Mm9a0e~1
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Mm9a0e~1 as PDF for free.
More details
- Words: 29,759
- Pages: 177
Loading documents preview...
Project Dwg. No: G101-25-1723.40-MM58
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) MECHANICAL MAINTENANCE MANUAL PT PAITON ENERGY PAITON EXPANSION PROJECT
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP) Maintenance Manual No. MM-M05.08 Revision 000
Note • This mechanical maintenance manual is intended to provide the Paiton Expansion Project mechanical maintenance personnel with the basic understanding required to perform preventive, routine, corrective and overhaul maintenance activities on the subject equipment.
•
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy Industries, Ltd. and Paiton Expansion Project.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Maintenance
Be sure to read this manual.
Contents
Safety
1
General
2
Specifications
3
Preventive Maintenance
4
Disassembly and Reassembly
5
Corrective Maintenance
Recommended Lubrication
Appendixes
7
Revision Record Description of Revision
Revision Issue Date
Date Revised
Pages Inserted
MM-M05.08
Rev.000
Page Number
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
i
Important Information Purpose of the Plant Usage This plant is designed to generate electric power of 815 MW by the steam turbine generator. The plant is only used for the electric power generation purpose that supports stable and reliable electric power supply to the power grid and supplying steam for the auxiliary equipment in the power station.
General 1.
To satisfy the purpose mentioned above the following points must be strictly observed, a)
The operation, maintenance and inspection of Equipment must be performed by the persons who have basic technical knowledge and have been trained concerning the hazard of the Equipment and the avoidance of the hazard.
b)
The operators and maintainers must read and understand these manuals before starting the operation, maintenance or inspection. It is often experienced that serious damage to the equipment or personnel have occurred by the unexpected action of operators or maintainers who do not fully understand the equipment.
c)
The modification or change of operational specification must be performed under MHI supervision or as per the written acceptances of MHI. The modification or change of specification causes not only a decline in performance but also a decline in safety for operation of the equipment. The Customer is requested to contact MHI regarding any modification or proposed changes before the work commences.
MM-M05.08
Rev.000
The address for MHI to be contacted is shown in this chapter. 2.
The operation and maintenance must be performed according to the applicable laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local legal regulations.
4.
The copyright of software, drawings and other documents provided by MHI at all times, is still reserved by MHI.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ii
5
Use or copying of the whole or part of any information provided by MHI for any purpose other than operation and maintenance of this plant without written consent is strictly prohibited.
Important General Notice for Safety 1.
The operator and maintainer must have knowledge about the equipment to maintain good operating condition and to avoid danger when using the equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as a “Safety and Health management system” and operate continuously. The Safety and Health management system must include the following points, a) Instruction for use and the maintenance of the personal protective equipment issued to operators and maintainers b) The establishment of a work management organization to make clear the operation directives and work procedures c) Implementation of training for operator and maintainer
4.
The Customer must train the operators and maintainers to act positively and to prevent the occurrence of an accident by using their knowledge of the power plant.
5.
The Customer must make the operators and maintainers understand that the most important purpose of safety control is to protect all personnel from accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to observe the notices of this manual and to keep the correct operation according to the description provided in this manual. If the notices are not observed, the following dangers could occur to the operator, and to the maintainer.
MM-M05.08
Rev.000
7.
a)
Risk of a fatal accident
b)
Danger to lose his health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as danger due to human error and/or dangers caused by the operating environment. As this manual and the alert label cannot cover all of the dangers, the operators and maintainers have to pay their full attention to all general safety notices.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
iii
8.
MHI can not be responsible for damages and injury caused by neglecting the notices in this manual, and other necessary general notices.
Instruction of this Manual This manual is provided for people familiar with the use of English. If some person not familiar with English is going to operate the plant, the Customer must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local office or MHI’s official agent.
MM-M05.08
Rev.000
1.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
iv
Warranty •
The provisions set forth in this section are in addition to all liability and warranty disclaimers and limitations set forth in the Contract, whether arising under law or from course of performance, course of dealing, or usage of trade.
•
Nothing in these provisions shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Warranty Limitations section shall have the respective meanings ascribed to them in the Contract.
•
The Contract Warranties are subject to the construction, installation and Commissioning works having been performed in full compliance with the requirements stated in (a) the Contract, (b) all manuals provided by MHI, including this manual, (c) all applicable rules, regulations and laws prevailing in the location where the Plant has been installed and will operate, and (d) any other instructions, if any, provided by MHI (collectively, “Rules and Requirements”). The Contract Warranties will NOT cover any accidents, partial or total failure of the Plant, losses or damages to personnel or property (including, without limitation, the Plant’s components, parts, systems and other equipment), or any other liability (collectively, “Accidents and Damages”) in the case of any breach of the stated Rules and Requirements.
•
For the detailed terms and conditions of the warranty concerning the Works and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the following Accidents and Damages: Accidents and Damages caused by any deviation from the Rules and Requirements;
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
v
Accidents and Damages caused by the modification or re-installation of the Plant after the original installation, or caused by operation of the Plant for a purpose other than that for which it is designed;
•
Accidents and Damages caused by natural disasters or accidents during transfer or related handling;
•
Accidents and Damages occurring after the term of the warranty has expired;
•
Accidents and Damages due to faulty operation or operation not in accordance with the Rules and Requirements;
•
Accidents and Damages due to inappropriate maintenance or servicing performed by the Customer, its personnel or any other party.
•
Accidents and Damages caused by any components, parts, systems or other equipment other than those delivered by MHI;
•
Accidents and Damages caused by unidentifiable reasons including loss of the damaged parts which is necessary to pinpoint a cause of the failure;
•
Accidents and Damages caused by referring to inadequate, or incorrect references, data or information provided by the Customer;
•
Accidents and Damages or rust/corrosion due to inadequate handling and/or storage by the Customer; or
•
Accidents and Damages due to handling, storage and/ or use of the Plant under severe conditions or in an environment that does not meet the design specification conditions.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
vi
Limitations of Liability General •
Nothing in this Limitation of Liability section or manual shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Limitation of Liability section shall have the respective meanings ascribed to them in the Contract.
•
The contents of this manual are subject to change without prior notice and without any obligation or liability to MHI.
Use and Disposal •
Use of the Plant must be limited to the use specified by MHI, including without limitation, use of the Plant in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI. The Plant components, parts, systems and other equipment (collectively, “Equipment”) must be appropriately disposed of in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI.
For Documents and Safety Training
MM-M05.08
Rev.000
•
The Customer’s personnel must read, understand and abide by all documents provided by MHI, including without limitation, the operation and maintenance manuals, safety manuals, and instruction manuals (collectively, “Safety Manuals”) and must have received all required and/or necessary safety training prior to the start of their work. Persons who have not received such safety training are not permitted to work on the installed Plant. This initial training, however, is merely the minimum requirements prior to allowing any personnel to work on the installed Plant. The Customer must, on a continual and regular schedule, give up-to-date training to its personnel on safety requirements, provide testing or other methods to confirm their understanding of the safety training, and confirm that they have the physical and mental capability to perform their respective roles. The Customer’s obligation for safety training and personnel supervision is an ongoing obligation and must be continuously performed and kept current throughout the operation of the Plant. Accidents, partial or total failure of the Plant, damage to personnel or property, loss, injuries, and other liability (collectively, “Liability”) caused by inadequate safety training or the Customer’s personnel’s failure to abide by the documents provided by MHI are expressly excluded from the coverage of any warranty provided by MHI and are the sole and exclusive responsibility of the Customer.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
vii
•
MHI will NOT be liable for any Liability caused by modification or changes made in Plant-related documents (including any Safety Manual) by anyone other than MHI.
For Damage to the Plant Accidents may occur by use of Equipment that is acquired from anyone other than MHI or anyone not appointed by MHI to modify or repair this Plant. The Customer shall not be permitted to modify or repair the Plant or change Equipment of the Plant without MHI’s prior written approval, under any circumstance.
•
MHI will NOT be liable for any Liability resulting from any abuse, misuse, misapplication of the Equipment supplied by MHI.
•
MHI will NOT be liable for any Liability caused by an act by the Customer in violation of the Contract, this manual, any applicable law or regulation, or any Safety Manual or any other instruction provided by MHI, including without limitation, a change of the installation environment or the removal and installation of any Equipment in a location different to that originally selected by MHI.
•
MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault, in material or Equipment that was used during a repair, even when such repair was performed by or under an instruction given by MHI.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
viii
Copyright COPYRIGHT © 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED. All of the content contained in this manual is protected by Japanese, International and/or United States copyright laws.
•
All copyright, trade secrets, and other proprietary and intellectual property rights in the documents provided by Mitsubishi Heavy Industries, Ltd.(“MHI”) (including safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject to your compliance with the restrictions set forth below, MHI grants to you a limited, non-exclusive license in the copyright for the sole purpose of allowing you to use, operate, maintain and inspect the Plant.
•
Use, copying, other reproduction of the whole or part of the documents provided by MHI (including safety-and-instruction manuals) for any purpose other than the purpose described above without MHI’s prior written consent is strictly prohibited.
•
The act of rewriting, translating, modifying, revising, creating electronic copies, uploading, selling, sublicensing, or otherwise disclosing the whole or part of the manuals is strictly prohibited.
•
Except as specifically set forth above, no right, title or license to the documents provided by MHI, whether arising from contract, implication, estoppel or otherwise, is being granted or otherwise transferred.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ix
Personnel to whom the Manual is Directed This Manual was prepared for all personnel who will participate in the operation and maintenance of the plant, and the other related mechanical plant and equipment installed. In this Manual, MHI classifies personnel into the following two classes based on their ability, experience and their attitude to the safety of personnel, and the plant installed. Only the personnel recognized by the Customer as trained personnel are allowed to perform the operation and maintenance specified in the manuals. Maintainers and Operators are required to have read and understood the contents of the safety, operation, and maintenance manuals and sufficiently understand the work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge Engineer are permitted to handle materials to be used in the operation of the plant. Operators are allowed to turn on the power supply, startup equipment, open up or remove covers or panels on receipt of an instruction or authorization from their superior. Operators are permitted access to emergency stop devices following instructions given by their superior when dangerous or hazardous situations are recognized.
Maintainer
MM-M05.08
Rev.000
Maintainers are permitted to perform maintenance on the plant. They will also perform troubleshooting routine and periodical inspections of the installed equipment. The maintainer will also work under the supervision of MHI’s supervisors during on-the-job training and annual maintenance and overhaul work if MHI’s supervisors are requested to witness periodical inspections, etc. Maintainers MUST have attended the training programme initially provided by MHI and subsequently by the Customer, and they must have obtained the necessary knowledge and maintenance skills to understand the characteristics of their tasks before actually starting their work. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
x
Contact Address For any question or any clarification required, please do not hesitate to contact MHI through the following address (es).
For Support before Operation: MITSUBISHI HEAVY INDUSTRIES, Ltd. Nagasaki Shipyard & Machinery Works 1-1, Akunoura Machi, Nagasaki 850-91
For Support after Commissioning and in an Emergency
MM-M05.08
Rev.000
(Later)
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xi
Abbreviations ABB.
EXPANDED FORM
ABB.
EXPANDED FORM
AOP
Auxiliary Oil Pump
NDE
Non-destructive Examination
CCW
Closed Cooling Water
NWL
Normal Working Level
EOP
Emergency Oil Pump
OJT
On Job Training
FL
Floor Level
P&ID
Process and Instrumentation Diagram
I&C
Instrument and Control
PPE
Personal Protective Equipment
MOP
Main Oil Pump
PTW
Permit to Work
IP
Intermediate Pressure
RTD
Resistance Temperature Detector
MOT
Main Oil Tank
TOP
Turning
MSDS
Material Safety Data Sheet
MM-M05.08
Rev.000
Oil Pump
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xii
List of Vendor Manuals
MM-M05.08
Rev.000
LATER
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xiii
A rr a n g e m e n t o f t h e S y s t e m Maintenance Manual This manual is arranged as follows. Chapter 1 Describes health and safety issues during maintenance, disassembly and reassembly of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP).
Chapter 2 Describes the construction, purpose, and function of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP) and the associated parts.
Chapter 3 Describes the Turbine Main Oil Tank and the various Pumps using the relevant Data Sheets.
Chapter 4 Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5 Describes the disassembly and reassembly procedures, necessary to obtain access to internal parts for inspection and repair during the Main Oil Tank and the various pumps overhaul.
Chapter 6 Describes the corrective maintenance procedures to be followed to investigate, identify and remedy defects occurring during operation.
Rev.000
Chapter 7
MM-M05.08
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xiv
Contents
Contents Revision Record ······························································································· i Important Information ······················································································ ii Warranty·········································································································· v Limitations of Liability ·····················································································vii Copyright········································································································ ix Personnel to whom the Manual is Directed······················································ x Contact Address ····························································································· xi Abbreviations ·································································································xii List of Vendor Manuals ··················································································xiii Arrangement of the System Maintenance Manual ·········································xiv
Chapter1
Safety ____________________________
1.1
Features of Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Safety ······························································1-1
1.2
Warnings Description······································································1-2 1.2.1
Definitions of “Serious Injury”, “Minor Injury”, “Serious Damage to Property”, and “Minor Damage to Property” ······1-3
1.2.2
Symbol················································································1-4
1.2.3
Hazard Warning Label ························································1-5
1.2.4
Hazard Area········································································1-7
1.3
Risk Assessment Standard ·····························································1-8
1.4
Safety Measures···········································································1-10 1.4.1
Work Permit System (Lockout/Tagout) ····························1-10
1.4.2
General Cautions on Personnel in Working Area············· 1-11
1.4.2.1
Caution against Rotating Equipment ······························ 1-11
1.4.2.2 Cautions against Electrical Equipment ···························· 1-11 1.4.2.3 Cautions against High Temperature Sections··················1-12 1.4.2.4 Cautions for Steam Leak in the Plant ······························1-13 1.4.2.5 Cautions against Oil Leak in the Plant·····························1-13 1.4.2.6 Cautions against Chemicals············································1-14
MM-M05.08
Rev.000
1.4.2.7 Cautions against Combustible Materials/Storage Areas ··1-14 1.4.2.8 Cautions against Lack of Oxygen····································1-15 1.4.2.9 Cautions against Lifting Heavy Object·····························1-16 1.4.2.10 Caution against Sharp Objects········································1-16 1.4.2.11 Cautions using Fork Lift···················································1-16
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
1
Contents
Chapter1
Safety (Continued from previous page…) 1.4.2.12 Cautions using Crane······················································1-17 1.4.2.13 Disposal··········································································1-18
1.5
Emergency Measure·····································································1-19 1.5.1 Evacuation on Emergency Case········································1-19 1.5.1.1 Evacuation Route······························································1-19 1.5.1.2 Evacuation of disabled persons who cannot move by themselves········································································1-19
MM-M05.08
Rev.000
1.5.1.3 Evacuation from Power House··········································1-20 1.5.2
Fire Accident ·····································································1-21
1.5.3
Earthquake ·······································································1-22
1.5.4
Explosion Accident····························································1-22
1.6
Qualification and Training ·····························································1-23
Chapter2
General___________________________
2.1
Purpose ··························································································2-1
2.2
References ·····················································································2-1
2.3
Overview of the Main Oil Tank and the AOP, TOP & EOP ···············2-3
2.4
Construction ·················································································2-10 2.4.1
Oil Pumps ········································································· 2-11
2.4.2
Vapor Extractor Fan ··························································2-12
2.4.3
Oil Mist Separator ·····························································2-13
2.4.4
Oil Ejectors ·······································································2-13
2.4.5
Oil Level Gauge ································································2-14
2.4.6
Oil Strainers ······································································2-14
2.4.7
Oil Cooler·········································································· 2-15
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites···················································································4-1
4.2
4.1.1
Scheduling··········································································4-1
4.1.2
Departmental Interface/Notification ·····································4-2
4.1.3
Isolation of Equipment·························································4-2
4.1.4
Safety Precautions······························································4-2
Routine Maintenance······································································4-3 4.2.1
Preparation ·········································································4-3
4.2.2
Inspection and Maintenance ···············································4-4
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
2
Contents
Chapter4
Preventive Maintenance (Continued) ______
4.3
Annual Outage Maintenance···························································4-8 4.3.1
Preparation ·········································································4-8
4.3.2
Inspection and Maintenance ···············································4-9
Chapter5
Disassembly and Reassembly ________
5.1
Main Oil Tank Disassembly and Reassembly··································5-1
5.2
Disassembly and Reassembly of the Auxiliary Oil Pump·················5-3
5.3
Disassembly and Reassembly of Turning Oil Pump······················5-12
5.4
Disassembly and Reassembly of Emergency Oil Pump················5-19
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites···················································································6-1
6.2
Preparation ·····················································································6-2
6.3
Troubleshooting ··············································································6-2
Chapter7
Recommended Lubrication __________
Appendixes Torque Chart ···································································· A-1
Appendix B
Recommended Spare Parts ············································· B-1
Appendix C
Special Tools ···································································· C-1
Appendix D
Coupling Alignment ·························································· D-1
Appendix E
Applicable Reference Drawings ······································· E-1
MM-M05.08
Rev.000
Appendix A
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
3
Contents
MM-M05.08
Rev.000
List of Figures Figure 1-1
Types of Hazard Warning Labels·······································1-6
Figure 1-2
Mapping for Hazard Areas·················································1-9
Figure 2-1
Oil Purifier, Oil Piping Diagram··········································2-6
Figure 2-2
Schematic Arrangement of Main Oil Tank and Associated Equipment ······················································2-7
Figure 2-3
Arrangement of Main Oil Tank ···········································2-8
Figure 2-4
Partially Exploded View of Main Oil Tank···························2-9
Figure 2-5
Cutaway View of the Main Oil Tank ·································2-17
Figure 2-6
Main Oil Tank Internal Piping···········································2-18
Figure 2-7
Isometric View of Auxiliary Oil Pump ·······························2-19
Figure 2-8
Cutaway View of the Auxiliary Oil Pump··························2-20
Figure 2-9
Sectional View of the Auxiliary Oil Pump ·······················2-21
Figure 2-10
Isometric View of the Turning Oil Pump···························2-22
Figure 2-11
Cutaway View of the Turning Oil Pump ···························2-23
Figure 2-12
Sectional View of the Turning Oil Pump ··························2-24
Figure 2-13
Isometric View of the Emergency Oil Pump·····················2-25
Figure 2-14
Cutaway View of the Emergency Oil Pump ·····················2-26
Figure 2-15
Sectional View of the Emergency Oil Pump ···················2-27
Figure 2-16
Sectional View of the Vapor Extractor Fan ······················2-28
Figure 2-17
Oil Mist Separator ···························································2-29
Figure 2-18
Arrangement of No. 1 and 2 Oil Ejectors ·························2-30
Figure 2-19
Main Oil Tank Level Gauge Assembly ·····························2-31
Figure 2-20
Lubricating Oil Strainer Assembly····································2-32
Figure 2-21
Return Oil Strainer···························································2-33
Figure 2-22
Turbine Oil Cooler ···························································2-34
Figure 2-23
Bearing Oil Pressure Adjusting Valve ······························2-35
Figure 4-1
Auxiliary Oil Pump Clearance Drawing····························4-16
Figure 4-2
Turning Oil Pump Clearance Drawing ·····························4-17
Figure 4-3
Emergency Oil Pump Clearance Drawing ·······················4-18
Figure 5-1
Exploded View of the Auxiliary Oil Pump························· 5-11
Figure 5-2
Exploded View of Turning Oil Pump ································5-20
Figure 7-1
Recommended Lubricant List Main Oil Tank ·····················7-2
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
4
Contents
Figure 7-2
Recommended Lubricant for AOP·····································7-3
Figure 7-3
Recommended Lubricant for TOP ···································7-4
Figure 7-4
Recommended Lubricant for EOP ···································7-5
Figure 7-5
Recommended Lubricants for Vapor Extractor Fan ·········7-6
Figure B-1
Operating Spare Parts for Auxiliary Oil Pump ··················· B-2
Figure B-2
Operating Spare Parts for Turning Oil Pump ···················· B-3
Figure B-3
Operating Spare Parts for Emergency Oil Pump ·············· B-4
Figure B-4
Operating Spare Parts for MOT Vapor Extractor ············· B-5
Figure B-5
Operating Spare Parts for Mist Separator························· B-6
Figure E-1
Arrangement Drawing of Main Oil Tank ···························· E-2
Figure E-2
Outline Drawing of AOP ··················································· E-3
Figure E-3
Assembly Drawing of AOP (1 of 3) ··································· E-4
Figure E-4
Assembly Drawing of AOP (2 of 3) ··································· E-5
Figure E-5
Assembly Drawing of AOP (3 of 3) ··································· E-6
Figure E-6
Expected Performance Curve of AOP ······························ E-7
Figure E-7
Torque Characteristic Curve for AOP································ E-8
Figure E-8
Outline Drawing for AOP Motor ········································ E-9
Figure E-9
Outline Drawing of TOP ················································· E-10
Figure E-10
Assembly Drawing of TOP (1 of 3) ··································E-11
Figure E-11
Assembly Drawing of TOP (2 of 3) ································· E-12
Figure E-12
Assembly Drawing of TOP (3 of 3) ································· E-13
Figure E-13
Expected Performance Curve of TOP ···························· E-14
Figure E-14
Torque Characteristic Curve for TOP······························ E-15
Figure E-15
Outline Drawing for TOP Motor ······································ E-16
Figure E-16
Outline Drawing of EOP ················································· E-17
Figure E-17
Assembly Drawing of EOP (1 of 3)································· E-18
Figure E-18
Assembly Drawing of EOP (2 of 3)································· E-19
Figure E-19
Assembly Drawing of EOP (3 of 3)································· E-20
Rev.000
Figure E-20
Expected Performance Curves of EOP ·························· E-21
Figure E-21
Torque Characteristic Curve for EOP ····························· E-22
MM-M05.08
List of Figures (Continued from previous page)
Figure E-22
Outline Drawing for EOP Motor ······································ E-23
Figure E-23
Vapor Extractor Fan (1 of 3) ··········································· E-24
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
5
Contents
List of Figures (Continued from previous page) Vapor Extractor Fan (2 of 3) ··········································· E-25
Figure E-25
Vapor Extractor Fan (3 of 3) ··········································· E-26
Figure E-26
Oil Mist Separator (1 of 2) ·············································· E-27
Figure E-27
Oil Mist Separator (2 of 2) ·············································· E-28
Figure E-28
Oil Level Gauge ····························································· E-29
Figure E-29
Lubricating Oil Strainer··················································· E-30
Figure E-30
Return Oil Strainer·························································· E-31
Figure E-31
Turbine Oil Cooler (1 of 2)·············································· E-32
Figure E-32
Turbine Oil Cooler (2 of 2)·············································· E-33
MM-M05.08
Rev.000
Figure E-24
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
6
Contents
List of Tables Risk Assessment Standard················································1-8
Table 3-1
Main Oil Tank ····································································3-1
Table 3-2
Auxiliary Oil Pump·····························································3-1
Table 3-3
Turning Oil Pump ······························································3-2
Table 3-4
Emergency Oil Pump ························································3-2
Table 3-5
Main Oil Tank Vapor Extractor Fan ····································3-3
Table 3-6
Oil Mist Separator ·····························································3-4
Table 3-7
Main Oil Tank Level Gauge ···············································3-4
Table 3-8
Lube Oil Strainer ·······························································3-5
Table 3-9
Return Oil Strainer·····························································3-5
Table 3-10
Turbine Oil Cooler ·····························································3-6
Table 4-1
Routine Maintenance Checklist·········································4-6
Table 4-2
Annual Outage Maintenance Checklist····························4-14
Table 6-1
Troubleshooting – Main Oil Tank and Vapor Extractor Fan ····································································6-3
Table A-1
Torque Chart ···································································· A-1
MM-M05.08
Rev.000
Table 1-1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
7
Chapter 1
Safety
Chapter
1 Safety 1.1
Features of the Turbine Main Oil Tank and AOP, TOP & EOP The lubricating and control oil requirements of the main turbine oil tank are provided by any of the four turbine oil pumps viz. MOP, AOP, TOP, and EOP at any given operating condition. The turbine oil pumps when in service are subjected to near constant discharge oil pressure with high flow variations. The flow variations occur due to the operation of the various turbine steam admission valves or the turbine protective devices. The oil flow and hence pressure variations caused during the main turbine operation are relieved by relief valves installed on the lubricating oil and control oil piping. However, due to the sudden oil pressure fluctuation and ageing of flange gaskets, the oil piping has a risk of flange/pipe leakage. Any oil leakage in the vicinity of the turbine could lead to a fire, which could damage the nearby components and/or personnel working nearby. The main oil tank is operated under a slight vacuum by the operation of the vapor extractor fan. The turbine bearing pedestals, connected to the main oil tank through the drain lines, are also maintained at a slight vacuum. The negative pressure in the bearing pedestals prevents leakage of oil or oil vapor from the bearing pedestals. Any oil or vapor leakage could lead to a fire which could damage the nearby components. All personnel should pay strict attention to this aspect, check for any damage to main oil tank and to any of the associated pumps.
All operators and maintainers must realize the danger and keep themselves safe, following the recommendation written in this chapter.
MM-M05.08
Rev.000
The turbine oil pumps operate with close internal clearances and accurate alignment. Any disturbance in the pump clearances or alignment, due to ageing and/or wear of components, can cause internal rubbing and damage to the pump components. The disturbed clearances or alignment can also lead to abnormal vibration in the oil pumps. All operators and maintainers should pay special attention if any abnormal rubbing noise or vibration is observed on the oil pumps to reduce consequential damages.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description Safety of personnel working in the power plant is the most important matter and all kind of consideration to avoid dangerous condition are studied and applied to the design of the power plant. However, certain risks are unavoidable due to the nature of the plant. This manual classifies the severity and hazard level of such risks by two categories, “DANGER” and “CAUTION”. Read and understand the indications thoroughly before operation or maintenance of the plant. The contents of wordings, “DANGER” and “CAUTION” are described as follows; Kinds
Meaning of Warnings “DANGER” indicates an imminently hazardous situation in handling of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP), which, if not avoided, could result in death or serious injury, or serious damage to the property or environment. “CAUTION” indicates a potentially hazardous situation during use of the Turbine Main Oil Tank and Auxiliary Oil
CAUTION
Pumps (AOP, TOP & EOP), which, if not avoided, may result in minor injury, or minor damage to the property or environment.
This manual also uses the following indicators in addition to the hazard level indications described above.
Kinds
Meaning of Warnings “IMPORTANT” describes the particular information or items that personnel must know during operation and
IMPORTANT
maintenance of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP), and that, if not heeded, may result in an accident of an in-assessable hazard level.
Notice
“NOTICE” describes useful information and tips for operation and maintenance of the Turbine Main Oil Tank
MM-M05.08
Rev.000
and Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-2
Chapter 1
Safety
1.2.1 Definitions of “serious injury”, “minor injury”, “serious damage to property”, and “minor damage to property” “Serious Injury” This term describes injuries, which leave after effects such as loss of eye sight, permanent disability, bone fracture or breakage, gas inhalation, asphyxiation, electric shock, hospitalization or prolonged hospital visits for treatment.
“Minor Injury” This term describes injuries, which do not require hospitalization or prolonged attention at a hospital (injuries other than “the serious injuries” described above).
“Serious Damage to Property” This term describes damages, which require a suspension of productive activity for one day or more due to restoration of the damaged property.
