NAVABHARAT ENERGY INDIA Ltd , PALONCHA

LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 LOG SHEETS.

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 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

1.0 PLANT DETAILS

1.1 150 MW unit is provided with lube oil and Jacking oil systems which
consisting of the following equipments to cater to the lubrication and
shaft lifting requirement of entire Turbine and Generator bearings and
Turning gear system.

1.2 1 No. AC driven Auxiliary oil pump and 1 No DC driven emergency oil
pump are meant to supply oil to the bearings and turning gear at
required pressures.

1.3 2 Nos. of AC driven and 1 No DC driven Jacking Oil pumps are meant
for supplying high pressure oil to the bearings in order to lift the shaft
while the machine is on barring gear.

1.4 1 No Main oil pump to supply oil to the bearings while the unit is in
operation.

1.5 2 Nos. of injectors to boost the suction pressure to MOP.

1.6 2 Nos. of coolers, one in service & the other as standby to remove the
heat from the oil coming from the bearings.

1.7 Oil temperature control is d0ne by providing 4 No of space heater in

MOT.

1.8 Duplex filters in oil line to bearings: - This is to remove the mechanical
impurities from the oil so that the damage to the bearings is avoided.
One is normally in service and the other is kept as standby.

1.9 Throttles at the inlet to the bearings. These are meant for
regulating the flow of oil entering the bearings so that the bearing
metal temperatures are maintained within operating limits.

1.10 Hydraulic Turning gear shut off valve is meant for admitting the
power oil for turning gear device during shutdown of the unit.

1.11 Main Oil Tank serves as reservoir of Oil. The AC and DC Auxiliary Oil
Pumps are mounted inside the Main oil tank. and Jacking oil pumps
mounted 6 meters below the Main oil tank.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

1.12 2 Nos. Vapour Exhauster fans are meant for removing oil vapour from
the oil system and to maintain a little amount of vacuum. Normally one
fan is in service and the other is kept as standby.

2.0 OBJECTIVE:

2.1 To flush complete TG Lube Oil & Jacking oil systems with Turbine oil to
remove mechanical impurities.

3.0 PROPOSAL

3.1 Scheme of oil flushing for lube oil and Jacking oil systems shall be as
per the enclosed sketch.

3.2 Thermal shocks shall be given to the system by sudden changes in oil
temperature to make the flushing effective. Tapping of the oil lines shall
be carried out during thermal shocks especially at weld joints.

3.3 Oil flushing shall be carried out using the normal operating Turbine oil .
The quantity of oil required for flushing will be approx. 40 KL.

3.4 For the purpose of analysis, oil samples shall be collected from
centrifuge inlet with centrifuge in service

4.0 SERVICES REQUIRED

4.1 Availability of Electrical heating / Steam heating arrangement for

heating the CW to turbine oil cooler for giving thermal shocks during
oil flushing.

4.2 Availability of cooling water system for Turbine oil coolers.

4.3 Availability of laboratory facility for analysis of oil sample.

4.4 Availability of service air and thinner/petrol for filter cleaning.

4.5 Availability of sufficient skilled manpower for execution and supervision

of the process.

4.6 Availability of required quantity of Turbine oil

4.7 Availability of portable fire extinguisher at oil flushing area.

4.8 Availability of proper lighting and communication facility.

 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

5.0 SAFETY PRECAUTIONS:

5.1 Staircases, platforms, handrails for MOT and required approaches as

decided at site should be ready.

5.2 Safety and protective equipments like hand gloves, helmet etc should
be available during the process.

5.3 Precautions should be taken to avoid spillage and contamination of oil.

5.4 Service water source should be available near the activity area.

5.5 Availability of first aid kit near the process area should be ensured.

5.6 Availability of Portable fire extinguishers and buckets containing sand

should be ensured near the activity area.

