TP0000056 (C) Oil Module

Supplier Data
Engineering & General Equipment Ltd. (Centralube)

LUBRICATION RECIRCULATION MODULE
(Document No.TI 1471 Issue A)
Document No: TP0000056 (Was ALC0193)

Issue: C
Date: November 2003
Brush Electrical Machines Ltd.

PO Box 18, Loughborough, Leicestershire, LE11 1HJ, England
Telephone: +44 (1509) 611511 Telefax: +44 (1509) 610440
E-Mail: sales@bem.fki-et.com Web site: http://www.fki-et.com/bem
Homepage Previous Document

ENGINEERING & GENERAL EQUIPMENT LTD.
OPERATING AND MAINTENANCE INSTRUCTIONS

FOR
SERVING BDAX-7-290ER
TP & M TWIN PAC GENERATOR
T.I. 1471 (Issue A)
CUSTOMER: BRUSH ELECTRICAL MACHINES LTD
CUSTOMER ORDER NOS: BE 706779 & BEB 83201
EGE LTD
Contract Ref: J23250 & J24358
No. of Consoles: 111 off
Serial Nos: 27-864 to 27-891

27-955 to 27-959
27-980 to 27-1005
27-1059 to 27-1110
Page 1


FOR
T.I. 1471 (Issue A)
I NDEX
1.0 EQUIPMENT SPECIFICATION
1.1 General Details
1.2 Reservoir (Tank)
1.3 Pumps
1.4 Air Blast Cooler
1.5 Filter/Strainers
1.6 Air Cleaner
1.7 Heaters
1.8 Valves
1.9 Pipework
1.10 Instrumentation
1.11 Terminal Enclosures
1.12 Paintwork
2.0 PRE-INSTALLATION TEST AND FLUSHING PROCEDURES
3.0 INSTALLATION AND COMMISSIONING
4.0 FAULT FINDING
5.0 MAINTENANCE/DATA SHEETS
6.0 DRAWINGS
Page 2


FOR
T.I. 1471 (Issue A)
1.0 EQUIPMENT SPECIFICATION
1.1 General Details
Each Lubrication Module comprises a fabricated steel reservoir surmounted by three

vertically mounted pumps (2 – AC and 1 – DC) driven through the top of the reservoir.
The pumps are electrically driven and oil flow is directed to a cooler and thence
through a filter to the two delivery outlet flanges of the module.
The Reservoir is equipped with heaters to improve cold start conditions and the
module is equipped with pressure and temperature instruments.
1.2 Reservoir (Tank)
Construction is an all welded fabrication executed in 6mm mild steel plate, suitably
stiffened to prevent deflection or distortion. Mounting pads are provided for pumps,
heaters and air cleaner, together with flanged return connection points. The drain
point is fitted with a lockable gate valve. An internal baffle plate separates the return
flow from the suction zone to promote deaeration. The reservoir is fitted with a
pressurised filler/breather and sampling points and painted internally and externally in
accordance with ‘Brush’ specifications (see 1.12).
1.3 Pumps
1.3.1 A.C. Powered (P3001 and P3003) – Duty and Standby
The system is equipped with two vertically mounted AC driven pumps

capable of delivering 345 litres/min of ISO VG 32 oil against 4 bar head with
7 bar relief valve.
1.3.2 D.C. Powered (P3002) – Emergency Standby
A D.C. Powered Pump capable of delivering 209 litres/min of ISOVG 32 oil

provides emergency power failure back-up.
Page 3


FOR
T.I. 1471 (Issue A)
1.0 EQUIPMENT SPECIFICATION (Contd./)
1.3 Pumps (Contd/)
1.3.3 Motor Details (AC – M3001/M3003, DC – M3002)
AC - Marelli Motors 400v, 3ph, 50Hz/460v, 3ph,60Hz

7.5kW, 2945/3500 rpm, wired Delta
12.7 A F.L.C.
Frame size D132MD – IP55, Tropicalised
DC - Thrige Scott
4kW, 1950rpm, 125v DC compound wound, 36.4A
F.L.C., I.E.C. 34:1, Pure D.C.
Frame size LAK132C
Fitted with 35w, 110v AC anti-condensation heater
1.4 Air Blast Cooler (AC3001)
1.4.1 The system is equipped with a twin Air Blast Cooler horizontally
mounted and fitted with two 50% duty motorised fans.
(Air travel is vertically upwards).
Performance parameters as follows:-
Oil flow rate = 282 Litres/min

Temperature IN = 76.7°C
Temperature OUT = 65°C
Heat Dissipation = 95kW
Ambient air temperatures = -10 to + 50°C max
1.4.2 Motor Details (M3007 and M3005)
Marelli Motors 400v, 3ph, 50Hz/460v, 3ph, 60Hz

