] LUBE OIL FLUSHING PROCEDURE FOR | PS?:1G& TC 202 | STEAM TURBINE SETS ry me 23-01-2020. | BHARAT HEAVY ELECTRICALS LIMITED Ramachandrapuram, Hyderabad-32 Lube Oil Flushing Procedure for Steam Turbine Sets RefNo :ESP:TG& TC 202 Rev : Date :23-01-2020 Prepared by, Reviewed by, ‘Approved by, E eS o ‘ae SUSTLE DLPATANGE | | a ae etka afieel ton ikea il open) at Os 7 DGM J Compressor wie, Gre BH se Rey_| Date Remarks 01 [30-11-2010 Updated as per machine requirement. 02 [07-07-2018 |i, Updated as per feedbacks from system engineering ii, JOP system added | ISSUED BY: EXTERNAL SERVICES DEPARTMENT— “| LUBE OIL FLUSHING PROCEDURE FOR Everio 202 STEAM TURBINE SETS Sear yioaa aaa SNo Description Page no, de General 3 TL. Introduction z I. Flushing Oil 3 IV. Objective 3 V. Flushing operation a VI. System Readiness 4 VII. Services/Consumables required 5 Vill. Stages in Flushing 6 VIILA. Main supply header & Barring Gear header 6 VIILB. Governing header & OHT 8 VIILC. Individual bearing inlets, Gear Box & EOP discharge line 10 VIILD. Through bearings & Gearbox 11 VIILE. Governing system flushing 13 VIILF. Jacking oil flushing 14 Ix. Completion Criteria 15 Annexure-1: Check list 16 Annexure-2:Lube oil flushing Protocol 18 Legends: ‘MOT: Main Oil Tank MOP: Main Oil Pump AOP: Auxiliary Oil Pump smergency Oil Pump PCV: Pressure Control Valve. TCV: Temperature Control Valve Non Return Valve GB: Gear Box OHT: Over Head Tank MOV: Motor operated valve JOP: Jacking oil pump NAS: National aerospace standards ‘Mg- Main supply header D- Drain header J- Journal bearings ‘T- Thrust bearing B-Barring gear header G- Governing header F-Suction strainer Ov-Overflow of OHT S-Supply line DOT: Drain oil tank ‘Mesh sizes: Mesh no. vs micron size (ref: ASTM standards) Mesh no. 40=~420 microns Mesh no. 60=~250 microns Mesh no. 80 = ~180 microns Mesh no. 100=~150 microns Mesh no. 120=~125 microns Mesh no, 140 =~100 microns ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR | =SP:1G& TC 202 WITTE Page 3 of 19 STEAM TURBINE SETS REV.-03, DT 23-01-2020. |. GENERAL The lube oil flushing procedure and respective protocol are the guidelines for carrying out lube oil flushing activity at site. This documented procedure has the following objectives: © To assist and ensure all the activities are in line with BHEL standards ‘Joint inspection (i.e. by BHEL and customer representatives). * Confirmation of adherence to the available procedure/check list/protocols. Il. INTRODUCTION After completion of fabrication and installation of pipelines, flushing of oil system thoroughly, in order to eliminate all the contaminants, which have been entered into the oil system during erection activities. Carry out oil flushing to ensure that the oil system transports no foreign materials such as scales, sand, weld splatter particles, cutting chips & welding slags which are dangerous to the turbo set during regular operation. During oil flushing, high velocity oil flow in the lines can be achieved by temporarily removing the throttling points in the lube oil circuit such that drain oil pipe is ~2/3 full. This high velocity along with the thermal shocks will help in dislodging the foreign particles adhering to the pipe walls and weld joints. Ill. FLUSHING OIL, Oil system should be flushed with the same type of oil employed for normal turbine ‘operation'. il quantity required for flushing is approximately ~60% to 70% of full charge capacity. However, ensure oil pumps should not starve for oil at its suction, during flushing. Accordingly, maintain the tank level and record the same at regular intervals. If found below the min. level, top up the oil to maintain the min, level in the tank. Note: '- Ensure the oil quality to be NAS 6 for flushing operation. Adopt any of the cleaning procedure to achieve the NAS value IV. OBJECTIVE Remove harmful contaminants (like water, rust, loose scale, weld slag, sand, dirt and oil) from the lube oil system prior to commissioning thereby keeping the rotating & hydraulic equipment operating at peak performance; significantly reducing the potential of premature failure. IPTION Oil flushing operation, should be carried out in different stages to increase the flow and flow velocity. The same are described in section-VIIL. In centrifugal pumps', initially the pump discharge valve shall be in closed condition, After switching ON the pump, gradually open the same to maintain sufficient flow in the lines. Monitor pump motor current and if it rises above the rated current, throttle the pump discharge valve. In positive displacement pumps!, open pump discharge and recirculation valves fully in the line before switching ON the pump. ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR | PSP-TG& TC 202 Pe 4o0f19 STEAM TURBINE SETS Be ee ota Attend all the leakages found (if any) in the oil system before continuous flushing operation. Introduce a bucket/plate type strainer with required mesh number in the return header to the MOT & ensure 60 mesh element in pump suction strainer; clean the same at regular intervals uring the entire flushing operation Thorough cleaning of the pipes is achieved by employing thermal shocks during flushing operation. While in circulation, heat? the oil to 68-70° C? and circulate the same for 30 minutes. Then cool the oil rapidly by full opening the cooling water inlet valve to oil coolers to drop the il temperature to ~30-35 °C? (~ambient temp.). Repeat this procedure of thermal shock cycle, uring the entire process of flushing operation until the mesh screens obtained clean, Ensure all the pipes become hot during circulation or thermal cycles. If any pipe found cold, inspect the same for flow restriction and attend the same. Tapping/knocking with a wooden hammer or usage of a vibrator on the pipes (mainly on fittings & weld joints) on completion of thermal shock further improves the dislodgement of adhered materials from the pipe walls. Put in service oil centrifuge during entire oil flushing operation as a means of purification and heating source. Note: '- Perform priming of lube oil system before start of pumps. 2. Ensure not to raise the oil temperature beyond 85 °C as higher temperatures may alter the oil properties. +.measure and record the oil temperature in the MOT. ‘TEM READINESS: a, Readiness of MCC with all protections for all the lube oil pumps. b. Alloil pumps made ready in all aspects (including local & remote access). c. For turbine driven MOP, recommended to interconnect AOP discharge line to MOP discharge line before isolation valve to facilitate flushing operation. 4. Ensure all the system relevant erection work should be complete as per approved drawings (Lube oil & Jacking oil P&ID). e. Fabrication of permanent drain lines (1/2" or 3/4") with double isolation valve or single isolation valve with blind flange or plug: i, Lube oil header after NRV ii, Governing supply line after NRV Main drain header before bucket filter f. Cleaning of DOT, MOT, duplex filters & OHT! and shall be inspected by M/s. BHEL engineer before taking into the service. g. Hydro testing of all the oil supply pipelines at required pressure before start of flushing operation (availability of test report). h, Cardboard blasting of the all the pipelines” before start of oil flushing at a pressure of ~Skg/em?-g. For lines less than 2”, clean the same with air or LP dry steam. Assembly and commissioning of centrifuge. Readiness of oil vapor exhaust fans on MOT. Availability of cooling water supply” to oil coolers. ‘Weave mesh no. 60 (250 microns) in the suction strainers of MOP, AOP & EOP. Install 40-micron flushing filter elements in Duplex filter (supplied by M/s. BHEL~ Hyd) after mesh no.60 screen found clean in every stage. gorwte ISSUED BY: EXTERNAL SERVICES DEPARTMENT.Ciceaue F LUBE OIL FLUSHING PROCEDURE FOR Seca 202 TT STEAM TURBINE SETS i oe at n, Bucket or plate type arrangement to install. mesh screens in main drain header during entire flushing operation. ©. Charging of recommended oil in the MOT through centrifuge or oil filtration unit p. Jump-overs/temporary loops/hoses & blinds made available as per the flushing stage. 4. Removal all the flow: devices (control valves, MOV’s, NRV’s, flow orifices) and install spool pipes. Do not disturb the NRVs in the pump discharge. 