“Minor Damage to Property”
MM-M05.08
Rev.000
This term describes damage, which does not require any suspension of productive activity due to restoration of the damaged property.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbol In this manual, the following symbols are added for easy understanding of the contents of warnings and are found next to “DANGER”, “CAUTION” and indications. These symbols are in compliance with “ISO 3684”. Symbol
Description This symbol indicates the possible presence of high voltage, and warns of a hazard which may result in system shock, burn or death by electric shock if safety precautions are neglected or the system is handled incorrectly. This symbol indicates a movable section that is inside a safety cover or is exposed. Movable parts may inflict laceration or bone fracture to body parts such as a hand by pinching the hand and/or clothing. This symbol indicates the presence of parts the surface of which could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place your feet when moving around the area. Risk of injury by tripping is present near this symbol due to factors such as a location with an unstable surface, or obstructions such as scaffolding, temporary pipe lines, or other protrusions. This symbol indicates the possible presence of gas(es) harmful or asphyxiant to personnel. Be sure to ventilate fully before work commences. This symbol indicates caution against the handling of a heavy object or working in an abnormal position. Do not work in an abnormal posture which may damage your back or waist. This symbol indicates “prohibited” items or actions during the operation and maintenance of the Turbine Main Oil Tank and
MM-M05.08
Rev.000
Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-4
Chapter 1
Symbol
Safety
Description This symbol indicates that personnel must not touch since the surface is hot. Do NOT enter any area where this symbol is displayed. This symbol indicates that the entry of personnel is prohibited. Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited. Do NOT touch or enter a location or enclosure where this symbol is displayed. This symbol indicates that the stated items or actions in the warning notices relative to operation and maintenance of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) are mandatory.
1.2.3 Hazard Warning Label Hazard warning labels are applied where potential hazards are present during operation and maintenance activities. Hazard warning labels will be in appropriate sizes and colors that will catch the eye and the attention of personnel. They also have symbols that show the hazard types, in addition to the descriptions of warning contents.
IMPORTANT Personnel are requested to confirm the location of, and to read, and thoroughly understand the contents of all hazard warning labels applied to this Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Manual. If any of the hazard warning labels peel off/wear out or become unreadable, install a new label in the original location
MM-M05.08
Rev.000
without delay.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-5
Chapter 1
Safety
WARNING
DO NOT COME NEAR TO SHAFT EXPOSED ZONE WHEN IN OPERATION
STEEP DROP
DO NOT ENTER
DO NOT TOUCH
DO NOT TOUCH
MM-M05.08
Rev.000
TB0001_A
FIGURE 1-1
TYPES OF HAZARD WARNING LABELS
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-6
Chapter 1
Safety
1.2.4 Hazard Area
IMPORTANT Only trained maintainers and operators are allowed to enter the maintenance work area. Entry to the area by personnel untrained could cause not only injury but also serious damage to the Turbine
MM-M05.08
Rev.000
Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard The tables below are prepared as per MIL STD822D. TABLE 1-1
RISK ASSESSMENT STANDARD Detailed Description of Impact on each Object
Category
Safety
I
Catastrophic
- Unit shutdown (unit cannot be operated) - More than 4 days for repairing
- Death
II
Critical
- Unit shutdown (can not be operated) - Within 3 days for repairing
- Serious Injury
- Same as the above
III
Marginal
- Unit shutdown (can not be operated) - Can be repaired by Customer
- Minor Injury (with hospitalization)
VI
Negligible
- Same as the above - High temperature surface - High elevation or unstable - Not harmful and high pressure & temperature leakage -Mechanical protected
- Minor Injury (without hospitalization)
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, “it has happened”
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1 Hazard Categories Frequency of Occurrence
Rev.000
Environment - Harmful gas or oil leakage - High pressure and temperature material leakage such as steam, water, air and gas, oil etc. - Low oxygen
TABLE 1-1
MM-M05.08
Health
RISK ASSESSMENT STANDARD (CONTINUED) I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
1
3
7
13
(B)
Probable
2
5
9
16
(C)
Occasional
4
6
11
18
(D)
Remote
8
10
14
19
(E)
Improbable
12
15
17
20
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-8
Chapter 1
10 5 3 2
3
10 5 3 2
6
10 5 3 2
6
6
10 5 3 2
6
3
7 4 4 3
4 3 9 2 8 1 7
7 4 3
Safety
7 4 3 7 4 3
4 3
4
STAIR WAY
3 7 8
2 3 5 10
3 4 7
STAIR WAY
2 3 5 10
2 3 5 10
3
2 3 5 10
6
3
4
3 4 7
1 7 2 8 3 9 4
3 4 7
3 4 7 NOTES WARNING LABELS SHOUD BE IN ARABIC.
GEN. SIDE
3
MM-M05.08
Rev.000
1 YELLOW
AVOID INJURY WATCH YOUR STEP
2 YELLOW
FALL WATCH YOUR STEP
YELLOW
RISK OF A ROTATING A HAND
YELLOW
RISK OF A GEAR PINCHING A HAND
MPTD-3-0314
GOV. SIDE
(*1)
YELLOW
RISK OF A CHAIN PINCHING A HAND
YELLOW
PINCH POINT KEEP HANDS AWAY
4 YELLOW
5 YELLOW
DO NOT TOUCH HOT SURFACE
6 YELLOW
7 YELLOW
8 YELLOW
DISCONNECT AUTOMATIC START. ELECTRICAL POWER KEEP HANDS CLEAR. BEFORE SERVICING
DO NOT SMOKE IN THIS AREA.
10 RED
OPERATING PERIOD
(*1) THE MOST SUITABLE ONE WILL BE ADOPTED TO EACH PLACE.
FIGURE 1-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
9 RED
MAPPING FOR HAZARDOUS AREA
1-9
Chapter 1
1.4
Safety
Safety Measures 1.4.1 Work Permit System (Lockout/ Tagout)
MM-M05.08
Rev.000
Work permit system is applied when equipment is shutdown for maintenance work, to complete the maintenance work under a safe condition. The outline of the work permit system is as follows: (1)
The Maintenance Engineer applies for the work permit clearly indicating the content of the maintenance work that he wants to do, and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the operator to study and decide the isolation method from the line in operation on the mechanical and electrical view point and then report to the Shift Charge Engineer with the comments on the hazard conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and prepares necessary tags to show the work permit number and the situation of isolation by valves and power supply. He will then instruct the operators to set the isolation condition following the work permit form.
(4)
The operators will open the breaker and set the valves to the specified condition, they will also drain and vent the equipment to be worked on, and the breaker and the valves are to be locked. The operators return the work permit to the Shift Charge Engineer.
(5)
The Shift Charge Engineer checks the isolation and will issue the signed work permit to the Maintainer, or his representative.
(6)
The Maintenance Engineer orders the start of the maintenance work to the personnel nominated.
(7)
The Maintenance Engineer or his representative will then return the signed work permit to the Shift Charge Engineer after making sure the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the locks and return to the original situation.
(9)
The operators check the situation and report that the system is now back to the normal condition when signing off the work permit.
(10) The Shift Charge Engineer makes sure that the work under the permit is completed and files details in the log book. The work permit system is to clarify responsibility for the works on each step and to ensure that the work is performed safely.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-10
Chapter 1
1.4.2
Safety
General Cautions on Personnel in Working Area
1.4.2.1 Caution against Rotating Equipment All couplings on rotating machine are covered by the coupling cover but whole parts of the shaft are not fully covered. It is recommended that the following warning is observed strictly.
•
Do not approach or operate the equipment where protective covers have been removed. Get additional supervisor assistance.
•
Make sure that the breaker for the motor is opened when you are required to remove the cover.
•
Care must be taken of the exposed rotating parts especially in the area between the casing and the coupling.
•
All shafting, coupling and other rotating parts must be guarded in order to prevent accidental contact.
1.4.2.2 Cautions against Electrical Equipment
MM-M05.08
Rev.000
The electrical equipment covered under this section includes all the concerned plant equipment and the maintenance tools like grinders, lamps, welding equipment, etc. Though live parts of the plant or maintenance tools are insulated, be sure to observe the following cautions. Failure to observe them may cause fatal accidents, personal injuries and damage to the electrical equipment.
•
Always, confirm that power supply is disconnected at the up-stream side of power supply system and it is locked according to the Work Permit.
•
Do not remove or open panels or doors labeled with high voltage live part warning label not included in the Work Permit.
•
Ensure the proper earthing is provided for all electrically operated tools and equipment used for maintenance works.
•
In case of usage of lamps for internal inspection, ensure that a low voltage system (24volts) is available.
•
Make sure that no materials or Parts remain in the Panels or terminal box before closing them finally.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-11
Chapter 1
Safety
1.4.2.3 Cautions against High Temperature Sections Various equipment and pipelines contain high temperature fluid and they are insulated on their surface. There are however some pipe lines which are not insulated, and as their temperature is very high and you could get burned, please observe the following caution to avoid burn injury.
CAUTION Suitable Personal Protective clothing is always available and should always be worn, including gloves to avoid direct contact to hot spots in the plant
•
Level gauges of pressure vessels including connecting pipes are not insulated to cool down the steam to drain.
•
Sampling piping is not insulated to cool down the steam to suitable temperature for the analyzer except at the places located close to the work place.
•
All exhaust pipes of the safety valves, and the exhaust pipe of the boiler flush pipe are not insulated.
•
Always wear gloves.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant A steam leak especially from high temperature steam may cause serious injury to the personnel and it must be repaired at an early stage of the leakage. The following pre-cautions must be followed to find leakage at an early stage.
•
Water drips may occur at the insulated parts such as the connected part of the lagging. The leaking point can be found by removing insulation partially with great care.
•
As you approach the leakage, the water will change to visible steam. It is now too dangerous to remove the insulation.
•
Leakage of the superheated steam only makes whistling noise without generating white steam. It is very dangerous to approach the noise area.
•
Contact the Charge Engineer to obtain a Permit to Work to ensure plant isolation before repairing the damage.
•
Be well aware of the steam. The steam could leak from the water system containing water at 100ºC or higher even if it is a low pressure type water system.
•
High temperature drain or steam could leak from the flush pipe during start-up.
•
If not avoided, the steam or vapor can enter the inside of your working wear through the small gap between the body and the clothing.
1.4.2.5 Cautions against Oil Leak in the Plant
•
Oil leakage is very dangerous. It is a potential fire hazard.
•
Any oil spillage must be reported to the Shift Charge Engineer.
•
Oil leaks make the area slippery and people are advised to move around these areas carefully.
MM-M05.08
Rev.000
CAUTION
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals Pay attention to the items to prevent any accident related to the chemicals in the plant.
IMPORTANT Precaution against chemicals • Operate chemical injection systems by strictly following the instruction of the chemist. The operator must use suitable protective tools. Disposal: • Observe the rules and regulation of the installation site. Material safety data sheet (hereafter MSDS):
•
Always understand the content of the applicable MSDS before using, and observe the notified instructions when handling the chemical.
Emergency response
•
Solution against emergency must be thoroughly instructed to all personnel involved so that the fullest measures can be taken against any situation.
1.4.2.7 Cautions against Combustible Materials/ Storage Areas
IMPORTANT Storage containers must be clearly marked to indicate the content
•
Bunding must be provided for bulk tanks
•
Suitable fire protection must be provided for each area.
•
Do not store bulk combustible materials on the site.
•
Small quantities of combustible materials must be stored in fire resistant cupboards.
•
Combustible materials must be segregated from other equipment
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-14
Chapter 1
Safety
1.4.2.7 Cautions against Combustible Materials/ Storage Areas (Continued from previous page)
IMPORTANT •
Leakage of gasoline has the risk of fire. Maximum storage quantity of gasoline outside of the dispensing pump is five liters
Emergency response:
•
Personnel directly involved in combustible materials MUST be properly trained and thoroughly instructed. Other personnel in the vicinity must be aware of the dangers and take precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in any confined space is between 18~22% before entering, to ensure sufficient ventilation.
•
Continue monitoring oxygen and ventilation during inspection.
•
It is recommended that you do not enter the equipment, vessel or confined space alone but if the situation demands that you must enter, take the necessary preventive safety measure provided, breathing system etc, and find a partner who will wait for your return at the point of entry, keeping in verbal contact throughout.
•
Make complete arrangements for rescue.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-15
Chapter 1
1.4.2.9
Safety
Cautions against Lifting Heavy Object Be careful during the removal/installation of any equipment during maintenance.
CAUTION •
Do NOT attempt to move or lift equipment in an abnormal posture. ALWAYS install/remove equipment, using a forklift or a crane. A normal lift without mechanical aid should be shared between two or more persons.
•
Failure to observe the above may cause injury due to dropped equipment, back or waist injury or damage to the equipment.
1.4.2.10
Caution against Sharp Objects
CAUTION •
Use leather gloves when handling parts with sharp edges.
1.4.2.11
Cautions using Fork Lift
•
Do NOT permit anyone to stand under any item being lifted under any circumstance.
•
Failure to observe this may cause fatal accidents.
•
When using a forklift, ALWAYS lift the objects parallel to the ground while considering the center of gravity.
•
Otherwise, lifted objects may fall and serious damage could occur.
•
A forklift is often used to transfer small machines. Check fork insertion position for the forklift prior to use. Be careful, as marks which indicate the fork insertion positions are sometimes hidden by wraps or packing materials.
MM-M05.08
Rev.000
CAUTION
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-16
Chapter 1
1.4.2.12
Safety
Cautions using Crane
CAUTION •
A crane is often used to transfer heavy parts. Check for any possible risks which could occur during hoisting and transportation before operating the crane.
Check of the equipment:
•
Check the crane, the crane hook and all related items before use. Use wire ropes which can withstand the weight of the parts multiplied by a safety factor.
•
Inspect the shackles, eyebolts, jigs and wire ropes provided for the hoisting work prior to the actual hoisting.
•
Perform periodical inspection (dye penetrant test) of hoisting tools at least once a year.
Rigging/ Slinging work:
•
Only authorized personnel can perform slinging work and operation of the crane.
Work area:
•
Before hoisting, secure a working area around the part to be lifted and prohibit the entry of unrelated personnel.
Hoisting method:
•
Hoist the part parallel to the ground while paying attention to the center of gravity.
•
Do NOT permit any person to stand under the part being lifted.
•
Pay attention to and ensure that all persons are clear of the equipment being lifted.
Hoisting point:
•
Do NOT hoist any parts from a position other than the specified hoisting points.
Unpacking:
•
Do NOT unpack any part until it is located in the designated location.
Protection of machine: Avoid any impact to the unpacked parts.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-17
Chapter 1
1.4.2.13 a)
Safety
Disposal Water disposal including oily drain The water is disposed to the plant drain system. The water must be carefully disposed according to materials contained in the water. The water drain system is separated into three categories that are rain water, chemical water and oily water. The waste waters are treated and then discharged to the public drain system.
b)
Chemical disposal Chemicals must be handled following the instruction of MSDS and disposed in the chemical drain system.
c)
Solid disposal made by maintenance work.
MM-M05.08
Rev.000
For disposal from the site, observe the local legal regulations.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure 1.5.1 Evacuation in an Emergency 1.5.1.1
Evacuation Route Following items are considered on design and installation of emergency evacuation.
IMPORTANT •
Each building installed in the plant is provided with at least two exits. A clear indication of the exits can be seen from anywhere in the building as the exit sign is illuminated using the emergency power supply.
•
Evacuation routes are indicated on each floor of the building, directing personnel to the exits.
•
Keep the evacuation routes completely free from materials and tools.
1.5.1.2 Evacuation of Disabled Persons Who Cannot Move by Themselves The following are necessary items, prepared for emergency evacuation:
IMPORTANT It is recommended to keep a stretcher available for emergencies at the places selected as being secure at the safety meeting.
•
If you find this kind of accident, inform the rescue team, and attempt to bring the collapsed person to the first aid station.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-19
Chapter 1
Safety
1.5.1.3 Evacuation from the Power House Following are guidance for the evacuation from the power house.
IMPORTANT An evacuation place for personnel to gather in after evacuation from the power house in an emergency must be predetermined and explained beforehand in the emergency training.
•
Evacuation directive must be given by the responsible person such as Shift Charge Engineer, and all personnel must be alerted in the power house repeatedly with an available broadcast facility.
•
All people working in the power house must stop there work immediately and leave the power house to the gathering place.
•
When evacuated to the evacuation place, make sure that there is no one missing.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-20
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT Clearly show the location of fire alarm push button and fire extinguisher to make everybody take the first step at fire protection.
•
Inform everyone concerned that a fire has now started if you discover a fire.
•
Start fire fighting using the fire extinguisher located near the fire site.
•
The operators must check the plant is ready for trip, and wait for order from the responsible person.
•
The operator and other personnel must transfer the fire fighting to the fire fighting team when they arrive at the fire site and the operators must wait for instruction from the Shift Charge Engineer. All other personnel must immediately start evacuation.
•
If unit trip is decided, the operator must trip the plant manually.
•
The operators must evacuate from the power house according to the instruction of the responsible person immediately after shutdown of the unit.
•
If the fire is extinguished successfully, the operators should return to the power house as required by the Shift Charge Engineer and start inspection of the equipment for restart of the unit.
•
Based on the inspection, the responsible person should decide whether to operate the unit again or shutdown for repairing.
•
After the inspection or repair, and then checking the equipment and/or system, start up the unit again.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-21
Chapter 1
Safety
1.5.3 Earthquake In the case of an earthquake, the shift charge engineer or operator must judge whether the unit trip is necessary according to the intensity of the earthquake, and immediately trip the unit manually. If the unit is tripped, all equipment must be carefully checked on its operation status and tripped if abnormal phenomena are found. In the local area, mechanical and/or thermal shocks may be given to the equipment, piping, instruments and electrical panels. Be sure to observe the following when completing the inspection.
•
Check that the lubricating oil pump is running. Bearings of the equipment will be damaged if lubricating oil is not supplied.
•
Check the piping and equipment for steam and water leakage. The steam or high temperature water leakage may cause serious injury to the personnel and it must be repaired at an early stage of the leakage.
•
Check the pulverizers and / or coal silos for signs of a fire. If a coal fire does start, make sure that CO2 fire fighting system is properly operated.
•
Check the position of boiler seismic stopper. Since the boiler seismic stopper must be anchored at the original position, the boiler cannot be re-started if the slippage is found. If the stopper is not at the original position, please contact MHI.
CAUTION •
Check the piping and equipment for the breaking and the dropping of insulation. Since the exposure of the hot surface may cause burn injury, it must be repaired by a worker fully dressed in Personal Protective Equipment.
1.5.4 Explosion Accident
MM-M05.08
Rev.000
•
Do not use a fire in a hazardous area where the combustibles (hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or handled. Use of a fire in a hazardous area could cause serious injury to personnel and serious damage to equipment due to an explosion.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-22
Chapter 1
1.6
Safety
Qualification and Training The system must be operated only by authorized operators & maintenance supervisors. The customer must authorize all operators and maintainers, who are involved in the operation and maintenance of this plant, either by the training course given by Mitsubishi, or by the customer’s own personnel assessment. Operator and maintainer training course (both classroom training and the On-Job-Training (OJT)) will be provided by Mitsubishi before the handing over of this plant. The customer must train and assess each new operator and maintainer to joins after the turn-over, according to his own procedure and standard, (Mitsubishi training course may still be available if required).
•
Operator and Maintainer can read and fully understand the description of this manual.
•
Operator and Maintainer can understand the related P & ID, logic diagram.
•
Operator and Maintainer know location of the system equipment including pipe routes, valves and the various instruments.
•
Operator and Maintainer have fundamental knowledge of the function of each equipment.
•
Operator can operate the equipment and the system manually at local stations.
•
Operator can operate the system remotely using DCS system.
•
Operator can respond suitably for any kind of alarm.
•
Operator knows location of emergency exit on power house and is available to provide first aid treatment.
•
Operator knows emergency communication system operation.
•
Operator and Maintainer, following the Charge Engineers instruction are aware of the isolation method for mechanical, electrical and instrumental equipment being prepared for safe maintenance while the unit is in operation.
•
Maintainer must also be able to handle the maintenance tools provided by the customer and those supplied by the manufacturer.
MM-M05.08
Rev.000
As a minimum, operator and maintainer must satisfy the following:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-23
Chapter 2
General
Chapter
2 General 2.1
Purpose The purpose of this maintenance manual is to provide specific information to the Paiton Expansion Project operating and maintenance personnel regarding the maintenance of the Main Oil Tank and the Turbine Oil Pumps (AOP, TOP, EOP). Although this document will convey a good knowledge and direction regarding maintenance of the Main Oil Tank and Turbine Oil Pumps, it is recommended that in the event of a problem not covered in the document the person responsible should seek assistance or instruction from the manufacturer.
References a)
Main Oil Tank Outline Drawing (1/2, 2/2) MHI Dwg. No. : N26-P11-6083
b)
Control and Lubrication Oil System Diagram (2/5) Project Dwg. No. P101-51-3-TB-LT0002 MHI Dwg No: T3059AAAA210-2
c)
Control and Lubrication Oil System Diagram (4/5) Project Dwg. No. P101-51-3-TB-LT0004 MHI Dwg No: T3059AAAA210-4
d)
Oil Purifier Oil Piping Diagram 2/2 Project Dwg. No. P101-51-3-TB-LT0011 MHI Dwg No: T3059AAAA250-2
e)
Auxiliary Oil Pump MHI Dwg No: T3059MAY471
f)
Turning Oil Pump MHI Dwg No: T3059MAY472
g)
Emergency Oil Pump MHI Dwg No: T3059MAY473
g)
Drawing of Auxiliary Oil Pump Motor Project Dwg. No. G101-24-1820.00-G028 MHI Dwg No: 65500-5451-028
MM-M05.08
Rev.000
2.2
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-1
Chapter 2
Drawing of Turning Oil Pump Motor Project Dwg. No. G101-24-1820.00-G029 MHI Dwg No: 65500-5451-029
g)
Drawing of Turning Oil Pump Motor Project Dwg. No. G101-24-1820.00-G101 MHI Dwg No: 65500-5452-002
MM-M05.08
Rev.000
h)
General
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-2
Chapter 2
2.3
General
Overview of the Main Oil Tank and the AOP, TOP & EOP Refer to Figures 2-1 to 2-6. The total control and lubricating oil requirements for the main turbine and its auxiliaries are supplied by the Main Turbine Control and Lubrication Oil System. The main turbine oil system consists of a main oil tank with oil pumps, oil coolers, oil filters, vapor extractor, oil mist separator, etc. for meeting the above lubricating and control oil requirements. The details of the major components related to the Main Turbine Control and Lubrication Oil System are described in this maintenance manual. The main oil tank is the central part of the main turbine lubricating oil system in which the turbine lubricating and control oil are collected, stored and distributed to the turbine, generator and exciter bearings, the turbine protective devices and the steam admission valves. The stored oil in the main oil tank is distributed to the bearings and the protective devices through any of the turbine oil pumps as per the operating requirement. The main turbine oil system is provided with a main oil pump (MOP), an auxiliary oil pump (AOP), a turning oil pump (TOP) and an emergency oil pump (EOP) for this purpose. The main oil tank is a circular steel tank located below the mezzanine floor on the ground floor of the Turbine Building. The lubricating and the control oil are returned to the main oil tank under gravity by virtue of the elevation difference between the bearings, the steam admission valves and the main oil tank. The main oil tank has a maximum level, (High Alarm) of 40,180 liters with a normal working level of 36,800 liters, and a low working level of 33,310 liters sufficient to provide all oil requirements of the turbine generator. The working range between the High and Low levels provides an operating oil quantity of 6,870 liters. The main oil tank, under normal operating conditions, provides sufficient oil dwell time within the tank to permit the release of non-condensable gases and the settlement of fine particulate debris in the tank.
The MOP is installed on the HP-IP turbine rotor extension shaft and the AOP, TOP and EOP are mounted on the main oil tank. The discharge lines of these pumps are suitably interconnected with check valves inside the main oil tank to permit oil distribution at any operating condition. Details on the construction and maintenance for the MOP are provided in the mechanical maintenance manual No. M-05.06, Turbine Main Oil Pump and for the remaining turbine oil pumps refer to this mechanical maintenance manual No. M-05.08, Turbine Main Oil Tank and Auxiliary Pumps (AOP, TOP, EOP).
MM-M05.08
Rev.000
The four oil pumps (MOP, AOP, TOP and EOP) together with two water cooled oil coolers and two sets of oil filters supply clean filtered oil to the turbine bearings and the turbine protection devices at the desired pressure and temperature.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-3
Chapter 2
General
Oil from the turbine-generator bearings and the turbine protective devices is returned to the main oil tank through a return oil strainer installed inside the main oil tank. The hot oil in the main oil tank returned from the turbine-generator bearings is cooled to the desired temperature by two water-cooled oil coolers, one working and one standby. Cooling water for the oil coolers is supplied from the Closed Cycle Cooling Water (CCCW) System. The oil piping downstream of the oil coolers is provided with a spring loaded relief valve to maintain the lubricating oil pressure to the bearings between 1.0 and 1.8 barg. This is achieved by continuously relieving the excess oil into the main oil tank. The main oil tank is provided with a 17 m3/min AC motor driven vapor extractor fan to evacuate air, oil vapor and non-condensable gases from the main oil tank. This evacuation by the vapor extractor fan maintains a slight negative pressure inside the main oil tank. Thus the turbine bearing pedestals are also maintained under vacuum as they are connected to the main oil tank via the drain guard pipe. The vacuum inside the bearing pedestal prevents leakage of oil or oil vapor along the turbine shaft. The vapor extractor fans discharge the oil vapor and the non-condensable gases to atmosphere through an oil mist separator. Oil collected in the vapor extractor fan casing and the oil mist separator is returned to the main oil tank through U- loop seals. Local and remote oil level indications for the main oil tank are provided by level gauge and level switches. The level in the main oil tank is maintained between the high and the low working levels during operation. Loss of oil due to evaporation or leakage is topped up with fresh oil by a common storage oil transfer pump. The common storage oil transfer pump draws suction oil from either of the clean oil and dirty oil storage tanks and discharges either to the main oil tank or to the oil purifier.
