Gas Turbine Training o ae CITADEL ACADEMY Lube Oil System Lube Oil System Purposes The Lube Oil System provides critical operating functions for the turbine-driven generator package (refer to Figure 4.1). The engine, the speed reduction and accessory drive gearboxes, and the driven equipment all require lubricating oil for their bearings and gearing to help reduce friction. The circulating oil is also used as a cooling medium where it carries away heat from the engine both during operation and for a period of time just after shutdown.Lube Oil System Outline To/ From Cooler Température Control Valve Pressure Regulator Valve Figure 4.1 pee are Post Lube Relief Lube Oil System Purposes The oil is stored in an integral tank within the skid base frame beneath the Speed Reduction Gearbox. An engine-driven pump draws oil from the tank where it is first regulated in its pressure and temperature, filtered, and then circulated through a network of piping and distributed to all required components. The oil is then returned to the tank by a series of gravity-assisted drain lines.Lube Oil System Purposes Before the engine and generator are allowed to rotate, pre-lubrication is provided to their shaft bearings by means of a separate Pre/Post Lube Pump. This same pump also circulates oil for cooling the engine even after shutdown. In addition, a Backup Post Lube Pump is also provided to ensure the engine and driven equipment are cooled in the event the Pre/Post Lube Pump is not functioning. Lube Oil Type Petroleum Lubricating Oil Petroleum lubricating oilJ|SO VG 46 (S215)} is used on this installation. Refer to Solar Specification ES 9-224 f that can be used, Table 6.1.2 Unique Petroleum Oil ISO VG 46 ($215) Physical and Chemical Requirements Minimum Requirements For ASTM Std Ot Properies New Oi D445 | Viscosity at +104°F (r40°C) SSU (CSt- mms) Maximum | 235 (50.6) D445 Viscosity at +212°F (+100°C) SSU (cSt- mm/s) Minimum _ | 46.0 (6.04) 092 Flash Point, COC, °F (°C) Minimum +390 (+199) 92 Fire Point, COG, *F () Minimum +450 (232) 097 Pour Point, °F (@) Maximum 415 (95) 10664 | Neutralization (Total Add) Number, mgKOHIg Maximum —_| 0.20 01298 Specific Gravity, 60/60°F (15/15°C) 0.83-0.88 659 | Auto lonition Temperature °F (*C) Minimum +590 (310) 102270 | Viscosty Index, Minimum 2 Petroleum oll operating temperature limits for ISO VG 46 (S215) oil are as follows: il pour point shall be 11°F (6°C) below the minimum ambient temperature limit. + Operating oil temperature limits into engine, after a minimum of 30-minutes engine operation, are +125°F to +165°F (+52°C to +74°C),Major Components Overview Major Components The simplified system diagram below (refer to Figure 4.2) provides an overview of the lube system components that support the system’s lubrication, cooling, and jacking oil duties. The major system components include:Major Components MAIN LUBE SYSTEM Lube Oil Tank Engine-Driven Main Lube Pump Oil Regulation (Pressure, Temperature, Relief) Oil Cooler Assembly Filter(s) System Monitoring (RTD’s, Pressure Switches & Transmitters) Oil Vapour Separator Major Components PRE/POST LUBE SYSTEM Pre/Post Lube Pump Pressure Switch/Transmitter Pre/Post System Relief / Regulator ValveMajor Components BACKUP POST LUBE SYSTEM . Backup Post Lube Pump . Pressure Switch / Transmitter . Backup System Relief / Regulator Valve < In-Line Filter Major Components JACKING OIL SYSTEM . Jacking Oil Pump ° Jacking Oil Relief ValvesMain Lube Oil System Components Major ComponentsMajor Components: Lube oil Tank LUBE OIL TANK / RESERVOIR The lube oil is stored in a welded tank that is built within the skid or base frame, which also supports all the package components. The primary tank rests beneath the turbine engine and reduction gearbox. Depending on site conditions, a lube oil heater may be installed in the tank to maintain a minimum oil temperature when the engine is not running. The tank will also contain instrumentation for level monitoring and sensing internal tank pressures. The tank pressure monitoring system will initiate a tank over-pressure alarm or shutdown at predefined pressure setpoints. Engine Drain Lines LO Outline cost PestLubeRetet lube PumpMajor Components: Lube oil Tank Since a mixture of air and oil will be returning from the engine’s