TG Lub Oil Flushing

Station: NTPCBHEL Ref No.
PS-DC-202-500-0004
Ramagunda NTPC Ref no COS-COMM-RGM-Comm-PRO/013
Sheet 1 of 19
m
Plant area: TURBINE
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING OF TURBINE LUB-OIL AND
JACKING OIL SYSTEM
SLNO
1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PRECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) TECHNICAL SPECIFICATION
b) DRAWING.
c) LOG SHEETS.
Station: NTPCBHEL Ref No.PS-DC-202-500-0004

Ramagunda
NTPC Ref no COS-COMM-RGM-Comm-PRO/013
Sheet 2 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
1.
PLANT DETAILS
1.1
500 MW unit is provided with lub oil and Jacking oil systems
which consisting of the following equipments to cater to the
lubrication and shaft lifting requirement of entire Turbine and
Generator bearings and Turing gear system.
1.2
2 Nos. AC driven Auxiliary oil pumps and 1 No DC driven

emergency oil pump are meant to supply oil to the bearings and
turning gear at required pressures.
1.3
2 Nos. of AC driven and 1 No DC driven Jacking Oil pumps are

meant for supplying high pressure oil to the bearings in order to
lift the shaft while the machine is on barring gear.
1.4
1 No Main oil pump to supply oil to the bearings while the unit is
in operation.
1.5
2Nos. of injectors to boost the suction pressure to MOP.
1.6
2 Nos of coolers, one in service & the other as standby to remove

the heat from the oil coming from the bearings.
1.7
Oil temperature control valve. This in conjunction with oil coolers

maintains the oil temperature at inlet to bearings.
1.8
Duplex filters in oil line to Thrust bearing:- This is to remove the

mechanical impurities from the oil so that the damage to thust
bearing is avoided. One is normally in service and the other is
kept as standby.
1.9
Throttles at the inlet to the bearings. These are meant for

regulating the flow of oil entering the bearings so that the bearing
metal temperatures are maintained within operating limits.
Signatures
NTPC
BHEL

Sheet 3 of 19
Ramagundam NTPC Ref no COS-COMM-RGM-Comm-PRO/013
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
1.10
Hydraulic Turning gear shut off valve is meant for admitting the
power oil for turning gear device during shutdown of the unit.
1.11
Main Oil Tank serves as reservoir of Oil. The Auxiliary Oil Pump
and Jacking oil pumps are mounted inside the Main oil
tank. The tank contains two compartments, Namely dirty
and clean compartments separated by a partition & filter
element.
1.12
2Nos. Vapour Exhauster fans are meant for removing oil vapour
from the oil system and to maintain a little amount of vaccum.
Normally one fan is in service and the other is kept as standby.
2.0
OBJECTIVE:
2.1
To flush complete TG Oil & Jacking oil systems with Turbine oil
to remove mechanical impurties.
3.0
PROPOSAL
3.1
Scheme of oil flushing for lub oil and Jacking oil systems shall be
as per the enclosed sketch.
3.2
Thermal shocks shall be given to the system by sudden changes
in oil temperature to make the flushing effective. Rapping of the
oil lines shall be carried out during thermal shocks especially at
weld joints.
3.3
Oil flushing shall be carried out using the normal operating
Turbine oil as per Annexure. The quantity of oil required for
flushing will be approx. 40 KL.
3.4
For the purpose of analysis, oil samples shall be collected from
centrifuge inlet with centrifuge in service
Signatures
NTPC
BHEL

Ramagunda
Sheet 4 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
SLNO
STATUS
4.0
SERVICES REQUIRED
4.1
Availability of Electrical heating arrangement for heating the CW to

turbine oil cooler for giving thermal shocks during oil flushing.
4.2
Availability of laboratory facility for analysis of oil sample.
4.3
Availability of service air and thinner/petrol for filter cleaning.
4.4
Availability of sufficient skilled manpower for execution and supervision

of the process.
4.5
Availability of required quantity of Turbine oil
4.6
Availability of portable fire extinguisher at oil flushing area.
4.7
Availability of proper lighting and communication facility.
5.0
SAFETY PRECAUTIONS:
5.1
Staircases, platforms, hand-rails for MOT and required approaches as

decided at site should be ready.
5.2
Safety and protective equipments like hand gloves, helmet etc should
be available during the process.
5.3
Precautions should be taken to avoid spillage and contamination of oil.
5.4
Service water source should be available near the activity area.
5.5
Availability of first aid kit near the process area should be ensured.
5.6
Availability of Portable fire extinguishers and buckets containing sand

should be ensured near the activity area.
5.7
Once oil is filled in MOT no welding / cutting job should be carried out in
lub oil flushing area.
Signatures
NTPC
BHEL

