tg lub oil flushing

8/18/2019 Tg Lub Oil Flushing

1/25

Station: NTPC-

Ramagunda

m

BHEL Ref No.PS-DC-202-500-0004

NTPC Ref no COS-CO-R!-Comm-PRO"0#$ S%eet # of 19

P&ant a'ea: T(RB)NE

PROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N! O* T(RB)NE L(B-O)L ,ND,C)N! O)L S+STE

SLNO

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

PLANT DETAILS

OBJECTIVE

PROPOSAL

SERVICES REQUIRED

SAFETY PRECAUTIONS

EER!ENCY PROCEDURE

STATE OF T"E PLANT

ET"OD

COPLETION CRITERIA

APPENDICES

#$ TEC"NICAL SPECIFICATION

%$ DRA&IN!.

'$ LO! S"EETS.


2/25

Station: NTPC-

Ramagunda

m


NTPC Ref no COS-CO-R!-Comm-PRO"0#$ S%eet 2 of #/

P&ant a'ea: T(RB)NE

PROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N! O* T(RB)NE L(B-O)L ,ND

,C)N! O)L S+STE

SLNO

1.

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

PLANT DETAILS

500 MW unit is provided with lub oil and Ja!in" oil s#ste$swhih onsistin" o% the %ollowin" e&uip$ents to ater to thelubriation and sha%t li%tin" re&uire$ent o% entire 'urbine and(enerator bearin"s and 'urin" "ear s#ste$.

2 )os. *+ driven *u,iliar# oil pu$ps and 1 )o -+ drivene$er"en# oil pu$p are $eant to suppl# oil to the bearin"s andturnin" "ear at re&uired pressures.

2 )os. o% *+ driven and 1 )o -+ driven Ja!in" il pu$ps are$eant %or suppl#in" hi"h pressure oil to the bearin"s in order toli%t the sha%t while the $ahine is on barrin" "ear.

1 )o Main oil pu$p to suppl# oil to the bearin"s while the unit isin operation.

2)os. o% in/etors to boost the sution pressure to M.

2 )os o% oolers one in servie the other as standb# to re$ovethe heat %ro$ the oil o$in" %ro$ the bearin"s.

il te$perature ontrol valve. 'his in on/untion with oil oolers$aintains the oil te$perature at inlet to bearin"s.

-uple, %ilters in oil line to 'hrust bearin" 'his is to re$ove the$ehanial i$purities %ro$ the oil so that the da$a"e to thustbearin" is avoided. ne is nor$all# in servie and the other is!ept as standb#.

'hrottles at the inlet to the bearin"s. 'hese are $eant %or re"ulatin" the %low o% oil enterin" the bearin"s so that the bearin"$etal te$peratures are $aintained within operatin" li$its.

ST,T(S

Signatu'e

NTPC BHEL


3/25

Station: NTPC-

Ramagundam


NTPC Ref no COS-CO-R!-Comm-PRO"0#$S%eet $ of #/

P&ant a'ea: T(RB)NEPROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N! O* T(RB)NE L(B-O)L ,ND

,C)N! O)L S+STE

SLNO

1.10

1.11

1.12

2.0

2.1

3.0

3.1

3.2

3.3

3.4

#drauli 'urnin" "ear shut o%% valve is $eant %or ad$ittin" thepower oil %or turnin" "ear devie durin" shutdown o% the unit.

Main il 'an! serves as reservoir o% il. 'he *u,iliar# il u$pand Ja!in" oil pu$ps are $ounted inside the Main oiltan!. 'he tan! ontains two o$part$ents )a$el# dirt#

and lean o$part$ents separated b# a partition %ilter ele$ent.

2)os. apour ,hauster %ans are $eant %or re$ovin" oil vapour %ro$ the oil s#ste$ and to $aintain a little a$ount o% vau$.)or$all# one %an is in servie and the other is !ept as standb#.

