Opgs-0-Tur-Opn-19-33-00 Turbine Generator Lube Oil System Sop

OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/33/00
DOC TITLE SOP FOR TG LUBE OIL SYSTEM REV NO 0 DATE 12-02-2017
TURBINE GENERATOR (TG) LUBE OIL

SYSTEM
PREPARED BY APPROVED BY
DATE DATE
Page 1 of 12
Applicable Elements of Standard:

ISO 14001(2004) 4.4.4.6 Operational control
OHSAS 18001 (2007) 4.4.6 Operational control
1. OBJECTIVE
This procedure covers all the operational activities related to starting & operating the Turbine
generator lube oil system, which are carried out by operation personnel for safe operation of equipment and
which will improve the equipment availability always.
2. DESCRIPTION
A satisfactory and continuous supply of oil is essential for the safe and reliable running of the
turbines and their driven equipment. The oil supply should ensure the operational safety of bearings. The
system is of closed circuit type, i.e., a definite amount of oil quantity which is previously determined is
continuously recirculates and thus the bearings are lubricated and cooled.
The lube oil system comprises of following equipment’s and components

- Main oil tank MAV10 BB001
- Main oil pump-1(AC) MAV21 AP021
- Main oil pump-2(AC) MAV21 AP022
- Emergency oil pump (DC) MAV24 AP001
- Emergency oil pump (AC) MAV25 AP001
- Lube Oil Cooler -1 MAV41 AC001
- Lube Oil Cooler -2 MAV41 AC002
- Trans flow valve for Lube oil coolers MAV41 AA521
- Temperature control valve MAV41 AA001
- Lube oil filter – 1 MAV42 AT001
- Lube oil filter – 2 MAV42 AT002
- Trans flow valve for Lube oil filters MAV42 AA521
- Lube oil throttles MAV42 AA502 (#1 Bearing)
MAV42 AA503 (#2 Bearing)
- Hydromotor MAD11 AE001
- Lifting oil pump (AC) MAV31 AP001
- Lifting oil pump (DC) MAV32 AP001
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3. REFERENCE DOCUMENT
1. Operation and maintenance manual of M/s. BHEL Turbine and auxiliaries.

2. Scheme of documents: Lube Oil Scheme - 2-131-00-90101 (2 Sheets)
Oil Vapour Exhaust Scheme - 2-131-00-90102
Oil Discharge / Oil vent Scheme - 2-131-00-90103
Oil Purification Scheme - 2-131-00-90104
Dirty Fluid Scheme - 2-131-00-90105
Lifting Oil Scheme - 2-131-00-90106
Main Oil Tank Scheme - 2-131-00-90107
Lube Oil Cooler Scheme - 2-131-00-90108
4. SAFETY PRECAUTIONS
1. Hazard Identification and risk assessment of the activity shall be made aware to the
operator.
2. Only authorized person is allowed to operate the equipment.
3. All the access to the equipment shall be kept clear.
4. All the persons operating the equipment shall be provided with the proper training.
5. All the guards and coverings of the equipment shall be covered.
6. No flammable material or oil shall be scattered or spilled around the equipment.
7. Fire fighting system should be available.
8. Field operator should wear the relevant personal protective equipment like boiler suit,
safety shoes, helmet, safety hand gloves, safety goggle.
5. TECHNICAL SPECIFICATION
5.1 PUMP AND MOTOR

LIFTING LIFTING
MAIN OIL EMERGENCY EMERGENCY
UNITS OIL PUMP OIL PUMP
PUMP OIL PUMP AC OIL PUMP DC
AC DC
ALLWEILE ALLWEILER ALLWEILER LEISTRITZ ALLWEILE
Make
R AG AG AG R AG
Quantity 2 1 1 1 1
TUSHACO TUSHACO TUSHACO TUSHACO
Made for
PUMPS PUMPS PUMPS PUMPS
Capacity m3/hr 85 85 85 79 lpm 100 lpm
Discharge
bar 7 3 3 150 150
pressure
Speed rpm 2900 2900 2900 2900 2900
Drive AC AC DC AC DC
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motor
CROMPTON CROMPTON CROMPTON ZINA DE CROMPTON
Make GREAVES GREAVES GREAVES MASINI GREAVES
LTD LTD LTD ELECTRICE LTD
Type Induction Induction Shunt Induction Shunt
Enclosure IP 55 IP 55 IP 55 IP 55 IP 55
Voltage V 415 415 22o 415 220
Frequency Hz 50 50 50
Motor
kw 37 15 15 37 37
power
Current A 63 26 79 61 197
5.2 MOT TANK

