Turbine Lube Oil System Description

FICHTNER Consulting Engineers (India)

Private
0-1Limited, (FI) Chennai.

VENDOR DRAWING REVIEW STATUS

Manua l for lubrication System
Action - I Approved
1 Overview
Action - II Approved except as noted on drawing. Revise
drawing and resubmit for records.
Action - III Returned
with Comments. Resubmit for approval.
Action - IV Rejected
Action - V Information received.

Action - VI Information noted Retained for reference and records.
This document has been reviewed as noted with regard to general conformity
ISO-VG46
with the Contract specifications and requirements. The Vendor / Contractor is
responsible for correctness of design calculation and details. Approval of this
document does not relieve the Vendor / Contractor of his responsibility in
carrying out the work correctly and fulfilling the complete requirements of the

contract nor does it limit the purchaser's rights under the contract.

MOP-BOP mode is used in this lubrication system. MOP(Main Oil Pump) is directly driven
FI Letter Ref. No. by turbine main shaft
Date: and discharges HP oil to drive BOP(Booster Oil Pump) to run. The
CNT 1109171/ PM-6.1/7070/565 19/12/2011
oil system is designed to supply lubricating oil to bearings of turbogenerator unit, supply
sealing oil to generator hydrogen seal and supply sufficient oil to the jacking oil pump. The
Signature
working mediumInitials:
of theBRsystem is ISO-VG46 turbine oil.

2 System Compo sition

MOPBOPEOPMSP

TOP

The system mainly includes MOP(Main Oil Pump), BOP(Booster Oil Pump), Main oil tank,
EOP(Emergency Oil Pump), MSP(Motor Suction Oil Pump), TOP(Turning Oil Pump), oil
cooler, transfer valve, oil fume separator, oil jacking device, oil hydrogen separator
(provided by the motormaker), low oil-pressure shut-off switch, check valve, set of oil
pipeline, oil level indicator and connecting pipe, monitoring instruments etc.

3 Introduction to major equipments of the system

3.1 MOP (Main Oil Pump)

The MOP is a single stage double suction centrifugal oil pump installed in the front bearing
housing, directly coupled to turbine main shaft, and directly driven by turbine rotor. It

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supplies dynamic oil to BOP.

3.2 Main oil tank

(TOP)(EOP)

MSP,BOP

~47m3

The oil tank is integerated with a lot of devices of the oil system, e.g. TOP, EOP, MSP, BOP,
oil fume separator, oil level indicator and electric heater, etc concentrated in the tank for
easy operation and monitoring and simple plant arrangement for fire protection. In normal

operation, the oil tank capacity is about 47m3. See Main oil tank Instruction for further

information.

3.3 Oil cooler

50~55

The oil system is provided with two oil coolers (stainless steel tubular heat exchanger).
One is in operation, the another standby. It uses closed cooling water as cooling medium
to take away the heat generated by bearing friction, ensuring bearing oil temperature of

50-55.

3.4Oil fume separator

The system is provided with an oil fume separator installed on the cover of the Main oil
tank. It generates a slightly negative pressure in turbine return oil system and return oil
chambers of bearing housings to ensure smooth oil return, separate the oil-fume mixture
generated in the system, discharge the fume, return oil drops to the oil tank to reduce

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environment pollution and ensure oil system safety and reliability. Additionally, to prevent
water mixing in oil caused by high negative pressure in bearing housing chambers and
leak steam from turbine shaft seal entering bearing housing, the oil fume separator is
designed with a set of damper to control fume discharge flow and maintain slight negative
pressure in the bearing housing. See the attached manual for further information.

3.5Change-over valve

The transfer va lve is of c ylindrical plate type structu re, which is installed
between the two oil coolers. Refer to Instruction of transfe r valve for the

detailed desc ription .Characteristic data:

300mm Nominal diameter 300mm

0.5Mpa Operation pressure 0.5Mpa

80Maximum operation temperature 80

3.6Electric heater

660kWAC240V

2035

150100

In the Main oil tank, 6 electric heaters are installed, with a total power of 60kW, voltage

AC240V. Before starting the unit, if the oil temperature is below 20, start the electric

heater, and turn off it when the oil temperature is up to 35. The electric heater is

provided with a thermocouple to control the surface temperature. When the surface

temperature is higher than 150, stop heating; when the temperature is decreased to

100, restart heating.

