WRITE UP ON LUBE OIL SYSTEM

Ref: Lube oil P&I Diagram HY-TC-MPA1016-0101 (1-317-00-98562 S01/02)

PROJECT: DAINIK BHASKAR POWER LIMITED.

2X600 MW TPP
BFP DRIVE TURBINES (4 Nos.)

GENERAL

A satisfactory and continuous supply of oil is essential for the safe and reliable running of a
turbine and its driven equipment. The oil supply system should ensure the operational safety of
bearings. The system is of the closed circuit type i.e., a definite amount of oil quantity which is
previously determined is continuously recirculated.

Apart from this, the oil supply system has to ensure the oil required for the governing system
and the safety devices of the turbine at an increased pressure.

The Oil Supply System includes the following equipment: -

Main Oil tank or Lube oil reservoir (MTV10 BB001), containing the oil required for
lubricating and governing systems.

Lube oil pumps, 2X100% (MTV10 AP001, MTV10 AP002) driven by AC motors (4220 &
4230 respectively) for pumping oil, required for governing and lubricating oil systems,

Self actuated Pressure control valve (MTV10 AA301) to maintain steady control oil pressure,
by opening excess quantity to Main Oil Tank.

Emergency oil pump (MTV45 AP003) driven by DC motor 4241, supplies oil to the turbine
bearings after turbine trip during coasting down of the turbine, when all sources of oil fail,

Twin oil coolers (MTV20 AC001&002), in which the heat absorbed in turbine oil system is
dissipated,
Duplex type oil filters (MTV 30 AT001 & 002) to supply clean oil to the bearings,

Self actuated Pressure control valve (MTV40 AA302) to reduce and ensure steady oil
pressure at 2.5 kg/cm2(g) to bearing oil header,

Adjustable bearing oil throttles, which permit adjustment in the oil quantity, required for the
respective bearings,
Oil vapor extraction fans (MTV10 AN001&002) to remove oil vapors settled over the oil
surface in oil tank.

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OIL TANK (MTV10 BB001) :

The Oil tank is located on the ground. Capacity of the tank is 10m3.

The Oil tank serves for storing the oil volume required for governing and lubricating systems.
It allows the impurities to be settled at the bottom of the tank along with the oil sludge. Baffle plates
are provided to give a longer time in the tank so that the entrapped air is effectively released. The
level in the tank is indicated by level gauge (MTV10 CL 501).

Oil vapours accumulated in the oil tank are evacuated by the oil vapour extraction fans
(MTV10 AN001&002) mounted on the oil tank top plate. The exhaust is led to safe location out side
TG hall.

The oil tank is provided with connection for oil centrifuging. The oil centrifuge inlet
connection provided in the oil tank is with overflow sight fitting configuration in order to prevent
emptying of the oil tank in case of leakage in the oil purification circuit. If the oil level in the tank falls
below the minimum level, flow to centrifuge circuit is interrupted.

Level transmitters (MTV10 CL001&002) are provided to give signal to control room
wherefrom indication and low high alarms are generated and annunciated in control room. Due to
vaporization, there will be loss of oil in the circuit over a period of running of the set which results
dip in the oil level. Whenever this happens, oil is to be replenished by adding clarified oil.
Another signal is generated from same transmitter corresponding to normal level which will be used
for Turbine start permissive.

Oil temperature indications are provided for local (MTV10 CT501) and remote
(MTV10 CT001).

LUBE OIL PUMP (MTV10 AP001 & MTV10 AP002) :

The Lube oil pump is a screw pump driven by AC motor. The pump delivers the total oil
required for governing and lubricating oil systems. Isolation valves (MTV10 AA001&007 and
MTV10 AA002&008) are provided in suction and discharge. Being a positive displacement pump,
pressure relief valves (MTV10 AA304&305) is provided in the discharge upstream isolation valve.
Tap-off for governing circuit and motive oil to hydraulic turning device is taken immediately
after pump discharge. For lubricating purpose, oil is taken downstream the Lube oil pressure control
valve.
If the pump discharge pressure falls below 6.5 Kg/cm2 (g) or Lube oil header pressure falls
below (1.1kg/cm2g), the standby pump will be started through pressure switches/transmitters at

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respective locations (MTV10 CP001 and MTV 50 CP104).