bearing and seal areas, a tank vent stack is installed to help dissipate and exhaust the returning air vapor. The tank vent system incorporates an in-line separator to assist in removing any oil mist from the venting air. A Flame Arrestor is also installed downstream to isolate the separator and oil mist from any external flame source. Major Components: Engine Driven Main Lube Oil Pump ENGINE-DRIVEN MAIN LUBE PUMP A positive displacement pump is installed on the engine’s accessory drive / reduction gear unit and is powered by the turbine engine itself. The pump is sized to supply more oil flow and pressure than needed and thus, requires downstream pressure regulation. The pump may also have a small supply line providing “priming or wetting” oil tapped off the prelube circuit.LO Outline Major Components: Engine Driven Main Lube Oil PumpMajor Components: oil Regulating Valves (PRV) OIL REGULATION VALVES Positioned just downstream of the main engine-driven pump are the individual pressure and temperature control valves. Their function is to control the system pressure and oil temperature to within designed limits. A System Relief Valve is usually installed on the discharge of the main pump. The System Relief Valve is typically set fo 50 psighto protect the system piping from over pressurization. “Tol From Cooler LO OutlineMajor Components: oil Regulating Valves (PRV) Major Components: Pressure Control Valve (PCV) Depending on the engine type, the normal lube system pressure is maintained between|35 and 55 psig|by means of the Pressure Control Valve. The Pressure Control Valve uses a pressure reference tapped off the downstream side of the system filters to ensure the engine and driven equipment receive the proper supply pressure.Tol From Cooler LO Outline Lube PumpMajor Components: Temp Control Valve (TCV) In addition, a thermostatic Temperature Control Valve is provided to limit the temperature of the oil. Similar to the temperature control on an automobile engine, the thermostatic valve will react to temperature changes within the flow stream and force hot oil to a cooler assembly mounted outside the package. Depending on the anticipated cooling needs of the package and the type of oil used, the valve initially bypasses the oil cooler a iyert oil through the cooler at a typical value Tae complete flow through the cooler at 130°F - 150°F. “Tol From Cooler LO Outline Lube PumpLO Outline Lube Pump Major Components: Lube oil Filters LUBE OIL FILTER(S) Either a single (simplex) or dual (duplex) filter arrangement will be installed downstream of the pressure and temperature regulating valves. The function of the filter(s) is to remove any contamination to protect the close-tolerance bearings and meshing gears. The filtering elements are typically rated at S- 10 microns and will be mo! ifferential pressure gage or transmitter usually set at 2 0 indicate when the filter elements need to be changed. For a duplex filter arrangement, a selector valve is installed to direct the oil flow into either filter as desired.LO OutlineLube Oil System Monitoring Lube Oil System Monitoring: Pressure & Temperature As the filtered and regulated oil is distributed throughout the package, it flows through a delivery network of piping. This distribution system is continually monitored for both pressure and temperature. During normal operation, the system pressureLube Oil System Monitoring: Pressure & Temperature Depending on engine model, a lube system pressure exceeding a typical value of between 45 — 65 psig will initiate a high-pressure alarm. Lube Oil System Monitoring: Pressure & Temperature Pressure monitoring setpoints are different during the pre-lube sequence an luring acceleration to operating Spee . ese prelube and acceleration setpoints.s ateri alarm is usually set at 140°F lesson. The system temperature| Eland the high lube|oil temperature shutdown set at] 165°F - 180°F!Major Components: Lube Oil Separator To avoid creating overpressure inside the tank, which would prevent oil from being drained correctly from bearings, with consequent leaks, an extraction system is installed on top of the tank; SEALING AIR LUBE OIL, _- BEARING SEALS BEARING SUPPORT ‘TURBINE SHAFT END LO OutlineMajor Components: Lube Oil Separator Pre/Post Lube Oil