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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 Electro-
hydraulic 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

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AC LUBE OIL PUMP

Lift Head 39 m

Flow 2000L/min

Speed 2950r/min
Motor
30kW
power
Power
AC 400V
supply

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2018
DC LUBE OIL PUMP

Head 23 m
Flow 2000L/min
Speed 3000r/min
Motor
17kW
power
Power
DC110V
supply

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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

Name Outlet Outlet


pressure flow
MPa L/min
Oil feeding 0.1525 1898
injector (I)

Lubrication 0.336 2000


injector (II)

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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 oil
pressure of 0.09~0.12
main oil MPa
pump
Outlet oil
pressure of 1.75~1.85
main oil MPa
pump
Rated speed
of main oil 3000r/min
pump
Power
~200kW
consumed
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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 Unit Result


Flash Point ASTM D93 °C 200
Karl Fischer ASTM D6304 ppm 11
TAN no. ASTM D974 ppm 0.08
TBN ASTM D4739 ppm 2.1
Kinematic Viscosity at 40 °C
ASTM D7042 cSt 30.6
Demulsibility IP19 Sec 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

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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

A10VSO100
Type type plunger
pump
Motor
YB250M-4
type
Speed 1480 r/min
Motor
55 kW
power
Power
400V
supply

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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 PANEL OF EMRV
BOILER STOP VALVE

BOILER STOP
VALVE WITH
INTEGRAL
BYPASS 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 bypass
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
PASS 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 PASS

CRH PIPE LINE


ENTERING
BOILER
PRIMARY
REHEATER
FOR
REHEATING
PURPOSE
HOT REHEAT (HRH) PIPING

HOT REHEAT PIPE


COMING OUT
FROM PRIMARY
REHEATER
(CONVECTIVE
PASS) 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 ADJOINING
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 Bypass

 High Pressure bypass (HPBP) and Low Pressure bypass (LPBP) are
primarily meant to enable boiler operation independent of the turbine.
 Opening of these bypass 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 Bypass
HP and LP Bypass

 By providing HP and LP bypass, 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 bypass the HP turbine and dumps steam into the Cold Reheat
(CRH) line, inlet of the re heater.
 LPBP bypasses IP and LP turbine and dumps steam into the
condenser. The capacity of HP/LP bypass (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 BYPASS PRESSURE CONTROL
VALVE AT TURBINE HALL

 HYDRAULIC
OPERATED HP
BYPASS PRESSURE
CONTROL VALVE
ASSEMBLY WITH
ACCUMULATOR
ARRANGEMENT

HP BYPASS SPRAY


POINT TO MAINTAIN
HP BYPASS
DOWNSTREAM
TEMPERATURE
EQUIVALENT TO CRH
TEMPERATURE
HP BYPASS LINE CONNECTING WITH
HRH LINE

HP BYPASS 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 BYPASS SPRAY BLOCK VALVE AND
PRESSURE CONTROL VALVE

o HP BYPASS SPRAY
BLOCK VALVE USED AS
A ISOLATION VALVE
WHICH IS ON/OFF TYPE.

o HP BYPASS SPRAY
CONTROL VALVE
MAINTAINS THE
DOWNSTREAM
TEMPERATURE OF HP
BYPASS STEAM. IN THIS
TEMPERATURE
TRIPPING HAS BEEN
ENABLED.

oIN GENERAL SPRAY


WATER TAPPING FOR HP
BYPASS IS TAKEN FROM
BOILER FEED PUMP
DISCHARGE.
LP BYPASS PRESSURE CONTROL
VALVE

REDUCES HRH
PRESSURE
AND DUMP
THE STEAM
INTO THE
CONDENSER
LP BYPASS SPRAY BLOCK VALVE AND
SPRAY CONTROL VALVE

oLP BYPASS SPRAY


BLOCK VALVE USED AS
A ISOLATION VALVE
WHICH IS ON/OFF TYPE.

o LP BYPASS SPRAY
CONTROL VALVE
MAINTAINS THE
DOWNSTREAM
TEMPERATURE OF LP
BYPASS STEAM. IN THIS
TEMPERATURE LP
BYPASS FAST CLOSING
TRIPPING HAS BEEN
ENABLED.

oIN GENERAL SPRAY


WATER TAPPING FOR LP
BYPASS IS TAKEN FROM
CONDENSATE PUMP
DISCHARGE.
LP BYPASS DUMP BOX SPRAY OR 3RD
STAGE SPRAY

LP BYPASS 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 BYPASS HYDRAULIC SKID

• HP LP BYPASS 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 BYPASS HYDRAULIC OIL TANK
HP, LP BYPASS HYDRAULIC OIL PUMPS
HYDRAULIC OIL PUMP SUCTION
FILTERS
HPLP BYPASS 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 BYPASS OIL RECIRCULATION
PUMP

THROUGH THIS
PUMP OIL
FILLING,
DRAINING,
FILTERATION
AND COOLING
ARE
ESTABLISHED
HPLP BYPASS 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 BYPASS
LP BYPASS

• As the condenser is associated with LP bypass 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 bypass.

• The LP bypass 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 bypass valves
and spray water valves.
LP BYPASS
• LP Bypass 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 BYPASS SYSTEM AND ITS SIGNIFICANCE


• WERE UNDERSTOOD

 HP LP BYPASS PRESSURE AND TEMPERATURE


• CONTROL OPERATION

 HPLP BYPASS PROTECTIONS AND INTERLOCKS

 HP, LP BYPASS HYDRAULIC SKID AND INDIVIDIUAL


• EQUIPMENTS IN SKID WERE UNDERSTOOD
CONCLUSION

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