5.7 Once oil is filled in MOT no welding / cutting job should be carried out
in lub oil flushing area.

5.8 Load on AOP shall not exceed full load current of the motor.

5.9 Provision for emergency stopping of oil pumps from local/UCB has to
be made.

5.10 Oil flushing area should be properly cordoned off.

5.11 Display of caution sign boards, danger tags should be made at

concerned locations.

5.12 Round the clock manning should be made for monitoring of oil flushing
activity.

5.13 Testing of permanent fire fighting system shall be completed before

filling oil in MOT.

6.0 EMERGENCY PROCEDURE:

6.1 Emergency operating instructions, to deal with fire or any other

emergency conditions, should be prepared in advance and displayed
at the identified locations.

6.2 The operator posted in the oil flushing area should be aware of fire
extinguisher operating procedures.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

6.3 The team members should be aware of procedure to be followed in

case of accident involving injury/ Electrical Shock.

6.4 An operator should be posted near the pump area and instructed to trip
the pumps in the event of emergency being notified to him by any team
member / observers.

6.5 The team members should be aware of restarting the flushing

operation in case of system stoppage due to failure of power supply.

7.0 STATE OF THE PLANT

7.1 Erection of the lube-oil system is complete as per drawing.

7.2 The entire temporary piping which are included in the process, are
separately cleaned before their installation.

7.3 Thermal shock scheme is ready, as per the details given in the
enclosed drawing.

7.4 MAIN OIL TANK:

7.4.1 Oil injector float valve are kept in position. Screw plugs will be
provided in its drain holes.

7.4.2 MOP suction and discharge are looped with its oil flushing device
supplied from Works. A vent line is provided in the flushing
device.

7.4.3 All C & I installations like MOT level indicators; level switches etc are
fitted before oil filling.

7.4.4 Vapour extraction fans are available for operation.

7.4.5 All bearing Pedestals and MOT strainer are manually cleaned and
inspected before start of oil flushing. Marking cloth only is to be used
for cleaning.

7.4.6 AOPs, JOPs, and centrifuge are available with required alarms,
interlocks and protections.

7.5 LUB OIL SYSTEM:

 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

7.5.1 All flanges in the system are tightened after checking for gaskets.

7.5.2 Oil throttle for oil injector I is to be removed and temporary pipe
at one end and dummy at other end as shown in scheme is
provided. Throttle of injector II provided with spool piece.

7.5.3 The turning gear nozzle box inside bearing pedestal is removed and its
flushing device provided before boxing up of pedestal.

7.5.4 Lube oil header is connected to Drain Header with a temporary loop of
the lube oil header size, with an isolating valve.

7.5.5 Oil supply & return lines for each of Generator front, rear bearings are
looped with temporary pipes.

7.5.6 Flushing device are provided for bearings 1 to 5.

7.5.7 Thrust bearing Pads are removed.

7.5.8 Oil throttle before oil cooler is replaced with spool piece such that
maximum oil flow is achieved during oil flushing.

7.5.9 Turbine oil cooler is bypassed during first stage of flushing, with
a temporary pipe connection from cooler inlet to outlet.

7.5.10 Duplex filter elements shall be taken out during oil flushing. These are
introduced in the circuit only in the final stage flushing.

7.5.11 All throttles in the lube oil supply line to bearings are kept fully closed
prior to oil flushing. Also, screw plugs are fixed in small holes provided
in these throttles.

7.5.12 MOP is removed and its suction & discharge are looped with the help
of flushing device.

7.5.13 Temporary pipe with valve as shown in enclosed scheme (between first
injector throttle to MOT) is provided.

7.5.14 Remove injector nozzles in MOP suction lines.

7.5.15 Oil coolers are inspected through oil line connection and if required are
cleaned before start of the oil flushing.

7.5.16 Temperature indicators before and after oil cooler for oil as well as
cooling water is made available.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

7.6 JACKING OIL SYSTEM:

7.6.1 From the dummy flange at the end of JOP supply header, a temporary
connection (JOP supply header size) with an isolating valve is taken to
oil return pipe for initial flushing.

