PROCEDURE FOR OIL FLUSHING OF LUBE OIL SYSTEM OF TURBINE & GENERATOR

PROJECT: GSEGL HAZIRA (1X350 MW)

BHARAT HEAVY ELECTRICALS LIMITED TECHNICAL SERVICES DEPARTMENT POWER SECTOR WESTERN REGION NAGPUR

GSEG HAZIRA

ST LUBE OIL FLUSHING PROCEDURE

DOCUMENT NO.: PW: TSX: GSEG: STLF: 005 REV:00 EFFECTIVE DATE: 22/07/2011

PREPARED BY:

REVIEWED BY:

APPROVED BY:

ISSUED TO : COPY NO. : ISSUED BY: DATE OF ISSUE: HEAD/TSX

BHARAT HEAVY ELECTRICALS LTD. POWER SECTOR: WESTERN REGION NAGPUR

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GSEG HAZIRA
OBJECTIVE:

ST LUBE OIL FLUSHING PROCEDURE

To clean the TG OIL system piping by removing the dirt & other foreign materials before the fresh Oil is taken into regular service.

STATE OF THE PLANT:

Ensure that the oil pipelines are erected as per the applicable schemes and all measurement points (pressure, temperatures etc) are available in the laid piping. If not take corrective action. Ensure that all permanent pipelines have been laid and all permanent supports are erected. LT supply available for oil pumps and centrifuge Ensure the DC supply is available for DC EOP, JOP Centrifuge gearbox is filled with recommended oil up to( normally of gauge glass in standstill condition) specified level Centrifuge is assembled in clarifier mode (smallest size gravity disc is to be assembled-see the supplier instruction manual) Motor trial (greasing of motor bearings is to be ensured) of oil pumps is completed. All works inside pedestal have been completed and bearings are boxed up with the oil bypass device. Throttles in the lines are installed and free to operate. MOT inspection has been carried out. All the suction pipes at the suction of AOPs, EOP, JOPs are erected as per drawing. Record the dimension of MOT (length, breadth and height) and ensure all the fasteners are locked. The lubricating pipe from the pump discharge is correctly laid so that oil is sprayed to the bearings. Record the gap between the MOT bottom plate and the individual pump suction pipe for all pumps. All hot works (cutting, welding, grinding etc) have been completed
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GSEG HAZIRA

ST LUBE OIL FLUSHING PROCEDURE

Arrangement for draining the duplex filters (during cleaning) and oil coolers and pumping back to MOT (in case of emergency) to be ensured before oil filling. This is most important during flushing because if any leakage develops in coolers during first charging and cooler needs opening, the oil inside cooler is to be drained out back to MOT. Normally cooler and the filter drain is temporarily connected to the centrifuge suction during oil flushing till the drain oil handling system is made ready.

Coolers and filters vents must have separate isolating valves for proper isolation Break-up- flanges has to ensured at places where maintenance is required Installation of MOT local level gauge is to be completed Completion of vapor exhaust lines from bearing and MOT to outside through the oil stripper.

Ensure the availability of the line filters in good condition and their dummies Ensure that the relief holes in the throttles are available. The temporary piping works is to be completed and air blasting is to be completed

Fill oil in MOT up to half of the gauge glass. Isolate the system properly so that oil does not flow to unwanted lines. Keep open the vents of the system and keep persons near the vents (cooler/ filter) and in other location for informing oil leakage (if any). Ensure operation of local start /stop push bottom.

Install the discharge pressure gauges and charge the impulse line. Keep all other impulse line root valve closed.

Start the pump from local and stop after few seconds (5-10 sec). Repeat start/ stop sequence two- three times to fill the system. Ensure there are no leakages. The bucket filter will choke in a very short time. So, stop the pump and clean the bucket filter.

Start the pump and pressurized the system and ensure there is no leakage. Run the system with one AOP for one day. After ensuring that there is no leakages, start the second AOP and established operation as per requirement.

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GSEG HAZIRA

ST LUBE OIL FLUSHING PROCEDURE

Charge JOP discharge line and establish flow. Adjust the bearing flow by opening the throttles/ valves to maximum loading of the pumps.

Run both AOP together and flush with two/ three loops for higher pressure and velocity.

1ST STAGE FLUSHING:

First stage oil is circulated through supply header to drain header bypassing the cooler and all the bearing pedestals. Check the bucket strainer of main oil tank after 1 hr. circulation and clean the same. Check the bucket strainer periodically when changing the flushing lines. Keep centrifuge (clarifier mode- smallest gravity disc in position) in operation with heater in service. Periodically clean the bowl. Continue flushing bypassing the bearings till the bucket filters are found clean. Maintain the time log for operating hours of different loops (SAMPLE AS BELOW)
Lub oil 1 2 3 4 5 6 Jop 1 2 3 4 5 6 SUPPLY HEADER TO DRAIN HEADER DAY

Once all the lines are flushed for more than 48 hrs and bucket filters are clean, stop flushing for inclusion of coolers. Take shut down to include coolers into circuit.

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GSEG HAZIRA

ST LUBE OIL FLUSHING PROCEDURE

2ND STAGE (flushing with coolers):

Ensure sufficient level in MOT. If less, make it up. Ensure one cooler operation and keep its vent open. Start/ stop pump and fill the cooler. Keep the bucket filters cleaning. This will clean the coolers and lines effectively. Continue flushing till the bucket filters are clean.

3RD STAGE:
Install filter element in one lube oil duplex filter. Keep the visual choking indicator line charged for immediate indication. Clean the filter once choking is 50 %. Continue cleaning the duplex filter, till the duplex filter is not choked for 24 hrs. Stop flushing and install the line filters. In order to control overloading of Lube oil pumps, suitable flow orifice should be installed in pump discharge line. Stop flushing and clean the line filter. Continue operation like this till the line filters are not choking for at least 12 hrs. STOP FLUSHING AND CONDUCT THE LUB OIL LINE AND JOP LINE HYDROTEST. DC EOP After completion of 3rd stage flushing, arrange to run DC EOP. Run the pump for 4 hours with all bearing in service. NOTE: MINOR CHANGES IN PROCEDURE / STAGES CAN BE DONE AT SITE BY BHEL ENGINEERS IN CONSULTATION WITH PSWR / TSX.

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GSEG HAZIRA
FOR HYDROTEST:

ST LUBE OIL FLUSHING PROCEDURE

Arrange a hydro test pump (max 20 kg/cm2) beforehand Install pressure gauge (0-20 kg/cm2) in the system for observation Install the flushing device in the bearing in reverse direction for dummy. Keep open vents and run AOP. Vent the system thoroughly. Close drain valves in the system. Ensure to dummy the interconnecting line which supplies oil to the front bearing pedestal. The test oil supply to the testing device is be dummied. Stop AOP and start the pressurizing pump keeping the vent valve open. Slowly close the vent keeping watch on the pressure gauge till it reaches 1.5 times of the discharge pressure. Hold the pressure for 30 min with pump running and vent crack open. Depressurize the system and give clearance for draining oil and normalization of the system.

COMPLETION CRITERIA:
Main oil tank filter should remain clean for 24hrs of flushing. Duplex filter element should remain clean for continuous of 12hrs flushing.

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