.7
Oil Cooler 2-15
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites4-1
4.2
4.1.1
Scheduling4-1
4.1.2
Departmental Interface/Notification 4-2
4.1.3
Isolation of Equipment4-2
4.1.4
Safety Precautions4-2
Routine Maintenance4-3
4.2.1
Preparation 4-3
4.2.2
Inspection and Maintenance 4-4
Mitsubishi
Contents
Chapter4
Preventive Maintenance (Continued) ______
4.3
Annual Outage Maintenance4-8

4.3.1
Preparation 4-8
4.3.2
Inspection and Maintenance 4-9
Chapter5
Disassembly and Reassembly ________
5.1
Main Oil Tank Disassembly and Reassembly5-1
5.2
Disassembly and Reassembly of the Auxiliary Oil Pump5-3
5.3
Disassembly and Reassembly of Turning Oil Pump5-12
5.4
Disassembly and Reassembly of Emergency Oil Pump5-19
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites6-1
6.2
Preparation 6-2
6.3
Troubleshooting 6-2
Chapter7
Recommended Lubrication __________
Appendixes
Torque Chart A-1
Appendix B
Recommended Spare Parts B-1
Appendix C
Special Tools C-1
Appendix D
Coupling Alignment D-1
Appendix E
Applicable Reference Drawings E-1
MM-M05.08
Rev.000
Appendix A
Mitsubishi
Contents
MM-M05.08
Rev.000
List of Figures
Figure 1-1
Types of Hazard Warning Labels1-6
Figure 1-2
Mapping for Hazard Areas1-9
Figure 2-1
Oil Purifier, Oil Piping Diagram2-6
Figure 2-2
Schematic Arrangement of Main Oil Tank and

Associated Equipment 2-7
Figure 2-3
Arrangement of Main Oil Tank 2-8
Figure 2-4
Partially Exploded View of Main Oil Tank2-9
Figure 2-5
Cutaway View of the Main Oil Tank 2-17
Figure 2-6
Main Oil Tank Internal Piping2-18
Figure 2-7
Isometric View of Auxiliary Oil Pump 2-19
Figure 2-8
Cutaway View of the Auxiliary Oil Pump2-20
Figure 2-9
Sectional View of the Auxiliary Oil Pump 2-21
Figure 2-10
Isometric View of the Turning Oil Pump2-22
Figure 2-11
Cutaway View of the Turning Oil Pump 2-23
Figure 2-12
Sectional View of the Turning Oil Pump 2-24
Figure 2-13
Isometric View of the Emergency Oil Pump2-25
Figure 2-14
Cutaway View of the Emergency Oil Pump 2-26
Figure 2-15
Sectional View of the Emergency Oil Pump 2-27
Figure 2-16
Sectional View of the Vapor Extractor Fan 2-28
Figure 2-17
Figure 2-18
Arrangement of No. 1 and 2 Oil Ejectors 2-30
Figure 2-19
Main Oil Tank Level Gauge Assembly 2-31
Figure 2-20
Lubricating Oil Strainer Assembly2-32
Figure 2-21
Return Oil Strainer2-33
Figure 2-22
Turbine Oil Cooler 2-34
Figure 2-23
Bearing Oil Pressure Adjusting Valve 2-35
Figure 4-1
Auxiliary Oil Pump Clearance Drawing4-16
Figure 4-2
Turning Oil Pump Clearance Drawing 4-17
Figure 4-3
Emergency Oil Pump Clearance Drawing 4-18
Figure 5-1
Exploded View of the Auxiliary Oil Pump 5-11
Figure 5-2
Exploded View of Turning Oil Pump 5-20
Figure 7-1
Recommended Lubricant List Main Oil Tank 7-2
Mitsubishi
Contents
Figure 7-2
Recommended Lubricant for AOP7-3
Figure 7-3
Recommended Lubricant for TOP 7-4
Figure 7-4
Recommended Lubricant for EOP 7-5
Figure 7-5
Recommended Lubricants for Vapor Extractor Fan 7-6
Figure B-1
Operating Spare Parts for Auxiliary Oil Pump B-2
Figure B-2
Operating Spare Parts for Turning Oil Pump B-3
Figure B-3
Operating Spare Parts for Emergency Oil Pump B-4
Figure B-4
Operating Spare Parts for MOT Vapor Extractor B-5
Figure B-5
Operating Spare Parts for Mist Separator B-6
Figure E-1
Arrangement Drawing of Main Oil Tank E-2
Figure E-2
Outline Drawing of AOP E-3
Figure E-3
Assembly Drawing of AOP (1 of 3) E-4
Figure E-4
Figure E-5
Figure E-6
Expected Performance Curve of AOP E-7
Figure E-7
Torque Characteristic Curve for AOP E-8
Figure E-8
Outline Drawing for AOP Motor E-9
Figure E-9
Outline Drawing of TOP E-10
Figure E-10
Assembly Drawing of TOP (1 of 3) E-11
Figure E-11
Figure E-12
Figure E-13
Expected Performance Curve of TOP E-14
Figure E-14
Torque Characteristic Curve for TOP E-15
Figure E-15
Outline Drawing for TOP Motor E-16
Figure E-16
Outline Drawing of EOP E-17
Figure E-17
Assembly Drawing of EOP (1 of 3) E-18
Figure E-18
Figure E-19
Rev.000
Figure E-20
Expected Performance Curves of EOP E-21
Figure E-21
Torque Characteristic Curve for EOP E-22
MM-M05.08
List of Figures (Continued from previous page)
Figure E-22
Outline Drawing for EOP Motor E-23
Figure E-23
Vapor Extractor Fan (1 of 3) E-24
Mitsubishi
Contents
List of Figures (Continued from previous page)

Figure E-25
Figure E-26
Oil Mist Separator (1 of 2) E-27
Figure E-27
Oil Mist Separator (2 of 2) E-28
Figure E-28
Oil Level Gauge E-29
Figure E-29
Lubricating Oil Strainer E-30
Figure E-30
Return Oil Strainer E-31
Figure E-31
Turbine Oil Cooler (1 of 2) E-32
Figure E-32
Turbine Oil Cooler (2 of 2) E-33
MM-M05.08
Rev.000
Figure E-24
Mitsubishi
Contents
List of Tables
Risk Assessment Standard1-8
Table 3-1
Main Oil Tank 3-1
Table 3-2
Auxiliary Oil Pump3-1
Table 3-3
Turning Oil Pump 3-2
Table 3-4
Emergency Oil Pump 3-2
Table 3-5
Main Oil Tank Vapor Extractor Fan 3-3
Table 3-6
Table 3-7
Main Oil Tank Level Gauge 3-4
Table 3-8
Lube Oil Strainer 3-5
Table 3-9
Return Oil Strainer3-5
Table 3-10
Turbine Oil Cooler 3-6
Table 4-1
Routine Maintenance Checklist4-6
Table 4-2
Annual Outage Maintenance Checklist4-14
Table 6-1
Troubleshooting Main Oil Tank and Vapor

Extractor Fan 6-3
Table A-1
Torque Chart A-1
MM-M05.08
Rev.000
Table 1-1
Mitsubishi
Chapter 1
Safety
Chapter
1 Safety
1.1
Features of the Turbine Main Oil Tank and AOP, TOP & EOP
The lubricating and control oil requirements of the main turbine oil tank are
provided by any of the four turbine oil pumps viz. MOP, AOP, TOP, and EOP at
any given operating condition.
The turbine oil pumps when in service are subjected to near constant discharge
oil pressure with high flow variations. The flow variations occur due to the
operation of the various turbine steam admission valves or the turbine protective
devices.
The oil flow and hence pressure variations caused during the main turbine
operation are relieved by relief valves installed on the lubricating oil and control
oil piping. However, due to the sudden oil pressure fluctuation and ageing of
flange gaskets, the oil piping has a risk of flange/pipe leakage.
Any oil leakage in the vicinity of the turbine could lead to a fire, which could
damage the nearby components and/or personnel working nearby.
The main oil tank is operated under a slight vacuum by the operation of the
vapor extractor fan. The turbine bearing pedestals, connected to the main oil
tank through the drain lines, are also maintained at a slight vacuum. The
negative pressure in the bearing pedestals prevents leakage of oil or oil vapor
from the bearing pedestals. Any oil or vapor leakage could lead to a fire which
could damage the nearby components. All personnel should pay strict attention
to this aspect, check for any damage to main oil tank and to any of the
associated pumps.
All operators and maintainers must realize the danger and keep themselves
safe, following the recommendation written in this chapter.
MM-M05.08
Rev.000
The turbine oil pumps operate with close internal clearances and accurate
alignment. Any disturbance in the pump clearances or alignment, due to ageing
and/or wear of components, can cause internal rubbing and damage to the
pump components. The disturbed clearances or alignment can also lead to
abnormal vibration in the oil pumps. All operators and maintainers should pay
special attention if any abnormal rubbing noise or vibration is observed on the
oil pumps to reduce consequential damages.
Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description
Safety of personnel working in the power plant is the most important matter and
all kind of consideration to avoid dangerous condition are studied and applied to
the design of the power plant. However, certain risks are unavoidable due to the
nature of the plant.
This manual classifies the severity and hazard level of such risks by two
categories, DANGER and CAUTION. Read and understand the indications
thoroughly before operation or maintenance of the plant.
The contents of wordings, DANGER and CAUTION are described as follows;
Kinds
Meaning of Warnings
DANGER indicates an imminently hazardous situation
in handling of the Turbine Main Oil Tank and Auxiliary Oil
Pumps (AOP, TOP & EOP), which, if not avoided, could
result in death or serious injury, or serious damage to
the property or environment.
CAUTION indicates a potentially hazardous situation
during use of the Turbine Main Oil Tank and Auxiliary Oil
CAUTION
Pumps (AOP, TOP & EOP), which, if not avoided, may

result in minor injury, or minor damage to the property or
environment.
This manual also uses the following indicators in addition to the hazard level
indications described above.
Kinds
Meaning of Warnings
IMPORTANT describes the particular information or
items that personnel must know during operation and
IMPORTANT
maintenance of the Turbine Main Oil Tank and Auxiliary

Oil Pumps (AOP, TOP & EOP), and that, if not heeded,
may result in an accident of an in-assessable hazard
level.
Notice
NOTICE describes useful information and tips for

operation and maintenance of the Turbine Main Oil Tank
MM-M05.08
Rev.000
and Auxiliary Oil Pumps (AOP, TOP & EOP).
Mitsubishi
1-2
Chapter 1
Safety
1.2.1 Definitions of serious injury, minor injury,

serious damage to property, and minor damage to
property
Serious Injury
This term describes injuries, which leave after effects such as loss of
eye sight, permanent disability, bone fracture or breakage, gas
inhalation, asphyxiation, electric shock, hospitalization or prolonged
hospital visits for treatment.
Minor Injury
This term describes injuries, which do not require hospitalization or
prolonged attention at a hospital (injuries other than the serious
injuries described above).
Serious Damage to Property

This term describes damages, which require a suspension of
productive activity for one day or more due to restoration of the
damaged property.
Minor Damage to Property
MM-M05.08
Rev.000
This term describes damage, which does not require any suspension
of productive activity due to restoration of the damaged property.
Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbol
In this manual, the following symbols are added for easy understanding
of the contents of warnings and are found next to DANGER,
CAUTION and indications.
These symbols are in compliance with ISO 3684.
Symbol
Description
This symbol indicates the possible presence of high voltage, and
warns of a hazard which may result in system shock, burn or
death by electric shock if safety precautions are neglected or the
system is handled incorrectly.
This symbol indicates a movable section that is inside a safety
cover or is exposed.
Movable parts may inflict laceration or bone fracture to body parts
such as a hand by pinching the hand and/or clothing.
This symbol indicates the presence of parts the surface of which
could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place
your feet when moving around the area.
Risk of injury by tripping is present near this symbol due to
factors such as a location with an unstable surface, or
obstructions such as scaffolding, temporary pipe lines, or other
protrusions.
This symbol indicates the possible presence of gas(es) harmful or
asphyxiant to personnel.
Be sure to ventilate fully before work commences.
This symbol indicates caution against the handling of a heavy
object or working in an abnormal position.
Do not work in an abnormal posture which may damage your back
or waist.
This symbol indicates prohibited items or actions during the
operation and maintenance of the Turbine Main Oil Tank and
MM-M05.08
Rev.000
Auxiliary Oil Pumps (AOP, TOP & EOP).
Mitsubishi
1-4
Chapter 1
Symbol
Safety
Description
This symbol indicates that personnel must not touch since the
surface is hot.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that the entry of personnel is prohibited.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited.

Do NOT touch or enter a location or enclosure where this symbol
is displayed.
This symbol indicates that the stated items or actions in the
warning notices relative to operation and maintenance of the
are mandatory.
1.2.3 Hazard Warning Label

Hazard warning labels are applied where potential hazards are present
during operation and maintenance activities.
Hazard warning labels will be in appropriate sizes and colors that will
catch the eye and the attention of personnel. They also have symbols
that show the hazard types, in addition to the descriptions of warning
contents.
IMPORTANT
Personnel are requested to confirm the location of, and to read, and
thoroughly understand the contents of all hazard warning labels
applied to this Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,
TOP & EOP) Manual. If any of the hazard warning labels peel off/wear
out or become unreadable, install a new label in the original location
MM-M05.08
Rev.000
without delay.
Mitsubishi
1-5
Chapter 1
Safety
WARNING
DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION
STEEP
DROP
DO NOT
ENTER
DO NOT
TOUCH
DO NOT
TOUCH
MM-M05.08
Rev.000
TB0001_A
FIGURE 1-1
TYPES OF HAZARD WARNING LABELS
Mitsubishi
1-6
Chapter 1
Safety
1.2.4 Hazard Area
IMPORTANT
Only trained maintainers and operators are allowed to enter the
maintenance work area. Entry to the area by personnel untrained
could cause not only injury but also serious damage to the Turbine
MM-M05.08
Rev.000
Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP).
Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard

The tables below are prepared as per MIL STD822D.
TABLE 1-1
RISK ASSESSMENT STANDARD

Detailed Description of Impact on each Object
Category
Safety
Catastrophic
- Unit shutdown (unit cannot be

operated)
- More than 4 days for repairing
- Death
II
Critical
- Unit shutdown (can not be operated)

- Within 3 days for repairing
- Serious Injury
- Same as the above
III
Marginal
- Unit shutdown (can not be operated)

- Can be repaired by Customer
- Minor Injury
(with
hospitalization)
VI
Negligible
- Same as the above

- High temperature surface
- High elevation or unstable
- Not harmful and high
pressure & temperature
leakage
-Mechanical protected
- Minor Injury
(without
hospitalization)
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, it has happened
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1
Hazard
Categories
Frequency
of Occurrence
Rev.000
Environment
- Harmful gas or oil leakage
- High pressure and
temperature material leakage
such as steam, water, air and
gas, oil etc.
- Low oxygen
TABLE 1-1
MM-M05.08
Health
RISK ASSESSMENT STANDARD (CONTINUED)

I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
13
(B)
Probable
16
(C)
Occasional
11
18
(D)
Remote
10
14
19
(E)
Improbable
12
15
17
20
Mitsubishi
1-8
Chapter 1
10
5
3
2
10
5
3
2
10
5
3
2
10
5
3
2
7
4
4 3
4
3 9
2 8
1 7
7
4
3
Safety
7
4
3
7
4
3
4
3
STAIR WAY
3
7
8
2
3
5
10
3
4
7
STAIR WAY
2
3
5
10
2
3
5
10
2
3
5
10
3
4
7
1 7
2 8
3 9
4
3
4
7
3
4
7
NOTES
WARNING LABELS SHOUD BE IN ARABIC.
GEN. SIDE
MM-M05.08
Rev.000
1 YELLOW
AVOID INJURY
WATCH YOUR STEP
2 YELLOW
FALL
WATCH YOUR STEP
YELLOW
RISK OF A ROTATING
A HAND
YELLOW
RISK OF A GEAR
PINCHING A HAND
MPTD-3-0314
GOV. SIDE
(*1)
YELLOW
RISK OF A CHAIN
PINCHING A HAND
YELLOW
PINCH POINT
KEEP HANDS AWAY
4 YELLOW
5 YELLOW
DO NOT TOUCH
HOT SURFACE
6 YELLOW
7 YELLOW
8 YELLOW
DISCONNECT
AUTOMATIC START.
ELECTRICAL POWER
KEEP HANDS CLEAR.
BEFORE SERVICING
DO NOT SMOKE
IN THIS AREA.
10 RED
OPERATING PERIOD
(*1) THE MOST SUITABLE ONE WILL BE ADOPTED TO EACH PLACE.
FIGURE 1-2
Mitsubishi
9 RED
MAPPING FOR HAZARDOUS AREA
1-9
Chapter 1
1.4
Safety
Safety Measures
1.4.1 Work Permit System (Lockout/ Tagout)
MM-M05.08
Rev.000
Work permit system is applied when equipment is shutdown for

maintenance work, to complete the maintenance work under a safe
condition. The outline of the work permit system is as follows:
(1)
The Maintenance Engineer applies for the work permit clearly

indicating the content of the maintenance work that he wants to
do, and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the
operator to study and decide the isolation method from the line in
operation on the mechanical and electrical view point and then
report to the Shift Charge Engineer with the comments on the
hazard conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and

prepares necessary tags to show the work permit number and
the situation of isolation by valves and power supply. He will then
instruct the operators to set the isolation condition following the
work permit form.
(4)
The operators will open the breaker and set the valves to the
specified condition, they will also drain and vent the equipment to
be worked on, and the breaker and the valves are to be locked.
The operators return the work permit to the Shift Charge
Engineer.
(5)
The Shift Charge Engineer checks the isolation and will issue the
signed work permit to the Maintainer, or his representative.
(6)
The Maintenance Engineer orders the start of the maintenance

work to the personnel nominated.
(7)
The Maintenance Engineer or his representative will then return

the signed work permit to the Shift Charge Engineer after making
sure the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the
locks and return to the original situation.
(9)
The operators check the situation and report that the system is
now back to the normal condition when signing off the work
permit.
(10) The Shift Charge Engineer makes sure that the work under the
permit is completed and files details in the log book.
The work permit system is to clarify responsibility for the works on each step
and to ensure that the work is performed safely.
Mitsubishi
1-10
Chapter 1
1.4.2
Safety
General Cautions on Personnel in Working Area
1.4.2.1 Caution against Rotating Equipment