7.6.2 The hose connection of Jacking oil lines to bearings is disconnected

from the bearing bottom and kept open to drain inside pedestals.

7.6.3 All the NRVs of Jacking oil pump discharge and supply lines to
bearings are removed.

7.6.4 Jacking oil Pressure limiting valve are removed and necessary
temporary lines / blanking provided.

7.6.5 AOP discharge header is looped with an isolating valve to jacking oil
lines bypassing the JOPs.

7.7 GENERAL:

7.7.1 Turbine Insulation work should not be carried out during oil flushing
activity.

7.7.2 Erection and testing of fire fighting system envisaged for lub oil system
should be complete before MOT is filled with oil.

7.7.3 All the pipelines are cleaned loop wise by cardboard blasting method

7.7.4 Lub oil supply lines are to be checked for leakages by pressurizing with
instrument air before filling oil in MOT.

7.7.5 A check list is prepared for all the items removed / fitted temporarily
and is referred to at the time of normalization.

8.0 METHOD:

8.1 OIL FILLING:

8.1.1 Required quantity of oil is made available and the oil is tested for its
quality. Test certificate can also be obtained from the supplier.

8.1.2 Turbine oil is filled into the MOT preferably through the centrifuge. Oil
filling can also be done through bearing drain header by mounting a
temporary filling funnel at its exciter dummy end.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

8.1.3 Care is to be taken that all the drains of the system are closed and no
oil leakage occurs during filling.

8.1.4 The operation of oil tank level indicator is checked during oil filling.
Level is to be closely monitored to avoid any overflow.

8.1.5 Centrifuging of MOT oil is to be done continuously with its heaters ON

Centrifuge bowl is to be cleaned intermittently to remove sludge
collected.

8.1.6 MOT filter is to be cleaned as and when required.

8.2 LUB OIL SYSTEM FLUSHING:

8.2.1 System is lined up for flushing lub oil lines directly from lub oil header
to drain through the temporary valve. Oil coolers are kept bypassed. All
other sections are kept isolated.

8.2.2 Direction of rotation of the oil pumps is to be checked with short start /
stop command. The trial run of the pumps is to be taken up along with
oil flushing process.

8.2.3 Flushing is started with DC Emergency Oil Pump in service. System is

checked for leakages if any, and attended.

8.2.4 AOP is to be taken in to service for further oil flushing after making the
system leak proof. Centrifuge is to be run continuously with its heaters
ON.

8.2.5 Care is to be taken that AOP load is limited to full load current of the
AOP motor..

8.2.6 Main oil tank filters shall be inspected and cleaned every hour
during initial flushing operation. Thereafter the frequency is to be
gradually reduced to once a day depending upon the filter
condition.

8.2.7 When once a day MOT filter cleaning is established, lub oil
coolers shall be taken in service one by one for further oil
flushing. Normally 2-3 days of flushing with coolers in bypassed
condition sufficient.

8.2.8 Thermal shock to the oil system is started by heating the oil with
thermal shock arrangement.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

8.2.9 Temperature of oil after cooler shall be raised to about 70-75 deg C.
Oil temperature should not exceed 80 deg C.

8.2.10 Thermal shock is given by charging cooling water as fast as possible

and oil temperature before cooler is brought down by about 35 40
deg C.

8.2.11 Further oil flushing is continued with repetitive thermal shocks and
intermittent tapping of the oil lines at weld joints.

8.2.12 Oil flushing with thermal shocks is continued (bearing pedestals

in bypassed condition) till main oil tank basket filter is found
clean, which normally takes 2 3 days of flushing.

8.2.13 Close temporary valve between lube oil header and drain header .

8.2.14 Further flushing is done through bearing pedestals. 2 to 3 bearings at

a time are selected for flushing. The throttles of the bearings, which
are selected for flushing, are kept wide open and those of remaining
bearings are kept closed. This ensures maximum possible oil flow in
bearing return oil lines.