MM-M05.08
Rev.000
The drain line of the main oil tank is connected to an oil transfer pump to transfer oil from the main oil tank to the clean/dirty oil storage tank. Excess oil in the main oil tank during operation can be pumped to the clean oil storage tank through the oil transfer pump. The oil in the main oil tank can also be transferred to the dirty oil storage tank through the oil transfer pump if the entire oil is to be replaced due to contamination or ageing. The main oil tank drain line is lock-closed and is only opened during the transfer of oil from the main oil tank or to obtain oil samples during shut-down. For sampling purposes a sampling connection is provided on the tank drain line downstream of the drain valve. Another sampling connection provided in the main oil tank overflow line permits sampling of the circulating lube oil during turbine operation enabling the operator to evaluate the necessity of continuous usage of the oil purifier.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-4
Chapter 2
General
MM-M05.08
Rev.000
The main oil tank is provided with an oil purifier unit to filter the oil in the main oil tank during operation. The main oil tank is connected to the oil purifier suction through the overflow and the drain lines. Oil to the oil purifier unit is supplied through the overflow line for purification during turbine operation and through the drain line during unit shut-down. Oil after purification can be transferred either to the main oil tank or to the clean oil storage tank. The construction, operation and maintenance of the oil purifier unit, refer to the vendor operation and maintenance manual No. OM-02.03, Oil Purifier.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-5
Chapter 2
General
CONN. TO ROAD TANKER FOR INLET OIL
OIL MAKE-UP WEATHER CAP MIST SEPARATOR
VAPOR EXTRACTOR
LI 91
TURBINE OIL STORAGE TANK
DAMPER M
LUBE.OIL (TO BEARING)
LUBE.OIL (FROM MAIN OIL TANK)
BEARING OIL PUMP
TURNING GEAR OIL PUMP
M
OIL PUMP FROM BFPT-A
CONN. TO ROAD TANKER @ FOR OUTLET OIL
LUBE OIL STRAINER(A)
LUBE OIL STRAINER(B)
TURBINE OIL COOLER (A)
TURBINE OIL COOLER (A)
OVERFLOW PIPE
SAMPLING
SAMPLING
FROM BFPT-B
PI 92
MAIN OIL TANK
L.C
OIL SUPPLY PUMP
PI 91
SAMPLING OIL TRANSFER PUMP
OIL PURIFIER COALESCER FILTER
LS 92
H
LS 93
L
LI 92
DPI 93
PI 95
R.V
DPI 94
SAMPLING TO BFPT-B
HH
TO BFPT-A
LS 91
FROM BFPT-B
FROM BFPT-A
DCS
OIL PURIFIER INLET PUMP
S
SV 6
MM-M05.08
Rev.000
LOCAL CONTROL PANEL
MPTD-3-0752
FIGURE 2-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
OIL PURIFIER, OIL PIPING DIAGRAM 2-6
Chapter 2 N-15
General
N-16
HOLE
N-6
C DRAIN GUARD PIPE N-17
M.O.P SUCTION PIPE
190
25
190
AIR VENT PIPE
DRAIN
HP. OIL PIPE
N-14
N-14 BRG. OIL SUPPLY PIPE
M.O.P DISCHARGE PIPE
N-12
175 175 185
N-5
C
VIEW A N-9
RETURN OIL FILTER
MAIN OIL TANK BRG. OIL INLET 250A (TO OIL COOLER)
PRESSURE GAUGE PANEL
BRG. OIL INLET 250A (FROM OIL COOLER)
AC TURNING OIL PUMP
DC EMERGENCY OIL PUMP
PRESSURE GAUGE PANEL
MAN HOLE COVER OIL LEVEL GAUGE
DC EMERGENCY OIL PUMP
TO PRESSURE GAUGE PANEL
AC AUXILIARY OIL PUMP
A
N-1
MEZZANINE FLOOR
N-7
N-7 CL MAIN OIL TANK
N-3
380
MAX. LEVEL NOR. LEVEL LOW. LEVEL
150 150
N-8
N-2
N-9
N-4
MM-M05.08
Rev.000
SLIDING SUPPORT
FIXED SUPPORT
SLIDING SUPPORT
GLOUND FLOOR
MPTD-3-0481
FIGURE 2-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
SCHEMATIC ARRANGEMENT OF MAIN OIL TANK AND ASSOCIATED EQUIPMENT 2-7
Chapter 2
General
OIL LEVEL GAUGE
MAN HOLE COVER
PRESSURE GAUGE PANEL
MM-M05.08
Rev.000
LUBE OIL INLET PIPE (FROM COOLER) LUBE OIL OUTLET PIPE (TO COOLER) RETURN OIL STRAINER
FIGURE 2-3 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ARRANGEMENT OF MAIN OIL TANK 2-8
Chapter 2
General
O IL L E V EL G AU G E
M A N H O L E C O VE R
Rev.000
PR ESSU RE GAUGE PANEL
LU B E O IL IN LE T PIP E (F R O M C O O LE R ) L U B E O IL O U T LE T P IP E (T O C O O L ER )
MM-M05.08
R E T U R N O IL ST R A IN E R
FIGURE 2-4 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
PARTIALLY EXPLODED VIEW OF MAIN OIL TANK 2-9
Chapter 2
2.4
General
Construction Refer to Figures 2-4 to 2-6. The main oil tank is a circular, horizontal fabricated steel tank which has a nominal storage capacity of 36,800 liters at the NWL, sufficient to provide the lube oil requirements of the turbine and the generator. The tank has a capacity of 40,180 liters at the maximum operating level and 33,310 liters at the minimum operating level. The main oil tank is supported on a steel support frame fabricated from channel beams and grouted to a concrete foundation. The outside surfaces of the main oil tank are welded with stiffeners at regular intervals to provide rigidity to the tank. The main oil tank is provided with an earthing terminal, which is connected to the plant electrical grounding system, to discharge any leakage of current on the main oil tank to the earth. Stools are provided on top of the main oil tank onto which the AOP, TOP and EOP are mounted. The pumps extend down into the oil tank such that their suctions are located well below the low oil level. Within the main oil tank, the high pressure oil discharged from the MOP or AOP (HP pump) enters a control oil line, which is further connected to the turbine protective devices and the steam admission valves. Likewise, the low pressure oil discharged from the AOP, TOP or EOP enters a common lube oil header, which also receives oil from the No. 2 oil ejector, providing a single lubricating oil line. A bearing oil pressure regulating (relief) valve (Figure 2-23) installed in the lubricating oil line, downstream of the lubricating oil filter, maintains the lube oil pressure at a near constant value by continuously relieving excess oil. The main oil tank is provided with nozzles for the termination of the turbine lube oil drain guard pipe, vents from oil coolers, tank oil temperature indicators, tank drain, filter drains, tank overflow, oil supply and return lines for oil coolers and oil purifier. The main oil tank is also provided with nozzles for the installation of the oil level gauge, level switches and for connecting the vapor extractor fan suction pipe.
MM-M05.08
Rev.000
A duplex type lube oil filter is installed on a grating extension at the top of the main oil tank. A basket type filter is located inside the tank to filter all oil returning to the tank. A hinged door installed above the strainer provides access for the removal of the filter for cleaning or maintenance. A cantilevered extension of the grating at the top of the main oil tank is provided to support the vapor extractor fan. A manhole cover on the top of the tank provides access for internal inspection and maintenance. The main oil tank is also provided with bolted doors at the top for adjusting oil supply adjustable check valve for the MOP, adjustable check valve for bearing oil and bearing oil pressure regulating valve. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-10
Chapter 2
General
A pressure gauge panel is provided on the tank to indicate the oil pump discharge pressures, main oil tank vacuum and the lubricating oil pressure after the cooler. The main oil tank is provided with a ladder to provide access to the equipment installed on the top of the tank. Handrails are installed at the top of the oil tank to provide safety for the operating and maintenance personnel. The major equipment associated with the main oil tank and the turbine lubricating oil system are the following: •
Oil pumps
•
Vapor extractor fan
•
Oil mist separator
•
Oil ejectors
•
Oil level indicators
•
Oil strainers
•
Oil cooler.
2.4.1 Oil Pumps Refer to Figures 2-7 to 2-15. The AOP, TOP and EOP are installed vertically on stools welded to the top of the main oil tank. The AOP is of the shaft type consisting of three impellers which are installed on a common pump shaft driven by an electrical motor. The pump is of the three stage centrifugal pump and delivers 100 l/min of oil at a pressure of 1.08 MPa. The AOP is driven by a 150 kW, 380 V AC, 50Hz motor at a speed of 2950 rpm. The TOP is of the vertically mounted single stage centrifugal type oil pump. The TOP delivers 6100 l/min of oil at a pressure of 0.34 MPa and is driven by a 65 kW, 380 V AC, 50Hz motor at a speed of 1480 rpm. The EOP is also of the vertically mounted single stage centrifugal type oil pump. The EOP delivers 5800 l/min of oil at a pressure of 0.35 MPa and is driven by a 65 kW, 250 V DC motor at a speed of 1480 rpm.
MM-M05.08
Rev.000
The AOP, TOP and EOP are provided with suction strainers, at the pump inlets, to prevent entry of foreign material during operation. The discharges of the AOP pump, TOP and EOP are connected within the main oil tank to provide a common lubricating oil line. Likewise the discharges of the AOP HP pump and the MOP are connected together to provide a single HP oil line. Check valves are installed in the discharge line of each pump to prevent reverse rotation of the standby pumps. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-11
Chapter 2
General
2.4.2 Vapor Extractor Fan Refer to Figure 2-16. The vapor extractor fan is of the single stage centrifugal type. It draws suction from the main oil tank and discharges the oil vapor and non-condensable gases to the atmosphere. The vapor extractor fan maintains a slight vacuum inside the main oil tank. The turbine and generator bearing pedestals connected to the main oil tank via the lube oil return line are also under a slight vacuum. The vacuum in the bearing pedestal prevents leakage of oil or oil vapor along the turbine shaft. The extractor fan is also provided with a butterfly damper at the suction side to adjust gas flow and hence vacuum in the main oil tank. The vapor extractor fan consists of a volute casing (1) which encloses an impeller (2). The impeller is formed from two flat discs enclosing narrow vanes between them. The inlet side disc is shaped to provide an opening and a boss to allow the flow of incoming gases. The impeller is bolted to an impeller hub (3) and the whole assembly is keyed onto the motor shaft (4) and secured with an impeller set bolt (7) and a retainer plate (21). The impeller is overhung inside the volute casing and is supported by the bearings of the drive motor (11). The fan casing is a steel fabricated component which is made in two parts; a casing (1) and a front cover (22). The casing is secured to the motor base frame (12) by welding. The front cover is welded onto the suction cone (5) and is bolted to the fan casing using the suction cone set bolts (6) such that the cone is set inside the impeller boss with a small running clearance. The suction damper (14) is installed in the suction cone adjacent to the suction cone inlet flange (23). The fan casing is provided with a drain pipe (13) to drain any liquid trapped in the fan casing. Any oil droplet collected in the fan casing is drained into the main oil tank overflow line through a U-loop seal.
MM-M05.08
Rev.000
The suction cone, the fan casing and the discharge pipe are shaped to smoothly guide the flow of air and vapor to promote efficient performance of the fan. The suction cone and the discharge pipe are flanged for connection to their respective ducts. An oil seal assembly is provided on the fan casing, where the shaft penetrates the casing, to prevent leakage of oil droplets and/or vapor along the shaft. The oil seal assembly consists of an oil seal housing (20) which is secured to the fan rear casing by welding. The shaft seal consists of two oil seal rings (10) mounted one on either side of a grease-packed lantern-ring (9) inside the oil seal housing and secured by a retainer ring (19). Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-12
Chapter 2
General
A grease nipple (15) is provided on the top of the oil seal housing to facilitate injection of seal lubrication during operation and a drain line with a cock (16) at the bottom to drain the spent grease. The impeller is rotated by a 3.7 kW, 400 V induction motor (11) at 3500 rpm. The motor is mounted on a bracket welded to the base frame.
2.4.3 Oil Mist Separator Refer to Figure 2-17. The oil mist separator is installed at the exit of the discharge line of the vapor extractor fan to remove any traces of oil present in the oil vapor. The oil mist separator consists of a shell (3) in which six demister cartridges (5) are arranged in a circle. The shell is divided into two compartments, the inlet compartment (22) and the outlet compartment (23). The gas vapor enters the inlet compartment and passes through the six cartridges which are arranged in the outlet compartment. Each demister cartridge is secured to the compartment division plate with an element holder (6), tie-bolts (7) and nuts (8). The shell is flanged at the top end and is closed with a cover (1). The flanged joint between the shell and the cover is sealed by an O-ring (9) using bolts (10) and nuts (11). Drain connections (12) are provided both in the inlet and the outlet compartments. The oil droplets present in the oil vapor are trapped by the cartridges and returned to the inlet compartment, then to the main oil tank through a U-loop seal.
2.4.4 Oil Ejectors Refer to Figure 2-18. Two oil ejectors (No. 1 and No. 2 oil ejectors) are installed within the main oil tank, one on the suction line of the MOP and the other on the lubricating oil line as indicated in Figure 2-6.
MM-M05.08
Rev.000
The No. 1 oil ejector draws oil from the main oil tank and discharges to the suction of the MOP. The No. 2 oil ejector discharges the oil drawn from the main oil tank to the turbine bearing lubricating oil header. Each oil ejector consists of an inlet pipe (16), a nozzle block (5), a diffuser (15) and a check plate (1). The ejectors draw oil from the main oil tank by virtue of the vacuum developed by the motive oil flow from the discharge of the MOP through the nozzles. The check plate provided around the nozzle box prevents back-flow of oil into the main oil tank when the MOP is not in service. The ejector draws oil from the main oil tank through a suction strainer (17).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-13
Chapter 2
General
2.4.5 Oil Level Gauge Refer to Figure 2-19. A float type level gauge is provided on the top of the tank to indicate the oil level locally. The oil level gauge consists of a hollow polypropylene float (1) which is in contact the oil inside the main oil tank from where a float rod (2) extends upwards from the main oil tank. The float is guided within a circular body (16) and the float rod within a flange (3) during its vertical movement. An indicator (7) secured at the top end of the float rod moves vertically indicating the actual level in the oil tank. A graduation pipe (8), made of acrylic material and secured between the flange (3) and the upper flange (11), provides the actual indication of the tank level. A cover (13) secured between the flange (3) and the upper flange (11) prevents entry of dust into the main oil tank through the gap between the float rod (2) and the flange (3). Two level switches/contacts (5 and 10) are installed on the stud bolt (6) to provide remote high and low level alarms in the central control room (CCR). An alarm is initiated in the CCR to alert the operators when the oil level in the tank exceeds the low or high contacts.
2.4.6 Oil Strainers The main turbine lubricating oil system is provided with a lube oil strainer, and a return oil strainer to ensure trouble-free operation of the main turbine.
Lube Oil Strainer Refer to Figure 2-20.
MM-M05.08
Rev.000
The lube oil strainer provided in the bearing lube oil supply line is of the duplex type. It consists of a twin body (1) interconnected by a cock plug, each body containing one filter element (31). The cock plug directs the unfiltered oil to the selected filter and the filtered oil to the outlet line. A cock handle (11) enables selection of one of the filters when moved to the extreme position. Positioning of the cock handle in the mid-position enables both filter elements to be in service. This ensures a smooth change over of the filter elements. The adjusting handle (21) enables locking of the cock handle in position after a change-over. The adjusting handle is moved up by rotating it in the anti-clockwise direction and the cock handle is changed over and then the adjusting handle is turned in the clockwise direction to lock the cock plug. Each filter body is provided with a cover (2), which is held in position by stud bolt (16) arrangement, for easy removal and replacement of the filter element. Each filter element is provided with a handle (34) at the top, which abuts the body cover and secures the filter element tightly to the filter brim. An O-ring (19) inserted between the filter cover and the filter body prevents oil leakage. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-14
Chapter 2
General
Each filter body is provided with a drain plug (36) and an air vent (40) with isolating valves to drain and replace oil during filter maintenance. An equalizing line is provided with an equalizing valve (42) between the two filter element bodies to enable filling oil after maintenance, thereby avoiding a pressure drop during filter changeover. The equalizing valve is normally in the closed position and is opened only to fill the standby filter body. Inlet and outlet nozzles are cast integral with the body and are connected to the change over plug chamber through internal passages.
Return Oil Strainer Refer to Figure 2-21. The return oil strainer is of the vertical, cylindrical, basket type. The cylindrical strainer body is fabricated from steel SS400 and the filter element is wire gauze made from SUS304W. The strainer assembly consists of a cylindrical body (3) onto which a wire gauze set (10, 11) is secured using countersunk screws (12, 15) and bolts (13). The wire gauze set consists of an 80 mesh sandwiched between a 6 mesh and a 16 mesh for normal turbine operation. The strainer is also provided with an additional 100 wire mesh set to be used during turbine oil flushing. The return oil strainer is placed inside the return oil compartment within the main oil tank. The return oil enters through the inlet to the strainer and flows outwards thus retaining any debris contained in the returning oil. The main oil tank is provided with a hinged cover above the filter for periodical inspection and cleaning of the strainer.
2.4.7 Oil Cooler Refer to Figure 2-22. The main turbine lubricating oil system is provided with two plate type oil coolers for the temperature control of oil in the main oil tank. A transfer valve installed between the two oil coolers enables the selection of the oil cooler to be in service.
MM-M05.08
Rev.000
The oil cooler consists of several heat transfer plates (3) arranged in a line between a fixed S-frame (1) located at the front and a movable E-frame (2). The heat transfer plates are arranged in a line and held together by the E-frame. The E-frame is tightened uniformly by ten tightening bolts (7) and nuts (8) to provide a leak-tight joint between the adjacent heat transfer plates. The heat transfer plates and the E-frame are supported in a lower guide bar (4) at the bottom and guided by an upper guide bar (5) at the top. The lower guide bar and the upper guide bar are supported by the S-frame (1) at the front end and a guide bar support (6) at the rear end.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-15
Chapter 2
General
The entire cooler assembly is supported by the S-frame and the guide bar support by bolting them to the concrete foundation. The S-frame contains the supply and return nozzles for both lubricating oil and cooling water. Hot oil enters the bottom right nozzle (S4) and leaves the top right nozzle (S2) whereas the cooling water enters the top left nozzle (S1) and leaves the bottom left nozzle (S3).
MM-M05.08
Rev.000
For further details about the turbine oil cooler, refer to the vendor operation and maintenance manual No. OM – 02.01, Turbine Oil Cooler.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-16
Chapter 2
General
O IL LEVEL G AUG E
M AN HO LE CO VER
NO .2 O IL EJECTOR
MM-M05.08
Rev.000
SLID ING SU PPO RT
FIGURE 2-5 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
CUTAWAY VIEW OF THE MAIN OIL TANK 2-17
General
DRAIN GUARD PIPE 900A AIR VENT
MAIN BRG. OIL
MAIN OIL PUMP DISCHARGE
PRESSURE GAUGE PANEL
HP OIL
MAIN OIL PUMP SUCTION
Chapter 2
65A
8A
25A
OIL COOLER AIR VENT
25A B C
50A 100A
50A
100A
ANGLE TYPE CHECK VALVE
BFPT OIL INLET
100A
PURIFIED OIL INLET LUBE OIL STRAINER STRAINER (A) 25A
80A 80A
25A 20A
200A
B
250A
6-WAY VALVE
250A
200A
200A
(B) 80A
125A 200A
ORIFICE
ORIFICE
250A
OIL COOLER
250A
250A
MAIN OIL TANK INTERNAL PIPING DIAGRAM
200A
(A)
200A
200A
20A
MPTD-3-0484(B)
MM-M05.08
Rev.000
LUBE OIL STRAINER STRAINER (B)
250A
125A
No.2EJECTOR
250A
MOP
80A
200A
200A
NON-RETURN VALVE
No.1EJECTOR
200A 80A
250A
BRG
100A
80A
25A
250A
OIL COOLER
O10
TO OIL PURIFIER
15A
15A
15A
O5
15A
DRAIN BOX
50A
M
RELIEF VALVE
125A
M
STRAINER
100A
M
250A
AOP AC
250A
TOP AC
250A
EOP DC
8A
8A
8A
8A
MAIN OIL TANK
FIGURE 2-6 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
MAIN OIL TANK (INTERNAL PIPING) 2-18
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-7 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE AUXILIARY OIL PUMP 2-19
MM-M05.08
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi FIGURE 2-8 MPTD-3-0486
STRAINER
CASING (1st STAGE)
CASING (2nd STAGE)
AIR VENT
AIR VENT
CASING (3rd STAGE)
SLEEVE BEARING
OIL FLINGER
OIL SEAL
PUMP FRAME
SUCTION COVER (LP)
IMPELLER (1st STAGE)
SLEEVE BEARING
IMPELLER (2nd STAGE)
SLEEVE BEARING
IMPELLER (3rd STAGE)
COLUMN PIPE
SHAFT
THRUST BEARING
BEARING COVER
COUPLING
MOTOR
Chapter 2 General
CUTAWAY VIEW OF THE AUXILIARY OIL PUMP 2-20
MM-M05.08
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 37
52b
25
27
28
32
36
23
21
17
FIGURE 2-9
26
3
31
30
11
45
DETAIL OF "X"
48a 49a 50a 51a
12
4
14
15
48c 49c 50c 51c
53
18
48e 49e 50e 51e
40
41
44
43
Rev.000
8
13c
38
13a
22
24
52a
13b
56
1
47
49d 49e 49f
49a 49b 49c
DETAIL OF "Y"
50d 50e 50f
50a 50b 50c
48d 48e 48f
AIR VENT HEXAGONAL HEAD BOLT DRIVE MOTOR BOLTS, MOTOR TO FRAME BOLTS, FRAME TO M.O.T
SET SCREW
SET SCREW
IMPELLER RING
CASING RING
PUMP FRAME COLUMN PIPE SHAFT 1st STAGE CASING 1st STAGE IMPELLER SUCTION COVER STRAINER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER KEY HEXAGONAL HEAD BOLT SCREW SLEEVE BEARING SHAFT SLEEVE O-RING 2nd STAGE CASING SHAFT SLEEVE 2nd STAGE IMPELLER O-RING IMPELLER KEY SLEEVE BEARING HEXAGONAL HEAD BOLT O-RING IMPELLER KEY SLEEVE BEARING 3rd STAGE CASING HEXAGONAL HEAD BOLT 3rd STAGE IMPELLER THRUST (BALL) BEARING COLLAR BEARING NUT BEARING WASHER OIL FEED TUBE OIL FLINGER OIL SEAL HEXAGONAL HEAD BOLT KNOCK BOLT BEARING COVER V-RING COUPLING HALF (PUMP) COUPLING HALF (MOTOR) COUPLING BOLT & NUT COUPLING BUSH KEY COUPLING COVER HEXAGONAL HEAD BOLT
DESCRIPTION
51d 51e 51f
1 2 3 4 5 6 7 8 9 10 11 12 13a,b,c 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48a,b,c, d,e,f 49a,b,c, d,e,f 50a,b,c, d,e,f 51a,b,c, d,e,f 52 a,b 53 54 55 56
ITEM
48a 48b 48c
7
6
16
5
48b 49b 50b 51b
20
19
"X"
2
34
33
35
38
39
42
55
51a 51b 51c
10
9
"Y"
46
Chapter 2 General
SECTIONAL VIEW OF THE AUXILIARY OIL PUMP 2-21
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-10 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE TURNING OIL PUMP 2-22
MM-M05.08
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi FIGURE 2-11 MPTD-3-0489
PUMP CASING
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
OIL FLINGER
STRAINER
SUCTION COVER
IMPELLER
SLEEVE BEARING
BEARING COVER
Chapter 2 General
CUTAWAY VIEW OF THE TURNING OIL PUMP 2-23
Rev.000
MSD-3-0584
MM-M05.08
Y
DETAIL OF "X"
X
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 27
10
9
48
DESCRIPTION
29 33
PUMP FRAME COUPLING COVER (SAFETY) COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT HEX. BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR TUBE CONNECTOR OIL FEED TUBE HEX. HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEX. HEAD BOLT & LOCK WASHER HEX. HEAD BOLT & LOCK WASHER HEX. SOCKET SET SCREW HEX. SOCKET SET SCREW PUMP CASING SLEEVE BEARING PLUG TUBE CONNECTOR O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER HEX. SOCKET SET SCREW HEX. HEAD BOLT & LOCK WASHER DRIVE MOTOR BOLTS, FRAME TO M.O.T BOLTS, MOTOR TO FRAME
DETAIL OF "Y"
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
ITEM
Chapter 2 General
FIGURE 2-12 SECTIONAL VIEW OF THE TURNING OIL PUMP 2-24
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-13 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE EMERGENCY OIL PUMP 2-25
PUMP CASING
STRAINER
SUCTION COVER
IMPELLER
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
General
MM-M05.08
Rev.000
OIL FLINGER
SLEEVE BEARING
BEARING COVER
Chapter 2
FIGURE 2-14 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
CUTAWAY VIEW OF THE EMERGENCY OIL PUMP 2-26
MM-M05.08
45
10
6
4
5
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 18
20
29
21
19
22
33
28
31
32
36
41
42
15
14
12
14
2
DETAIL OF "X"
40
23
27
39
25
24
35
26
37
8
9
3
17
13
16
44
7
1
33
29
24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
27
20
33
PUMP FRAME COUPLING COVER COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR TUBE CONNECTOR OIL FEED TUBE HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEAD BOLT & LOCK WASHER HEAD BOLT & LOCK WASHER SOCKET SET SCREW SOCKET SET SCREW PUMP CASING SLEEVE BEARING PLUG TUBE CONNECTOR O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER SOCKET SET SCREW HEAD BOLT & LOCK WASHER
DESCRIPTION
DETAIL OF "Y"
ITEM
Chapter 2 General
FIGURE 2-15 SECTIONAL VIEW OF THE EMERGENCY OIL PUMP 2-27
Chapter 2
3
General
15
17
9 19 10 8
7
VIEW A - A 4
21 20
DETAIL OF SHAFT SEAL
24 1
6 2 24
14
A
A
15
20
11
23 5 18
12
Rev.000 MM-M05.08
16
16
22
13 MPTD-3-0494
FIGURE 2-16 SECTIONAL VIEW OF THE VAPOR EXTRACTION FAN Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
2-28
Chapter 2
A
"C"
General
19 20 21 1
2 6
15
8
16
7
1
23
VIEW A
5 14
18 3 3 14
B
B
17
13 4 4
22
B-B
10 12
9
2 3
11
MM-M05.08
Rev.000
DETAIL "C"
MPTD-4-1089
FIGURE 2-17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
COVER SHELL FLANGE SHELL END PLATE DEMISTER CARTRIDGE ELEMENT HOLDER TIE BOLT NUT O-RING BOLT NUT PLAIN WASHER FLANGE NOZZLE PIPE FLANGE NOZZLE PIPE DRAIN CONNECTION NAME PLATE EYE NUT BOLT PLAIN WASHER INLET COMPARTMENT OULET COMPARTMENT
OIL MIST SEPARATOR
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-29
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-18 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ARRANGEMENT OF NO. 1 & 2 OIL EJECTOR
2-30
Chapter 2
General
11
13
12 8
7
6
4
14 15
3
17
2
1 150
HIGH ALARM OIL LEVEL
150
NORMAL WORKING LEVEL 16
MM-M05.08
Rev.000
LOW ALARM OIL LEVEL
MPTD-4-0499
FIGURE 2-19
MAIN OIL TANK LEVEL GAUGE ASSEMBLY
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-31
Chapter 2 41
42
General
45 44
34
43
UP S
O
32
30
VIEW B - B
9
23 18
12
20
38
17
13 24
10
16
15
A
2 19
22
B
3
21
14 11
35
28
24
B
DETAIL "C"
27 29 2
26
8
9
25
40 39
37
46 34
A 19
"C"
7
32
8 16
35 1
31
19
MM-M05.08
Rev.000
8 36 5
MPTD-3-0496
33
4
6
16
19
VIEW A - A FIGURE 2-20
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
LUBRICATING OIL STRAINER ASSEMBLY 2-32
Chapter 2
5
General
10 14
1
6
12 7
16 O MESH 80 O MESH
DETAIL "A"
5
16O MESH 1 DETAIL "A"
10 3
8
14 11
6 17 7 9 16 O MESH
12
80 O MESH
3
10
16 O MESH 15
4 8 9
13 4
MM-M05.03
Rev.000
2
11
16 2
DETAIL "B"
DETAIL "B"
MPTD-3-0497
FIGURE 2-21 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
RETURN OIL STRAINER 2-33
Chapter 2
CW INLET
1 2 3 4 5 6 7 8 9 10 11 12
OIL OUTLET
S- FRAME E- FRAME HEAT TRANSFER PLATE LOWER GUDE BAR UPPER GUDE BAR GUIDE BAR SUPPORT TIGHTENING BOLT NUT S1-NOZZLE (CW INLET) S3- NOZZLE (CW OUTLET) S4-NOZZLE (OIL INLET) S2- NOZZLE (OIL OUTLET)
LUBE OIL O UTLET
CW O UTLET
LUBE O IL INLET
PLATE NO. 1 3
CW OUTLET
CW INLET
A SIDE
S
6
General
B SIDE
D1234
PLATE NO. 2 4
OIL INLET
179
178
E 0000 E
PLATE ARRANGEMENT
(B) SIDE 1234 89 0234 1034 1204 1230 0034 1200 0230 1004
Rev.000
6
MM-M05.08
TOTAL
89
(A) SIDE 1234 88 1230 1204 1034 0234 1200 0034 0230 1004
THE POSITIONS OF HOLE ARE CALLED 1,2,3 AND 4. THE PART HAVING NO HOLE IS INDICATED BY 0 INSTEAD OF 1,2,3, AND 4. * SHOWS DRAIN HOLES AND AIR VENT. 1
0
1O
2
O4
3O
4
D1234 E000
1 1
*
TOTAL
90
B10*4
A1234
MPTD-3-1090
FIGURE 2-22 TURBINE OIL COOLER Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
2-34
Chapter 2
A
General
A
14
10
19
23
18 2
20
A-A
MM-M05.08
Rev.000
MPTD-4-0498
FIGURE 2-23
BEARING OIL PRESSURE ADJUSTING VALVE
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-35
Chapter 3
Specifications
Chapter
3 Specifications TABLE 3-1
MAIN OIL TANK
Description
Details
Equipment Number
03MAV01BB101
Quantity
1 set
Manufacturer
Mitsubishi Heavy Industries Limited
Type
Horizontal, cylindrical
Capacity at NWL
36,800 liters
Capacity at High level
40,180 liters
Capacity at Low level
33310 liters
Fluid
Turbine Oil (ISO VG32)
Tank Dimensions
8140mm x 3050mm
Weight
Empty
23.5 ton
Full
71.8 ton
TABLE 3-2
AUXILIARY OIL PUMP
Description
Details
Equipment Number
03MAV03AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
3DVCW-50B-NA
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
100 L/min
Discharge pressure
1.08 MPa
Suction pressure
0
Rotation
View from driver - CW
MM-M05.08
Rev.000
Material Discharge bore rating
ANSI 300LB-50A-FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
22kW, 380V, 3Ø,50Hz,
Speed (synchronous)
3000 min
Weight (Pump + Motor)
(310 kg + 181kg)
-1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-1
Chapter 3
TABLE 3-3
Specifications
TURNING OIL PUMP
Description
Details
Equipment Number
03MAV04AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
DVC-200E-NE
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
6100 L/min
Discharge pressure
0.34 MPa
Suction pressure
0
Rotation
View from driver - CW
Construction Discharge bore rating
ANSI 150LB-200A.FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
65kW, 380V, 3Ø,50Hz
Speed (synchronous)
1500 min-1
Weight (Pump + Motor)
(700 kg + 560kg)
TABLE 3-4
EMERGENCY OIL PUMP
Description
Details
Equipment Number
03MAV05AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
DVC-200E-NE
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
5800 L/min
Discharge pressure
0.35 MPa
Suction pressure
0
Rotation
View from driver - CW
MM-M05.08
Rev.000
Construction Discharge bore rating
ANSI 150LB-200A.FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
65kW, 250VDC, 3Ø, 50Hz,
Speed
1500 min-1
Weight (Pump + Motor)
(700 kg. +
1465kg)
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-2
Chapter 3
TABLE 3-5
MAIN OIL TANK VAPOR EXTRACTOR FAN
Description
Details
Equipment number
03MAV07AN101/102
Quantity
2
Fan
Manufacturer
Azuma Sofuki Co. Ltd.