Oil tank capacity operating / flooded 8/11 m3
Oil circulation per hour 10
Highest oil level from top of tank 390 Mm
Lowest oil level from top of tank 440 Mm
First oil filling (estimated) 11 m3
Flushing oil quantity (estimated) 11 m3
5.3 TG LUBE OIL FILTER

Make HYDAC
Capacity 2*65L
Working pressure 12 kg/cm2
Test pressure 18 kg/cm2
2*3*ELEMENTS 1700
W/MC/-KB
Flow rate 1440 Lpm
Degree of filtration 25 Microns
Bhel code TC9754251010
5.4 LIFTING OIL FILTER

Make HYDAC
Capacity 2*1.5L
Working pressure 165 kg/cm2
Test pressure 250 kg/cm2
Working temperature 45 C
Flow rate 85 lpm
Degree of filtration 10 microns
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5.5 TG LUBE OIL COOLER

SHELL TUBE
SIDE SIDE
Make BHEL
Capacity 2*100 %
Design pressure 9 6 kg/cm2
Design temperature 100 80 C
Shell id*thickness 750*12
Surface area 496 mm2
5.6 OIL VAPOUR EXHAUST FAN AND MOTOR

Make CB DOCTOR
Capacity 2*100 %
Capacity 0.18 m3/sec
Speed 2800 rpm
Drive AC MOTOR
Make KIRLOSKAR ELECTRIC
Voltage 415 V
Frequency 50 Hz
Power 1.1 kw
Speed 2820 rpm
Current 2.35 A
MAIN OIL TANK

The main oil tank contains oil necessary for lubricating, cooling and lifting oil systems. It not only
serves as a storage tank but also for deaerating the oil.
The capacity of the tank is such that the retention time from entry into the tank to suction by the
pumps is 8minutes. This time allows sedimentation and detrainment of the oil.
Oil returning to the tank from the oil supply system first lows through a submerged inlet into the riser
section of the tank where the first stage of deaeration takes place as the oil rises to the top of the tank. Oil
overflows from the riser section through the oil strainer into the adjacent section of the tank where it is then
drawn off on the opposite side by the oil pumps.
The lube and lifting oil pumps are submerged in the tank and are driven by electric motors which are
fixed to base plates of the tank cover. The pumps draw oil from the deepest point in order to obtain oil as
free of air as possible.
The basket type oil strainer is mounted in the tank. It is brass wire mesh of 0.25 mm filtration
particle size and can be exchanged by opening the tank cover.
The whole tank is made as air tight as possible. Oil vapour exhaust produce slight negative pressure
in the tank, in the return drain lines and in the spaces in the bearing pedestals so that oil vapour arising is
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drawn off. The main oil tank has a direct reading oil level indicator (MAV10CL521) and oil level sensors.
These sensors transmit signals to control room for various applications.
MAV10CL021- For level indication in control room
MAV10CL021- Trip of turbine at low-low level (490mm)
MAV10CL023- Alarm at low level (440mm)
MAV10CL022- Alarm at high level (340mm)
Extra tank volume is provided between the normal operating level and the tank cover to accept oil
from the entire oil supply system when the turbine is shutdown. The tank is constructed with a sloping
bottom with drain connections in riser and main sections.
A sampling connection is provided to the main oil tank to take out oil and analyse for its properties.
LUBE OIL PUMP (MAV21AP021/AP022)

