MM M05 3

Project Dwg. No: G101-25-1700.
01-MM56
Turbine Main Oil Pump

MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT
Turbine Main Oil Pump Maintenance

Manual No. MM-M05.06
Revision 001
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 Pump
Maintenance
Be sure to read this manual.

Contents
Safety
General
Specifications
Preventive Maintenance
Disassembly and Reassembly
Corrective Maintenance
Recommended Lubrication
Appendixes
Contents
Contents
Revision Record i
Important Informationii
Warranty v
Limitation of Liabilityvii
Copyrightix
Personnel to whom the Manual is Directed x
Contact Addressxi
Abbreviations xii
List of Vendor Manuals xiii
Arrangement of the System Maintenance Manualxiv
Chapter1
Safety ____________________________
1.1
Feature of Turbine Main Oil Pump Safety 1-1
1.2
Warnings Description 1-2

1.2.1
Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property 1-3
1.2.2
Symbol 1-4
1.2.3
Hazard Warning Label 1-5
1.2.4
Hazard Area 1-7
1.3
Risk Assessment Standard 1-8
1.4
Safety Measures 1-10

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 High Voltage Section 1-11
1.4.2.3 Cautions against High Temperature Sections 1-12
1.4.2.4 Cautions for Steam Leak in the Plant 1-13
1.4.2.5 Cautions against Oil Leak in the Plant 1-13
1.4.2.6 Cautions against Chemicals 1-14
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-14
Rev.001
1.4.2.8 Cautions against Lack of Oxygen 1-15

1.4.2.9 Cautions against Lifting Heavy Object 1-16
1.4.2.10 Caution against Sharp Objects 1-16
MM-M05.06
1.4.2.11 Cautions using Fork Lift 1-16

1.4.2.12 Cautions using Crane 1-17
Mitsubishi
Contents
Chapter1
Safety (Continued from previous page)

1.4.2.13 Disposal 1-18
1.5
Emergency Measure 1-19

1.5.1
Evacuation on Emergency Case 1-19
1.5.1.1 Evacuation Route 1-19

1.5.1.2 Evacuation of disabled persons who cannot move by
themselves 1-19
1.5.1.3 Evacuation from Power House 1-20
Fire Accident 1-21
1.5.3
Earthquake 1-22
1.5.4
Explosion Accident 1-22
1.6
Qualification and Training 1-23
Chapter2
General ___________________________
2.1
Purpose 2-1
2.2
References 2-1
2.3
Overview of the Turbine Main Oil Pump 2-2
2.4
Construction 2-6
2.4.1
Pump Casing 2-6
2.4.2
Impeller and Shaft Assembly 2-7
2.4.3
Impeller Seal Rings 2-8
2.4.4
Shaft Penetration Seal Rings 2-8
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites 4-1
4.2
4.3
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1.5.2

Mitsubishi
4.1.1
Scheduling 4-1
4.1.2
Departmental Interface/Notification 4-2
4.1.3
Isolation of Equipment 4-2
4.1.4
Safety Precautions 4-2
Routine Maintenance 4-3

4.2.1
Preparation 4-3
4.2.2
Inspection and Maintenance 4-4
Annual Outage Maintenance 4-7

4.3.1
Preparation 4-7
4.3.2
Inspection and Maintenance 4-8
Contents
Chapter5
Disassembly and Reassembly ________
5.1
Turbine Main Oil Pump Disassembly and Reassembly 5-1
5.2
Impeller Removal and Replacement 5-5
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites 6-1
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 Vendor Drawings E-1
Appendix F
Instruction ManualF-1
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Appendix A

Mitsubishi
Contents
List Of Figures
Figure 1-1
Types of Hazard Warning Labels 1-6
Figure 1-2
Mapping for Hazard Areas 1-9
Figure 2-1
Main Turbine Lubricating Oil Flow Diagram 2-3
Figure 2-2
Overview and Location of Main Oil Pump 2-4
Figure 2-3
Isometric View of Turbine Main Oil Pump 2-5
Figure 2-4
Cutaway View of Turbine Main Oil Pump 2-9
Figure 2-5
Sectional View of Turbine Main Oil Pump 2-10
Figure 4-1
Turbine Main Oil Pump Clearance Drawing 4-15
Figure 5-1
Exploded View of Turbine Main Oil Pump 5-7
Figure B-1
Spare Parts for Main Oil Pump 1/2B-2
Figure B-2
Spare Parts for Main Oil Pump 2/2B-3
Figure E-1
Turbine Main Oil Pump Assembly (1/2)E-2
Figure E-2
Turbine Main Oil Pump Assembly (2/2)E-3
List Of Tables
Risk Assessment Standard 1-8
Table 3-1
Turbine Main Oil Pump 3-1
Table 4-1
Routine Maintenance Checklist 4-6
Table 4-2
Annual Outage Maintenance Checklist 4-12
Table 6-1
Troubleshooting Turbine Main Oil Pump 6-3
Table A-1
Torque Chart A-1
MM-M05.06
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Table 1-1

Mitsubishi
Revision Record
Page Number
General
Description of Revision
Revision record added and all
pages changed to rev. 0001
Revision Issue
Date
Date Revised
Pages
Inserted
2012/03/30
2012/03/30
DRS (drawing review sheet)

added.
Appendix F para. 7 modified.
MM-M05.06
Rev.001
F-1

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 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-M05.06
Rev.001
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 regulations.

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ii
4.
The copyright of software, drawings and other documents provided by MHI at

all times, is still reserved by MHI.
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.
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.
MM-M05.06
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If the notices are not observed, the following dangers could occur to the
operator, and to the maintainer.
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.

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iii
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.
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-M05.06
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1.

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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

Customer 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-M05.06
Rev.001

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-M05.06
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vi
Limitation 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-M05.06
Rev.001
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

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vii
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.
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,
MM-M05.06
Rev.001
in material or Equipment that was used during a repair, even when such repair
was performed by or under an instruction given by MHI.

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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
MM-M05.06
Rev.001
provided by MHI, whether arising from contract, implication, estoppel or

otherwise, is being granted or otherwise transferred.

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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-M05.06
Rev.001
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-M05.06
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(Later)

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xi
Abbreviations
Abb.
Expanded Form
Abb.
Expanded Form
Alternating Current
MOST
Mechanical Overspeed Trip
Gen End
Generator End
MSDS
Material Safety Data Sheet
Gov End
Governor End
NDE
Non-Destructive Examination
HP
High Pressure
OJT
On Job Training
IP
Intermediate Pressure
P&ID
Process and Instrumentation

Diagram
I&C
Instrumentation and Control
PPE
Personal Protective Equipment
LH
Left-hand
PTW
Permit to Work
LP
Low Pressure
RH
Right-Hand
MOP
Main Oil pump
TOP
Turning Oil Pump
MM-M05.06
Rev.001
AC

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xii
List of Vendor Manuals
MM-M05.06
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NIL

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xiii
Arrangement of the System

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 Pump.
Chapter 2
Describes the construction, purpose, and function of the Turbine Main Oil Pump and
the associated parts.
Chapter 3
Describes the Turbine Main Oil Pump parts, 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 Turbine Main Oil Pump overhaul.
Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.
MM-M05.06
Rev.001
Chapter 7
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents

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xiv
Chapter 1
Safety
C h a p t er
1 S af et y
1.1
Feature of Turbine Main Oil Pump Safety

The main oil pump is the equipment that rotates at the same speed of the main
turbine. The main oil pump when in service is subject 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 when there is a
turbine trip.
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 high risk of flange/pipe leakage. Leaked oil
from the oil piping can cause extensive damages in the vicinity of the turbine
and/or person working near, if it catches fire.
Oil lines supplying the control and lubricating oils to the main turbine are located
around the main turbine. Any oil leakage in the vicinity of the turbine could lead
to a fire which could damage the nearby components. All personnel should pay
strict attention and rectify any oil leakage at the first sight of leakage.
The main oil pump operates with close internal clearances and any disturbance
in the turbine rotor alignment can cause internal rubbing and damage to the
main oil pump components. All operators and maintainers should pay special
attention if any rubbing noise is observed near the HP pedestal where the Main
Oil Pump is installed.
MM-M05.06
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All operators and maintainers must realize the danger and keep themselves
safe, following the recommendations written in this chapter.

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1-1
Chapter 1
1.2
Safety
Warnings Description
Safety of personnel working in the power plant is the most important matter and
all kinds of consideration to avoid dangerous conditions 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
during use of the Turbine Main Oil Pump, 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
CAUTION
during use of the Turbine Main Oil Pump, 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 Pump, and that, if

not heeded, may result in an accident of an
in-assessable hazard level.
NOTICE describes useful information and tips for
Notice
operation and maintenance of the Turbine Main Oil
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Pump.

