DOCUMENT STATUS: FOR APPROVAL

A 30/01/04 First issue

Rev. Date Description Drwn. Chkd. Appd.

UONG BI 300 MW EXTENSION POWER PLANT

Owner:

EPC Contractor:

Subcontractor:

POWER MACHINES

Document Title:
Turbine lubrication oil system.
System description.

Project No. Format: A4 Total Pages: 11

Designed by:
Function Name Sign Date
Approved Knjazev 30.01.04
Checked Tarasenko 30.01.04
Draw Troshin 30.01.04
Date: Rev:
Document No.: UBEX1-M2-I-08-MAV-0001 30/01/04 A
xx
File: 644753470.doc
 CONTENTS

1. EQUIPMENT 3

2. MAIN FUNCTION 4

3. SYSTEM OPERATION 5

4. DISTURBANCE HANDLING 7

5. CONTROL LOOPS 8

6. ALARMS 11

UBEX1-M2-I-08-MAV-0001
Rev. Sheet Document № Signature Date
Draw Stage Sheet Sheets
Turbine lubrication oil system. 2 11
Check
System description.
Approve
File: 644753470.doc
 1. EQUIPMENT

1.1. Lubrication oil tank (10MAV10BB001)

Capacity 35 m3
Materials corrosion-resistant steel

1.2. Main lubrication oil pumps (10MAV11AP001, 10MAV12AP001)

Flow 250 m3/h
Head 34 m H2O
Motor 55 kW

1.3. Emergency lubrication oil pumps (10MAV13AP001, 10MAV14AP001)

Flow 180 m3/h
Head 22 m H2O
Motor 22 kW

1.4. Lubrication oil tank fan (10MAQ10AN001)

Flow 7000 m3/h
Head 150 mm H2O
Motor 5,5 kW

1.5. Lubrication oil coolers (10MAV21AC001, 10MAV22AC001)

Cooling surface 440 m2
Oil flow 330 m3/h
Cooling water flow 300 m3/h

1.6. Lubrication oil fine filter (10MAV39AT001)

Type cloth
Working surface 3,5 m2
Productivity 20 m3/h

1.7. Lubrication oil electric heater (10MAV16AC001)

Power 96 kW

1.8. Lubrication oil recirlulation pump (10MAV15AP001)

Flow 10 m3/h
Motor 5,5 kW

Sheet
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 2. MAIN FUNCTION

2.1. Oil supply to bearings

Oil for the bearing lubrication is supplied from clean section of oil tank by electrical pumps.
Two AC motor-driven pumps are provided for turbine and generator requirements. One pump is a
working pump; the other is a stand-by one. Two emergency DC motor-driven oil pumps are
provided for oil supply to the turbo-generator bearings in case of blackout of both AC oil pumps
failure due to some other reasons.
Oil pressure on the turbine axis level at operation of AC motor-driven oil pumps is maintained
equal to 1,2 kgf/cm2 by means of the pressure control valve, provided with an automatic hydraulic
drive of direct action.
Oil is supplied to bearing inserts through emergency tanks located on the bearing covers.
Emergency tanks are designed to supply oil at turbine run-out, stopped with vacuum surge in case of
auxiliaries and DC voltage loss.

2.2. Oil cooling

Oil for turbine and generator bearing lubrication is cooled by means of two coolers supplied
by main oil pumps. One cooler is in operation normally; another cooler is being a stand-by one.
Oil temperature is controlled by changing water flow by means of control valve on the line of
cooling water supply to the oil coolers. The valve is controlled with electronic oil temperature
controller.

2.3. Oil purification

Oil purification is ensured by two rows of gauzes with cells of 0,25 mm dimensions, installed
inside the tank and divided the tank into dirty and clean sections. Oil is discharged into dirty section.
To separate air contained in oil provision is made to install air separator. It represents a set of metal
plates, inclined to the oil flow directions.
To clean the oil supplied for lubrication, there is a full-flow duplex oil filter in oil supply line
from the AC motor-driven pumps to the oil coolers besides the gauze filters in the oil tank.
Moreover the oil is continuously cleaned with filtration cleanness of about 12 micron by supplying
the oil portion from the supply oil piping through the fine filter to the clean section of the oil tank.

