PULVERISER LUBE OIL SYSTEM

OPERATING PROCEDURE
(WITH PLANETARY GEARBOX)

PROJECT: WBPDCL Sagardighi TPP PHASE II 2x500 MW

DOC NO. 16119085974D REV.: 00
DT: 30.09.2011

The Pulveriser lube oil system (PLOS) consists of a oil tank, 2x100 % Screw pump &
motor, basket filter, oil cooler etc. Lube oil pump capacity is 150 LPM. Filtered and
cooled oil, to the required temperature range of 30 to 50 deg C, is supplied to the
gearbox thrust pad bearing, input shaft bearings and gears. The return line from the
gear box is connected to the tank. A heater of 3 KW (or two heaters of 1.5 KW each)
(HVA AH001) provided in the oil tank keeps the oil temperature in the required
range, provided the pump is ON.

The following instrumentation is provided in the PLOS for interlocks & protection,
alarm and indication.

1.0 TEMPERATURE MEASUREMENT:

- Temperature Elements - RTD‟s (Duplex PT 100-4 wire) are provided in the lube
oil system -

a) Two No.‟s on the lube oil tank (HVA CT003, CT004).

b) Two No.‟s at the cooler outlet (HVA CT001, CT002).

- Six No.‟s RTD‟s (Duplex PT 100-4wire) are also provided on the gear box to
measure the temperature of input shaft bearings (2nos.-HFC01 CT 024, CT025),
the thrust pad bearing (4 nos.- HFC01 CT020 TO CT023).

- Temperature indicators are provided-

a) One on the oil tank (HVA CT502).

b) One each at the cooler inlet & outlet (HVA CT501, CT500).

2.0 PRESSURE MEASUREMENT:

- Two Pressure Switches (HVA CP101, CP102) are provided in the lube oil line,
after the oil cooler assembly. The pressure switches are used for interlock &
protections.

- A differential pressure switch (HVA CP100) is provided across the oil filter unit
for alarm. A differential pressure indicator (local HVA CP503) is also provided.

- Pressure indicators are provided-

a) One each at the filter inlet and outlet (HVA CP500, CP502).
b) One at the cooler outlet (HVA CP501).

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 3.0 LEVEL MEASUREMENT:

- Two oil level Switches (HVA CL100, CL101), one for high level alarms and the
other for low level (pump trip), are provided in the oil tank.
- One oil level gauge (HVA CL500) is provided on the oil tank for visual check of
“OIL LEVEL”.

4.0 FLOW MEASUREMENT:

- Two oil flow switches cum point indicators (HVA CF100, CF101) are provided in
the lube oil line after cooler assembly.

PLOS PRE-COMMISSIONING CHECKS:

1. Ensure electrical connections to MOTOR & Instruments, if any.

2. All the flanges in the system are tightly fastened.

3. Ensure valves position, which are to be kept open.

4. Avoid air pockets while priming the system.

5. Maintain oil level in the tank to the required level after priming the lube oil
system.

6. Start & stop the Motor to check the direction of rotation of pump and Motor.
Ensure correct direction as shown on the pump.

7. Start the Motor and allow the system to run for 4 hours (trial run cum system
flushing operations).

8. Run the system with the required oil pressure at cooler outlet.

NOTE: 1) Avoid dry running of the pump as it results in seizer of moving parts.
2) The relief valve at the pump outlet is factory set at 8.5 bar.

PLOS OPERATION:

Once the lube oil system flushing along with the gear box is completed the same is
declared ready for normal operation.
When the oil temperature in the tank (HVA CT003 OR CT004) is greater than 10 deg.
C the lube oil pump is permitted to start and at oil temperature value greater than 30
deg. C at the cooler outlet (HVA CT001 OR CT002) the mill is released for start.
Below 30 deg. C oil temperature (temp. low) in the tank (HVA CT003 OR CT004)
the oil heater (HVA AH001) is energized, provided the pump is in service. The heater
is de-energised at the tank oil temperature (HVA CT003 OR CT004) of 36 deg.C
(temp. adequate) OR when the lube oil pump is stopped.