The lube oil pump is a vertical one stage centrifugal pump with a radial impeller and spiral casing. It
is fixed to the cover of the oil tank and submerges into the oil with the pump body. It is driven by an AC
motor that is bolted to the cover plate. The oil enters the suction connection from underneath and is supplied
to oil system via the discharge pipe. 2 x 100% lube oil pumps are provided.
A check valve is provided in pump discharge to prevent back flow of oil into the pump when it is not
in operation. The standby pump is started automatically when the pressure in the discharge header falls
below 5.0 kg/cm2 through pressure transmitter MAV21CP001.
The following pressure sensors are provided on lube oil header:
MAV42CP017 for pressure indication in control room
MAV42CP011/12 for lube oil pressure low (<3.4 kg/cm2) – EOP start
MAV42CP016/17/18 for lube oil pressure very low (<3.2 kg/cm2) – turbine trip
MAV42CP019 for lube oil pressure low (pressure switch) – DC EOP DCS start
EMERGENCY OIL PUMP (MAV24AP001, MAV25AP001)

The emergency oil pump is of the vertical, centrifugal submerged type and serves for lubrication and
cooling of bearings when all sources of oil supply fail. The pump and motor unit is attached to mounting
plate which is bolted to the top of the main oil tank.
Two numbers of emergency oil pumps are envisaged for this project. EOP (MAV24AP001) is driven
by DC motor and EOP (MAV25AP001) is driven by AC motor. Pressure switch MAV42CP011&012 is
used for auto start of DC EOP in the event of DCS failure. The pump construction shall be similar to that of
lube oil pump.
To increase reliability of lube oil to bearings, the emergency oil pump discharge is directly connected
to lube oil header by passing cooler and filter.
Emergency oil pump (AC) shall be started automatically when the lube oil header pressure falls
below 3.0 kg/cm2 which will be derived through pressure switches MAV42CP011 & MAV42CP012.
Similarly Emergency oil pump (DC) shall be started automatically when AC EOP is not in operation and the
pressure falls
OIL COOLER (MAV41AC001/AC002)

The heat absorbed by the oil in the bearings and elsewhere in the oil system is dissipated in the oil
cooler which is of shell and tube design. The system consists of two oil coolers each of 100% capacity. A
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change over device (double three way Trans flow valve arrangements) is provided for switching over to
standby oil cooler whenever it is necessary to take the main oil cooler for maintenance. The change over
device is so designed that under any circumstances both the coolers are not allowed to be shutdown.
Whenever feasible, the switching over to the standby oil cooler is to be carried out during the stand still
condition of the turbine. If it proves unavoidable that the switching be made in the course of turbine
operation, it should be done with utmost care. Before switching over to another oil cooler, this must be
generously vented and the bearing oil pressure must be observed during a considerable period afterwards. A
temperature high Alarm (MAV42CT001) is provided for lube oil cooler outlet temperature.
LUBE OIL TEMPERATURE CONTROL VALVE (MAV41 AA001)

A 3 way temperature control valve is provided to maintain the lube oil cooler outlet temperature. The
control valve bypasses the cooler, by connecting cooler outlet with uncooled oil whenever the cooler outlet
temperature drops due to fall in cooling water temperature. Converse also shall take place. The control valve
is of thermostatic type. For more details refer suppliers Catalogue of AKO Germany.
OIL FILTER (MAV42 AT001/AT002)

The duplex type of Oil filter with reusable filter element with filtration of 25 microns is provided.
This is in addition to the oil strainer arrangement provided in the oil tank. A change over device is fitted for
switching over to standby Oil filter in case of choking of the working filter. The change over device is so
designed that under any circumstances both the filters are not allowed to be shutdown. A differential
pressure switch (MAV42 CP013) set at 0.9 kg/cm2 is provided to annunciate high differential pressure.
HYDROMOTOR (MAD11AE001)
If a hot turbine is shut down and the turbine rotor is not turned distortion of the rotor will occur after
some time and is of a particular importance. If any immediate restart is required the resultant eccentricity of
the rotor can cause serious damage to the blade tip sealing or to the blades themselves due to rubbing. Also
the excessive vibration due to unbalance of the rotor can lead to premature wear of the bearings. Continuous
or regular intermittent turning of the turbine rotor in these circumstances will allow the turbine to be
restarted without danger. For turning of turbine rotor, Hydromotor is employed. Hydromotor gets motive
fluid from lifting oil circuit. For construction details refer 2-1440-01. Motive oil to Hydromotor is provided
through a solenoid valve MAV51AA501 which is hooked up with Turbine start-up system.
OIL VAPOUR EXHAUST FANS (MAV82AN001/AN002)