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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-M05.06
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This term describes damage, which does not require any suspension
of productive activity due to restoration of the damaged property.

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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
MM-M05.06
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operation and maintenance of the Turbine Main Oil Pump.

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1-4
Chapter 1
1.2.2
Safety
Symbols (Continued from previous page)
Symbol
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
Turbine Main Oil Pump are mandatory.
This symbol indicates a movable section that is inside a safety
cover or exposed.
Do NOT touch any equipment where this symbol is displayed.
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
labels peel off/wear out or become unreadable, install a new label in
the original location without delay.
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applied to this Turbine Main Oil Pump. If any of the hazard warning

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1-5
Chapter 1
WARNING
Safety
DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION
PINCH POINT
STEEP
DROP
DO NOT
ENTER
DO NOT
TOUCH
DO NOT
TOUCH
MM-M05.06
Rev.001
TB0001_A
FIGURE 1-1
Mitsubishi
TYPES OF HAZARD WARNING LABEL
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-M05.06
Rev.001
Main Oil Pump.

Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard

As prepared by the Design Section as per MIL STD822D.
TABLE 1-1
RISK ASSESSMENT STANDARD

Detailed Description of Impact on each Object
Category
Safety
- Death
- Harmful gas or oil leakage

- High pressure and
temperature material leakage
such as steam, water, air and
gas, oil etc.
- Low oxygen
Catastrophic
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.001
Environment
- Unit shutdown (unit cannot be

operated)
- More than 4 days for repairing
TABLE 1-1
MM-M05.06
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
3
4
3 9
2 8
1 7
7
4
3
Safety
7
4
3
7
4
3
4
3
STAIR WAY
2
3
5
10
3
7
8
3
4
7
STAIR WAY
2
3
5
10
2
3
5
10
2
3
5
10
3
4
7
3
4
7
1 7
2 8
3 9
4
3
4
7
NOTES
WARNING LABELS SHOUD BE IN ARABIC.
GEN. SIDE
MM-M05.06
Rev.001
YELLOW
AVOID INJURY
WATCH YOUR STEP
YELLOW
FALL
WATCH YOUR STEP
MPTD-3-0314
YELLOW
RISK OF A ROTATING
A HAND
YELLOW
RISK OF A GEAR
PINCHING A HAND
GOV. SIDE
(*1)
YELLOW
RISK OF A CHAIN
PINCHING A HAND
YELLOW
PINCH POINT
KEEP HANDS AWAY
YELLOW
YELLOW
DO NOT TOUCH
HOT SURFACE
YELLOW
YELLOW
DISCONNECT
AUTOMATIC START.
ELECTRICAL POWER
KEEP HANDS CLEAR.
BEFORE SERVICING
RED
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
YELLOW
MAPPING FOR HAZARDOUS AREA
1-9
Chapter 1
1.4
Safety
Safety Measures
1.4.1 Work Permit System (Lockout/ Tagout)
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:
(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.
Rev.001
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.
(10) The Shift Charge Engineer makes sure that the work under the
permit is completed and files details in the log book.
MM-M05.06
(1)
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
Safety
1.4.2 General Cautions on Personnel in Working Area

1.4.2.1
Cautions against Rotating Equipment

All couplings on rotating machines 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-M05.06
Rev.001
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.

Mitsubishi
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.
1-11
Chapter 1
1.4.2.3
Safety
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

a 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-M05.06
Rev.001

Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant

The 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 using 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 Caution against Oil Leak in the Plant
MM-M05.06
Rev.001
CAUTION

Mitsubishi
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.
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals

Pay attention to the items listed below 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-M05.06
Rev.001

Mitsubishi
1-14
Chapter 1
1.4.2.7
Safety
Cautions against Combustible Materials /

Storage Areas (Continued)
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

the confined space is between 18~22% before entering, and
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-M05.06
Rev.001

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 Cautions against Sharp Objects
CAUTION
Use leather gloves when handling parts with sharp edges.
1.4.2.11 Cautions using Fork Lift
MM-M05.06
Rev.001
CAUTION

Mitsubishi
Do NOT permit anyone to stand below 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.
1-16
Chapter 1
Safety
1.4.2.12 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:
MM-M05.06
Rev.001

Mitsubishi
Avoid any impact to the unpacked parts.
1-17
Chapter 1
Safety
1.4.2.13 Disposal
a)
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 the MSDS
and disposed to the chemical drain system.
c)
Solid disposal made by maintenance work.
MM-M05.06
Rev.001
For disposal from the site, observe the local legal regulations.

Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure
1.5.1 Evacuation on Emergency Case
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-M05.06
Rev.001

Mitsubishi
1-19
Chapter 1
1.5.1.3
Safety
Evacuation from 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 their 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-M05.06
Rev.001

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-M05.06
Rev.001

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 fire does start, make sure that the 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.
MM-M05.06
Rev.001
1.5.4 Explosion Accident

Mitsubishi
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.
1-22
Chapter 1
1.6
Safety
Qualification and Training

The system must be operated only by authorized operators & maintenance
supervisors.
The customer shall 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 customers own personnel assessment.
Operator and maintainer training course (both classroom training and On the
Job Training (OJT)) will be provided by Mitsubishi before the handing over of
this plant. The customer must train and assess new operators and maintainers
who join after the turn-over according to his own procedure and standard,
(Mitsubishi training course may still be available if required).
MM-M05.06
Rev.001
As a minimum, operator and maintainer must satisfy the following:
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 the 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 know from their discussions with the Shift Charge
Engineer the isolation method for mechanical, electrical and instrumental
equipment to ensure safety for maintenance work during plant operation.
Maintainer must also be able to handle the maintenance tools provided by

the owner and those supplied by the manufacturer.

Mitsubishi
1-23
Chapter 2
General
C h a p t er
2 General
2.1
Purpose
The purpose of this maintenance manual is to provide specific information to the
Paiton Expansion Project maintenance personnel regarding the maintenance of
the turbine main oil pump. Although this document will convey a good
knowledge and direction regarding maintenance of the turbine main oil pump, 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 turbine
manufacturer.
References
a)
Turbine Sectional Assembly

MHI Dwg No: T3059AAAA001
Project Dwg No: P101-50-3-TB-TGO003.
b)
Control and Lubrication Oil System Diagram

MHI Dwg No: T3059AAAA210-1
Project Dwg No: P101-51-3-TB-LT0001.
c)

d)

e)
Main Oil Pump Assembly (1/2, 2/2)

MHI Dwg No: N26-T19-5054.
MM-M05.06
Rev.001
2.2

Mitsubishi
2-1
Chapter 2
2.3
General
Overview of the Turbine Main Oil Pump

Refer to Figures 2-1 to 2-3.
The turbine main oil pump (MOP) is installed in the High Pressure (HP) pedestal
in front of the HP turbine and is located on the turbine operating floor level. It is
driven directly by the HP-IP turbine rotor extension stub shaft.
As the turbine reaches normal speed the MOP discharge pressure exceeds and
replaces the discharge pressure of the auxiliary oil pump (AOP) and the turning
oil pump (TOP). Hence, the oil from the MOP discharge side becomes the high
pressure protection oil for the turbine protective devices (HP oil) and low
pressure lubricating oil for the turbine and generator bearings (lube oil).
The turbine MOP starts, stops and operates as the main turbine does. During
normal operation it turns with the main turbine rotor shaft at 3000 rpm.
The MOP is of the horizontal, single stage, conventional double suction,
centrifugal type.
The MOP draws suction oil from the outlet of No. 1 oil ejector and provides the
protection and lubricating oil requirements for the main turbine. The MOP
discharges high pressure oil (HP oil) to the turbine protection system and motive
oil for the Nos. 1 and 2 oil ejectors. The No. 1 oil ejector serves as a MOP
suction booster and the No. 2 oil ejector as a booster for the lubricating oil flow
for the thrust and journal bearings of the turbine and the generator. The seal oil
back-up line to the generator seal oil system is provided from the turbine bearing
lubricating oil system.
The MOP has no self-priming function; therefore prior to startup, the MOP is
supplied with suction oil from the TOP. This oil is used to prime and purge air
continuously from the inside of the MOP through the air vent plugs installed on
the MOP casing cover.
The extension shaft, bolted directly to the end of the HP-IP rotor at the governor
end (Gov End), carries the impeller of the MOP.
Sealing of the impeller shroud to casing and of the shaft penetrations is

achieved using floating wind-back type sealing rings.
MM-M05.06
Rev.001
The stub extension shaft also carries the centrifugally activated mechanical
overspeed trip (MOST) device and a rotor position measurement plate. It also
has provisions for installing the pick-ups for the rotor speed, rotor eccentricity,
rotor position and phase detection devices.