All couplings on rotating machine are covered by the
coupling cover but whole parts of the shaft are not fully
covered. It is recommended that the following warning is
observed strictly.
Do not approach or operate the equipment where protective

covers have been removed. Get additional supervisor
assistance.
Make sure that the breaker for the motor is opened when you
are required to remove the cover.
Care must be taken of the exposed rotating parts especially in

the area between the casing and the coupling.
All shafting, coupling and other rotating parts must be

guarded in order to prevent accidental contact.
1.4.2.2 Cautions against Electrical Equipment
MM-M05.08
Rev.000
The electrical equipment covered under this section includes

all the concerned plant equipment and the maintenance tools
like grinders, lamps, welding equipment, etc. Though live parts
of the plant or maintenance tools are insulated, be sure to
observe the following cautions. Failure to observe them may
cause fatal accidents, personal injuries and damage to the
electrical equipment.
Always, confirm that power supply is disconnected at the

up-stream side of power supply system and it is locked
according to the Work Permit.
Do not remove or open panels or doors labeled with high

voltage live part warning label not included in the Work
Permit.
Ensure the proper earthing is provided for all electrically

operated tools and equipment used for maintenance works.
In case of usage of lamps for internal inspection, ensure

that a low voltage system (24volts) is available.
Make sure that no materials or Parts remain in the Panels or

terminal box before closing them finally.
Mitsubishi
1-11
Chapter 1
Safety
1.4.2.3 Cautions against High Temperature Sections

Various equipment and pipelines contain high temperature
fluid and they are insulated on their surface. There are
however some pipe lines which are not insulated, and as their
temperature is very high and you could get burned, please
observe the following caution to avoid burn injury.
CAUTION
Suitable Personal Protective clothing is always available
and should always be worn, including gloves to avoid
direct contact to hot spots in the plant
Level gauges of pressure vessels including connecting

pipes are not insulated to cool down the steam to drain.
Sampling piping is not insulated to cool down the steam to

suitable temperature for the analyzer except at the places
located close to the work place.
All exhaust pipes of the safety valves, and the exhaust pipe
of the boiler flush pipe are not insulated.
Always wear gloves.
MM-M05.08
Rev.000
Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant

A steam leak especially from high temperature steam may
cause serious injury to the personnel and it must be repaired
at an early stage of the leakage. The following pre-cautions
must be followed to find leakage at an early stage.
Water drips may occur at the insulated parts such as the

connected part of the lagging. The leaking point can be found
by removing insulation partially with great care.
As you approach the leakage, the water will change to visible

steam. It is now too dangerous to remove the insulation.
Leakage of the superheated steam only makes whistling

noise without generating white steam. It is very dangerous to
approach the noise area.
Contact the Charge Engineer to obtain a Permit to Work to

ensure plant isolation before repairing the damage.
Be well aware of the steam. The steam could leak from the
water system containing water at 100C or higher even if it is
a low pressure type water system.
High temperature drain or steam could leak from the flush

pipe during start-up.
If not avoided, the steam or vapor can enter the inside of your
working wear through the small gap between the body and
the clothing.
1.4.2.5 Cautions against Oil Leak in the Plant
Oil leakage is very dangerous. It is a potential fire hazard.
Any oil spillage must be reported to the Shift Charge

Engineer.
Oil leaks make the area slippery and people are advised to
move around these areas carefully.
MM-M05.08
Rev.000
CAUTION
Mitsubishi
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals

Pay attention to the items to prevent any accident related to
the chemicals in the plant.
IMPORTANT
Precaution against chemicals
Operate chemical injection systems by strictly following
the instruction of the chemist. The operator must use
suitable protective tools.
Disposal:
Observe the rules and regulation of the installation site.
Material safety data sheet (hereafter MSDS):
Always understand the content of the applicable MSDS

before using, and observe the notified instructions when
handling the chemical.
Emergency response
Solution against emergency must be thoroughly instructed

to all personnel involved so that the fullest measures can
be taken against any situation.
1.4.2.7 Cautions against Combustible Materials/

Storage Areas
IMPORTANT
Storage containers must be clearly marked to indicate the
content
Bunding must be provided for bulk tanks
Suitable fire protection must be provided for each area.
Do not store bulk combustible materials on the site.
Small quantities of combustible materials must be stored in

fire resistant cupboards.
Combustible materials must be segregated from other

equipment
MM-M05.08
Rev.000
Mitsubishi
1-14
Chapter 1
Safety
1.4.2.7 Cautions against Combustible Materials/

Storage Areas (Continued from previous page)
IMPORTANT
Leakage of gasoline has the risk of fire. Maximum storage

quantity of gasoline outside of the dispensing pump is five
liters
Emergency response:
Personnel directly involved in combustible materials MUST

be properly trained and thoroughly instructed. Other
personnel in the vicinity must be aware of the dangers and
take precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in

any confined space is between 18~22% before entering, to
ensure sufficient ventilation.
Continue monitoring oxygen and ventilation during

inspection.
It is recommended that you do not enter the equipment,

vessel or confined space alone but if the situation demands
that you must enter, take the necessary preventive safety
measure provided, breathing system etc, and find a partner
who will wait for your return at the point of entry, keeping in
verbal contact throughout.
Make complete arrangements for rescue.
MM-M05.08
Rev.000
Mitsubishi
1-15
Chapter 1
1.4.2.9
Safety
Cautions against Lifting Heavy Object

Be careful during the removal/installation of any
equipment during maintenance.
CAUTION
Do NOT attempt to move or lift equipment in an abnormal

posture. ALWAYS install/remove equipment, using a forklift
or a crane. A normal lift without mechanical aid should be
shared between two or more persons.
Failure to observe the above may cause injury due to

dropped equipment, back or waist injury or damage to the
equipment.
1.4.2.10
Caution against Sharp Objects
CAUTION
Use leather gloves when handling parts with sharp edges.
1.4.2.11
Cautions using Fork Lift
Do NOT permit anyone to stand under any item being lifted

under any circumstance.
Failure to observe this may cause fatal accidents.
When using a forklift, ALWAYS lift the objects parallel to the

ground while considering the center of gravity.
Otherwise, lifted objects may fall and serious damage could

occur.
A forklift is often used to transfer small machines. Check fork

insertion position for the forklift prior to use. Be careful, as
marks which indicate the fork insertion positions are
sometimes hidden by wraps or packing materials.
MM-M05.08
Rev.000
CAUTION
Mitsubishi
1-16
Chapter 1
1.4.2.12
Safety
Cautions using Crane
CAUTION
A crane is often used to transfer heavy parts. Check for any

possible risks which could occur during hoisting and
transportation before operating the crane.
Check of the equipment:
Check the crane, the crane hook and all related items
before use. Use wire ropes which can withstand the weight
of the parts multiplied by a safety factor.
Inspect the shackles, eyebolts, jigs and wire ropes

provided for the hoisting work prior to the actual hoisting.
Perform periodical inspection (dye penetrant test) of

hoisting tools at least once a year.
Rigging/ Slinging work:
Only authorized personnel can perform slinging work and

operation of the crane.
Work area:
Before hoisting, secure a working area around the part to

be lifted and prohibit the entry of unrelated personnel.
Hoisting method:
Hoist the part parallel to the ground while paying attention

to the center of gravity.
Do NOT permit any person to stand under the part being

lifted.
Pay attention to and ensure that all persons are clear of the
equipment being lifted.
Hoisting point:
Do NOT hoist any parts from a position other than the

specified hoisting points.
Unpacking:
Do NOT unpack any part until it is located in the designated

location.
Protection of machine:
Avoid any impact to the unpacked parts.
MM-M05.08
Rev.000
Mitsubishi
1-17
Chapter 1
1.4.2.13
a)
Safety
Disposal
Water disposal including oily drain
The water is disposed to the plant drain system. The water must
be carefully disposed according to materials contained in the
water. The water drain system is separated into three categories
that are rain water, chemical water and oily water.
The waste waters are treated and then discharged to the public
drain system.
b)
Chemical disposal
Chemicals must be handled following the instruction of MSDS
and disposed in the chemical drain system.
c)
Solid disposal made by maintenance work.
MM-M05.08
Rev.000
For disposal from the site, observe the local legal regulations.
Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure
1.5.1 Evacuation in an Emergency
1.5.1.1
Evacuation Route
Following items are considered on design and installation of
emergency evacuation.
IMPORTANT
Each building installed in the plant is provided with at least

two exits. A clear indication of the exits can be seen from
anywhere in the building as the exit sign is illuminated using
the emergency power supply.
Evacuation routes are indicated on each floor of the building,

directing personnel to the exits.
Keep the evacuation routes completely free from materials

and tools.
1.5.1.2 Evacuation of Disabled Persons Who Cannot

Move by Themselves
The following are necessary items, prepared for emergency
evacuation:
IMPORTANT
It is recommended to keep a stretcher available for
emergencies at the places selected as being secure at the
safety meeting.
If you find this kind of accident, inform the rescue team, and
attempt to bring the collapsed person to the first aid station.
MM-M05.08
Rev.000
Mitsubishi
1-19
Chapter 1
Safety
1.5.1.3 Evacuation from the Power House

Following are guidance for the evacuation from the power
house.
IMPORTANT
An evacuation place for personnel to gather in after evacuation
from the power house in an emergency must be predetermined
and explained beforehand in the emergency training.
Evacuation directive must be given by the responsible person

such as Shift Charge Engineer, and all personnel must be
alerted in the power house repeatedly with an available
broadcast facility.
All people working in the power house must stop there work
immediately and leave the power house to the gathering place.
When evacuated to the evacuation place, make sure

that there is no one missing.
MM-M05.08
Rev.000
Mitsubishi
1-20
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT
Clearly show the location of fire alarm push button and fire
extinguisher to make everybody take the first step at fire
protection.
Inform everyone concerned that a fire has now started if you

discover a fire.
Start fire fighting using the fire extinguisher located near the
fire site.
The operators must check the plant is ready for trip, and wait
for order from the responsible person.
The operator and other personnel must transfer the fire

fighting to the fire fighting team when they arrive at the fire
site and the operators must wait for instruction from the Shift
Charge Engineer. All other personnel must immediately start
evacuation.
If unit trip is decided, the operator must trip the plant

manually.
The operators must evacuate from the power house according

to the instruction of the responsible person immediately after
shutdown of the unit.
If the fire is extinguished successfully, the operators should

return to the power house as required by the Shift Charge
Engineer and start inspection of the equipment for restart of
the unit.
Based on the inspection, the responsible person should

decide whether to operate the unit again or shutdown for
repairing.
After the inspection or repair, and then checking the

equipment and/or system, start up the unit again.
MM-M05.08
Rev.000
Mitsubishi
1-21
Chapter 1
Safety
1.5.3 Earthquake
In the case of an earthquake, the shift charge engineer or operator
must judge whether the unit trip is necessary according to the intensity
of the earthquake, and immediately trip the unit manually. If the unit is
tripped, all equipment must be carefully checked on its operation status
and tripped if abnormal phenomena are found.
In the local area, mechanical and/or thermal shocks may be given to
the equipment, piping, instruments and electrical panels. Be sure to
observe the following when completing the inspection.
Check that the lubricating oil pump is running. Bearings of the

equipment will be damaged if lubricating oil is not supplied.
Check the piping and equipment for steam and water leakage.
The steam or high temperature water leakage may cause
serious injury to the personnel and it must be repaired at an
early stage of the leakage.
Check the pulverizers and / or coal silos for signs of a fire. If a

coal fire does start, make sure that CO2 fire fighting system is
properly operated.
Check the position of boiler seismic stopper. Since the boiler

seismic stopper must be anchored at the original position, the
boiler cannot be re-started if the slippage is found. If the
stopper is not at the original position, please contact MHI.
CAUTION
Check the piping and equipment for the breaking and the
dropping of insulation. Since the exposure of the hot surface
may cause burn injury, it must be repaired by a worker fully
dressed in Personal Protective Equipment.
1.5.4 Explosion Accident
MM-M05.08
Rev.000
Do not use a fire in a hazardous area where the combustibles

(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or
handled. Use of a fire in a hazardous area could cause serious
injury to personnel and serious damage to equipment due to
an explosion.
Mitsubishi
1-22
Chapter 1
1.6
Safety
Qualification and Training

The system must be operated only by authorized operators & maintenance
supervisors.
The customer must authorize all operators and maintainers, who are involved in
the operation and maintenance of this plant, either by the training course given
by Mitsubishi, or by the customers own personnel assessment.
Operator and maintainer training course (both classroom training and the
On-Job-Training (OJT)) will be provided by Mitsubishi before the handing over
of this plant. The customer must train and assess each new operator and
maintainer to joins after the turn-over, according to his own procedure and
standard, (Mitsubishi training course may still be available if required).
Operator and Maintainer can read and fully understand the description of
this manual.
Operator and Maintainer can understand the related P & ID, logic diagram.
Operator and Maintainer know location of the system equipment including

pipe routes, valves and the various instruments.
Operator and Maintainer have fundamental knowledge of the function of

each equipment.
Operator can operate the equipment and the system manually at local
stations.
Operator can operate the system remotely using DCS system.
Operator can respond suitably for any kind of alarm.
Operator knows location of emergency exit on power house and is available

to provide first aid treatment.
Operator knows emergency communication system operation.
Operator and Maintainer, following the Charge Engineers instruction are

aware of the isolation method for mechanical, electrical and instrumental
equipment being prepared for safe maintenance while the unit is in
operation.
Maintainer must also be able to handle the maintenance tools provided by

the customer and those supplied by the manufacturer.
MM-M05.08
Rev.000
As a minimum, operator and maintainer must satisfy the following:
Mitsubishi
1-23
Chapter 2
General
Chapter
2 General
2.1
Purpose
The purpose of this maintenance manual is to provide specific information to the
Paiton Expansion Project operating and maintenance personnel regarding the
maintenance of the Main Oil Tank and the Turbine Oil Pumps (AOP, TOP, EOP).
Although this document will convey a good knowledge and direction regarding
maintenance of the Main Oil Tank and Turbine Oil Pumps, it is recommended
that in the event of a problem not covered in the document the person
responsible should seek assistance or instruction from the manufacturer.
References
a)
Main Oil Tank Outline Drawing (1/2, 2/2)

MHI Dwg. No. : N26-P11-6083
b)
Control and Lubrication Oil System Diagram (2/5)

Project Dwg. No. P101-51-3-TB-LT0002
MHI Dwg No: T3059AAAA210-2
c)
Control and Lubrication Oil System Diagram (4/5)

d)
Oil Purifier Oil Piping Diagram 2/2

e)
Auxiliary Oil Pump

MHI Dwg No: T3059MAY471
f)
Turning Oil Pump

g)
Emergency Oil Pump

g)
Drawing of Auxiliary Oil Pump Motor

Project Dwg. No. G101-24-1820.00-G028
MHI Dwg No: 65500-5451-028
MM-M05.08
Rev.000
2.2
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP)
Mitsubishi
2-1
Chapter 2
Drawing of Turning Oil Pump Motor

Project Dwg. No. G101-24-1820.00-G029
MHI Dwg No: 65500-5451-029
g)
Drawing of Turning Oil Pump Motor

