Turbine Lube Oil System b726b
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Turbine Lube oil system, Jacking oil system, Oil purification system and MS CRH HRH LINES
OBJECTIVES
Lubrication & Cooling of the Bearings Lifting of rotor shaft during barring gear operation
Governing of the turbine Actuation of Hydraulic Servomotors Purification of lube oil
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Characteristics of the Turbine Oil Physical &chemical stability To provide adequate lubrication to the turbine bearings, to avoid friction, to cool the heat generated in the bearing High oxidation stability in the face of moisture, air and impurities Air release property
Demulsifying property Anti-rusting
Stable viscosity over the operating temp range
Turbine oils For small turbine operating at high speeds very much above 3000 rpm, the viscosity grade 46 base-oils are used. In Morupule-B power station, this grade of oil is used for Electrohydraulic Governing. While large turbines operating at 3000 rpm, viscosity grade 32 base-oils are used. In Morupule-B power station, this grade of oil is used for turbine lubrication. Oil companies use additives for imparting and strengthening the required characteristics of the oil As such, the oils of different companies may differ in their micro constituents and should not be mixed
LP Protection System Lube oil enters the piston chamber of emergency trip device through reset & test group valve (1YV) to accept reset and test signals. Turbine pressure oil goes into the cavity chamber via oil guide ring through reset & test group valve (2YV), to accept 2YV control signals. Manual trip mechanism, mechanical trip solenoid, and trip & isolated group valve are connected with emergency trip device through mechanical trip mechanism, and HP trip oil is linked to non-pressurized oil drainpipe of hydraulic power unit through trip & isolated group valve.
The Accessories for turbine oil system The following accessories are essentially provided to maintain the health of the turbine oil while in operation. They are : a) Main oil tank b) AC lube oil pump (1 No.) c) DC lube oil pump (1 No.) d) AC oil vapor exhauster fan e) DC oil vapor eXhauster fan f) Main Oil Coolers (PHE) g) Main Oil Filters (Duplex Filter) h) Pressure Relief valve (PRV) i) Oil injector j) Turbine shaft driven main oil pump
Hydraulic Oil-HLP : 32 ISO-Viscosity grade : VG 32 DIN 51519 Density at +15°C : 0,880 g/cm³ DIN 51757 Viscosity at +40°C : 32 mm²/s DIN 51562 Viscosity at +100°C : 5,4 mm²/s DIN 51562 Viscosity index : 99 DIN ISO 2909 Flash point : 214 °C DIN ISO 2592 Pour point : - 24 °C DIN ISO 3016 Ash, sulfate : 0,17 g/100g DIN 51575 Neutralization number, acid : 0,5 mg KOH/g DIN 51558 part 1 Corrosion effect on Cu : Korr.-Gr. 1-125 A3 DIN 51759 Foaming Test : S1B-30/0 DIN 51566
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Main oil tank:
MOT is the reservoir for turbine lube oil system whose working volume/Effective volume is 26 m3 and Full volume is 28.8 m3, Design pressure : 0.2 Mpa, Design Temp: 100 deg C Donnerstag, 16. August 2018
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AC LUBE OIL PUMP
Lift Head
39 m
Flow
2000L/min
Speed
2950r/min
Motor power Power supply
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30kW AC 400V
9
DC LUBE OIL PUMP
Head
23 m
Flow
2000L/min
Speed
3000r/min
Motor power Power supply
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17kW DC110V
10
LUBE OIL COOLER CHANGEOVER VALVE
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TURBINE LUBE OIL COOLER (PHE)
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DUPLEX FILTER:
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DUPLEX FILTER LOCAL DP GAUGE AND DP SWITCH
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OIL VAPOUR EXHAUSTER (DC AND AC)
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The oil vapour extractor fan The vapour extractor fan is provided in the Main Oil Tank, so as to maintain a little vacuum over the oil level in the tank , so that a small vacuum is maintained in the return oil lines at the bearing. The butterfly valve on the suction side of the fan can be operated for adjusting the vacuum in the return oil line at the bearings
Oil Injector
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Name
Outlet pressure MPa
Outlet flow L/min
Oil feeding injector (I)
0.1525
1898
Lubrication injector (II)
0.336
2000
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PRESSURE RELIEF VALVE CHAMBER
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TURBINE SHAFT DRIVEN MAIN OIL PUMP (SUPPLY AND RETURN LINE) Main Oil Pump
Inlet pressure main pump Outlet pressure main pump
oil of 0.09~0.12 oil MPa oil of 1.75~1.85 oil MPa
Rated speed of main oil 3000r/min pump Power consumed Donnerstag, 16. August 2018
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~200kW 19
TURBINE BEARING NO.1 LUBE OIL SUPPLY AND RETURN LINE, HP FRONT PEDESTRAL SUPPLY AND RETURN LINE
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BEARING OIL SUPPLY AND RETURN LINE
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TURBINE BARRING GEAR LUBE OIL SUPPLY LINE FOR GEAR TRAIN
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GENERATOR BEARING (BRG. 5) LUBE OIL SUPPLY AND RETURN LINE
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Health of The Turbine Oil As
the turbine is put into operation, the turbine oil receives its loading. Each & every molecule gets heated on cooling the bearings and must receive heat from the bearing. Similarly, debris from the bearings as well as water vapour from the turbine glands will enter with every cycle of operation Also, the air entrapped with each circulation has to be removed
Air in Turbine Oil Agitation of lubricating oil with air in equipment, such as bearings, couplings, gears, pumps, and oil return lines, may produce a dispersion of finely divided air bubbles in the oil.
If the residence time in the reservoir is too short to allow the air bubbles to rise to the oil surface, a mixture of air and oil will circulate through the lubricating oil system. This may result in an inability to maintain oil pressure (particularly with centrifugal pumps), incomplete oil films in bearings and gears, and poor hydraulic system performance or failure.