Mitsubishi
2-2
INSTRUMENT AIR
Chapter 2
PI
24
PIT
26
TRIP LEVER
TRIP
PIT
31
PS
31
PS
32
PS
33
PS
34
35
MANUAL TRIP DEVICE
General
SOLENOID VALVE
(TURBINE MASTER RESET)
TO ATMOSPHER
DRAIN
EH EMERGENCY TRIP OIL
RESET
RESET LEVER
FROM EH HP OIL
LIMIT SWITCH
S
S
OVERSPEED TRIP DEVICE

TEST LEVER
EMERGENCY
TRIP VALVE
S
TEST
DRAIN
PIT
25
DRAIN
EH DRAIN OIL
DRAIN
LIMIT SWITCH
MECHANICAL OVERSPEED TRIP DEVICE
AUTO STOP OIL
HP OIL
DIFFERENTIAL EXPANSION
PICK-UP
MAIN OIL PUMP
PIT
24
PI
22
PHASE DETECTOR
PICK-UP
NO1.BRG.
ROTOR ECCENTRICITY
PICK-UP
TE
4
TE
6
TE
8
NO3.BRG.
NO2.BRG.
TE
9
TE
10
NO4.BRG.
TE
12
TE
11
NO5.BRG.
TE
14
TE
13
SOLENOID VALVE
(GEAR DISENGAGE)
NO6.BRG.
TE
15
SOLENOID VALVE
(GEAR ENGAGE)
SOLENOID VALVE
OIL SUPPLY TO
TURNING GEAR
THR.BRG.
AIR
INSTRUMENT AIR
AC
M
TE
16
ATMOSPHERE
ENGAGE
TEST VALVE
TE
5
TE
23
TE
21
SHAFT POSITION
PICK-UP
PIT
21
MOP DISCHARGE OIL
MOP SUCTION OIL
MAIN
OIL PUMP
PI
25
TE
24
TE
22
TE
25
PI
1
TE
26
PI
2
TE
28
TE
27
PI
4
PI
3
DISENGAGE
COUPLING
SPRAY
HP CASING EXPANSION
COUPLING SPRAY
TE
7
COUPLING SPRAY
HP REDESTAL
LIMIT SWITCH
(GEAR ENGAGE)
TURNING GEAR ENGAGING SYSTEM

TO GENERATOR
TO GENERATOR
LUBE OIL
JACKING OIL
HP OIL
LEVEL GAUGE
VAPOUR
EXTRACTOR
PI
1
PI
5
PIT
11
PI
4
PI
21
PI
2
LUBE OIL
FILTER
OIL
RETURN
AC
M
AC
AC
LIMIT SWITCH
(GEAR DISENGAGE)
DC
M
AC
M
JACKING
OIL
PUMP(A)
AC
M
TE
3
PI
12
PI
11
3-WAY
VALVE
PIT
12
JACKING
OIL
PUMP(B)
AC
M
PIT
13
TI
3
400 Mesh.
LT
1
TURBINE OIL COOLER

TURNING
OIL PUNP
TE
1
Rev.001
TI
1
EMERGENCY
OIL PUMP
(A)
DPI
13
400 Mesh.
DPI
14
(B)
AUXILIARY
OIL PUMP
3-WAY VALVE
MOP SUCTION
EJECTOR
TURBINE LUBRICATION
EJECTOR
TE
2
MM-M05.06
MAIN OIL TANK
MPTD-3-0193
FIGURE 2-1
Mitsubishi
MAIN TURBINE LUBRICATING OIL FLOW DIAGRAM
2-3
Chapter 2
General
MAIN STEAM
INLET
IP EXHAUST
REHEAT STEAM
INLET
GOV. SIDE
GEN.SIDE
NO.1 MAIN BEARING
NO. 2&3 BEARING

PEDESTAL
THRUST BEARING
NO.2 MAIN
BEARING
MAIN OIL PUMP
HP PEDESTAL
HIP TURBINE
OPERATING FLOOR
HP EXHAUST
MAIN STEAM
INLET
MPTD-3-0194
MM-M05.06
Rev.001
REHEAT STEAM
INLET
FIGURE 2-2
Mitsubishi
OVERVIEW AND LOCATION OF TURBINE MAIN OIL PUMP
2-4
Chapter 2
D E S C R IP T IO N
P U M P C A S IN G C O V E R
P U M P C A S IN G B A S E
R O T O R P O S IT IO N IN D IC A T O R D IS C
T R IP O V E R S P E E D A S S 'Y
SHAFT
MM-M05.06
Rev.001
IT E M
1
2
3
4
5
General
FIGURE 2-3
Mitsubishi
ISOMETRIC VIEW OF TURBINE MAIN OIL PUMP
2-5
Chapter 2
2.4
General
Construction
The MOP consists of the following major components:
Pump casing
Impeller and shaft assembly
Impeller seal rings
Shaft penetration seal rings.
2.4.1 Pump Casing

Refer to Figure 2-5.
The MOP casing is a casting made of cast steel (material SC450). It is
made in two halves, the lower half forming the pump casing base (2)
and upper half the pump casing cover (1). The pump casing is
supported from below on the base of the HP pedestal.
The pump casing is formed with integral suction and discharge ports.
The suction and discharge port stubs of the casing base are supported
and secured on matching flanges welded onto the HP pedestal base
using studs (13 and 14) and U-nuts (23).
O-rings (20 and 21) installed in slots machined in the support flanges
provide effective sealing for the flange joints. Accurate location of the
casing base is achieved by the use of a set of parallel pin (18, 34) and
bush (19, 35) in each flange. The bushes are tack-welded to the
flanges and to the parallel pins after installation.
The outlet pipe of No. 1 ejector is welded to the suction port in the HP
pedestal base and the MOP discharge pipe to the discharge port.
The pump casing is divided into three sections, two extreme sections
for the pump suction and the middle section for the pump discharge. Oil
flow across these three sections is minimized during operation by two
impeller oil seal rings (11) installed in slots machined in the pump
casing and operating with a fine impeller clearance.
MM-M05.06
Rev.001
The suction port of the casing base is provided with a splitter

arrangement which splits and supplies suction oil to both suction ends
of the pump casing.
The pump casing is split horizontally so that the casing cover can be
removed to facilitate HP-IP rotor and stub extension shaft (8) assembly
removal. The horizontal joint is assembled face to face (i.e. without a
gasket).
Mitsubishi
2-6
Chapter 2
General
The two casing halves are located by two taper pins and nuts (16), and
secured by stud bolts (12 and 17) and U-nuts (22 and 24). The stud
bolts are screwed into the casing base and are tightened by the U-nuts
to secure the casing cover. The pump casing is provided with two
starting bolts (15) to facilitate removal of the casing cover during
maintenance.
Air vent plugs (27) are fitted to the casing cover, one on the discharge
section and one on each of the suction sections of the casing, to
release entrapped air.
Threaded blind holes are provided on the casing cover for the
installation of lifting eyebolts for handling purposes.
The pump casing base at the Gov End is provided with an extended
flange for mounting the mechanical overspeed trip (MOST) trigger
assembly.
2.4.2 Impeller and Shaft Assembly

The impeller (3) is made of stainless steel (material SCS1-T1) and is
keyed to the stub extension shaft with a fine clearance fit.
The axial position of the impeller in relation to the pump casing is
determined by a spacer ring (6) positioned between the impeller and a
shoulder on the extension shaft. An impeller nut (4), screwed onto a
thread machined on the extension shaft, secures the impeller. The
impeller nut is locked to the extension shaft in three positions radially at
120 apart by three sets of straight pins (25) and plugs (26).
Two vent holes are provided axially in the impeller hub and the impeller
nut to expel any entrapped air. These vent holes are interconnected by
an internal groove machined in the impeller nut. These vent holes
provide a continuous bleeding of oil/air from the pump suction casing
into the HP pedestal.
Two wear rings (5) are fitted to the impeller shroud, one on each end, to
provide a running surface for the two impeller seal rings (11). The
impeller wear rings are an interference fit on the shrouds and are
secured by grub screws (38).
The pump requires no dedicated bearings, the extension being sized
MM-M05.06
Rev.001
so that no deflection of the extension shaft occurs in normal operation.