Project Dwg. No. G101-24-1820.00-G101
MHI Dwg No: 65500-5452-002
MM-M05.08
Rev.000
h)
General
Mitsubishi
2-2
Chapter 2
2.3
General
Overview of the Main Oil Tank and the AOP, TOP & EOP
Refer to Figures 2-1 to 2-6.
The total control and lubricating oil requirements for the main turbine and its
auxiliaries are supplied by the Main Turbine Control and Lubrication Oil System.
The main turbine oil system consists of a main oil tank with oil pumps, oil
coolers, oil filters, vapor extractor, oil mist separator, etc. for meeting the above
lubricating and control oil requirements. The details of the major components
related to the Main Turbine Control and Lubrication Oil System are described in
this maintenance manual.
The main oil tank is the central part of the main turbine lubricating oil system in
which the turbine lubricating and control oil are collected, stored and distributed
to the turbine, generator and exciter bearings, the turbine protective devices and
the steam admission valves. The stored oil in the main oil tank is distributed to
the bearings and the protective devices through any of the turbine oil pumps as
per the operating requirement. The main turbine oil system is provided with a
main oil pump (MOP), an auxiliary oil pump (AOP), a turning oil pump (TOP)
and an emergency oil pump (EOP) for this purpose.
The main oil tank is a circular steel tank located below the mezzanine floor on
the ground floor of the Turbine Building. The lubricating and the control oil are
returned to the main oil tank under gravity by virtue of the elevation difference
between the bearings, the steam admission valves and the main oil tank.
The main oil tank has a maximum level, (High Alarm) of 40,180 liters with a
normal working level of 36,800 liters, and a low working level of 33,310 liters
sufficient to provide all oil requirements of the turbine generator. The working
range between the High and Low levels provides an operating oil quantity of
6,870 liters. The main oil tank, under normal operating conditions, provides
sufficient oil dwell time within the tank to permit the release of non-condensable
gases and the settlement of fine particulate debris in the tank.
The MOP is installed on the HP-IP turbine rotor extension shaft and the AOP,
TOP and EOP are mounted on the main oil tank. The discharge lines of these
pumps are suitably interconnected with check valves inside the main oil tank to
permit oil distribution at any operating condition. Details on the construction and
maintenance for the MOP are provided in the mechanical maintenance manual
No. M-05.06, Turbine Main Oil Pump and for the remaining turbine oil pumps
refer to this mechanical maintenance manual No. M-05.08, Turbine Main Oil
Tank and Auxiliary Pumps (AOP, TOP, EOP).
MM-M05.08
Rev.000
The four oil pumps (MOP, AOP, TOP and EOP) together with two water cooled
oil coolers and two sets of oil filters supply clean filtered oil to the turbine
bearings and the turbine protection devices at the desired pressure and
temperature.
Mitsubishi
2-3
Chapter 2
General
Oil from the turbine-generator bearings and the turbine protective devices is
returned to the main oil tank through a return oil strainer installed inside the
main oil tank.
The hot oil in the main oil tank returned from the turbine-generator bearings is
cooled to the desired temperature by two water-cooled oil coolers, one working
and one standby. Cooling water for the oil coolers is supplied from the Closed
Cycle Cooling Water (CCCW) System.
The oil piping downstream of the oil coolers is provided with a spring loaded
relief valve to maintain the lubricating oil pressure to the bearings between 1.0
and 1.8 barg. This is achieved by continuously relieving the excess oil into the
main oil tank.
The main oil tank is provided with a 17 m3/min AC motor driven vapor extractor
fan to evacuate air, oil vapor and non-condensable gases from the main oil tank.
This evacuation by the vapor extractor fan maintains a slight negative pressure
inside the main oil tank. Thus the turbine bearing pedestals are also maintained
under vacuum as they are connected to the main oil tank via the drain guard
pipe. The vacuum inside the bearing pedestal prevents leakage of oil or oil
vapor along the turbine shaft.
The vapor extractor fans discharge the oil vapor and the non-condensable
gases to atmosphere through an oil mist separator. Oil collected in the vapor
extractor fan casing and the oil mist separator is returned to the main oil tank
through U- loop seals.
Local and remote oil level indications for the main oil tank are provided by level
gauge and level switches. The level in the main oil tank is maintained between
the high and the low working levels during operation. Loss of oil due to
evaporation or leakage is topped up with fresh oil by a common storage oil
transfer pump. The common storage oil transfer pump draws suction oil from
either of the clean oil and dirty oil storage tanks and discharges either to the
main oil tank or to the oil purifier.
MM-M05.08
Rev.000
The drain line of the main oil tank is connected to an oil transfer pump to transfer
oil from the main oil tank to the clean/dirty oil storage tank. Excess oil in the
main oil tank during operation can be pumped to the clean oil storage tank
through the oil transfer pump. The oil in the main oil tank can also be transferred
to the dirty oil storage tank through the oil transfer pump if the entire oil is to be
replaced due to contamination or ageing.
The main oil tank drain line is lock-closed and is only opened during the transfer
of oil from the main oil tank or to obtain oil samples during shut-down. For
sampling purposes a sampling connection is provided on the tank drain line
downstream of the drain valve. Another sampling connection provided in the
main oil tank overflow line permits sampling of the circulating lube oil during
turbine operation enabling the operator to evaluate the necessity of continuous
usage of the oil purifier.
Mitsubishi
2-4
Chapter 2
General
MM-M05.08
Rev.000
The main oil tank is provided with an oil purifier unit to filter the oil in the main oil
tank during operation. The main oil tank is connected to the oil purifier suction
through the overflow and the drain lines. Oil to the oil purifier unit is supplied
through the overflow line for purification during turbine operation and through
the drain line during unit shut-down. Oil after purification can be transferred
either to the main oil tank or to the clean oil storage tank. The construction,
operation and maintenance of the oil purifier unit, refer to the vendor operation
and maintenance manual No. OM-02.03, Oil Purifier.
Mitsubishi
2-5
Chapter 2
General
CONN. TO ROAD TANKER FOR INLET OIL
OIL MAKE-UP
WEATHER CAP
MIST
SEPARATOR
VAPOR
EXTRACTOR
LI
91
TURBINE OIL STORAGE TANK
DAMPER
M
LUBE.OIL
(TO BEARING)
LUBE.OIL
(FROM MAIN OIL TANK)
BEARING
OIL PUMP
TURNING
GEAR
OIL PUMP
OIL PUMP
FROM BFPT-A
CONN. TO
ROAD TANKER @
FOR OUTLET OIL
LUBE OIL
STRAINER(A)
LUBE OIL
STRAINER(B)
TURBINE OIL
COOLER (A)
TURBINE OIL
COOLER (A)
OVERFLOW PIPE
SAMPLING
SAMPLING
FROM BFPT-B
PI
92
MAIN OIL TANK
L.C
OIL SUPPLY PUMP
PI
91
SAMPLING
OIL TRANSFER PUMP
OIL PURIFIER
COALESCER
FILTER
LS
92
LS
93
LI
92
DPI
93
PI
95
R.V
DPI
94
SAMPLING
TO BFPT-B
HH
TO BFPT-A
LS
91
FROM BFPT-B
FROM BFPT-A
DCS
OIL PURIFIER
INLET PUMP
SV
6
MM-M05.08
Rev.000
LOCAL
CONTROL
PANEL
MPTD-3-0752
FIGURE 2-1
Mitsubishi
OIL PURIFIER, OIL PIPING DIAGRAM

2-6
Chapter 2
N-15
General
N-16
HOLE
N-6
C
DRAIN GUARD PIPE
N-17
M.O.P SUCTION PIPE
190
25
190
AIR VENT PIPE
DRAIN
HP. OIL PIPE
N-14
N-14
BRG. OIL SUPPLY PIPE
M.O.P DISCHARGE PIPE
N-12
175 175 185
N-5
VIEW A
N-9
RETURN OIL FILTER
MAIN OIL TANK

BRG. OIL INLET 250A
(TO OIL COOLER)
PRESSURE
GAUGE PANEL
BRG. OIL INLET 250A

(FROM OIL COOLER)
AC TURNING OIL PUMP
DC EMERGENCY OIL PUMP
PRESSURE
GAUGE PANEL
MAN HOLE COVER

OIL LEVEL GAUGE
DC EMERGENCY OIL PUMP
TO PRESSURE
GAUGE PANEL
AC AUXILIARY OIL PUMP
N-1
MEZZANINE FLOOR
N-7
N-7
CL MAIN OIL TANK
N-3
380
MAX. LEVEL
NOR. LEVEL
LOW. LEVEL
150 150
N-8
N-2
N-9
N-4
MM-M05.08
Rev.000
SLIDING SUPPORT
FIXED SUPPORT
SLIDING SUPPORT
GLOUND FLOOR
MPTD-3-0481
FIGURE 2-2
Mitsubishi
SCHEMATIC ARRANGEMENT OF MAIN OIL TANK AND ASSOCIATED EQUIPMENT

2-7
Chapter 2
General
OIL LEVEL GAUGE
MAN HOLE COVER
PRESSURE GAUGE PANEL
MM-M05.08
Rev.000
LUBE OIL INLET PIPE

(FROM COOLER)
LUBE OIL OUTLET PIPE
(TO COOLER)
RETURN OIL STRAINER
FIGURE 2-3
Mitsubishi
ARRANGEMENT OF MAIN OIL TANK

2-8
Chapter 2
General
O IL L E V EL G AU G E
M A N H O L E C O VE R
Rev.000
PR ESSU RE GAUGE PANEL
LU B E O IL IN LE T PIP E
(F R O M C O O LE R )
L U B E O IL O U T LE T P IP E
(T O C O O L ER )
MM-M05.08
R E T U R N O IL ST R A IN E R
FIGURE 2-4
Mitsubishi
PARTIALLY EXPLODED VIEW OF MAIN OIL TANK

2-9
Chapter 2
2.4
General
Construction
The main oil tank is a circular, horizontal fabricated steel tank which has a
nominal storage capacity of 36,800 liters at the NWL, sufficient to provide the
lube oil requirements of the turbine and the generator. The tank has a capacity
of 40,180 liters at the maximum operating level and 33,310 liters at the minimum
operating level.
The main oil tank is supported on a steel support frame fabricated from channel
beams and grouted to a concrete foundation. The outside surfaces of the main
oil tank are welded with stiffeners at regular intervals to provide rigidity to the
tank.
The main oil tank is provided with an earthing terminal, which is connected to
the plant electrical grounding system, to discharge any leakage of current on the
main oil tank to the earth.
Stools are provided on top of the main oil tank onto which the AOP, TOP and
EOP are mounted. The pumps extend down into the oil tank such that their
suctions are located well below the low oil level.
Within the main oil tank, the high pressure oil discharged from the MOP or AOP
(HP pump) enters a control oil line, which is further connected to the turbine
protective devices and the steam admission valves. Likewise, the low pressure
oil discharged from the AOP, TOP or EOP enters a common lube oil header,
which also receives oil from the No. 2 oil ejector, providing a single lubricating oil
line. A bearing oil pressure regulating (relief) valve (Figure 2-23) installed in the
lubricating oil line, downstream of the lubricating oil filter, maintains the lube oil
pressure at a near constant value by continuously relieving excess oil.
The main oil tank is provided with nozzles for the termination of the turbine lube
oil drain guard pipe, vents from oil coolers, tank oil temperature indicators, tank
drain, filter drains, tank overflow, oil supply and return lines for oil coolers and oil
purifier. The main oil tank is also provided with nozzles for the installation of the
oil level gauge, level switches and for connecting the vapor extractor fan suction
pipe.
MM-M05.08
Rev.000
A duplex type lube oil filter is installed on a grating extension at the top of the
main oil tank. A basket type filter is located inside the tank to filter all oil
returning to the tank. A hinged door installed above the strainer provides access
for the removal of the filter for cleaning or maintenance.
A cantilevered extension of the grating at the top of the main oil tank is provided
to support the vapor extractor fan.
A manhole cover on the top of the tank provides access for internal inspection
and maintenance. The main oil tank is also provided with bolted doors at the top
for adjusting oil supply adjustable check valve for the MOP, adjustable check
valve for bearing oil and bearing oil pressure regulating valve.
Mitsubishi
2-10
Chapter 2
General
A pressure gauge panel is provided on the tank to indicate the oil pump
discharge pressures, main oil tank vacuum and the lubricating oil pressure after
the cooler.
The main oil tank is provided with a ladder to provide access to the equipment
installed on the top of the tank. Handrails are installed at the top of the oil tank to
provide safety for the operating and maintenance personnel.
The major equipment associated with the main oil tank and the turbine
lubricating oil system are the following:
Oil pumps
Vapor extractor fan
Oil mist separator
Oil ejectors
Oil level indicators
Oil strainers
Oil cooler.
2.4.1 Oil Pumps

The AOP, TOP and EOP are installed vertically on stools welded to the
top of the main oil tank.
The AOP is of the shaft type consisting of three impellers which are
installed on a common pump shaft driven by an electrical motor. The
pump is of the three stage centrifugal pump and delivers 100 l/min of oil
at a pressure of 1.08 MPa. The AOP is driven by a 150 kW, 380 V AC,
50Hz motor at a speed of 2950 rpm.
The TOP is of the vertically mounted single stage centrifugal type oil
pump. The TOP delivers 6100 l/min of oil at a pressure of 0.34 MPa
and is driven by a 65 kW, 380 V AC, 50Hz motor at a speed of 1480
rpm.
The EOP is also of the vertically mounted single stage centrifugal type
oil pump. The EOP delivers 5800 l/min of oil at a pressure of 0.35 MPa
and is driven by a 65 kW, 250 V DC motor at a speed of 1480 rpm.
MM-M05.08
Rev.000
The AOP, TOP and EOP are provided with suction strainers, at the
pump inlets, to prevent entry of foreign material during operation.
The discharges of the AOP pump, TOP and EOP are connected within
the main oil tank to provide a common lubricating oil line. Likewise the
discharges of the AOP HP pump and the MOP are connected together
to provide a single HP oil line. Check valves are installed in the
discharge line of each pump to prevent reverse rotation of the standby
pumps.
Mitsubishi
2-11
Chapter 2
General
2.4.2 Vapor Extractor Fan

Refer to Figure 2-16.
The vapor extractor fan is of the single stage centrifugal type. It draws
suction from the main oil tank and discharges the oil vapor and
non-condensable gases to the atmosphere.
The vapor extractor fan maintains a slight vacuum inside the main oil
tank. The turbine and generator bearing pedestals connected to the
main oil tank via the lube oil return line are also under a slight vacuum.
The vacuum in the bearing pedestal prevents leakage of oil or oil vapor
along the turbine shaft.
The extractor fan is also provided with a butterfly damper at the suction
side to adjust gas flow and hence vacuum in the main oil tank.
The vapor extractor fan consists of a volute casing (1) which encloses
an impeller (2). The impeller is formed from two flat discs enclosing
narrow vanes between them. The inlet side disc is shaped to provide
an opening and a boss to allow the flow of incoming gases. The
impeller is bolted to an impeller hub (3) and the whole assembly is
keyed onto the motor shaft (4) and secured with an impeller set bolt (7)
and a retainer plate (21). The impeller is overhung inside the volute
casing and is supported by the bearings of the drive motor (11).
The fan casing is a steel fabricated component which is made in two
parts; a casing (1) and a front cover (22). The casing is secured to the
motor base frame (12) by welding. The front cover is welded onto the
suction cone (5) and is bolted to the fan casing using the suction cone
set bolts (6) such that the cone is set inside the impeller boss with a
small running clearance. The suction damper (14) is installed in the
suction cone adjacent to the suction cone inlet flange (23).
The fan casing is provided with a drain pipe (13) to drain any liquid
trapped in the fan casing. Any oil droplet collected in the fan casing is
drained into the main oil tank overflow line through a U-loop seal.
MM-M05.08
Rev.000
The suction cone, the fan casing and the discharge pipe are shaped to
smoothly guide the flow of air and vapor to promote efficient
performance of the fan. The suction cone and the discharge pipe are
flanged for connection to their respective ducts.
An oil seal assembly is provided on the fan casing, where the shaft
penetrates the casing, to prevent leakage of oil droplets and/or vapor
along the shaft. The oil seal assembly consists of an oil seal housing
(20) which is secured to the fan rear casing by welding. The shaft seal
consists of two oil seal rings (10) mounted one on either side of a
grease-packed lantern-ring (9) inside the oil seal housing and secured
by a retainer ring (19).
Mitsubishi
2-12
Chapter 2
General
A grease nipple (15) is provided on the top of the oil seal housing to
facilitate injection of seal lubrication during operation and a drain line
with a cock (16) at the bottom to drain the spent grease.
The impeller is rotated by a 3.7 kW, 400 V induction motor (11) at 3500
rpm. The motor is mounted on a bracket welded to the base frame.
2.4.3 Oil Mist Separator

The oil mist separator is installed at the exit of the discharge line of the
vapor extractor fan to remove any traces of oil present in the oil vapor.
The oil mist separator consists of a shell (3) in which six demister
cartridges (5) are arranged in a circle. The shell is divided into two
compartments, the inlet compartment (22) and the outlet compartment
(23). The gas vapor enters the inlet compartment and passes through
the six cartridges which are arranged in the outlet compartment. Each
demister cartridge is secured to the compartment division plate with an
element holder (6), tie-bolts (7) and nuts (8).
The shell is flanged at the top end and is closed with a cover (1). The
flanged joint between the shell and the cover is sealed by an O-ring (9)
using bolts (10) and nuts (11).
Drain connections (12) are provided both in the inlet and the outlet
compartments. The oil droplets present in the oil vapor are trapped by
the cartridges and returned to the inlet compartment, then to the main
oil tank through a U-loop seal.
2.4.4 Oil Ejectors

Two oil ejectors (No. 1 and No. 2 oil ejectors) are installed within the
main oil tank, one on the suction line of the MOP and the other on the
lubricating oil line as indicated in Figure 2-6.
MM-M05.08
Rev.000
The No. 1 oil ejector draws oil from the main oil tank and discharges to
the suction of the MOP. The No. 2 oil ejector discharges the oil drawn
from the main oil tank to the turbine bearing lubricating oil header.
Each oil ejector consists of an inlet pipe (16), a nozzle block (5), a
diffuser (15) and a check plate (1). The ejectors draw oil from the main
oil tank by virtue of the vacuum developed by the motive oil flow from
the discharge of the MOP through the nozzles. The check plate
provided around the nozzle box prevents back-flow of oil into the main
oil tank when the MOP is not in service. The ejector draws oil from the
main oil tank through a suction strainer (17).
Mitsubishi
2-13
Chapter 2
General
2.4.5 Oil Level Gauge

A float type level gauge is provided on the top of the tank to indicate the
oil level locally. The oil level gauge consists of a hollow polypropylene
float (1) which is in contact the oil inside the main oil tank from where a
float rod (2) extends upwards from the main oil tank.
The float is guided within a circular body (16) and the float rod within a
flange (3) during its vertical movement. An indicator (7) secured at the
top end of the float rod moves vertically indicating the actual level in the
oil tank. A graduation pipe (8), made of acrylic material and secured
between the flange (3) and the upper flange (11), provides the actual
indication of the tank level. A cover (13) secured between the flange (3)
and the upper flange (11) prevents entry of dust into the main oil tank
through the gap between the float rod (2) and the flange (3).
Two level switches/contacts (5 and 10) are installed on the stud bolt (6)
to provide remote high and low level alarms in the central control room
(CCR). An alarm is initiated in the CCR to alert the operators when the
oil level in the tank exceeds the low or high contacts.
2.4.6 Oil Strainers

The main turbine lubricating oil system is provided with a lube oil
strainer, and a return oil strainer to ensure trouble-free operation of the
main turbine.
Lube Oil Strainer

MM-M05.08
Rev.000
The lube oil strainer provided in the bearing lube oil supply line is of the
duplex type. It consists of a twin body (1) interconnected by a cock plug,
each body containing one filter element (31). The cock plug directs the
unfiltered oil to the selected filter and the filtered oil to the outlet line. A
cock handle (11) enables selection of one of the filters when moved to
the extreme position. Positioning of the cock handle in the mid-position
enables both filter elements to be in service. This ensures a smooth
change over of the filter elements. The adjusting handle (21) enables
locking of the cock handle in position after a change-over. The
adjusting handle is moved up by rotating it in the anti-clockwise
direction and the cock handle is changed over and then the adjusting
handle is turned in the clockwise direction to lock the cock plug.
Each filter body is provided with a cover (2), which is held in position by
stud bolt (16) arrangement, for easy removal and replacement of the
filter element. Each filter element is provided with a handle (34) at the
top, which abuts the body cover and secures the filter element tightly to
the filter brim. An O-ring (19) inserted between the filter cover and the
filter body prevents oil leakage.
Mitsubishi
2-14
Chapter 2
General
Each filter body is provided with a drain plug (36) and an air vent (40)
with isolating valves to drain and replace oil during filter maintenance.
An equalizing line is provided with an equalizing valve (42) between the
two filter element bodies to enable filling oil after maintenance, thereby
avoiding a pressure drop during filter changeover. The equalizing valve
is normally in the closed position and is opened only to fill the standby
filter body.
Inlet and outlet nozzles are cast integral with the body and are
connected to the change over plug chamber through internal passages.
Return Oil Strainer