Demulsification of turbine oil The ability of lubricating oil to separate water and resist emulsion is an important performance characteristic for application involving water contamination and turbulence Emulsion acts as a catalyst for oxidation and causes foaming in oil and hydraulic controls start malfunctioning. Poor water separability of lube oil can lead to : Rusting & Corrosion, Cavitation, and premature mechanical failure of bearing. High moisture content in turbine oil, (300ppm) is not acceptable
Thick film Lubrication For Steam Turbine Main Bearings, Bearing pressure, p= 0,5 – 2 Mpa Co-Eff. Of friction, µ= 0,002-0,016 and, Bearing Modulus,µ.n/D= 25,0 x 10-8 Nb : For thick film lubrication, minͫ value of modulus is = 10-9
Hydrodynamic Lub. –journal bearing
Water Separability Test
40 ml of test oil is heated to test temperature of 130°F (or 180°F) as 40 ml of distilled water is gradually added to a graduated cylinder containing the mixture. Once the contents reach test temperature, a stir rod is lowered into the cylinder to stir the mixture at 1,500 rpm for 5 minutes. At constant temperature, the contents are left undisturbed, the separation of the oil and water is recorded at one minute intervals for the first ten minutes, then at 15, 20, 30, 40, 50 and 60 minutes. This test method provides a guide for determining the water separation characteristics for oils. This test was developed specifically for steam turbine oils having viscosities of 32 to 150 cSt at 40°C. This is the method recommended for use with synthetic oils.
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Water Separability Test
Relationship between the bearing Friction Coefficient and the Bearing Modulus
Actual test result-Hyd. Oil Test Method Flash Point ASTM D93 Karl Fischer ASTM D6304 TAN no. ASTM D974 TBN ASTM D4739 Kinematic Viscosity at 40 °C ASTM D7042 Demulsibility IP19
Unit °C ppm ppm ppm
Result 200 11 0.08 2.1
cSt Sec
30.6 210
JACKING OIL SKID/SYSTEM
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SYSTEM COMPONENTS:
Jacking oil system comprises of following components: I. Backwash strainer II. Suction filter III.AC Jacking oil pump IV.DC Jacking oil pump V. Discharge Filter VI.Discharge manifold VII.Individual Bearing supply pipe line Donnerstag, 16. August 2018
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PICTURE DEPICTING JACKING OIL TAPPING POINT FROM LUBE OIL COOLER OUTLET LINE
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BACKWASH STRAINER:
FLOW : 450 LPM FILTER SIZE : 32 Microns DESIGN PRESSURE : 0.6 Mpa
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JOP PUMPS SUCTION FILTER
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AC JACKING OIL PUMP
Type Motor type Speed Motor power Power supply
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A10VSO100 type plunger pump YB250M-4 1480 r/min 55 kW
400V
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DC JACKING OIL PUMP
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JACKING OIL DISCHARGE FILTER
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JACKING OIL DISCHARGE MANIFOLD
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JACKING OIL DISTRIBUTION PIPE TO DIFFERENT BEARINGS
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Fire Resistant oil Gr 46
Viscosity, cst @ 100 ⁰C : 6 -7 Viscosity, cst @ 40 ⁰C : 41-51 Viscosity index, min : 100 Flash Point, coc,⁰C min : 215 Pour point, ⁰C max : (-30) Tan No, mg KOH/gm, max : 0.10-0.15 Air release Value @ 50 ⁰C minutes, max : 4
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TURBINE LUBE OIL PURIFICATION SKID ( OIL CENTRIFUGE)
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CENTRIFUGE OIL FEED PUMP
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PURIFICATION OIL COOLING AND HEATER ASSEMBLY
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Cleaning of oil system & oil charging The oil tank and the piping and valves etc must be free of any dirt, dust and corrosion product. As such very elaborate procedure for chemical cleaning and flushing out the debris is adopted After the cleaning and chemical treatment the lot of turbine oil supplied for the purpose is tested for its impurities(Water & Debris) and charged. The charging is done slowly through centrifuge machine.
DIRTY OIL CHAMBER
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CLEAN OIL CHAMBER
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OIL TRANSFER PUMP
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DIRTY AND CLEAN OIL CHAMBER OIL INLET PIPE LINES AND VENTING PIPE LINES WITH BREATHER
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MAIN STEAM LINE
• Main steam line after going through different coils of Boiler (Like Roof SH, LTSH, Platen SH and Final SH) comes out on Left and Right side as MS left and MS Right which conveys high pressure and high temperature steam to execute work on HP turbine.
MS LINE EMERGING OUT FROM BOILER
MAIN STEAM LINE SPRING LOADED PRESSURE RELIEF VALVE (SAFETY VALVE)
Spring loaded safety valve (2 Nos.) provided on both left and right side of Boiler
ELECTRO MATIC RELIEF VALVE (EMRV) EMRV is solenoid operated valve operates with respect to the preset pressure set by the operator and helps in avoiding nuisance opening of spring loaded safety valves. Provided on both MS line (Left and Right side of Boiler)
In general it is provided with isolation valve
LOCAL CONTROL OF EMRV
BOILER STOP VALVE
BOILER STOP VALVE WITH INTEGRAL BY VALVE WHICH IS USED TO ISOLATE BOILER STEAM ENTERING IN TURBINE SIDE
MAIN STEAM LINE (RIGHT) WITH DRAIN
MS LINE (LEFT & RIGHT SIDE) JUNCTION POINT
MS Line (Left and Right side) interconnection point (above feeder floor) from where it is going as single line towards turbine hall.