Model
CTB-E-MD/6-75 Turbo Blower
Type
Single stage, horizontal, centrifugal type
Motor Rating
7.5 kW, 2P, 380 V AC, 3-Ø, 50 Hz
Rotating speed
2900 rpm
Direction of rotation
Clockwise (viewed from motor end)
Capacity
17 m3/min
Static pressure
6.86 kPa at 60ºC
Inlet pressure
– 1.47 kPa
Outlet pressure
5.39 kPa
Fluid
Oil vapor
Fluid temperature (design)
60°C
Major material
Impeller
SS400
Impeller hub
S45C
Casing
SS400
Blower
300 kg
Motor
62 kg
MM-M05.08
Rev.000
Weight
Specifications
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-3
Chapter 3
TABLE 3-6
Specifications
OIL MIST SEPARATOR
Description
Details
Equipment number
03MAV07AT101
Quantity
1 set
Manufacturer
Taiyo Techno Ltd.
Model
ME6-839-150/250A-V
Fluid
Air + Oil mist (ISO VG32)
Flow rate
17 m3/min
Design pressure
0.1 barg
Design temperature
80°C
Operating pressure
450 mmAq (0.044 barg)
Operating temperature
60°C
Differential pressure
Less than 150 mmAq (0.0147 bar) @ Normal flow
Maximum allowable differential pressure
750 mmAq (0.074 bar)
Major material
Shell
SUS304TP-A
Cover
SS304
Cartridge
Fiber glass
Oil mist separator
330 kg
Cartridge
5.5 kg x 6
Weight
TABLE 3-7
MAIN OIL TANK LEVEL GAUGE
Description
Details
Equipment number
03MAV01CL101
Quantity
1 set
Manufacturer
Demper Kogyo Co, Ltd.
Type
Float type
Fluid
Turbine Oil (ISO VG32)
Specific gravity
0.845
Range
L200-NO-H600 Float
Polypropylene
Float rod
SUS304
Gasket
V#6500
MM-M05.08
Rev.000
Major material
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-4
Chapter 3
TABLE 3-8
LUBE OIL STRAINER
Description
Details
Equipment number
03MAV10AT501/502
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Duplex
Fluid
Turbine Oil (ISO VG32)
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
Wire mesh size
P x 16 x 150 x 16
Effective filter passage area
6243 cm2
Max. allowable differential pressure (at 59ºC and 2800 l/min)
0.122 bar
Major material
Body
FCD450
Filter cylinder
SUS304
Wire mesh (filter element)
SUS304
Weight
2540 kg
TABLE 3-9
RETURN OIL STRAINER
Description
Details
Equipment number
03MAV01AT501
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Basket type
Fluid
Turbine Oil (ISO VG32)
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
No. of holes
6415
Wire mesh size
80 mesh, 16 mesh, 6 mesh
Effective passage area
2474 cm2
Max. allowable differential pressure
0.03 MPa
Major material
Filter cylinder
SS400
Wire mesh (filter element)
SUS304
Under cylinder bush
SS400
Upper cylinder bush
SS400
Weight (Approx.)
43 kg
MM-M05.08
Rev.000
Specifications
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-5
Chapter 3
TABLE 3-10
TURBINE OIL COOLER
Description
Details
Equipment number
03MAV08AC101/102
Quantity
2
Manufacturer
Hisaka Works, Ltd.
Type
Horizontal, Plate type
Model
UX-915-KNHP-179
Relative direction of fluids
Counter current
No. of plates
179
Heat transfer area (m2)
322.14
Heat exchanged (kW)
3694
No of passes
Specifications
Cold Side
Hot Side
1
1
Cooling Water
Oil ISO VG32
Flow rate (m /h)
600
366
Inlet temperature (ºC)
38.0
67.6
Outlet temperature (ºC)
43.3
46.0
Pressure drop (MPa)
0.068
0.042
Design pressure (MPag)
1.00
0.41
Design temperature (ºC)
80
80
89 x 1
89 x 1
Fluid 3
Plate arrangement Material
SA-240-304
Plate gasket
G-NBR
Frame
SA-516 Gr60
Nozzle
SA-240-316L
Empty
5390 kg
Flooded
7330 kg
MM-M05.08
Rev.000
Weight (approx.)
Plate
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-6
Chapter 4
Preventive Maintenance
Chapter
4 Preventive Maintenance Preventive maintenance is performed to avoid or minimize the possibility of failure or deterioration of equipment performance. This requires a constant effort from maintenance staff to ensure that the equipment is available on demand. There are two categories of preventive maintenance, Routine Maintenance and Annual Outage Maintenance. Routine maintenance helps to reduce the possibility of outage and hence the downtime of machinery. Annual outage maintenance is required to maintain the internal components of the installed equipment. Though vendor/manufacturer’s recommendations provide a good basis for the provision of a preventive maintenance schedule, the frequency and other details should be updated from time to time based on practical experience and actual feedback gathered through inspection and normal operation of the equipment/plant. Consideration of these site related specific issues will make the preventive maintenance more effective.
4.1
Prerequisites The necessary prerequisites for the preventive maintenance of the Main Oil Tank, Auxiliary oil Pumps and Vapor Extractor Fan are as follows:
Scheduling is the first activity in the preparation of a preventive maintenance program; the schedule is to include planning to attend all operating equipment on a fixed regular basis. Initially, schedules will be prepared based on vendor/manufacturer’s generic instructions, the schedules will however be updated (frequency, nature of inspection etc.) as site-specific data becomes available. Preventive maintenance is to be coordinated with other concerned departments. In the case of a major scheduled outage, maintenance personnel and other concerned departments should jointly produce a plan of activities, well in advance, to decide the inspection activities and other logistics (such as availability and supply of required equipment, spare parts, tools and tackle, etc.). The schedule should clearly identify the critical path. Priority is to be assigned to specific tasks that also involve parallel activities to reduce the equipment downtime and to complete the work within scheduled time.
MM-M05.08
Rev.000
4.1.1 Scheduling
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--1
Chapter 4
Preventive Maintenance
4.1.2 Department Interface/Notification Departmental communication is essential and interfacing between departments is to be maintained to avoid any lack of communication that may arise and adversely affect routine or annual outage maintenance work. Prior to commencing preventive maintenance all concerned persons (shift supervisor, operators, etc.) are to be made aware of the schedule and the nature of the activities that are to take place. If it becomes clear that there is a problem or a conflict of interests in the schedule (e.g. the maintenance schedule interferes with another group’s work), this is to be resolved by mutual agreement between the parties involved.
4.1.3 Isolation of Equipment It is important that isolations are agreed and valid clearances and work permits are obtained before any maintenance work is performed. The isolation boundaries of the particular equipment to be taken under maintenance are to be clearly identified. In the case of an electrical isolation the power supply shall be disconnected and/or the fuses removed. In the case of mechanical isolations, the valves or other mechanical means of isolation, at the isolation boundaries are to be closed and if possible locked closed. The system within the isolation boundaries is to be de-pressurized.
4.1.4 Safety Precautions
Prior to commencement of actual work the person carrying out the work is to make a safety check based on the above method statement and also use his own judgment to ensure that the equipment and the prevailing working conditions are safe. During maintenance work, every employee should follow the safe working procedures detailed in the method statement.
MM-M05.08
Rev.000
Before the commencement of any maintenance work, the person in charge of the work site is to perform a risk assessment and method statement for the safe execution of the job scope activities, described within the work permit. Risk assessment includes identifying, recognizing and understanding the potential hazards associated with the work. The method statement is to illustrate the safe working practices in accordance with the safety manual and manufacturer’s instruction manual to prevent personal injury and/or equipment damage.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--2
Chapter 4
4.2
Preventive Maintenance
Routine Maintenance The purpose of routine maintenance is the implementation of the preventive maintenance program on a day-to-day basis through a planned and correctly executed inspection. The routine maintenance activities are very important in that if they are properly carried out, they will enhance equipment reliability. As a result, good routine maintenance activities may help in cost reduction in the long run through minimization of equipment downtime. Cleaning is an important and necessary maintenance activity to prevent the ingress of foreign material. Other major points are as follows: (Summarized major routine activities are also shown in Table 4-1.)
4.2.1 Preparation a)
Parts, Tools and Equipment It is important to prepare the necessary parts, tools and equipment before commencing actual work. Routine maintenance generally requires a standard mechanical toolkit, consumables, cleaning materials etc. Any shortages of these items will affect the maintenance activity and may delay the schedule. Personal Protective Equipment (PPE) is necessary for maintenance staff at all times. Upon completion of work, all tools and equipment should be serviced and stored correctly to ensure availability for further use.
b)
Documentation
MM-M05.08
Rev.000
Documentation is an important part of any maintenance duty. All findings should be noted on a comprehensive log sheet, reporting all aspects of the equipment observed during the routine inspection. The data recorded in these documents will be useful in determining the root cause of equipment failure found during the annual outage/corrective maintenance work. Any abnormalities, if observed, are to be immediately communicated to the concerned department/personnel for rectification and are to be detailed in the report.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--3
Chapter 4
Preventive Maintenance
4.2.2 Inspection and Maintenance a)
Main Oil Tank Visually check the external surfaces of the tank for signs of leakage, corrosion or damage (any damage should immediately be reported to the supervisor). Monitor the oil level in the main oil tank and ensure that a continuous oil circulation is maintained through the oil purifier. Also ensure that the tank oil level is maintained nearer to the NWL and below the maximum oil level to accommodate the flow-back oil quantity expected on Unit shutdown. The minimal-optimum vacuum is to be maintained to prevent oil and/or vapor leakage. All bolts and nuts securing manhole and tank nozzle connections are to be checked for tightness. Check the position of vapor extractor fan suction damper and readjust to achieve the required vacuum. Lock the damper handle after vacuum adjustment. Monitor the running pump for discharge pressure and for signs of abnormal vibration and temperature. If any abnormality is observed, take remedial measures as indicated in this manual, if the trouble still exists advise your supervisor. Monitor the lube oil filter differential pressure at regular intervals and changeover to the standby filter when blockage is indicated. After changeover, clean or replace the blocked filter and place it in standby mode. Check the return oil strainer regularly to prevent any accumulation of debris. Clean the strainer and remove any foreign matter. Check the strainer for any signs of damage that could occur with prolonged use. Monitor the E/H oil pump suction and discharge filters differential pressures at regular intervals. Clean or replace the filters as necessary when blockage is indicated.
MM-M05.08
Rev.000
Collect periodic oil sample from the tank overflow line and analyze the sample for oil properties in a laboratory. Ensure the oil sample results are within permissible limits.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--4
Chapter 4
b)
Preventive Maintenance
Auxiliary Oil Pumps Auxiliary oil pumps to be monitored for vibration. Check for any loose motor holding bolts and tightened them if vibration is observed. Another area that deserves attention is the identification of any abnormal noise. Any abnormal noise generated should be investigated and the source must be identified.
c)
Vapor Extractor Fan
DANGER Take care near rotating machinery, hands and clothing can be drawn into machinery. Always check that all guards are in place before starting any rotating machinery. The vapor extractor fan is to be monitored for vibration. Check for any loose motor holding bolts and tighten them if vibration is observed. Perform an alignment check and correct if any misalignment is observed. Vibration may also be generated by an imbalance of the impeller wheel resulting from corrosion or deposit of impurities on the impeller or accumulation of oil in the fan casing. Check for any accumulated oil in the fan casing and blockage in the casing drain if vibration is apparent. If records indicate an increased vibration level, the fan should be monitored closely and if the increase persists, inspection and rectification should be arranged.
MM-M05.08
Rev.000
The vapor extractor fan motor and seals are to be checked for any abnormal increase in temperature. Inject fresh grease into the seal housing and/or the motor bearings through the grease nipples provided and if an increase in temperature is observed. Remove the spent grease through the drain cock while greasing. Observe the performance of the bearings and/or seals after greasing and if higher temperature persists, inspection and replacement should be arranged. Another area that deserves attention is the identification of any abnormal noise. Any abnormal noise generated should be investigated and the source identified. Visually inspect the extractor fan for any leakage or damage and rectify as required.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--5
Chapter 4
TABLE 4-1
No.
1
Description
Main oil tank
Major Check Item
Preventive Maintenance
ROUTINE MAINTENANCE CHECKLIST
Check Method
Check Reference
Action to be Taken (if beyond acceptable limit)
Leakage, corrosion Visual or damage
No leakage, corrosion or damage
Isolate and repair as necessary
Oil level
Level gauge
NWL
Add fresh oil if level is low and transfer oil if level is high
Vacuum inside the tank
Installed instrument
-0.5 ~ -1 kPa(g)
Check manhole doors and adjust extractor fan suction damper
Oil quality
Lab analysis
No trace of oil contamination
Check oil purifier operation
Remarks
Recommended Maintenance Frequency
Daily
Daily Daily
Monthly
2
Oil pumps
Running oil pump pressure, vibration and overheating
Portable testing instruments and installed instrument
Normal pressure, vibration and temperature
Analyze and rectify causes for low discharge pressure, high vibration and overheating
Daily
3
Lube oil pressure
Differential pressure
Installed instrument
<0..5 bar
Changeover to the standby filter and clean or replace the blocked filter
Daily
5
Return oil strainer
Blockage
Visual
No blockage
Clean the filter element
MM-M05.09
Rev.000
Monthly
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4--6
Chapter 4
Preventive Maintenance
Continued from previous page. TABLE 4-1 No.
6
Description
Vapor extractor fan
Major Check Item
Vibration
ROUTINE MAINTENANCE CHECKLIST
Check Method
Portable vibration meter
Check Reference
Action to be Taken (if beyond acceptable limit)
Remarks
Recommended Maintenance Frequency
No tangible vibration Check and tighten motor holding
bolts Shut down and check the impeller wheel balance
Daily
Perform alignment check Motor bearing and seal Portable temperature thermometer
Allowable Inject fresh grease. If the temperature temperature of 750C is still high, stop the fan and investigate or ambient plus 400C the cause of overheating whichever is less
Abnormal noise
Audible
No abnormal noise
Check for internal rubbing
Daily
Vapor leakage
Visual, audible and by touch
No tangible vapor leakage
Shutdown and rectify the leakage
Daily
MM-M05.09
Rev.000
Daily
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4--7
Chapter 4
4.3
Preventive Maintenance
Annual Outage Maintenance The purpose of annual outage maintenance is the implementation of a preventive maintenance program on a yearly (or some multiple) basis through a planned and correctly executed maintenance work program accompanying necessary inspections. Such outage maintenance activities are very important in the sense that if properly undertaken these enhance the life and reliability of the equipment. The turbine manufacturer/vendor has a recommended interval for inspection and maintenance of the lubrication system in general it is two years. A two year interval is defined by the turbine manufacturer/vendor as a minor overhaul interval. The turbine major overhaul interval is four years. However, some of the lubrication equipment may have maintenance requirements outside this framework. These situations are indicated in the text. Major activities related to annual outage maintenance are as follows: (Summarized major activities for outage maintenance are also shown in Table 4-2).
4.3.1 Preparation a)
Parts Tools and Equipment Refer to Subsection 4.2.1 a), Parts Tools and Equipment. In addition, it will be necessary to identify and request the provision of any spare part requirements. Annual outage will, in certain cases, require the use of material handling equipment. Unused spare parts are to be returned for correct storage and used spare parts are to be replaced.
b)
Documentation Refer to Subsection 4.2.1 b), Documentation.
On completion of annual outage maintenance work, the equipment is to be monitored for correct operation and maintenance data logging. This will help to determine the correct intervals of preventive maintenance activities to ensure optimum plant availability. The correct recording of the findings during inspection will build a valuable document for future reference.
MM-M05.08
Rev.000
Records are to be maintained to record information regarding spares and consumables used. These records will be used for future reference and spare parts replacement.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-8
Chapter 4
Preventive Maintenance
4.3.2 Inspection and Maintenance Normal run down, cooling and isolation procedures are to be followed. It should be noted that there is a manufacturer/vendor statement of preference to keep the turning gear in operation whenever possible, between shut down and start up. If access to equipment that affects the turbine rotating parts is required quickly from operating conditions, there are clear procedures that must be followed. Loss of availability of lubrication and conditioning equipment will normally affect turbine operation. The procedures for various shutdown situations are provided in Appendix F, Turning Gear Operation During Shutdown. Operations personnel are to carry out the turbine shutdown with due regard to these procedures. These are standard procedures for various shutdown situations but dependent on the work content and the intended duration of the outage it is normal that the actual stoppage of the turning gear, lubricating oil, seal oil pumps, etc. is a joint operational and maintenance department decision. Limited access to the lubricating oil system for maintenance may be possible with the Unit in operation. However, the annual outage inspection and maintenance of the lubricating oil pumps requires entry into the MOT to disconnect and secure the discharge piping, and the subsequent pump removal. These situations are assessed by the Operations personnel and, due to the nature of this equipment, will depend in part on local conditions at the time. For this reason, it is not possible to outline the possibilities/restrictions in this manual.
MM-M05.08
Rev.000
A safety document detailing the precautions to be observed while working inside the main oil tank is to be obtained. Rules relating to work in confined spaces are to be followed.
The manufacturer/vendor recommends overhaul of the pump annually. However, some components only require inspection every two or four years. These are identified in the text. Inspections and checks should be carried out on the pump internal components. Suitability for further service is determined by comparing inspection results with the reference information in Table 4-2.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-9
Chapter 4
Preventive Maintenance
The pre-outage records for vibration and noise levels should also be consulted. The manufacturer/vendor recommends that the pump bearings are changed automatically if there has been any irregularity in the recorded vibration and noise levels.
a)
Casing and Casing Wear Rings Pump casings and discharge casing are to be inspected for wear, crack or damage. The mating surfaces of the casings with their suction covers and the guide bearings are to be inspected for any flow erosion damage. Damaged components are to be repaired or replaced as required. The column pipe and the casing air vent holes are to be checked for blockage and cleared, if necessary. The casing wear rings are to be inspected while remaining attached to their casings. Examine the bore of each casing wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance between the casing and impeller wear rings exceeds the maximum allowable limit, the wear rings should be replaced with new.
b)
Impeller and Impeller Wear rings The impellers are to be inspected for damage to the keyways or to the bores which may have occurred during operation or dismantling. Ensure that the impeller bores are perfectly smooth and free from distortion. Inspect the impeller necks for damage or excessive wear. Light radial scoring is acceptable provided the clearance to the casing wear ring is within tolerance. If the wear ring requires replacement, the opportunity is to be taken to restore the impeller neck surface by machining if this is required.
Perform dimensional checks on the impeller wear rings while remaining attached to their impellers and ensure that they are within tolerance. Examine the surface of each impeller wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance or dimension exceeds the maximum allowable limit, the wear rings should be replaced with new.
MM-M05.08
Rev.000
Restore the bore of any impeller which reveals damage and remove any burrs. If an impeller cannot be brought to a satisfactory condition, it is to be replaced with new.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-10
Chapter 4
c)
Preventive Maintenance
Suction Covers and Strainers The suction covers are to be inspected for damage or wear. Inspect for evidence of rubbing by the rotating components and replace damaged suction covers with new. The wear rings installed in the suction covers are to be inspected while remaining attached to their suction covers. Examine the bore of each wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance between the suction cover wear ring and impeller wear ring exceeds the maximum allowable limit, the wear rings should be replaced with new. The suction strainers are to be inspected for accumulation of debris and for crack or damage. Accumulated debris is to be removed and a damaged filter assembly should be repaired or replaced.
d)
Column Pipe The column pipe is to be inspected for the presence of any weld crack or damage and repaired as required. The thrust bearing housing is to be checked for weld crack or damage to the bearing seating surface and repaired as required. The lubricating oil supply port in the bearing housing is to be inspected for blockage and cleared if blockage is observed.
e)
Shaft and Shaft Sleeve The pump shaft is to be removed and checked for run-out using V-blocks. If the shaft exceeds the maximum allowable run-out, the shaft is to be changed for new.
MM-M05.08
Rev.000
The shaft is to be checked for surface roughness or scoring in the areas where the sleeve bearings and the oil seal are located. Minor scoring marks are to be polished with an oil stone and more severe scoring is to be machined. If the damage is beyond repair, the shaft is to be replaced with new. The keys, keyways and threads on the shaft are to be checked for any damage. Damaged keyway and threads are to be repaired as found necessary. Any key which is a loose fit in its shaft keyway or in the impeller/coupling keyway is to be replaced with new. Any burrs raised during removal of the keys are to be removed using an oil stone.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-11
Chapter 4
Preventive Maintenance
The shaft sleeve is to be checked for surface roughness or scoring in the areas where the sleeve bearings are located. If the shaft sleeve has scoring marks or excessive wear, it is to be replaced with new.
f)
Bearings The thrust bearing is to be inspected for any signs of damage and pitting marks on the balls and the inner & outer races. A damaged or pitted bearing is to be replaced with new. The sleeve bearings are to be examined for any damage, scratches or excessive wear on the white metal lining. Minor scratches or damage on the white metal can be removed with a metal scraper. Replace any bearing which reveals excessive damage or wear. Perform a dimensional check on the inside diameter (ID) of the sleeve bearings and calculate the clearance between each bearing and its respective shaft/sleeve. If the clearance exceeds the maximum allowable limit, the bearing should be replaced and the clearance adjusted as required. The original bearing should be re-metalled and machined for future use.
g)
Coupling The coupling bolts and the rubber bushes are to be inspected for damage or excessive wear. The coupling bolts exhibiting wear or damage are to be replaced with new and the rubber bushes exhibiting excessive wear or damage are to be replaced as a set.
h)
Oil Seal The oil seal is to be replaced with new if leakage was observed during operation or if seal replacement is due as per the recommended maintenance schedule. Inspect the oil flinger for any signs of contact with the bearing cover. If contact is apparent, polish the damaged surface and readjust the clearance during reassembly.
MM-M05.08
Rev.000
i)
Piping and Discharge Valves The discharge pipe flange gaskets, once removed, must be replaced with new. The flanges are to be thoroughly cleaned, and any old adhered gasket material is to be removed prior to replacement. The disc/flap and the seat of the discharge check valves are to be inspected for any dents, scratches or damage. The disc/flap is to be rectified by lapping with the respective valve seat.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-12
Chapter 4
Preventive Maintenance
The orifices in the air vents of the discharge pipes are to be inspected and cleared if any blockage is observed.
MM-M05.08
Rev.000
The thrust bearing lubricating oil pipe supports are to be inspected for their integrity and rigidity. Loose supports are to be tightened as required. Oil pipe without support may result in breakage of the line causing damage to the bearing.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-13
Chapter 4
TABLE 4-2 No 1
2
Description Main oil tank
Major Check Item Corrosion, damage or leakage
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Visual and by No corrosion, touch damage or leakage
Action to be Taken (if beyond acceptable limit)
No damage or defective weld
Repair or replace
Oil separator drain blockage
Visual
No blockage
Clear blockage
Visual
No blockage
Clear accumulated debris
Visual
No wear or damage
Repair or replace defective components Repair or replace
AOP, TOP, EOP Suction strainer
3
Check valve
Wear or damage Visual on disc/flap and seat
No wear or damage
4
Oil ejector
Nozzle wear or blockage
Visual
No abnormal wear or Clean or replace blockage
Check plate
Visual
Freedom for movement
Repair or replace
Strainer
Visual
No clogging
Clean the strainer
Strainer condition
Visual
No damage
Replace the strainer
No clogging
Clean the strainer
Return oil strainer
Inspection Date
Inspector
Results
MM-M05.08
5
Remarks
Repair and apply preservative paint
Baffle plates and Visual supports
Pump internal components
Rev.000
Check Method
Preventive Maintenance
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4-14
Chapter 4
Preventive Maintenance
Continued from previous page. TABLE 4-2 No 6
7
Description Oil level gauge
Vapor extractor fan
Major Check Item
Check Method
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Action to be Taken (if beyond acceptable limit)
Damage to float Visual
No damage
Repair or replace
Accumulation of Visual debris
No debris
Clean
Wear, crack or Visual damage and deposit of debris
No dust build up
Replace the impeller wheel
Wear, crack or Visual damage to rotor shaft
No wear, crack or damage
Repair the shaft
Corrosion, Visual debris deposit in casing
No corrosion or debris deposit
Remove corrosion and debris.