The return oil strainer is of the vertical, cylindrical, basket type. The
cylindrical strainer body is fabricated from steel SS400 and the filter
element is wire gauze made from SUS304W.
The strainer assembly consists of a cylindrical body (3) onto which a
wire gauze set (10, 11) is secured using countersunk screws (12, 15)
and bolts (13). The wire gauze set consists of an 80 mesh sandwiched
between a 6 mesh and a 16 mesh for normal turbine operation.
The strainer is also provided with an additional 100 wire mesh set to be
used during turbine oil flushing.
The return oil strainer is placed inside the return oil compartment within
the main oil tank. The return oil enters through the inlet to the strainer
and flows outwards thus retaining any debris contained in the returning
oil. The main oil tank is provided with a hinged cover above the filter for
periodical inspection and cleaning of the strainer.
2.4.7 Oil Cooler

The main turbine lubricating oil system is provided with two plate type
oil coolers for the temperature control of oil in the main oil tank. A
transfer valve installed between the two oil coolers enables the
selection of the oil cooler to be in service.
MM-M05.08
Rev.000
The oil cooler consists of several heat transfer plates (3) arranged in a
line between a fixed S-frame (1) located at the front and a movable
E-frame (2). The heat transfer plates are arranged in a line and held
together by the E-frame. The E-frame is tightened uniformly by ten
tightening bolts (7) and nuts (8) to provide a leak-tight joint between the
adjacent heat transfer plates.
The heat transfer plates and the E-frame are supported in a lower
guide bar (4) at the bottom and guided by an upper guide bar (5) at the
top. The lower guide bar and the upper guide bar are supported by the
S-frame (1) at the front end and a guide bar support (6) at the rear end.
Mitsubishi
2-15
Chapter 2
General
The entire cooler assembly is supported by the S-frame and the guide
bar support by bolting them to the concrete foundation.
The S-frame contains the supply and return nozzles for both lubricating
oil and cooling water. Hot oil enters the bottom right nozzle (S4) and
leaves the top right nozzle (S2) whereas the cooling water enters the
top left nozzle (S1) and leaves the bottom left nozzle (S3).
MM-M05.08
Rev.000
For further details about the turbine oil cooler, refer to the vendor
operation and maintenance manual No. OM 02.01, Turbine Oil
Cooler.
Mitsubishi
2-16
Chapter 2
General
O IL LEVEL G AUG E
M AN HO LE CO VER
NO .2 O IL EJECTOR
MM-M05.08
Rev.000
SLID ING SU PPO RT
FIGURE 2-5
Mitsubishi
CUTAWAY VIEW OF THE MAIN OIL TANK

2-17
General
DRAIN GUARD PIPE

900A
AIR VENT
MAIN BRG. OIL
MAIN OIL PUMP DISCHARGE
PRESSURE GAUGE PANEL
HP OIL
MAIN OIL PUMP SUCTION
Chapter 2
65A
8A
25A
OIL COOLER AIR VENT
25A
B
C
50A
100A
50A
100A
ANGLE TYPE
CHECK VALVE
BFPT OIL INLET
100A
PURIFIED OIL INLET

LUBE OIL STRAINER
STRAINER (A)
25A
80A
80A
25A
20A
200A
250A
6-WAY VALVE
250A
200A
200A
(B)
80A
125A
200A
ORIFICE
ORIFICE
250A
OIL
COOLER
250A
250A
MAIN OIL TANK INTERNAL PIPING DIAGRAM
200A
(A)
200A
200A
20A
MPTD-3-0484(B)
MM-M05.08
Rev.000
LUBE OIL STRAINER

STRAINER (B)
250A
125A
No.2EJECTOR
250A
MOP
80A
200A
200A
NON-RETURN
VALVE
No.1EJECTOR
200A
80A
250A
BRG
100A
80A
25A
250A
OIL COOLER
O10
TO OIL PURIFIER
15A
15A
15A
O5
15A
DRAIN
BOX
50A
RELIEF VALVE
125A
STRAINER
100A
250A
AOP
AC
250A
TOP
AC
250A
EOP
DC
8A
8A
8A
8A
MAIN OIL TANK
FIGURE 2-6
Mitsubishi
MAIN OIL TANK (INTERNAL PIPING)

2-18
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-7
Mitsubishi
ISOMETRIC VIEW OF THE AUXILIARY OIL PUMP

2-19
MM-M05.08
Rev.000
Mitsubishi
FIGURE 2-8
MPTD-3-0486
STRAINER
CASING
(1st STAGE)
CASING
(2nd STAGE)
AIR VENT
AIR VENT
CASING
(3rd STAGE)
SLEEVE BEARING
OIL FLINGER
OIL SEAL
PUMP FRAME
SUCTION COVER (LP)
IMPELLER
(1st STAGE)
SLEEVE BEARING
IMPELLER
(2nd STAGE)
SLEEVE BEARING
IMPELLER
(3rd STAGE)
COLUMN PIPE
SHAFT
THRUST BEARING
BEARING COVER
COUPLING
MOTOR
Chapter 2
General
CUTAWAY VIEW OF THE AUXILIARY OIL PUMP

2-20
MM-M05.08
Mitsubishi
37
52b
25
27
28
32
36
23
21
17
FIGURE 2-9
26
31
30
11
45
DETAIL OF "X"
48a 49a 50a 51a
12
14
15
48c 49c 50c 51c
53
18
48e 49e 50e 51e
40
41
44
43
Rev.000
13c
38
13a
22
24
52a
13b
56
47
49d 49e 49f
49a 49b 49c
DETAIL OF "Y"
50d 50e 50f
50a 50b 50c
48d 48e 48f
AIR VENT
HEXAGONAL HEAD BOLT
DRIVE MOTOR
BOLTS, MOTOR TO FRAME
BOLTS, FRAME TO M.O.T
SET SCREW
SET SCREW
IMPELLER RING
CASING RING
PUMP FRAME
COLUMN PIPE
SHAFT
1st STAGE CASING
1st STAGE IMPELLER
SUCTION COVER
STRAINER
IMPELLER NUT
IMPELLER WASHER
LOCK PLATE
IMPELLER KEY
HEXAGONAL HEAD BOLT
SCREW
SLEEVE BEARING
SHAFT SLEEVE
O-RING
2nd STAGE CASING
SHAFT SLEEVE
2nd STAGE IMPELLER
O-RING
IMPELLER KEY
SLEEVE BEARING
HEXAGONAL HEAD BOLT
O-RING
IMPELLER KEY
SLEEVE BEARING
3rd STAGE CASING
HEXAGONAL HEAD BOLT
3rd STAGE IMPELLER
THRUST (BALL) BEARING
COLLAR
BEARING NUT
BEARING WASHER
OIL FEED TUBE
OIL FLINGER
OIL SEAL
HEXAGONAL HEAD BOLT
KNOCK BOLT
BEARING COVER
V-RING
COUPLING HALF (PUMP)
COUPLING HALF (MOTOR)
COUPLING BOLT & NUT
COUPLING BUSH
KEY
COUPLING COVER
HEXAGONAL HEAD BOLT
DESCRIPTION
51d 51e 51f
1
2
3
4
5
6
7
8
9
10
11
12
13a,b,c
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48a,b,c,
d,e,f
49a,b,c,
d,e,f
50a,b,c,
d,e,f
51a,b,c,
d,e,f
52 a,b
53
54
55
56
ITEM
48a 48b 48c
16
48b 49b 50b 51b
20
19
"X"
34
33
35
38
39
42
55
51a 51b 51c
10
"Y"
46
Chapter 2
General
SECTIONAL VIEW OF THE AUXILIARY OIL PUMP

2-21
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-10
Mitsubishi
ISOMETRIC VIEW OF THE TURNING OIL PUMP

2-22
MM-M05.08
Rev.000
Mitsubishi
FIGURE 2-11
MPTD-3-0489
PUMP CASING
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
OIL FLINGER
STRAINER
SUCTION COVER
IMPELLER
SLEEVE BEARING
BEARING COVER
Chapter 2
General
CUTAWAY VIEW OF THE TURNING OIL PUMP

2-23
Rev.000
MSD-3-0584
MM-M05.08
DETAIL OF "X"
Mitsubishi
27
10
48
DESCRIPTION
29
33
PUMP FRAME
COUPLING COVER (SAFETY)
COUPLING BUSH
COUPLING BOLT & NUT
HEX. BOLT / SPRING WASHER
BEARING COVER
V. RING
OIL SEAL
OIL FLINGER
BEARING NUT
BEARING WASHER
THRUST BEARING
COLLAR
TUBE CONNECTOR
OIL FEED TUBE
HEX. HEAD BOLT & WASHER
SUCTION STRAINER
SUCTION COVER
IMPELLER NUT
IMPELLER WASHER
LOCK PLATE
IMPELLER
IMPELLER KEY
CASING RING
CASING RING
IMPELLER RING
IMPELLER RING
KNOCK BOLT, NUT, WASHER
HEX. HEAD BOLT & LOCK WASHER
HEX. SOCKET SET SCREW
PUMP CASING
SLEEVE BEARING
PLUG
TUBE CONNECTOR
O-RING
KEY (COUPLING)
SHAFT
COLUMN PIPE
AIR VENT PLUG
DRIVE MOTOR
DETAIL OF "Y"
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
ITEM
Chapter 2
General
FIGURE 2-12 SECTIONAL VIEW OF THE TURNING OIL PUMP

2-24
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-13
Mitsubishi
ISOMETRIC VIEW OF THE EMERGENCY OIL PUMP

2-25
PUMP CASING
STRAINER
SUCTION COVER
IMPELLER
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
General
MM-M05.08
Rev.000
OIL FLINGER
SLEEVE BEARING
BEARING COVER
Chapter 2
FIGURE 2-14
Mitsubishi
CUTAWAY VIEW OF THE EMERGENCY OIL PUMP

2-26
MM-M05.08
45
10
Rev.000
Mitsubishi
18
20
29
21
19
22
33
28
31
32
36
41
42
15
14
12
14
DETAIL OF "X"
40
23
27
39
25
24
35
26
37
17
13
16
44
33
29
24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
27
20
33
PUMP FRAME
COUPLING COVER
COUPLING BUSH
COUPLING BOLT & NUT
BOLT / SPRING WASHER
BEARING COVER
V. RING
OIL SEAL
OIL FLINGER
BEARING NUT
BEARING WASHER
THRUST BEARING
COLLAR
TUBE CONNECTOR
OIL FEED TUBE
HEAD BOLT & WASHER
SUCTION STRAINER
SUCTION COVER
IMPELLER NUT
IMPELLER WASHER
LOCK PLATE
IMPELLER
IMPELLER KEY
CASING RING
CASING RING
IMPELLER RING
IMPELLER RING
HEAD BOLT & LOCK WASHER
SOCKET SET SCREW
SOCKET SET SCREW
PUMP CASING
SLEEVE BEARING
PLUG
TUBE CONNECTOR
O-RING
KEY (COUPLING)
SHAFT
COLUMN PIPE
AIR VENT PLUG
SOCKET SET SCREW
DESCRIPTION
DETAIL OF "Y"
ITEM
Chapter 2
General
FIGURE 2-15 SECTIONAL VIEW OF THE EMERGENCY OIL PUMP

2-27
Chapter 2
General
15
17
9
19
10
8
VIEW A - A
4
21
20
DETAIL OF SHAFT SEAL
24
1
6
2
24
14
15
20
11
23
5
18
12
Rev.000
MM-M05.08
16
16
22
13
MPTD-3-0494
FIGURE 2-16 SECTIONAL VIEW OF THE VAPOR EXTRACTION FAN

Mitsubishi
2-28
Chapter 2
"C"
General
19 20 21
1
2
6
15
16
23
VIEW A
5
14
18
3
3
14
17
13
4
4
22
B-B
10
12
2
3
11
MM-M05.08
Rev.000
DETAIL "C"
MPTD-4-1089
FIGURE 2-17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
COVER
SHELL FLANGE
SHELL
END PLATE
DEMISTER CARTRIDGE
ELEMENT HOLDER
TIE BOLT
NUT
O-RING
BOLT
NUT
PLAIN WASHER
FLANGE
NOZZLE PIPE
FLANGE
NOZZLE PIPE
DRAIN CONNECTION
NAME PLATE
EYE NUT
BOLT
PLAIN WASHER
INLET COMPARTMENT
OULET COMPARTMENT
OIL MIST SEPARATOR
Mitsubishi
2-29
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-18
Mitsubishi
ARRANGEMENT OF NO. 1 & 2 OIL EJECTOR
2-30
Chapter 2
General
11
13
12
8
14
15
17
1
150
HIGH ALARM OIL LEVEL
150
NORMAL WORKING LEVEL

16
MM-M05.08
Rev.000
LOW ALARM OIL LEVEL
MPTD-4-0499
FIGURE 2-19
MAIN OIL TANK LEVEL GAUGE ASSEMBLY
Mitsubishi
2-31
Chapter 2
41
42
General
45
44
34
43
UP
S
32
30
VIEW B - B
23
18
12
20
38
17
13
24
10
16
15
2
19
22
21
14
11
35
28
24
DETAIL "C"
27
29
2
26
25
40
39
37
46
34
A
19
"C"
32
8
16
35
1
31
19
MM-M05.08
Rev.000
8
36
5
MPTD-3-0496
33
16
19
VIEW A - A
FIGURE 2-20
Mitsubishi
LUBRICATING OIL STRAINER ASSEMBLY

2-32
Chapter 2
General
10
14
12
7
16 O MESH
80 O MESH
DETAIL "A"
16O MESH
1
DETAIL "A"
10
3
14
11
6
17
7
9
16 O MESH
12
80 O MESH
10
16 O MESH
15
4
8
9
13
4
MM-M05.03
Rev.000
11
16
2
DETAIL "B"
DETAIL "B"
MPTD-3-0497
FIGURE 2-21
Mitsubishi
RETURN OIL STRAINER

2-33
Chapter 2
CW
INLET
1
2
3
4
5
6
7
8
9
10
11
12
OIL
OUTLET
S- FRAME
E- FRAME
HEAT TRANSFER PLATE
LOWER GUDE BAR
UPPER GUDE BAR
GUIDE BAR SUPPORT
TIGHTENING BOLT
NUT
S1-NOZZLE (CW INLET)
S3- NOZZLE (CW OUTLET)
S4-NOZZLE (OIL INLET)
S2- NOZZLE (OIL OUTLET)
LUBE OIL O UTLET
CW O UTLET
LUBE O IL INLET
PLATE
NO.
1
3
CW
OUTLET
CW INLET
A SIDE
General
B SIDE
D1234
PLATE
NO.
2
4
OIL
INLET
179
178
E 0000
E
PLATE ARRANGEMENT
(B) SIDE
1234
89
0234
1034
1204
1230
0034
1200
0230
1004
Rev.000
MM-M05.08
TOTAL
89
(A) SIDE
1234
88
1230
1204
1034
0234
1200
0034
0230
1004
THE POSITIONS
OF HOLE ARE
CALLED 1,2,3
AND 4. THE PART
HAVING NO HOLE
IS INDICATED
BY 0 INSTEAD
OF 1,2,3, AND 4.
* SHOWS
DRAIN HOLES
AND AIR VENT.
1
1O
O4
3O
D1234
E000
1
1
TOTAL
90
B10*4
A1234
MPTD-3-1090
FIGURE 2-22 TURBINE OIL COOLER