OBJECTIVE(

'o %lush o$plete '( il Ja!in" oil s#ste$s with 'urbine oilto re$ove $ehanial i$purties.

PROPOSAL

he$e o% oil %lushin" %or lub oil and Ja!in" oil s#ste$s shall beas per the enlosed s!eth.

'her$al sho!s shall be "iven to the s#ste$ b# sudden han"esin oil te$perature to $a!e the %lushin" e%%etive. appin" o% theoil lines shall be arried out durin" ther$al sho!s espeiall# atweld /oints.

il %lushin" shall be arried out usin" the nor$al operatin"'urbine oil as per *nne,ure. 'he &uantit# o% oil re&uired %or %lushin" will be appro,. 40 :;.


4/25

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NEPROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N! O* T(RB)NE L(B-O)L ,ND

,C)N! O)L S+STE


5/25

SLNO

4.0

4.1

4.2

4.3

4.4

4.5

4.6

4.7

5.0

5.1

5.2

5.3

5.4

5.5

5.6

5.7

SERVICES REQUIRED

*vailabilit# o% letrial heatin" arran"e$ent %or heatin" the +W toturbine oil ooler %or "ivin" ther$al sho!s durin" oil %lushin".

*vailabilit# o% laborator# %ailit# %or anal#sis o% oil sa$ple.

*vailabilit# o% servie air and thinner=petrol %or %ilter leanin".

*vailabilit# o% su%%iient s!illed $anpower %or e,eution and supervisiono% the proess.

*vailabilit# o% re&uired &uantit# o% 'urbine oil

*vailabilit# o% portable %ire e,tin"uisher at oil %lushin" area.

*vailabilit# o% proper li"htin" and o$$uniation %ailit#.

SAFETY PRECAUTIONS(

tairases plat%or$s handrails %or M' and re&uired approahes asdeided at site should be read#.

a%et# and protetive e&uip$ents li!e hand "loves hel$et et shouldbe available durin" the proess.

reautions should be ta!en to avoid spilla"e and onta$ination o% oil.

ervie water soure should be available near the ativit# area.

*vailabilit# o% %irst aid !it near the proess area should be ensured.

*vailabilit# o% ortable %ire e,tin"uishers and bu!ets ontainin" sandshould be ensured near the ativit# area.

ne oil is %illed in M' no weldin" = uttin" /ob should be arried out inlub oil %lushin" area.

ST,T(S

Signatu'e

NTPC BHEL

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE



6/25

,C)N! O)L S+STE

SLNO

5.8

5.9

5.10

5.11

5.12

5.13

6.0

6.1

6.2

6.3

6.4

6.5

;oad on * shall not e,eed %ull load urrent o% the $otor.

rovision %or e$er"en# stoppin" o% oil pu$ps %ro$ loal=>+?has to be $ade.

rovision %or e$er"en# drainin" o% M' to the tan! o% +entral oiluri%iation >nit should be $ade.

il %lushin" area should be properl# ordoned o%%.

-ispla# o% aution si"n boards dan"er ta"s should be $ade atonerned loations.

ound the lo! $annin" should be $ade %or $onitorin" o% oil%lushin" ativit#.

EER!ENCY PROCEDURE(

$er"en# operatin" instrutions to deal with %ire or an# other e$er"en# onditions should be prepared in advane anddispla#ed at the identi%ied loations.

'he operator posted in the oil %lushin" area should be aware o% %ire e,tin"uisher operatin" proedures.

'he tea$ $e$bers should be aware o% proedure to be %ollowedin ase o% aident involvin" in/ur#= letrial ho!.

*n operator should be posted near the pu$p area and instrutedto trip the pu$ps in the event o% e$er"en# bein" noti%ied to hi$b# an# tea$ $e$ber = observers.

'he tea$ $e$bers should be aware o% restartin" the %lushin"operation in ase o% s#ste$ stoppa"e due to %ailure o% powersuppl#.