1.7kW, 1400rpm, wired star
3.6A F.L.C.
Page 4


FOR
T.I. 1471 (Issue A)
1.0 EQUIPMENT SPECIFICATION (Contd/)
1.5 Filters/Strainers
1.5.1 Each pump is fitted with a strainer at the foot of the suction pipe.
Filtration rating 125µm.
1.5.2 The main filter unit (F3001 and F3002) is a duplex filter, with 2.1/2” S.A.E.
connections and fitted with disposable paper, 10µm, elements and a visual
indicator set at 2.2 bar.
1.6 Air Cleaner (OME3001)
The reservoir is vented via a ‘Trion’ T1001 electrostatic air cleaner, which serves to
attract any residual oil mist, carried over. Air is discharged to atmosphere via an
extractor fan.
Any oil extracted is piped back to the reservoir via 10mm o.d. tubing.
Unit voltage is 110v, 1ph, 60Hz having 50w power consumption.
Extractor Fan Motor Details:-
0.55kW, 460v, 3ph, 50Hz, 1.4A F.L.C., tropicalised.
1.7 Heaters (H3004-1, H3004-2 and H3004-3)
The reservoir is equipped with three oil immersion heaters each rated at 1.76kW.
They are suitable for Dual Voltage, 415/460v, 3ph, 50/60Hz. They are withdrawable
and rated at 4w/in2 .
All three heaters are controlled by 1 thermostat (TSH3003) having a range of 5° to

80°C (set @ 20°C).
Page 5


FOR
T.I. 1471 (Issue A)
1.8 Valves
1.8.1 Pressure Control (PCV3001)
Dumping flow prior to cooler and with external pressure sensing at module
discharge point. ESME 1.1/2”, Type: R1490 Diaphragm Control Valve.
Range 1.0 to 2.3 bar.
1.8.2 Check Valves
Non-Return Valve, Wafer type, located in pipework immediately downstream

of each pump.
1.8.3 Temperature Control Valve (TCV3001)
‘AMOT’, 3 way, mixing type, 2.1/2” n.b. flanged ANSI 125lb, located after the
cooler.
The valve is actuated by an integral thermostat set at 54°C.
1.8.4 Instrument Valves
Instrument isolation valves are stainless steel needle valves, with integral
hex head bleed plug.
1.9 Pipework
1.9.1 Pipework is constructed from 40mm (1.1/2”) and 65mm (2.1/2”)

n.b. API 5L seamless pipe and BS1740 fittings utilising
screwed connection, back-welded to effect total seal at all joints.
All pipework after filter is stainless steel.
Page 6


FOR
T.I. 1471 (Issue A)
1.10 Instrumentation
Note: All instruments are Dual scale (°C/°F – Bar/Psi)
1.10.1 Pressure
a] ‘Star Instruments, pressure gauges are provided, monitoring

pressure at pumps delivery connections, cooler discharge and at
outlet of lubrication module. Size: 100mm∅ dial, liquid filled
Range: 0-11 bar Tag Nos: PI3001 to PI3006.
b] A ‘Star Instruments’ differential pressure gauge monitors

pressure drop across the filter unit and hence condition of
element. Size: 100mm∅ dial, liquid filled. Range: 0 to 4 bar
(PDI3001)
c] ‘Pyropress’ Model P2103 Pressure switches, range 0.5 to 2.5

bar, monitor output from pumps. Tag Nos. PSL3001 to
PSL3003. Set at 1.3 bar falling.
d] A ‘Delta’ differential pressure switch, type DP2503

(PDSH3001), monitors filter conditions. Range: 0.5 to 5.5 bar
Set at 2.5 bar rising.
e] A “Delta” pressure transmitter (PT3004) is located on the

outlet of the lubrication module. Range: 4-20mm up to 5 bar.
1.10.2 Temperature
a] Temperature gauges are provided monitoring oil temperature

into and out of the cooler, system supply and tank.
They have dial 100mm∅ dial.
Range: 0°C to 100°C. Sensors are located in thermowells
(TI3001 to TI3004).
Page 7


FOR
T.I. 1471 (Issue A)
1.10 Instrumentation (Contd/)
1.10.2 Temperature (Contd/)
b] For Heater Control see Section 1.7
c] ‘Sensing Devices’ ‘3 wire’ Temperature RTD’s are provided for

cooler fan control, remote monitoring of tank and system
supply temperatures. (TE3001, TE3002 and TE3005)
1.10.3 Level
a] The Reservoir is equipped with 4 off ‘TAV’, type 70A, Level