MS PIPE TRAVELLING AT PRDS FLOOR
MS PIPING AT TURBINE HALL
Picture depicts MS piping and HP by junction point or tapping point at Turbine hall (9.0 mtr)
MS LINE AT TURBINE 5.0 MTR ELEVATION
PICTURE DEPICTS GLAND STEAM SUPPLY TAPPING FROM MAIN STEAM PIPE LINE
MS BRANCH PIPE
MS LINE BRANCH PIPING WHICH FURTHER LEADS TO MS LEFT AND MS RIGHT TO ENTER INTO HP TURBINE
MS LINE LEFT & RIGHT ENTERING HP TURBINE
MS LINE LEFT & RIGHT ENTERING HP TURBINE CANOPY AT TURBINE HALL
HP TURBINE CONTROL VALVES
HPCV 1, 2
HPCV 3, 4
COLD REHEAT PIPING SYSTEM
• After doing work in HP Turbine, steam is being taken back to Boiler for Reheating purpose in order to improve the efficiency. So, this steam piping is called as Cold reheat steam pipe
COLD REHEAT PIPE OR HP EXHAUST PIPE LINE
HP EXHUAST OR CRH PIPE LEFT AND RIGHT COMING OUT FROM HP TURBINE EXHAUST
COLD REHEAT LINE NRV
COLD REHEAT PIPE NRV/CHECK VALVE (2 NOS.) WHICH HELPS IN PREVENTING STEAM BACK CHARGING
CRH PIPE LINE DRIP LEG CRH PIPE LINE WITH DRIP LEG (BEFORE AND AFTER CHECK VALVE)AND DRAIN LINE ASSEMBLY. DIP LEG WITH TWO LEVEL SWITCHES (H, HH) HAS BEEN PROVIDED TO INDICATE PRESENCE OF TRAPPED CONDENSATE
CRH PIPING (LEFT) AT BOILER AREA
CRH PIPING COMING FROM HP TURBINE TO BOILER CONVECTIVE FOR REHATING PURPOSE
CRH LINE HYRDO STATIC PLUG
CRH PIPE (RIGHT) WITH HYDROSTATIC PLUG – MEANT FOR HYDRO TEST OF REHEATER COIL
CRH CIRCUIT • SOOT BLOWING STEAM SOURCE TAPPING TAKEN FROM CRH CIRCUIT • CRH CIRCUIT HAS 2 NOS. OF SPRING LOADED SAFETY VALVES (PRESURE RELIEF VALVES) PLACED EACH 1 ON BOTH LEFT AND RIGHT SIDE
CRH LINE ENTERING INTO CONVECTIVE
CRH PIPE LINE ENTERING BOILER PRIMARY REHEATER FOR REHEATING PURPOSE
HOT REHEAT (HRH) PIPING
HOT REHEAT PIPE COMING OUT FROM PRIMARY REHEATER (CONVECTIVE ) TO SECONDARY OR FINAL REHATER WHICH IS LOCATED AT FBHE (RIGHT)
HRH PIPING CIRCUIT
HRH LINE LEFT AND RIGHT TO FBHE (RIGHT)
FLUIDISED BED HEAT EXCHANGER (RIGHT)
FBHE (RIGHT) OUTLET HOT REHEAT PIPING LEFT & RIGHT SIDE ADING POINT
HOT REHEAT STEAM PIPING
• After raising temperature from Boiler reheat coils steam piping coming out of FBHE (Right) outlet is called as Hot Reheat pipe which carries reheated steam to Intermediate pressure (IP) turbine to execute work.
HRH PIPING WITH SAFETY VALVE ASSEMBLY
HRH PIPE HAS SPRING LOADED SAFETY VALVES (2 NOS) ERECTED IN SERIES
HRH STEAM BRANCH PIPE
HRH STEAM PIPE BIFURCATION POINT WHERE IT BECOMES HRH LEFT AND RIGHT AND FINALLY ENTERS INTO IP TURBINE
HP and LP By
High Pressure by (HPBP) and Low Pressure by (LPBP) are primarily meant to enable boiler operation independent of the turbine. Opening of these by will ensure minimum steam flow through the super heater and reheater tubes during unit start-up, low load operation and sudden unloading of the unit. These can also be utilized for building up of steam parameters quickly before starting of the turbine rolling. After boiler lit up till the opening of turbine steam stop and control valves, there will not be any steam demand from the turbine and therefore virtually no steam flow through the boiler steam tubes. This condition will lead to starvation and there by overheating of super heater and reheater tubes, a highly dangerous situation responsible for the premature failure of tubes. Similar situations may also arise when the turbine trips from loaded condition, with the boiler remains in service.
HP and LP By
HP and LP By
By providing HP and LP by, and alternative steam path is ensured so that boiler operation can be continued without stressing or damaging the steam tubes, during startup, low load periods or even during turbine trip. HPBP by the HP turbine and dumps steam into the Cold Reheat (CRH) line, inlet of the re heater. LPBP byes IP and LP turbine and dumps steam into the condenser. The capacity of HP/LP by (MBPS) is 60% of BMCR steam flow. Timely operation of HP during sudden unloading or tripping of the turbine reduces the chances of opening of boiler safety valves at raised steam pressures. It also helps to maintain sufficient steam pressure in the CRH line for the auxiliary steam supply purpose during low load operation (if auxiliary steam is taken from CRH)
HP LP IS USED FOR
HP BY PRESSURE CONTROL VALVE AT TURBINE HALL HYDRAULIC OPERATED HP BY PRESSURE CONTROL VALVE ASSEMBLY WITH ACCUMULATOR ARRANGEMENT HP BY SPRAY POINT TO MAINTAIN HP BY DOWNSTREAM TEMPERATURE EQUIVALENT TO CRH TEMPERATURE
HP BY LINE CONNECTING WITH HRH LINE
HP BY LINE CONNECTING POINT WITH CRH LINE AT 5.0 MTR ELEVATION OF TURBINE HALL (TO AVOID REHATER TUBES STARVATION DURING SUDDEN OUTAGE OF TURBINE)
HP BY SPRAY BLOCK VALVE AND PRESSURE CONTROL VALVE o HP BY SPRAY BLOCK VALVE USED AS A ISOLATION VALVE WHICH IS ON/OFF TYPE. o HP BY SPRAY CONTROL VALVE MAINTAINS THE DOWNSTREAM TEMPERATURE OF HP BY STEAM. IN THIS TEMPERATURE TRIPPING HAS BEEN ENABLED. oIN GENERAL SPRAY WATER TAPPING FOR HP BY IS TAKEN FROM BOILER FEED PUMP DISCHARGE.