ST,T(S

Signatu'e

NTPC BHEL


7/25

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

7.0

7.1

7.2

7.3

7.4

7.5

7.5.1

7.5.2

7.5.3

7.5.4

7.5.5

7.5.6

STATE OF T"E PLANT

retion o% the lubeoil s#ste$ is o$plete as per drawin".

*ll the te$porar# pipin" whih are inluded in the proess areseparatel# leaned be%ore their installation.

'her$al sho! she$e is read# as per the details "iven in theenlosed drawin". @e%er dr". )o.4'A014600B

-irt# lean oil tan!s and the related s#ste$s o% the +entral il

uri%iation unit @+>B are read# %or drainin" and pu$pin" ba!o% oil to M'

AIN OIL TAN)

il in/etor %loat valve are !ept in position. rew plu"s will beprovided in its drain holes.

M sution and dishar"e are looped with its oil %lushin" deviesupplied %ro$ Wor!s with a CD vent valve.

*ll + E installations li!e M' level indiators level swithes etare %itted be%ore oil %illin".

apour e,tration %ans are available %or operation.

*ll bearin" edestals and M' strainer are $anuall# leanedand inspeted be%ore start o% oil %lushin". Mar!in loth onl# is tobe used %or leanin".

*s Js and entri%u"e are available with re&uired alar$sinterlo!s and protetions.

ST,T(S

Signatu'e

NTPC BHEL


8/25

Station: NTPC-

Ramagundam


NTPC Ref no COS-CO-R!-Comm-PRO"0#$S%eet of #/

P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

7.6

7.6.1

7.6.2

7.6.3

7.6.4

7.6.5

7.6.6

7.6.7

7.6.8

7.6.9

7.6.10

7.6.11

7.6.12

7.6.13

LUB OIL SYSTE(

*ll %lan"es in the s#ste$ are ti"htened a%ter he!in" %or "as!ets.

il throttles at * dishar"e %or oil in/etor E and EE are replaedwith suitable adapters=distane piees

'he turnin" "ear noFFle bo, inside bearin" )o.3 pedestal isre$oved and its %lushin" devie provided be%ore bo,in" up o% pedestal.

;ub oil header is onneted to -rain eader with a te$porar#

loop o% the lub oil header siFe with an isolatin" valve.

il suppl# return lines %or eah o% (enerator %ront rear ande,iter bearin"s are looped with te$porar# pipes.


9/25

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

7.6.14

7.6.15

7.7

7.7.1

7.7.2

7.7.3

7.7.4

7.7.5

7.8

7.8.1

7.8.2

7.8.3

il oolers are inspeted throu"h oil line onnetion and i% re&uired areleaned be%ore start o% the oil %lushin".

'e$perature indiators be%ore and a%ter oil ooler %or oil as well asoolin" water are $ade available.

JAC)IN! OIL SYSTE(


10/25

Station: NTPC-

Ramagundam


NTPC Ref no COS-CO-R!-Comm-PRO"0#$S%eet / of #/

P&ant a'ea: T(RB)NE

Teting " Commiioning S%edu&e: T(RB)NE O)L *L(SH)N!

SLNO

7.8.4

8.0

8.1

8.1.1

8.1.2

8.1.3

8.1.4

8.1.5

8.1.6

8.2

8.2.1

8.2.2

8.2.3

* he! list is prepared %or all the ite$s re$oved = %ittedte$porail# and is re%erred to at the ti$e o% nor$aliFation.

ET"OD(

OIL FILLIN!(

e&uired &uantit# o% oil is $ade available and the oil is tested %or its &ualit#. 'est erti%iate an also be obtained %ro$ the supplier.

'urbine oil is %illed into the M' pre%erabl# throu"h the entri%u"e.il %illin" an also be done throu"h bearin" drain header b#$ountin" a te$porar# %illin" %unnel at its e,iter du$$# end.