If the standby pump also fails, the turbine will be tripped through a pressure signal
generated from transmitters (MTV50 CP002, 003& 004) in 2/3 voting logic. The set value is
0.8 Kg/cm2(g) on Lube oil header .

EMERGENCY OIL PUMP (MTV45AP003):

A certain time period is required by the unit to stop completely after the trip owing to the high
inertia of the rotating masses. Therefore sufficient oil quantity should be supplied to the bearings until
the unit comes to standstill.

During coasting down of turbine, when lube oil pump is not available, lubricating oil is
provided by Emergency oil pump. This pump is driven by a DC motor.

The EOP will cut in automatically by lube oil pressure transmitter (MTV50 CP002,
003&004) set at 0.8 Kg/cm2(g). In order to ensure positive supply of oil to the bearings, this pump is
connected directly to the lube oil header without going through cooler and filters. This also reduces
motor power and battery capacity requirements.
To take care of abnormal condition of power supply failure in turbine control system, a pressure
switch (MTV50 CP104) is directly connected to DCSC to start the EOP automatically

Strainers are provided in pump suction for Lube oil pump and EOP to ensure clean oil to the
pumps.

OIL COOLER (MTV20 AC001 & MTV20 AC002):

The heat absorbed in the bearings 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 change over device (double
3 way transflow valve arrangement.) is provided for switching over to stand by oil cooler manually.
The change over device is so designed that under all circumstances oil is led to either of the coolers.
A small amount of cooled oil goes to the standby cooler through a valve provided across transflow
valve and after filling, overflows to oil tank through crack open valve (MTV20 AA020), orifice
(MTV20 BP303) and sight flow glass FG 3102.This will facilitate standby cooler to come into
service immediately when required.

Oil cooler outlet temperature is maintained at steady value by regulating Cooling water flow
through the cooler. A control valve (PGK20 AA303) is provided in the Cooling water outlet of the
cooler which is operated from temperature control (MTV20 CT003&004). This is basically to take
care of varying cooling water temperatures during different seasons.

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 Oil cooler out temperature high alarm is provided (MTV20 CT003&004) which is set at
45 deg C. This will prompt the operator to switchover to standby cooler and take the running cooler,
for maintenance.

OIL FILTERS (MTV30 AT001& MTV30 AT002):

The duplex type of Oil filter with disposable cartridge type with filtration of 10 microns (nom.) is
provided. A change over device is fitted for switching over to standby filter in case of choking of the
working filter. A small amount of filtered oil goes to the standby filter continuously facilitating
standby filter to come into service immediately when required.

A differential pressure switch (MTV30 CP102) set at 1.5 Kg/cm2 is provided to annunciate
high differential pressure across the filter warranting the maintenance.

TURNING DEVICE (MTV50 AE001 & MTV50 AE002):

During turbine start up and post shut down cooling period, the rotor has to be turned .If a hot
turbine is shut down and the turbine rotor is not turned, distortion of the rotor will occur after some
time. 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 with out danger. This is achieved by the turning device.

Hydraulic turning device (MTV50 AE001) which gets motive oil from Lube oil pump
discharge through a motor operated regulating valve (MTV50 AA201) shall serve above purpose.
During start up, the motor operated valve shall be in full open position, to break away the Initial
torque. Once the speed picks up and reaches the barring speed, the valve shall be made to open
partially to maintain the barring speed. The motor operated valve is controlled from Turbine control
system.

OIL THROTTLES:

Throttle valves (MTV50 BP311-314) are provided in each bearing oil inlet to reduce the
pressure to individual requirement. During first commissioning, oil throttles are positioned by
observing the drain temperature and position is locked. The throttles construction is such that a
minimum opening is provided in the throttle even when the device is fully closed ensuring no
interruption of oil to the bearings.

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