Sheet 5 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM

SLNO
STATUS
5.8
Load on AOP shall not exceed full load current of the motor.
5.9
Provision for emergency stopping of oil pumps from local/UCB

has to be made.
5.10
Provision for emergency draining of MOT to the tank of Central oil

Purification Unit should be made.
5.11
Oil flushing area should be properly cordoned off.
5.12
Display of caution sign boards, danger tags should be made at

concerned locations.
5.13
Round the clock manning should be made for monitoring of oil

flushing activity.
6.0
EMERGENCY PROCEDURE:
6.1
Emergency operating instructions, to deal with fire or any other

emergency conditions, should be prepared in advance and
displayed at the identified locations.
6.2
The operator posted in the oil flushing area should be aware of

fire extinguisher operating procedures.
6.3
The team members should be aware of procedure to be followed

in case of accident involving injury/ Electrical Shock.
6.4
An operator should be posted near the pump area and instructed

to trip the pumps in the event of emergency being notified to him
by any team member / observers.
6.5
The team members should be aware of restarting the flushing

operation in case of system stoppage due to failure of power
supply.
Signatures
NTPC
BHEL

Sheet 6 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
7.0
STATE OF THE PLANT
7.1
Erection of the lube-oil system is complete as per drawing.
7.2
All the temporary piping which are included in the process, are
separately cleaned before their installation.
7.3
Thermal shock scheme is ready, as per the details given in the

enclosed drawing. (Refer drg. No.4:PS:TSX:0146:00)
7.4
Dirty & clean oil tanks and the related systems of the Central Oil
Purification unit (COPU) are ready for draining and pumping back
of oil to MOT
7.5
MAIN OIL TANK:
7.5.1
Oil injector float valve are kept in position. Screw plugs will be
provided in its drain holes.
7.5.2
MOP suction and discharge are looped with its oil flushing device
supplied from Works, with a vent valve.
7.5.3
All C & I installations like MOT level indicators, level switches etc
are fitted before oil filling.
7.5.4
Vapour extraction fans are available for operation.
7.5.5
All bearing Pedestals and MOT strainer are manually cleaned

and inspected before start of oil flushing. Markin cloth only is to
be used for cleaning.
7.5.6
AOPs, JOPs, and centrifuge are available with required alarms,

interlocks and protections.
Signatures
NTPC
BHEL

Sheet 7 of 19
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
7.6
LUB OIL SYSTEM:
7.6.1
All flanges in the system are tightened after checking for gaskets.
7.6.2
Oil throttles at AOP discharge for oil injector I and II are replaced
with suitable adapters/distance pieces
7.6.3
The turning gear nozzle box inside bearing No.3 pedestal is

removed and its flushing device provided before boxing up of
pedestal.
7.6.4
Lub oil header is connected to Drain Header with a temporary

loop of the lub oil header size, with an isolating valve.
7.6.5
Oil supply & return lines for each of Generator front, rear and
exciter bearings are looped with temporary pipes.
7.6.6
Flushing device are provided for bearings 1 to 4.
7.6.7
Thrust bearing Pads are removed.
7.6.8
Oil throttle before oil cooler is kept in position and adjusted such
that maximum oil flow is achieved during oil flushing .
7.6.9
Turbine oil cooler is bypassed during first stage of flushing, with a

temporary pipe connection from cooler inlet to outlet.
7.6.10
Duplex filter elements shall be taken out during oil flushing.

These are introduced in the circuit only in the final stage flushing.
7.6.11
All throttles in the lub oil supply line to bearings are kept fully
closed prior to oil flushing. Also, screw plugs are fixed in small
holes provided in these throttles.
7.6.12
MOP is removed and its suction & discharge are looped with the
help of flushing device.
7.6.13
A dummy is provided at flange B as shown in scheme.
Signatures
NTPC
BHEL