Visual and physical check
Inspection Date
Inspector
Results
No wear or cracks
Flange bolts properly Retighten the flange bolts tightened
MM-M05.08
Rev.000
Tightness of flange bolts
Remarks
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4-15
Chapter 4
Preventive Maintenance
SLEEVE BEARING
IM PELLER RING
IM PELLER RING
IM PELLER RING
SHAFT SHAFT SLEEVE
CASING RING
A
CASING RING
MM-M05.08
Rev.000
CASING (1st STAGE)
FIGURE 4-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
AUXILIARY OIL PUMP CLEARANCE DRAWING 4-16
Chapter 4
Preventive Maintenance
MM-M05.03
Rev.000
SHAFT
FIGURE 4-2 TURNING OIL PUMP CLEARANCE DRAWING Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4-17
Chapter 4
Preventive Maintenance
MM-M05.03
Rev.000
SHAFT
FIGURE 4-3 EMERGENCY OIL PUMP CLEARANCE DRAWING Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4-18
Chapter 5
Disassembly and Reassembly
Chapter
5 Disassembly and Reassembly Disassembly and reassembly are the activities to be conducted when internal parts of the equipment are required to be accessed. An important part of the activities is the preparatory work. This should identify the manpower, spares and tools that may be required during the maintenance work. A shortfall of any of these may affect the schedule and the operational status of the plant. The major steps associated with disassembly and reassembly are as follows.
5.1
Main Oil Tank Disassembly and Reassembly
CAUTION Prior to carrying out any maintenance, confirm the equipment is shut down and all isolations are in place. Disassembly and reassembly of the main oil tank is limited to the opening and closing of manholes.
a)
Preparation If main oil tank disassembly becomes necessary, all associated internal and external equipment is to be mechanically and electrically isolated and the tank is to be drained and an oil free certificate issued. An authorized clearance and work permit shall be in place prior to the commencement of work. The following points are also to be considered when preparing for inspection: •
b)
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to start of work.
Disassembly
CAUTION
MM-M05.08
Rev.000
When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-1
Chapter 5
Disassembly and Reassembly
Refer to Figures 2-2 to 2-5A/B. 1
Ensure that the main oil tank is drained fully, vented and purged with nitrogen gas.
2
Remove the fasteners securing the manhole cover and then remove the manhole cover.
CAUTION If weld repairs are necessary, arrange for the appropriate gas and oil free certification and for the appropriate ventilation facilities, before commencing any welding work, on, within, or in the vicinity of the oil tank.
Note During the inspection always use the low voltage safety lamps.
c)
3
Visually inspect the internal tank welds for signs of cracking. Repair if cracks are found.
4
Inspect the inside and outside surfaces of the tank for any signs of corrosion. If corrosion is found, clean off the affected area, repair as necessary and treat with a suitable preservative.
5
Visually inspect the instrument pockets for blockage or cracking. Repair to the approved procedure if cracks are found.
6
Visually inspect the pipes, valves and the pipe supports inside the tank for corrosion or damage. Repair or replace, as applicable, if corrosion or damage is apparent.
7
Visually inspect the flange joints inside the main oil tank for loose bolts and tighten them as necessary.
Reassembly The reassembly procedure is carried out in the reverse sequence to that of the disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified. Before closing the main oil tank ensure that all parts are in position and securely attached. Ensure that all tools and equipment are removed and accounted for.
2
Using a new gasket replace and secure the manhole cover.
MM-M05.08
Rev.000
1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-2
Chapter 5
5.2
Disassembly and Reassembly
Disassembly and Reassembly of the Auxiliary Oil Pump
CAUTION Prior to carrying out any maintenance, confirm all isolations are in place and the equipment is shutdown.
a)
Preparation If AOP disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized clearance and work permit is to be in place prior to the commencement of work. The following points are also to be considered when preparing for disassembly and reassembly: •
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to the start of work.
•
Prepare the necessary handling facilities to remove and store the various parts of the equipment.
•
Prepare separate temporary structures of adequate height and strength, to receive the motor and the complete pump as they are removed from the tank. The structure for the pump should be high enough and strong enough to support the pump in both the vertical position and the horizontal position.
•
Co-ordinate with the Instrument and Control (I&C) Department to remove all the attached instrumentation such as pressure indicators before starting disassembly work.
•
Co-ordinate with the Electrical Department to disconnect and remove the motor power cable before starting disassembly work.
Note
MM-M05.08
Rev.000
Work on the oil pumps requires entry into the main oil tank, which must be emptied, cleaned and pronounced safe for entry, by a competent person who should issue a relevant safety document before work commences.
A safety document detailing the precautions to be observed while working inside the main oil tank is to be obtained. Any national or local rules relating to work in confined spaces are to be followed.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-3
Chapter 5
b)
Disassembly and Reassembly
Disassembly Refer to Figure 2-9 and 5-1. Before starting disassembly, prepare a laydown area where equipment can be stored and worked on without undue risk of contamination or damage. Before removing the pumping unit, make sure the pump is isolated then make suitable arrangements for the following: (i)
Removal of the motor. The coupling is designed such that the motor can be lifted off after the coupling bolts (43), and the bolts securing the motor to the pump frame (55) are removed.
(ii)
During disassembly, tag all components for identification purposes and, if necessary, bag or wrap to prevent miscellaneous losses and ensure adequate protection.
CAUTION When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows:
MM-M05.08
Rev.000
Removal of the Motor 1
Unbolt and remove the safety covers from the pump frame (1).
2
Ensure that match marks are clearly visible on the pump frame, and on the oil tank mounting location.
3
Loosen and remove the coupling bolts and nuts (43) and the coupling bushes (44) from the coupling.
4
Refer to Chapter 3 for the weight of the motor then attach suitable slings from the crane hook to the eyebolts provided on the motor and remove the slackness from the slings.
5
Check the supports arranged in the laydown area to ensure that the motor will be supported without the protruding coupling contacting the floor.
6
Remove the fasteners (55) securing the motor to the pump frame (1).
7
Lift the motor, transport it to the laydown area and protect it with a secured plastic cover.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-4
Chapter 5
Disassembly and Reassembly
Removal of the Auxiliary Oil Pump Assembly from the Main Oil Tank 8
Confirm that all tank entry precautions have been implemented. The outlet surface of all motor operated pumps should be cleaned, and all available to be worked on. The oil tank manhole cover and the return oil filter should be removed to ensure air circulation. When safety has been assured personnel may enter the tank with one additional person always stationed at the tank entry to assist in any emergency.
9
Remove the nuts and bolts securing the discharge pipes to the respective pumps, securely supporting the connected valves and piping, within the tank, to facilitate the removal of the complete pump assembly from the tank.
10
Remove the hexagon head bolts (56) securing the pump frame (1) to the main oil tank. (Store these bolts for use during reassembly)
CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Special consideration is to be given to the center of gravity of the assembly. Refer to Section 3 for the weight of the pump. 11
Attach suitable lifting equipment to the pump frame and make a trial lift to ensure a smooth lift of the pump assembly. Readjust slings as required.
Note Special care should be taken while lifting the pump assembly. Use additional chain blocks, if necessary, to ensure a smooth lift.
CAUTION
MM-M05.08
Rev.000
Oil will drain from the pump as it is raised from the main oil tank. If cleaning materials or fluids are used to clean the pump prior to transporting it to the laydown area, care must be taken that they do not enter the main oil tank. 12
Transport the removed pump to the laydown area and locate it vertically or horizontally as decided by the Maintenance Engineer on the pre-arranged supports. In this manual, we have the pump arranged with the frame horizontal on the prepared structure so the shaft (3) can be removed vertically.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-5
Chapter 5
Disassembly and Reassembly
CAUTION During the pump disassembly care must be taken when removing the strainers, suction covers, impellers, pump casings, etc. They are moderately heavy and will be oil soaked. The individual parts should be placed on stacked timbers, wooden frame or a low wheeled bogie, then removed from the area for cleaning and inspection.
Disassembly of the Auxiliary Oil Pump Refer to Figures 2-9 and 5-1 and follow the removal system in the description column starting at the suction side of the pump. 13
Disconnect and remove the oil feed tube (34) between the 1st stage casing (4) and the column pipe (2).
14
Provide a suitable support for the suction strainer (7), remove the hexagonal head bolts and lock washers (12) and then remove the suction strainer and the pump suction cover (6). Remove the O-ring (16) between the suction cover (6) and the 1st stage pump casing (4).
15
Check the clearance between the casing wear ring (48) and the impeller wear ring (49). If the clearance check indicates that the disassembly of the casing and the impeller wear rings is necessary remove the set screws (50) & (51) to release casing and the impeller wear rings.
16
Straighten the bent tongue of the lock plate and then remove the impeller nut (8), the lock plate (10) and the impeller washer (9).
17
Remove the 1st. stage pump impeller (5) clean, and then examine the impeller to remove any defects.
Wear suitable protective clothing when handling heated components.
MM-M05.08
Rev.000
Note If difficulty is experienced when attempting to remove the impeller, apply heat around the periphery, working slowly towards the hub. Do not initially heat the hub as this will cause the impeller to grip tighter on the shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-6
Chapter 5
Disassembly and Reassembly
18
Recover the impeller key (11) from the shaft (3). Check the oil clearance between the sleeve bearing (14) and the shaft sleeve (15), if the clearance is excessive change the shaft sleeve or the sleeve bearing whichever has worn the most, or if necessary change them both.
19
Remove the hexagon head bolts 23) to release the 1st stage casing (4). Recover the ‘O’ ring (20) and remove the shaft sleeve (15).
20
Remove the 2nd stage impeller (19). After checking the clearance between the casing and the impeller wear rings and if the wear ring clearances need adjustment remove the set screws provided in (50a-f) and (51a-f).
21
Remove the impeller key (21). Check the oil clearance between the sleeve bearing (22) and the shaft sleeve (18), and if the clearance is excessive, change the shaft sleeve or the sleeve bearing which ever has worn the most, or if necessary change them both.
22
Clean and remove any defects noted on the impeller.
23
Remove the hexagon head bolts (53) to release the second stage casing (17) and to recover the ‘O’ ring (24). Remove the shaft sleeve (18).
24
Remove the 3rd stage impeller (29), check the clearance between the casing and the impeller wear rings and if any clearance changes are required this can be done after removing the set screws provided (50a-f) and (51a-f).
25
Remove the impeller key (25). Check the oil clearance between the sleeve bearing (26) and the shaft (3), any change in the oil clearances can be made by replacing the sleeve bearing (26) using the securing screws (13c).
Note From this position with the 3rd stage impeller removed, please check the shaft (3) and the column pipe (2), and please make and record any changes made, and also make the changes made apparent during the checks made during the pump disassembly.
Inspection and check on the Thrust Bearing.
MM-M05.08
Rev.000
Refer to Figure 2-9 and 5-1. 1
Using a suitable bearing puller remove the coupling half (41) from the pump shaft (3) and recover the coupling key (45).
2
Remove the V-ring (40) from the shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-7
Chapter 5
Disassembly and Reassembly
3
Remove the bolts (47) and then remove the bearing cover (39). Remove the oil seal (36) from the bearing cover, inspect the oil seal and replace it if wear or damage is apparent.
4
Remove the securing screw and the remove the oil flinger (35) from the shaft.
5
Withdraw the shaft (3) with the thrust ball bearing (30) still in position in the column pipe (2) through the coupling end of the pump.
6
If the thrust bearing replacement is necessary, straighten the bent tongue of the bearing washer (33), unscrew and remove the bearing nut (32). Using a bearing puller, remove the thrust bearing (30). Check the collar (31) for inspection and./or replacement.
Installation of the Thrust Bearing when the change is required 7
Confirm that the collar (31) is in position on the shaft, that it is undamaged and is full contact with the step provided on the pump shaft.
Wear suitable protective clothing when handling heated components. 8
Heat the thrust ball bearing (30) to about 100ºC in an electric oven and insert it over the shaft and butt it against the collar (31).
9
Immediately after installation of the bearing, install the bearing washer and the bearing nut, and hand tighten the bearing nut to apply a small force to locate the bearings in position while cooling.
Note
MM-M05.08
Rev.000
This activity should be performed quickly as any delay could cool the bearings, and this may lead to incorrect positioning of the bearings and subsequent dismantling and reinstallation.
10
Tighten the bearing nut (32), fully after the bearings have cooled to near ambient temperature. Bend the tongue of the bearing washer to lock the bearing nut.
11
Install the oil flinger (35) onto the shaft and secure it using the set screw.
12
Ensure that the pump frame (1) with column pipe (2) is supported vertically on a suitable support and that the column pipe is located correctly below the pump frame.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-8
Chapter 5
Disassembly and Reassembly
13
Insert the shaft assembly into the column pipe (2) such that the thrust bearing (30) slide smoothly into the thrust bearing housing in the column pipe. Ensure that the thrust bearing seats correctly in the thrust bearing housing.
14
Install the oil seal (36) into the groove provided in the bearing cover (39). Insert the bearing cover over the shaft (3) from the pump coupling end such that the oil seal slides smoothly over the shaft.
15
After ensuring that the bearing cover is properly seated on the pump frame (1), secure it to the pump frame using the fixing bolts (47).
16
Replace and secure the V-ring (40) to the shaft.
With a new thrust bearing installed we can return to the re-assembly of the Auxiliary oil pump.
MM-M05.08
Rev.000
Reassembly of the AOP 17
Clean the lower flange of the column pipe, and replace the 3rd stage casing (27), checking that the air vent (52a/b) is correctly located, install all hexagon bolts (28) and knock bolts (38).
18
Install the sleeve bearing (26) using the securing screws (13c).
19
Install the 3rd stage impeller upper casing ring and secure using the set screws.
20
Install the 3rd stage impeller key.
21
Replace the 3rd stage impeller, upper and lower rings and secure using set screws.
22
Replace the 3rd stage impeller (29) in its position.
23
Apply lubricating oil into the location of the 3rd stage impeller.
24
Prepare to make the 2nd stage casing (17) ready for installation. Shaft sleeve (18) is to be installed on the shaft (3) and the sleeve bearing (22) must be installed over the shaft sleeve (18), and secure using the securing screws (13b).
25
Install the ‘O’ ring (24), replace the casing (17) and secure it using the hexagonal head bolts (53).
26
Confirm that the impeller upper casing ring is located correctly in its position with set screws already installed.
27
Replace the impeller key (21), and install the No. 2 impeller (19) with the impeller rings already installed.
28
Apply lubricating oil onto the locations of the 2nd stage impeller.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-9
Chapter 5
Disassembly and Reassembly
To prepare the 1st stage casing for installation, install the shaft sleeve (15) and then install the sleeve bearing (14) held in position with securing screws (13a).
30
Replace the ‘O’ ring (20), then install the 1st stage casing, using the hexagon head screws (23), and also install the upper and the lower impeller rings.
31
In the 1st stage casing, we must install the upper casing ring, using the hexagon head screws, and we also install the upper and the lower impeller rings.
32
Install the impeller key (11), and install the 1st stage impeller.
32
Check that all 1st stage casing rings and impeller rings are secure, then install the impeller washer (9), the lock plate (10) and the impeller nut (8).
33
Apply lubrication oil onto the location of the 1st stage impeller.
34
Restore the suction cover (6), the strainer (7) and the ‘O’ ring (16) using the hexagon head bolts (12).
35
Replace the oil feed tube (34) connected between the 1st stage casing (4) and the column pipe (2).
MM-M05.08
Rev.000
29
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-10
Chapter 5
Disassembly and Reassembly
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13a,b,c 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48a,b,c, d,e,f 49a,b,c, d,e,f 50a,b,c, d,e,f 51a,b,c, d,e,f 52 a,b 53 54 55 56
40 55
47 39
35 36
32 33 30
2 1
31 38
38 37 28 38
CASING RING IMPELLER RING SET SCREW SET SCREW AIR VENT HEXAGONAL HEAD BOLT DRIVE MOTOR BOLTS, MOTOR TO FRAME BOLTS, FRAME TO M.O.T
MM-M05.08
Rev.000
34
DESCRIPTION PUMP FRAME COLUMN PIPE SHAFT 1st STAGE CASING 1st STAGE IMPELLER SUCTION COVER STRAINER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER KEY HEXAGONAL HEAD BOLT SCREW SLEEVE BEARING SHAFT SLEEVE O-RING 2nd STAGE CASING SHAFT SLEEVE 2nd STAGE IMPELLER O-RING IMPELLER KEY SLEEVE BEARING HEXAGONAL HEAD BOLT O-RING IMPELLER KEY SLEEVE BEARING 3rd STAGE CASING HEXAGONAL HEAD BOLT 3rd STAGE IMPELLER THRUST (BALL) BEARING COLLAR BEARING NUT BEARING WASHER OIL FEED TUBE OIL FLINGER OIL SEAL HEXAGONAL HEAD BOLT KNOCK BOLT BEARING COVER V-RING COUPLING HALF (PUMP) COUPLING HALF (MOTOR) COUPLING BOLT & NUTS COUPLING BUSH KEY COUPLING COVER HEXAGONAL HEAD BOLT
FIGURE 5-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
EXPLODED VIEW OF THE AUXILIARY OIL PUMP 5-11
Chapter 5
5.3
Disassembly and Reassembly
Disassembly and Reassembly of Turning Oil Pump a) Preparation If Turning Oil Pump disassembly becomes necessary, all associated equipment shall be mechanically and electrically isolated and an authorized clearance and work permit shall be in place prior to the commencement of work. The permit should include entry into the main oil tank. The following points are also to be considered when preparing for disassembly and reassembly. •
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to start of work.
•
Prepare the necessary handling facilities (e.g. crane facilities, temporary supports, etc.) to remove and store the various parts of the equipment.
•
Prepare separate temporary structures of adequate height and strength, to receive first the motor, and then the complete pump as they are removed from the tank.
•
Co-ordinate with the I&C Department to remove all instrumentation from the equipment before starting disassembly work.
•
Coordinate with Electrical department to have the power cable removed from the motor.
b) Disassembly Before starting disassembly, prepare a laydown area where equipment can be stored and worked on without undue risk of contamination or damage.
MM-M05.08
Rev.000
Before removing the pumping unit, make suitable arrangements for the following: (i)
Removal of the motor. The coupling is designed such that the motor can be lifted off after the coupling bolts (6) and the bolts securing the motor to the pump frame (49) are removed.
(ii)
Lifting of the pump and containment of the oil which will drain from the pump after it has been removed from the MOT. If cleaning materials or fluids are used for cleaning the pumping unit prior to transporting it to the laydown area, they should not be allowed to enter the MOT.
During disassembly, tag all components for identification purposes and, if necessary, bag or wrap to prevent miscellaneous losses and ensure adequate protection.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-12
Chapter 5
Disassembly and Reassembly
CAUTION When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows: Refer to Figures 2-12 and 5-2.
Removal of the Motor 1
Unbolt and remove the safety covers (2) from the pump frame (1).
2
Ensure that match marks are clearly visible on the motor (47), the pump frame (1), and on the main oil tank mounting flange.
3
Loosen and remove the coupling bolts and nuts (6) from the coupling.
4
Refer to Chapter 3 for the weight of the motor, then attach suitable slings from the crane hook to the eyebolts provided on the motor and remove the slackness from the slings.
5
Check the supports arranged in the laydown area to ensure that the motor will be supported without the protruding coupling contacting the floor.
6
Remove the bolts (49) securing the motor to the pump frame.
7
Lift the motor, transport it to the prepared laydown area and protect it with a secured plastic cover.
MM-M05.08
Rev.000
Removal of the Pump 8
Confirm that the Permit to work (PTW) covers entry into the MOT, that the MOT has been cleaned, is gas free, and ventilated. Maintenance personnel can then enter the MOT to remove the pump discharge flange bolts, and to secure the discharge piping within the MOT.
9
Remove the bolts (48) securing the pump frame (1) to the MOT, then using the appropriate lifting gear, lift the complete pump assembly from the MOT. Transport the removed pump assembly to the laydown area and locate it vertically on the pre-arranged supports.
10 Confirm that there is sufficient working area directly above the pump for the withdrawal of the pump shaft. 11 Using a suitable bearing puller, remove the pump side coupling half (4) and recover the key (40) from the pump shaft (41). 12 Remove the ‘V’ ring (9) from the pump shaft. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-13
Chapter 5
Disassembly and Reassembly
13 Remove the bolts and washers (7) and then remove the bearing cover (8) from the pump frame (1). 14 Remove the oil seal (10) from the bearing cover. 15 Remove the set screws (45) and then remove the oil flinger (11) from the pump shaft. 16 Remove the oil feed tube (17), and seal the open ends to prevent the entry of dust or debris.
CAUTION During the pump disassembly care should be taken when removing the strainer, suction cover, impeller and pump casing. They are moderately heavy and will be oil soaked. The individual parts should be lowered onto stacked timbers (wood) or a low wheeled bogie, then removed from under the pump for inspection. 17 Straighten the bent tongue of the lock washers, remove the bolts and the lock washers (18) and then remove the strainer (19) and the suction cover (20). Remove the O-ring (39) between the suction cover (20) and the pump casing (35). 18 Straighten the bent tongue of the lock plate (23) and then loosen and remove the impeller nut (21), the lock plate (23) and the impeller washer (22). 19 Withdraw the impeller (24) from the impeller end of the shaft and recover the impeller key (25) from the shaft (41).
Wear suitable protective clothing when handling heated components.
Note
MM-M05.08
Rev.000
If difficulty is experienced when attempting to remove the impeller, apply heat around the periphery, working slowly towards the hub. Do not initially heat the hub as this will cause the impeller to grip tighter on the shaft. 20 Remove the knock bolts (30) which locate the pump casing (35) and the column pipe (42).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-14
Chapter 5
Disassembly and Reassembly
21 Remove the bolts and lock washers (31) and then withdraw the pump casing (35). 22 The pump casing should be examined for signs of wear and reference should be made to the manufacturer if wear is apparent. 23 Remove the bolts and washers (32) and then remove the sleeve bearing (36) from inside the pump casing. 24 Inspect the impeller (24) for wear or damage, paying particular attention to the suction entry blade tips, the impeller rings (28, 29) and the casing rings (26, 27). 25 Measure the bore of the casing wear rings and the OD of the impeller wear rings and calculate the wear. If the wear ring clearances are beyond the tolerance limit, remove the casing and impeller wear rings.
Note The above wear rings are located in both the suction and discharge sides of the pump. The casing wear rings are retained by set screws or peening and the impeller wear rings by set screws. It is not necessary for the rings to be removed from the casing and the impeller unless damaged, worn, or due for replacement.
26 Replace excessively worn casing rings, impeller rings and any other component which fails to meet the acceptance criteria. 27 Inspect the sleeve bearing (36) for wear or damage. Measure the clearance between the sleeve bearing and the shaft. Replace the bearing with a new one if the clearance exceeds the acceptable limit. 28 The pump shaft assembly containing the shaft, bearing nut, bearing washer and thrust bearing can now be removed through the motor end of the pump frame. Timber and a hydraulic jack should be available to raise the shaft assembly. 29 Straighten the bent tongue of the bearing washer and then remove the bearing nut (12) and the bearing washer (13).
MM-M05.08
Rev.000
30 Using a suitable bearing puller, withdraw the thrust bearing (14) from the pump shaft. 31 The thrust bearing should be inspected for ball or ball race damage and the bearing should be replaced if damage is apparent. 32 If there are doubts regarding the shaft concentricity, a shaft run-out check should be performed to confirm that the acceptable limit of 0.05 mm at the shaft journals is not exceeded.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-15
Chapter 5
c)
Disassembly and Reassembly
Reassembly Refer to Figure 5-2. 1
Before reassembly, ensure that all components have been cleaned thoroughly.
2
Lubricate the internal pump parts with clean turbine oil where necessary.
3
Confirm that the collar (15) is in its original location on the pump shaft (41). And if the thrust bearing is to be changed proceed as follows:
Wear suitable protective clothing when handling heated components. 4
Heat the thrust bearing (14) to about 100°C in an electric oven and insert it over the shaft and butt it against the collar (15).
5
Immediately after installation of the bearing, install the bearing washer (13) and the bearing nut (12), and hand tighten the bearing nut to apply a small force to locate the bearing in position while cooling.
Note This activity should be performed quickly as any delay could cool the bearing, and this may lead to incorrect positioning of the bearing and subsequent dismantling and reinstallation.
6
Tighten the bearing nut fully after the bearing has cooled to near ambient temperature. Bend the tongue of the bearing washer to lock the bearing nut.
7
Install the pump frame and column pipe assembly vertically on the prepared support such that the pump frame is located above the column pipe.
8
Replace the shaft with the assembled thrust bearing into the column pipe (42) confirming that the collar (15) and the thrust bearing (14) are correctly located.
9
Install the oil flinger (11) and secure it with the set screws (45).
11 Replace the bearing cover (8) (with oil seal) into the pump frame (1) and secure it with the hexagonal head bolts and spring washers (7).
MM-M05.08
Rev.000
10 Replace the oil seal (10) in the slot provided in the bearing cover (8).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-16
Chapter 5
Disassembly and Reassembly
12 Install the ‘V’ ring (9) onto the pump shaft. 13 Replace the key (40) in the slot on the shaft.
Wear suitable protective clothing when handling heated components. 14 Heat the pump coupling half (4) in an electric oven and then ensuring that the coupling keyway aligns with the shaft key (40), insert the coupling half over the pump shaft until it comes into contact with the step on the shaft. 15 Rotate the shaft by hand and ensure the shaft is free to rotate. 16 Replace the casing wear ring (26) in the pump casing (35) and the casing wear ring (27) on the suction cover (20) and secure them. 17 Replace the impeller wear rings (28 and 29) on the impeller (24) and secure them with the set screws (33 and 34). 18 Confirm that the wear ring clearances are within tolerance. 19 Rotate and support the pump frame and column pipe assembly on the prepared support such that the column pipe is located above the pump frame. Provide suitable temporary side-supports for the shaft from the column pipe, if required. 20 Check the pump casing flanges for bumps or burrs and remove any, using emery cloth or a smooth file. Check for cleanliness and locate the casing (35) on the column pipe (42) using the knock bolts and nuts (30). 21 Secure the casing to the column pipe using the lock washers and bolts (31). 22 Check the condition of the sleeve bearing (36) and remove any burrs. Apply a coating of oil and install it in the pump casing using the hexagonal head bolts (32).
24 Install the impeller (24) ensuring that it locates correctly on the shaft key.
MM-M05.08
Rev.000
23 Check the impeller key (25), then insert it in the keyway on the pump shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-17
Chapter 5
Disassembly and Reassembly
Note The bore of the impeller is machined to the same size as the diameter of the shaft with a small tolerance. It may or may not be possible to slide the impeller onto the shaft. Try to install the impeller on the shaft by hand. If the impeller will not slide onto the shaft, heat may be applied evenly around the hub and then installed.
CAUTION Force must not be used when installing the impeller. If the impeller fails to butt against the shaft shoulder, remove the impeller and check for any burrs or dirt which may have been overlooked during inspection. Clean up as necessary. Do not attempt to install the impeller if the shaft temperature is above ambient.
Wear suitable protective clothing when handling heated components. 25 Replace the impeller washer (22) and the lock plate (23) and then tighten them with the impeller nut (21).The tongue of the lock plate should be bent after fully tightening the impeller nut to prevent loosening. 26 Clean and check the condition of the suction cover (20), smear oil over the internal surfaces and replace the O-ring (39). 27 Replace the suction cover (20) and the suction strainer (19) onto the pump casing and secure them using the hexagonal head bolts and lock washers (18). 28 Replace the oil feed tube (17) between the pump casing and the column pipe, and secure it with the removed supports.