LP BY PRESSURE CONTROL VALVE
REDUCES HRH PRESSURE AND DUMP THE STEAM INTO THE CONDENSER
LP BY SPRAY BLOCK VALVE AND SPRAY CONTROL VALVE oLP BY SPRAY BLOCK VALVE USED AS A ISOLATION VALVE WHICH IS ON/OFF TYPE. o LP BY SPRAY CONTROL VALVE MAINTAINS THE DOWNSTREAM TEMPERATURE OF LP BY STEAM. IN THIS TEMPERATURE LP BY FAST CLOSING TRIPPING HAS BEEN ENABLED. oIN GENERAL SPRAY WATER TAPPING FOR LP BY IS TAKEN FROM CONDENSATE PUMP DISCHARGE.
LP BY DUMP BOX SPRAY OR 3RD STAGE SPRAY
LP BY DUMP BOX SPRAY – FORMS A RING HEADER AND SPRAY NOZZLES USED TO SPRAY CONDENSATE WATER TO BRING DOWN THE TEMPERATURE
HP BP HYDRAULIC SYSTEM
HP, LP BY HYDRAULIC SKID • HP LP BY HYDRAULIC SKID CONSISTS OF:
HYDRAULIC OIL TANK WITH BREATHER HYDRAULIC OIL PUMPS (2 NOS.) LOCAL LEVEL GAUGE AND LEVEL SWITCHES SUCTION AND DISCHARGE FILTERS DISCHARGE MANIFOLD PRESSURE RELIEF VALVES ACCUMULATOR RECIRCULATION PUMP EARTH FILTER HYDRAULIC OIL COOLER
HP, LP BY HYDRAULIC OIL TANK
HP, LP BY HYDRAULIC OIL PUMPS
HYDRAULIC OIL PUMP SUCTION FILTERS
HPLP BY OIL PUMP DISCHARGE MANIFOLD WITH DISCHARGE FILTER ASSEMBLY
ACCUMULATOR
• TO TAKE CARE OF DAMPENING OF OIL PRESSURE • ACTS AS A BUFFER TANK AND SUPPLIES OIL FOR VALVE ACTUATION IN TRANSIENT CONDITIONS
HP LP BY OIL RECIRCULATION PUMP
THROUGH THIS PUMP OIL FILLING, DRAINING, FILTERATION AND COOLING ARE ESTABLISHED
HPLP BY RECIRCULATION PUMP OIL COOLER
Controls in HP BP Steam Pressure Control This control is used for maintaining the steam pressure ahead of HPBP at any desired value and can be operated in MANUAL or AUTO modes. MS pressure at HPT inlet is the set reference value.
If the controller is in AUTO, HPBP steam pressure should be adjusted in such a way that under no condition HPBP should close below 20 – 25%. This minimum HPBP opening along with proper opening in LPBP will ensure minimum steam flow through the boiler steam tubes.
TEMPERATURE CONTROL • Temperature controller governs the operation of spray valves. Spray system valves can be operated in MANUAL or AUTO modes. HP BP down stream steam temperature (CRH line) is the set reference value for Auto operation. • Spray water for HPBP is taken from BFP discharge. Spray block valve is used for maintaining required water pressure in the spray header and this pressure can be set using a separate controller. • In the event of fast opening of HPBP steam valves, the Electro Hydraulic actuators of the spray water system make it possible to open the spray valves in the shortest minimum period. To offset the time gap between the temperature measurement and the spray controller response, a minimum amount of water is in injected immediately after opening of the HPBP.
HP BP INTERLOCKS
LP BY
LP BY • As the condenser is associated with LP by system, which is part of the main turbine, the control circuit and hydraulic section for the LPBP is linked with the Turbine Governing System, unlike the HP by. • The LP by is designed as a combination of electronic circuit and hydraulic system. An Electro Hydraulic Converter (EHC) converts the electronic signals into proportional hydraulic impulse for the operation of steam by valves and spray water valves.
LP BY • LP By can be operated either in Manual mode or in Auto mode. In Manual mode, using the increase/decrease push buttons provided on the console, command can be given to the LPBP Electro Hydraulic Converter (EHC). In Auto mode, signal for the operation of EHC is electronically generated by using the HRH pressure as the reference value.
• Changes in the position of the LPBP EHC change the draining rate of two Follow-up pistons and thereby the downstream pressure of the Follow-up Pistons varies. • One set of Signal Oil is used for the operation of Spray Water valves and the second one is used for the operation of Steam Stop and Control Valves.