Sheet 8 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
7.6.14 Oil coolers are inspected through oil line connection and if required are
cleaned before start of the oil flushing.
7.6.15 Temperature indicators before and after oil cooler for oil as well as
cooling water are made available.
7.7
JACKING OIL SYSTEM:
7.7.1
From the dummy flange at the end of JOP supply header, a temporary
connection (JOP supply header size) with an isolating valve is taken to
oil return pipe for initial flushing.
7.7.2
The hose connection of Jacking oil lines to bearings is disconnected

from the bearing bottom and kept open to drain inside pedestals.
7.7.3
All the NRVs internals of Jacking oil pump discharge and supply lines to
bearings are removed.
7.7.4
Jacking oil PRV are removed and necessary temporary lines blanking
provided.
7.7.5
AOP discharge header is looped with an isolating valve to jacking oil

lines bypassing the JOPs.
7.8
GENERAL:
7.8.1
Turbine Insulation work should not be carried out during oil flushing
activity.
7.8.2
Erection and testing of fire fighting system envisaged for lub oil system
should be complete before MOT is filled with oil.
7.8.3
Generally the pipelines of Lub oil & Jacking oil systems are chemically
cleaned at works before dispatch. Howerver, if traces of pitting / rusting
are observed in any of the pipe line, (inspected jointly by NTPC &
BHEL at site), acid cleaning of the pipe lines are carried out.
Signatures
NTPC
BHEL

Plant area: TURBINE
Testing / Commissioning Schedule: TURBINE OIL FLUSHING
SLNO
7.8.4
Sheet 9
STATUS
A check list is prepared for all the items removed / fitted

temporaily and is referred to at the time of normalization.
8.0
METHOD:
8.1
OIL FILLING:
8.1.1
Required quantity of oil is made available and the oil is tested for
its quality. Test certificate can also be obtained from the supplier.
8.1.2
Turbine oil is filled into the MOT preferably through the centrifuge.
Oil filling can also be done through bearing drain header by
mounting a temporary filling funnel at its exciter dummy end.
8.1.3
Care is to be taken that all the drains of the system are closed
and no oil leakage occur during filling.
8.1.4
The operation of oil tank level indicator is checked during oil

filling. Level is to be closely monitored to avoid any overflow.
8.1.5
Centrifuging of MOT oil is to be done continuously with its heaters

ON Centrifuge bowl is to be cleaned intermittently to remove
sludge collected.
8.1.6
MOT filters is to be cleaned as and when required.
8.2
LUB OIL SYSTEM FLUSHING:
8.2.1
System is lined up for flushing lub oil lines directly from lub oil
header to drain through the temporary valve. Oil coolers are kept
bypassed. All other sections are kept isolated.
8.2.2
Direction of rotation of the oil pumps is to be checked with short

start / stop command. The trial run of the pumps is to be taken up
along with oil flushing process.
8.2.3
Flushing is started with DC Emergency Oil Pump in service.

System is checked for leakages if any, and attended.
Signatures
NTPC
of 19
BHEL

Sheet 10 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
8.2.4
AOPs are to be taken in to service. for further oil flushing after

making the system leak proof. Centrifuge is to be run continously
with its heaters ON.
8.2.5
Care is to be taken that AOP load is limited to full load current of

the AOP motor. If required both AOPs shall be run.
8.2.6
Main oil tank filters shall be inspected and cleaned every hour
during initial flushing operation. Thereafter the frequency is be
gradually reduced to once a day depending upon the filter
condition.
8.2.7
When once a day MOT filter cleaning is established, lub oil

coolers shall be taken in service one by one for further oil
flushing. Normally 2-3 days of flushing with coolers in bypassed
condition sufficient.
8.2.8
Thermal shock to the oil system is started by heating the oil with
thermal shock arrangement.
8.2.9
Temperature of oil after cooler shall be raised to about

deg C. Oil temperature should not exceed 80 deg C.
8.2.10
Thermal shock is given by charging cooling water as fast as

possible and oil temperature before cooler is brought down by
about 35 40 deg C.
8.2.11
Further oil flushing is continued with repetitive thermal shocks

and intermittent rapping of the oil lines at weld joints.
8.2.12
Oil flushing with thermal shocks is continued (bearing pedestals

in bypassed condition) till completion criteria are met.
8.2.13
Once the completion criteria for flushing of oil lines are met the
temporary valve between lub oil header and drain header is
closed.
70-75
Signatures
NTPC
BHEL

