Turbine Lub Oil Sys

6 September 2014 PMI Revision 00 1

Presentation outline
Purpose of lubrication system.
Components of lubrication system.
Lub Oil circuit
Specification of oil

Importance of the lubrication system
To reduce the wear and tear of the rotating elements.

To maintain the temperature of the bearings.
Essentially oil is required by the bearings in order to provide continuous oil
wedge on which the shaft revolves. This requires only a small quantity of oil.
However shaft conductivity, surface friction and turbulence set up in the oil
produce a considerable amount of heat and in order to keep the bearing
temperature constant at the desired level, a further quantity of oil is required to
remove the heat. Most of the oil is supplied to bearings performs the latter
function.

Oil is supplied to the bearings at a pressure from 5 to 25lb/in
2
(0.35 to 1.75
kg/cm
2
) gauge. This pressure is required to ensure that the pressure in the
upper part of the bearing does not fall below atmospheric in which case
discontinuities in the oil film would form. On the other hand if the oil pressure are
too high the oil will be sprayed out from the bearings at a high velocity and will
become finely atomized, in this condition the oil may easily escape from the
bearing housing.
HYDRODYNAMIC LUBRICATION
Turbine bearings are hydro dynamically Lubricated. For this to happen
following things are important
1. Viscosity of oil which is directly related to the oil Temperature.
2. Rotation/speed of the Rotor.
3. Desired Clearances/Converging Wedge in the Bearings. (convergence
should be in the direction of rotation)
In fact the Pressure of the Lube oil is mainly just to ensure that oil
reaches the Bearing. However it is also very important and requires
to be maintained as per design.

HYDRODYNAMIC FILM LUBRICATION
The distinguishing characteristic of this form of lubrication is the creation of a
High pressure wedge of oil, in the relatively large spaces between the bearing
and the journal faces.

The bearing oil is supplied at a pressure of about 10-20psi (1.4 to 1.7 ksc), and
the drag, coupled with the journal speed, creates a pressure in the oil wedge such
that the journal begins to float on the oil. The heat generated at the bearing in this
case is almost all due to shear between oil films. But even so the total power loss
at the bearings of a 500MW set is about 5MW or 1%.

Heavily loaded low speed bearings require a heavy oil (High viscosity). But a
lighter oil is recommended for the high speed bearings of turbo generators which
depend on hydrodynamic film lubrication. The low viscosity reduces the drag and
the consequent power loss.
The high surface speed of the turbine bearings generates
high temperatures in the lubricating oil film, due to high rate
of shear. Thus an oil with a comparatively low viscosity is
chosen for turbine oils to keep the local temperatures below
a level where high rate of oxidation would occur.

On the other hand, an oil with a very low viscosity would
result in discontinuities in the bearing oil films at the high
bearing operating temperatures and pressures. The
viscosity of the oil is normally chosen as a compromise
between these conflicting requirements.
LUBRICATION
As rotor rotates at low speed ,initially there is no film
lubrication but as its speed increases there is
conversion of boundary layer lubrication into Film
lubrication.
From zero speed to appx. 540 RPM there is no
continuos film between rotor and bearings and there is
chance of rubbing between rotor and Bearing. Therefore
JOP is used to prevent the contact between rotor and
bearings.
At Above 540 RPM the JOP can be Switched off, as film
lubrication comes into picture.

Purpose of Turbine oil system
Lubrication of turbine.
Cooling of bearings
Sealing medium in Hydrogen cooling system
Turbine barring gear operation.
Working fluid in Governing system

Lubrication system components
Main oil Pump.
Auxiliary oil pump
Emergency oil pump
Jack oil pump
Main Oil Tank
Oil coolers
Oil Filters
Oil Injectors
Centrifuge
Vapour Extractors
Lubrication system components
Injector
Lubrication Oil Circuit
IPT
LPT
HPT
Gen
MOP
JOP
Oil cooler
Filter
AOP
EOP
MOT
Vap. Ext
Emergency operation of Lub. Oil System:
In case of AC failure ( Black out ).

EOP will start
Extend the DG supply to the emergency MCC
Start AOP
Start JOP.
Rotate turbine with Barring gear.

Specifications of Oil:
Specific Gravity 0.852 @ 50
0
C
Kinematic Viscosity 28 cs
Flash point 201
0
C (Min)
Pour Point - 6.6
0
C (Max)
Mechanical Impurities Nil

The recommended turbine oil Servo prime-46 of IOC.

MAIN OIL PUMP(MOP)
LOCATION: This pump is mounted in the front bearing
pedestal. It is coupled with turbine rotor through a gear
coupling.
Oil suction from MOT Through two number of injectors
connected in series.
Takes over when turbine speed > 2800 rpm.
Supplies oil for turbine bearing lubrication as well as for
the turbine governing system. .
MOP
AUXILIARY OIL PUMPS(AOPS)
Two in number, AC motor driven
Vertical one stage rotory pump with radial impeller & spiral
casing.
Supplies oil during turbo-set starting and stopping when the
turbine is running at speed lower than 2800 rpm supplies oil to
governing system as well as to the lubrication system.
It also serves as standby to main centrifugal oil pump.
Submerged pump body

EMERGENCY OIL PUMP(EOP)
This is a centrifugal pump, driven by D.C. electric motor.
Vertical
Centrifugal submerged
This automatically cuts in when ever there is failure of A.C.
supply at power station and or the lub oil pressure falls below a
certain value. This pump can meet the lubrication system
requirement under the conditions mentioned above.

JACKING OIL PUMPS(JOPS)
JOP1 & JOP2
Both pumps are AC driven but in some of the plants one
of the JOP is DC driven also.
To lift the rotor assembly during TG start up and shut
down.
Suction from MOT.
delivers a pressure of 120kg/cm2 for lifting of rotor.

OIL COOLERS
To cool the lubricating oil

Consists of tube nest, inner & outer shell & water boxes

The cooling medium for these coolers is circulating water.

The pressure of the cooling water is kept lower than that of oil to
avoid its mixing with oil in the event of tube rupture.

OIL TEMP. CONTROLLER for maintaining the lub oil temp at
rated value by controlling the flow through the coolers.
The efficiency of a centrifugal pump may be of the order of 55% and the
remaining 45% of the pump input energy generates heat in the oil. The oil also
absorbs a large amount of heat from bearing friction and shaft conduction. To
remove this heat the oil is passed through coolers which reduce the temperature
to that required for the bearings.

The oil and water passes are arranged in counter flow. This arrangement has
thermodynamic advantages and also reduces the amount of sludge precipitated
in the cooler, as the hot oil entering the cooler does not strike the coldest part of
the cooler tubes.

Coolers are usually mounted vertically for easy removal of the tube nest and
water passing upwards through the tubes ensures complete flooding at all times.
The temperature of the oil must be kept within limits.

If the oil temperature, entering the bearing is too low, inefficient bearing lubrication
will occur due to the high viscosity of the oil.

If the oil temperature on leaving the bearing is too high, this will lead to deterioration
of the oil due to high rates of oxidation.

The temperature of the oil leaving bearing is limited to 160 F (71
0
C) so that the
Maximum temperature within the bearing is not more than 165 F ( 74
0
C). There is
a tendency, however, for these figures for rise on modern machines.

The temperature of the oil entering the bearing is about 100-110 F(37-43
0
C) and
the required leaving temperature is achieved by adjusting the supply of oil to each
bearing.

To allow adequate adjustment, generous piping diameters are used and a removable
orifice plate is often inserted in series with the control valve.
VAPOUR EXTRACTION SYSTEM

Two Vapour Extractor fans
Exhaust fans
Maintains -ve pressure inside MOT
Removes oil fumes from the MOT.

OIL Filter

Basket type filter inside the oil tank
For thrust bearing
Duplex filter
Filter changeover required after choking.
Oxidation of turbine oils usually leads to the formation of sludge which
is deposited in various parts of the lubrication system, particularly in the
areas of low temperature and points of low turbulence.

Water is the most important contaminant of oil, and may enter the
lubricating system from leaking shaft glands, or from the condensation
of humid air in reservoirs, bearing pedestals, or drain lines.

Water in oil may cause dust or scale formation in the lubricating
system. The corrosion products may score the bearings or cause
malfunctioning of the governing system and they also act as catalyst
increasing the oxidation rate of oil.
Main Oil Centrifuge
Required for removing moisture from the turbine oil.

A portion of oil is continuously circulated through the centrifuge
to remove the moisture from the oil.

Centrifuge unit

Turbine Lub Oil Sys

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6 September 2014 PMI Revision 00 1

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