SUMMARY FROM ABOVE WE UNDERSTOOD THE PURPOSE AND •
FUNCTIONS OF MS, CRH AND HRH PIPING
EQUIPMENTS INVOLVED IN MS, CRH & HRH SYSTEM, • IT’S IMPORTANCE AND ROLES WERE DISCUSSED HP AND LP BY SYSTEM AND ITS SIGNIFICANCE • WERE UNDERSTOOD HP LP BY PRESSURE AND TEMPERATURE • CONTROL OPERATION
HPLP BY PROTECTIONS AND INTERLOCKS HP, LP BY HYDRAULIC SKID AND INDIVIDIUAL • EQUIPMENTS IN SKID WERE UNDERSTOOD
CONCLUSION
OBJECTIVES
Lubrication & Cooling of the Bearings Lifting of rotor shaft during barring gear operation
Governing of the turbine Actuation of Hydraulic Servomotors Purification of lube oil
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Characteristics of the Turbine Oil Physical &chemical stability To provide adequate lubrication to the turbine bearings, to avoid friction, to cool the heat generated in the bearing High oxidation stability in the face of moisture, air and impurities Air release property
Demulsifying property Anti-rusting
Stable viscosity over the operating temp range
Turbine oils For small turbine operating at high speeds very much above 3000 rpm, the viscosity grade 46 base-oils are used. In Morupule-B power station, this grade of oil is used for Electrohydraulic Governing. While large turbines operating at 3000 rpm, viscosity grade 32 base-oils are used. In Morupule-B power station, this grade of oil is used for turbine lubrication. Oil companies use additives for imparting and strengthening the required characteristics of the oil As such, the oils of different companies may differ in their micro constituents and should not be mixed
LP Protection System Lube oil enters the piston chamber of emergency trip device through reset & test group valve (1YV) to accept reset and test signals. Turbine pressure oil goes into the cavity chamber via oil guide ring through reset & test group valve (2YV), to accept 2YV control signals. Manual trip mechanism, mechanical trip solenoid, and trip & isolated group valve are connected with emergency trip device through mechanical trip mechanism, and HP trip oil is linked to non-pressurized oil drainpipe of hydraulic power unit through trip & isolated group valve.
The Accessories for turbine oil system The following accessories are essentially provided to maintain the health of the turbine oil while in operation. They are : a) Main oil tank b) AC lube oil pump (1 No.) c) DC lube oil pump (1 No.) d) AC oil vapor exhauster fan e) DC oil vapor eXhauster fan f) Main Oil Coolers (PHE) g) Main Oil Filters (Duplex Filter) h) Pressure Relief valve (PRV) i) Oil injector j) Turbine shaft driven main oil pump
Hydraulic Oil-HLP : 32 ISO-Viscosity grade : VG 32 DIN 51519 Density at +15°C : 0,880 g/cm³ DIN 51757 Viscosity at +40°C : 32 mm²/s DIN 51562 Viscosity at +100°C : 5,4 mm²/s DIN 51562 Viscosity index : 99 DIN ISO 2909 Flash point : 214 °C DIN ISO 2592 Pour point : - 24 °C DIN ISO 3016 Ash, sulfate : 0,17 g/100g DIN 51575 Neutralization number, acid : 0,5 mg KOH/g DIN 51558 part 1 Corrosion effect on Cu : Korr.-Gr. 1-125 A3 DIN 51759 Foaming Test : S1B-30/0 DIN 51566
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Main oil tank:
MOT is the reservoir for turbine lube oil system whose working volume/Effective volume is 26 m3 and Full volume is 28.8 m3, Design pressure : 0.2 Mpa, Design Temp: 100 deg C Donnerstag, 16. August 2018
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AC LUBE OIL PUMP
Lift Head
39 m
Flow
2000L/min
Speed
2950r/min
Motor power Power supply
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30kW AC 400V
9
DC LUBE OIL PUMP
Head
23 m
Flow
2000L/min
Speed
3000r/min
Motor power Power supply
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17kW DC110V
10
LUBE OIL COOLER CHANGEOVER VALVE
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TURBINE LUBE OIL COOLER (PHE)
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DUPLEX FILTER:
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DUPLEX FILTER LOCAL DP GAUGE AND DP SWITCH
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OIL VAPOUR EXHAUSTER (DC AND AC)
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The oil vapour extractor fan The vapour extractor fan is provided in the Main Oil Tank, so as to maintain a little vacuum over the oil level in the tank , so that a small vacuum is maintained in the return oil lines at the bearing. The butterfly valve on the suction side of the fan can be operated for adjusting the vacuum in the return oil line at the bearings
Oil Injector
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Name
Outlet pressure MPa
Outlet flow L/min
Oil feeding injector (I)
0.1525
1898
Lubrication injector (II)
0.336
2000
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PRESSURE RELIEF VALVE CHAMBER
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TURBINE SHAFT DRIVEN MAIN OIL PUMP (SUPPLY AND RETURN LINE) Main Oil Pump
Inlet pressure main pump Outlet pressure main pump
oil of 0.09~0.12 oil MPa oil of 1.75~1.85 oil MPa
Rated speed of main oil 3000r/min pump Power consumed Donnerstag, 16. August 2018
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~200kW 19
TURBINE BEARING NO.1 LUBE OIL SUPPLY AND RETURN LINE, HP FRONT PEDESTRAL SUPPLY AND RETURN LINE
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BEARING OIL SUPPLY AND RETURN LINE
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TURBINE BARRING GEAR LUBE OIL SUPPLY LINE FOR GEAR TRAIN
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GENERATOR BEARING (BRG. 5) LUBE OIL SUPPLY AND RETURN LINE
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Health of The Turbine Oil As
the turbine is put into operation, the turbine oil receives its loading. Each & every molecule gets heated on cooling the bearings and must receive heat from the bearing. Similarly, debris from the bearings as well as water vapour from the turbine glands will enter with every cycle of operation Also, the air entrapped with each circulation has to be removed
Air in Turbine Oil Agitation of lubricating oil with air in equipment, such as bearings, couplings, gears, pumps, and oil return lines, may produce a dispersion of finely divided air bubbles in the oil.
If the residence time in the reservoir is too short to allow the air bubbles to rise to the oil surface, a mixture of air and oil will circulate through the lubricating oil system. This may result in an inability to maintain oil pressure (particularly with centrifugal pumps), incomplete oil films in bearings and gears, and poor hydraulic system performance or failure.