Ramagunda
Sheet 11 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
8.2.14
Further flushing is done through bearing pedestals. 2 to 3

bearings at a time are selected for flushing. The throttles of the
bearings, which are selected for flushing, are kept wide open and
those of remaining bearings are kept closed. This ensures
maximum possible oil flow in bearing return oil lines.
8.2.15
The bearing pedestal flushing operation is continued till the

completion criteria is accomplished for each group of bearings.
8.2.16
Turning gear oil line is flushed by opening the turning gear valve
in such a way that AOP motor doesnt get overloaded. This is
done everyday with one or two thermal shocks.
8.3
JACKING OIL SYSTEM FLUSHING:
8.3.1
Flushing is carried out using temporary connection from AOP

discharge header.
8.3.2
Flushing of Jacking oil lines is started once the MOT filters are
reasonably clean after start of thermal shocks.
8.3.3
Initially, jacking oil header is flushed from its dead end to bearing
lub oil drain header.
8.3.4
After flushing above circuit for few days, the above connection is
to be closed / normalised and jacking oil lines to individual
bearings are to be flushed taking 2 or 3 lines at a time for
effective flushing.
8.3.5
Jacking oil lines flushing is continued till oil flushing is declared

complete based on completion criteria.
8.3.6
The temporary connection from AOP discharge header to jacking

oil lines is removed at the end of the flushing. JOP discharge
NRV internals, PRV and discharge pipelines are normalised for
running of JOPs.
Signatures
NTPC
BHEL

Ramagunda
Sheet 12 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
8.3.7
Keeping PRV fully released, one JOP is started and discharge

pressure raised to approximately 10 kg/cm 2 for further oil flushing
of jacking oil lines for two days.
8.4
FINAL STAGE FLUSHING:
8.4.1
After all the circuits have been taken for flushing and MOT
strainer remains clean for 24 Hrs., Duplex filter elements shall be
introduced in the flushing circuit
8.4.2
The internals of bearing oil throttles ( 2 to 3 bearings at a time )

are removed and line filters, supplied from works, are introduced.
8.4.3
Complete oil system flushing is continued using thermal shocks.

Oil sample analysis is carried out. Duplex / Line filters are
cleaned with cleaning agent. Flushing is declared complete
based on completion criteria.
8.5
HYDRAULIC TESTING OF LINES:
8.5.1
GENERAL:
8.5.1.1
Hydraulic test of various lines shall be carried out as per chart

given below.
S.No
System/Item
Std. Pr.
Test Pr.
1.
2.
3.
LUB OIL
2.5 kg/cm2
12 kg/cm2
JACKING OIL 120 kg/CM2 180 kg/CM2
OIL COOLER
2.5 kg/cm2 12 kg/cm2
Duration
10 min
10 min
10 min
NOTE: Oil Coolers are received at site after duly conducting

hydraulic test at works (Test certificates are to be referred
at site). Oil coolers are hydraulically tested at above
parameters after concluding oil flushing.
Signatures
NTPC
BHEL

Sheet 13 of 19
Ramagundam
Plant area: TURBINE
JACKING OIL SYSTEM
SLNO
8.5.2
STATUS
PREPRATION:
8.5.2.1
Before conducting hydraulic test, it is to be ensured that

discharge piping of JOPs including its discharge NRV and PRV
have been normalised and trial run of jacking oil pumps
completed.
8.5.2.2
Required temporary connection shall be made between the

subsystems. Blank flanges shall be installed wherever the
subsystem are connected to drain as per flushing scheme.
8.5.2.3
Test gauges of suitable range are provided.
8.5.2.4
Equipments not subjected to test are kept isolated.
8.5.2.5
Impulse line valves of all process pressure gauges / transmitters

are to be kept closed.
8.5.2.6
Safety relief valves of JOPs. are to be checked for their setting.

System pressure during Hydraulic test is to be regulated using
pressure regulating valve.
8.5.2.7
Venting arrangements are provided at blind ends with valve.
8.5.2.8
Jacking oil discharge lines are suitably tapped off to lub oil
system separately with isolating valves.
8.5.2.9
Lub oil throttles to all bearings are closed.
8.6
PROCEDURE:
8.6.1
Lub Oil System:
8.6.1.1
DC EOP is run and system is filled.
8.6.1.2
Venting of total system is carried out.
Signatures
NTPC