2.4. Removal of oil vapours

One AC motor-driven fan is provided for suction of oil vapours from turbine bearing cases and
lubrication oil tank. Discharge from the fan is carried out via the ventilating pipe on the building
roofing. When fan is out of operation due repair, extraction of oil vapors from the oil tank is
provided due to the natural draught within the ventilation pipeline, that allow for the installation to
be limited time in operation, when the fan being out of operation.

Sheet
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 3. SYSTEM OPERATION

3.1. Normal operation

During operation of system, one main lubrication oil pump is switched on and ensures oil flow
for the bearings lubrication. The rest pumps of lubrication system are in stand-by condition and
ready for emergency start-up. Gate-valves at the lubricating oil system pump suction and discharge
lines should be opened.
One lubrication oil cooler is in operation, the cooler gate-valves at the oil and water inlet and
outlet, should be opened. The second oil cooler is switched off; gate-valves at water and oil lines
should be closed. Gate-valve on the oil cooler bypass at the oil line should be also closed.
The control valve at cooling water line of oil coolers is switched over to automatic control
mode and controlled by electronic oil temperature regulator.
The fan of the lubrication oil system is in operation. Gate-valve at the fan bypass should be
closed.

3.2. System start-up

Lubrication oil supply system is started up after switching on of operating main oil pump. The
lubrication oil pump start-up after erection, repair or prolonged staying should be done at the
discharge gate-valve being closed. After pump motor switching on the discharge gate-valve should
be opened gradually to fill the piping and the oil cooler space. During normal operation and after
staying without system emptying the lubrication oil pump start-up may be done at the discharge
gate-valve being open.
The lubrication oil system start-up is possible if the operating oil pump is selected by operator,
the oil level in the oil tank higher than 0,6 m and the oil temperature in the lubrication oil tank
higher than 30 ºC. In this case according to the group start-up program the following actions take
place:
- the fan of the lubrication oil tank (10MAQ10AN001) is started;
- the main oil pump chosen as a working one (10MAV11AP001, 10MAV12AP001) is
started;
- the lubrication oil temperature regulator (10MAV30DT001) is set to automatic control
mode.

3.3. System shutdown

The lubrication oil system shut down is possible, if the turbine is tripped, the barring gear is
switched off and the HP and IP cylinders metal temperature is lower than 170 ºC, i.e. if there is no
necessity for the lubrication oil system operation. According to the group shutdown program the
following actions take place:
- all lubrication oil pumps (10MAV11AP001, 10MAV12AP001, 10MAV13AP001) are
stopped;

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 - the lubrication oil temperature regulator (10MAV30DT001) is turned over to manual
control mode and control valve (10PCB43AA001) is closed;
- the fan of the lubrication oil tank (10MAQ10AN001) is stopped with time delay 15 min
after lubrication oil pumps switching off.

Sheet
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 4. DISTURBANCE HANDLING

4.1. Lubrication oil pressure drop

In case of the oil pressure falls down to 0,7 kgf/cm 2 as well as in case of the operating oil
pump switching off in situations when lubrication oil supply system is required to operate, the stand-
by AC motor-driven pump and simultaneously the DC motor-driven emergency pump No1 are
switched on automatically. If at the same conditions oil pressure falls down to 0,3 kgf/cm 2, the DC
motor-driven emergency pump No2 is switched on automatically.

4.2. Lubrication oil temperature rise

In case of oil temperature rises up to 50 ºC, the temperature regulator is disconnected from the
control valve at the cooling water line and the control valve is open automatically. Then, working
personnel should control oil temperature manually.

4.3. Oil level drop in oil tank

In case of oil level falls in the tank and there is no oil leakage from the system, lubrication oil
should be added into the tank during Unit operation so that normal level is reached.

4.4. Filters contamination

In case of pressure rise in the fine filter casing or rise of differential pressure at the gauzes
inside the oil tank or at the duplex oil filter, the respective filter should be cleaned during the unit
operation.

4.5. Failure of oil tank fan

In case of fan is out of operation due repair, extraction of oil vapours due to the natural
draught within the ventilation pipeline, that allow for the installation to be limited time in operation.

4.6. Fire
In case of the fire, if the push-button "FIRE" on the CCR is pushed with delay of 60 sec after
closing stop valves of the turbine and disconnecting the generator from the main, the stand-by and
emergency pumps switching on logic is blocked and all operating oil pumps are switched off.