Replacement of the Turning Oil Pump Assembly
MM-M05.08
Rev.000
CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Special consideration is to be given to the center of gravity of the assembly.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-18
Chapter 5
Disassembly and Reassembly
29 Carefully transport the pump frame/pump assembly from the laydown area to the location of the MOT and align it above the respective opening on the MOT. 30 Confirm that the mating flange faces are clean and smooth, then slowly lower the oil pump assembly into the tank until the pump frame (1) is located properly on the mounting flange. 31 Secure the pump frame to the MOT using the fasteners (48). 32 Using new gaskets, replace the pump discharge pipes inside the main oil tank. 33 Replace new rubber coupling bushes (5) into the coupling flange (3) on the motor shaft if the inspection or the maintenance schedules necessitates their replacement. 34 Using the lifting equipment, lift the motor onto the pump frame and secure it with the fixing bolts and nuts (49). 35 Perform an alignment check as per the procedure indicated in Appendix D. 36 When the coupling alignment is completed, replace the coupling bolts and nuts (6) and tighten them in sequence. 37 Replace the safety covers (2) onto the motor frame. 38 Reinstall the removed instrumentation and reconnect the electrical power cable removed during disassembly. 39 Clean the main oil tank thoroughly and refill with the recommended oil to the required operating level. 40 Start the pump as per the recommended starting procedure and ensure that the pump operates satisfactory without any oil leakage.
5.4
Disassembly and Reassembly of the Emergency Oil Pump
MM-M05.08
Rev.000
Although, as their titles suggest, the EOP and the TOP have different (motor) drives, the pumping units are the same. If disassembly of the EOP becomes necessary, refer to Section 5.2, Turning Oil Pump Disassembly and Reassembly and follow the same procedure.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-19
Chapter 5
ITEM
DESCRIPTION PUMP FRAME COUPLING COVER (SAFETY) COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT HEX. BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR OIL FEED TUBE HEX. HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEX. HEAD BOLT & LOCK WASHER HEX. HEAD BOLT & LOCK WASHER HEX. SOCKET SET SCREW HEX. SOCKET SET SCREW PUMP CASING SLEEVE BEARING O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER SET SCREW HEX. HEAD BOLT & LOCK WASHER DRIVE MOTOR BOLTS, FRAME TO M.O.T BOLTS, MOTOR TO FRAME
MM-M05.08
Rev.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 39 40 41 42 43 44 45 46 47 48 49
Disassembly and Reassembly
FIGURE 5-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
EXPLODED VIEW OF TURNING OIL PUMP 5-20
Chapter-6
Corrective Maintenance
Chapter
6 Corrective Maintenance Corrective maintenance is the repair or replacement work undertaken for sudden failure of any part or component of the equipment. Though a well-planned preventive maintenance program tries to minimize the probability of occurrence of sudden failure of equipment, provision for attending these unscheduled maintenance requirements should be made. Corrective maintenance work is to be given priority depending on the seriousness of the problem faced and the impact on plant operations. The schedule for repair of any equipment should be carefully planned to keep outage time to a minimum. During such repair or replacement work, inspection should be conducted carefully to determine why the equipment has failed. Good corrective maintenance requires, not only quick restoration of the failed equipment back into service but also demands every effort to identify and record the root cause of the failure. The inspection results can be of significant help in exploring the exact reason for the failure. The findings along with possible rectification proposals are to be used as a feedback to update the preventive maintenance procedures.
6.1
Prerequisites The necessary prerequisites for the corrective maintenance of the main oil tank and the vapor extractor fan are as follows:
a)
Scheduling Unlike preventive maintenance, scheduling activity only starts after failure of the equipment. Depending on the severity of the problem, the importance of the service provided by the failed equipment and availability of manpower to attend to the problem, a contingency schedule is to be prepared to solve the problem at the earliest opportunity. The schedule should clearly indicate the critical path activity and assign the priority for different parallel activities. Finally, once the schedule is agreed, strict adherence to it is to be maintained to ensure timely completion of the maintenance activity.
b)
Inter Departmental Cooperation/Communication Refer to Section 4.1.2, Departmental Interface/Notification.
c)
Isolation of Equipment
d)
Safety Precautions Refer to Section 4.1.4, Safety Precautions.
MM-M05.08
Rev.000
Refer to Section 4.1.3, Isolation of Equipment.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-1
Chapter-6
6.2
Corrective Maintenance
Preparation a)
Parts, Tools and Equipment Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.
b)
Documentation Refer to Subsection 4.2.1 b), Documentation.
6.3
Troubleshooting
MM-M05.08
Rev.000
This section provides information about carrying out troubleshooting and servicing for the main oil tank and vapor extractor fan, pertaining to the mechanical maintenance staff. A table of Faults, Possible Causes and Remedies has been provided to assist in troubleshooting by qualified users. If any new kind of problem is encountered which is not listed in the following table, contact the manufacturer for assistance.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-2
Chapter-6
TABLE 6-1
Corrective Maintenance
TROUBLESHOOTING – MAIN OIL TANK AND VAPOR EXTRACTOR FAN Fault
Abnormal decrease of oil level in the tank
Possible Cause
Remedy
Loose flange connection
Retighten the connection
Oil emission through the mist separator
Adjust vapor extractor fan suction damper
Failure of oil purifier seal
Correct oil purifier
Evaporation loss
Top-up with fresh oil
Manhole cover left open or loose
Close cover securely
Loose inspection covers
Tighten the inspection covers properly
Vapor extractor fan suction closed or throttled
Readjust the suction damper
Steam ingress from turbine glands
Check and correct gland sealing pressure and gland steam condenser vacuum
Improper oil purifier water separation
Check and correct the oil purifier
Main oil pump suction oil pressure low
Faulty No. 1 ejector
Shutdown and rectify No. 1 ejector
AOP/TOP/EOP discharge pressure low
Suction strainer blocked
Shutdown and clean suction strainer
Oil piping leakage
Rectify oil leakage
Relief valve seat leakage due to debris
Clean and remove debris/foreign matter
Oil piping leakage
Rectify oil leakage
Increase in MOP internal clearances
Shutdown and correct MOP internal clearances
Internal leakage in the discharge check valve of the standby pump (AOP/TOP/EOP)
Rectify the check valve internal leakage
High oil temperature
Check and rectify problems of oil cooler
Standby pump rotating in reverse direction (AOP/TOP/EOP)
Internal leakage in the discharge check valve of the standby pump
Rectify the check valve internal leakage
High oil temperature
Malfunctioning of oil cooler
Check and rectify problems of oil cooler
Loss of vacuum in the oil tank
High water content in oil
MM-M05.08
Rev.000
Reduction of lube / HP oil pressure
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-3
Chapter-7
Recommended Lubrication
Chapter
MM-M05.08
Rev.000
7 Recommended Lubrication
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-1
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1069
FIGURE 7-1
RECOMMENDED LUBRICANTS LIST FOR MAIN OIL TANK
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-2
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1070
FIGURE 7-2
RECOMMENDED LUBRICANTS LIST FOR AOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-3
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1071
FIGURE 7-3
RECOMMENDED LUBRICANTS LIST FOR TOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-4
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1072
FIGURE 7-4
RECOMMENDED LUBRICANTS LIST FOR EOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-5
MM-M05.08
Rev.000
Chapter-7
Recommended Lubrication
MPTD-4-1073
FIGURE 7-5
RECOMMENDED LUBRICANTS LIST FOR VAPOR EXTRACTOR FAN
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-6
Appendix A
Appendix
A Torque Chart TABLE A-1
TORQUE CHART
Bolt Size
Tightening Torque (Nm)
M6
4
M7
10
M10
20
M12
35
M16
80 – 90
M20
155 – 175
M24
275 – 305
M30
545 – 605
M36
950 – 1050
M42
1520 – 1680
M48
2300 – 2520
M56
3690 – 4070
M64
5560 – 6150
Note This table is to be used in absence of torque value recommended by the vendor.
(1)
Apply anti-seize compound to bolts.
(2)
Tighten nuts 20% of the calculated torque in a cross-diagonal sequence.
(3)
Following the sequence, tighten the nuts to 80% of calculated torque.
(4)
Following the sequence, tighten the nuts to 100% of calculated torque.
MM-M05.08
Rev.000
Perform the following steps in sequence:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
A-1
Appendix B
Recommended B Spare Parts
MM-M05.08
Rev.000
Appendix
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-1
MM-M05.08
Rev.000
Appendix B
MPTD-4-0776
FIGURE B-1
OPERATING SPARE PARTS LIST FOR AUXILIARY OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-2
Rev.000
Appendix B
MM-M05.08
MPTD-4-0777
FIGURE B-2
OPERATING SPARE PARTS LIST FOR TURNING OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-3
Rev.000
Appendix B
MM-M05.08
MPTD-4-0778
FIGURE B-3
OPERATING SPARE PARTS LIST FOR EMERGENCY OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-4
MM-M05.08
Rev.000
Appendix B
MPTD-4-1130
FIGURE B-4
OPERATING SPARE PARTS FOR MOT VAPOR EXTRACTOR
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-5
MM-M05.08
Rev.000
Appendix B
MPTD-4-1131
FIGURE B-5
OPERATING SPARE PARTS FOR MIST SEPARATOR
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-6
Appendix C
Appendix
C Special Tools
MM-M05.08
Rev.000
The manufacturer of these pumps does not recommend any special tools for maintenance work.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
C-1
Appendix D
Appendix
D Coupling Alignment The following basic alignment procedure is suitable for most motor to driven machine couplings. However, if additional details are required, reference should be made to the manufacturers instructions. Peripheral Alignment Using a Dial Test Indicator (DTI): Match mark the coupling halves.
With both match marks at the top: Check DTI reading at zero.
2
Turn both shafts 90°, check DTI reading at 90°.
3
Turn both shafts a further 90°, check DTI reading at 180°.
4
Turn both shafts a further 90°, check DTI reading at 270°.
5
Turn both shafts to zero, recheck DTI reading at zero.
MM-M05.08
Rev.000
1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
D-1
Appendix D
Axial Alignment An inside micrometer or a tapered gap gauge can be used dependent upon the size of the gap between the coupling faces. This example uses an inside micrometer. Ensure both match marks at the top: 1
With shafts stationary, measure a, b, c, d.
2
Turn both shafts 180° (match marks at the bottom).
3
With shafts stationary, measure c, d, a, b.
From the readings obtained, adjustments can be made to the liners (shims) installed under the feet of the driving/driven equipment. Allowable tolerances are as follows: Flexible Couplings
Rigid Couplings
0.05 mm
Peripheral
0.03 mm
Axial
0.03 mm
Axial
0.02 mm
MM-M05.08
Rev.000
Peripheral
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
D-2
Appendix E
Applicable E Reference Drawings
MM-M05.08
Rev.000
Appendix
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-1
MM-M05.08
Rev.000
Appendix E
MPTD-3-0754
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
FIGURE E-1
ARRANGEMENT DRAWING OF MAIN OIL TANK E-2
MM-M05.08
Rev.000
Appendix E
MPTD-4-0755
FIGURE E-2
OUTLINE DRAWING OF AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-3
MM-M05.08
Rev.000
Appendix E
MPTD-4-0756
FIGURE E-3
ASSEMBLY DRAWING OF AOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-4
MM-M05.08
Rev.000
Appendix E
MPTD-4-0757
FIGURE E-4
ASSEMBLY DRAWING OF AOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-5
MM-M05.08
Rev.000
Appendix E
MPTD-4-0758
FIGURE E-5
ASSEMBLY DRAWING OF AOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-6
MM-M05.08
Rev.000
Appendix E
MPTD-4-0759
FIGURE E-6
EXPECTED PERFORMANCE CURVES FOR AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-7
MM-M05.08
Rev.000
Appendix E
MPTD-4-0760
FIGURE E-7
TORQUE CHARACTERISTIC CURVES FOR AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-8
MM-M05.08
Rev.000
Appendix E
MPTD-4-0761
FIGURE E-8
OUTLINE DRAWING OF AOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-9
MM-M05.08
Rev.000
Appendix E
MPTD-4-0762
FIGURE E-9
OUTLINE DRAWING OF TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-10
MM-M05.08
Rev.000
Appendix E
MPTD-4-0763
FIGURE E-10
ASSEMBLY DRAWING OF TOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-11
MM-M05.08
Rev.000
Appendix E
MPTD-4-0764
FIGURE E-11
ASSEMBLY DRAWING OF TOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-12
MM-M05.08
Rev.000
Appendix E
MPTD-4-0765
FIGURE E-12
ASSEMBLY DRAWING OF TOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-13
MM-M05.08
Rev.000
Appendix E
MPTD-4-0766
FIGURE E-13
EXPECTED PERFORMANCE CURVES FOR TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-14
MM-M05.08
Rev.000
Appendix E
MPTD-4-0767
FIGURE E-14
TORQUE CHARACTERISTIC CURVES FOR TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-15
MM-M05.08
Rev.000
Appendix E
MPTD-4-0768
FIGURE E-15
OUTLINE DRAWING OF TOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-16
MM-M05.08
Rev.000
Appendix E
MPTD-4-0769
FIGURE E-16
OUTLINE DRAWING OF EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-17
MM-M05.08
Rev.000
Appendix E
MPTD-4-0770
FIGURE E-17
ASSEMBLY DRAWING OF EOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-18
MM-M05.08
Rev.000
Appendix E
MPTD-4-0771
FIGURE E-18
ASSEMBLY DRAWING OF EOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-19
MM-M05.08
Rev.000
Appendix E
MPTD-4-0772
FIGURE E-19
ASSEMBLY DRAWING OF EOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-20
MM-M05.08
Rev.000
Appendix E
MPTD-4-0773
FIGURE E-20
EXPECTED PERFORMANCE CURVES FOR EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-21
MM-M05.08
Rev.000
Appendix E
MPTD-4-0774
FIGURE E-21
TORQUE CHARACTERISTIC CURVES FOR EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-22
MM-M05.08
Rev.000
Appendix E
MPTD-4-0775
FIGURE E-22
OUTLINE DRAWING OF EOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-23
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-24
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-25
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-26
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-27
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-28
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-29
MM-M05.08
Rev.000
Appendix E
MPTD-3-1038
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
FIGURE E-29
LUBRICATING OIL STRAINER E-30
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-31
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-32
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-33
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) MECHANICAL MAINTENANCE MANUAL PT PAITON ENERGY PAITON EXPANSION PROJECT
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP) Maintenance Manual No. MM-M05.08 Revision 000
Note • This mechanical maintenance manual is intended to provide the Paiton Expansion Project mechanical maintenance personnel with the basic understanding required to perform preventive, routine, corrective and overhaul maintenance activities on the subject equipment.
•
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy Industries, Ltd. and Paiton Expansion Project.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Maintenance
Be sure to read this manual.
Contents
Safety
1
General
2
Specifications
3
Preventive Maintenance
4
Disassembly and Reassembly
5
Corrective Maintenance
Recommended Lubrication
Appendixes
7
Revision Record Description of Revision
Revision Issue Date
Date Revised
Pages Inserted
MM-M05.08
Rev.000
Page Number
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
i
Important Information Purpose of the Plant Usage This plant is designed to generate electric power of 815 MW by the steam turbine generator. The plant is only used for the electric power generation purpose that supports stable and reliable electric power supply to the power grid and supplying steam for the auxiliary equipment in the power station.
General 1.
To satisfy the purpose mentioned above the following points must be strictly observed, a)
The operation, maintenance and inspection of Equipment must be performed by the persons who have basic technical knowledge and have been trained concerning the hazard of the Equipment and the avoidance of the hazard.
b)
The operators and maintainers must read and understand these manuals before starting the operation, maintenance or inspection. It is often experienced that serious damage to the equipment or personnel have occurred by the unexpected action of operators or maintainers who do not fully understand the equipment.
c)
The modification or change of operational specification must be performed under MHI supervision or as per the written acceptances of MHI. The modification or change of specification causes not only a decline in performance but also a decline in safety for operation of the equipment. The Customer is requested to contact MHI regarding any modification or proposed changes before the work commences.
MM-M05.08
Rev.000
The address for MHI to be contacted is shown in this chapter. 2.
The operation and maintenance must be performed according to the applicable laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local legal regulations.
4.
The copyright of software, drawings and other documents provided by MHI at all times, is still reserved by MHI.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ii
5
Use or copying of the whole or part of any information provided by MHI for any purpose other than operation and maintenance of this plant without written consent is strictly prohibited.
Important General Notice for Safety 1.
The operator and maintainer must have knowledge about the equipment to maintain good operating condition and to avoid danger when using the equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as a “Safety and Health management system” and operate continuously. The Safety and Health management system must include the following points, a) Instruction for use and the maintenance of the personal protective equipment issued to operators and maintainers b) The establishment of a work management organization to make clear the operation directives and work procedures c) Implementation of training for operator and maintainer
4.
The Customer must train the operators and maintainers to act positively and to prevent the occurrence of an accident by using their knowledge of the power plant.
5.
The Customer must make the operators and maintainers understand that the most important purpose of safety control is to protect all personnel from accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to observe the notices of this manual and to keep the correct operation according to the description provided in this manual. If the notices are not observed, the following dangers could occur to the operator, and to the maintainer.
MM-M05.08
Rev.000
7.
a)
Risk of a fatal accident
b)
Danger to lose his health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as danger due to human error and/or dangers caused by the operating environment. As this manual and the alert label cannot cover all of the dangers, the operators and maintainers have to pay their full attention to all general safety notices.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
iii
8.
MHI can not be responsible for damages and injury caused by neglecting the notices in this manual, and other necessary general notices.
Instruction of this Manual This manual is provided for people familiar with the use of English. If some person not familiar with English is going to operate the plant, the Customer must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local office or MHI’s official agent.
MM-M05.08
Rev.000
1.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
iv
Warranty •
The provisions set forth in this section are in addition to all liability and warranty disclaimers and limitations set forth in the Contract, whether arising under law or from course of performance, course of dealing, or usage of trade.
•
Nothing in these provisions shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Warranty Limitations section shall have the respective meanings ascribed to them in the Contract.
•
The Contract Warranties are subject to the construction, installation and Commissioning works having been performed in full compliance with the requirements stated in (a) the Contract, (b) all manuals provided by MHI, including this manual, (c) all applicable rules, regulations and laws prevailing in the location where the Plant has been installed and will operate, and (d) any other instructions, if any, provided by MHI (collectively, “Rules and Requirements”). The Contract Warranties will NOT cover any accidents, partial or total failure of the Plant, losses or damages to personnel or property (including, without limitation, the Plant’s components, parts, systems and other equipment), or any other liability (collectively, “Accidents and Damages”) in the case of any breach of the stated Rules and Requirements.
•
For the detailed terms and conditions of the warranty concerning the Works and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the following Accidents and Damages: Accidents and Damages caused by any deviation from the Rules and Requirements;
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
v
Accidents and Damages caused by the modification or re-installation of the Plant after the original installation, or caused by operation of the Plant for a purpose other than that for which it is designed;
•
Accidents and Damages caused by natural disasters or accidents during transfer or related handling;
•
Accidents and Damages occurring after the term of the warranty has expired;
•
Accidents and Damages due to faulty operation or operation not in accordance with the Rules and Requirements;
•
Accidents and Damages due to inappropriate maintenance or servicing performed by the Customer, its personnel or any other party.
•
Accidents and Damages caused by any components, parts, systems or other equipment other than those delivered by MHI;
•
Accidents and Damages caused by unidentifiable reasons including loss of the damaged parts which is necessary to pinpoint a cause of the failure;
•
Accidents and Damages caused by referring to inadequate, or incorrect references, data or information provided by the Customer;
•
Accidents and Damages or rust/corrosion due to inadequate handling and/or storage by the Customer; or
•
Accidents and Damages due to handling, storage and/ or use of the Plant under severe conditions or in an environment that does not meet the design specification conditions.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
vi
Limitations of Liability General •
Nothing in this Limitation of Liability section or manual shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Limitation of Liability section shall have the respective meanings ascribed to them in the Contract.
•
The contents of this manual are subject to change without prior notice and without any obligation or liability to MHI.
Use and Disposal •
Use of the Plant must be limited to the use specified by MHI, including without limitation, use of the Plant in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI. The Plant components, parts, systems and other equipment (collectively, “Equipment”) must be appropriately disposed of in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI.
For Documents and Safety Training
MM-M05.08
Rev.000
•
The Customer’s personnel must read, understand and abide by all documents provided by MHI, including without limitation, the operation and maintenance manuals, safety manuals, and instruction manuals (collectively, “Safety Manuals”) and must have received all required and/or necessary safety training prior to the start of their work. Persons who have not received such safety training are not permitted to work on the installed Plant. This initial training, however, is merely the minimum requirements prior to allowing any personnel to work on the installed Plant. The Customer must, on a continual and regular schedule, give up-to-date training to its personnel on safety requirements, provide testing or other methods to confirm their understanding of the safety training, and confirm that they have the physical and mental capability to perform their respective roles. The Customer’s obligation for safety training and personnel supervision is an ongoing obligation and must be continuously performed and kept current throughout the operation of the Plant. Accidents, partial or total failure of the Plant, damage to personnel or property, loss, injuries, and other liability (collectively, “Liability”) caused by inadequate safety training or the Customer’s personnel’s failure to abide by the documents provided by MHI are expressly excluded from the coverage of any warranty provided by MHI and are the sole and exclusive responsibility of the Customer.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
vii
•
MHI will NOT be liable for any Liability caused by modification or changes made in Plant-related documents (including any Safety Manual) by anyone other than MHI.
For Damage to the Plant Accidents may occur by use of Equipment that is acquired from anyone other than MHI or anyone not appointed by MHI to modify or repair this Plant. The Customer shall not be permitted to modify or repair the Plant or change Equipment of the Plant without MHI’s prior written approval, under any circumstance.
•
MHI will NOT be liable for any Liability resulting from any abuse, misuse, misapplication of the Equipment supplied by MHI.
•
MHI will NOT be liable for any Liability caused by an act by the Customer in violation of the Contract, this manual, any applicable law or regulation, or any Safety Manual or any other instruction provided by MHI, including without limitation, a change of the installation environment or the removal and installation of any Equipment in a location different to that originally selected by MHI.
•
MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault, in material or Equipment that was used during a repair, even when such repair was performed by or under an instruction given by MHI.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
viii
Copyright COPYRIGHT © 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED. All of the content contained in this manual is protected by Japanese, International and/or United States copyright laws.
•
All copyright, trade secrets, and other proprietary and intellectual property rights in the documents provided by Mitsubishi Heavy Industries, Ltd.(“MHI”) (including safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject to your compliance with the restrictions set forth below, MHI grants to you a limited, non-exclusive license in the copyright for the sole purpose of allowing you to use, operate, maintain and inspect the Plant.
•
Use, copying, other reproduction of the whole or part of the documents provided by MHI (including safety-and-instruction manuals) for any purpose other than the purpose described above without MHI’s prior written consent is strictly prohibited.
•
The act of rewriting, translating, modifying, revising, creating electronic copies, uploading, selling, sublicensing, or otherwise disclosing the whole or part of the manuals is strictly prohibited.
•
Except as specifically set forth above, no right, title or license to the documents provided by MHI, whether arising from contract, implication, estoppel or otherwise, is being granted or otherwise transferred.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ix
Personnel to whom the Manual is Directed This Manual was prepared for all personnel who will participate in the operation and maintenance of the plant, and the other related mechanical plant and equipment installed. In this Manual, MHI classifies personnel into the following two classes based on their ability, experience and their attitude to the safety of personnel, and the plant installed. Only the personnel recognized by the Customer as trained personnel are allowed to perform the operation and maintenance specified in the manuals. Maintainers and Operators are required to have read and understood the contents of the safety, operation, and maintenance manuals and sufficiently understand the work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge Engineer are permitted to handle materials to be used in the operation of the plant. Operators are allowed to turn on the power supply, startup equipment, open up or remove covers or panels on receipt of an instruction or authorization from their superior. Operators are permitted access to emergency stop devices following instructions given by their superior when dangerous or hazardous situations are recognized.
Maintainer
MM-M05.08
Rev.000
Maintainers are permitted to perform maintenance on the plant. They will also perform troubleshooting routine and periodical inspections of the installed equipment. The maintainer will also work under the supervision of MHI’s supervisors during on-the-job training and annual maintenance and overhaul work if MHI’s supervisors are requested to witness periodical inspections, etc. Maintainers MUST have attended the training programme initially provided by MHI and subsequently by the Customer, and they must have obtained the necessary knowledge and maintenance skills to understand the characteristics of their tasks before actually starting their work. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
x
Contact Address For any question or any clarification required, please do not hesitate to contact MHI through the following address (es).
For Support before Operation: MITSUBISHI HEAVY INDUSTRIES, Ltd. Nagasaki Shipyard & Machinery Works 1-1, Akunoura Machi, Nagasaki 850-91
For Support after Commissioning and in an Emergency
MM-M05.08
Rev.000
(Later)
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xi
Abbreviations ABB.
EXPANDED FORM
ABB.
EXPANDED FORM
AOP
Auxiliary Oil Pump
NDE
Non-destructive Examination
CCW
Closed Cooling Water
NWL
Normal Working Level
EOP
Emergency Oil Pump
OJT
On Job Training
FL
Floor Level
P&ID
Process and Instrumentation Diagram
I&C
Instrument and Control
PPE
Personal Protective Equipment
MOP
Main Oil Pump
PTW
Permit to Work
IP
Intermediate Pressure
RTD
Resistance Temperature Detector
MOT
Main Oil Tank
TOP
Turning
MSDS
Material Safety Data Sheet
MM-M05.08
Rev.000
Oil Pump
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xii
List of Vendor Manuals
MM-M05.08
Rev.000
LATER
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xiii
A rr a n g e m e n t o f t h e S y s t e m Maintenance Manual This manual is arranged as follows. Chapter 1 Describes health and safety issues during maintenance, disassembly and reassembly of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP).
Chapter 2 Describes the construction, purpose, and function of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP,TOP & EOP) and the associated parts.
Chapter 3 Describes the Turbine Main Oil Tank and the various Pumps using the relevant Data Sheets.
Chapter 4 Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5 Describes the disassembly and reassembly procedures, necessary to obtain access to internal parts for inspection and repair during the Main Oil Tank and the various pumps overhaul.
Chapter 6 Describes the corrective maintenance procedures to be followed to investigate, identify and remedy defects occurring during operation.