Ramagunda
m
Plant area: TURBINE
BHEL
Sheet 14 of 19

JACKING OIL SYSTEM
STATUS
SLNO
8.6.1.3
DC EOP is stopped.
8.6.1.4
One JOP is started with pressure regulating valve fully released.
8.6.1.5
Lines connecting jacking oil to lub oil systems are opened.
8.6.1.6
Pressure is raised to 12 kg/cm 2 and held for 10 minutes. System

is checked for leakages.
8.6.2
Jacking Oil System:
8.6.2.1
Pressure regulating valve is kept fully released.
8.6.2.2
After completion of hydraulic test of lub oil system the temporary

connection from JOP discharge header to lub oil system are
removed and jacking oil system is normalised.
8.6.2.3
One J.O.P is started and pressure is raised to 20 kg/cm 2 .
8.6.2.4
Lines to each bearing are vented and then isolating valves to

bearings closed.
8.6.2.5
Leakages, if any, are attended.
8.6.2.6
Pressure is gradually raised to 180 kg/cm 2.
8.6.2.7
System is again checked for leakages.
8.6.2.8
Pressure is held for 10 minutes and system is then depressurised
8.6.2.9
The PRV is adjusted to the operating value of jacking oil header

pressure.
8.6.3.0
If leakages are observed, system is depressurised and leakages

attended and hydraulic test is repeated.
Signatures
NTPC
BHEL

Sheet 15 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM

SLNO
8.7
STATUS
Normalisation:
8.7.1
Oil is drained from the total system in the dirty oil tank of central
oil purification unit. Quality of this oil is tested and if found
suitable the oil may be used for oil flushing of other unit.
8.7.2
MOT and SOST are cleaned and inspected.
8.7.3
Oil coolers tube nest are cleaned and inspected.
8.7.4
Oil injector foot valve are cleaned and normalised after checking
the seating by blue matching. Also screw plug provided in drain
hole is removed.
8.7.5
Bearing oil throttles are normalised after removing their screw

plugs and their lift are adjusted for normal operation as per flow
curve. Locking of throttle is to be done properly.
8.7.6
All the TG bearings and MOP are normalised.
8.7.7
Each pedestal is cleaned of any foreign material, if any.
8.7.8
All the provisional arrangements made in the system for oil

flushing are removed and system normalised.
8.7.9
All jacking oil connections to the bearings are normalised.
8.7.10
Jacking oil line NRV internals removed prior to oil flushing are
installed.
8.7.11
JOP is run and all JOP connections to bearings are checked for
leakages. Leakages observed, if any are attended.
8.7.12
Bearing pedestal are boxed up after ensuring completion of all

C & I jobs.
8.7.13
Oil injector and oil cooler throttles are normalised / adjusted for
normal operation.
Signatures
NTPC
BHEL

Sheet 16 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
8.7.14
Fresh oil is used for refilling the Main Oil Tank. Filling is done
through centrifuge.
9.0
COMPLETION CRITERIA:
9.1
Mechanical impurities and moisture content in the oil sample

should be each less than 100 ppm (by weight).
9.2
Main oil Tank filter should remain clean after 24 Hrs. of flushing.
9.3
Duplex filter elements should require cleaning after 12 hours of

flushing (For final stage of flushing).
Signatures
NTPC
BHEL

Sheet 17 of 19
m
Plant area: TURBINE
JACKING OIL SYSTEM
STATUS
SLNO
OIL TECHNICAL SPECIFICATION
10.0 (a) The properties of Turbine oil are given below:
I.
Appearance
Clear
1.
Kinematic Visoosity
At 40 deg C (CST)
41.4
2.
Viscosity Index
96
3.
ASTM Colour
2.5
4.
Density at
15 deg C (gm/ml)
0.9
5.
Pour Point (deg C)
(-) 6
6.
Flash Point (deg C)
210
7.
Neutralisation No.
(mg. KOH/gm)
0.15
8.
Deaeration Capacity
at 50 deg C Max (minutes)
9.
Corrosive action on
Copper max
10.
6
Corrosiveness 2
Reaction with Ammonia

Content
11.
FZG Rating
12.
Water Content
13.
Solid Content
14.
De-emulsification No.
15.
Air release value

At 50 deg C Minutes
<0.10% by Weight.
<0.05% by Weight.
4.0
Signatures
NTPC
BHEL
SHEET 18 OF 19
LOG SHEET
AOP NO # 1 / # 2 RUN STATUS
DATE
TIME
AOP
Current
Dis. Pr.
Lub oil
Header
Pr.
Lub oil Temo.