Mitsubishi
2-34
Chapter 2
General
14
10
19
23
18
2
20
A-A
MM-M05.08
Rev.000
MPTD-4-0498
FIGURE 2-23
BEARING OIL PRESSURE ADJUSTING VALVE
Mitsubishi
2-35
Chapter 3
Specifications
Chapter
3 Specifications
TABLE 3-1
MAIN OIL TANK
Description
Details
Equipment Number
03MAV01BB101
Quantity
1 set
Manufacturer
Mitsubishi Heavy Industries Limited
Type
Horizontal, cylindrical
Capacity at NWL
36,800 liters
Capacity at High level
40,180 liters
Capacity at Low level
33310 liters
Fluid
Turbine Oil (ISO VG32)
Tank Dimensions
8140mm x 3050mm
Weight
Empty
23.5 ton
Full
71.8 ton
TABLE 3-2
AUXILIARY OIL PUMP
Description
Details
Equipment Number
03MAV03AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
3DVCW-50B-NA
Operating condition
Liquid name
Turbine oil ISO VG 32
Capacity
100 L/min
Discharge pressure
1.08 MPa
Suction pressure
Rotation
View from driver - CW
MM-M05.08
Rev.000
Material
Discharge bore rating
ANSI 300LB-50A-FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
22kW, 380V, 3,50Hz,
Speed (synchronous)
3000 min
Weight (Pump + Motor)
(310 kg + 181kg)
-1
Mitsubishi
3-1
Chapter 3
TABLE 3-3
Specifications
TURNING OIL PUMP
Description
Details
Equipment Number
03MAV04AP101
Quantity
1 set
Manufacturer
Type
DVC-200E-NE
Operating condition
Liquid name
Capacity
6100 L/min
Discharge pressure
0.34 MPa
Suction pressure
Rotation
Construction
ANSI 150LB-200A.FF
Bearing Type
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
65kW, 380V, 3,50Hz
Speed (synchronous)
1500 min-1
(700 kg + 560kg)
TABLE 3-4
EMERGENCY OIL PUMP
Description
Details
Equipment Number
03MAV05AP101
Quantity
1 set
Manufacturer
Type
DVC-200E-NE
Operating condition
Liquid name
Capacity
5800 L/min
Discharge pressure
0.35 MPa
Suction pressure
Rotation
MM-M05.08
Rev.000
Construction
ANSI 150LB-200A.FF
Bearing Type
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
65kW, 250VDC, 3, 50Hz,
Speed
1500 min-1
(700 kg. +
1465kg)
Mitsubishi
3-2
Chapter 3
TABLE 3-5
MAIN OIL TANK VAPOR EXTRACTOR FAN
Description
Details
Equipment number
03MAV07AN101/102
Quantity
Fan
Manufacturer
Azuma Sofuki Co. Ltd.
Model
CTB-E-MD/6-75 Turbo Blower
Type
Single stage, horizontal, centrifugal type
Motor Rating
7.5 kW, 2P, 380 V AC, 3-, 50 Hz
Rotating speed
2900 rpm
Direction of rotation
Clockwise (viewed from motor end)
Capacity
17 m3/min
Static pressure
6.86 kPa at 60C
Inlet pressure
1.47 kPa
Outlet pressure
5.39 kPa
Fluid
Oil vapor
Fluid temperature (design)
60C
Major material
Impeller
SS400
Impeller hub
S45C
Casing
SS400
Blower
300 kg
Motor
62 kg
MM-M05.08
Rev.000
Weight
Specifications
Mitsubishi
3-3
Chapter 3
TABLE 3-6
Specifications
OIL MIST SEPARATOR
Description
Details
Equipment number
03MAV07AT101
Quantity
1 set
Manufacturer
Taiyo Techno Ltd.
Model
ME6-839-150/250A-V
Fluid
Air + Oil mist (ISO VG32)
Flow rate
17 m3/min
Design pressure
0.1 barg
Design temperature
80C
Operating pressure
450 mmAq (0.044 barg)
Operating temperature
60C
Differential pressure
Less than 150 mmAq (0.0147 bar) @ Normal flow
Maximum allowable differential pressure
750 mmAq (0.074 bar)
Major material
Shell
SUS304TP-A
Cover
SS304
Cartridge
Fiber glass
Oil mist separator
330 kg
Cartridge
5.5 kg x 6
Weight
TABLE 3-7
MAIN OIL TANK LEVEL GAUGE
Description
Details
Equipment number
03MAV01CL101
Quantity
1 set
Manufacturer
Demper Kogyo Co, Ltd.
Type
Float type
Fluid
Specific gravity
0.845
Range
L200-NO-H600
Float
Polypropylene
Float rod
SUS304
Gasket
V#6500
MM-M05.08
Rev.000
Major material
Mitsubishi
3-4
Chapter 3
TABLE 3-8
LUBE OIL STRAINER
Description
Details
Equipment number
03MAV10AT501/502
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Duplex
Fluid
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
Wire mesh size
P x 16 x 150 x 16
Effective filter passage area
6243 cm2
Max. allowable differential pressure (at

59C and 2800 l/min)
0.122 bar
Major
material
Body
FCD450
Filter cylinder
SUS304
Wire mesh (filter element)
SUS304
Weight
2540 kg
TABLE 3-9
RETURN OIL STRAINER
Description
Details
Equipment number
03MAV01AT501
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Basket type
Fluid
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
No. of holes
6415
Wire mesh size
80 mesh, 16 mesh, 6 mesh
Effective passage area
2474 cm2
Max. allowable differential pressure
0.03 MPa
Major
material
Filter cylinder
SS400
Wire mesh (filter element)
SUS304
Under cylinder bush
SS400
Upper cylinder bush
SS400
Weight (Approx.)
43 kg
MM-M05.08
Rev.000
Specifications
Mitsubishi
3-5
Chapter 3
TABLE 3-10
TURBINE OIL COOLER
Description
Details
Equipment number
03MAV08AC101/102
Quantity
Manufacturer
Hisaka Works, Ltd.
Type
Horizontal, Plate type
Model
UX-915-KNHP-179
Relative direction of fluids
Counter current
No. of plates
179
Heat transfer area (m2)
322.14
Heat exchanged (kW)
3694
No of passes
Specifications
Cold Side
Hot Side
Cooling Water
Oil ISO VG32
Flow rate (m /h)
600
366
Inlet temperature (C)
38.0
67.6
Outlet temperature (C)
43.3
46.0
Pressure drop (MPa)
0.068
0.042
Design pressure (MPag)
1.00
0.41
Design temperature (C)
80
80
89 x 1
89 x 1
Fluid
3
Plate arrangement
Material
SA-240-304
Plate gasket
G-NBR
Frame
SA-516 Gr60
Nozzle
SA-240-316L
Empty
5390 kg
Flooded
7330 kg
MM-M05.08
Rev.000
Weight (approx.)
Plate
Mitsubishi
3-6
Chapter 4
Chapter
4 Preventive Maintenance
Preventive maintenance is performed to avoid or minimize the possibility of failure or
deterioration of equipment performance. This requires a constant effort from
maintenance staff to ensure that the equipment is available on demand.
There are two categories of preventive maintenance, Routine Maintenance and Annual
Outage Maintenance. Routine maintenance helps to reduce the possibility of outage
and hence the downtime of machinery. Annual outage maintenance is required to
maintain the internal components of the installed equipment.
Though vendor/manufacturers recommendations provide a good basis for the
provision of a preventive maintenance schedule, the frequency and other details should
be updated from time to time based on practical experience and actual feedback
gathered through inspection and normal operation of the equipment/plant.
Consideration of these site related specific issues will make the preventive
maintenance more effective.
4.1
Prerequisites
The necessary prerequisites for the preventive maintenance of the Main Oil
Tank, Auxiliary oil Pumps and Vapor Extractor Fan are as follows:
Scheduling is the first activity in the preparation of a preventive

maintenance program; the schedule is to include planning to attend all
operating equipment on a fixed regular basis. Initially, schedules will be
prepared based on vendor/manufacturers generic instructions, the
schedules will however be updated (frequency, nature of inspection
etc.) as site-specific data becomes available. Preventive maintenance
is to be coordinated with other concerned departments. In the case of a
major scheduled outage, maintenance personnel and other concerned
departments should jointly produce a plan of activities, well in advance,
to decide the inspection activities and other logistics (such as
availability and supply of required equipment, spare parts, tools and
tackle, etc.). The schedule should clearly identify the critical path.
Priority is to be assigned to specific tasks that also involve parallel
activities to reduce the equipment downtime and to complete the work
within scheduled time.
MM-M05.08
Rev.000
4.1.1 Scheduling
Mitsubishi
4--1
Chapter 4
4.1.2 Department Interface/Notification

Departmental communication is essential and interfacing between
departments is to be maintained to avoid any lack of communication
that may arise and adversely affect routine or annual outage
maintenance work. Prior to commencing preventive maintenance all
concerned persons (shift supervisor, operators, etc.) are to be made
aware of the schedule and the nature of the activities that are to take
place. If it becomes clear that there is a problem or a conflict of
interests in the schedule (e.g. the maintenance schedule interferes with
another groups work), this is to be resolved by mutual agreement
between the parties involved.
4.1.3 Isolation of Equipment

It is important that isolations are agreed and valid clearances and work
permits are obtained before any maintenance work is performed. The
isolation boundaries of the particular equipment to be taken under
maintenance are to be clearly identified.
In the case of an electrical isolation the power supply shall be
disconnected and/or the fuses removed. In the case of mechanical
isolations, the valves or other mechanical means of isolation, at the
isolation boundaries are to be closed and if possible locked closed. The
system within the isolation boundaries is to be de-pressurized.
4.1.4 Safety Precautions
Prior to commencement of actual work the person carrying out the work
is to make a safety check based on the above method statement and
also use his own judgment to ensure that the equipment and the
prevailing working conditions are safe. During maintenance work, every
employee should follow the safe working procedures detailed in the
method statement.
MM-M05.08
Rev.000
Before the commencement of any maintenance work, the person in

charge of the work site is to perform a risk assessment and method
statement for the safe execution of the job scope activities, described
within the work permit. Risk assessment includes identifying,
recognizing and understanding the potential hazards associated with
the work. The method statement is to illustrate the safe working
practices in accordance with the safety manual and manufacturers
instruction manual to prevent personal injury and/or equipment
damage.
Mitsubishi
4--2
Chapter 4
4.2
Routine Maintenance
The purpose of routine maintenance is the implementation of the preventive
maintenance program on a day-to-day basis through a planned and correctly
executed inspection. The routine maintenance activities are very important in
that if they are properly carried out, they will enhance equipment reliability. As a
result, good routine maintenance activities may help in cost reduction in the long
run through minimization of equipment downtime.
Cleaning is an important and necessary maintenance activity to prevent the
ingress of foreign material. Other major points are as follows: (Summarized
major routine activities are also shown in Table 4-1.)
4.2.1 Preparation
a)
Parts, Tools and Equipment

It is important to prepare the necessary parts, tools and
equipment before commencing actual work. Routine
maintenance generally requires a standard mechanical toolkit,
consumables, cleaning materials etc. Any shortages of these
items will affect the maintenance activity and may delay the
schedule. Personal Protective Equipment (PPE) is necessary for
maintenance staff at all times.
Upon completion of work, all tools and equipment should be
serviced and stored correctly to ensure availability for further use.
b)
Documentation
MM-M05.08
Rev.000
Documentation is an important part of any maintenance duty. All

findings should be noted on a comprehensive log sheet, reporting
all aspects of the equipment observed during the routine
inspection. The data recorded in these documents will be useful
in determining the root cause of equipment failure found during
the annual outage/corrective maintenance work. Any
abnormalities, if observed, are to be immediately communicated
to the concerned department/personnel for rectification and are
to be detailed in the report.
Mitsubishi
4--3
Chapter 4
4.2.2 Inspection and Maintenance

a)
Main Oil Tank

Visually check the external surfaces of the tank for signs of
leakage, corrosion or damage (any damage should immediately
be reported to the supervisor).
Monitor the oil level in the main oil tank and ensure that a
continuous oil circulation is maintained through the oil purifier.
Also ensure that the tank oil level is maintained nearer to the
NWL and below the maximum oil level to accommodate the
flow-back oil quantity expected on Unit shutdown.
The minimal-optimum vacuum is to be maintained to prevent oil
and/or vapor leakage. All bolts and nuts securing manhole and
tank nozzle connections are to be checked for tightness. Check
the position of vapor extractor fan suction damper and readjust to
achieve the required vacuum. Lock the damper handle after
vacuum adjustment.
Monitor the running pump for discharge pressure and for signs of
abnormal vibration and temperature. If any abnormality is
observed, take remedial measures as indicated in this manual, if
the trouble still exists advise your supervisor.
Monitor the lube oil filter differential pressure at regular intervals
and changeover to the standby filter when blockage is indicated.
After changeover, clean or replace the blocked filter and place it
in standby mode.
Check the return oil strainer regularly to prevent any
accumulation of debris. Clean the strainer and remove any
foreign matter. Check the strainer for any signs of damage that
could occur with prolonged use.
Monitor the E/H oil pump suction and discharge filters differential
pressures at regular intervals. Clean or replace the filters as
necessary when blockage is indicated.
MM-M05.08
Rev.000
Collect periodic oil sample from the tank overflow line and
analyze the sample for oil properties in a laboratory. Ensure the
oil sample results are within permissible limits.
Mitsubishi
4--4
Chapter 4
b)
Auxiliary Oil Pumps

Auxiliary oil pumps to be monitored for vibration. Check for any
loose motor holding bolts and tightened them if vibration is
observed.
Another area that deserves attention is the identification of any
abnormal noise. Any abnormal noise generated should be
investigated and the source must be identified.
c)
Vapor Extractor Fan
DANGER
Take care near rotating machinery, hands and clothing can be
drawn into machinery. Always check that all guards are in
place before starting any rotating machinery.
The vapor extractor fan is to be monitored for vibration. Check for
any loose motor holding bolts and tighten them if vibration is
observed. Perform an alignment check and correct if any
misalignment is observed.
Vibration may also be generated by an imbalance of the impeller
wheel resulting from corrosion or deposit of impurities on the
impeller or accumulation of oil in the fan casing. Check for any
accumulated oil in the fan casing and blockage in the casing
drain if vibration is apparent. If records indicate an increased
vibration level, the fan should be monitored closely and if the
increase persists, inspection and rectification should be
arranged.
MM-M05.08
Rev.000
The vapor extractor fan motor and seals are to be checked for
any abnormal increase in temperature. Inject fresh grease into
the seal housing and/or the motor bearings through the grease
nipples provided and if an increase in temperature is observed.
Remove the spent grease through the drain cock while greasing.
Observe the performance of the bearings and/or seals after
greasing and if higher temperature persists, inspection and
replacement should be arranged.
Another area that deserves attention is the identification of any
abnormal noise. Any abnormal noise generated should be
investigated and the source identified.
Visually inspect the extractor fan for any leakage or damage and
rectify as required.
Mitsubishi
4--5
Chapter 4
TABLE 4-1
No.
Description
Main oil tank
Major Check Item
ROUTINE MAINTENANCE CHECKLIST
Check Method
Check Reference
Action to be Taken
(if beyond acceptable limit)
Leakage, corrosion Visual

or damage
No leakage,
corrosion or
damage
Isolate and repair as necessary
Oil level
Level gauge
NWL
Add fresh oil if level is low and

transfer oil if level is high
Vacuum inside the

tank
Installed instrument
-0.5 ~ -1 kPa(g)
Check manhole doors and adjust

extractor fan suction damper
Oil quality
Lab analysis
No trace of oil
contamination
Check oil purifier operation
Remarks
Recommended
Maintenance
Frequency
Daily
Daily
Daily
Monthly
Oil pumps
Running oil pump

pressure, vibration
and overheating
Portable testing
instruments and
installed instrument
Normal pressure,
vibration and
temperature
Analyze and rectify causes for low

discharge pressure, high vibration
and overheating
Daily
Lube oil pressure
Differential
pressure
Installed instrument
<0..5 bar
Changeover to the standby filter and

clean or replace the blocked filter
Daily
Return oil strainer
Blockage
Visual
No blockage
Clean the filter element
MM-M05.09
Rev.000
Monthly
Main Oil Tank and Vapor Extractor Fan

Mitsubishi
4--6
Chapter 4
Continued from previous page.

TABLE 4-1
No.
Description
Vapor extractor fan
Major Check Item
Vibration
ROUTINE MAINTENANCE CHECKLIST
Check Method
Portable
vibration meter
Check Reference
Action to be Taken
Remarks
Recommended
Maintenance
Frequency
No tangible vibration Check and tighten motor holding
bolts
Shut down and check the impeller
wheel balance
Daily
Perform alignment check

Motor bearing and seal Portable
temperature
thermometer
Allowable
Inject fresh grease. If the temperature
temperature of 750C is still high, stop the fan and investigate
or ambient plus 400C the cause of overheating
whichever is less
Abnormal noise
Audible
No abnormal noise
Check for internal rubbing
Daily
Vapor leakage
Visual, audible
and by touch
No tangible vapor
leakage
Shutdown and rectify the leakage
Daily
MM-M05.09
Rev.000
Daily

Mitsubishi
4--7
Chapter 4
4.3
Annual Outage Maintenance

The purpose of annual outage maintenance is the implementation of a
preventive maintenance program on a yearly (or some multiple) basis through a
planned and correctly executed maintenance work program accompanying
necessary inspections. Such outage maintenance activities are very important
in the sense that if properly undertaken these enhance the life and reliability of
the equipment.
The turbine manufacturer/vendor has a recommended interval for inspection
and maintenance of the lubrication system in general it is two years. A two year
interval is defined by the turbine manufacturer/vendor as a minor overhaul
interval. The turbine major overhaul interval is four years. However, some of the
lubrication equipment may have maintenance requirements outside this
framework. These situations are indicated in the text.
Major activities related to annual outage maintenance are as follows:
(Summarized major activities for outage maintenance are also shown in
Table 4-2).
4.3.1 Preparation
a)
Parts Tools and Equipment

Refer to Subsection 4.2.1 a), Parts Tools and Equipment.
In addition, it will be necessary to identify and request the
provision of any spare part requirements.
Annual outage will, in certain cases, require the use of material
handling equipment.
Unused spare parts are to be returned for correct storage and
used spare parts are to be replaced.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
On completion of annual outage maintenance work, the

equipment is to be monitored for correct operation and
maintenance data logging. This will help to determine the correct
intervals of preventive maintenance activities to ensure optimum
plant availability. The correct recording of the findings during
inspection will build a valuable document for future reference.
MM-M05.08
Rev.000
Records are to be maintained to record information regarding

spares and consumables used. These records will be used for
future reference and spare parts replacement.
Turbine Oil Pumps (AOP, TOP, EOP)

Mitsubishi
4-8
Chapter 4
4.3.2 Inspection and Maintenance

Normal run down, cooling and isolation procedures are to be followed.
It should be noted that there is a manufacturer/vendor statement of
preference to keep the turning gear in operation whenever possible,
between shut down and start up.
If access to equipment that affects the turbine rotating parts is required
quickly from operating conditions, there are clear procedures that must
be followed. Loss of availability of lubrication and conditioning
equipment will normally affect turbine operation.
The procedures for various shutdown situations are provided in
Appendix F, Turning Gear Operation During Shutdown. Operations
personnel are to carry out the turbine shutdown with due regard to
these procedures.
These are standard procedures for various shutdown situations but
dependent on the work content and the intended duration of the outage
it is normal that the actual stoppage of the turning gear, lubricating oil,
seal oil pumps, etc. is a joint operational and maintenance department
decision.
Limited access to the lubricating oil system for maintenance may be
possible with the Unit in operation. However, the annual outage
inspection and maintenance of the lubricating oil pumps requires entry
into the MOT to disconnect and secure the discharge piping, and the
subsequent pump removal. These situations are assessed by the
Operations personnel and, due to the nature of this equipment, will
depend in part on local conditions at the time. For this reason, it is not
possible to outline the possibilities/restrictions in this manual.
MM-M05.08
Rev.000
A safety document detailing the precautions to be observed

while working inside the main oil tank is to be obtained. Rules
relating to work in confined spaces are to be followed.
The manufacturer/vendor recommends overhaul of the pump annually.

However, some components only require inspection every two or four
years. These are identified in the text.
Inspections and checks should be carried out on the pump internal
components. Suitability for further service is determined by comparing
inspection results with the reference information in Table 4-2.