+are is to be ta!en that all the drains o% the s#ste$ are losedand no oil lea!a"e our durin" %illin".

'he operation o% oil tan! level indiator is he!ed durin" oil%illin". ;evel is to be losel# $onitored to avoid an# over%low.

+entri%u"in" o% M' oil is to be done ontinuousl# with its heaters

) +entri%u"e bowl is to be leaned inter$ittentl# to re$oveslud"e olleted.

M' %ilters is to be leaned as and when re&uired.

LUB OIL SYSTE FLUS"IN!(

#ste$ is lined up %or %lushin" lub oil lines diretl# %ro$ lub oilheader to drain throu"h the te$porar# valve. il oolers are !eptb#passed. *ll other setions are !ept isolated.

-iretion o% rotation o% the oil pu$ps is to be he!ed with shortstart = stop o$$and. 'he trial run o% the pu$ps is to be ta!en upalon" with oil %lushin" proess.


11/25

Station: NTPC-

Ramagunda

m


NTPC Ref no COS-CO-R!-Comm-PRO"0#$ S%eet #0 of #/

P&ant a'ea: T(RB)NE


,C)N! O)L S+STESLNO

8.2.4

8.2.5

8.2.6

8.2.7

8.2.8

8.2.9

8.2.10

8.2.11

8.2.12

8.2.13

*s are to be ta!en in to servie. %or %urther oil %lushin" a%ter $a!in" the s#ste$ lea! proo%. +entri%u"e is to be run ontinousl#with its heaters ).

+are is to be ta!en that * load is li$ited to %ull load urrent o% the * $otor. E% re&uired both *s shall be run.

Main oil tan! %ilters shall be inspeted and leaned ever# hour

durin" initial %lushin" operation. 'herea%ter the %re&uen# is be"raduall# redued to one a da# dependin" upon the %ilter ondition.

When one a da# M' %ilter leanin" is established lub oiloolers shall be ta!en in servie one b# one %or %urther oil%lushin". )or$all# 23 da#s o% %lushin" with oolers in b#passedondition su%%iient.

'her$al sho! to the oil s#ste$ is started b# heatin" the oil withther$al sho! arran"e$ent.

'e$perature o% oil a%ter ooler shall be raised to about 7075de" +. il te$perature should not e,eed 80 de" +.

'her$al sho! is "iven b# har"in" oolin" water as %ast aspossible and oil te$perature be%ore ooler is brou"ht down b#about 35 I 40 de" +.


12/25

Station: NTPC-

Ramagunda

m


NTPC Ref no COS-CO-R!-Comm-PRO"0#$ S%eet ## of #/

P&ant a'ea: T(RB)NE


,C)N! O)L S+STESLNO

8.2.14

8.2.15

8.2.16

8.3

8.3.1

8.3.2

8.3.3

8.3.4

8.3.5

8.3.6


13/25

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

8.3.7

8.4

8.4.1

8.4.2

8.4.3

8.5

8.5.1

8.5.1.1

:eepin" %ull# released one J is started and dishar"epressure raised to appro,i$atel# 10 !"=$2 %or %urther oil %lushin"o% /a!in" oil lines %or two da#s.

FINAL STA!E FLUS"IN!(

*%ter all the iruits have been ta!en %or %lushin" and M'strainer re$ains lean %or 24 rs. -uple, %ilter ele$ents shall beintrodued in the %lushin" iruit

'he internals o% bearin" oil throttles @ 2 to 3 bearin"s at a ti$e Bare re$oved and line %ilters supplied %ro$ wor!s are introdued.

+o$plete oil s#ste$ %lushin" is ontinued usin" ther$al sho!s.il sa$ple anal#sis is arried out. -uple, = ;ine %ilters areleaned with leanin" a"ent.