8.2.15 The bearing pedestal flushing operation is continued till the completion
criterion is accomplished for each group of bearings.

8.2.16 Turning gear oil line is flushed by opening the turning gear valve in
such a way that AOP motor doesnt get overloaded. This is done
everyday with one or two thermal shocks.

8.3 JACKING OIL SYSTEM FLUSHING:

8.3.1 Flushing is carried out using temporary connection from AOP

discharge header.

8.3.2 Flushing of jacking oil lines are started once the MOT filters are
reasonably clean after start of thermal shocks.

8.3.3 Initially, jacking oil header is flushed from its dead end to bearing lube
oil drain header.

8.3.4 After flushing above circuit for few days, the above connection is to be
closed / normalised and jacking oil lines to individual bearings are to be
flushed taking 2 or 3 lines at a time for effective flushing.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

8.3.5 Jacking oil lines flushing is continued till oil flushing is declared
complete based on completion criteria.

8.3.6 The temporary connection from AOP discharge header to jacking oil
lines is removed at the end of the flushing. JOP discharge NRV
internals, Pressure limiting valve and discharge pipelines are
normalised for running of JOPs.

8.3.7 Keeping Pressure limiting valve fully released, one JOP is started and
discharge pressure raised to approximately 10-15 kg/cm 2 for further oil
flushing of jacking oil lines for two days.

8.4 FINAL STAGE FLUSHING:

8.4.1 After all the circuits have been taken for flushing and MOT strainer
remains clean for 24 Hrs., Duplex filter elements shall be introduced in
the flushing circuit

8.4.2 The internals of bearing oil throttles ( 2 to 3 bearings at a time ) are

removed and line filters, supplied from works, are introduced.

8.4.3 Spool piece in place of Lube oil main throttle before lube oil
cooler/duplex filter shall be removed and throttle shall be erected. The
lube oil header pressure is to be maintained around 2 2.5 ksc by
adjusting the throttle. The line filters will get damaged at higher
pressures.

Note: Everytime when the pumps are started, the lub oil supply
header loop at exciter end should be kept open and to be closed
after establishing circulation.

8.4.4 Complete oil system flushing is continued using thermal shocks. Oil
sample analysis is carried out. Duplex / Line filters are cleaned with
cleaning agent. Flushing is declared complete based on completion
criteria.

8.5 HYDRAULIC TESTING OF LINES:

8.5.1 GENERAL:

8.5.1.1 Hydraulic test of various lines shall be carried out as per chart given
below.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

S.No System/Item Std. Pr. Test Pr. Duration

1. LUB OIL 2.5 kg/cm2 12 kg/cm2 10 min

2. JACKING OIL 180 kg/CM2 200 kg/CM2 10 min
3. OIL COOLER 2.5 kg/cm2 12 kg/cm2 10 min

NOTE: Oil Coolers are received at site after duly conducting hydraulic test at
works (Test certificates are to be referred at site). Oil coolers are
hydraulically tested at above parameters after concluding oil flushing.

8.5.2 PREPARATION:

8.5.2.1 Before conducting hydraulic test, it is to be ensured that discharge

piping of JOPs including its discharge NRV and Pressure limiting valve
have been normalised and trial run of jacking oil pumps completed.

8.5.2.2 Required temporary connection shall be made between the

subsystems. Blank flanges shall be installed wherever the subsystem
are connected to drain as per flushing scheme.

8.5.2.3 Test gauges of suitable range are provided.

8.5.2.4 Equipments not subjected to test are kept isolated.

8.5.2.5 Impulse line valves of all process pressure gauges / transmitters are to
be kept closed.

8.5.2.6 Safety relief valves of JOPs. are to be checked for their setting.
System pressure during Hydraulic test is to be regulated using
pressure regulating valve.