Mitsubishi
4-9
Chapter 4
The pre-outage records for vibration and noise levels should also be
consulted. The manufacturer/vendor recommends that the pump
bearings are changed automatically if there has been any irregularity in
the recorded vibration and noise levels.
a)
Casing and Casing Wear Rings

Pump casings and discharge casing are to be inspected for wear,
crack or damage. The mating surfaces of the casings with their
suction covers and the guide bearings are to be inspected for any
flow erosion damage. Damaged components are to be repaired
or replaced as required.
The column pipe and the casing air vent holes are to be checked
for blockage and cleared, if necessary.
The casing wear rings are to be inspected while remaining
attached to their casings. Examine the bore of each casing wear
ring for damage or excessive wear. Light radial scoring is
acceptable but axial grooves will affect pump performance. If
axial grooves are revealed, or if the clearance between the
casing and impeller wear rings exceeds the maximum allowable
limit, the wear rings should be replaced with new.
b)
Impeller and Impeller Wear rings

The impellers are to be inspected for damage to the keyways or
to the bores which may have occurred during operation or
dismantling. Ensure that the impeller bores are perfectly smooth
and free from distortion. Inspect the impeller necks for damage or
excessive wear. Light radial scoring is acceptable provided the
clearance to the casing wear ring is within tolerance. If the wear
ring requires replacement, the opportunity is to be taken to
restore the impeller neck surface by machining if this is required.
Perform dimensional checks on the impeller wear rings while

remaining attached to their impellers and ensure that they are
within tolerance. Examine the surface of each impeller wear ring
for damage or excessive wear. Light radial scoring is acceptable
but axial grooves will affect pump performance. If axial grooves
are revealed, or if the clearance or dimension exceeds the
maximum allowable limit, the wear rings should be replaced with
new.
MM-M05.08
Rev.000
Restore the bore of any impeller which reveals damage and

remove any burrs. If an impeller cannot be brought to a
satisfactory condition, it is to be replaced with new.

Mitsubishi
4-10
Chapter 4
c)
Suction Covers and Strainers

The suction covers are to be inspected for damage or wear.
Inspect for evidence of rubbing by the rotating components and
replace damaged suction covers with new.
The wear rings installed in the suction covers are to be inspected
while remaining attached to their suction covers. Examine the
bore of each wear ring for damage or excessive wear. Light radial
scoring is acceptable but axial grooves will affect pump
performance. If axial grooves are revealed, or if the clearance
between the suction cover wear ring and impeller wear ring
exceeds the maximum allowable limit, the wear rings should be
replaced with new.
The suction strainers are to be inspected for accumulation of
debris and for crack or damage. Accumulated debris is to be
removed and a damaged filter assembly should be repaired or
replaced.
d)
Column Pipe
The column pipe is to be inspected for the presence of any weld
crack or damage and repaired as required.
The thrust bearing housing is to be checked for weld crack or
damage to the bearing seating surface and repaired as required.
The lubricating oil supply port in the bearing housing is to be
inspected for blockage and cleared if blockage is observed.
e)
Shaft and Shaft Sleeve

The pump shaft is to be removed and checked for run-out using
V-blocks. If the shaft exceeds the maximum allowable run-out,
the shaft is to be changed for new.
MM-M05.08
Rev.000
The shaft is to be checked for surface roughness or scoring in the

areas where the sleeve bearings and the oil seal are located.
Minor scoring marks are to be polished with an oil stone and
more severe scoring is to be machined. If the damage is beyond
repair, the shaft is to be replaced with new.
The keys, keyways and threads on the shaft are to be checked
for any damage. Damaged keyway and threads are to be
repaired as found necessary. Any key which is a loose fit in its
shaft keyway or in the impeller/coupling keyway is to be replaced
with new. Any burrs raised during removal of the keys are to be
removed using an oil stone.

Mitsubishi
4-11
Chapter 4
The shaft sleeve is to be checked for surface roughness or

scoring in the areas where the sleeve bearings are located. If the
shaft sleeve has scoring marks or excessive wear, it is to be
replaced with new.
f)
Bearings
The thrust bearing is to be inspected for any signs of damage and
pitting marks on the balls and the inner & outer races. A damaged
or pitted bearing is to be replaced with new.
The sleeve bearings are to be examined for any damage,
scratches or excessive wear on the white metal lining. Minor
scratches or damage on the white metal can be removed with a
metal scraper. Replace any bearing which reveals excessive
damage or wear.
Perform a dimensional check on the inside diameter (ID) of the
sleeve bearings and calculate the clearance between each
bearing and its respective shaft/sleeve. If the clearance exceeds
the maximum allowable limit, the bearing should be replaced and
the clearance adjusted as required. The original bearing should
be re-metalled and machined for future use.
g)
Coupling
The coupling bolts and the rubber bushes are to be inspected for
damage or excessive wear. The coupling bolts exhibiting wear or
damage are to be replaced with new and the rubber bushes
exhibiting excessive wear or damage are to be replaced as a set.
h)
Oil Seal
The oil seal is to be replaced with new if leakage was observed
during operation or if seal replacement is due as per the
recommended maintenance schedule.
Inspect the oil flinger for any signs of contact with the bearing
cover. If contact is apparent, polish the damaged surface and
readjust the clearance during reassembly.
MM-M05.08
Rev.000
i)
Piping and Discharge Valves

The discharge pipe flange gaskets, once removed, must be
replaced with new. The flanges are to be thoroughly cleaned, and
any old adhered gasket material is to be removed prior to
replacement.
The disc/flap and the seat of the discharge check valves are to be
inspected for any dents, scratches or damage. The disc/flap is to
be rectified by lapping with the respective valve seat.

Mitsubishi
4-12
Chapter 4
The orifices in the air vents of the discharge pipes are to be

inspected and cleared if any blockage is observed.
MM-M05.08
Rev.000
The thrust bearing lubricating oil pipe supports are to be

inspected for their integrity and rigidity. Loose supports are to be
tightened as required. Oil pipe without support may result in
breakage of the line causing damage to the bearing.

Mitsubishi
4-13
Chapter 4
TABLE 4-2
No
1
Description
Main oil tank
Major Check
Item
Corrosion,
damage or
leakage
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Visual and by No corrosion,

touch
damage or leakage
Action to be Taken
No damage or
defective weld
Repair or replace
Oil separator
drain blockage
Visual
No blockage
Clear blockage
Visual
No blockage
Clear accumulated debris
Visual
No wear or damage
Repair or replace defective

components
Repair or replace
AOP, TOP, EOP Suction strainer
Check valve
Wear or damage Visual

on disc/flap and
seat
No wear or damage
Oil ejector
Nozzle wear or
blockage
Visual
No abnormal wear or Clean or replace

blockage
Check plate
Visual
Freedom for
movement
Repair or replace
Strainer
Visual
No clogging
Clean the strainer
Strainer
condition
Visual
No damage
Replace the strainer
No clogging
Clean the strainer
Return oil
strainer
Inspection
Date
Inspector
Results
MM-M05.08
Remarks
Repair and apply preservative paint
Baffle plates and Visual

supports
Pump internal
components
Rev.000
Check
Method

Mitsubishi
4-14
Chapter 4
Continued from previous page.

TABLE 4-2
No
6
Description
Oil level gauge
Vapor extractor
fan
Major Check
Item
Check
Method
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Action to be Taken
Damage to float Visual
No damage
Repair or replace
Accumulation of Visual
debris
No debris
Clean
Wear, crack or Visual

damage and
deposit of debris
No dust build up
Replace the impeller wheel
Wear, crack or Visual

damage to rotor
shaft
No wear, crack or
damage
Repair the shaft
Corrosion,
Visual
debris deposit in
casing
No corrosion or
debris deposit
Remove corrosion and debris.
Visual and
physical
check
Inspection
Date
Inspector
Results
No wear or cracks
Flange bolts properly Retighten the flange bolts

tightened
MM-M05.08
Rev.000
Tightness of
flange bolts
Remarks

Mitsubishi
4-15
Chapter 4
SLEEVE BEARING
IM PELLER RING
IM PELLER RING
IM PELLER RING
SHAFT
SHAFT SLEEVE
CASING RING
CASING RING
MM-M05.08
Rev.000
CASING (1st STAGE)
FIGURE 4-1
Mitsubishi
AUXILIARY OIL PUMP CLEARANCE DRAWING

4-16
Chapter 4
MM-M05.03
Rev.000
SHAFT
FIGURE 4-2 TURNING OIL PUMP CLEARANCE DRAWING

Mitsubishi
4-17
Chapter 4
MM-M05.03
Rev.000
SHAFT
FIGURE 4-3 EMERGENCY OIL PUMP CLEARANCE DRAWING

Mitsubishi
4-18
Chapter 5
Chapter
5 Disassembly and Reassembly

Disassembly and reassembly are the activities to be conducted when internal parts of
the equipment are required to be accessed. An important part of the activities is the
preparatory work. This should identify the manpower, spares and tools that may be
required during the maintenance work. A shortfall of any of these may affect the
schedule and the operational status of the plant. The major steps associated with
disassembly and reassembly are as follows.
5.1
Main Oil Tank Disassembly and Reassembly
CAUTION
Prior to carrying out any maintenance, confirm the equipment is
shut down and all isolations are in place.
Disassembly and reassembly of the main oil tank is limited to the opening and
closing of manholes.
a)
Preparation
If main oil tank disassembly becomes necessary, all associated internal
and external equipment is to be mechanically and electrically isolated and
the tank is to be drained and an oil free certificate issued. An authorized
clearance and work permit shall be in place prior to the commencement of
work. The following points are also to be considered when preparing for
inspection:
b)
Have all necessary drawings (assembly drawings, sectional

drawings, part details, etc.) and documents (log sheets, field record
book, etc.) ready prior to start of work.
Disassembly
CAUTION
MM-M05.08
Rev.000
When separating joints and flanges use jacking bolts and wooden
mallets. Never apply force with hammers, chisels or screwdrivers.
All data is to be recorded during disassembly. During disassembly, make
match marks on adjoining parts for ease of identification during
reassembly. The disassembly procedure is described as follows:
Mitsubishi
5-1
Chapter 5
Refer to Figures 2-2 to 2-5A/B.

1
Ensure that the main oil tank is drained fully, vented and purged with
nitrogen gas.
Remove the fasteners securing the manhole cover and then remove
the manhole cover.
CAUTION
If weld repairs are necessary, arrange for the appropriate gas and
oil free certification and for the appropriate ventilation facilities,
before commencing any welding work, on, within, or in the
vicinity of the oil tank.
Note
During the inspection always use the low voltage safety
lamps.
c)
Visually inspect the internal tank welds for signs of cracking. Repair if
cracks are found.
Inspect the inside and outside surfaces of the tank for any signs of
corrosion. If corrosion is found, clean off the affected area, repair as
necessary and treat with a suitable preservative.
Visually inspect the instrument pockets for blockage or cracking.

Repair to the approved procedure if cracks are found.
Visually inspect the pipes, valves and the pipe supports inside the
tank for corrosion or damage. Repair or replace, as applicable, if
corrosion or damage is apparent.
Visually inspect the flange joints inside the main oil tank for loose
bolts and tighten them as necessary.
Reassembly
The reassembly procedure is carried out in the reverse sequence to that
of the disassembly. Install all parts in the same positions they were
removed from, referring to the match marks and checking that the
clearances are maintained as specified.
Before closing the main oil tank ensure that all parts are in position
and securely attached. Ensure that all tools and equipment are
removed and accounted for.
Using a new gasket replace and secure the manhole cover.
MM-M05.08
Rev.000
Mitsubishi
5-2
Chapter 5
5.2
Disassembly and Reassembly of the Auxiliary Oil Pump
CAUTION
Prior to carrying out any maintenance, confirm all isolations
are in place and the equipment is shutdown.
a)
Preparation
If AOP disassembly becomes necessary, all associated equipment is to
be mechanically and electrically isolated and an authorized clearance and
work permit is to be in place prior to the commencement of work. The
following points are also to be considered when preparing for disassembly
and reassembly:
Have all necessary drawings (assembly drawings, sectional drawings,

part details, etc.) and documents (log sheets, field record book, etc.)
ready prior to the start of work.
Prepare the necessary handling facilities to remove and store the

various parts of the equipment.
Prepare separate temporary structures of adequate height and

strength, to receive the motor and the complete pump as they are
removed from the tank. The structure for the pump should be high
enough and strong enough to support the pump in both the vertical
position and the horizontal position.
Co-ordinate with the Instrument and Control (I&C) Department to

remove all the attached instrumentation such as pressure indicators
before starting disassembly work.
Co-ordinate with the Electrical Department to disconnect and remove

the motor power cable before starting disassembly work.
Note
MM-M05.08
Rev.000
Work on the oil pumps requires entry into the main oil tank, which
must be emptied, cleaned and pronounced safe for entry, by a
competent person who should issue a relevant safety document
before work commences.
A safety document detailing the precautions to be observed

while working inside the main oil tank is to be obtained. Any
national or local rules relating to work in confined spaces are to
be followed.
Mitsubishi
5-3
Chapter 5
b)
Disassembly
Refer to Figure 2-9 and 5-1.
Before starting disassembly, prepare a laydown area where equipment
can be stored and worked on without undue risk of contamination or
damage.
Before removing the pumping unit, make sure the pump is isolated then
make suitable arrangements for the following:
(i)
Removal of the motor. The coupling is designed such that the motor
can be lifted off after the coupling bolts (43), and the bolts securing
the motor to the pump frame (55) are removed.
(ii)
During disassembly, tag all components for identification purposes

and, if necessary, bag or wrap to prevent miscellaneous losses and
ensure adequate protection.
CAUTION
When separating joints and flanges use jacking bolts and
wooden mallets. Never apply force with hammers, chisels or
screwdrivers.
MM-M05.08
Rev.000
Removal of the Motor

1
Unbolt and remove the safety covers from the pump frame (1).
Ensure that match marks are clearly visible on the pump frame, and
on the oil tank mounting location.
Loosen and remove the coupling bolts and nuts (43) and the
coupling bushes (44) from the coupling.
Refer to Chapter 3 for the weight of the motor then attach suitable
slings from the crane hook to the eyebolts provided on the motor
and remove the slackness from the slings.
Check the supports arranged in the laydown area to ensure that the
motor will be supported without the protruding coupling contacting
the floor.
Remove the fasteners (55) securing the motor to the pump frame
(1).
Lift the motor, transport it to the laydown area and protect it with a
secured plastic cover.
Mitsubishi
5-4
Chapter 5
Removal of the Auxiliary Oil Pump Assembly from the Main Oil
Tank
8
Confirm that all tank entry precautions have been implemented.

The outlet surface of all motor operated pumps should be cleaned,
and all available to be worked on. The oil tank manhole cover and
the return oil filter should be removed to ensure air circulation. When
safety has been assured personnel may enter the tank with one
additional person always stationed at the tank entry to assist in any
emergency.
Remove the nuts and bolts securing the discharge pipes to the
respective pumps, securely supporting the connected valves and
piping, within the tank, to facilitate the removal of the complete pump
assembly from the tank.
10
Remove the hexagon head bolts (56) securing the pump frame (1)
to the main oil tank. (Store these bolts for use during reassembly)
CAUTION
Rigging and transportation of equipment must be carried out
by authorized persons. Special consideration is to be given to
the center of gravity of the assembly.
Refer to Section 3 for the weight of the pump.
11
Attach suitable lifting equipment to the pump frame and make a trial
lift to ensure a smooth lift of the pump assembly. Readjust slings as
required.
Note
Special care should be taken while lifting the pump
assembly. Use additional chain blocks, if necessary, to
ensure a smooth lift.
CAUTION
MM-M05.08
Rev.000
Oil will drain from the pump as it is raised from the main oil
tank. If cleaning materials or fluids are used to clean the pump
prior to transporting it to the laydown area, care must be
taken that they do not enter the main oil tank.
12
Transport the removed pump to the laydown area and locate it

vertically or horizontally as decided by the Maintenance Engineer on
the pre-arranged supports. In this manual, we have the pump
arranged with the frame horizontal on the prepared structure so the
shaft (3) can be removed vertically.
Mitsubishi
5-5
Chapter 5
CAUTION
During the pump disassembly care must be taken when
removing the strainers, suction covers, impellers, pump
casings, etc. They are moderately heavy and will be oil
soaked. The individual parts should be placed on stacked
timbers, wooden frame or a low wheeled bogie, then removed
from the area for cleaning and inspection.
Disassembly of the Auxiliary Oil Pump

Refer to Figures 2-9 and 5-1 and follow the removal system in the
description column starting at the suction side of the pump.
13
Disconnect and remove the oil feed tube (34) between the 1st stage
casing (4) and the column pipe (2).
14
Provide a suitable support for the suction strainer (7), remove the
hexagonal head bolts and lock washers (12) and then remove the
suction strainer and the pump suction cover (6). Remove the O-ring
(16) between the suction cover (6) and the 1st stage pump casing
(4).
15
Check the clearance between the casing wear ring (48) and the
impeller wear ring (49). If the clearance check indicates that the
disassembly of the casing and the impeller wear rings is necessary
remove the set screws (50) & (51) to release casing and the impeller
wear rings.
16
Straighten the bent tongue of the lock plate and then remove the
impeller nut (8), the lock plate (10) and the impeller washer (9).
17
Remove the 1st. stage pump impeller (5) clean, and then examine
the impeller to remove any defects.
Wear suitable protective clothing when handling heated

components.
MM-M05.08
Rev.000
Note
If difficulty is experienced when attempting to remove the
impeller, apply heat around the periphery, working slowly
towards the hub. Do not initially heat the hub as this will
cause the impeller to grip tighter on the shaft.
Mitsubishi
5-6
Chapter 5
18
Recover the impeller key (11) from the shaft (3). Check the oil
clearance between the sleeve bearing (14) and the shaft sleeve (15),
if the clearance is excessive change the shaft sleeve or the sleeve
bearing whichever has worn the most, or if necessary change them
both.
19
Remove the hexagon head bolts 23) to release the 1st stage casing
(4). Recover the O ring (20) and remove the shaft sleeve (15).
20
Remove the 2nd stage impeller (19). After checking the clearance
between the casing and the impeller wear rings and if the wear ring
clearances need adjustment remove the set screws provided in
(50a-f) and (51a-f).
21
Remove the impeller key (21). Check the oil clearance between the
sleeve bearing (22) and the shaft sleeve (18), and if the clearance is
excessive, change the shaft sleeve or the sleeve bearing which ever
has worn the most, or if necessary change them both.
22
Clean and remove any defects noted on the impeller.
23
Remove the hexagon head bolts (53) to release the second stage
casing (17) and to recover the O ring (24). Remove the shaft sleeve
(18).
24
Remove the 3rd stage impeller (29), check the clearance between
the casing and the impeller wear rings and if any clearance changes
are required this can be done after removing the set screws
provided (50a-f) and (51a-f).
25
Remove the impeller key (25). Check the oil clearance between the
sleeve bearing (26) and the shaft (3), any change in the oil
clearances can be made by replacing the sleeve bearing (26) using
the securing screws (13c).
Note
From this position with the 3rd stage impeller removed, please
check the shaft (3) and the column pipe (2), and please make and
record any changes made, and also make the changes made
apparent during the checks made during the pump disassembly.
Inspection and check on the Thrust Bearing.
MM-M05.08
Rev.000
Refer to Figure 2-9 and 5-1.