Demulsification of turbine oil The ability of lubricating oil to separate water and resist emulsion is an important performance characteristic for application involving water contamination and turbulence Emulsion acts as a catalyst for oxidation and causes foaming in oil and hydraulic controls start malfunctioning. Poor water separability of lube oil can lead to : Rusting & Corrosion, Cavitation, and premature mechanical failure of bearing. High moisture content in turbine oil, (300ppm) is not acceptable
Thick film Lubrication For Steam Turbine Main Bearings, Bearing pressure, p= 0,5 – 2 Mpa Co-Eff. Of friction, µ= 0,002-0,016 and, Bearing Modulus,µ.n/D= 25,0 x 10-8 Nb : For thick film lubrication, minͫ value of modulus is = 10-9
Hydrodynamic Lub. –journal bearing
Water Separability Test
40 ml of test oil is heated to test temperature of 130°F (or 180°F) as 40 ml of distilled water is gradually added to a graduated cylinder containing the mixture. Once the contents reach test temperature, a stir rod is lowered into the cylinder to stir the mixture at 1,500 rpm for 5 minutes. At constant temperature, the contents are left undisturbed, the separation of the oil and water is recorded at one minute intervals for the first ten minutes, then at 15, 20, 30, 40, 50 and 60 minutes. This test method provides a guide for determining the water separation characteristics for oils. This test was developed specifically for steam turbine oils having viscosities of 32 to 150 cSt at 40°C. This is the method recommended for use with synthetic oils.
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Water Separability Test
Relationship between the bearing Friction Coefficient and the Bearing Modulus
Actual test result-Hyd. Oil Test Method Flash Point ASTM D93 Karl Fischer ASTM D6304 TAN no. ASTM D974 TBN ASTM D4739 Kinematic Viscosity at 40 °C ASTM D7042 Demulsibility IP19
Unit °C ppm ppm ppm
Result 200 11 0.08 2.1
cSt Sec
30.6 210
JACKING OIL SKID/SYSTEM
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SYSTEM COMPONENTS:
Jacking oil system comprises of following components: I. Backwash strainer II. Suction filter III.AC Jacking oil pump IV.DC Jacking oil pump V. Discharge Filter VI.Discharge manifold VII.Individual Bearing supply pipe line Donnerstag, 16. August 2018
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PICTURE DEPICTING JACKING OIL TAPPING POINT FROM LUBE OIL COOLER OUTLET LINE
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BACKWASH STRAINER:
FLOW : 450 LPM FILTER SIZE : 32 Microns DESIGN PRESSURE : 0.6 Mpa
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JOP PUMPS SUCTION FILTER
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AC JACKING OIL PUMP
Type Motor type Speed Motor power Power supply
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A10VSO100 type plunger pump YB250M-4 1480 r/min 55 kW
400V
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DC JACKING OIL PUMP
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JACKING OIL DISCHARGE FILTER
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JACKING OIL DISCHARGE MANIFOLD
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JACKING OIL DISTRIBUTION PIPE TO DIFFERENT BEARINGS
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Fire Resistant oil Gr 46
Viscosity, cst @ 100 ⁰C : 6 -7 Viscosity, cst @ 40 ⁰C : 41-51 Viscosity index, min : 100 Flash Point, coc,⁰C min : 215 Pour point, ⁰C max : (-30) Tan No, mg KOH/gm, max : 0.10-0.15 Air release Value @ 50 ⁰C minutes, max : 4
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TURBINE LUBE OIL PURIFICATION SKID ( OIL CENTRIFUGE)
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CENTRIFUGE OIL FEED PUMP
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PURIFICATION OIL COOLING AND HEATER ASSEMBLY
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Cleaning of oil system & oil charging The oil tank and the piping and valves etc must be free of any dirt, dust and corrosion product. As such very elaborate procedure for chemical cleaning and flushing out the debris is adopted After the cleaning and chemical treatment the lot of turbine oil supplied for the purpose is tested for its impurities(Water & Debris) and charged. The charging is done slowly through centrifuge machine.
DIRTY OIL CHAMBER
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CLEAN OIL CHAMBER
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OIL TRANSFER PUMP
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DIRTY AND CLEAN OIL CHAMBER OIL INLET PIPE LINES AND VENTING PIPE LINES WITH BREATHER
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MAIN STEAM LINE
• Main steam line after going through different coils of Boiler (Like Roof SH, LTSH, Platen SH and Final SH) comes out on Left and Right side as MS left and MS Right which conveys high pressure and high temperature steam to execute work on HP turbine.
MS LINE EMERGING OUT FROM BOILER
MAIN STEAM LINE SPRING LOADED PRESSURE RELIEF VALVE (SAFETY VALVE)
Spring loaded safety valve (2 Nos.) provided on both left and right side of Boiler
ELECTRO MATIC RELIEF VALVE (EMRV) EMRV is solenoid operated valve operates with respect to the preset pressure set by the operator and helps in avoiding nuisance opening of spring loaded safety valves. Provided on both MS line (Left and Right side of Boiler)
In general it is provided with isolation valve
LOCAL CONTROL OF EMRV
BOILER STOP VALVE
BOILER STOP VALVE WITH INTEGRAL BY VALVE WHICH IS USED TO ISOLATE BOILER STEAM ENTERING IN TURBINE SIDE
MAIN STEAM LINE (RIGHT) WITH DRAIN
MS LINE (LEFT & RIGHT SIDE) JUNCTION POINT
MS Line (Left and Right side) interconnection point (above feeder floor) from where it is going as single line towards turbine hall.