Switches. 1 off located at low level (300mm) and 3 off at
low/low level (480mm). Tag Nos: LSL3001 and LSLL3001 to
LSLL3003.
b] The Reservoir is equipped with a Seetru Quickmount sight

gauge (LI3001), complete with integral shut-off valves, top and
bottom. Valves incorporate automatic shut off ball in the event
of glass breakage.
1.11 Terminal Enclosures
The Unit is equipped with three terminals enclosures, grouped as follows:-
a] Digital - Drawing No.J24358-05-01

Enclosure ‘Klippon’ TB11EX. (G.D.)
b] Power - Drawing No. J24358-05-02

Enclosure ‘Klippon’ TB11EX. (G.P.)
c] Analogue - Drawing No.J24358-05-03

Enclosure ‘Klippon’ TB10EX. (G.A.)
Page 8


FOR
T.I. 1471 (Issue A)
1.12 Paintwork
The Interior of reservoir is painted in accordance with ‘Brush’ specification

PS2265.
The Exterior of reservoir & pipework is painted in accordance with ‘Brush’
specification PS2828, finish colour light blue to BS4800 18E51.
2.0 PRE-INSTALLATION TEST AND FLUSHING PROCEDURE
2.1 The Systems have been thoroughly flushed through and tested in respect of
both performance and cleanliness at fabrication Works.
3.1 Installation
The Lubrication Units should be installed on flat level surface.
The terminating pipe connections are as follows:-
Lubrication
Feedlines – 2 off - 2.1/2” NB ANSI 150# Flange
Lubrication
Return Line – 2 off - 4” ANSI 150# Flange
3.2 Services
Pumps )
Heaters )
Air Blast Cooler Fans ) 380-415v, 3ph, 50Hz / 440-480v, 3ph, 60Hz
Precipitator Fan )
Precipitator 110-120v, 1ph, 50/60Hz
Emergency Pump 125v Pure D.C.
Page 9


FOR
T.I. 1471 (Issue A)
3.3 Pipework
Install site pipework, ensuring all traces of swarf, weld splatter and debris are thoroughly
removed before making connections.
3.4 Commissioning
a] Flushing
Before connection to lubrication module, site installed system pipework must

be thoroughly flushed through to remove foreign solids. Use either the same
oil as the final fill, or flushing oil as recommended by the lubricant supplier.
Before commencing flushing, bypass the lubrication points with flexible hoses
or temporary pipework to avoid possible damage by loose abrasive matter.
Thoroughly flush pipework via external flushing circuit until system is clean.
To dislodge dirt and scale, site piping should be hammered, with soft mallet during
flushing; special attention being paid to the areas of site welds.
In all, flushing should continue for at least 48 hours or until the test screen
meets required standard.
After flushing, drain the oil and connect oil lubrication system to system
pipework.
Page 10


FOR
T.I. 1471 (Issue A)
3.0 INSTALLATION AND COMMISSIONING (Contd/)
b] Checking Main Items of System
Check that the tank is filled to run down level.
Note: If the pipework is extensive, or considerable oil is held in the

equipment, it may be necessary to top up the tank. Never fill the tank
whilst system is running.
On initial start up, ensure pipework system has been filled with oil and oil is
returning to the tank. Check all flanges and unions for tightness; adjust as
necessary to accommodate any loosening arising in transit. Switch off pump
and wait for available oil to drain back to the tank. Note level of tank in this
condition. This is the run down level and maximum to be encountered. More
oil may then be added to bring the level to approximately 150mm below tank
top.
Check that all switches are set to the desired set point.
Check that the heaters thermostat is set to desired operating temperature.
Air Blast Cooler
Check operation of fans and oil Temperature control valve
c] Running Tests and Adjustments
Ensure the system is at minimum permissive cold start of 20°C
If required, the two AC pumps may be initially run together to provide greater oil
flow to the generator.
Adjust pressure control valve (PCV3001) as necessary – factory set at 1.7 bar.
See Schematic Drawing J24358-01-01 for details of factory settings on all

switches.
Page 11


FOR
T.I. 1471 (Issue A)

4.0 FAULT FINDING
Action in the event of trouble, is best determined by reference to the chart below:-
CONDITION CAUSE ACTION
System will not start Incorrect electrical supply to pump Check electrics
motor and/or pressure switch
interlocks
Pump jammed Investigate cause and rectify
Other switch interlocks(levels etc) Check electrics
System will not build up Leaking pipework Locate and repair

required pressure
Loss of pump prime Check suction pipework for leaks.
Check if relief valve jammed open
Blocked system filtered Inspect, clean or replace
Low oil level in tank Check and top us.