1
Using a suitable bearing puller remove the coupling half (41) from
the pump shaft (3) and recover the coupling key (45).
Remove the V-ring (40) from the shaft.
Mitsubishi
5-7
Chapter 5
Remove the bolts (47) and then remove the bearing cover (39).
Remove the oil seal (36) from the bearing cover, inspect the oil seal
and replace it if wear or damage is apparent.
Remove the securing screw and the remove the oil flinger (35) from
the shaft.
Withdraw the shaft (3) with the thrust ball bearing (30) still in position
in the column pipe (2) through the coupling end of the pump.
If the thrust bearing replacement is necessary, straighten the bent

tongue of the bearing washer (33), unscrew and remove the bearing
nut (32). Using a bearing puller, remove the thrust bearing (30).
Check the collar (31) for inspection and./or replacement.
Installation of the Thrust Bearing when the change is required

7
Confirm that the collar (31) is in position on the shaft, that it is

undamaged and is full contact with the step provided on the pump
shaft.

components.
8
Heat the thrust ball bearing (30) to about 100C in an electric oven
and insert it over the shaft and butt it against the collar (31).
Immediately after installation of the bearing, install the bearing

washer and the bearing nut, and hand tighten the bearing nut to
apply a small force to locate the bearings in position while cooling.
Note
MM-M05.08
Rev.000
This activity should be performed quickly as any delay could cool

the bearings, and this may lead to incorrect positioning of the
bearings and subsequent dismantling and reinstallation.
10
Tighten the bearing nut (32), fully after the bearings have cooled to
near ambient temperature. Bend the tongue of the bearing washer
to lock the bearing nut.
11
Install the oil flinger (35) onto the shaft and secure it using the set
screw.
12
Ensure that the pump frame (1) with column pipe (2) is supported
vertically on a suitable support and that the column pipe is located
correctly below the pump frame.
Mitsubishi
5-8
Chapter 5
13
Insert the shaft assembly into the column pipe (2) such that the
thrust bearing (30) slide smoothly into the thrust bearing housing in
the column pipe. Ensure that the thrust bearing seats correctly in the
thrust bearing housing.
14
Install the oil seal (36) into the groove provided in the bearing cover
(39). Insert the bearing cover over the shaft (3) from the pump
coupling end such that the oil seal slides smoothly over the shaft.
15
After ensuring that the bearing cover is properly seated on the pump
frame (1), secure it to the pump frame using the fixing bolts (47).
16
Replace and secure the V-ring (40) to the shaft.
With a new thrust bearing installed we can return to the re-assembly of the
Auxiliary oil pump.
MM-M05.08
Rev.000
Reassembly of the AOP

17
Clean the lower flange of the column pipe, and replace the 3rd stage
casing (27), checking that the air vent (52a/b) is correctly located,
install all hexagon bolts (28) and knock bolts (38).
18
Install the sleeve bearing (26) using the securing screws (13c).
19
Install the 3rd stage impeller upper casing ring and secure using the
set screws.
20
Install the 3rd stage impeller key.
21
Replace the 3rd stage impeller, upper and lower rings and secure
using set screws.
22
Replace the 3rd stage impeller (29) in its position.
23
Apply lubricating oil into the location of the 3rd stage impeller.
24
Prepare to make the 2nd stage casing (17) ready for installation.
Shaft sleeve (18) is to be installed on the shaft (3) and the sleeve
bearing (22) must be installed over the shaft sleeve (18), and secure
using the securing screws (13b).
25
Install the O ring (24), replace the casing (17) and secure it using
the hexagonal head bolts (53).
26
Confirm that the impeller upper casing ring is located correctly in its
position with set screws already installed.
27
Replace the impeller key (21), and install the No. 2 impeller (19) with
the impeller rings already installed.
28
Apply lubricating oil onto the locations of the 2nd stage impeller.
Mitsubishi
5-9
Chapter 5
To prepare the 1st stage casing for installation, install the shaft
sleeve (15) and then install the sleeve bearing (14) held in position
with securing screws (13a).
30
Replace the O ring (20), then install the 1st stage casing, using the
hexagon head screws (23), and also install the upper and the lower
impeller rings.
31
In the 1st stage casing, we must install the upper casing ring, using
the hexagon head screws, and we also install the upper and the
lower impeller rings.
32
Install the impeller key (11), and install the 1st stage impeller.
32
Check that all 1st stage casing rings and impeller rings are secure,
then install the impeller washer (9), the lock plate (10) and the
impeller nut (8).
33
Apply lubrication oil onto the location of the 1st stage impeller.
34
Restore the suction cover (6), the strainer (7) and the O ring (16)
using the hexagon head bolts (12).
35
Replace the oil feed tube (34) connected between the 1st stage
casing (4) and the column pipe (2).
MM-M05.08
Rev.000
29
Mitsubishi
5-10
Chapter 5
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13a,b,c
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48a,b,c,
d,e,f
49a,b,c,
d,e,f
50a,b,c,
d,e,f
51a,b,c,
d,e,f
52 a,b
53
54
55
56
40
55
47
39
35
36
32
33
30
2
1
31
38
38
37
28
38
CASING RING
IMPELLER RING
SET SCREW
SET SCREW
AIR VENT
HEXAGONAL HEAD BOLT
DRIVE MOTOR
MM-M05.08
Rev.000
34
DESCRIPTION
PUMP FRAME
COLUMN PIPE
SHAFT
1st STAGE CASING
1st STAGE IMPELLER
SUCTION COVER
STRAINER
IMPELLER NUT
IMPELLER WASHER
LOCK PLATE
IMPELLER KEY
HEXAGONAL HEAD BOLT
SCREW
SLEEVE BEARING
SHAFT SLEEVE
O-RING
2nd STAGE CASING
SHAFT SLEEVE
2nd STAGE IMPELLER
O-RING
IMPELLER KEY
SLEEVE BEARING
HEXAGONAL HEAD BOLT
O-RING
IMPELLER KEY
SLEEVE BEARING
3rd STAGE CASING
HEXAGONAL HEAD BOLT
3rd STAGE IMPELLER
THRUST (BALL) BEARING
COLLAR
BEARING NUT
BEARING WASHER
OIL FEED TUBE
OIL FLINGER
OIL SEAL
HEXAGONAL HEAD BOLT
KNOCK BOLT
BEARING COVER
V-RING
COUPLING BOLT & NUTS
COUPLING BUSH
KEY
COUPLING COVER
HEXAGONAL HEAD BOLT
FIGURE 5-1
Mitsubishi
EXPLODED VIEW OF THE AUXILIARY OIL PUMP

5-11
Chapter 5
5.3
Disassembly and Reassembly of Turning Oil Pump

a) Preparation
If Turning Oil Pump disassembly becomes necessary, all associated
equipment shall be mechanically and electrically isolated and an
authorized clearance and work permit shall be in place prior to the
commencement of work. The permit should include entry into the main oil
tank. The following points are also to be considered when preparing for
disassembly and reassembly.
Have all necessary drawings (assembly drawings, sectional drawings,

part details, etc.) and documents (log sheets, field record book, etc.)
ready prior to start of work.
Prepare the necessary handling facilities (e.g. crane facilities,

temporary supports, etc.) to remove and store the various parts of the
equipment.
Prepare separate temporary structures of adequate height and

strength, to receive first the motor, and then the complete pump as
they are removed from the tank.
Co-ordinate with the I&C Department to remove all instrumentation

from the equipment before starting disassembly work.
Coordinate with Electrical department to have the power cable

removed from the motor.
b) Disassembly
Before starting disassembly, prepare a laydown area where equipment
can be stored and worked on without undue risk of contamination or
damage.
MM-M05.08
Rev.000
Before removing the pumping unit, make suitable arrangements for the
following:
(i)
Removal of the motor. The coupling is designed such that the motor
can be lifted off after the coupling bolts (6) and the bolts securing the
motor to the pump frame (49) are removed.
(ii)
Lifting of the pump and containment of the oil which will drain from
the pump after it has been removed from the MOT. If cleaning
materials or fluids are used for cleaning the pumping unit prior to
transporting it to the laydown area, they should not be allowed to
enter the MOT.
During disassembly, tag all components for identification purposes and, if

necessary, bag or wrap to prevent miscellaneous losses and ensure
adequate protection.
Mitsubishi
5-12
Chapter 5
CAUTION
When separating joints and flanges use jacking bolts and
wooden mallets. Never apply force with hammers, chisels or
screwdrivers.
Refer to Figures 2-12 and 5-2.
Removal of the Motor

1
Unbolt and remove the safety covers (2) from the pump frame (1).
Ensure that match marks are clearly visible on the motor (47), the
pump frame (1), and on the main oil tank mounting flange.
Loosen and remove the coupling bolts and nuts (6) from the coupling.
Refer to Chapter 3 for the weight of the motor, then attach suitable
slings from the crane hook to the eyebolts provided on the motor and
remove the slackness from the slings.
Check the supports arranged in the laydown area to ensure that the
motor will be supported without the protruding coupling contacting the
floor.
Remove the bolts (49) securing the motor to the pump frame.
Lift the motor, transport it to the prepared laydown area and protect it
with a secured plastic cover.
MM-M05.08
Rev.000
Removal of the Pump

8
Confirm that the Permit to work (PTW) covers entry into the MOT, that
the MOT has been cleaned, is gas free, and ventilated. Maintenance
personnel can then enter the MOT to remove the pump discharge
flange bolts, and to secure the discharge piping within the MOT.
Remove the bolts (48) securing the pump frame (1) to the MOT, then
using the appropriate lifting gear, lift the complete pump assembly
from the MOT. Transport the removed pump assembly to the laydown
area and locate it vertically on the pre-arranged supports.
10 Confirm that there is sufficient working area directly above the pump
for the withdrawal of the pump shaft.
11 Using a suitable bearing puller, remove the pump side coupling half
(4) and recover the key (40) from the pump shaft (41).
12 Remove the V ring (9) from the pump shaft.
Mitsubishi
5-13
Chapter 5
13 Remove the bolts and washers (7) and then remove the bearing cover
(8) from the pump frame (1).
14 Remove the oil seal (10) from the bearing cover.
15 Remove the set screws (45) and then remove the oil flinger (11) from
the pump shaft.
16 Remove the oil feed tube (17), and seal the open ends to prevent the
entry of dust or debris.
CAUTION
During the pump disassembly care should be taken when
removing the strainer, suction cover, impeller and pump
casing. They are moderately heavy and will be oil soaked. The
individual parts should be lowered onto stacked timbers
(wood) or a low wheeled bogie, then removed from under the
pump for inspection.
17 Straighten the bent tongue of the lock washers, remove the bolts and
the lock washers (18) and then remove the strainer (19) and the
suction cover (20). Remove the O-ring (39) between the suction cover
(20) and the pump casing (35).
18 Straighten the bent tongue of the lock plate (23) and then loosen and
remove the impeller nut (21), the lock plate (23) and the impeller
washer (22).
19 Withdraw the impeller (24) from the impeller end of the shaft and
recover the impeller key (25) from the shaft (41).

components.
Note
MM-M05.08
Rev.000
If difficulty is experienced when attempting to remove the

impeller, apply heat around the periphery, working slowly
towards the hub. Do not initially heat the hub as this will
cause the impeller to grip tighter on the shaft.
20 Remove the knock bolts (30) which locate the pump casing (35) and
the column pipe (42).
Mitsubishi
5-14
Chapter 5
21 Remove the bolts and lock washers (31) and then withdraw the pump
casing (35).
22 The pump casing should be examined for signs of wear and reference
should be made to the manufacturer if wear is apparent.
23 Remove the bolts and washers (32) and then remove the sleeve
bearing (36) from inside the pump casing.
24 Inspect the impeller (24) for wear or damage, paying particular
attention to the suction entry blade tips, the impeller rings (28, 29) and
the casing rings (26, 27).
25 Measure the bore of the casing wear rings and the OD of the impeller
wear rings and calculate the wear. If the wear ring clearances are
beyond the tolerance limit, remove the casing and impeller wear
rings.
Note
The above wear rings are located in both the suction and
discharge sides of the pump. The casing wear rings are retained
by set screws or peening and the impeller wear rings by set
screws. It is not necessary for the rings to be removed from the
casing and the impeller unless damaged, worn, or due for
replacement.
26 Replace excessively worn casing rings, impeller rings and any other
component which fails to meet the acceptance criteria.
27 Inspect the sleeve bearing (36) for wear or damage. Measure the
clearance between the sleeve bearing and the shaft. Replace the
bearing with a new one if the clearance exceeds the acceptable limit.
28 The pump shaft assembly containing the shaft, bearing nut, bearing
washer and thrust bearing can now be removed through the motor
end of the pump frame. Timber and a hydraulic jack should be
available to raise the shaft assembly.
29 Straighten the bent tongue of the bearing washer and then remove
the bearing nut (12) and the bearing washer (13).
MM-M05.08
Rev.000
30 Using a suitable bearing puller, withdraw the thrust bearing (14) from
the pump shaft.
31 The thrust bearing should be inspected for ball or ball race damage
and the bearing should be replaced if damage is apparent.
32 If there are doubts regarding the shaft concentricity, a shaft run-out
check should be performed to confirm that the acceptable limit of 0.05
mm at the shaft journals is not exceeded.
Mitsubishi
5-15
Chapter 5
c)
Reassembly
1
Before reassembly, ensure that all components have been cleaned

thoroughly.
Lubricate the internal pump parts with clean turbine oil where
necessary.
Confirm that the collar (15) is in its original location on the pump shaft
(41). And if the thrust bearing is to be changed proceed as follows:

components.
4
Heat the thrust bearing (14) to about 100C in an electric oven and
insert it over the shaft and butt it against the collar (15).
Immediately after installation of the bearing, install the bearing washer

(13) and the bearing nut (12), and hand tighten the bearing nut to
apply a small force to locate the bearing in position while cooling.
Note
This activity should be performed quickly as any delay could cool
the bearing, and this may lead to incorrect positioning of the
bearing and subsequent dismantling and reinstallation.
Tighten the bearing nut fully after the bearing has cooled to near
ambient temperature. Bend the tongue of the bearing washer to lock
the bearing nut.
Install the pump frame and column pipe assembly vertically on the
prepared support such that the pump frame is located above the
column pipe.
Replace the shaft with the assembled thrust bearing into the column
pipe (42) confirming that the collar (15) and the thrust bearing (14) are
correctly located.
Install the oil flinger (11) and secure it with the set screws (45).
11 Replace the bearing cover (8) (with oil seal) into the pump frame (1)
and secure it with the hexagonal head bolts and spring washers (7).
MM-M05.08
Rev.000
10 Replace the oil seal (10) in the slot provided in the bearing cover (8).
Mitsubishi
5-16
Chapter 5
12 Install the V ring (9) onto the pump shaft.