MS PIPE TRAVELLING AT PRDS FLOOR
MS PIPING AT TURBINE HALL
Picture depicts MS piping and HP by junction point or tapping point at Turbine hall (9.0 mtr)
MS LINE AT TURBINE 5.0 MTR ELEVATION
PICTURE DEPICTS GLAND STEAM SUPPLY TAPPING FROM MAIN STEAM PIPE LINE
MS BRANCH PIPE
MS LINE BRANCH PIPING WHICH FURTHER LEADS TO MS LEFT AND MS RIGHT TO ENTER INTO HP TURBINE
MS LINE LEFT & RIGHT ENTERING HP TURBINE
MS LINE LEFT & RIGHT ENTERING HP TURBINE CANOPY AT TURBINE HALL
HP TURBINE CONTROL VALVES
HPCV 1, 2
HPCV 3, 4
COLD REHEAT PIPING SYSTEM
• After doing work in HP Turbine, steam is being taken back to Boiler for Reheating purpose in order to improve the efficiency. So, this steam piping is called as Cold reheat steam pipe
COLD REHEAT PIPE OR HP EXHAUST PIPE LINE
HP EXHUAST OR CRH PIPE LEFT AND RIGHT COMING OUT FROM HP TURBINE EXHAUST
COLD REHEAT LINE NRV
COLD REHEAT PIPE NRV/CHECK VALVE (2 NOS.) WHICH HELPS IN PREVENTING STEAM BACK CHARGING
CRH PIPE LINE DRIP LEG CRH PIPE LINE WITH DRIP LEG (BEFORE AND AFTER CHECK VALVE)AND DRAIN LINE ASSEMBLY. DIP LEG WITH TWO LEVEL SWITCHES (H, HH) HAS BEEN PROVIDED TO INDICATE PRESENCE OF TRAPPED CONDENSATE
CRH PIPING (LEFT) AT BOILER AREA
CRH PIPING COMING FROM HP TURBINE TO BOILER CONVECTIVE FOR REHATING PURPOSE
CRH LINE HYRDO STATIC PLUG
CRH PIPE (RIGHT) WITH HYDROSTATIC PLUG – MEANT FOR HYDRO TEST OF REHEATER COIL
CRH CIRCUIT • SOOT BLOWING STEAM SOURCE TAPPING TAKEN FROM CRH CIRCUIT • CRH CIRCUIT HAS 2 NOS. OF SPRING LOADED SAFETY VALVES (PRESURE RELIEF VALVES) PLACED EACH 1 ON BOTH LEFT AND RIGHT SIDE
CRH LINE ENTERING INTO CONVECTIVE
CRH PIPE LINE ENTERING BOILER PRIMARY REHEATER FOR REHEATING PURPOSE
HOT REHEAT (HRH) PIPING
HOT REHEAT PIPE COMING OUT FROM PRIMARY REHEATER (CONVECTIVE ) TO SECONDARY OR FINAL REHATER WHICH IS LOCATED AT FBHE (RIGHT)
HRH PIPING CIRCUIT
HRH LINE LEFT AND RIGHT TO FBHE (RIGHT)
FLUIDISED BED HEAT EXCHANGER (RIGHT)
FBHE (RIGHT) OUTLET HOT REHEAT PIPING LEFT & RIGHT SIDE ADING POINT
HOT REHEAT STEAM PIPING
• After raising temperature from Boiler reheat coils steam piping coming out of FBHE (Right) outlet is called as Hot Reheat pipe which carries reheated steam to Intermediate pressure (IP) turbine to execute work.
HRH PIPING WITH SAFETY VALVE ASSEMBLY
HRH PIPE HAS SPRING LOADED SAFETY VALVES (2 NOS) ERECTED IN SERIES
HRH STEAM BRANCH PIPE
HRH STEAM PIPE BIFURCATION POINT WHERE IT BECOMES HRH LEFT AND RIGHT AND FINALLY ENTERS INTO IP TURBINE
HP and LP By
High Pressure by (HPBP) and Low Pressure by (LPBP) are primarily meant to enable boiler operation independent of the turbine. Opening of these by will ensure minimum steam flow through the super heater and reheater tubes during unit start-up, low load operation and sudden unloading of the unit. These can also be utilized for building up of steam parameters quickly before starting of the turbine rolling. After boiler lit up till the opening of turbine steam stop and control valves, there will not be any steam demand from the turbine and therefore virtually no steam flow through the boiler steam tubes. This condition will lead to starvation and there by overheating of super heater and reheater tubes, a highly dangerous situation responsible for the premature failure of tubes. Similar situations may also arise when the turbine trips from loaded condition, with the boiler remains in service.
HP and LP By
HP and LP By
By providing HP and LP by, and alternative steam path is ensured so that boiler operation can be continued without stressing or damaging the steam tubes, during startup, low load periods or even during turbine trip. HPBP by the HP turbine and dumps steam into the Cold Reheat (CRH) line, inlet of the re heater. LPBP byes IP and LP turbine and dumps steam into the condenser. The capacity of HP/LP by (MBPS) is 60% of BMCR steam flow. Timely operation of HP during sudden unloading or tripping of the turbine reduces the chances of opening of boiler safety valves at raised steam pressures. It also helps to maintain sufficient steam pressure in the CRH line for the auxiliary steam supply purpose during low load operation (if auxiliary steam is taken from CRH)
HP LP IS USED FOR
HP BY PRESSURE CONTROL VALVE AT TURBINE HALL HYDRAULIC OPERATED HP BY PRESSURE CONTROL VALVE ASSEMBLY WITH ACCUMULATOR ARRANGEMENT HP BY SPRAY POINT TO MAINTAIN HP BY DOWNSTREAM TEMPERATURE EQUIVALENT TO CRH TEMPERATURE
HP BY LINE CONNECTING WITH HRH LINE
HP BY LINE CONNECTING POINT WITH CRH LINE AT 5.0 MTR ELEVATION OF TURBINE HALL (TO AVOID REHATER TUBES STARVATION DURING SUDDEN OUTAGE OF TURBINE)
HP BY SPRAY BLOCK VALVE AND PRESSURE CONTROL VALVE o HP BY SPRAY BLOCK VALVE USED AS A ISOLATION VALVE WHICH IS ON/OFF TYPE. o HP BY SPRAY CONTROL VALVE MAINTAINS THE DOWNSTREAM TEMPERATURE OF HP BY STEAM. IN THIS TEMPERATURE TRIPPING HAS BEEN ENABLED. oIN GENERAL SPRAY WATER TAPPING FOR HP BY IS TAKEN FROM BOILER FEED PUMP DISCHARGE.