Investigate loss of oil
Pump relief valve bypassing Check and re-set, repair or

replace
Control valve incorrectly set Check and adjust
Faulty pump Check and re-set, repair or

replace
Oil in tank too cold, i.e. too viscous Check heater/temperature
Page 12


FOR
T.I. 1471 (Issue A)
4.0 FAULT FINDING
CONDITION CAUSE ACTION
High differential pressure Filter dirty/blocked Clean or replace element as

across filter necessary
Oil fails to reach points of Flow control valve wrongly adjusted Check and re-set
application
Blockage or restriction in delivery line Trace, clean out or replace, as

necessary
Oil temperature abnormally Oil cooler not operating correctly Check and adjust
high
Air flow restricted Check and clear
Oil temperature too low Tank heater set too high or not cutting Check and re-set or replace
out
System builds up abnormally Pressure relief valve incorrectly set or Check and adjust or clean as
high pressure blocked necessary
Blockage in system pipework Check and clear as necessary
Page 13


FOR
T.I. 1471 (Issue A)
5.0 MAINTENANCE SHEETS
MS11-36A Pressure Control Valve
MS11-37A Temperature Control Valve
MS12-29 Pumps
MS12-30 A.C. Pump Motors
MS12-31 D.C. Pump Motor
MS15-19 Air Blast Cooler
MS21-14A Electrostatic Precipitator
MS21-8 Sight Gauge
MS4-39 Filter
MS6-22 Level Switches
MS7-21 Immersion Heaters
MS8-39 Pressure Switches
MS8-40 Differential Pressure Switches
MS8-46 Pressure Transmitter
Page 14


FOR
T.I. 1471 (Issue A)
6.0 DRAWINGS
6.1 Pump and Module Drawings
Oil Recirculation Module G.A. EGE Drg No. J24358-02-01
Oil Recirculation Module

Schematic Diagram EGE Drg No. J24358-01-01
Parts List EGE Drg No. J24358-pl-001
6.2 Terminal Box Drawings
Digital Terminal Box EGE Drg No. J24358-05-01
Power Terminal Box EGE Drg No. J24358-05-02
Analogue EGE Drg No. J24358-00-03
6.3 Spares Drawings
Spares G.A. EGE Drg No. J24358-02-02
Spares Parts List EGE Drg No. J24358-pl-004
Page 15


TP0000056 (C) Oil Module

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Supplier Data

Engineering & General Equipment Ltd. (Centralube)

(Document No.TI 1471 Issue A)

Document No: TP0000056 (Was ALC0193)

Brush Electrical Machines Ltd.

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

CUSTOMER: BRUSH ELECTRICAL MACHINES LTD

CUSTOMER ORDER NOS: BE 706779 & BEB 83201

No. of Consoles: 111 off

Serial Nos: 27-864 to 27-891

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

1.1 General Details

1.2 Reservoir (Tank)

1.4 Air Blast Cooler

1.6 Air Cleaner

1.11 Terminal Enclosures

2.0 PRE-INSTALLATION TEST AND FLUSHING PROCEDURES

3.0 INSTALLATION AND COMMISSIONING

4.0 FAULT FINDING

5.0 MAINTENANCE/DATA SHEETS

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

1.0 EQUIPMENT SPECIFICATION

1.1 General Details

Each Lubrication Module comprises a fabricated steel reservoir surmounted by three

1.2 Reservoir (Tank)

1.3.1 A.C. Powered (P3001 and P3003) – Duty and Standby

The system is equipped with two vertically mounted AC driven pumps

1.3.2 D.C. Powered (P3002) – Emergency Standby

A D.C. Powered Pump capable of delivering 209 litres/min of ISOVG 32 oil

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

1.0 EQUIPMENT SPECIFICATION (Contd./)

1.3 Pumps (Contd/)

1.3.3 Motor Details (AC – M3001/M3003, DC – M3002)

AC - Marelli Motors 400v, 3ph, 50Hz/460v, 3ph,60Hz

1.4 Air Blast Cooler (AC3001)

Performance parameters as follows:-

Oil flow rate = 282 Litres/min

1.4.2 Motor Details (M3007 and M3005)

Marelli Motors 400v, 3ph, 50Hz/460v, 3ph, 60Hz

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

1.0 EQUIPMENT SPECIFICATION (Contd/)

1.6 Air Cleaner (OME3001)

Unit voltage is 110v, 1ph, 60Hz having 50w power consumption.

Extractor Fan Motor Details:-

0.55kW, 460v, 3ph, 50Hz, 1.4A F.L.C., tropicalised.

1.7 Heaters (H3004-1, H3004-2 and H3004-3)

All three heaters are controlled by 1 thermostat (TSH3003) having a range of 5° to

Homepage Previous Document

OPERATING AND MAINTENANCE INSTRUCTIONS

T.I. 1471 (Issue A)

1.0 EQUIPMENT SPECIFICATION (Contd/)

1.8.1 Pressure Control (PCV3001)

1.8.2 Check Valves