13 Replace the key (40) in the slot on the shaft.

components.
14 Heat the pump coupling half (4) in an electric oven and then ensuring
that the coupling keyway aligns with the shaft key (40), insert the
coupling half over the pump shaft until it comes into contact with the
step on the shaft.
15 Rotate the shaft by hand and ensure the shaft is free to rotate.
16 Replace the casing wear ring (26) in the pump casing (35) and the
casing wear ring (27) on the suction cover (20) and secure them.
17 Replace the impeller wear rings (28 and 29) on the impeller (24) and
secure them with the set screws (33 and 34).
18 Confirm that the wear ring clearances are within tolerance.
19 Rotate and support the pump frame and column pipe assembly on the
prepared support such that the column pipe is located above the
pump frame. Provide suitable temporary side-supports for the shaft
from the column pipe, if required.
20 Check the pump casing flanges for bumps or burrs and remove any,
using emery cloth or a smooth file. Check for cleanliness and locate
the casing (35) on the column pipe (42) using the knock bolts and
nuts (30).
21 Secure the casing to the column pipe using the lock washers and
bolts (31).
22 Check the condition of the sleeve bearing (36) and remove any burrs.
Apply a coating of oil and install it in the pump casing using the
hexagonal head bolts (32).
24 Install the impeller (24) ensuring that it locates correctly on the shaft
key.
MM-M05.08
Rev.000
23 Check the impeller key (25), then insert it in the keyway on the pump
shaft.
Mitsubishi
5-17
Chapter 5
Note
The bore of the impeller is machined to the same size as the
diameter of the shaft with a small tolerance. It may or may not
be possible to slide the impeller onto the shaft. Try to install
the impeller on the shaft by hand. If the impeller will not slide
onto the shaft, heat may be applied evenly around the hub and
then installed.
CAUTION
Force must not be used when installing the impeller. If the
impeller fails to butt against the shaft shoulder, remove the
impeller and check for any burrs or dirt which may have been
overlooked during inspection. Clean up as necessary. Do not
attempt to install the impeller if the shaft temperature is above
ambient.

components.
25 Replace the impeller washer (22) and the lock plate (23) and then
tighten them with the impeller nut (21).The tongue of the lock plate
should be bent after fully tightening the impeller nut to prevent
loosening.
26 Clean and check the condition of the suction cover (20), smear oil
over the internal surfaces and replace the O-ring (39).
27 Replace the suction cover (20) and the suction strainer (19) onto the
pump casing and secure them using the hexagonal head bolts and
lock washers (18).
28 Replace the oil feed tube (17) between the pump casing and the
column pipe, and secure it with the removed supports.
Replacement of the Turning Oil Pump Assembly
MM-M05.08
Rev.000
CAUTION
Rigging and transportation of equipment must be carried out
by authorized persons. Special consideration is to be given to
the center of gravity of the assembly.
Mitsubishi
5-18
Chapter 5
29 Carefully transport the pump frame/pump assembly from the laydown

area to the location of the MOT and align it above the respective
opening on the MOT.
30 Confirm that the mating flange faces are clean and smooth, then
slowly lower the oil pump assembly into the tank until the pump frame
(1) is located properly on the mounting flange.
31 Secure the pump frame to the MOT using the fasteners (48).
32 Using new gaskets, replace the pump discharge pipes inside the main
oil tank.
33 Replace new rubber coupling bushes (5) into the coupling flange (3)
on the motor shaft if the inspection or the maintenance schedules
necessitates their replacement.
34 Using the lifting equipment, lift the motor onto the pump frame and
secure it with the fixing bolts and nuts (49).
35 Perform an alignment check as per the procedure indicated in
Appendix D.
36 When the coupling alignment is completed, replace the coupling bolts
and nuts (6) and tighten them in sequence.
37 Replace the safety covers (2) onto the motor frame.
38 Reinstall the removed instrumentation and reconnect the electrical
power cable removed during disassembly.
39 Clean the main oil tank thoroughly and refill with the recommended oil
to the required operating level.
40 Start the pump as per the recommended starting procedure and
ensure that the pump operates satisfactory without any oil leakage.
5.4
Disassembly and Reassembly of the Emergency Oil Pump
MM-M05.08
Rev.000
Although, as their titles suggest, the EOP and the TOP have different (motor)
drives, the pumping units are the same. If disassembly of the EOP becomes
necessary, refer to Section 5.2, Turning Oil Pump Disassembly and
Reassembly and follow the same procedure.
Mitsubishi
5-19
Chapter 5
ITEM
DESCRIPTION
PUMP FRAME
COUPLING COVER (SAFETY)
COUPLING BUSH
COUPLING BOLT & NUT
HEX. BOLT / SPRING WASHER
BEARING COVER
V. RING
OIL SEAL
OIL FLINGER
BEARING NUT
BEARING WASHER
THRUST BEARING
COLLAR
OIL FEED TUBE
HEX. HEAD BOLT & WASHER
SUCTION STRAINER
SUCTION COVER
IMPELLER NUT
IMPELLER WASHER
LOCK PLATE
IMPELLER
IMPELLER KEY
CASING RING
CASING RING
IMPELLER RING
IMPELLER RING
PUMP CASING
SLEEVE BEARING
O-RING
KEY (COUPLING)
SHAFT
COLUMN PIPE
AIR VENT PLUG
SET SCREW
DRIVE MOTOR
MM-M05.08
Rev.000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
39
40
41
42
43
44
45
46
47
48
49
FIGURE 5-2
Mitsubishi
EXPLODED VIEW OF TURNING OIL PUMP

5-20
Chapter-6
Chapter
6 Corrective Maintenance
Corrective maintenance is the repair or replacement work undertaken for sudden failure of
any part or component of the equipment. Though a well-planned preventive maintenance
program tries to minimize the probability of occurrence of sudden failure of equipment,
provision for attending these unscheduled maintenance requirements should be made.
Corrective maintenance work is to be given priority depending on the seriousness of the
problem faced and the impact on plant operations. The schedule for repair of any
equipment should be carefully planned to keep outage time to a minimum.
During such repair or replacement work, inspection should be conducted carefully to
determine why the equipment has failed. Good corrective maintenance requires, not only
quick restoration of the failed equipment back into service but also demands every effort to
identify and record the root cause of the failure. The inspection results can be of significant
help in exploring the exact reason for the failure. The findings along with possible
rectification proposals are to be used as a feedback to update the preventive maintenance
procedures.
6.1
Prerequisites
The necessary prerequisites for the corrective maintenance of the main oil tank and
the vapor extractor fan are as follows:
a)
Scheduling
Unlike preventive maintenance, scheduling activity only starts after failure of
the equipment. Depending on the severity of the problem, the importance of
the service provided by the failed equipment and availability of manpower to
attend to the problem, a contingency schedule is to be prepared to solve the
problem at the earliest opportunity. The schedule should clearly indicate the
critical path activity and assign the priority for different parallel activities.
Finally, once the schedule is agreed, strict adherence to it is to be maintained
to ensure timely completion of the maintenance activity.
b)
Inter Departmental Cooperation/Communication

Refer to Section 4.1.2, Departmental Interface/Notification.
c)
Isolation of Equipment
d)
Safety Precautions
Refer to Section 4.1.4, Safety Precautions.
MM-M05.08
Rev.000
Refer to Section 4.1.3, Isolation of Equipment.
Mitsubishi
6-1
Chapter-6
6.2
Preparation
a)
Parts, Tools and Equipment

Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.
b)
Documentation
Refer to Subsection 4.2.1 b), Documentation.
6.3
Troubleshooting
MM-M05.08
Rev.000
This section provides information about carrying out troubleshooting and servicing
for the main oil tank and vapor extractor fan, pertaining to the mechanical
maintenance staff. A table of Faults, Possible Causes and Remedies has been
provided to assist in troubleshooting by qualified users. If any new kind of problem
is encountered which is not listed in the following table, contact the manufacturer for
assistance.
Mitsubishi
6-2
Chapter-6
TABLE 6-1
TROUBLESHOOTING MAIN OIL TANK AND VAPOR EXTRACTOR FAN

Fault
Abnormal decrease of oil level

in the tank
Possible Cause
Remedy
Loose flange connection
Retighten the connection
Oil emission through the mist

separator
Adjust vapor extractor fan suction

damper
Failure of oil purifier seal
Correct oil purifier
Evaporation loss
Top-up with fresh oil
Manhole cover left open or loose
Close cover securely
Loose inspection covers
Tighten the inspection covers

properly
Vapor extractor fan suction closed

or throttled
Readjust the suction damper
Steam ingress from turbine glands
Check and correct gland sealing

pressure and gland steam
condenser vacuum
Improper oil purifier water

separation
Check and correct the oil purifier
Main oil pump suction oil pressure

low
Faulty No. 1 ejector
Shutdown and rectify No. 1 ejector
AOP/TOP/EOP discharge pressure

low
Suction strainer blocked
Shutdown and clean suction

strainer
Oil piping leakage
Rectify oil leakage
Relief valve seat leakage due to

debris
Clean and remove debris/foreign

matter
Oil piping leakage
Rectify oil leakage
Increase in MOP internal

clearances
Shutdown and correct MOP

internal clearances
Internal leakage in the discharge

check valve of the standby pump
(AOP/TOP/EOP)
Rectify the check valve internal

leakage
High oil temperature
Check and rectify problems of oil

cooler
Standby pump rotating in reverse

direction (AOP/TOP/EOP)
Internal leakage in the discharge

check valve of the standby pump
Rectify the check valve internal

leakage
High oil temperature
Malfunctioning of oil cooler
Check and rectify problems of oil

cooler
Loss of vacuum in the oil tank
High water content in oil
MM-M05.08
Rev.000
Reduction of lube / HP oil pressure
Mitsubishi
6-3
Chapter-7
Chapter
MM-M05.08
Rev.000
7 Recommended Lubrication
Mitsubishi
7-1
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1069
FIGURE 7-1
RECOMMENDED LUBRICANTS LIST FOR MAIN OIL TANK
Mitsubishi
7-2
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1070
FIGURE 7-2
RECOMMENDED LUBRICANTS LIST FOR AOP
Mitsubishi
7-3
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1071
FIGURE 7-3
RECOMMENDED LUBRICANTS LIST FOR TOP
Mitsubishi
7-4
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1072
FIGURE 7-4
RECOMMENDED LUBRICANTS LIST FOR EOP
Mitsubishi
7-5
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1073
FIGURE 7-5
RECOMMENDED LUBRICANTS LIST FOR VAPOR EXTRACTOR FAN
Mitsubishi
7-6
Appendix A
Appendix
A Torque Chart
TABLE A-1
TORQUE CHART
Bolt Size
Tightening Torque (Nm)
M6
M7
10
M10
20
M12
35
M16
80 90
M20
155 175
M24
275 305
M30
545 605
M36
950 1050
M42
1520 1680
M48
2300 2520
M56
3690 4070
M64
5560 6150
Note
This table is to be used in absence of torque value recommended by the vendor.
(1)
Apply anti-seize compound to bolts.
(2)
Tighten nuts 20% of the calculated torque in a cross-diagonal sequence.
(3)
Following the sequence, tighten the nuts to 80% of calculated torque.
(4)
Following the sequence, tighten the nuts to 100% of calculated torque.
MM-M05.08
Rev.000
Perform the following steps in sequence:
Mitsubishi
A-1
Appendix B
Recommended
B Spare Parts
MM-M05.08
Rev.000
Appendix
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP)
Mitsubishi
B-1
MM-M05.08
Rev.000
Appendix B
MPTD-4-0776
FIGURE B-1
OPERATING SPARE PARTS LIST FOR AUXILIARY OIL PUMP
Mitsubishi
B-2
Rev.000
Appendix B
MM-M05.08
MPTD-4-0777
FIGURE B-2
OPERATING SPARE PARTS LIST FOR TURNING OIL PUMP
Mitsubishi
B-3
Rev.000
Appendix B
MM-M05.08
MPTD-4-0778
FIGURE B-3
OPERATING SPARE PARTS LIST FOR EMERGENCY OIL PUMP
Mitsubishi
B-4
MM-M05.08
Rev.000
Appendix B
MPTD-4-1130
FIGURE B-4
OPERATING SPARE PARTS FOR MOT VAPOR EXTRACTOR
Mitsubishi
B-5
MM-M05.08
Rev.000
Appendix B
MPTD-4-1131
FIGURE B-5
OPERATING SPARE PARTS FOR MIST SEPARATOR
Mitsubishi
B-6
Appendix C
Appendix
C Special Tools
MM-M05.08
Rev.000
The manufacturer of these pumps does not recommend any special tools for maintenance work.
Mitsubishi
C-1
Appendix D
Appendix
D Coupling Alignment
The following basic alignment procedure is suitable for most motor to driven machine couplings.
However, if additional details are required, reference should be made to the manufacturers
instructions.
Peripheral Alignment
Using a Dial Test Indicator (DTI):
Match mark the coupling halves.
With both match marks at the top:

Check DTI reading at zero.
Turn both shafts 90, check DTI reading at 90.
Turn both shafts a further 90, check DTI reading at 180.
Turn both shafts a further 90, check DTI reading at 270.
Turn both shafts to zero, recheck DTI reading at zero.
MM-M05.08
Rev.000
Mitsubishi
D-1
Appendix D
Axial Alignment
An inside micrometer or a tapered gap gauge can be used dependent upon the size of the gap
between the coupling faces. This example uses an inside micrometer.
Ensure both match marks at the top:
1
With shafts stationary, measure a, b, c, d.
Turn both shafts 180 (match marks at the bottom).
With shafts stationary, measure c, d, a, b.
From the readings obtained, adjustments can be made to the liners (shims) installed under the
feet of the driving/driven equipment. Allowable tolerances are as follows:
Flexible Couplings
Rigid Couplings
0.05 mm
Peripheral
0.03 mm
Axial
0.03 mm
Axial
0.02 mm
MM-M05.08
Rev.000
Peripheral
Mitsubishi
D-2
Appendix E
Applicable
E Reference Drawings
MM-M05.08
Rev.000
Appendix
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP)
Mitsubishi
E-1
MM-M05.08
Rev.000
Appendix E
MPTD-3-0754
Mitsubishi
FIGURE E-1
ARRANGEMENT DRAWING OF MAIN OIL TANK

E-2
MM-M05.08
Rev.000
Appendix E
MPTD-4-0755
FIGURE E-2
OUTLINE DRAWING OF AOP
Mitsubishi
E-3
MM-M05.08
Rev.000
Appendix E
MPTD-4-0756
FIGURE E-3
ASSEMBLY DRAWING OF AOP (1/3)
Mitsubishi
E-4
MM-M05.08
Rev.000
Appendix E
MPTD-4-0757
FIGURE E-4
Mitsubishi
E-5
MM-M05.08
Rev.000
Appendix E
MPTD-4-0758
FIGURE E-5
Mitsubishi
E-6
MM-M05.08
Rev.000
Appendix E
MPTD-4-0759
FIGURE E-6
EXPECTED PERFORMANCE CURVES FOR AOP
Mitsubishi
E-7
MM-M05.08
Rev.000
Appendix E
MPTD-4-0760
FIGURE E-7
TORQUE CHARACTERISTIC CURVES FOR AOP
Mitsubishi
E-8
MM-M05.08
Rev.000
Appendix E
MPTD-4-0761
FIGURE E-8
OUTLINE DRAWING OF AOP MOTOR
Mitsubishi
E-9
MM-M05.08
Rev.000
Appendix E
MPTD-4-0762
FIGURE E-9
OUTLINE DRAWING OF TOP
Mitsubishi
E-10
MM-M05.08
Rev.000
Appendix E
MPTD-4-0763
FIGURE E-10
ASSEMBLY DRAWING OF TOP (1/3)
Mitsubishi
E-11
MM-M05.08
Rev.000
Appendix E
MPTD-4-0764
FIGURE E-11
Mitsubishi
E-12
MM-M05.08
Rev.000
Appendix E
MPTD-4-0765
FIGURE E-12
Mitsubishi
E-13
MM-M05.08
Rev.000
Appendix E
MPTD-4-0766
FIGURE E-13
EXPECTED PERFORMANCE CURVES FOR TOP
Mitsubishi
E-14
MM-M05.08
Rev.000
Appendix E
MPTD-4-0767
FIGURE E-14
TORQUE CHARACTERISTIC CURVES FOR TOP
Mitsubishi
E-15
MM-M05.08
Rev.000
Appendix E
MPTD-4-0768
FIGURE E-15
OUTLINE DRAWING OF TOP MOTOR
Mitsubishi
E-16
MM-M05.08
Rev.000
Appendix E
MPTD-4-0769
FIGURE E-16
OUTLINE DRAWING OF EOP
Mitsubishi
E-17
MM-M05.08
Rev.000
Appendix E
MPTD-4-0770
FIGURE E-17
ASSEMBLY DRAWING OF EOP (1/3)
Mitsubishi
E-18
MM-M05.08
Rev.000
Appendix E
MPTD-4-0771
FIGURE E-18
Mitsubishi
E-19
MM-M05.08
Rev.000
Appendix E
MPTD-4-0772
FIGURE E-19
Mitsubishi
E-20
MM-M05.08
Rev.000
Appendix E
MPTD-4-0773
FIGURE E-20
EXPECTED PERFORMANCE CURVES FOR EOP
Mitsubishi
E-21
MM-M05.08
Rev.000
Appendix E
MPTD-4-0774
FIGURE E-21
TORQUE CHARACTERISTIC CURVES FOR EOP
Mitsubishi
E-22
MM-M05.08
Rev.000
Appendix E
MPTD-4-0775
FIGURE E-22
OUTLINE DRAWING OF EOP MOTOR
Mitsubishi
E-23
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-24
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-25
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-26
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-27
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-28
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-29
MM-M05.08
Rev.000
Appendix E
MPTD-3-1038
Mitsubishi
FIGURE E-29
LUBRICATING OIL STRAINER

E-30
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-31
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-32
MM-M05.08
Rev.000
Appendix E
Mitsubishi
E-33

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Project Dwg. No: G101-25-1723.

Turbine Main Oil Tank and

Be sure to read this manual.

Disassembly and Reassembly

The operation, maintenance and inspection of Equipment must be

The modification or change of operational specification must be performed

The address for MHI to be contacted is shown in this chapter.

The operation and maintenance must be performed according to the applicable

The copyright of software, drawings and other documents provided by MHI at

Important General Notice for Safety

The protection measures must satisfy all of the operational functions.

The safety activity must be planned systematically as a Safety and Health

To prevent accidents involving personnel and equipment, it is necessary to

Risk of a fatal accident

Danger to lose his health and fitness

Danger of damage to the equipment

Instruction of this Manual

The warning labels are to be expressed in the English language.

This manual contains optional matters.

MHI may change the content of this manual without notice.

Nothing in these provisions shall constitute or be deemed to constitute any

The Contract Warranties are subject to the construction, installation and

Accidents and Damages caused by the modification or re-installation of the

Accidents and Damages caused by natural disasters or accidents during

Accidents and Damages due to faulty operation or operation not in accordance

Accidents and Damages due to inappropriate maintenance or servicing

Accidents and Damages caused by any components, parts, systems or other

Accidents and Damages caused by unidentifiable reasons including loss of the

Accidents and Damages caused by referring to inadequate, or incorrect

Accidents and Damages or rust/corrosion due to inadequate handling and/or

Nothing in this Limitation of Liability section or manual shall constitute or be

Use and Disposal

For Documents and Safety Training

For Damage to the Plant

Use, copying, other reproduction of the whole or part of the documents

The act of rewriting, translating, modifying, revising, creating electronic copies,

Personnel to whom the

For Support before Operation:

For Support after Commissioning and in an Emergency

Auxiliary Oil Pump

Closed Cooling Water

Normal Working Level

Emergency Oil Pump

Process and Instrumentation

Instrument and Control

Personal Protective Equipment

Main Oil Pump

Resistance Temperature Detector

Main Oil Tank

Material Safety Data Sheet

List of Vendor Manuals

Features of Turbine Main Oil Tank and Auxiliary Oil Pumps

Definitions of Serious Injury, Minor Injury, Serious

Hazard Warning Label 1-5

Risk Assessment Standard 1-8

Work Permit System (Lockout/Tagout) 1-10

General Cautions on Personnel in Working Area 1-11

Caution against Rotating Equipment 1-11

1.4.2.2 Cautions against Electrical Equipment 1-11

1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-14

Safety (Continued from previous page)

1.5.1.3 Evacuation from Power House1-20

Fire Accident 1-21