The extension shaft is secured to the HP-IP rotor shaft with a flanged
rigid coupling. It is provided with a collar outside the pump casing
between MOP and No. 1 main bearing for locating the main turbine
thrust bearing. An overspeed trip device (33) and a rotor position disc
(7) are also installed on the extension shaft outside the pump casing at
the governor end (Gov End).
Mitsubishi
2-7
Chapter 2
General
2.4.3 Impeller Seal Rings

The cast bronze impeller seal rings (11) (material LBC4) are
manufactured in halves. The seal ring halves are secured by pins and
locked by caulking.
Each seal ring has a spiral machined on its bore and is sized to a
thickness that allows it to float radially in its slot in the casing halves. A
radial clearance of 3 mm is provided between the top of the seal ring
and the pump casing. This arrangement accommodates the radial shaft
movement required by the clearances in the HP-IP rotor bearing while
maintaining acceptable shaft and impeller sealing.
The spirals machined into the rings fitted to the Gov End are machined
left-hand (LH) and those fitted to the generator end (Gen End) are
machined right-hand (RH). This ensures that, when the shaft rotates,
the spirals tend to wind back the oil to the high pressure discharge
side.
2.4.4 Shaft Penetration Seal Rings

The shaft penetrations are sealed by two shaft penetration seal rings
(10) (material LBC4). The construction of the shaft penetration seal ring
is similar to that of the impeller seal ring.
The floating shaft penetration seal rings are located in slots provided at
each end of the pump casing. Internal spirals tend to wind back the oil
into the suction area of the pump.
MM-M05.06
Rev.001
Since the complete pump is contained in the oil tight environment of the
HP pedestal casing, further sealing is not necessary.

Mitsubishi
2-8
Chapter 2
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
8
13
13
General
DESCRIPTION
PUMP CASING COVER
PUMP CASING BASE
IMPELLER
SLEEVE
WEAR RING
SPACER
ROTOR POSITION INDICATOR DISC
SHAFT
KEY
SHAFT PENETRATION SEAL RIMNG
TRIP OVER SPEED ASS'Y
IMPELLER SEAL RIMNG
AIR VENT PLUG
10
11
6
9
5
12
3
MM-M05.06
Rev.001
FIGURE 2-4
Mitsubishi
CUTAWAY VIEW OF TURBINE MAIN OIL PUMP
2-9
Chapter 2
25
10
26
27
DETAIL A
A
24 17
27
General
DETAIL B
11
38
3
9
12 22
10
16
15
ITEM
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
33
34
35
38
DESCRIPTION
PUMP CASING COVER
PUMP CASING BASE
IMPELLER
SLEEVE
WEAR RING
SPACER
ROTOR POSITION INDICATOR DISC
SHAFT
KEY
SHAFT PENETRATION SEAL RING
IMPELLER SEAL RING
STUD BOLT
STUD BOLT
STUD BOLT
STARTING BOLT
TAPER PIN
STUD BOLT
PARALLEL PIN
BUSH
"O" RING
"O" RING
U-NUT
U-NUT
U-NUT
STRAIGHT PIN
PLUG
AIR VENT PLUG
SPRING RETAINING DISC
SPRING
SOCKET HEAD BOLT
TRIP OVER SPEED ASS'Y
PARALLEL PIN
BUSH
GRUB SCREW
33
ROTATION
29
CL OF ROTOR
28
OIL
OIL
30
8
2
2
13 23
19 18
10
INLET
23 14
34
11
CL OF PUMP
C
L O
FS
UC
TIO
C
L OF DISCHARGE
INLET
Rev.001
35
MM-M05.06
20
21
A-A
MPTD-3-0197
FIGURE 2-5
Mitsubishi
SECTIONAL VIEW OF TURBINE MAIN OIL PUMP
2-10
Chapter 3
Specifications
C h a p t er
3 Specifications
TABLE 3-1
TURBINE MAIN OIL PUMP
Subject
Specifications
Equipment Number
03MAV02AP1
Quantity
Location
Enclosed within the HP pedestal at the Gov End of

the HP-IP cylinder
Manufacturer
Mitsubishi Heavy Industries (MHI)
Type
Horizontal, axially split, double suction volute,

centrifugal type, turbine shaft driven
Rotation
Clockwise (viewed from Gov End)
Fluid
Turbine oil ISO VG32
Fluid temperature
15C - 60C
Viscosity
15 - 120 cSt
Specific gravity
0.87 @ 15C
Lubrication
Not required (casing seal rings are lubricated by

the pumped oil)
Capacity
7600 litres/minute
Discharge pressure (at 3000 rpm)
2.35 MPa (g) [24 kg/cm2 (g)]
Suction pressure
0.18 MPa (g) [1.8 kg/cm2 (g)]
Speed
3000 rpm
Weight
37 kg
Casing Cover
193 kg
Casing Base
246 kg
MM-M05.06
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Impeller assembly

Mitsubishi
3-1
Chapter 3
Specifications
Continued from previous page
TABLE 3-1
TURBINE MAIN OIL PUMP
Subject
Specifications
Construction
Impeller diameter
438 mm (OD)
Impeller width
164 mm
No of vanes
Suction bore
204 mm
Discharge bore
152 mm
Bearing
None (overhung shaft)
Shaft coupling
Rigid flange coupling
Shaft seal
Floating ring (split in halves)
Material
Stainless Steel SCS1-T1
Casing
Cast Steel SC450
Impeller nut
Carbon Steel S35C
Impeller wear ring
Carbon Steel S35C
Seal rings
Cast Bronze LBC4
MM-M05.06
Rev.001
Impeller

Mitsubishi
3-2
Chapter 4
C h a p t er
4 Preventive Maintenance
Preventive maintenance is carried out 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 turbine main
oil pump 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 co-ordinated 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 the availability and supply of required equipment, spare parts, and
tools, 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 the scheduled time.
MM-M05.06
Rev.001
4.1.1 Scheduling

Mitsubishi
4-1
Chapter 4
4.1.2 Departmental 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
isolation, 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 depressurized.
4.1.4 Safety Precautions

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 the manufacturers
instruction manual to prevent personal injury and/or equipment
damage.
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-M05.06
Rev.001
Prior to the commencement of actual work, the person carrying out the
work is to make a safety check based on the above method statement

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-M05.06
Rev.001
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 may be useful
in determining the root cause of equipment failure found during
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
Beware of any noise inside the turbine enclosure when

inspecting the HP pedestal. There can be invisible superheat
steam leakage which can cause heavy burn injuries. Always
wear gloves.
Extreme care must be taken while inspecting near a hot steam

turbine. Hands and clothing can be burned by contact with the
steam turbine parts. Always wear gloves.
CAUTION
Wear ear protection and gloves when performing inspection
near a running machine.
a)
Piping
The oil piping external to the HP pedestal is to be inspected each
shift for evidence of leakage. Minor leakage of oil can lead to a
fire hazard and severe damage to the plant. Major leakage
reduces the ability of the oil system to meet the demands placed
upon it by the requirements of the main turbine.
Perform rectification of oil leakage with the topmost priority when
leakage is discovered.
b)
Rotating Components and Casing

The noise emanating from the HP pedestal is to be monitored. An
Rev.001
increase in the noise from the HP pedestal may indicate that the
pump rotating components are near failure or that they are
coming into contact with the casing.
MM-M05.06
The turbine is to be shut down for investigation and rectification

as required.

Mitsubishi
4-4
Chapter 4
c)
Impeller and Shaft Penetration Seal Rings

The pump is located within the HP pedestal and is not readily
accessible. Hence the checks that may be performed are limited
to monitoring of the suction and discharge pressures. The suction
and discharge pressure indications are to be regularly recorded.
The records are to be reviewed periodically to trend the
performance of the pump.
MM-M05.06
Rev.001
If there is any abnormal reduction in suction and/or discharge

pressure, the pump should be shutdown and inspected for any
blockage or excessive internal clearance. The impeller wear rings,
the impeller seal rings and the shaft penetration seal rings are to
be inspected for excessive wear and replaced if abnormal wear
or excessive clearance is observed.