1. Availability of dry steam or instrument air to blow the pipe components, which are not flushed during flushing operation. s. For heating of oil to 65-70° C one or more of the following extemal heating sources? should be made available (other than BHEL scope of supply): i. Electric heater in MOT (only after ensuring sufficient oil level in the MOT recommended by the heater OEM so that the heating zone of the coil remains immersed in oil) ii, Wrapping SR coils (coil temperature‘) on oil pipes. iii, Using steam coils inside MOT (preferably LP dry steam). iv. Hot water supply to oil coolers. t. All the vents of Oil cooler shall be provided and kept in open condition. u. Disconnect oil supply pipelines to the bearings and interconnect the same with respective drain lines as per the stage of flushing, v. Ensure all the lines (including temporary loops) properly supported. ww. All the adjustable orifices in the flushing oil circuit kept full open. Remove fixed orifice (ifany) present in the line. x. Install instruments associated with the MOT, pumps and temperature gauges before & afier cooler (as per annexure-1). ‘Note-'- OT should be isolated during the entire flushing operation. The same shall be thoroughly cleaned and Jointly inspected before taking in normal operation (to be charged before barring operation) % Quality of cooling water should bein line with oil coolers data sheet. + Heating source should be in service onty when lube oil is in circulation. + Recommended to wrap the SR coil on the lines between coolers to filter. Do not rise coil temperature beyond 200° C. VII. SERVICES/CONSUMABLES REQUIRED: a, Trial run of oil pump motor (MOP, AOP & AC JOP) on no load for 4 hours. b. Availability of sufficient lube oil during flushing operation c. Availability of following tools, tackles & consumables for flushing: ‘© Filter meshes of required size (mesh no. 40, 60, 80, 100, 120 & 140), ‘+ Kerosene / Diesel/Petrol or its equivalent. © Mark-in cloth (cotton waste not be used). * Permanent magnet (2no.) © Oil gaskets (non-asbestos sheet)/Teflon sheet * Tools and tackles as per requirement. 4, Availability of instrument air. Infrared temperature measuring instrument. SR coil for wrapping on pipes. ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR | pon fOr TEAM TURBINE SETS REV.-03, DT 23-01-2020. VIII. STAGES IN FLUSHIN' To ensure full flow with high velocity within different sections of lube oil lines, carry out the flushing operation in various stages as represented below: 2po0l during Mushin MoT Fig. 1: Lube oil system block VIIA. Stage 1: Main supply header & Barring Gear header VIILB. Stage 2: Governing System & OHT supply and overflow lines VIII.C. Stage 3: Individual bearing inlets, Gear Box & EOP VIILD. Stage 4: Through bearings & Gearbox. VIILE. Stage 5: Governing system flushing, VIILF. Stage 6: Jacking oil system. VIII.A. Stage 1: - MAIN HEADER & BARRING GEAR HEADER: a, System requirements: i, Both the lube oil pumps taken in service alternately every 12 hours. ii, Provide inter-connecting line (hose or temporary pipe) of minimum 80% supply header size between Ms' to D & B to D. iii, Blind the following lines: * Governing header * Close the isolation valve in OHT supply line & place dummy plate in orifice. # Individual bearing supply lines. ISSUED BY: EXTERNAL SERVICES DEPARTMENTA LUBE OIL FLUSHING PROCEDURE FOR Dae ea iT STEAM TURBINE SETS env ebsyT.23°01-0020 iv. A bucket/plate type arrangement with mesh screens installed in the drain header. ¥. Install spool piece of the same size by removing MOY present in barring gear header and PCV in the downstream of filter. vi. Throttle the pump discharge valve to maintain a min. of 3.0 to 5.0 kg/em?-g, Remove end connect a spool re ' sate , Bucket et pypiace wih 1 ibe on T= spool piece | cv ier Lube ot aL cas MOT Lube oi mv Pumps (a0P & MoP) Fig. 2 Block diagram for Stage 1 b. Procedure: i, Inthis stage, flushing for M, to D and B to D shall be carried Interconnect both the lines (Ms to D & B to D) with a clean temporary loop/ flexible hose as shown in fig. 2. Initially, blind the barring gear line Start the oil pump and check the system for oil leakages. If found any, attend the same immediately. iv. Afier attending the leakages, circulate the oil in the system without mesh screens and flushing filter element in duplex filter for 60-72 hours. v. Place screens of mesh no.40 in the drain header to MOT and make the system ready for thermal shocks. vi. Raise the oil temperature to ~70° C while in circulation. After attaining the ‘temperature, circulate the hot oil for 30 min. vii. Full throttle of cooling water lines of oil coolers for rapid cooling (5-8 min) of oil to ~30-35° C. Take both the oil coolers in service by interchanging every 12 hours (record temp. drop vs time taken). viii. Changeover both the lube oil pumps (MOP/AOP) every 12 hours. ix, Progressively replace the 40 no. mesh screen with 60, 80, 100, 120 & 140 no. meshes once found clean. x, Install flushing filter element in duplex filter after mesh no.60 found clean. xi, Changeover and clean the filters of the oil circuit frequently as DP across the filter is equals 1.5 kg/em?-g. ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR | 55)°)68 10202 age 8 of 19 STEAM TURBINE SETS REV.-03, DT 23-01-2020 xii, Continue thermal shocks until all the mesh no, 140 screens provided in the lines found clean without any slag or dust particles. xiii, Once the M, comes out clean, interconnect the B ~ D & proceed to barring gear line flushing xiv. Isolate the Ms by closing the temporary isolation and continue the flushing in B line until the temperature raises to ~70° C. xv. Continue flushing of B? with thermal shocks as mentioned above. xvi. On inspection and evaluation of all the 140 no. mesh screens provided in the line with minimum of two thermal shocks in oil circulation cycle time of 12 hours, proceed to Stage-2 flushing. c. Normalization: i, Disconnect the interconnecting pipes & normalize the following: ¢MstoD *BtoD ii, Install MOV in B. ‘Note-'- Inter-connect lube oil header accumulator line to drain header during M, to D. 2. Lube oil coolers are not in barring gear supply line. Hence, to cool the oil rapidly, temporary isolation valve provided in the temporary loop of M, to D shall be open. VIILB. Stage 2: - GOVERNING SYSTEM & OHT: |. System requirements: i. Remove NRV of G. G and S$ connected to D & Oy! respectively. ii. Blind the following lines: © Main supply line & Drain end flanges Individual bearing supply and drain headers Barring gear header iii, Interconnecting of servomotor inlet and its drain. iv. Interconnecting of governing accumulator inlet to drain. v. A bucket/plate type arrangement with mesh screens installed in the drain header. vi. Throttle the pump discharge valve to maintain a min, of 3-5 kg/em*-g. b. Procedure: i. In this stage, flushing for Governing system and OHTT line shall be carried out. Interconnect G to D & S to Oy independently. Initially, blind the G. i, Start the oil pump and check the system for oil leakages. If found any, attend the same immediately. iv. After attending the leakages, circulate the oil in the system without mesh screens and flushing filter elements in duplex filter for 40-48 hours. y. Place screens of mesh no.40 in drain header to MOT and make the system ready for thermal shocks. vi. Raise the oil temperature to ~70° C while in circulation. After attaining the temperature, circulate the hot oil for 30 min, ISSUED BY; EXTERNAL SERVICES DEPARTMENTe é a ESP:TG& TC 202 LUBE OIL FLUSHING PROCEDURE FOR Page 9 of 19 STEAM TURBINE SETS | REV.-03, DT 23-01-2020. vii, Pull throttle of cooling water lines of oil coolers for rapid cooling (5-8 min) of oil to ~30-35° C. Take both the oil coolers in service by interchanging every 12 hours (record temp. drop vs time taken). viii, Changeover both the lube oil pumps (MOP/AOP) every 12 hours. - PL -- he 9 TT > be t a @ To Governing Fitre i Remove NRY MoT Lube of nA Pumps (AP & HOP) 3: Block diagram of Stage 2 ix. Progressively replace the 40 no. mesh screen with 60, 80, 100, 120 & 140 no. meshes once found clean x. Install flushing filter element in duplex filter after mesh no.60 found clean. xi, Changeover and clean the filters of the oil circuit frequently as DP across the filter is equals 1.5 kg/em?-g. xii, Continue thermal shocks until all the mesh no. 140 screens provided in the lines found clean without any slag or dust particles. xiii. Full open the isolation valve in G and close the isolation valve of OHT. xiv. Continue flushing as mentioned above. During thermal shock cycle, open the isolation valve? of the OHT for rapid cooling. ISSUED BY: EXTERNAL SERVICES DEPARTMENT= con | LUBE OIL FLUSHING PROCEDURE FOR ype iveelb at re STEAM TURBINE SET: REV_-03, DT 23-01-2020. xv. On inspection and evaluation of all the 140 no, mesh screens provided in the line with minimum of two thermal shocks in oil circulation cycle time of 12 hours, proceed to Stage-3 flushing ¢. Normalization: i. Disconnect the interconnecting pipes between the following: #8100, *GtoD ii, Place blind in the S & Ov. iii, Install NRV in G. Note: '= For compressor sets, ovo overflow lines are provided in OHT. Both the lines are to be taken for flushing ane ata time 2 Lube oil coolers are not in governing supply line. Hence, 10 cool the oil rapidly, OHT valve shail be opened. VIIL.C. Stage 3: - INDIVIDUAL BEARING INLETS, GEAR BOX & EO} a, System requirements: i, Individual bearings (all Js & T) and GB supply lines connected to respective D. ii, Blind the following lines: ‘* Governing header (G) « Barring gear header (B) * ONT (S) & (Oy) line. iii, Full open adjustable orifice in the bearing inlets and remove adjustable orifice in GB inlet. iv. A bucket/plate type arrangement with mesh screens installed in the drain header y. Install flow glass in individual bearing drain lines. b. Procedure: i. In this stage, flushing for J, T & GB to resp. D as shown in the fig. 4 ii, Interconnect the following lines with temporary loop/hose to respective D independently. # Individual journal bearing supply to respective drain. + Thrust bearing supply to respective drain. © GB supply to respective drain. iii, Initially place blind in the GB supply line. iv, Start the oil pump and check the system for oil leakages. If found any, attend the same immediately. vy. After attending the leakages, circulate the oil in the system without mesh screens and flushing filter element in duplex filter for 40-48 hours. vi. Place screens of mesh no.40 in drain header to MOT make the system ready for thermal shocks. vii. Raise the oil temperature to ~70°C while in circulation. After attaining the temperature, circulate the hot oil for 30 min. ISSUED BY: EXTERNAL SERVICES DEPARTMENTESP:TG& TC 202 LUBE OIL FLUSHING PROCEDURE FOR Page 11 of 19 STEAM TURBINE SETS REV-03, DT23-01-2020. fs tt HOP my cor Labeott Pomp ‘J-Joumal bearing GB. Gearbox T-Thwustbearing MOP BMOP) Fig. 4: Block diagram of Stage 3 viii, Full throttle of cooling water lines of oil coolers for rapid cooling (5-8 min) of oil to ~30-35° C. Take both the oil coolers in service by interchanging every 12 hours (record temp. drop vs time taken), ix. Changeover both the lube oil pumps every 12 hours x, Progressively replace the 40 no. mesh screen with 60, 80, 100, 120 & 140 no. meshes once found clean. Install flushing filter element in the filters after mesh no.60 found clean. Changeover and clean the filters of the oil circuit frequently as DP across the filter is equals 1.5 kg/cm?-g. xifi, Continue thermal shocks until all mesh no. 140 screens provided in the lines found clean without any slag or dust particles. xiv. Remove blind in the gearbox. xv. Place 100 no, mesh screen & full close the adjustable orifice in bearing supply lines. xvi. Continue flushing of GB as mentioned above. xvii, On inspection and evaluation of all the 140 no. mesh screens provided in the line with minimum of two thermal shocks in oil circulation cycle time of 12 hours, stop MOP/AOP and proceed to EOP discharge line flushing xviii. Switch ON EOP and circulate the oil with mesh screen (mesh no. 60, 80, 100, 120 & 140) in bucket filter of the drain header. xix. On inspection and evaluation of all the 140 no. mesh screens provided in the drain header after 12 hours oil circulation, proceed to Stage 4 flushing, VIILD. Stage 4:- THROUGH BEARINGS! AND GEARBOX (FRESH OIL): a, System requirements: i, Drain out the flushed oil completely from the following: # Lube oil reservoir (MOT) ISSUED RY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR Pee obs a STEAM TURBINE SETS | REV.03, DT 23-01-2000, | vii viii i ii iii vii ix, ii, iti, iv. vie xi, iv. vi. Vii. Drain oil tank ‘© Oil trapped in the lube oil lines # Lube oil coolers Lube oil filters Clean & inspect MOT, DOT & OHT thoroughly. Connect all the inlet and drain lines to respective individual bearing housings & ‘gearbox as per “Lube oil P&ID”. Remove the filter element and clean the filter assembly thoroughly. Charge fresh oil in the MOT through centrifuge or filtration unit. Blind the following lines: * Governing header « Barring gear + OHT « All the instrument point on all the bearing housings. Removal of thrust bearing assembly and all the journal bearings top half. ‘Thoroughly clean all the bearing housings and reassemble the same. Install mesh no. 100 screens in all the bearing and gearbox inlets. Throttle all adjustable orifices in the bearing inlet lines and gear box to maintain ~2kglem?-g. ‘A bucket/flange type arrangement with mesh screens installed in the drain header. Procedure: In this stage, flushing through individual bearing and gearbox. Place screens of mesh no.100 mesh in the bearings and gearbox supply lines and make the system ready for thermal shocks. Install flushing filter element. After attending the leakages, circulate the oil in the system for 24-36 hours without thermal shocks. Raise the oil temperature to ~70°C while in circulation, After attaining the temperature, circulate the hot oil for 30 min. Fall throttle of cooling water lines of oil coolers for rapid cooling (5-8 min) of oil to ~30-35° C. Take both the oil coolers in service by interchanging every 12 hours (record temp. drop vs time taken). Changeover both the lube oil pumps every 12 hours. Changeover and clean the filters of the oil circuit frequently as DP across the filter is equals 1.5 kg/em?-g. Progressively replace the 40 no. mesh screen with 60, 80, 100, 120 & 140 no. mesh once found cle: Continue thermal shocks until all mesh no. 140 screens provided in the lines found clean without any slag or dust particles. ISSUED BY: EXTERNAL SERVICES DEPARTMENT; + ‘G& TC 202 LUBE OIL FLUSHING PROCEDURE FOR Page 13 of 19 STEAM TURBINE SETS. REV.-03, DT 23-01-2020. xi. On inspection and evaluation of all the 140 no. mesh screens provided in the line with min. of two thermal shocks in oil circulation cycle time of 12 hours, proceed to Stage-5 flushing. Note: - ! -For compressor sets, oil is admitted to compressor bearings only after the DGS installation and charging of barrier seals. ¢. Normalization: i, Check and inspect all bearings & dead ends of pipelines for cleanliness. ii, Remove all the blinds and screen meshes except for bearing inlets*. iii, Replace the flushing filter element (40 microns) with the normal operating filter element (10 microns). iv, Remove all the spool pieces and install the respective PCV's & NRV’s as per the drawing after manual cleaning. v. Install the following as per the drawing: ‘* Adjustable orifices * Fixed orifice (if any) Note:- * remove the mesh screens at bearing inlets before putting machine on barring gear operation. VIILE. Stage 5: - GOVERNING SYSTEM (FRESH OIL): a, System requirements: i, All piping to be air blown prior to flushing. ii, Installation of NRV after thorough cleaning in the governing header. iii, Remove VH converter along with the O-rings in the governing console & replace it with the flushing plate along with gasket. iv, Remove servomotor internals. v. Keep the hand tripping device lever in latched condition. vi. Energize trip solenoids or reverse direction to admit oil into the skid. vii, Close all the gauge drains. viii, Fabricate a common header for ESV lines (Start up, trip oil, tester oil and drain). ix. Replace damping devise in the secondary oil line with spool pipe of same dia. x. Install 10-12 mm orifice plate in the control oil inlet to servomotor before flexible hose connection. xi, Ensure governing filter element in service. b. Procedure: i. Start the pump; slowly admit the oil into the governing console by throttling the isolation valve of governing header. ii, After attending the leakages, circulate the oil in the system for 12-18 hours without mesh screens iii, Place sereens of mesh no. 60 in the drain line from Servomotor. iv. Start the oil circulation, v. Progressively the same can be replaced with 80, 100, 120 & 140 no meshes ISSUED BY: EXTERNAL SERVICES DEPARTMENTCorer ron) LUBE OIL FLUSHING PROCEDURE FOR | po 10 Srig Te STEAM TURBINE SETS REV_03, DT 23-01-2020. vi, Slowly raise the oil temperature to 70°C while in circulation. After attaining the temperature, circulate the hot oil for 30 min. Allow oil to cool to ambient temperature by switching OFF the heating arrangement. vii. Tap the lines with mallet hammer. viii, Changeover both the lube oil pumps every 12 hours. ix, Progressively replace the 60 no. mesh screen with 0, 100, 120 & 140 no. meshes once found clean. x. On inspection and evaluation of all the 140 no, mesh screens provided in the line with minimum of two thermal shocks in oil circulation cycle time of 12 hours, proceed to Stage-6 flushing. ¢. Normalization’ i. Remove the flushing plate and install I/H converter. ii, Replace the duplex filter elements of the console. iii, Trip lever to be disengaged. iv. Assembly the servomotor intemals. v. Connect ESV oil lines. vi, Install damping device in the secondary oil inlet to servomotor. vii. Remove orifice plate in control oil inlet to servomotor. VIILF, Stage 6:- JACKING OIL SYSTEM (FRESH OIL): a. System requirement: i, JOP suction line! from lube oil tank and suction tapping after lube oil filter shall be cleaned with steam blowing. ii, Hydro test of all the lines. iii, Readiness of both the jacking oil pumps (both AC & DC) iv. Full open all the PRVs. y. Disconnect all individual flexible hoses connections to bearings and release in the bearing housing internally. vi. Full open all the needle valves in the inlet to bearings. vii. Keep the strainer and suction isolation valves full open b. Procedure: i, Line up the suction line from MOT/ after lube oil filter. Start the pump and check for high-pressure leakage. | iii. Regulate the flow to each bearing inlet lines individually by throttling respective needle valves. | iv. Circulate the oil through each line for I hour. vy. Altemately, change over the pumps (if any) every 2 hours. c. Normalization: i, Clean the suction filter & strainer of the JOP. ii, Connect the flexible hose to respective journal bearings. Note: '- Confirm the oil purity o NAS 7 before connecting suction o JOP from MOT to avoid pump failure. ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR me seis a STEAM TURBINE SETS REV.-03, DT 23-01-2020. IX. COMPLETION CRITERIA: a. Visual inspection (in day light illumination) of the mesh screens made to verify system cleanliness. b. On inspection and evaluation of all the 140 no. mesh screens provided in the line with minimum of two thermal shocks in a cycle time of 12 hours. The system shall be considered clean when no foreign particles such as scale, rust, metal shavings, and sand are visible to the naked eye and grittiness is not detectable to touch. ¢. Oil contamination should be as per NAS 7 or its equivalent. Attach test report with flushing protocol. * Do not use the oil used in flushing for regular operation. * All the hoses, temporary loop fitings and its support is out of Mis. BHEL-Hyd supply scope, shall be arranged by ereetion agency: + External heating sources are not in Mis. BHEL-Hyd scope, shall be arranged by external agency. ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR STEAM TURBINE SETS ESP:TG& TC 202 Page 16 of 19 REV.-03, DT 23-01-2020. Annexure-1: Check list SNo. Activity Description Remarks Cleaning of MOT before charging of oil for flushing MOP, AOP & EOP no load run for 4 hours through MCC MOP, AOP & EOP alignment & couple run Centrifuge assembly and commissioning al ale} o[= Fabrication of drain lines (1/2" or 3/4") with isolation valve: a._| Main drain header before bucket filter b. | Governing supply line downstream of NRV c. | Lube oil header after NRV Cardboard blasting of the lube lines 2” & above Fabrication of jump-overs/temporary spool pieces/flexible hose ‘a._| Main Supply header to drain header Individual bearing supply to respective drains ‘Barring gear header to drain Gear box supply to drain Governing header to drain plelalels [OHT supply to overflow line g. | Accumulator’ supply to drain header/MOT Installation of bucket/plate filter with 40 mesh in drain header near MOT MOV5, PCV and TCV to be dropped and accordingly install spool piece for effective flushing of the line 10 Charging of MOT through centrifuge only (min 60% of charged capacity) 1 Installation of flushing filters (40 micron) in filters 12 MOT heater to be taken in line for thermal shocks B Coolers to be commissioned and taken inline 14 ‘Accumulators to be isolated (both lube oil and governing sys) 15, Bellows in the lube lines to be provided with rigid supports 16 Governing system to be isolated 7 Fabrication of supply from MOT and filters to JOP as per the Jacking oil P&ID 18 Flushing to be done in stages as mentioned in the procedure: Stage! _| Supply header & BG supply to respective drain Stage II_ | Governing header & OAT Stage IIl_| Individual bearing inlets, GB & EOP discharge Stage IV | Through Bearings and Gearbox (Fresh Oil) Stage V_| Governing System (Fresh Oi) Stage VI | Jacking Oil System (Fresh Oil) Customer BHEL-HYD ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR STEAM TURBINE SETS ESP:TG& TC 202 Page 17 of 19 REV.-03, DT 23-01-2020. 19 | Following Instruments® to be installed and taken inline during Hlushing a._| MOT temperature element MOT level gauge Pump suction pressure gauge Pump discharge pressure gauge Before cooler temperature gauge ‘After cooler temperature gauge Differential pressure gauge (filters) Ble|mle ee] s| Lube oil header pressure gauge Note: 1. Size ofthe jump overs/temporary spools or hose should be 80-1002 of the respective supply line *. Accumulators should be isolated during the entre flushing operation to avoid puncture of air balloons. + MOY present in the hydraulie barring gear supply line + Isolate al the instrument tapings other than list furnished in sno. 19. Remarks: Customer BHEL-HYD ISSUED BY: EXTERNAL SERVICES DEPARTMENTCrerran) CT STEAM TURBINE SETS LUBE OIL FLUSHING PROCEDURE FOR ESP:TG& TC 202 Page 18 of 19 REV.-03, DT 23-01-2020. Annexure-2: LUBE OIL FLUSHING PROTOCOL Lube oil grade Lube oil make Main Oil Tank capacity ‘Minimum Oil Quantity Litre (60% of MOT Capacity) ‘SNo.| Activity Description i,_ Main Supply header to drain header 1. | Oil tank, Auxiliaries™ and piping a. Initial Cleaning of MOT Dt: b. Card Board bursting i. Inlet Header Dt: “| ___ ii, Drain Header — a Dt iii, Governing Header Dt: iv. Control oil line (HP, IP, LP) Dt: ¢. Commissioning of oil centrifuge with heater Dt 4d. Trial ran of MOP & AOP Dt: ©. Trial ran of EOP £ Trail ran of JOP g. Flushing filter element installation in main filters | Type: Size: h, Provision of Mesh at suction strainer of the pump | Yes/No iesh Size: i, Provision of Bucket/plate type arrangement at drain header near MOT Yes/No j. Both main and standby oil pumps taken for flushing | Yes/No. k. EOP taken for flushing Yes/No 1. Both coolers taken for flushing Yes/No m.Both filters taken for flushing Yes/No [ n, Removal of PCV Yes/No o. Removal of TCV Yes/No . Operational check of filter change over valve Yes/No 4. Operational check of oil cooler change over valve _| Yes/No +, Jump over (I 0) provided Inlet Pipe size | Jump Over size ii. Individual bearing supply to respective drains iii, Barring gear header to drain_ iv. Gear box supply to drain v. Governing header to drain vi. OHT supply to overflow line vii. Accumulator supply to drain header/MOT Customer BHEL-HYD ISSUED BY: EXTERNAL SERVICES DEPARTMENTLUBE OIL FLUSHING PROCEDURE FOR STEAM TURBINE SETS ESP:TG& TC 202 Page 19 of 19 REV.-03, DT 23-01-2020. Lube Off Flushing a, Parameters during oil flushing: i Pump discharge pressure ii, ‘Lube oil header pressure _ ili, ‘Max oil temp achieved for thermal shock iv. Min oil temp achieved for thermal shock v. Avg. time taken to achieve min. temp vi MOT level ’b. Lube oil with Jump Overs Mesh Size” Start Dt | End Dt i ‘Main header to drain header ii, Talet Tine to Drain line (GB/hydraulic) iii, OHT inlet to drain line iv. Governing inlet to drain ine Talet Tine to Drain Tine (bearings) vi. ‘Through bearing housing vii. Through Gearbox (if any) Vili. TOP flushing w/o mesh ¢. Final Overhead oil tank cleaning Dt. . Final mesh condition e. Final Cleaning of MOT & DOT Dt Note: \. Auxiliaries inelude MOT, OHT, MOP, AOP, EOP, Lube oil filters, oil coolers, Centrifige 2. Final mesh no. for declaration ofthe flushing is 140 mesh no. or 100-mieron mesh >. Flushing with fresh oil only. Customer BHEL-HYD ISSUED BY: EXTERNAL SERVICES DEPARTMENT