Sheet
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 5. CONTROL LOOPS

5.1. Main lubrication oil pumps (10MAV11AP001, 10MAV12AP001)

5.1.1. The automatic oil pumps switching on is possible if any of the following conditions has
taken place:
- the shaft barring gear motor (10MAK10AE001) is in operation;
- no signal of closing of the turbine's stop valves;
- metal temperature of the top surface of HPC (10MAA10CT011) is above 170 ºC;
- metal temperature of the top surface of IPC is above 170 ºС (10MAB10CT011);
- the turbine rotor speed is other than zero.
5.1.2. The pump is started automatically, as a stand-by unit, when main lubrication pump
chosen as a working one is stopped either by the motor's electric protections or due to de-energizing,
or due to a lubrication oil pressure drop below 0,70 kgf/cm 2 (10MAV30CP101). The automation of
start-up of the standby lubrication pump is activated with a time delay of 60 sec after the working
main lubrication oil pump has been started, and remains operative until any of the conditions listed
in 5.1.1 still exists.
5.1.3. When the push-button "FIRE" is pushed with delay of 60 sec after closing of the turbine
stop valves and disconnecting of the generator from the mains, the pump is automatically stopped. If
the pump has not been in operation, it's starting should be forbidden.
5.1.4. Manually from the CCR the pump can be started if it is not forbidden according to item
5.1.3. The pump can be stopped if none of the conditions listed in 5.1.1 exist, or if the push-button
"FIRE" is pushed and the same time the turbine stop valves are closed and the generator is
disconnected from the mains. The stand-by pump also can be stopped if another AC motor-driven
pump is in operation and the lubrication oil pressure being above 0,7 kgf/cm2 (10MAV30CP101).

5.2. Emergency lubrication oil pump No1 (10MAV13AP001)

5.2.1. The pump is started automatically when main lubrication oil pump chosen as a working
one (10MAV11AP001 or 10MAV12AP001) is switched off by action of the motor electrical
protection or because of the motor power supply loss, or when lubricating oil pressure falls below
0,7 rgf/cm2 (10MAV30CP101). The automation of start-up of the pump is activated with a time
delay of 60 sec after the working main lubrication oil pump has been started, and remains operative
until any of the conditions listed in 5.1.1 still exists.
5.2.2. When the push-button "FIRE" is pushed with delay of 60 sec after closing of the turbine
stop valves and disconnecting of the generator from the mains, the pump is automatically stopped. If
the pump has not been in operation, it's starting should be forbidden.
5.2.3. Manually from the CCR the pump can be started if it is not forbidden according to item
5.2.2. The pump can be stopped if none of the conditions listed in 5.1.1 exist, or if the push-button
"FIRE" is pushed and the same time the turbine stop valves are closed and the generator is

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 disconnected from the mains, or if any AC motor-driven lubrication oil pump is in operation and the
lubrication oil pressure being above 0,7 kgf/cm2 (10MAV30CP101).

5.3. Emergency lubrication oil pump No2 (10MAV14AP001)

5.3.1. The pump is started automatically when lubricating oil pressure falls below 0,3 kgf/cm 2
(10MAV30CP102). The automation of start-up of the pump is activated with a time delay of 60 sec
after the working main lubrication oil pump has been started, and remains operative until any of the
conditions listed in 5.1.1 still exists. The pump should be switched on without time delay, if the DC
motor-driven pump No1 (10MAV13AP001) previously was not switched on and, in case of
switching on of the last one, – with time delay of 3 sec from the moment of the DC motor-driven
pump No1 switching on.
5.3.2. When the push-button "FIRE" is pushed with delay of 60 sec after closing of the turbine
stop valves and disconnecting of the generator from the mains, the pump is automatically stopped. If
the pump has not been in operation, it's starting should be forbidden.
5.3.3. Manually from the CCR the pump can be started if it is not forbidden according to item
5.3.2. The pump can be stopped if none of the conditions listed in 5.1.1 exist, or if the push-button
"FIRE" is pushed and the same time the turbine stop valves are closed and the generator is
disconnected from the mains, or if any AC motor-driven lubrication oil pump is in operation and the
lubrication oil pressure being above 0,3 kgf/cm2 (10MAV30CP102).