Rev.000
Chapter 7
MM-M05.08
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
xiv
Contents
Contents Revision Record ······························································································· i Important Information ······················································································ ii Warranty·········································································································· v Limitations of Liability ·····················································································vii Copyright········································································································ ix Personnel to whom the Manual is Directed······················································ x Contact Address ····························································································· xi Abbreviations ·································································································xii List of Vendor Manuals ··················································································xiii Arrangement of the System Maintenance Manual ·········································xiv
Chapter1
Safety ____________________________
1.1
Features of Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Safety ······························································1-1
1.2
Warnings Description······································································1-2 1.2.1
Definitions of “Serious Injury”, “Minor Injury”, “Serious Damage to Property”, and “Minor Damage to Property” ······1-3
1.2.2
Symbol················································································1-4
1.2.3
Hazard Warning Label ························································1-5
1.2.4
Hazard Area········································································1-7
1.3
Risk Assessment Standard ·····························································1-8
1.4
Safety Measures···········································································1-10 1.4.1
Work Permit System (Lockout/Tagout) ····························1-10
1.4.2
General Cautions on Personnel in Working Area············· 1-11
1.4.2.1
Caution against Rotating Equipment ······························ 1-11
1.4.2.2 Cautions against Electrical Equipment ···························· 1-11 1.4.2.3 Cautions against High Temperature Sections··················1-12 1.4.2.4 Cautions for Steam Leak in the Plant ······························1-13 1.4.2.5 Cautions against Oil Leak in the Plant·····························1-13 1.4.2.6 Cautions against Chemicals············································1-14
MM-M05.08
Rev.000
1.4.2.7 Cautions against Combustible Materials/Storage Areas ··1-14 1.4.2.8 Cautions against Lack of Oxygen····································1-15 1.4.2.9 Cautions against Lifting Heavy Object·····························1-16 1.4.2.10 Caution against Sharp Objects········································1-16 1.4.2.11 Cautions using Fork Lift···················································1-16
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
1
Contents
Chapter1
Safety (Continued from previous page…) 1.4.2.12 Cautions using Crane······················································1-17 1.4.2.13 Disposal··········································································1-18
1.5
Emergency Measure·····································································1-19 1.5.1 Evacuation on Emergency Case········································1-19 1.5.1.1 Evacuation Route······························································1-19 1.5.1.2 Evacuation of disabled persons who cannot move by themselves········································································1-19
MM-M05.08
Rev.000
1.5.1.3 Evacuation from Power House··········································1-20 1.5.2
Fire Accident ·····································································1-21
1.5.3
Earthquake ·······································································1-22
1.5.4
Explosion Accident····························································1-22
1.6
Qualification and Training ·····························································1-23
Chapter2
General___________________________
2.1
Purpose ··························································································2-1
2.2
References ·····················································································2-1
2.3
Overview of the Main Oil Tank and the AOP, TOP & EOP ···············2-3
2.4
Construction ·················································································2-10 2.4.1
Oil Pumps ········································································· 2-11
2.4.2
Vapor Extractor Fan ··························································2-12
2.4.3
Oil Mist Separator ·····························································2-13
2.4.4
Oil Ejectors ·······································································2-13
2.4.5
Oil Level Gauge ································································2-14
2.4.6
Oil Strainers ······································································2-14
2.4.7
Oil Cooler·········································································· 2-15
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites···················································································4-1
4.2
4.1.1
Scheduling··········································································4-1
4.1.2
Departmental Interface/Notification ·····································4-2
4.1.3
Isolation of Equipment·························································4-2
4.1.4
Safety Precautions······························································4-2
Routine Maintenance······································································4-3 4.2.1
Preparation ·········································································4-3
4.2.2
Inspection and Maintenance ···············································4-4
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
2
Contents
Chapter4
Preventive Maintenance (Continued) ______
4.3
Annual Outage Maintenance···························································4-8 4.3.1
Preparation ·········································································4-8
4.3.2
Inspection and Maintenance ···············································4-9
Chapter5
Disassembly and Reassembly ________
5.1
Main Oil Tank Disassembly and Reassembly··································5-1
5.2
Disassembly and Reassembly of the Auxiliary Oil Pump·················5-3
5.3
Disassembly and Reassembly of Turning Oil Pump······················5-12
5.4
Disassembly and Reassembly of Emergency Oil Pump················5-19
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites···················································································6-1
6.2
Preparation ·····················································································6-2
6.3
Troubleshooting ··············································································6-2
Chapter7
Recommended Lubrication __________
Appendixes Torque Chart ···································································· A-1
Appendix B
Recommended Spare Parts ············································· B-1
Appendix C
Special Tools ···································································· C-1
Appendix D
Coupling Alignment ·························································· D-1
Appendix E
Applicable Reference Drawings ······································· E-1
MM-M05.08
Rev.000
Appendix A
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
3
Contents
MM-M05.08
Rev.000
List of Figures Figure 1-1
Types of Hazard Warning Labels·······································1-6
Figure 1-2
Mapping for Hazard Areas·················································1-9
Figure 2-1
Oil Purifier, Oil Piping Diagram··········································2-6
Figure 2-2
Schematic Arrangement of Main Oil Tank and Associated Equipment ······················································2-7
Figure 2-3
Arrangement of Main Oil Tank ···········································2-8
Figure 2-4
Partially Exploded View of Main Oil Tank···························2-9
Figure 2-5
Cutaway View of the Main Oil Tank ·································2-17
Figure 2-6
Main Oil Tank Internal Piping···········································2-18
Figure 2-7
Isometric View of Auxiliary Oil Pump ·······························2-19
Figure 2-8
Cutaway View of the Auxiliary Oil Pump··························2-20
Figure 2-9
Sectional View of the Auxiliary Oil Pump ·······················2-21
Figure 2-10
Isometric View of the Turning Oil Pump···························2-22
Figure 2-11
Cutaway View of the Turning Oil Pump ···························2-23
Figure 2-12
Sectional View of the Turning Oil Pump ··························2-24
Figure 2-13
Isometric View of the Emergency Oil Pump·····················2-25
Figure 2-14
Cutaway View of the Emergency Oil Pump ·····················2-26
Figure 2-15
Sectional View of the Emergency Oil Pump ···················2-27
Figure 2-16
Sectional View of the Vapor Extractor Fan ······················2-28
Figure 2-17
Oil Mist Separator ···························································2-29
Figure 2-18
Arrangement of No. 1 and 2 Oil Ejectors ·························2-30
Figure 2-19
Main Oil Tank Level Gauge Assembly ·····························2-31
Figure 2-20
Lubricating Oil Strainer Assembly····································2-32
Figure 2-21
Return Oil Strainer···························································2-33
Figure 2-22
Turbine Oil Cooler ···························································2-34
Figure 2-23
Bearing Oil Pressure Adjusting Valve ······························2-35
Figure 4-1
Auxiliary Oil Pump Clearance Drawing····························4-16
Figure 4-2
Turning Oil Pump Clearance Drawing ·····························4-17
Figure 4-3
Emergency Oil Pump Clearance Drawing ·······················4-18
Figure 5-1
Exploded View of the Auxiliary Oil Pump························· 5-11
Figure 5-2
Exploded View of Turning Oil Pump ································5-20
Figure 7-1
Recommended Lubricant List Main Oil Tank ·····················7-2
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
4
Contents
Figure 7-2
Recommended Lubricant for AOP·····································7-3
Figure 7-3
Recommended Lubricant for TOP ···································7-4
Figure 7-4
Recommended Lubricant for EOP ···································7-5
Figure 7-5
Recommended Lubricants for Vapor Extractor Fan ·········7-6
Figure B-1
Operating Spare Parts for Auxiliary Oil Pump ··················· B-2
Figure B-2
Operating Spare Parts for Turning Oil Pump ···················· B-3
Figure B-3
Operating Spare Parts for Emergency Oil Pump ·············· B-4
Figure B-4
Operating Spare Parts for MOT Vapor Extractor ············· B-5
Figure B-5
Operating Spare Parts for Mist Separator························· B-6
Figure E-1
Arrangement Drawing of Main Oil Tank ···························· E-2
Figure E-2
Outline Drawing of AOP ··················································· E-3
Figure E-3
Assembly Drawing of AOP (1 of 3) ··································· E-4
Figure E-4
Assembly Drawing of AOP (2 of 3) ··································· E-5
Figure E-5
Assembly Drawing of AOP (3 of 3) ··································· E-6
Figure E-6
Expected Performance Curve of AOP ······························ E-7
Figure E-7
Torque Characteristic Curve for AOP································ E-8
Figure E-8
Outline Drawing for AOP Motor ········································ E-9
Figure E-9
Outline Drawing of TOP ················································· E-10
Figure E-10
Assembly Drawing of TOP (1 of 3) ··································E-11
Figure E-11
Assembly Drawing of TOP (2 of 3) ································· E-12
Figure E-12
Assembly Drawing of TOP (3 of 3) ································· E-13
Figure E-13
Expected Performance Curve of TOP ···························· E-14
Figure E-14
Torque Characteristic Curve for TOP······························ E-15
Figure E-15
Outline Drawing for TOP Motor ······································ E-16
Figure E-16
Outline Drawing of EOP ················································· E-17
Figure E-17
Assembly Drawing of EOP (1 of 3)································· E-18
Figure E-18
Assembly Drawing of EOP (2 of 3)································· E-19
Figure E-19
Assembly Drawing of EOP (3 of 3)································· E-20
Rev.000
Figure E-20
Expected Performance Curves of EOP ·························· E-21
Figure E-21
Torque Characteristic Curve for EOP ····························· E-22
MM-M05.08
List of Figures (Continued from previous page)
Figure E-22
Outline Drawing for EOP Motor ······································ E-23
Figure E-23
Vapor Extractor Fan (1 of 3) ··········································· E-24
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
5
Contents
List of Figures (Continued from previous page) Vapor Extractor Fan (2 of 3) ··········································· E-25
Figure E-25
Vapor Extractor Fan (3 of 3) ··········································· E-26
Figure E-26
Oil Mist Separator (1 of 2) ·············································· E-27
Figure E-27
Oil Mist Separator (2 of 2) ·············································· E-28
Figure E-28
Oil Level Gauge ····························································· E-29
Figure E-29
Lubricating Oil Strainer··················································· E-30
Figure E-30
Return Oil Strainer·························································· E-31
Figure E-31
Turbine Oil Cooler (1 of 2)·············································· E-32
Figure E-32
Turbine Oil Cooler (2 of 2)·············································· E-33
MM-M05.08
Rev.000
Figure E-24
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
6
Contents
List of Tables Risk Assessment Standard················································1-8
Table 3-1
Main Oil Tank ····································································3-1
Table 3-2
Auxiliary Oil Pump·····························································3-1
Table 3-3
Turning Oil Pump ······························································3-2
Table 3-4
Emergency Oil Pump ························································3-2
Table 3-5
Main Oil Tank Vapor Extractor Fan ····································3-3
Table 3-6
Oil Mist Separator ·····························································3-4
Table 3-7
Main Oil Tank Level Gauge ···············································3-4
Table 3-8
Lube Oil Strainer ·······························································3-5
Table 3-9
Return Oil Strainer·····························································3-5
Table 3-10
Turbine Oil Cooler ·····························································3-6
Table 4-1
Routine Maintenance Checklist·········································4-6
Table 4-2
Annual Outage Maintenance Checklist····························4-14
Table 6-1
Troubleshooting – Main Oil Tank and Vapor Extractor Fan ····································································6-3
Table A-1
Torque Chart ···································································· A-1
MM-M05.08
Rev.000
Table 1-1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, & EOP) Mitsubishi
7
Chapter 1
Safety
Chapter
1 Safety 1.1
Features of the Turbine Main Oil Tank and AOP, TOP & EOP The lubricating and control oil requirements of the main turbine oil tank are provided by any of the four turbine oil pumps viz. MOP, AOP, TOP, and EOP at any given operating condition. The turbine oil pumps when in service are subjected to near constant discharge oil pressure with high flow variations. The flow variations occur due to the operation of the various turbine steam admission valves or the turbine protective devices. The oil flow and hence pressure variations caused during the main turbine operation are relieved by relief valves installed on the lubricating oil and control oil piping. However, due to the sudden oil pressure fluctuation and ageing of flange gaskets, the oil piping has a risk of flange/pipe leakage. Any oil leakage in the vicinity of the turbine could lead to a fire, which could damage the nearby components and/or personnel working nearby. The main oil tank is operated under a slight vacuum by the operation of the vapor extractor fan. The turbine bearing pedestals, connected to the main oil tank through the drain lines, are also maintained at a slight vacuum. The negative pressure in the bearing pedestals prevents leakage of oil or oil vapor from the bearing pedestals. Any oil or vapor leakage could lead to a fire which could damage the nearby components. All personnel should pay strict attention to this aspect, check for any damage to main oil tank and to any of the associated pumps.
All operators and maintainers must realize the danger and keep themselves safe, following the recommendation written in this chapter.
MM-M05.08
Rev.000
The turbine oil pumps operate with close internal clearances and accurate alignment. Any disturbance in the pump clearances or alignment, due to ageing and/or wear of components, can cause internal rubbing and damage to the pump components. The disturbed clearances or alignment can also lead to abnormal vibration in the oil pumps. All operators and maintainers should pay special attention if any abnormal rubbing noise or vibration is observed on the oil pumps to reduce consequential damages.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description Safety of personnel working in the power plant is the most important matter and all kind of consideration to avoid dangerous condition are studied and applied to the design of the power plant. However, certain risks are unavoidable due to the nature of the plant. This manual classifies the severity and hazard level of such risks by two categories, “DANGER” and “CAUTION”. Read and understand the indications thoroughly before operation or maintenance of the plant. The contents of wordings, “DANGER” and “CAUTION” are described as follows; Kinds
Meaning of Warnings “DANGER” indicates an imminently hazardous situation in handling of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP), which, if not avoided, could result in death or serious injury, or serious damage to the property or environment. “CAUTION” indicates a potentially hazardous situation during use of the Turbine Main Oil Tank and Auxiliary Oil
CAUTION
Pumps (AOP, TOP & EOP), which, if not avoided, may result in minor injury, or minor damage to the property or environment.
This manual also uses the following indicators in addition to the hazard level indications described above.
Kinds
Meaning of Warnings “IMPORTANT” describes the particular information or items that personnel must know during operation and
IMPORTANT
maintenance of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP), and that, if not heeded, may result in an accident of an in-assessable hazard level.
Notice
“NOTICE” describes useful information and tips for operation and maintenance of the Turbine Main Oil Tank
MM-M05.08
Rev.000
and Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-2
Chapter 1
Safety
1.2.1 Definitions of “serious injury”, “minor injury”, “serious damage to property”, and “minor damage to property” “Serious Injury” This term describes injuries, which leave after effects such as loss of eye sight, permanent disability, bone fracture or breakage, gas inhalation, asphyxiation, electric shock, hospitalization or prolonged hospital visits for treatment.
“Minor Injury” This term describes injuries, which do not require hospitalization or prolonged attention at a hospital (injuries other than “the serious injuries” described above).
“Serious Damage to Property” This term describes damages, which require a suspension of productive activity for one day or more due to restoration of the damaged property.
“Minor Damage to Property”
MM-M05.08
Rev.000
This term describes damage, which does not require any suspension of productive activity due to restoration of the damaged property.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbol In this manual, the following symbols are added for easy understanding of the contents of warnings and are found next to “DANGER”, “CAUTION” and indications. These symbols are in compliance with “ISO 3684”. Symbol
Description This symbol indicates the possible presence of high voltage, and warns of a hazard which may result in system shock, burn or death by electric shock if safety precautions are neglected or the system is handled incorrectly. This symbol indicates a movable section that is inside a safety cover or is exposed. Movable parts may inflict laceration or bone fracture to body parts such as a hand by pinching the hand and/or clothing. This symbol indicates the presence of parts the surface of which could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place your feet when moving around the area. Risk of injury by tripping is present near this symbol due to factors such as a location with an unstable surface, or obstructions such as scaffolding, temporary pipe lines, or other protrusions. This symbol indicates the possible presence of gas(es) harmful or asphyxiant to personnel. Be sure to ventilate fully before work commences. This symbol indicates caution against the handling of a heavy object or working in an abnormal position. Do not work in an abnormal posture which may damage your back or waist. This symbol indicates “prohibited” items or actions during the operation and maintenance of the Turbine Main Oil Tank and
MM-M05.08
Rev.000
Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-4
Chapter 1
Symbol
Safety
Description This symbol indicates that personnel must not touch since the surface is hot. Do NOT enter any area where this symbol is displayed. This symbol indicates that the entry of personnel is prohibited. Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited. Do NOT touch or enter a location or enclosure where this symbol is displayed. This symbol indicates that the stated items or actions in the warning notices relative to operation and maintenance of the Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) are mandatory.
1.2.3 Hazard Warning Label Hazard warning labels are applied where potential hazards are present during operation and maintenance activities. Hazard warning labels will be in appropriate sizes and colors that will catch the eye and the attention of personnel. They also have symbols that show the hazard types, in addition to the descriptions of warning contents.
IMPORTANT Personnel are requested to confirm the location of, and to read, and thoroughly understand the contents of all hazard warning labels applied to this Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Manual. If any of the hazard warning labels peel off/wear out or become unreadable, install a new label in the original location
MM-M05.08
Rev.000
without delay.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-5
Chapter 1
Safety
WARNING
DO NOT COME NEAR TO SHAFT EXPOSED ZONE WHEN IN OPERATION
STEEP DROP
DO NOT ENTER
DO NOT TOUCH
DO NOT TOUCH
MM-M05.08
Rev.000
TB0001_A
FIGURE 1-1
TYPES OF HAZARD WARNING LABELS
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-6
Chapter 1
Safety
1.2.4 Hazard Area
IMPORTANT Only trained maintainers and operators are allowed to enter the maintenance work area. Entry to the area by personnel untrained could cause not only injury but also serious damage to the Turbine
MM-M05.08
Rev.000
Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard The tables below are prepared as per MIL STD822D. TABLE 1-1
RISK ASSESSMENT STANDARD Detailed Description of Impact on each Object
Category
Safety
I
Catastrophic
- Unit shutdown (unit cannot be operated) - More than 4 days for repairing
- Death
II
Critical
- Unit shutdown (can not be operated) - Within 3 days for repairing
- Serious Injury
- Same as the above
III
Marginal
- Unit shutdown (can not be operated) - Can be repaired by Customer
- Minor Injury (with hospitalization)
VI
Negligible
- Same as the above - High temperature surface - High elevation or unstable - Not harmful and high pressure & temperature leakage -Mechanical protected
- Minor Injury (without hospitalization)
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, “it has happened”
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1 Hazard Categories Frequency of Occurrence
Rev.000
Environment - Harmful gas or oil leakage - High pressure and temperature material leakage such as steam, water, air and gas, oil etc. - Low oxygen
TABLE 1-1
MM-M05.08
Health
RISK ASSESSMENT STANDARD (CONTINUED) I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
1
3
7
13
(B)
Probable
2
5
9
16
(C)
Occasional
4
6
11
18
(D)
Remote
8
10
14
19
(E)
Improbable
12
15
17
20
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-8
Chapter 1
10 5 3 2
3
10 5 3 2
6
10 5 3 2
6
6
10 5 3 2
6
3
7 4 4 3
4 3 9 2 8 1 7
7 4 3
Safety
7 4 3 7 4 3
4 3
4
STAIR WAY
3 7 8
2 3 5 10
3 4 7
STAIR WAY
2 3 5 10
2 3 5 10
3
2 3 5 10
6
3
4
3 4 7
1 7 2 8 3 9 4
3 4 7
3 4 7 NOTES WARNING LABELS SHOUD BE IN ARABIC.
GEN. SIDE
3
MM-M05.08
Rev.000
1 YELLOW
AVOID INJURY WATCH YOUR STEP
2 YELLOW
FALL WATCH YOUR STEP
YELLOW
RISK OF A ROTATING A HAND
YELLOW
RISK OF A GEAR PINCHING A HAND
MPTD-3-0314
GOV. SIDE
(*1)
YELLOW
RISK OF A CHAIN PINCHING A HAND
YELLOW
PINCH POINT KEEP HANDS AWAY
4 YELLOW
5 YELLOW
DO NOT TOUCH HOT SURFACE
6 YELLOW
7 YELLOW
8 YELLOW
DISCONNECT AUTOMATIC START. ELECTRICAL POWER KEEP HANDS CLEAR. BEFORE SERVICING
DO NOT SMOKE IN THIS AREA.
10 RED
OPERATING PERIOD
(*1) THE MOST SUITABLE ONE WILL BE ADOPTED TO EACH PLACE.
FIGURE 1-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
9 RED
MAPPING FOR HAZARDOUS AREA
1-9
Chapter 1
1.4
Safety
Safety Measures 1.4.1 Work Permit System (Lockout/ Tagout)
MM-M05.08
Rev.000
Work permit system is applied when equipment is shutdown for maintenance work, to complete the maintenance work under a safe condition. The outline of the work permit system is as follows: (1)
The Maintenance Engineer applies for the work permit clearly indicating the content of the maintenance work that he wants to do, and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the operator to study and decide the isolation method from the line in operation on the mechanical and electrical view point and then report to the Shift Charge Engineer with the comments on the hazard conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and prepares necessary tags to show the work permit number and the situation of isolation by valves and power supply. He will then instruct the operators to set the isolation condition following the work permit form.
(4)
The operators will open the breaker and set the valves to the specified condition, they will also drain and vent the equipment to be worked on, and the breaker and the valves are to be locked. The operators return the work permit to the Shift Charge Engineer.
(5)
The Shift Charge Engineer checks the isolation and will issue the signed work permit to the Maintainer, or his representative.
(6)
The Maintenance Engineer orders the start of the maintenance work to the personnel nominated.
(7)
The Maintenance Engineer or his representative will then return the signed work permit to the Shift Charge Engineer after making sure the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the locks and return to the original situation.
(9)
The operators check the situation and report that the system is now back to the normal condition when signing off the work permit.
(10) The Shift Charge Engineer makes sure that the work under the permit is completed and files details in the log book. The work permit system is to clarify responsibility for the works on each step and to ensure that the work is performed safely.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-10
Chapter 1
1.4.2
Safety
General Cautions on Personnel in Working Area
1.4.2.1 Caution against Rotating Equipment All couplings on rotating machine are covered by the coupling cover but whole parts of the shaft are not fully covered. It is recommended that the following warning is observed strictly.
•
Do not approach or operate the equipment where protective covers have been removed. Get additional supervisor assistance.
•
Make sure that the breaker for the motor is opened when you are required to remove the cover.
•
Care must be taken of the exposed rotating parts especially in the area between the casing and the coupling.
•
All shafting, coupling and other rotating parts must be guarded in order to prevent accidental contact.
1.4.2.2 Cautions against Electrical Equipment
MM-M05.08
Rev.000
The electrical equipment covered under this section includes all the concerned plant equipment and the maintenance tools like grinders, lamps, welding equipment, etc. Though live parts of the plant or maintenance tools are insulated, be sure to observe the following cautions. Failure to observe them may cause fatal accidents, personal injuries and damage to the electrical equipment.
•
Always, confirm that power supply is disconnected at the up-stream side of power supply system and it is locked according to the Work Permit.
•
Do not remove or open panels or doors labeled with high voltage live part warning label not included in the Work Permit.
•
Ensure the proper earthing is provided for all electrically operated tools and equipment used for maintenance works.
•
In case of usage of lamps for internal inspection, ensure that a low voltage system (24volts) is available.
•
Make sure that no materials or Parts remain in the Panels or terminal box before closing them finally.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-11
Chapter 1
Safety
1.4.2.3 Cautions against High Temperature Sections Various equipment and pipelines contain high temperature fluid and they are insulated on their surface. There are however some pipe lines which are not insulated, and as their temperature is very high and you could get burned, please observe the following caution to avoid burn injury.
CAUTION Suitable Personal Protective clothing is always available and should always be worn, including gloves to avoid direct contact to hot spots in the plant
•
Level gauges of pressure vessels including connecting pipes are not insulated to cool down the steam to drain.
•
Sampling piping is not insulated to cool down the steam to suitable temperature for the analyzer except at the places located close to the work place.
•
All exhaust pipes of the safety valves, and the exhaust pipe of the boiler flush pipe are not insulated.
•
Always wear gloves.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-12
Chapter 1
1.4.2.4
Safety
Cautions for Steam Leak in the Plant A steam leak especially from high temperature steam may cause serious injury to the personnel and it must be repaired at an early stage of the leakage. The following pre-cautions must be followed to find leakage at an early stage.
•
Water drips may occur at the insulated parts such as the connected part of the lagging. The leaking point can be found by removing insulation partially with great care.
•
As you approach the leakage, the water will change to visible steam. It is now too dangerous to remove the insulation.
•
Leakage of the superheated steam only makes whistling noise without generating white steam. It is very dangerous to approach the noise area.
•
Contact the Charge Engineer to obtain a Permit to Work to ensure plant isolation before repairing the damage.
•
Be well aware of the steam. The steam could leak from the water system containing water at 100ºC or higher even if it is a low pressure type water system.
•
High temperature drain or steam could leak from the flush pipe during start-up.
•
If not avoided, the steam or vapor can enter the inside of your working wear through the small gap between the body and the clothing.
1.4.2.5 Cautions against Oil Leak in the Plant
•
Oil leakage is very dangerous. It is a potential fire hazard.
•
Any oil spillage must be reported to the Shift Charge Engineer.
•
Oil leaks make the area slippery and people are advised to move around these areas carefully.
MM-M05.08
Rev.000
CAUTION
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-13
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals Pay attention to the items to prevent any accident related to the chemicals in the plant.
IMPORTANT Precaution against chemicals • Operate chemical injection systems by strictly following the instruction of the chemist. The operator must use suitable protective tools. Disposal: • Observe the rules and regulation of the installation site. Material safety data sheet (hereafter MSDS):
•
Always understand the content of the applicable MSDS before using, and observe the notified instructions when handling the chemical.
Emergency response
•
Solution against emergency must be thoroughly instructed to all personnel involved so that the fullest measures can be taken against any situation.
1.4.2.7 Cautions against Combustible Materials/ Storage Areas
IMPORTANT Storage containers must be clearly marked to indicate the content
•
Bunding must be provided for bulk tanks
•
Suitable fire protection must be provided for each area.
•
Do not store bulk combustible materials on the site.
•
Small quantities of combustible materials must be stored in fire resistant cupboards.
•
Combustible materials must be segregated from other equipment
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-14
Chapter 1
Safety
1.4.2.7 Cautions against Combustible Materials/ Storage Areas (Continued from previous page)
IMPORTANT •
Leakage of gasoline has the risk of fire. Maximum storage quantity of gasoline outside of the dispensing pump is five liters
Emergency response:
•
Personnel directly involved in combustible materials MUST be properly trained and thoroughly instructed. Other personnel in the vicinity must be aware of the dangers and take precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in any confined space is between 18~22% before entering, to ensure sufficient ventilation.
•
Continue monitoring oxygen and ventilation during inspection.
•
It is recommended that you do not enter the equipment, vessel or confined space alone but if the situation demands that you must enter, take the necessary preventive safety measure provided, breathing system etc, and find a partner who will wait for your return at the point of entry, keeping in verbal contact throughout.
•
Make complete arrangements for rescue.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-15
Chapter 1
1.4.2.9
Safety
Cautions against Lifting Heavy Object Be careful during the removal/installation of any equipment during maintenance.
CAUTION •
Do NOT attempt to move or lift equipment in an abnormal posture. ALWAYS install/remove equipment, using a forklift or a crane. A normal lift without mechanical aid should be shared between two or more persons.
•
Failure to observe the above may cause injury due to dropped equipment, back or waist injury or damage to the equipment.
1.4.2.10
Caution against Sharp Objects
CAUTION •
Use leather gloves when handling parts with sharp edges.
1.4.2.11
Cautions using Fork Lift
•
Do NOT permit anyone to stand under any item being lifted under any circumstance.
•
Failure to observe this may cause fatal accidents.
•
When using a forklift, ALWAYS lift the objects parallel to the ground while considering the center of gravity.
•
Otherwise, lifted objects may fall and serious damage could occur.
•
A forklift is often used to transfer small machines. Check fork insertion position for the forklift prior to use. Be careful, as marks which indicate the fork insertion positions are sometimes hidden by wraps or packing materials.
MM-M05.08
Rev.000
CAUTION
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-16
Chapter 1
1.4.2.12
Safety
Cautions using Crane
CAUTION •
A crane is often used to transfer heavy parts. Check for any possible risks which could occur during hoisting and transportation before operating the crane.
Check of the equipment:
•
Check the crane, the crane hook and all related items before use. Use wire ropes which can withstand the weight of the parts multiplied by a safety factor.
•
Inspect the shackles, eyebolts, jigs and wire ropes provided for the hoisting work prior to the actual hoisting.
•
Perform periodical inspection (dye penetrant test) of hoisting tools at least once a year.
Rigging/ Slinging work:
•
Only authorized personnel can perform slinging work and operation of the crane.
Work area:
•
Before hoisting, secure a working area around the part to be lifted and prohibit the entry of unrelated personnel.
Hoisting method:
•
Hoist the part parallel to the ground while paying attention to the center of gravity.
•
Do NOT permit any person to stand under the part being lifted.
•
Pay attention to and ensure that all persons are clear of the equipment being lifted.
Hoisting point:
•
Do NOT hoist any parts from a position other than the specified hoisting points.