System ComponentsPre/Post L.O.S. Components: ac Motor Pump PRE/POST LUBE PUMP AND MOTOR The Pre/Post Lube Oil Pump is normally a positive displacement pump powered by an AC motor. The pump’s function is to provide lubrication to the engine and driven equipment bearings and gearing before the engine is allowed to rotate. Once the engine is operating on its own, and a predefined system pressure is achieved, the Pre/Post Pump is turned off until it is needed later to provide critical bearing area cooling in a post lube mode, once the engine is shut down ind its rotation has stopped. The maximum allowable pre or post lube pressure is typically 15 — 25 psig with an alarm generated if the pressure exceeds this setpoint for more than 15 - 30 seconds. Should a system malfunction occur, the pump’s discharge pressure is protected by a downstream system Relief Valve and is typically set between 12 - 25 psig. “Tol From Cooler LO Outline [Lube PumpPre/Post L.O.S. Components: Ac Motor Pump Pre/Post L.O.S. Components: Pre/Post Lube Pr. Trans PRE/POST LUBE PRESSURE SWITCH / TRANSMITTER Just downstream of the Pre/Post Lube Pump is a dedicated pressure switch or transmitter installed to verify a minimum pressure setting has been achieved, verifying the pump is operating properly.Backup Post Lube Oil System Components Pre/Post L.O.S. Components: Dc Motor Pump BACKUP POST LUBE PUMP AND MOTOR The Backup Post Lube Pump ensures postlube cooling is accomplished even if the Pre/Post Lube Pump becomes inoperable. A DC motor normally drives the Backup Pump so it can perform the critical postlube cooling of the engine even if there is a local power outage. Depending on the engine model, the maximum allowable eos lube oe is typically ereaais this setpoint for more than 15 -30 seconds. Should a system malfunction occur, the pump’s discharge is limited to normally 12 — 25 psig by an external Backup system elief valve. Since it is vital for the Backup Pump to be available for any emergency post lube cycle needs, the pump is operationally checked daily for a brief run period.Tol From Cooler LO OutlinePre/Post L.O.S. Components: Backup Press. Switch BACKUP PRESSURE SWITCH Positioned just downstream of the Backup Pump is a pressure switch or transmitter that monitors for minimum backup system pressure. The switch is usually set for 12 psig increasing and 9 psig decreasing. Its purpose is to verify the pump is functioning properly during its daily run check. Pre/Post L.O.S. Components: Backup Sys. Filter BACKUP SYSTEM FILTER Since the Backup system flowpath bypasses the main filter(s), the supply piping to the turbine engine has its own dedicated 10 micron filter to protect the downstream components.Tol From Cooler LO Outline Lube Pump Lube Oil Drains Once the oil has lubricated and cooled the engine and driven equipment bearings and gearing, the oil is returned to the oil tank by a series of gravity-assisted drain lines. These drain lines will usually have a temperature sensor at each engine drain location to monitor the returning oil temperature. Any high temperature reading may indicate either restricted oil flow or a potential bearing problem. On some units, the drain temperature monitoring is a function of tracking the differential between lube oil supply temperature and drain temperatures. In addition, a sight glass may be provided at each drain to visually verify drainage flow.LO Outline Lube Oil Sequence of OperationLube Oil Sequence of Operation: Pre Lube checks PRE CRANK — PUMP CHECKS & PRELUBE PERIOD Once a start command has been received, the control system begins a pump check sequence by first turning on the Backup ostlube Pump. The Backup Pump must achieve a minimum pressure within a specified period of time — typically, at least -8 psig within 15- 30 seconds Lube Oil Sequence of Operation: pre Lube checks PRELUBE LUBE OIL PUMP CHE BEGIN. PAGKAG! E BACKUP. LUBE OL_PUM ENERGIZE PRE /POST CUB START OR ENERGIZE BACKUPLube Oil Sequence of Operation: pre Lube checks Once the pressure is sensed, the Backup Pump is turned off and the Pre/Post Lube Pump is switched on. The Pre/Post Lube Pump must now achieve its own minimum pressure (typically 6-8 psig) within a specified time period of being turned on. Lube Oil Sequence of Operation: pre Lube checks URE SETPOIN IME BELUBE LUBE OL PUMP CHEK COMPLETE BEGIN: PACKAGE E BACKUP LUBE lL. PUMP PRESSURE DROP COMPLETE, ENERG ZE PRE/POST LUBE OIL PUMA START OR TEST ORANC Ri K_REQUES ENERGIZE BACKUP LUBE OIL PUNLube Oil Sequence of Operation: Pre Lube checks Once the minimum Pre/Post pump pressure is achieved, a typical 30-second Prelube Period begins. During this time, the prelube system pressure must be maintained at, or above, a specified amount (for example, 8 psig) ensuring sufficient bearing lubrication before rotation is permitted. Also at this time, the Jacking Oil pump is energized supplying oil pressure to the Generator bearings to lessen the breakaway torque needed for initial rotation. Lube Oil Sequence of Operation ENGINE STARTUP AND ACCELERATION Once the prelube permissive has been met, the Pre/Post Lube Pump will remain on as the turbine engine begins its rotation. During engine acceleration and up through 90% Ngp, the lube system must follow a prescribed min/max pressure schedule (see Figure 4.4). If system pressures fall outside these limits, Alarms and/or Shutdowns will be initiated. These pressure levels should be easily achieved with both the Pre/Post Lube Pump, and the now accelerating Engine-Driven Pump, supplying oil to the distribution manifold. The Jacking Oil system will be commanded to turn off once the engine speed has achieved approximately 8-10% Ngp.Lube Oil Sequence of Operation: start-up s acceleration a aot |_| | - NY BTATE OPERATING RANGE. 350 : } — g m0 | _ 26 psig gy a |__| _{__j | j|— 5 0 LOW LUBE|OIL Delayed cn Pressure unit ['45s9] 7 shutdown — £ 18 p39 ‘5s maximum 150 7 hd [s psig Unfired Rundi 100 t 1 50 Bearing Inspettion Required ~ 00 * o 0 2 » @ © © 7m 8% 9 100 GAS TURBINE SPEED, % of Rated ‘me an woone one Lube Oil Sequence of Operation: seirsustainspeed& Norm. oP ENGINE SELF-SUSTAINING OPERATION At Starter Dropout speed (60 - 75% Ngp), the Pre/Post Lube Pump is shut down as long as system pressure is above a predetermined setting — usually 25-28 psig.Lube Oil Sequence of Operation: seirsustainspeeds worm. oP | If, during normal operation, the system pressure drops below at preset level|(usually 27 psig)} an alarm will sound. If the e continues to drop below the typical shutdown oint of 25 the Pre/Post Lube Pump is turned on 5 second delay timer}will begin timing. If the pressure still below the setpoint after the time delay, a fast stop package shutdown will be initiated and Pre/Post Lube Pump will complete its normal postlube duties. Ss Lube Oil Sequence of Operation: seirsustainspeed& Norm. oP If the s stem ressure ever drops Coe alt pical palue) of 15Lube Oil Sequence of Operation: seirsustainspeeds worm. oP Depending on engine model, if the lube system pressure drops clow_ 4 value between 4 — 8 psig}while the engine and driven lequipment are still rotating, a shutdown will be annunciated indicating that the equipment bearings may have been damaged| and require inspection. \ ly * 7 Lube Oil Sequence of Operation: seirsustainspeed« Norm. oP During normal operation, a|High Pressure} alarm will be annunciated if the system pressure ever exceeds a iff pressure ) for more than 15 - 30 secon (ALERT @ N aLube Oil Sequence of Operation: saisustainspeeds norm. oP This is to ensure that excessive pressure does not damage the system components or force lube oil across the engine labyrinth seals, which may contaminate the engine’s air pathways and thereby, reduce its efficiency. Also during normal package operation, the oil temperature control valve, working in conjunction with the oil cooler, maintains oil temperature. Total system flow is directed through the cooler anytime system temperature is above 110°F - 130°F. System high temperature alarm settings hre usually between{I35°F -] 155°F hind the ¢hutdown between 160°F - 185°F| Lube Oil Sequence of Operation: run cHecks BACKUP PUMP PERIODIC RUN CHECKS every 24 hours at a preset time. If the Backup Pump does not achieve a minimum setpoint pressure, usually 12 psig within 30 seconds, the pump is shutdown and a Backup Pump Check Fail alarm is annunciated. As long as the pump produces the preset pressure for its prescribed time period, the pump is shutdown and the test is considered successful. An operator can also initiate this pump run test manually, at any time. The identical pressure and time requirements must be met as described in the auto pump check sequence just mentioned.Lube Oil Sequence of Operation: post tube cycle POSTLUBE CYCLE (After Ignition) Once the control system initiates a shutdown command, the fuel is turned off and the engine begins to coast down in speed. During this time, the engine-driven pump is still supplying system pressure. Once the engine speed drops below starter dropout speed, or if system pressure drops below 25 psig, the AC Pre/Post Lube Pump is then activated. When the Run Down Timer expires, signifying that the engine and driven equipment are no longer rotating, the Postlube timer takes over to maintain the Pre/Post Lube Pump operation for the duration of the postlube period. Lube Oil Sequence of Operation: post tube cycle BACKUP POSTLUBE CYCLE If system pressure ever drops below 4 psig during the post lube period, the DC Backup Postlube Pump will turn on to continue the cooling process. To conserve DC power, the pump will run continuously for a period of | hour, and then cycle off for a period (9 % minutes) and then back on for a period (2 ¥2 minutes) and continue this on/off cycle until the full postlube period expires. Note that the DC Backup Pum is of much lower capacity than the AC Pre/Post Lube Pump. Since the function of the oil during the postlube is cooling, the oil delivered from this pump is| {hot engine bearings (2 F3}]and sometimes to the driven equipment.Lube Oil Sequence of Operation: post tube cycle POSTLUBE CYCLE (Fire Detected) If a fire has been detected, the engine will automat shutdown and the standard coast-down postlube commence. However, once the Run Down Timer has expired, the postlube proces: halted for 10 minutes to avoid the possibility of a ruptured or leaking lube oil line fueling the fire. After this prescribed delay, the control system turns the jutes, a shutdown annunciation will indicate that the gs may require inspection, and a package start will be ed for a period of 12 hours to allow the equipment to ool down, Lube Oil System Potential MalfunctionsLube Oil System Potential Malfunctions The following table lists potential sequential or operational malfunctions associated with the Direct AC Start System. Although general hints on possible causes have been provided, adherence to a methodical troubleshooting proc strongly recommended when investigating turbomachinery problems. Lube Oil System Potential Malfunctions Malfunction Description ‘Typical Causes: Lube Oil Header Lube Oil Header RTD fo) GaoteriGustmctsn /(Gontamanated| Temperature High reading above its alarm setting or higher Fan / Motor Faulty + Malfunctioning Thermal Valve + Faulty / Out of Calibration RTDLube Oil System Potential Malfunctions Malfunction Description ‘Typical Causes Lube Oil Header Header Pressure Falls to Engine-Driven Pump Malfunction Pressure Low alarm or shutdown levels, idea opeciton Distribution Line Rupture / Leak Malfunctioning Regulator / Pressure Control Valve Faulty / Out of Calibration Switch / Transmitter Lube Oil System Potential Malfunctions Malfunction ‘Typical Causes Lube Oil Tank Level Low | Tank Level Sensors reading |* Need to Add Lube Oil to Tank less than normal + Faulty Seals within Engine or Driven Equipment + Distribution Line Rupture / Leak + Faulty / Out of Calibration Level Switch / TransmitterLube Oil System Potential Malfunctions Malfunction Description ‘Typical Causes Pre/Post Lube Pump | Pump discharge pressure |* AC Motor Problem / PD Pump Fail does not reach required Malfunction increasing pressure setting during Pump Check or drops below the decreasing | . Faulty / Out of Calibration Press. Switch + Faulty Pre/Post Relief Valve pressure setting for more 7 Tranembior than the allowable time during Post Lube + Discharge Line Rupture / Leak Lube Oil System Potential Malfunctions Malfunction Description ‘Typical Causes Backup Lube Oil Pump | Backup Pump commanded DC Motor Problem / PD Pump Fail ON but either Header Malfunction Pressure does not reach minimum pressure (typically Speld) ocdedieated Backup Faulty / Out of Calibration Press. Switch Pump pressure switch does | Transmitter not transfer within 15-30 seconds Discharge Line Rupture / Leak Faulty Backup Relief Valve