5.4. Lubrication oil system fan (10MAQ10AN001)

Manually from the CCR the fan can be started and stopped at any time.

5.5. Lubrication oil temperature control valve (10PCB43AA001)

5.5.1. In automatic control mode the control valve is operated from the lubrication oil
temperature regulator (10MAV30DT001). Transmitted to the input of the regulator are signals of
lubrication oil temperature (combined signal of transducers 10MAV30CT001, 10MAV30CT002)
and of the control valve position. The static characteristic of the regulator is set in such a way, so
that the opening degree of the control valve will be proportional to the change in the lubrication oil
temperature in the range from 40 to 45 ºC.
5.5.2. The control valve automatically is switched over to the manual control mode and is
opened when the bearing lubrication oil temperature rises above 50 ºC (10MAV30CT001). If the
lubrication oil temperature (10MAV30CT001) is lower then 50 ºC the operator can switch over the
control valve to automatic control mode.
5.5.3. Manually from the CCR the valve can be switched over to manual control mode at any
time, and in this mode the valve can be open, closed or stopped in the intermediate position.

Sheet
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 5.6. Lubrication oil recirculation pump (10MAV15AP001)
Manually from the CCR the pump can be stopped at any time, and can be so started if all
lubrication oil pumps (10MAV11AP001, 10MAV12AP001, 10MAV13AP001) are stopped.

5.7. Lubrication oil electric heater (10MAV16AC001)

5.7.1. When the heater is switched on, it is controlled in response to the signals of the
thermostatic switch installed inside the heater shell. In this mode the heater is automatically
energized if the oil temperature at the heater outlet is below the preset value and the contact of the
thermostatic switch is closed (10MAV16CT101). The heater is automatically deenergized if the oil
temperature at the heater outlet achieves the preset value and the contact of the thermostatic switch
is opened.
5.7.2. The electric heater is switched off automatically with prohibition for switched on when
the lubrication oil recirculation pump (10MAV15AP001) is switched off or when the oil
temperature inside the electric heater rises higher than maximum preset value (10MAV16CT102).
5.7.3. Manually from the CCR the electric heater can be switched off at any time, and can be
so switched on if the oil temperature in the lubrication oil tank (10MAV10CT001) is lower than
30ºC and at the same time there is not forbidden according to item 5.7.2.

Sheet
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 6. ALARMS
6.1. If the lubrication oil pressure is lower than 0,7 kgf/cm 2 (10MAV30CP101) and any of the
conditions for oil pumps automatic switching on has taken place (item 5.1.1), the alarm
"LUBRICTION OIL PRESSURE IS LOW" appears.
6.2. If any AC motor-driven lubrication oil pump (10MAV11AP001, 10MAV12AP001) is in
operation and the lubrication system fan (10MAQ10AN001) is not in operation, the alarm
"LUBRCATION SYSTEM FAN IS SWITCHED OFF" appears.
6.3. If the oil level in lubrication oil tank (10MAV10CL001) is lower than 0,2 m, the alarm
"LUBRICATION OIL TANK LEVEL IS LOW" appears.
6.4. If the oil level in lubrication oil tank (10MAV10CL001) is higher than 0,9 m, the alarm
"LUBRICATION OIL TANK LEVEL IS HIGH" appears.
6.5. If the oil pressure difference over the lubrication oil tank gauge (10MAV10CP001) is
higher than 0,015 kgf/cm2, the alarm "LUBRICATION OIL TANK GAUGE PRESSURE
DIFFERENCE IS HIGH" appears.
6.6. If the oil pressure difference over the lubrication oil filter (10MAV20CP001) is higher
than 0,8 kgf/cm2, the alarm "LUBRICATION OIL FILTER PRESSURE DIFFERENCE IS HIGH"
appears.
6.7. If the lubrication oil temperature (10MAV30CT001) is higher than 50 ºC, the alarm
"LUBRICATION OIL TEMPERATURE IS HIGH" appears.
6.8. If the lubrication oil temperature (10MAV30CT001) is lower than 40 ºC and at the same
time any of the conditions for oil pumps automatic switching on has taken place (item 5.1.1), the
alarm "LUBRICATION OIL TEMPERATURE IS LOW" appears.

Sheet
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