14/25

Station: NTPC-

Ramagundam


NTPC Ref no COS-CO-R!-Comm-PRO"0#$S%eet #$ of #/

P&ant a'ea: T(RB)NE

PROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N! O* T(RB)NE L(B-O)L ,ND,C)N! O)L S+STE


15/25

SLNO

8.5.2

8.5.2.1

8.5.2.2

8.5.2.3

8.5.2.4

8.5.2.5

8.5.2.6

8.5.2.7

8.5.2.8

8.5.2.9

8.6

8.6.1

8.6.1.1

8.6.1.2

PREPRATION(

?e%ore ondutin" h#drauli test it is to be ensured thatdishar"e pipin" o% Js inludin" its dishar"e ) and have been nor$alised and trial run o% /a!in" oil pu$pso$pleted.

e&uired te$porar# onnetion shall be $ade between thesubs#ste$s. ?lan! %lan"es shall be installed wherever thesubs#ste$ are onneted to drain as per %lushin" she$e.

'est "au"es o% suitable ran"e are provided.

&uip$ents not sub/eted to test are !ept isolated.

E$pulse line valves o% all proess pressure "au"es = trans$ittersare to be !ept losed.

a%et# relie% valves o% Js. are to be he!ed %or their settin".#ste$ pressure durin" #drauli test is to be re"ulated usin"pressure re"ulatin" valve.

entin" arran"e$ents are provided at blind ends with valve.

Ja!in" oil dishar"e lines are suitabl# tapped o%% to lub oils#ste$ separatel# with isolatin" valves.

;ub oil throttles to all bearin"s are losed.

PROCEDURE(

L*% O+, S-/(

-+ is run and s#ste$ is %illed.

entin" o% total s#ste$ is arried out.

ST,T(S

Signatu'e

NTPC BHEL

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE


16/25


,C)N! O)L S+STE

SLNO

8.6.1.3

8.6.1.4

8.6.1.5

8.6.1.6

8.6.2

8.6.2.1

8.6.2.2

8.6.2.3

8.6.2.4

8.6.2.5

8.6.2.6

8.6.2.7

8.6.2.8

8.6.2.9

8.6.3.0

-+ is stopped.

ne J is started with pressure re"ulatin" valve %ull# released.

;ines onnetin" /a!in" oil to lub oil s#ste$s are opened.

ressure is raised to 12 !"=$2 and held %or 10 $inutes. #ste$is he!ed %or lea!a"es.

J#'+ O+, S-/(

ressure re"ulatin" valve is !ept %ull# released.

*%ter o$pletion o% h#drauli test o% lub oil s#ste$ the te$porar#onnetion %ro$ J dishar"e header to lub oil s#ste$ are

re$oved and /a!in" oil s#ste$ is nor$alised.

ne J.. is started and pressure is raised to 20 !"=$2 .

;ines to eah bearin" are vented and then isolatin" valves tobearin"s losed.

;ea!a"es i% an# are attended.

ressure is "raduall# raised to 180 !"=$2.

#ste$ is a"ain he!ed %or lea!a"es.

ressure is held %or 10 $inutes and s#ste$ is then depressurised

'he is ad/usted to the operatin" value o% /a!in" oil header pressure.

E% lea!a"es are observed s#ste$ is depressurised and lea!a"esattended and h#drauli test is repeated.

ST,T(S

Signatu'e

NTPC BHEL

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE



17/25

,C)N! O)L S+STE

SLNO

8.7

8.7.1

8.7.2

8.7.3

8.7.4

8.7.5

8.7.6

8.7.7

8.7.8

8.7.9

8.7.10

8.7.11

8.7.12

8.7.13

N#,+#/+(

il is drained %ro$ the total s#ste$ in the dirt# oil tan! o% entraloil puri%iation unit. ualit# o% this oil is tested and i% %oundsuitable the oil $a# be used %or oil %lushin" o% other unit.