Mitsubishi
4-5
Chapter 4
TABLE 4-1
No.
Description
Piping
Major Check Item
Oil Leakage
Check Method
No visible leakage
ROUTINE MAINTENANCE CHECKLIST
Check Reference
No leakage
(external to the HP
pedestal)
Action to be Taken
(if beyond acceptable limit)
Remarks
Shut down and replace piping gasket

/ O-rings
Rotating
Components
Rubbing
Audible
No abnormality
Shut down turbine and inspect pump

rotating components
Impeller
Wear
Permanent suction
pressure
instrument
Higher than normal

suction pressure
(Normal: 0.18 MPa)
Shut down turbine and inspect

impeller for abnormal wear or damage
Suction pressure
deterioration below
0.18 MPa
Shutdown and inspect No. 1 oil

ejector
Recommended
Maintenance
Frequency
Every Shift
Every Shift
Every Shift
Seal Rings
Wear
Permanent
Delivery pressure
discharge pressure below 2.35 MPa
instrument
Shutdown and inspect internal

clearances
Permanent suction
pressure
instrument
Shut down turbine and inspect shaft

penetration seal rings
Suction pressure
deterioration below
0.18 MPa
Beware of
rotating shaft
during
maintenance
Every Shift
Rev.001
Every Shift
MM-M05.06
Permanent
Delivery pressure
discharge pressure below 2.35 MPa
instrument

Mitsubishi
Shut down turbine and inspect

impeller seal rings and wear rings
4-6
Chapter 4
4.3
Annual Outage Maintenance

The purpose of annual outage maintenance is the implementation of a
preventive maintenance program on a yearly basis through a planned and
correctly executed maintenance work program accompanying necessary
inspections. The annual outage maintenance activities are very important in the
sense that if properly undertaken these enhance the life and reliability of the
equipment.
Major activities related to annual outage maintenance are as follows:
(Summarized major activities for annual outage maintenance are also shown in
Table 4-2).
4.3.1 Preparation
a)

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.
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.
On completion of annual outage maintenance work, the
equipment is to be monitored for correct operation and
MM-M05.06
Rev.001
maintenance data logging. This will help to determine the correct

intervals of preventive maintenance activities to ensure optimum
plant availability. The correct recording of findings during
inspection will build a valuable document for future reference.

Mitsubishi
4-7
Chapter 4
4.3.2 Inspection and Maintenance

The turbine has to be shutdown and the turning gear stopped prior to
inspection of the turbine MOP. Normal rundown, cooling and isolation
procedures are to be followed. The lubricating oil system is to remain in
service until the turbine control stage outlet metal temperature is below
180C. Lubricating oil circulation is to be stopped before access to
MOP is permitted. Therefore access to the MOP is not possible until
this degree of cooling has taken place.
It should be noted that there is a manufacturer/vendor statement of
preference to keep the turning gear in operation whenever possible
when the turbine is shut down.
In the event that access to the turbine rotating parts is required quickly
from operating conditions, there are clear procedures that must be
followed.
The procedures for various shutdown situations are provided in
Appendix F, Turning Gear Operation During Shutdown. Operational
personnel will carry out the turbine shutdown with due regard to these
procedures.
Refer to Figure 4-1.
a)
Pump Casing
The pump casing is to be inspected for wear or deterioration that
has occurred during normal operation. Wear or deterioration can
restrict oil flow through the pump by the creation of turbulence.
The pump casing base and the casing cover are to be cleaned
using an approved solvent and lint-free cloth. Perform a visual
examination of each casing half, looking for erosion, pitting,
corrosion or cracks. Corrosion, pitting and cracks can propagate
leading to failure of the casing to contain the pumped oil and
possible destruction of the pump.
Rev.001
Carefully inspect the slots into which the impeller and shaft
penetration seal rings fit looking for fretting or wear. Sticking seal
rings cause unnecessary wear to the impeller wear ring, impeller
nut or shaft, and to the bore of the seal ring.
MM-M05.06
Measure the width of each slot and compare it to the thickness of

the respective seal ring. Replace parts to restore any clearance
that is not within the range specified in the annual outage
maintenance checklist table (Table 4-2).

Mitsubishi
4-8
Chapter 4
b)
Impeller and Shaft

Thoroughly clean the impeller and shaft using an approved
solvent and lint-free cloth. Carefully examine the impeller and
shaft for corrosion or wear. Corrosion of the shaft can lead to
cracking and failure in service and lead to destruction of the
pump.
The impeller is to be manually checked for security on the shaft.
A loose impeller will move on the shaft causing considerable
internal damage to the pump. Ensure that the impeller nut is
properly tightened to the specified torque value and the lock pins
and plugs are properly secured.
The impeller is to be inspected for cracks. Minor cracks can
rapidly increase in size during service. Severe cracking leads to
failure of the impeller and destruction of the pump. Repair or
replace the impeller as necessary.
A suitably qualified and experienced person is to perform a
Non-Destructive Examination (NDE) of the impeller using the dye
penetrant method.
The surfaces on the shaft, the impeller nut and the impeller wear
rings upon which the seal rings bear are to be inspected for
scratches or ridges. Minor wear in the form of ridges and
scratches causes accelerated wear to the bore of the casing and
impeller oil seal rings. Minor imperfections are to be reduced or
removed by an oilstone.
Concentricity between the HP-IP rotor shaft and the extension
shaft is to be checked. A deterioration of concentricity will induce
excessive vibration. An extreme deterioration in concentricity will
cause impact between the rotating and stationary components of
the pump.
Any deterioration in concentricity exceeding the acceptable limit
as specified in the outage maintenance checklist table
(Table 4-2) is to be corrected. This correction will require that the
HP-IP rotor shaft to extension shaft coupling position be adjusted.
MM-M05.06
Rev.001
If the impeller has been removed from the extension shaft, a

check for cracks in the area normally concealed by the hub of the
impeller is to be performed. Cracks in the area normally
concealed by the impeller hub can rapidly propagate causing
failure of the extension shaft and destruction of the pump.
A suitably qualified and experienced person is to perform an NDE
of the extension shaft using the dye penetrant method.
Mitsubishi
4-9
Chapter 4
c)
Impeller Seal Rings

The impeller seal rings are to be thoroughly cleaned using an
approved solvent and lint-free cloth. Each seal ring is to be
inspected for the formation of wear ridges and overall wear, on its
side faces, that has occurred during normal operation. Wear
ridges restrict the radial movement of the seal ring in the casing
and cause accelerated wear to the impeller wear ring and seal
ring bore. Excessive wear to the side faces of the impeller seal
rings causes leakage between the low pressure suction and high
pressure discharge sections within the pump causing a loss of
efficiency.
The bore of each impeller seal ring is to be inspected for damage
or excessive wear. Each impeller seal ring is to be assembled
and the bore measured. The bore size is to be compared to the
respective impeller wear ring OD (outer diameter). Replace parts
with new to restore any impeller seal ring clearance which is
greater than that specified in the annual outage maintenance
checklist table (Table 4-2).
The thickness of each impeller seal ring is to be measured. The
thickness of each ring is to be compared to the width of its
respective slot in both the pump casing base and the casing
cover. Replace parts with new to restore any clearance which is
greater than that specified in the annual outage maintenance
checklist table (Table 4-2).
d)
Shaft Penetration Seal Rings
Rev.001
The shaft penetration seal rings are to be thoroughly cleaned

using an approved solvent and lint-free cloth. Each ring is to be
inspected for the formation of wear ridges and overall wear, on its
side faces, that has occurred during normal operation. Wear
ridges restrict the radial movement of the seal ring in the casing
and cause accelerated wear to the extension shaft and/or the
impeller nut and the shaft penetration seal ring bore. Excessive
wear to the side faces of the shaft penetration seal rings causes
excessive leakage along the extension shaft causing a loss of
efficiency.
MM-M05.06
Each shaft penetration seal ring is to be reassembled and the

bore measured. The bore size of the Gen End shaft penetration
seal ring is to be compared with the shaft diameter and the bore
size of the Gov End shaft penetration seal ring is to be compared
with the impeller nut on which it runs.
Mitsubishi
4-10
Chapter 4
Replace parts with new to restore any shaft penetration seal ring
clearance which is greater than that specified in the annual
outage maintenance checklist table (Table 4-2).
MM-M05.06
Rev.001
The thickness of each shaft penetration seal ring is to be

measured. The thickness of each ring is to be compared to the
width of its respective slot in both the pump casing base and the
casing cover. Replace parts with new to restore any clearance
that is greater that that specified in the annual outage
maintenance checklist table (Table 4-2).