The oil vapour exhaust fan produces a slight vacuum in the main oil tank and in the bearing housings
so that accumulation of oil vapour is prevented. The butterfly valves provided in each of the extraction line
can be adjusted such that the pressure in the bearing housings is about 5 to 10mm of water column below
atmospheric pressure. 2 x 100% oil vapour exhaust fans are provided which are mounted on the oil tank. The
smooth function is monitored with a flow switch in the discharge of OVEF fans (MAV82CF001). Whenever
the flow is less than the set value, the second fan will start automatically.
LIFTING OIL PUMP (MAV31/32 AP001)

In Stand still state, the turbine shaft journals are in contact with white metal of the bearings due to
the weight of rotor. Lubricating oil cannot reach these contact areas because of low pressure. A Considerable
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torque would be required to break off the shaft from stand still-state. To facilitate the start-up, oil is admitted
with high pressure below the bearing journals of the shaft, whereby the shaft floats on oil film.
In this condition, the shaft assembly can be turned with much lesser torque. To provide high pressure
oil 2 x 100% lifting oil pumps are provided.
The pump is self-priming, screw spindle pump with three spindles and internal bearings. The pump
is connected to the cover plate via a support and is driven by an electric motor through flexible coupling.
The entire assembly is installed vertically in the oil tank. The oil entering the pump is transported by the
rotating spindle to the pressure chamber from where it is forced into the pressure pipe, which is bolted to the
pump and welded to the support.
The pump is driven by AC and DC Motor and 2x100% pumps are provided Source of AC should be
different. One pump will be driven by DC motor.
If the main pump cannot build up the required oil pressure, then the Stand by pump is started by
pressure sensor (MAV35CP001) provided on the lifting oil header. The pressure oil piping of the pump
which is not in operation is closed by the stop cum check valve (MAV31/32AA003). As the oil system is
designed only for 100% delivery rate, the pumps are interlocked for avoiding parallel operation. In order to
protect the lifting oil system from damage due to improper switching on of the lifting oil pump when the
check valve is closed, spring loaded safety valves (MAV31/32AA390) are situated in the piping between the
pump and check valve.
The acceleration of the pump against full pressure of lifting oil pressure is inadmissible. Thus, the
pump operation is interlocked until it falls below 100 kg/cm2.
The necessary pressure in the system is kept constant by means of the pressure limiting valve
(MAV35AA001). The pressure limiting valve can be relieved by the bypass valve (MAV35AA501). The
superfluous flow from the pump is returned to main oil tank.
The necessary lifting oil pressures are set for each bearing by the needle valves (MAV66AA501
etc.). Check valves (MAV66AA001 etc.) in the lifting oil lines prevent oil from flowing out of the bearings
into the header during turbine operation when the lifting oil system is switched off.
The lifting oil header pressure is indicated in control room by (MAV35CP001).A duplex type oil
filter is provided in the pump discharge to protect the bearings against the entry of unclean oil. Differential
pressure sensor (MAV35CP006) is provided for annunciating the pressure-high alarm in control room. This
should prompt the operator for switching over to standby filter. Lifting oil pump also provides motive fluid
for hydro motor during turning operation.
6. PRECHECKS
6.1 FIELD OPERATOR CHECKS