M' and ' are leaned and inspeted.

il oolers tube nest are leaned and inspeted.

il in/etor %oot valve are leaned and nor$alised a%ter he!in"the seatin" b# blue $athin". *lso srew plu" provided in drainhole is re$oved.

?earin" oil throttles are nor$alised a%ter re$ovin" their srewplu"s and their li%t are ad/usted %or nor$al operation as per %low

urve. ;o!in" o% throttle is to be done properl#.

*ll the '( bearin"s and M are nor$alised.

ah pedestal is leaned o% an# %orei"n $aterial i% an#.

*ll the provisional arran"e$ents $ade in the s#ste$ %or oil%lushin" are re$oved and s#ste$ nor$alised.

*ll /a!in" oil onnetions to the bearin"s are nor$alised.

Ja!in" oil line ) internals re$oved prior to oil %lushin" areinstalled.

J is run and all J onnetions to bearin"s are he!ed %orlea!a"es. ;ea!a"es observed i% an# are attended.

?earin" pedestal are bo,ed up a%ter ensurin" o$pletion o% all+ E /obs.

il in/etor and oil ooler throttles are nor$alised = ad/usted %or nor$al operation.

ST,T(S

Signatu'e

NTPC BHEL


18/25

Station: NTPC-

Ramagunda

m



P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

8.7.14

9.0

9.1

9.2

9.3


19/25

Station: NTPC-

Ramagunda

m


NTPC Ref no COS-CO-R!-Comm-PRO"0#$ S%eet # of #/

P&ant a'ea: T(RB)NE


,C)N! O)L S+STE

SLNO

10.0 @aBE.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

OIL TEC"NICAL SPECIFICATION

'he properties o% 'urbine oil are "iven below

*ppearane +lear

:ine$ati isoosit# *t 40 de" + @+'B 41.4

isosit# Ende, 96

*'M +olour 2.5

-ensit# at15 de" + @"$=$lB 0.9

our oint @de" +B @B 6


20/25

SHEET #3 O* #/

LO! S"EET

AOP NO 1 2 RUN STATUS

-*' 'EM *

+urrent-is. r.

;ub oileader

r.

;ub oil 'e$o. )o. o% 'her$alsho!


21/25

S"EET 19 OF 19

JOP N. 1 N.2 RUN STATUS

-*' 'EMJ

+urrent-is. r.

il 'e$p.)o. o% 'her$al

ho!?<

'her$alho!

*


22/25

PROCED(RE *OR H+DR,(L)C TEST ,ND *L(SH)N!

O* T(RB)NE L(B-O)L ,ND ,C)N! O)L S+STE

PS(TS(176(00(03

PROJECT ( RAA!UNDA 500 &

B"ARAT "EAVY ELECTRICALS LIITEDTEC"NICAL SERVICES DEPARTENT

PO&ER SECTOR : SOUT"ERN RE!IONC"ENNAI : 600 035.


23/25

J+' *M*(>)-*M 500MW >)E'7

+->N-*>;E+ '' *)- E)( < '>?E) ;>? E;

*)- J*+:E)( E; N'M

> <-+>M'

'E) = E)


24/25

RAMAGUNDAM 500 MW UNIT 7

FLUSHING OF TG LUB-OIL SYSTEM

DRG.NO.4:PS:TSX:0144: 00

DRAWN CHECKED APPROED DATED

K! MKS KB "#.0#.0$


FLUSHING OF TG !ACKING OIL SYSTEM

DRG.NO.4:PS:TSX:0145: 00


K! MKS KB "#.0#.0$


ARRANGEMENT FOR HEATING OF OIL % THERMAL

SHOCK

DRG.NO.4:PS:TSX:014&: 00


K! MKS KB "#.0#.0$

,RR,N!EENT *OR HE,T)N! O* O)L ,ND THER,L SHOC

T+P)C,L6

T(RB)NE O)L *L(SH)N! R,,!(ND, (N)T 7 500 8


25/25

tg lub oil flushing

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