Mitsubishi
4-11
Chapter 4
TABLE 4-2
No.
Description
Casing
Major Check
Item
Wear, cracks
Check method
Visual
Casing seal
Visual
ring slot wear
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Action to be Taken
(If beyond acceptable
limit)
Remarks
No visible wear or
cracks
Standard mechanical
casting recovery
methods
Performed by
specialists.
No visible ridges
Remove using
carborundum stone
Performed by
specialist contractors
Inspection Date
Inspector
Results
Remachine slot
2
Impeller
Impeller key
Extension
shaft
Visual
No visible
wear/erosion
NDE (dye
penetrant)
No crack
Visual
No visible
wear/erosion
NDE (dye
penetrant)
No crack
Wear
Visual
No visible wear
Replace extension shaft
Crack
Visual
No crack
Replace extension shaft
Wear, cracks
Wear, cracks
Replace the impeller
Replace the key
MM-M05.06
Rev.001
NDE (if
impeller
removed)
Misalignment Measurement Deterioration in
to HP-IP rotor
concentricity
shaft
between HP-IP
rotor shaft and
extension shaft
Realign extension shaft

to HP-IP rotor shaft
Maximum: 0.05 mm

Mitsubishi
4-12
Chapter 4
TABLE 4-2
No.
Description
Major Check
Item
Impeller seal Wear/ridging

ring
to side faces
Side face
wear
Check method
Visual
Check Reference
No wear or ridging
Action to be Taken
(If beyond acceptable limit)
Remarks
Inspection Date
Inspector
Results
Remove using fine file

and re-polish or change
seal ring
Measurement No excessive wear
Change seal ring when

Design clearance of clearance exceeds
seal ring to casing 0.20 mm
slot
0.06 mm 0.12 mm
Bore wear
Change seal ring when

seal ring to impeller 0.30 mm
wear ring
MM-M05.06
Rev.001
0.14 mm 0.22 mm

Mitsubishi
4-13
Chapter 4
TABLE 4-2
No.
Description
Shaft
penetration
seal ring
Major Check
Item
Check method
Check Reference
Wear/ridging
to side faces
Visual
No wear or ridging
Side face
wear
Action to be Taken
(If beyond acceptable limit)
Remarks
Inspection Date
Inspector
Results
Remove using fine file and

re-polish or change ring
Change ring when

seal ring to casing 0.20 mm
slot
0.06 mm 0.12 mm
Bore wear
Change ring when

0.30 mm
seal ring to shaft
(Gen End)
0.14 mm 0.22 mm
Design clearance of
seal ring to impeller
nut (Gov End)
MM-M05.06
Rev.001
0.14 mm 0.22 mm

Mitsubishi
4-14
10.5+1
-
0.06~0.12
0.06~0.12
MM-M05.06
0.06~0.12
CLEAR.(TOTAL)
0.06~0.12
CLEAR.(TOTAL)
FIGURE 4-1
Mitsubishi
CLEAR.ON DIA
CLEAR.(TOTAL)
0.14~0.22
CLEAR.ON DIA
Rev.001
0.14~0.22
CLEAR.(TOTAL)
MPTD-3-0198
CLEAR.ON DIA
0.14~0.22
CLEAR.ON DIA
0.14~0.22
3.04
4.5
10.5+1
-
4.5
Chapter 4
TURBINE MAIN OIL PUMP CLEARANCE DRAWING
4-15
Chapter 5
C h a p t er
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
Turbine Main Oil Pump Disassembly and Reassembly
CAUTION
Prior to carrying out any maintenance, confirm all isolations are
in place and the equipment is shut down.
The removal and replacement of the HP-IP rotor falls outside the scope of this
document. Details of the procedure for opening the HP-IP cylinder, and for
rigging and removing the HP-IP rotor are fully explained in the mechanical
maintenance manual No. M-05.01, Main Turbine Maintenance.
a)
Preparation
MM-M05.06
Rev.001
If turbine main 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 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.
Co-ordinate with the Instrument and Control (I&C) Department to

remove all the attached instrumentation pick-ups before starting
disassembly work.

Mitsubishi
5-1
Chapter 5
b)
Disassembly
CAUTION
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:
CAUTION
Remove the fasteners securing the front end cover from the HP
pedestal. Jack the cover away using the jack screws and transport it
to the lay-down area.
Remove the horizontal joint bolts securing the top cover of the HP
pedestal. Remove the HP pedestal cover and transport it to the
lay-down area.
Have the turbine instrumentation pickups and their associated

brackets removed in the vicinity of the main oil pump which may
hamper removal of the pump casing cover.
Remove the U-nuts (22) from the studs (12) and the U-nuts (24) from
the studs (17) securing the pump casing cover (1) to the casing base
(2).
Unscrew and remove the nuts from the taper pins (16), which locate
the casing cover to the casing base.
Using the starting bolts (15), separate the pump casing base (2) and
the casing cover (1).
Using the lifting equipment, slowly and carefully lift the pump casing
cover (1) away to the laydown area and cover it with a polythene
sheet.
MM-M05.06
Rev.001
Rigging and transportation of equipment must be carried out by

authorized persons. Care is to be taken where equipment weight
and center of gravity is to be considered. Care is to be taken to
protect machined surfaces.
Refer to Figures 2-5 and 5-1.

Mitsubishi
5-2
Chapter 5
Note
Ensure that the pump casing cover is positioned so that the
wetted surfaces are available for inspection.
Remove the taper pins (16) from the casing base, if replacement is
essential.
Using a pin punch and small hammer, tap the oil seal ring joining pins
(32) from the shaft penetration seal rings (10) and impeller seal rings
(11) through their caulking. Remove the top half shaft penetration seal
rings and impeller seal rings. Match mark the seal ring halves and
their locations.
10 Match mark, then rotate and remove the bottom half shaft penetration
seal rings and impeller seal rings from the pump casing base.
11 Clean, inspect and refurbish or replace any damaged or worn parts.
Note
For normal annual MOP maintenance requirements
disassembly up to this point should be adequate if
inspections have confirmed that the shaft, impeller and
impeller wear rings are in a satisfactory condition.
CAUTION
Do not disconnect the extension shaft from the HP-IP rotor shaft
without due reason.
c)
Reassembly
The reassembly procedure is carried out in the reverse sequence to that
for 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.
All contact surfaces are to be cleaned before starting reassembly and all
gaskets are to be replaced.
MM-M05.06
Rev.001
Ensure that all components are free from burrs and bruises, blending
away the defects using fine files, carborundum stones and emery cloth.

Mitsubishi
5-3
Chapter 5

1
Taking note of the markings made during disassembly, install the lower
half shaft penetration seal rings (10) and the impeller seal rings (11) in
the pump casing base (2).
Note
If new seals are being installed, those with a RH spiral go to
the Gen End and those with a LH spiral go to the Gov End.
Install the top half shaft penetration seal rings and impeller seal rings
in their respective positions. Fit the joint pins (32) in the seal ring
joints and caulk them in position using a prick punch.
CAUTION
Apply the anti-seize compound to the casing base and cover joint
sparingly, ensuring that none will be squeezed from the joint to
contaminate the oil.
3
Apply anti-seize compound onto the pump casing base (2) and cover
(1) horizontal joint surfaces.
Using lifting equipment, lift the pump casing cover and carefully lower
it into position on the pump casing base.
Install the taper pins (16), if removed during disassembly and locate
the casing cover on the casing base.
Lubricate, fit and tighten the stud bolts (17) if removed during
disassembly, then install and tighten the U-nuts (24).
Lubricate, fit and tighten the casing stud bolts (12), then install and
tighten the U-nuts (22).
Tighten all casing U-nuts (22 and 24) sequentially to the torque value
specified in Appendix A.
Arrange for the instrument pickups removed during disassembly to be

installed.
MM-M05.06
Rev.001
10 Using lifting equipment, lift and position the HP pedestal cover.

11 Fit and tighten the HP pedestal cover securing bolts.
12 Fit a new gasket if required, and lift the HP pedestal front end cover
into position and tighten the front end securing screws.

Mitsubishi
5-4
Chapter 5
5.2
Impeller Removal and Replacement

Note
The impeller should not be removed from the extension shaft unless
repair or replacement is required.
a)
Preparation
If removal of the impeller from the shaft becomes necessary, all
associated equipment shall be mechanically and electrically isolated and
an authorized clearance and work permit shall be in place prior to work
commencement. The following points shall also be considered while
preparing for disassembly and reassembly:
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.
Prepare the necessary handling facilities (e.g. heating and extraction

equipment).
Removal
MM-M05.06
Rev.001
With the HP-IP rotor removed from the HP-IP turbine cylinder and
temporarily located on the rotor stand proceed as follows:
1
Remove the holding spring (29) and remove the spring retaining disc
(28) from the rotor end of the extension stub shaft (8).
Remove the rotor position indicator disc (7) by removing the socket
head bolts (30).
Remove the plugs (26) and the straight pins (25) securing the sleeve
(4) to the shaft (8).
Unscrew and remove the sleeve (4).
If the impeller (3) is to be reused, clearly mark the Gov End.

Otherwise, note the impeller vane direction to aid the fitting of a
replacement impeller.
Using properly positioned pulling equipment withdraw the impeller

from the extension shaft (8).
Remove the impeller spacer ring (6) from the extension shaft.
Remove the impeller key (9), if the key requires repair or replacement.
Remove the set screws (38) and then remove the impeller wear rings
(5), if repair or replacement is necessary.

Mitsubishi
5-5
Chapter 5
c)
d)
Checks Prior to Impeller Replacement (Original or New

Impeller)
1
Using a fine oil stone, fine emery cloth and crocus paper, remove any
ridges, scratches or rust from the section of the shaft where the
impeller is located.
Measure the diameter of the shaft 25 mm from each end at the

location where the impeller is mounted and at three points 120
displaced from each other.
Similarly, measure the bore of the impeller to be fitted.
Calculate the clearance and ensure that it is between 0.015 and

0.025 mm.
Replacement
1
Replace the impeller spacer ring (6) on the extension shaft (8).
Replace the impeller key (9) if removed during disassembly.
Slide the impeller (3) onto the shaft (8) such that the impeller key slot
engages the impeller key and push it until the impeller abuts the
spacer ring (6).
Note
Insertion of the impeller should be performed after ensuring
absolute cleanliness of the shaft. Any sticking debris may prevent
smooth insertion of the impeller and possibly stick on the way. This
will lead to undesirable withdrawal of the impeller and repetition of
MM-M05.06
Rev.001
the whole reassembly procedure.
Fit the sleeve (4) and tighten it to the torque value specified in
Appendix A.
Fit the sleeve-locking straight pins (25) and the plugs (26) and tighten
the plugs.
Install the impeller wear rings (5) in the locations they were removed
from during disassembly and secure them with the set screws (38).
Re-install the rotor position indicator disc (7) and secure it using the
socket head bolts (30).
Replace the spring retaining disc (28) and secure it to the shaft using
the holding spring (29).

Mitsubishi
5-6
Chapter 5
Disassembly & Reassembly
31
ITE M
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
27
37
36
15
D E S C R IP TIO N
P U M P C A S IN G C O V E R
P U M P C A S IN G B A S E
IM P E LLER
S LE E VE
W E A R R IN G
SPACER
R O TO R P O S IT IO N IN D IC A TO R D IS C
S H A FT
KEY
S H A FT P E N E T R A TIO N S E A L R IN G
IM P E LLE R S E A L R IN G
S TU D BO LT
S TU D BO LT
S TU D BO LT
S TA R T IN G B O LT
TA P ER PIN
S TU D BO LT
P A R A LLE L P IN
BUSH
"O " R IN G
"O " R IN G
U -N U T
U -N U T
U -N U T
S TR A IG H T P IN
P LU G
A IR V E N T P LU G
S P R IN G R E TA IN IN G D IS C
S P R IN G
S O C K E T H E A D B O LT
LIF TIN G LU G
JO IN IN G P IN
TR IP O V ER S P E E D A SS 'Y
P A R A LLE L P IN
BUSH
IN S TR U M E N T P IC K U P S
P IC K U P H O LD E R
GRUB SCREW
34
38
M P T D -3-0199
MM-M05.06
Rev.001
35
FIGURE 5-1
Mitsubishi
EXPLODED VIEW OF TURBINE MAIN OIL PUMP

5-7
Chapter 6
C h a p t er
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 is to 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, an inspection is to be carefully conducted to
determine why the equipment has failed. Good corrective maintenance requires, not only
the 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 MOP 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)
Departmental Interface/Notification
Refer to Section 4.1.2, Departmental Interface/Notification.
MM-M05.06
Rev.001
c)
Isolation of Equipment
Refer to Section 4.1.3, Isolation of Equipment.
d)
Safety Precautions
Refer to Section 4.1.4, Safety Precautions.

Mitsubishi
6-1
Chapter 6
6.2
Preparation
a)

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-M05.06
Rev.001
This section provides information about carrying out troubleshooting and servicing
for the turbine MOP, pertaining to mechanical maintenance staff. Tables of faults,
possible causes and remedies have 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
Fault
Discharge pressure or
flow is low
TROUBLESHOOTING TURBINE MAIN OIL PUMP

Possible Cause
Remedy
Impeller worn or damaged
Check impeller and

repair/replace if required
Oil seal rings worn
Check clearance and

replace as required
No. 1 ejector plate is stuck
Overhaul No. 1 ejector
Oil leakage inside HP

pedestal
Shut down turbine and

repair oil leakage
Suction pressure at
start-up is low
Priming is insufficient
Adjust the turning oil pump

supply
Noise is
abnormal/excessive
Cavitation
Perform frequency analysis

and repair/replace
components as required
Internal contact
Investigate and repair
HP-IP rotor/extension shaft

joint loose
Overhaul to correct fault and

rebalance rotor
HP-IP rotor/extension shaft

misalignment
Realign
Internal rubbing between

pump rotary and stationary
components
Check and replace defective

components, and readjust
clearance
MM-M05.06
Rev.001
Vibration is abnormal
or excessive

Mitsubishi
6-3
Chapter 7
Recommended Lubrication
C h a p t er
7 Recommended Lubrication
Since the turbine MOP is supported by a shaft overhung from the HP-IP rotor, there are no
bearings. The impeller and shaft penetration seal rings are the only wearing surfaces and
these are lubricated by the pumped medium turbine lubricating oil.
Therefore there are no specific recommendations regarding lubrication.
MM-M05.06
Rev.001
For details of the turbine lubricating oil pumped by the main oil pump, refer to the
mechanical maintenance manual No. M-05.08, Turbine Main Oil Tank and Auxiliary Pumps
Maintenance.

Mitsubishi
7-1
Appendix A
A p p en d i x
A Torque Chart
TABLE A-1
Description
Impeller nut
Bolt Size
Quantity
Special thread
TORQUE CHART
Torque
Remarks
29010% (261~319) kg.m (OR)

284410% N.m (2560 ~ 3128 N.m)
Normal tightening torque
Suction flange nuts

(23)
M20
Discharge flange
nuts(23)
M20
12
32 (29 ~ 35) kg.m (OR)

310 (280 ~ 340) N.m
Casing cover nuts

(22)
M20
17
Casing cover nuts

(24)
M20
Add U-nut
friction to the
above normal
tightening
torque
Note
Perform the following steps in sequence.
Apply anti-seize compound to bolts.
Measure torque required to overcome U-nut friction.
Calculate final torque requirement.
Tighten nuts 20% of the calculated torque in a cross-diagonal sequence.
Following the sequence, tighten the nuts to 80% of calculated torque.
Following the sequence, tighten the nuts to 100% of calculated torque.
MM-M05.06
Rev.001

Mitsubishi
A-1
Appendix B
Recommended
B Spare Parts
A p p en d i x
OPERATING SPARE PARTS LIST

Item no.
Description
Part No.
Dwg. No.
Oil seal
Mark-A01
TE60E-00003-A
Oil seal
Mark-A02
TE60E-00004-A
Oil seal
Mark-A04
TE60E-00004-B
Oil seal
Mark-A03
TE60E-00003-B
MM-M05.06
Rev.001

Mitsubishi
B-1
Appendix B
MM-M05.06
Rev.001
SPARE PARTS
FIGURE B-1

Mitsubishi
SPARE PARTS FOR MAIN OIL PUMP 1/2
B-2
MM-M05.06
Rev.001
Appendix B
FIGURE B-2
Mitsubishi
SPARE PARTS MAIN OIL PUMP 2/2
B-3
Appendix C
A p p en d i x
C Special Tools
MM-M05.06
Rev.001
The main oil pump is shop-built and supplied as an assembly with the HP-IP turbine rotor shaft.
Therefore, no specific tools are recommended.

Mitsubishi
C-1
Appendix D
A p p en d i x
D Coupling Alignment
MM-M05.06
Rev.001
The oil pump is shop-built and supplied complete with the HP pedestal. The main oil pump shaft is
an extension of the HP-IP turbine rotor shaft. Therefore, no specific alignment procedure is
applicable to this equipment.

Mitsubishi
D-1
Appendix E
A p p en d i x
MM-M05.06
Rev.001
E Applicable Vendor Drawings

Mitsubishi
E-1
MM-M05.06
Rev.001
Appendix E
MPTD-3-0334
FIGURE E-1
Mitsubishi
TURBINE MAIN OIL PUMP ASSEMBLY (1 OF 2)

E-2
MM-M05.06
Rev.001
Appendix E
MSD-3-0335

Mitsubishi
FIGURE E-2
TURBINE MAIN OIL PUMP ASSEMBLY (2 OF 2)
E-3
Appendix F
A p p en d i x
F Instruction Manual
Turning Gear Operation During Shutdown
The turbine-generator rotor is driven by turning gear at a nominal speed of 3 rpm.
Following a shutdown, the turbine-generator unit turning gear will engage automatically as soon
as the unit stops rolling. The operator should verify that the turning gear is rolling the turbine. In
order to facilitate restating the unit, it is recommended that it be rolled by the turning gear
throughout the shutdown period. Continuing turning gear operation after the turbine is
comparatively cool, greatly increases the likelihood that eccentricity will be within acceptable
limits for start up by preventing bowing of the rotors if steam should leak into the turbine during
the shutdown period.
Normally the turbine should remain on turning gear following a hot shutdown until the rotors have
cooled to between 150C to 200C.
Maintaining turning gear operation for this duration will prevent a rotor bow and assure the
availability of the turbine for start up without delay.
The rate of heat conduction through the gland ends of the turbine rotors to the journals is low.
The normal oil circulation around the journals is sufficient to keep the journals cool whether the
unit is at rest or on turning gear. If lubricating oil is shut off, the journal temperatures will rise at a
rate depending on the turbine internal temperatures. When there is no oil circulation, a journal
temperature in excess of 135C may cause damage to the bearing Babbitt.
Bearing metal temperatures should be closely monitored during this time and oil circulation
restored if excessive temperatures result.
If the turbine is hot, that is the control stage outlet metal temperature is between 200C to 450C,
and the turbine turning gear motor is not available for some reason, oil system maybe shutdown
for about 2 to 3 hours. By this time the motor problem can be rectified. During this period take
care that the journal bearing metal temperature does not exceed the permissible limits. If the
control stage temperature is less than 200C, the stoppage can be extended to 10 hrs. However,
if the control stage temperature is more than 450C continue the lube oil until the temperature
comes to less than 450C for carrying out any maintenance on the turning gear motor.
MM-M05.06
Rev.001
When it can be arranged without delaying work schedules, the turning gear and the oil circulation
system should be kept in operation for not less than 48 hours after shutdown.
If continuous rolling during shutdown is not practical, the turning gear should be restarted and
remain in operation for a sufficient length of time before admitting steam to the turbine to allow
rotor straightening as determined by stable eccentricity within the limits mentioned in the Chapter
4 in the mechanical maintenance manual M-05.01, Main Turbine Maintenance.

Mitsubishi
F-1
Appendix F
1.
The turbine is to be dismantled

The turning gear should be kept in operation until the dismantling program requires
that it be stopped. If an emergency necessitates it, the turning gear may be shutdown
immediately, however, it must be recognized that this may subject the rotor to severe
bowing. Lubricating oil circulation must be maintained after shutdown to protect the
bearings against overheating. The minimum circulation period should be 24 hours
after shutdown. During this period, the oil temperature leaving the coolers should be
held between 20C and 35C, if possible.
2.
Shutdown for extensive repair or adjustment

Both the turning gear and the lubricating oil circulation system should be kept in
operation for a minimum of 24 hours. Oil temperature from the cooler should be
maintained between 20C and 35C, if possible. Both the turning gear and the oil
circulation may then be shutdown. When operation is to be resumed, the unit should
be placed on turning gear prior to turning on gland steam and establishing vacuum,
and can be rolled with steam upon attaining stable eccentricity conditions within
acceptable limits.
These recommendations also apply to the situation where rotor bearings are to be
inspected or repaired and it is necessary to shut off oil circulation. Metal temperatures
at all the bearings should be monitored during this period. To avoid overheating the
bearings, restore oil circulation as soon as possible.
Shutdown for minor repair or adjustment

Depending upon the nature of the work to be done, the following schedule may be
adopted:
a) Keep the turning gear and the bearing oil circulation system in operation for a
minimum of 3 hours. Both may then be shut off for a period of not more than 15
minutes. If practical, however, oil circulation should be maintained.
b) Following the 15 minute shutdown period in (a) above, roll the turbine on turning
gear for 2 hours or until stable eccentricity conditions exist, whichever occurs first.
Both turning gear and oil circulation may then be stopped for not more than 30
minutes: however, 15 minutes after stopping, the rotor is to be turned 180 with
MM-M05.06
Rev.001
the turning gear. Oil circulation should be on during the 180 turns to lubricate the
bearings.
c) Following the 30 minutes shutdown period in (b) above, the turbine should again
be rolled on turning gear with oil circulation for 2 hours or until stable eccentricity
conditions exists, whichever occurs first. The system may be shutdown indefinitely,
provided that the rotor is turned 180 at 30 minutes intervals for the next 6 hours.
Oil circulation should be on during the 180 degrees turns to lubricate the bearings.

Mitsubishi
F-2
Appendix F
Emergency turning gear operation

If for any reason the turbine unit is tripped and the rotor comes to rest, the unit should
be placed on turning gear operation immediately. If turning gear operation is
impossible because of interference between internal rotating and stationary parts due
to thermal shock and consequent distortion, try jogging the turning gear motor after a
one hour interval. If unsuccessful, repeat the attempt after another one hour interval. If
unsuccessful after the second attempt the rotor may be bowed and/or stationary parts
distorted to the extent that one or two days soaking in the arrested condition may be
necessary before making another attempt to break the rotor loose by turning gear
operation.
Under no circumstances should an attempt be made to free the

rotor by admission of steam to the unit or by use of a crane. Such
an attempt could have disastrous results such as increased blade
seal strip clearances, shroud or rotor gouging, broken blades, etc.
If turning gear power is not available and the rotor remains at rest, a rotor bow can be
expected. Experience indicates, however, that a one to two hours period on turning
gear prior to start-up will roll the rotors straight. By turning the rotors 180 degrees in 15
to 20 minutes intervals, the severity of the bow can be reduced and thus reduce the
required turning gear operating time period to start-up. In cases such as a water
incident where both rotor and cylinder might be bowed, cranking must not be
attempted in order to break bound parts loose.
5
Removal of insulation
MM-M05.06
Rev.001
The cylinder insulation should not be removed from the turbine elements until they
have cooled for 24 hours or longer. This delay is necessary to avoid thermally
stressing the cylinders, locally cooling and deforming the cylinders, and exceeding the
allowed differential cooling of the cylinder parts relative to the rotor.

Mitsubishi
F-3

MM M05 3

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Project Dwg. No: G101-25-1700.

Turbine Main Oil Pump

Turbine Main Oil Pump Maintenance

Be sure to read this manual.

Disassembly and Reassembly

Feature of Turbine Main Oil Pump Safety 1-1

Warnings Description 1-2

Definitions of Serious Injury, Minor Injury, Serious

Hazard Warning Label 1-5

Hazard Area 1-7

Risk Assessment Standard 1-8

Safety Measures 1-10

Work Permit System (Lockout/Tagout) 1-10

General Cautions on Personnel in Working Area 1-11

1.4.2.1 Caution against Rotating Equipment 1-11

1.4.2.8 Cautions against Lack of Oxygen 1-15

1.4.2.11 Cautions using Fork Lift 1-16

Safety (Continued from previous page)

Emergency Measure 1-19

Evacuation on Emergency Case 1-19

1.5.1.1 Evacuation Route 1-19

Explosion Accident 1-22

Qualification and Training 1-23

Overview of the Turbine Main Oil Pump 2-2

Pump Casing 2-6

Impeller and Shaft Assembly 2-7

Impeller Seal Rings 2-8

Shaft Penetration Seal Rings 2-8

Preventive Maintenance _____________

Turbine Main Oil Pump

Departmental Interface/Notification 4-2

Isolation of Equipment 4-2

Safety Precautions 4-2

Routine Maintenance 4-3

Inspection and Maintenance 4-4

Annual Outage Maintenance 4-7

Inspection and Maintenance 4-8

Disassembly and Reassembly ________

Turbine Main Oil Pump Disassembly and Reassembly 5-1

Impeller Removal and Replacement 5-5

Corrective Maintenance _____________

Recommended Lubrication __________

Recommended Spare Parts B-1

Special Tools C-1

Coupling Alignment D-1

Applicable Vendor Drawings E-1

Turbine Main Oil Pump

Types of Hazard Warning Labels 1-6

Mapping for Hazard Areas 1-9

Main Turbine Lubricating Oil Flow Diagram 2-3

Overview and Location of Main Oil Pump 2-4

Isometric View of Turbine Main Oil Pump 2-5

Cutaway View of Turbine Main Oil Pump 2-9

Sectional View of Turbine Main Oil Pump 2-10

Turbine Main Oil Pump Clearance Drawing 4-15

Exploded View of Turbine Main Oil Pump 5-7

Spare Parts for Main Oil Pump 1/2B-2

Spare Parts for Main Oil Pump 2/2B-3

Turbine Main Oil Pump Assembly (1/2)E-2

Turbine Main Oil Pump Assembly (2/2)E-3

Turbine Main Oil Pump 3-1

Routine Maintenance Checklist 4-6

Annual Outage Maintenance Checklist 4-12