1. Ensure the issued permit works for the equipment’s are completed.
2. Ensure the equipment and equipment areas are cleaned for safe operation.
3. Ensure the flanges near all the bearing pedestals in turbine and generator are properly
connected with oil gaskets.
4. Ensure all the bearing housing of turbine and generator is properly boxed up.
5. Ensure the pressure gauges are mounted in Generator bearing housing.
6. Ensure all drains in the lube oil system are closed.
7. Ensure the MOT manhole door is closed.
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8. Ensure the MOT bucket strainer inspection door is closed.
9. Ensure all local pressure, temperature Gauges, transmitters, switches on lube oil system is
lined up.
10. Ensure all the butterfly valve of OVEF exhaust line in each turbine pedestal and in return
line header is open.
11. Ensure the flange in the lube oil header for connection of flushing oil is properly isolated.
12. Ensure that closed circulating cooling water pump is running and the water is available
for the lube oil cooler.
13. Open the closed circulating cooling water outlet and inlet isolating valves for the lube oil
cooler.
14. Ensure all paths from pump discharge to tank return are lined up.
15. Ensure the panel supply of DC JOP and DC EOP is normal and selection switch.
6.2 SWITCH GEAR ENGINEER CHECKS

1. Check all the permits issued for the equipment are returned.
2. Check power supply and control supply healthiness of the feeder of MOP 1, MOP 2, AC
EOP, AC JOP, OVEF 1 and OVEF 2.
3. Before normalize the feeder of DC JOP motor, please ensure that starter should be in OFF
condition.
4. Before normalize the feeder of DC EOP motor, please ensure that starter should be in
OFF condition.
5. Check the emergency push button of feeder of all above mentioned equipment’s, if it is
acted release the same.
6. If above conditions are satisfied, give clearance to the control room engineer to start the
equipment.
6.3 CONTROL ROOM ENGINEER CHECKS

1. Check all the permits issued for the equipment are returned.
2. Ensure all pump and motor protections are in-line.
3. Closed circulating cooling water pressure to lube oil cooler is normal.
4. Check Main oil tank level is normal i.e., 390mm from top of the tank.
5. Run the oil centrifuge for at least one day to remove moisture in the MOT tank before
starting the TG lube oil system for continuous operation.
Note: Before normalize the DC EOP feeder at least start AC EOP or any one MOP. As a safety measure an
independent lube oil header pressure switch (MAV42CP012) shall give direct command to DC starter of
emergency oil pump (MAV24AP001). This feature has been built to guard the turbine and generator bearing
against the non-availability of 24 V DC supply to SLC.
7. PERMISSIVE
Not Applicable.
8. PROTECTION
Page 9 of 12
Not Applicable.
9. STARTING PROCEDURE
1. Switch ON the SLC of OVEF, the preselected fan would be switched ON automatically
and also check the standby fan by giving ON command.
2. Switch ON the SLC of MOP, the preselected MOP would be switched ON automatically
and also check the standby Main oil pump by giving ON command. Whenever the oil
pump discharge header pressure (MAV21CP001) or lube oil header pressure
(MAV42CP019) falls below the set value, the standby pump is automatically switched
ON.
3. Check the pump discharge header pressure should be >6 kg/cm2.
4. Check the lube oil header pressure should be >5.4 kg/cm2.
5. Ensure the lube oil filter dp is <0.9 kg/cm2. If filter dp is more changeover the filter.
6. Switch ON the SLC of EOP (DC), the emergency oil pump (MAV24AP001) is switched
“ON” automatically whenever lube oil pressure falls below set value. Additionally as a
safety measure an independent pressure switch (MAV42CP012) shall give direct
command to DC starter of emergency oil pump (MAV24AP001). This feature has been
built to guard against the non-availability of 24 V DC supply to SLC.
7. Switch ON the SLC of EOP (AC), the emergency oil pump (MAV25AP001) is switched
“ON” automatically whenever lube oil pressure falls below set value.
8. Switch ON the SLC of AC JOP, the lifting oil pump-1 (LOP) (MAV31AP001) is
switched ON, if speed falls below 510 RPM and switched OFF if speed raises above 540
RPM automatically.
9. Check the lifting oil header pressure should be >100 kg/cm2.
10. Switch ON the SLC of DC JOP, the lifting oil pump-2 (LOP) (MAV32AP001) is
switched ON, if speed remains below 8.5 S-1 (i.e. 510 RPM) for more than 5s and lifting
oil pressure (MAV35CP012) is below set value (less than 100kg/cm2).
10. SHUTDOWN PROCEDURE

1. Ensure the “HP mean shaft temperature (MAV01EP154) and HP inner casing
temperature (MAA50CT011) is less than 100°C”.
2. Close the turning gear SOV.
3. Ensure turbine speed reduces to zero (turbine standstill) and wait for 20minutes.
4. Switch OFF the SLC of AC JOP, Stop AC JOP.
5. Switch OFF the SLC of DC JOP, stop DC JOP.
6. Switch OFF the SLC of MOP, stop the running MOP.
7. Switch OFF the SLC of AC EOP, stop the running AC EOP.
8. Switch OFF the SLC of DC EOP, stop the DC EOP by switch OFF the starter from local.
9. Switch OFF the SLC of OVEF and stop the running OVEF.
Page 10 of 12
11. CHANGEOVER PROCEDURE

Consider MOP-1 in service,
1. Keep MOP SLC ON, start the standby MOP.
2. Check the pump discharge header pressure it should increase.
3. Check the lube oil header pressure it should increase.
4. Check the current of both the MOP.
5. Check both pump vibration and any abnormalities.
6. Stop the MOP-1.
Consider OVEF-1 in service,
1. Keep OVEF SLC ON, start the standby OVEF.
2. Check the fan abnormalities.
3. Stop the OVEF-1.
Consider AC JOP in service,
1. Start the DC JOP.
2. Check the pump vibration and any abnormalities.
3. Check the lifting oil header pressure should increase and should be >100 kg/cm2.
4. Stop the AC JOP.
12. STANDBY OPERATION PROCEDURE

Not applicable.
13. CONCLUSION
The purpose of this procedure is for proper understanding about the interlock and protection of
the TG lube oil system & safe operating procedure.
14. RECORD
Turbine desk log book
Turbine local log book
15. AMENDMENT HISTORY

PREVIOUS
CONDITION PREVIOUS
PRESENT CONDITION CURRENT REV.
S.NO (BEFORE REV. NO.&
(REASON MADE) NO & ISSUE DATE
THIS ISSUE DATE
REVISION)
1.
2.
3.
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Opgs-0-Tur-Opn-19-33-00 Turbine Generator Lube Oil System Sop

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OPGS POWER GUJARAT PVT LTD DOC NO:

2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/33/00

TURBINE GENERATOR (TG) LUBE OIL

Applicable Elements of Standard:

The lube oil system comprises of following equipment’s and components

1. Operation and maintenance manual of M/s. BHEL Turbine and auxiliaries.

5.1 PUMP AND MOTOR

5.2 MOT TANK

5.3 TG LUBE OIL FILTER

5.4 LIFTING OIL FILTER

5.5 TG LUBE OIL COOLER

5.6 OIL VAPOUR EXHAUST FAN AND MOTOR

MAIN OIL TANK

LUBE OIL PUMP (MAV21AP021/AP022)

EMERGENCY OIL PUMP (MAV24AP001, MAV25AP001)

OIL COOLER (MAV41AC001/AC002)

LUBE OIL TEMPERATURE CONTROL VALVE (MAV41 AA001)

OIL FILTER (MAV42 AT001/AT002)

OIL VAPOUR EXHAUST FANS (MAV82AN001/AN002)

LIFTING OIL PUMP (MAV31/32 AP001)

6.1 FIELD OPERATOR CHECKS

6.2 SWITCH GEAR ENGINEER CHECKS

6.3 CONTROL ROOM ENGINEER CHECKS

10. SHUTDOWN PROCEDURE

11. CHANGEOVER PROCEDURE

12. STANDBY OPERATION PROCEDURE

15. AMENDMENT HISTORY

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