8.5.2.7 Venting arrangements are provided at blind ends with valve.

8.5.2.8 Jacking oil discharge lines are suitably tapped off to lube oil system
separately with isolating valves.

8.5.2.9 Lube oil throttles to all bearings are closed.

8.6 PROCEDURE:

8.6.1 Lube Oil System:

 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

8.6.1.1 DC EOP is in running and system is filled.

8.6.1.2 Venting of total system is carried out.

8.6.1.3 DC EOP is stopped.

8.6.1.4 One JOP is started with pressure regulating valve fully released.

8.6.1.5 Lines connecting jacking oil to lube oil systems are opened.

8.6.1.6 Pressure is raised to 12 kg/cm 2 and held for 10 minutes. System

is checked for leakages.

8.6.2 Jacking Oil System:

8.6.2.1 Pressure regulating valve is kept fully released.

8.6.2.2 After completion of hydraulic test of lube oil system the temporary
connection from JOP discharge header to lube oil system are removed
and jacking oil system is normalised.

8.6.2.3 One J.O.P is started and pressure is raised to 20 kg/cm2 .

8.6.2.4 Lines to each bearing are vented and then isolating valves to bearings
closed.

8.6.2.5 Leakages, if any, are attended.

8.6.2.6 Pressure is gradually raised to 180 kg/cm2.

8.6.2.7 System is again checked for leakages.

8.6.2.8 Pressure is raised further gradually to 200 kg/cm 2 and ensure the
safety valve lifting. The safety valves for both pump discharge is
to be set at 200 kg/cm2 and system is then depressurized.

8.6.2.9 The Pressure limiting valve is adjusted to the operating value of jacking
oil header pressure.

8.6.2.10 If leakages are observed, system is depressurised and leakages

attended and hydraulic test is repeated.

8.7 Normalisation:

8.7.1 Oil shall be drained from the total system to clean oil barrels from
where oil was filled.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

8.7.2 MOT ,COT and DOT cleaned and inspected.

8.7.3 Oil coolers tube nest are cleaned and inspected.

8.7.4 Oil injector foot valve are cleaned and normalised after checking the
seating by blue matching. Also screw plug provided in drain hole is
removed.

8.7.5 Bearing oil throttles are normalised after removing their screw plugs
and their lift are adjusted for normal operation as per flow curve.
Locking of throttle is to be done properly.

8.7.6 All the TG bearings and MOP are normalised.

8.7.7 Each pedestal is cleaned of any foreign material, if any.

8.7.8 All the provisional arrangements made in the system for oil flushing are
removed and system normalised.

8.7.9 All jacking oil connections to the bearings are normalised.

8.7.10 Jacking oil line NRV internals are installed.

8.7.11 Fill Main oil tank with same oil collected in barrels through centrifuge.

8.7.12 JOP is run and all JOP connections to bearings are checked for
leakages. Leakages observed, if any are attended.

8.7.13 Bearing pedestals are boxed up after ensuring completion of all C & I
jobs.

8.7.14 Oil throttles to injector and oil cooler are normalised / adjusted for
normal operation.

9.0 COMPLETION CRITERIA:

9.1 Mechanical impurities in the oil sample should be less than 100 ppm
(by weight).

9.2 Main oil Tank filter should remain clean after 24 Hrs. of flushing.
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

9.3 Duplex filter elements should require cleaning after 12 hours of

flushing (For final stage of flushing).

10.0 LOG SHEET

AOP NO # 1 / # 2 RUN STATUS

Lub oil Lub oil Temp. No. of

AOP 1/2 Dis. Pr. Tank Filter
DATE TIME Header BEF AFT Thermal
Current AOP1/2 level Condition
Pr. Cooler Cooler shock
 NAVABHARAT ENERGY INDIA Ltd , PALONCHA

JOP No. 1 / No.2 RUN STATUS

Oil Temp.
JOP BEF AFT No. of Thermal
DATE TIME Dis. Pr.
Current Thermal Thermal Shock
Shock Shock