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Charge one of the duplex filters and the oil cooler. Once the permissive conditions
are met with, start the lube oil pump. The lube oil pump can be started either from
Local push button OR from REMOTE manual through a potential free contact & CRT
and when pump stop command is not present, lube oil level is not low (HVA CL101)
and tank oil temperature is not low (HVA CT003 OR CT004).
The filter change over can be done on line for cleaning the filter element. Cooler
change over can be done on line too.

MILL START PERMISSIVE CONDITIONS FROM THE PLOS:

THE MILL MOTOR CAN BE ENERGISED ONCE THE FOLLOWING

PERMISSIVE CONDITIONS ARE FULL FILLED.

1.0 Lube oil temperature is adequate (HVA CT001 OR CT002 > 30 deg. C)

2.0 Lube oil Pump „ON‟ for more than 15 minutes and Lube oil pressure at cooler
outlet is NOT LOW (HVA CP101 > 0.8 bar).

3.0 Lube oil filter not dirty (DPS- HVA CP100 < 2.0 bar)

4.0 Lube oil flow to the gearbox is NOT LOW (HVA CF100 > 120 LPM).

5.0 Any bearing temperature of Gearbox is within ALARM limits (i.e <75 deg.C).

AUTOMATIC MILL TRIP CONDITIONS FROM PLOS:

THE MILL IS TRIPPED IF ANY ONE OF THE FOLLOWING CONDITIONS

ARE PRESENT.

a. When both lube oil pumps are not „ON‟ for more than 2 sec.

b. Lube oil pump „ON‟ and lube oil pressure (HVA CP102 < 0.5 bar) after cooler is
very low, with a time delay of 15 seconds.

c. Lube oil temperature after cooler is very high (HVA CT001 OR CT002 > 65 deg.
C).

d. Lube oil flow to the gearbox is very low (HVA CF100 < 105 LPM).

PUMP TRIP CONDITIONS:

1.0 The lube oil pump stops/ shall be stopped when any one of the following
conditions are acknowledged or satisfied.

- Lube oil level in tank is low (HVA CL101).

- Lube oil temperature in tank is very low (HVA CT003 OR CT004 < 10 deg. C)
- Pulveriser OFF for more than 60 minutes and pump stop push bottom actuated.

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STAND-BY PUMP START CONDITIONS:

1. The running pump is „ON‟ for more than 60 seconds and discharge pressure at
pump outlet is low (HVA CP101 < 0.8 bar), the standby pump to start.

2. When Pump-1 (Main) fails to start on giving start command, after 10 sec. time
delay, the stand by pump to start.

3. Running Pump trips on fault, the stand-by pump shall start immediately.

OUTPUT CONTACTS PROVIDED:

- Pulveriser Start Permissive (to FSSS)

- Pulveriser Stop Command (to FSSS)
- Start lube oil pump (to motor starter)
- Stop lube oil pump (to motor starter)
- Both lube oil pumps not ON (to SOE in DDCMIS)

ALARMS LIST:

The following „ALARM‟ signals are provided.

i. Lube oil tank level low (HVA CL101).

ii. Lube oil tank level high (HVA CL100).

iii. Lube oil flow to gearbox is low (HVA CF100 < 120 LPM).

iv. Oil temperature after cooler high (HVA CT001 OR CT002 > 60 deg. C).

v. Any lube oil pump ON for more than 60 sec. and Oil Pressure after cooler low
(HVA CP101 < 0.8 bar).

vi. Lube oil filter dirty (HVA CP100 > 2.0 bar).

vii. Lube oil temperature in tank very low (HVA CT003 OR CT004 < 10 deg. C).

viii. Both lube oil pumps not ON

***

2 06.08.2012
Sanjoy Roy Gosthipaty

0803 06.08.2012