BEF
AFT
Cooler Cooler
No. of
Thermal
shock
Filter
Condition
Signatures
NTPC
BHEL
SHEET 19 OF 19
JOP No. 1 / No.2 RUN STATUS
DATE
TIME
JOP
Current
Dis. Pr.
Oil Temp.
BEF
AFT
Thermal
Thermal
Shock
Shock
No. of Thermal
Shock
Signatures
NTPC
BHEL
PROCEDURE FOR HYDRAULIC TEST AND FLUSHING

OF TURBINE LUB-OIL AND JACKING OIL SYSTEM
PS:TSX:176:00:03
PROJECT : RAMAGUNDAM 500 MW
BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL SERVICES DEPARTMENT
POWER SECTOR SOUTHERN REGION
CHENNAI 600 035.
PROJECT
RAMAGUNDAM 500MW, UNIT-7
PROCEDURE
HYDRAULIC TEST AND FLUSHING OF TURBINE LUB OIL

AND JACKING OIL SYSTEM
PURPOSE OF
DOCUMET
FOR EXECUTION / INFORMATION
DOCUMENT
PS:TSX:176:00:03
Copy No:
Issued to :
00
K.J
M.K.S
K.B
28.08.03
Rev.No.
Prepared by
Reviewed by
Approved by
Date
BHARAT HEAVY ELECTRICALS LIMITED

PSSR/TECHNICAL SERVICES
474, Anna Salai, Nandanam,
Chennai 600 035.
RAMAGUNDAM 500 MW UNIT 7

FLUSHING OF TG LUB-OIL SYSTEM
DRG.NO.4:PS:TSX:0144: 00
DRAWN
CHECKED
APPROVED
DATED
KJ
MKS
KB
28.08.03

FLUSHING OF TG JACKING OIL SYSTEM
DRAWN
CHECKED
APPROVED
DATED
KJ
MKS
KB
28.08.03

ARRANGEMENT FOR HEATING OF OIL & THERMAL
SHOCK
DRAWN
CHECKED
APPROVED
DATED
KJ
MKS
KB
28.08.03
ARRANGEMENT FOR HEATING OF OIL AND THERMAL SHOCK

(TYPICAL)
TURBINE OIL FLUSHING RAMAGUNDAM UNIT 7 500 MW

TG Lub Oil Flushing

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What is the purpose of flushing the turbine oil and jacking oil systems?

What equipment is involved in the lubrication and shaft lifting systems of the turbine?

What equipment is involved in the lubrication and shaft lifting systems of the turbine?

Station: NTPCBHEL Ref No.

STATE OF THE PLANT

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

2 Nos. AC driven Auxiliary oil pumps and 1 No DC driven

2 Nos. of AC driven and 1 No DC driven Jacking Oil pumps are

2Nos. of injectors to boost the suction pressure to MOP.

2 Nos of coolers, one in service & the other as standby to remove

Oil temperature control valve. This in conjunction with oil coolers

Duplex filters in oil line to Thrust bearing:- This is to remove the

Throttles at the inlet to the bearings. These are meant for

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

Availability of Electrical heating arrangement for heating the CW to

Availability of laboratory facility for analysis of oil sample.

Availability of service air and thinner/petrol for filter cleaning.

Availability of sufficient skilled manpower for execution and supervision

Availability of required quantity of Turbine oil

Availability of portable fire extinguisher at oil flushing area.

Availability of proper lighting and communication facility.

Staircases, platforms, hand-rails for MOT and required approaches as

Precautions should be taken to avoid spillage and contamination of oil.

Service water source should be available near the activity area.

Availability of Portable fire extinguishers and buckets containing sand

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

JACKING OIL SYSTEM

Provision for emergency stopping of oil pumps from local/UCB

Provision for emergency draining of MOT to the tank of Central oil

Oil flushing area should be properly cordoned off.

Display of caution sign boards, danger tags should be made at

Round the clock manning should be made for monitoring of oil

Emergency operating instructions, to deal with fire or any other

The operator posted in the oil flushing area should be aware of

The team members should be aware of procedure to be followed

An operator should be posted near the pump area and instructed

The team members should be aware of restarting the flushing

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

STATE OF THE PLANT

Erection of the lube-oil system is complete as per drawing.

Thermal shock scheme is ready, as per the details given in the

MAIN OIL TANK:

Vapour extraction fans are available for operation.

All bearing Pedestals and MOT strainer are manually cleaned

AOPs, JOPs, and centrifuge are available with required alarms,

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

LUB OIL SYSTEM:

The turning gear nozzle box inside bearing No.3 pedestal is

Lub oil header is connected to Drain Header with a temporary

Flushing device are provided for bearings 1 to 4.

Thrust bearing Pads are removed.

Turbine oil cooler is bypassed during first stage of flushing, with a

Duplex filter elements shall be taken out during oil flushing.

A dummy is provided at flange B as shown in scheme.

Station: NTPCBHEL Ref No.PS-DC-202-500-0004

JACKING OIL SYSTEM: