RUMAILA 3000 MW

COMBINED CYCLE POWER PLANT

MAPNA GROUP

Lube Oil Air Cooler - System Description

IN-HOUSE REVISIONS DOCUMENT REVISIONS

B B
A Design Progress Shafaat Torabi P.A/M.I GH.V/S.N 12.06.2016 A

0 First Issue Rahnavard - Aghaei Valizadeh 28.11.2015 0 First Issue Rahnavard - Aghaei Valizadeh 28.11.2015
DRAWN
REV. DESCRIPTION DESG CHK APP. DATE REV. DESCRIPTION DESG DRAWN CHKD APP. Date
.

Owner. No. : Rev:0

MD2-I3-00-MC-G-04-PA3-366

Design Stage:
File No. :
MAPNA GROUP (Public Stock) TUGA No.:
I3-DD-01-9D100-A-366
MAPNA'S DWG No. : MD2-I3-00-MC-G-04-PA3-366 Contract No. : Page 1 of 5
 RUMAILA 3000 MW
COMBINED CYCLE POWER PLANT
MAPNA GROUP

Page
Page
DOCUMENT REVISIONS Remarks No. IN-HOUSE REVISIONS Remarks
No.
0 A B C D E F G 0 A B C D E F G

1 * 1 * *
2 * 2 * *
3 * 3 * *
4 * 4 * *
5 * 5 * *
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
29 29
30 30

Owner. No. : Rev:0

MD2-I3-00-MC-G-04-PA3-366

Design Stage:
File No. :
MAPNA GROUP (Public Stock) TUGA No.:
I3-DD-01-9D100-A-366
MAPNA'S DWG No. : MD2-I3-00-MC-G-04-PA3-366 Contract No. : Page 2 of 5
 RUMAILA 3000 MW
COMBINED CYCLE POWER PLANT
MAPNA GROUP

1 Reference:

Lube Oil Cooling System - P & ID MD2-I3-00-MC-G-02-PA3-379

Lube and Lifting System - P & ID MD2-I3-00-TG-G-02-TO3-385
Lube and Lifting System - System Description MD2-I3-00-TG-G-04-TO3-385
Lube oil Tank - General Layout MD2-I3-00-TG-M-01-TO3-377

2 Function
The Lube oil cooler is an integrated component of the Lifting& Lube oil system MBV.
The lube oil system supplies oil to the compressor bearing and the turbine bearing of the gas turbine, as
well as to the generator bearings.
The removed heat from the bearings is submitted to the atmosphere by using the Lube oil cooler unit
MBV23.
The cooler MBV23 is located in the lube oil supply line. Control valve MBV24AA151(Lube and Lifting
System - P & ID) is used to control lube oil temperature by adjusting the fraction of lube oil which is fed
through the cooler bypass line.
Temperature control valve lift is varied as a function of the oil temperature in the supply line downstream
of the cooler. Adjustable orifices MBV22AA281 in the cooler bypass line and MBV24AA281
downstream of the point where the bypass line joins the main supply line permit adjustment and precise
control of the lube oil mass flow supplied to the bearings

3 Principal of operation

For the Lube oil cooler MBV23, three cooler bays MBV23AH010, MBV23AH020 and MBV23AH030
each handling 50% of the removed heat, are used. During normal one or two bays are in operation and 1
bay is on stand-by.

In case of a problem each cooler bay can be isolated by closing the manual shut off valves at each bay
inlet and outlet and switching off all fans of the concerned bay. The reserved bay will come to operation
manually by related valves.

Also in case of fan vibration more than set points, the vibration switches MBV23CY011 /012
(respectively MBV21/22 and MBV31/32) will stop the system.

4 Location of the cooler

The cooler is installed outdoors in an area which is close to the gas turbine systems. The cooler is
installed in a way that the cooling air flow to the cooler is not interfered with other HVAC systems, vent
or relief systems and the gas turbine air intake system.

The cooler is located on a steel platform at a level of + 2.5 meter.

Owner. No. : Rev:0

MD2-I3-00-MC-G-04-PA3-366

Design Stage:
File No. :
MAPNA GROUP (Public Stock) TUGA No.:
I3-DD-01-9D100-A-366
MAPNA'S DWG No. : MD2-I3-00-MC-G-04-PA3-366 Contract No. : Page 3 of 5
 RUMAILA 3000 MW
COMBINED CYCLE POWER PLANT
MAPNA GROUP

5 Components of the cooler

5.1 Heat exchanger bundles

The heat exchangers are plate-tube type means that aluminum plates are stacked on the copper tubes. The
plates are coated with an epoxy coat to ensure a good stiffness and also protection from the atmosphere
and from the cleaning devices.
Each tube bundle includes two heat exchangers whit inlet and outlet headers which lead the fluid to the
cooling tubes.
Each bay consists of two tube bundles which located beside each other in a v-type arrangement.

Inlet/outlet flanges are welded on each header. The flange connection is located in horizontal direction.
At each inlet header two connections are foreseen for permanent venting that are connected to an auto
vent valve. Also two drain connections are considered for drain.
The carbon steel header is coated with a resistant painting system to ensure a proper lifetime.

5.2 Cooling fan units

The cooling fan units consist of multiple numbers of fans and electrical motors to ensure an equal air
flow over the complete cooler bay. These equipments are located above the heat exchanger bundles.

5.3 steel structure

Heat exchanger bays are mounted on a steel structure that is made of carbon steel and the surface is
protected with a suitable coating.
On top of the cooler deck handrails are mounted and a protection grid is installed to ensure a safe area.
The cooler deck can be reached via ladders.

6 Control of the system

The air cooler consist of 3×50% cooling cells, each furnished with two fans, mentioned as fallow:

2 fan-coolers

Group 1: MBV23AN011/ AN 021

Group 2: MBV23AN012/ AN 022
Group 3: MBV23AN031/ AN 032

The activation of fans are done in groups and not as single activation of each individual fan based on the
cold oil temperature at cooler outlet (MBV23CT101 A/B) means that this temperature is monitored and
serves as input for the fans control.

Owner. No. : Rev:0

MD2-I3-00-MC-G-04-PA3-366

Design Stage:
File No. :
MAPNA GROUP (Public Stock) TUGA No.:
I3-DD-01-9D100-A-366
MAPNA'S DWG No. : MD2-I3-00-MC-G-04-PA3-366 Contract No. : Page 4 of 5
 RUMAILA 3000 MW
COMBINED CYCLE POWER PLANT
MAPNA GROUP

The system is started by the gas turbine operation program at step "lube oil cooling ON". Until cold oil
temperature (MBV23CT101) < 45 º c the cooling group 1 will be remained on. In case of cold oil
temperature (MBV23CT101) > 45ºc the group 2 will be started too.

If cold oil temperature decreases below 30ºc group 2 will be deactivated and finally at cold oil
temperature decrease below 20ºc, group 1 of the fans will be switched off too.

When the gas turbine is at turning gear mode, the group 1 will be remained active for the time of this
operation mode unless the lube oil temperature at MBV26 CT101 >55 ºc. If the temperature at MBV26
CT101 <45 ºc the group 1will be switched off.

The operation mode of control group 1 or 2 is monitored by I&C –system.

2 hours after of " cooling down turning" of the gas turbine the lube oil cooler will be switched to the
mode " after cooling ", in this case the group 2 will be controlled by means of temperature switch
MBV26 CT101. The switch is pre-adjusted with hysteresis of 5ºc between 58ºc and 53ºc.
The third group (group 3) is standby unless fan(s) of other groups failed or in case of unexpected
problems of other bays.

Owner. No. : Rev:0

MD2-I3-00-MC-G-04-PA3-366

Design Stage:
File No. :
MAPNA GROUP (Public Stock) TUGA No.:
I3-DD-01-9D100-A-366
MAPNA'S DWG No. : MD2-I3-00-MC-G-04-PA3-366 Contract No. : Page 5 of 5