LP BY PRESSURE CONTROL VALVE
REDUCES HRH PRESSURE AND DUMP THE STEAM INTO THE CONDENSER
LP BY SPRAY BLOCK VALVE AND SPRAY CONTROL VALVE oLP BY SPRAY BLOCK VALVE USED AS A ISOLATION VALVE WHICH IS ON/OFF TYPE. o LP BY SPRAY CONTROL VALVE MAINTAINS THE DOWNSTREAM TEMPERATURE OF LP BY STEAM. IN THIS TEMPERATURE LP BY FAST CLOSING TRIPPING HAS BEEN ENABLED. oIN GENERAL SPRAY WATER TAPPING FOR LP BY IS TAKEN FROM CONDENSATE PUMP DISCHARGE.
LP BY DUMP BOX SPRAY OR 3RD STAGE SPRAY
LP BY DUMP BOX SPRAY – FORMS A RING HEADER AND SPRAY NOZZLES USED TO SPRAY CONDENSATE WATER TO BRING DOWN THE TEMPERATURE
HP BP HYDRAULIC SYSTEM
HP, LP BY HYDRAULIC SKID • HP LP BY HYDRAULIC SKID CONSISTS OF:
HYDRAULIC OIL TANK WITH BREATHER HYDRAULIC OIL PUMPS (2 NOS.) LOCAL LEVEL GAUGE AND LEVEL SWITCHES SUCTION AND DISCHARGE FILTERS DISCHARGE MANIFOLD PRESSURE RELIEF VALVES ACCUMULATOR RECIRCULATION PUMP EARTH FILTER HYDRAULIC OIL COOLER
HP, LP BY HYDRAULIC OIL TANK
HP, LP BY HYDRAULIC OIL PUMPS
HYDRAULIC OIL PUMP SUCTION FILTERS
HPLP BY OIL PUMP DISCHARGE MANIFOLD WITH DISCHARGE FILTER ASSEMBLY
ACCUMULATOR
• TO TAKE CARE OF DAMPENING OF OIL PRESSURE • ACTS AS A BUFFER TANK AND SUPPLIES OIL FOR VALVE ACTUATION IN TRANSIENT CONDITIONS
HP LP BY OIL RECIRCULATION PUMP
THROUGH THIS PUMP OIL FILLING, DRAINING, FILTERATION AND COOLING ARE ESTABLISHED
HPLP BY RECIRCULATION PUMP OIL COOLER
Controls in HP BP Steam Pressure Control This control is used for maintaining the steam pressure ahead of HPBP at any desired value and can be operated in MANUAL or AUTO modes. MS pressure at HPT inlet is the set reference value.
If the controller is in AUTO, HPBP steam pressure should be adjusted in such a way that under no condition HPBP should close below 20 – 25%. This minimum HPBP opening along with proper opening in LPBP will ensure minimum steam flow through the boiler steam tubes.
TEMPERATURE CONTROL • Temperature controller governs the operation of spray valves. Spray system valves can be operated in MANUAL or AUTO modes. HP BP down stream steam temperature (CRH line) is the set reference value for Auto operation. • Spray water for HPBP is taken from BFP discharge. Spray block valve is used for maintaining required water pressure in the spray header and this pressure can be set using a separate controller. • In the event of fast opening of HPBP steam valves, the Electro Hydraulic actuators of the spray water system make it possible to open the spray valves in the shortest minimum period. To offset the time gap between the temperature measurement and the spray controller response, a minimum amount of water is in injected immediately after opening of the HPBP.
HP BP INTERLOCKS
LP BY
LP BY • As the condenser is associated with LP by system, which is part of the main turbine, the control circuit and hydraulic section for the LPBP is linked with the Turbine Governing System, unlike the HP by. • The LP by is designed as a combination of electronic circuit and hydraulic system. An Electro Hydraulic Converter (EHC) converts the electronic signals into proportional hydraulic impulse for the operation of steam by valves and spray water valves.
LP BY • LP By can be operated either in Manual mode or in Auto mode. In Manual mode, using the increase/decrease push buttons provided on the console, command can be given to the LPBP Electro Hydraulic Converter (EHC). In Auto mode, signal for the operation of EHC is electronically generated by using the HRH pressure as the reference value.
• Changes in the position of the LPBP EHC change the draining rate of two Follow-up pistons and thereby the downstream pressure of the Follow-up Pistons varies. • One set of Signal Oil is used for the operation of Spray Water valves and the second one is used for the operation of Steam Stop and Control Valves.
SUMMARY FROM ABOVE WE UNDERSTOOD THE PURPOSE AND •
FUNCTIONS OF MS, CRH AND HRH PIPING
EQUIPMENTS INVOLVED IN MS, CRH & HRH SYSTEM, • IT’S IMPORTANCE AND ROLES WERE DISCUSSED HP AND LP BY SYSTEM AND ITS SIGNIFICANCE • WERE UNDERSTOOD HP LP BY PRESSURE AND TEMPERATURE • CONTROL OPERATION
HPLP BY PROTECTIONS AND INTERLOCKS HP, LP BY HYDRAULIC SKID AND INDIVIDIUAL • EQUIPMENTS IN SKID WERE UNDERSTOOD
CONCLUSION
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