3.7Shaft raising gear

The device is designed to supply HP oil to bearings of the unit to jack journals forcibly

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during unit start, shutdown and gear turning so that a static pressure oil film is formed
between journal and bearing to eliminate dry friction between journal and bearing. See the
attached manual for further information.

3.8BOP (Booster Oil Pump)

0.10.15

MPa 0.140.18 MPa

The equipment uses the oil from MOP as dynamic oil to drive the booster pump to supply
the main oil pump with oil. After applying work, the depressurized dynamic oil is fed to
bearing, etc for lube oil. The throttle valve, bypass valve and overflow valve of the oil turbo
should be adjusted to maintain the main oil pump suction pressure at 0.1~0.15MPa and
the bearing inlet pressure at 0.14~0.18MPa.

3.9TOPTOP (Turning Oil Pump)

The pump provides lube oil to the system in turbine unit start, shutdown and emergency
conditions. See the attached instruction for operation. Its main parameters are as follows:

0.4MPa Outlet oil pressure 0.40MPa

7100 l/min Rated flow 7100l /min

110kW Rated power 110KW

AC415V Rated voltage AC415V

3.10EOPEOP (Emergency Oil Pump)

The pump is used when the TOP cannot meet the system demand or AC power is lost, to
provide the lube oil for smooth shutdown of the unit. See the attached instruction for
operation. Main parameters:

0.35MPa Outlet oil pressure 0.35MPa

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4990l/min Rated flow 4990L /min

75kW Rated power 75KW

DC220V Rated voltage DC220V

3.11 MSPMSP (Motor Suction Oil Pump)

This pump supplies oil to the main oil pump during unit start, shutdown or load rejection.

See the attached manual for operation. Main parameters:

0.28MPa Outlet oil pressure 0.28MPa

7800l/min Rated flow 7800L /min

90kW Rated power 90KW

AC415V Rated voltage AC415V

4 Oil supply system operation

4.1Start operation condition

20 35TOP

38

3.43MPa

MSP 2000r/min

3000r/min

Before starting the system, check that the oil in the system meets the cleanliness

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requirement for start operation and the oil of the oil tank is at the highest level. When the

oil temperature in the oil tank is lower than 20, turn off the cooling water of oil cooler,

heat the oil to 35, start the TOP, start the exhaust fan, operate the oil system for

circulation. When the oil temperature is 38, start the oil cooler cooling water valve to

operate the oil cooler. Start the jacking oil pump to jack the journals of each bearing,and
make sure their oil pressure is bigger than 3.43MPa, Now the turning gear can be
operated, and the unit oil system is ready for start. Start MSP. When the un it speed
reaches 2000 r/min, shut off the jacking device. During the unit speedup, the start-up
oil pump and auxiliary oil pump should operate normally to supply lubricating oil to the unit.

When the unit speed is 3000r/min and the oil pressures are stable, stop the start-up oil

pump and the auxiliary oil pump in follows:

Check the oil level of main oil tank, to ensure that the main oil tank oil level between the
highest and lowest oil level. If the oil level below the lowest oil level, must supply the oil, so
that the main oil tank oil level is located between the highest and lowest oil level.

2)

Ensure protection of oil in the interlock state.

MSP

TOP

Besides Satisfy the above two cases, MSP is stoped firstly, when MSP is stoped and all oil
pressure is normal and stable, TOP can be stoped.

The oil supply pressure. Can not be satisfied when start and supply oil initially, The baffle
valve, bypass valve and relief valve of the oil turbo should be adjusted to meet the
requirements of the system.

The valve of the BOP the role as follows

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Baffle valve

Increase or minish Mop suction oil pressure;

The raise or lower oil pressure lesserly.

Bypass valve
Increase or minish lubricating oil pressure;
The Increase or minish Mop inlet oil pressure lesserly.

Relief valve:

Increase or minish lubricating oil pressuresecondary purpose;

Under the rated speed the above three valve`s setting were completed, lubricating oil

pressure change was compensated automaticallyprimary purpose.

The adjustment procedure of oil turbo is as follows:

Jigger phase, preliminary adjustment.

()

TOPMSP

0.1MPa

Here, full open baffle valvefull close relief vale or small overflowing (Less than one third

overflowing flow) and full close bypass valve. When bearing import hydraulic record.
Before starting, TOP and MSP put into operation,inlet pressure of MOP and lube oil
pressure should be greater than 0.1 MPa.

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During speed-up phrase of stream turbineDont adjust oil turbo.

3000r/minMSP,0.07 MPa

(MSP)

(MSP)

When the speed is 3000r/min contantly, stop MSP firstly, if the suction pressure of mop is
less than 0.07Mpa, the MSP should be interlocked and start to supply oil to MOP, find out
problems, is not allowed to halt MSP forcibly.

(MSP)TOP,0.115 MPa

TOP(TOP)

When MSP was stopped normally, then stop TOP, if bearing oil pressure less than 0.115
MPa, TOP should be interlocked and start to supply oil to bearing, and find out problems,
is not allowed to halt TOP forcibly.

MSP(TOP)

When MSP and TOP was stopped normally, The adjustment of oil pressure could be
done, and their required valve (The gauge pressure of front bearing box) is:

0.10.15Mpa

0.18Mpa

MOP suction oil pressure: 0.10.15Mpa

Main pipe oil pressure: 0.18Mpa

Adjustment method is as follows:

a)

If the MOP suction oil pressure and main pipe oil pressure are on the high side, then turn
down baffle valve; Conversely, the turn up baffle valve;

b)

If the MOP suction oil pressure is on the high side, then turn down baffle valve; Conversely,
the turn up baffle valve;

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c)

If the main pipe oil pressure is on the high side, then turn down bypass valve; Conversely,
the turn up bypass valve;

d)

Repeat the above steps, make each oil pressure to match the requirements.

e)

After above adjustment, baffle valverelief valvebypass valve should be locked in.

4.2

Normal operation condition

When the unit is run normally, all high pressure oil in the system is supplied by the main oil
pump in the front bearing housing. The high pressure oil from the main oil pump is used as
the dynamic oil for oil turbo. The oil turbo sucks oil from the oil tank and supplies oil to the
main oil pump, and supplies oil to bearings, turning gear and hydrogen sealing system of
the unit for lubrication, cooling and sealing. In normal operation of the unit, the water flow
of the oil cooler should be adjusted according to the oil temperature in the lubricating oil
header to control bearing inlet oil temperature within the specified range.

TOPMSP

Before unit load rejection, start TOP and MSP for standby.

4.3Shutdown condition

2850r/min

2000r/min

0.03MPa

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In case of normal or emergency shutdown (hand trip or trip), TOP and MSP must be

started before the turbine is decelerated to 2850r/min, and the shaft jacking device must

be started when the turbine is decelerated to 2000 r/min. In case of auxiliary oil pump

failure, EOP should be interlocked to ensure safe shutdown.when the lubrication oil
pressure of bearings is less than 0.03MPa,stop jigger. During unit hand turning, the shaft

raising gear TOP and MSP must not be stopped before the turning gear is stopped.

5 Introduction of oil return system

276010900

10

The system is provided with two return oil headers. The oil from front bearing housing and
rear bearing housing returns the dirty oil area in the oil tank through 76010 and
90010 return oil headers respectively. The oil discharged by the shaft raising gear
returns to the oil tank. The return oil pipe should be installed with a downward inclination

(no less than 1) toward the oil tank so that the pipe is semi filled and the oil fume in the

bearing housing can flow to the oil tank through the space over the oil surface and be
separated by the exhaust device, then discharged to the atmosphere by the fan.

The return oil of generator bearing must be subjected to oil-hydrogen separation before it
is connected to the return oil header, otherwise, the unit safety will be threatened.

After returning the dirty oil area and being filtered by the strainer, the return oil enters the
clean oil area.

6
System maintenance and operating instructions

6.1 MSP

0.07MPa

An interlock protection should be provided between MSP and MOP, During normal
operation of the unit, if the outlet pressure of the MOP is lower than 0.07MPa, start the

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MSP and alarm.

6.2

0.140.18MPa0.115 MPa

0.105Mpa

An interlock protection should be provided between pressure signals of TOP, EOP and
lube oil header. When the turbine is in normal operation, the bearing inlet oil pressure is
0.14-0.18MPa. When the lubricating oil pressure drops to 0.115MPa, give out alarm and
start TOP, and check for the cause of oil pressure drop. If the oil pressure still drops after
TOP is started, EOP should be started when the oil pressure drops to 0.105MPa, The
above pressure values are of operation platform header oil gauge pressure. If the
pressure measuring position is different, the differential pressure should be considered
accordingly. A low oil pressure interlock protection test must be conducted every a half
month.

6.3Lubrication oil temperature

ISO-VG4650~55

70

This system uses ISO-VG46 turbine oil. Unit bearings require inlet oil temperature of

50-55 and normal return oil temperature of less than 70. In normal operation, the

water flow of the oil cooler should be adjusted according to the oil temperature in the lube
oil header to ensure bearing inlet oil temperature is in accordance with requirements.

6.4Oil tank level

Before putting into operation, set zero position at the middle position the mean value of
zero position the highest and the lowest oil level based on the drawing, as the normal oil
level of level indicator.

+100mm

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100mm

150mm

69

47

The highest level of oil tank in normal operation +100mm

The lowest oil level 100mm
Shutdown oil level 150mm

Max. operation capacity 69m3

Normal operation capacity 47 m3

The unit shutdown the oil tank above the highest oil level is normal. However, when the
unit is running, oil tank oil level should be working between the highest and lowest oil level.
when oil position is below the shutdown oil level, it is not allowed to start the electric
heater.

Before start the pump of oil tank, must ensure that the oil tank parked in the interlock state,
then oil level can be filled into that position. Between hghest level and overflow orifice.
After start the pump, the oil level drop down, but must ensure that oil level is between high
oil level and low oil level,. if the oil level is below the lowest level, must supply oil to ensure
that oil level is between high level and low level.

During shutdown, the oil level of main oil tank depends on the oil level of system operation.
when system is shutdown, these oil return to the main tank mostly. Oil level can be
checked through oil level meter intalled on main oil tank. The oil level must be maintained
at or higher than the lowest oil level indicated at the oil level gauge during turbine

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operation.

32420mA

For monitor the oil level of clean-oil area of oil tank, installation multi-magnetic level gauge
on the oil tank side. The magnetic level gauge at the highest oil level, low oil level each
have a separate alarm switch, installation three independent optical interlock switch in the
shutdown oil level, any two switches send signal to interlock and shutdown. At the same
time, it send out 4~20mA continuous signal based on magnetostriction principle to
measure the continuous oil level.

Top-loading magnetic flap oil level fauge have alarm switch is intalled on dirty oil area of
oil tank, to monitor oil level of the dirty oil area. When dirty oil level rise to alarm location,
suggest that the filter is blocked and should be cleaned immediately.

7Lubricating oil and oiliness

7.1 Maintenance and operation Suggestions

In the branch pipe of main pipe to supply oil for beating, set a coarse filter, at the
sametime, set a throatlle orifice in front of main beating. These filter only use when oil
flush, and should take out when run normally. Their frame work and throatlle orifice is
reserved.

50~5520,

The heat generation of beatings can be monitored by temperature test-point fixed on them,
and keep the monitoring process when steam turbine is running. The proper operation oil

temperature of inlet is 50~55, and temperature rising is not over 20,Oil flow can be

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adjusted by throattle orifice to assure above temperature limit.

7.2Oil system maintenance

Successful application of oil can only be realized by continuous maintenance, observation

and treatment. With proper filtration and maintenance, the oil can be used for months.
This depends on oil initial quality, treatment equipment, filter and the daily operation time
of oil treatment equipment.

The following rules must be observed:

a)

There should be sufficient high quality and clean oil in the oil tank.

b)

Sufficient oil should be stored to meet emergency requirements.

c)

Do not mix oil with water. Any accumulated water can be removed by separator.

d)

Check that pressure gauges on the instrument panel are recorded properly, and the cock
of pressure gauge can restrict flow effectively to reduce pointer shaking and wearing of
mechanisms in pressure gauges.

e) ,

If the oil temperature rises stably during normal operation, the oil cooler may be dirty or
the oil is aged. In this case, switch oil cooler operation or standby condition; fill the
system with new oil or purify the oil with oil filtering system to reuse it.

f)

Check oil cooler for water leakage regularly.

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g)

Maintain pumps, oil coolers and other devices in a proper operation condition.

h)

Sand or other solid objects in the oil can cause wearing and reduce bearing service life.

i)

Do not wipe the oil soaked inner surface with cotton waste or other cotton fabrics.

j)

Do not use gasoline as cleaning solution. Kerosene or petroleum alcohol can be used for
cleaning.

k)

To prevent explosion risk, keep all fire sources away from opened oil tank when the oil is
hot or vaporized.

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