Unpacking:
•
Do NOT unpack any part until it is located in the designated location.
Protection of machine: Avoid any impact to the unpacked parts.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-17
Chapter 1
1.4.2.13 a)
Safety
Disposal Water disposal including oily drain The water is disposed to the plant drain system. The water must be carefully disposed according to materials contained in the water. The water drain system is separated into three categories that are rain water, chemical water and oily water. The waste waters are treated and then discharged to the public drain system.
b)
Chemical disposal Chemicals must be handled following the instruction of MSDS and disposed in the chemical drain system.
c)
Solid disposal made by maintenance work.
MM-M05.08
Rev.000
For disposal from the site, observe the local legal regulations.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-18
Chapter 1
1.5
Safety
Emergency Measure 1.5.1 Evacuation in an Emergency 1.5.1.1
Evacuation Route Following items are considered on design and installation of emergency evacuation.
IMPORTANT •
Each building installed in the plant is provided with at least two exits. A clear indication of the exits can be seen from anywhere in the building as the exit sign is illuminated using the emergency power supply.
•
Evacuation routes are indicated on each floor of the building, directing personnel to the exits.
•
Keep the evacuation routes completely free from materials and tools.
1.5.1.2 Evacuation of Disabled Persons Who Cannot Move by Themselves The following are necessary items, prepared for emergency evacuation:
IMPORTANT It is recommended to keep a stretcher available for emergencies at the places selected as being secure at the safety meeting.
•
If you find this kind of accident, inform the rescue team, and attempt to bring the collapsed person to the first aid station.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-19
Chapter 1
Safety
1.5.1.3 Evacuation from the Power House Following are guidance for the evacuation from the power house.
IMPORTANT An evacuation place for personnel to gather in after evacuation from the power house in an emergency must be predetermined and explained beforehand in the emergency training.
•
Evacuation directive must be given by the responsible person such as Shift Charge Engineer, and all personnel must be alerted in the power house repeatedly with an available broadcast facility.
•
All people working in the power house must stop there work immediately and leave the power house to the gathering place.
•
When evacuated to the evacuation place, make sure that there is no one missing.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-20
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT Clearly show the location of fire alarm push button and fire extinguisher to make everybody take the first step at fire protection.
•
Inform everyone concerned that a fire has now started if you discover a fire.
•
Start fire fighting using the fire extinguisher located near the fire site.
•
The operators must check the plant is ready for trip, and wait for order from the responsible person.
•
The operator and other personnel must transfer the fire fighting to the fire fighting team when they arrive at the fire site and the operators must wait for instruction from the Shift Charge Engineer. All other personnel must immediately start evacuation.
•
If unit trip is decided, the operator must trip the plant manually.
•
The operators must evacuate from the power house according to the instruction of the responsible person immediately after shutdown of the unit.
•
If the fire is extinguished successfully, the operators should return to the power house as required by the Shift Charge Engineer and start inspection of the equipment for restart of the unit.
•
Based on the inspection, the responsible person should decide whether to operate the unit again or shutdown for repairing.
•
After the inspection or repair, and then checking the equipment and/or system, start up the unit again.
MM-M05.08
Rev.000
•
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-21
Chapter 1
Safety
1.5.3 Earthquake In the case of an earthquake, the shift charge engineer or operator must judge whether the unit trip is necessary according to the intensity of the earthquake, and immediately trip the unit manually. If the unit is tripped, all equipment must be carefully checked on its operation status and tripped if abnormal phenomena are found. In the local area, mechanical and/or thermal shocks may be given to the equipment, piping, instruments and electrical panels. Be sure to observe the following when completing the inspection.
•
Check that the lubricating oil pump is running. Bearings of the equipment will be damaged if lubricating oil is not supplied.
•
Check the piping and equipment for steam and water leakage. The steam or high temperature water leakage may cause serious injury to the personnel and it must be repaired at an early stage of the leakage.
•
Check the pulverizers and / or coal silos for signs of a fire. If a coal fire does start, make sure that CO2 fire fighting system is properly operated.
•
Check the position of boiler seismic stopper. Since the boiler seismic stopper must be anchored at the original position, the boiler cannot be re-started if the slippage is found. If the stopper is not at the original position, please contact MHI.
CAUTION •
Check the piping and equipment for the breaking and the dropping of insulation. Since the exposure of the hot surface may cause burn injury, it must be repaired by a worker fully dressed in Personal Protective Equipment.
1.5.4 Explosion Accident
MM-M05.08
Rev.000
•
Do not use a fire in a hazardous area where the combustibles (hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or handled. Use of a fire in a hazardous area could cause serious injury to personnel and serious damage to equipment due to an explosion.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-22
Chapter 1
1.6
Safety
Qualification and Training The system must be operated only by authorized operators & maintenance supervisors. The customer must authorize all operators and maintainers, who are involved in the operation and maintenance of this plant, either by the training course given by Mitsubishi, or by the customer’s own personnel assessment. Operator and maintainer training course (both classroom training and the On-Job-Training (OJT)) will be provided by Mitsubishi before the handing over of this plant. The customer must train and assess each new operator and maintainer to joins after the turn-over, according to his own procedure and standard, (Mitsubishi training course may still be available if required).
•
Operator and Maintainer can read and fully understand the description of this manual.
•
Operator and Maintainer can understand the related P & ID, logic diagram.
•
Operator and Maintainer know location of the system equipment including pipe routes, valves and the various instruments.
•
Operator and Maintainer have fundamental knowledge of the function of each equipment.
•
Operator can operate the equipment and the system manually at local stations.
•
Operator can operate the system remotely using DCS system.
•
Operator can respond suitably for any kind of alarm.
•
Operator knows location of emergency exit on power house and is available to provide first aid treatment.
•
Operator knows emergency communication system operation.
•
Operator and Maintainer, following the Charge Engineers instruction are aware of the isolation method for mechanical, electrical and instrumental equipment being prepared for safe maintenance while the unit is in operation.
•
Maintainer must also be able to handle the maintenance tools provided by the customer and those supplied by the manufacturer.
MM-M05.08
Rev.000
As a minimum, operator and maintainer must satisfy the following:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
1-23
Chapter 2
General
Chapter
2 General 2.1
Purpose The purpose of this maintenance manual is to provide specific information to the Paiton Expansion Project operating and maintenance personnel regarding the maintenance of the Main Oil Tank and the Turbine Oil Pumps (AOP, TOP, EOP). Although this document will convey a good knowledge and direction regarding maintenance of the Main Oil Tank and Turbine Oil Pumps, it is recommended that in the event of a problem not covered in the document the person responsible should seek assistance or instruction from the manufacturer.
References a)
Main Oil Tank Outline Drawing (1/2, 2/2) MHI Dwg. No. : N26-P11-6083
b)
Control and Lubrication Oil System Diagram (2/5) Project Dwg. No. P101-51-3-TB-LT0002 MHI Dwg No: T3059AAAA210-2
c)
Control and Lubrication Oil System Diagram (4/5) Project Dwg. No. P101-51-3-TB-LT0004 MHI Dwg No: T3059AAAA210-4
d)
Oil Purifier Oil Piping Diagram 2/2 Project Dwg. No. P101-51-3-TB-LT0011 MHI Dwg No: T3059AAAA250-2
e)
Auxiliary Oil Pump MHI Dwg No: T3059MAY471
f)
Turning Oil Pump MHI Dwg No: T3059MAY472
g)
Emergency Oil Pump MHI Dwg No: T3059MAY473
g)
Drawing of Auxiliary Oil Pump Motor Project Dwg. No. G101-24-1820.00-G028 MHI Dwg No: 65500-5451-028
MM-M05.08
Rev.000
2.2
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-1
Chapter 2
Drawing of Turning Oil Pump Motor Project Dwg. No. G101-24-1820.00-G029 MHI Dwg No: 65500-5451-029
g)
Drawing of Turning Oil Pump Motor Project Dwg. No. G101-24-1820.00-G101 MHI Dwg No: 65500-5452-002
MM-M05.08
Rev.000
h)
General
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-2
Chapter 2
2.3
General
Overview of the Main Oil Tank and the AOP, TOP & EOP Refer to Figures 2-1 to 2-6. The total control and lubricating oil requirements for the main turbine and its auxiliaries are supplied by the Main Turbine Control and Lubrication Oil System. The main turbine oil system consists of a main oil tank with oil pumps, oil coolers, oil filters, vapor extractor, oil mist separator, etc. for meeting the above lubricating and control oil requirements. The details of the major components related to the Main Turbine Control and Lubrication Oil System are described in this maintenance manual. The main oil tank is the central part of the main turbine lubricating oil system in which the turbine lubricating and control oil are collected, stored and distributed to the turbine, generator and exciter bearings, the turbine protective devices and the steam admission valves. The stored oil in the main oil tank is distributed to the bearings and the protective devices through any of the turbine oil pumps as per the operating requirement. The main turbine oil system is provided with a main oil pump (MOP), an auxiliary oil pump (AOP), a turning oil pump (TOP) and an emergency oil pump (EOP) for this purpose. The main oil tank is a circular steel tank located below the mezzanine floor on the ground floor of the Turbine Building. The lubricating and the control oil are returned to the main oil tank under gravity by virtue of the elevation difference between the bearings, the steam admission valves and the main oil tank. The main oil tank has a maximum level, (High Alarm) of 40,180 liters with a normal working level of 36,800 liters, and a low working level of 33,310 liters sufficient to provide all oil requirements of the turbine generator. The working range between the High and Low levels provides an operating oil quantity of 6,870 liters. The main oil tank, under normal operating conditions, provides sufficient oil dwell time within the tank to permit the release of non-condensable gases and the settlement of fine particulate debris in the tank.
The MOP is installed on the HP-IP turbine rotor extension shaft and the AOP, TOP and EOP are mounted on the main oil tank. The discharge lines of these pumps are suitably interconnected with check valves inside the main oil tank to permit oil distribution at any operating condition. Details on the construction and maintenance for the MOP are provided in the mechanical maintenance manual No. M-05.06, Turbine Main Oil Pump and for the remaining turbine oil pumps refer to this mechanical maintenance manual No. M-05.08, Turbine Main Oil Tank and Auxiliary Pumps (AOP, TOP, EOP).
MM-M05.08
Rev.000
The four oil pumps (MOP, AOP, TOP and EOP) together with two water cooled oil coolers and two sets of oil filters supply clean filtered oil to the turbine bearings and the turbine protection devices at the desired pressure and temperature.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-3
Chapter 2
General
Oil from the turbine-generator bearings and the turbine protective devices is returned to the main oil tank through a return oil strainer installed inside the main oil tank. The hot oil in the main oil tank returned from the turbine-generator bearings is cooled to the desired temperature by two water-cooled oil coolers, one working and one standby. Cooling water for the oil coolers is supplied from the Closed Cycle Cooling Water (CCCW) System. The oil piping downstream of the oil coolers is provided with a spring loaded relief valve to maintain the lubricating oil pressure to the bearings between 1.0 and 1.8 barg. This is achieved by continuously relieving the excess oil into the main oil tank. The main oil tank is provided with a 17 m3/min AC motor driven vapor extractor fan to evacuate air, oil vapor and non-condensable gases from the main oil tank. This evacuation by the vapor extractor fan maintains a slight negative pressure inside the main oil tank. Thus the turbine bearing pedestals are also maintained under vacuum as they are connected to the main oil tank via the drain guard pipe. The vacuum inside the bearing pedestal prevents leakage of oil or oil vapor along the turbine shaft. The vapor extractor fans discharge the oil vapor and the non-condensable gases to atmosphere through an oil mist separator. Oil collected in the vapor extractor fan casing and the oil mist separator is returned to the main oil tank through U- loop seals. Local and remote oil level indications for the main oil tank are provided by level gauge and level switches. The level in the main oil tank is maintained between the high and the low working levels during operation. Loss of oil due to evaporation or leakage is topped up with fresh oil by a common storage oil transfer pump. The common storage oil transfer pump draws suction oil from either of the clean oil and dirty oil storage tanks and discharges either to the main oil tank or to the oil purifier.
MM-M05.08
Rev.000
The drain line of the main oil tank is connected to an oil transfer pump to transfer oil from the main oil tank to the clean/dirty oil storage tank. Excess oil in the main oil tank during operation can be pumped to the clean oil storage tank through the oil transfer pump. The oil in the main oil tank can also be transferred to the dirty oil storage tank through the oil transfer pump if the entire oil is to be replaced due to contamination or ageing. The main oil tank drain line is lock-closed and is only opened during the transfer of oil from the main oil tank or to obtain oil samples during shut-down. For sampling purposes a sampling connection is provided on the tank drain line downstream of the drain valve. Another sampling connection provided in the main oil tank overflow line permits sampling of the circulating lube oil during turbine operation enabling the operator to evaluate the necessity of continuous usage of the oil purifier.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-4
Chapter 2
General
MM-M05.08
Rev.000
The main oil tank is provided with an oil purifier unit to filter the oil in the main oil tank during operation. The main oil tank is connected to the oil purifier suction through the overflow and the drain lines. Oil to the oil purifier unit is supplied through the overflow line for purification during turbine operation and through the drain line during unit shut-down. Oil after purification can be transferred either to the main oil tank or to the clean oil storage tank. The construction, operation and maintenance of the oil purifier unit, refer to the vendor operation and maintenance manual No. OM-02.03, Oil Purifier.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-5
Chapter 2
General
CONN. TO ROAD TANKER FOR INLET OIL
OIL MAKE-UP WEATHER CAP MIST SEPARATOR
VAPOR EXTRACTOR
LI 91
TURBINE OIL STORAGE TANK
DAMPER M
LUBE.OIL (TO BEARING)
LUBE.OIL (FROM MAIN OIL TANK)
BEARING OIL PUMP
TURNING GEAR OIL PUMP
M
OIL PUMP FROM BFPT-A
CONN. TO ROAD TANKER @ FOR OUTLET OIL
LUBE OIL STRAINER(A)
LUBE OIL STRAINER(B)
TURBINE OIL COOLER (A)
TURBINE OIL COOLER (A)
OVERFLOW PIPE
SAMPLING
SAMPLING
FROM BFPT-B
PI 92
MAIN OIL TANK
L.C
OIL SUPPLY PUMP
PI 91
SAMPLING OIL TRANSFER PUMP
OIL PURIFIER COALESCER FILTER
LS 92
H
LS 93
L
LI 92
DPI 93
PI 95
R.V
DPI 94
SAMPLING TO BFPT-B
HH
TO BFPT-A
LS 91
FROM BFPT-B
FROM BFPT-A
DCS
OIL PURIFIER INLET PUMP
S
SV 6
MM-M05.08
Rev.000
LOCAL CONTROL PANEL
MPTD-3-0752
FIGURE 2-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
OIL PURIFIER, OIL PIPING DIAGRAM 2-6
Chapter 2 N-15
General
N-16
HOLE
N-6
C DRAIN GUARD PIPE N-17
M.O.P SUCTION PIPE
190
25
190
AIR VENT PIPE
DRAIN
HP. OIL PIPE
N-14
N-14 BRG. OIL SUPPLY PIPE
M.O.P DISCHARGE PIPE
N-12
175 175 185
N-5
C
VIEW A N-9
RETURN OIL FILTER
MAIN OIL TANK BRG. OIL INLET 250A (TO OIL COOLER)
PRESSURE GAUGE PANEL
BRG. OIL INLET 250A (FROM OIL COOLER)
AC TURNING OIL PUMP
DC EMERGENCY OIL PUMP
PRESSURE GAUGE PANEL
MAN HOLE COVER OIL LEVEL GAUGE
DC EMERGENCY OIL PUMP
TO PRESSURE GAUGE PANEL
AC AUXILIARY OIL PUMP
A
N-1
MEZZANINE FLOOR
N-7
N-7 CL MAIN OIL TANK
N-3
380
MAX. LEVEL NOR. LEVEL LOW. LEVEL
150 150
N-8
N-2
N-9
N-4
MM-M05.08
Rev.000
SLIDING SUPPORT
FIXED SUPPORT
SLIDING SUPPORT
GLOUND FLOOR
MPTD-3-0481
FIGURE 2-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
SCHEMATIC ARRANGEMENT OF MAIN OIL TANK AND ASSOCIATED EQUIPMENT 2-7
Chapter 2
General
OIL LEVEL GAUGE
MAN HOLE COVER
PRESSURE GAUGE PANEL
MM-M05.08
Rev.000
LUBE OIL INLET PIPE (FROM COOLER) LUBE OIL OUTLET PIPE (TO COOLER) RETURN OIL STRAINER
FIGURE 2-3 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ARRANGEMENT OF MAIN OIL TANK 2-8
Chapter 2
General
O IL L E V EL G AU G E
M A N H O L E C O VE R
Rev.000
PR ESSU RE GAUGE PANEL
LU B E O IL IN LE T PIP E (F R O M C O O LE R ) L U B E O IL O U T LE T P IP E (T O C O O L ER )
MM-M05.08
R E T U R N O IL ST R A IN E R
FIGURE 2-4 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
PARTIALLY EXPLODED VIEW OF MAIN OIL TANK 2-9
Chapter 2
2.4
General
Construction Refer to Figures 2-4 to 2-6. The main oil tank is a circular, horizontal fabricated steel tank which has a nominal storage capacity of 36,800 liters at the NWL, sufficient to provide the lube oil requirements of the turbine and the generator. The tank has a capacity of 40,180 liters at the maximum operating level and 33,310 liters at the minimum operating level. The main oil tank is supported on a steel support frame fabricated from channel beams and grouted to a concrete foundation. The outside surfaces of the main oil tank are welded with stiffeners at regular intervals to provide rigidity to the tank. The main oil tank is provided with an earthing terminal, which is connected to the plant electrical grounding system, to discharge any leakage of current on the main oil tank to the earth. Stools are provided on top of the main oil tank onto which the AOP, TOP and EOP are mounted. The pumps extend down into the oil tank such that their suctions are located well below the low oil level. Within the main oil tank, the high pressure oil discharged from the MOP or AOP (HP pump) enters a control oil line, which is further connected to the turbine protective devices and the steam admission valves. Likewise, the low pressure oil discharged from the AOP, TOP or EOP enters a common lube oil header, which also receives oil from the No. 2 oil ejector, providing a single lubricating oil line. A bearing oil pressure regulating (relief) valve (Figure 2-23) installed in the lubricating oil line, downstream of the lubricating oil filter, maintains the lube oil pressure at a near constant value by continuously relieving excess oil. The main oil tank is provided with nozzles for the termination of the turbine lube oil drain guard pipe, vents from oil coolers, tank oil temperature indicators, tank drain, filter drains, tank overflow, oil supply and return lines for oil coolers and oil purifier. The main oil tank is also provided with nozzles for the installation of the oil level gauge, level switches and for connecting the vapor extractor fan suction pipe.
MM-M05.08
Rev.000
A duplex type lube oil filter is installed on a grating extension at the top of the main oil tank. A basket type filter is located inside the tank to filter all oil returning to the tank. A hinged door installed above the strainer provides access for the removal of the filter for cleaning or maintenance. A cantilevered extension of the grating at the top of the main oil tank is provided to support the vapor extractor fan. A manhole cover on the top of the tank provides access for internal inspection and maintenance. The main oil tank is also provided with bolted doors at the top for adjusting oil supply adjustable check valve for the MOP, adjustable check valve for bearing oil and bearing oil pressure regulating valve. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-10
Chapter 2
General
A pressure gauge panel is provided on the tank to indicate the oil pump discharge pressures, main oil tank vacuum and the lubricating oil pressure after the cooler. The main oil tank is provided with a ladder to provide access to the equipment installed on the top of the tank. Handrails are installed at the top of the oil tank to provide safety for the operating and maintenance personnel. The major equipment associated with the main oil tank and the turbine lubricating oil system are the following: •
Oil pumps
•
Vapor extractor fan
•
Oil mist separator
•
Oil ejectors
•
Oil level indicators
•
Oil strainers
•
Oil cooler.
2.4.1 Oil Pumps Refer to Figures 2-7 to 2-15. The AOP, TOP and EOP are installed vertically on stools welded to the top of the main oil tank. The AOP is of the shaft type consisting of three impellers which are installed on a common pump shaft driven by an electrical motor. The pump is of the three stage centrifugal pump and delivers 100 l/min of oil at a pressure of 1.08 MPa. The AOP is driven by a 150 kW, 380 V AC, 50Hz motor at a speed of 2950 rpm. The TOP is of the vertically mounted single stage centrifugal type oil pump. The TOP delivers 6100 l/min of oil at a pressure of 0.34 MPa and is driven by a 65 kW, 380 V AC, 50Hz motor at a speed of 1480 rpm. The EOP is also of the vertically mounted single stage centrifugal type oil pump. The EOP delivers 5800 l/min of oil at a pressure of 0.35 MPa and is driven by a 65 kW, 250 V DC motor at a speed of 1480 rpm.
MM-M05.08
Rev.000
The AOP, TOP and EOP are provided with suction strainers, at the pump inlets, to prevent entry of foreign material during operation. The discharges of the AOP pump, TOP and EOP are connected within the main oil tank to provide a common lubricating oil line. Likewise the discharges of the AOP HP pump and the MOP are connected together to provide a single HP oil line. Check valves are installed in the discharge line of each pump to prevent reverse rotation of the standby pumps. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-11
Chapter 2
General
2.4.2 Vapor Extractor Fan Refer to Figure 2-16. The vapor extractor fan is of the single stage centrifugal type. It draws suction from the main oil tank and discharges the oil vapor and non-condensable gases to the atmosphere. The vapor extractor fan maintains a slight vacuum inside the main oil tank. The turbine and generator bearing pedestals connected to the main oil tank via the lube oil return line are also under a slight vacuum. The vacuum in the bearing pedestal prevents leakage of oil or oil vapor along the turbine shaft. The extractor fan is also provided with a butterfly damper at the suction side to adjust gas flow and hence vacuum in the main oil tank. The vapor extractor fan consists of a volute casing (1) which encloses an impeller (2). The impeller is formed from two flat discs enclosing narrow vanes between them. The inlet side disc is shaped to provide an opening and a boss to allow the flow of incoming gases. The impeller is bolted to an impeller hub (3) and the whole assembly is keyed onto the motor shaft (4) and secured with an impeller set bolt (7) and a retainer plate (21). The impeller is overhung inside the volute casing and is supported by the bearings of the drive motor (11). The fan casing is a steel fabricated component which is made in two parts; a casing (1) and a front cover (22). The casing is secured to the motor base frame (12) by welding. The front cover is welded onto the suction cone (5) and is bolted to the fan casing using the suction cone set bolts (6) such that the cone is set inside the impeller boss with a small running clearance. The suction damper (14) is installed in the suction cone adjacent to the suction cone inlet flange (23). The fan casing is provided with a drain pipe (13) to drain any liquid trapped in the fan casing. Any oil droplet collected in the fan casing is drained into the main oil tank overflow line through a U-loop seal.
MM-M05.08
Rev.000
The suction cone, the fan casing and the discharge pipe are shaped to smoothly guide the flow of air and vapor to promote efficient performance of the fan. The suction cone and the discharge pipe are flanged for connection to their respective ducts. An oil seal assembly is provided on the fan casing, where the shaft penetrates the casing, to prevent leakage of oil droplets and/or vapor along the shaft. The oil seal assembly consists of an oil seal housing (20) which is secured to the fan rear casing by welding. The shaft seal consists of two oil seal rings (10) mounted one on either side of a grease-packed lantern-ring (9) inside the oil seal housing and secured by a retainer ring (19). Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-12
Chapter 2
General
A grease nipple (15) is provided on the top of the oil seal housing to facilitate injection of seal lubrication during operation and a drain line with a cock (16) at the bottom to drain the spent grease. The impeller is rotated by a 3.7 kW, 400 V induction motor (11) at 3500 rpm. The motor is mounted on a bracket welded to the base frame.
2.4.3 Oil Mist Separator Refer to Figure 2-17. The oil mist separator is installed at the exit of the discharge line of the vapor extractor fan to remove any traces of oil present in the oil vapor. The oil mist separator consists of a shell (3) in which six demister cartridges (5) are arranged in a circle. The shell is divided into two compartments, the inlet compartment (22) and the outlet compartment (23). The gas vapor enters the inlet compartment and passes through the six cartridges which are arranged in the outlet compartment. Each demister cartridge is secured to the compartment division plate with an element holder (6), tie-bolts (7) and nuts (8). The shell is flanged at the top end and is closed with a cover (1). The flanged joint between the shell and the cover is sealed by an O-ring (9) using bolts (10) and nuts (11). Drain connections (12) are provided both in the inlet and the outlet compartments. The oil droplets present in the oil vapor are trapped by the cartridges and returned to the inlet compartment, then to the main oil tank through a U-loop seal.
2.4.4 Oil Ejectors Refer to Figure 2-18. Two oil ejectors (No. 1 and No. 2 oil ejectors) are installed within the main oil tank, one on the suction line of the MOP and the other on the lubricating oil line as indicated in Figure 2-6.
MM-M05.08
Rev.000
The No. 1 oil ejector draws oil from the main oil tank and discharges to the suction of the MOP. The No. 2 oil ejector discharges the oil drawn from the main oil tank to the turbine bearing lubricating oil header. Each oil ejector consists of an inlet pipe (16), a nozzle block (5), a diffuser (15) and a check plate (1). The ejectors draw oil from the main oil tank by virtue of the vacuum developed by the motive oil flow from the discharge of the MOP through the nozzles. The check plate provided around the nozzle box prevents back-flow of oil into the main oil tank when the MOP is not in service. The ejector draws oil from the main oil tank through a suction strainer (17).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-13
Chapter 2
General
2.4.5 Oil Level Gauge Refer to Figure 2-19. A float type level gauge is provided on the top of the tank to indicate the oil level locally. The oil level gauge consists of a hollow polypropylene float (1) which is in contact the oil inside the main oil tank from where a float rod (2) extends upwards from the main oil tank. The float is guided within a circular body (16) and the float rod within a flange (3) during its vertical movement. An indicator (7) secured at the top end of the float rod moves vertically indicating the actual level in the oil tank. A graduation pipe (8), made of acrylic material and secured between the flange (3) and the upper flange (11), provides the actual indication of the tank level. A cover (13) secured between the flange (3) and the upper flange (11) prevents entry of dust into the main oil tank through the gap between the float rod (2) and the flange (3). Two level switches/contacts (5 and 10) are installed on the stud bolt (6) to provide remote high and low level alarms in the central control room (CCR). An alarm is initiated in the CCR to alert the operators when the oil level in the tank exceeds the low or high contacts.
2.4.6 Oil Strainers The main turbine lubricating oil system is provided with a lube oil strainer, and a return oil strainer to ensure trouble-free operation of the main turbine.
Lube Oil Strainer Refer to Figure 2-20.
MM-M05.08
Rev.000
The lube oil strainer provided in the bearing lube oil supply line is of the duplex type. It consists of a twin body (1) interconnected by a cock plug, each body containing one filter element (31). The cock plug directs the unfiltered oil to the selected filter and the filtered oil to the outlet line. A cock handle (11) enables selection of one of the filters when moved to the extreme position. Positioning of the cock handle in the mid-position enables both filter elements to be in service. This ensures a smooth change over of the filter elements. The adjusting handle (21) enables locking of the cock handle in position after a change-over. The adjusting handle is moved up by rotating it in the anti-clockwise direction and the cock handle is changed over and then the adjusting handle is turned in the clockwise direction to lock the cock plug. Each filter body is provided with a cover (2), which is held in position by stud bolt (16) arrangement, for easy removal and replacement of the filter element. Each filter element is provided with a handle (34) at the top, which abuts the body cover and secures the filter element tightly to the filter brim. An O-ring (19) inserted between the filter cover and the filter body prevents oil leakage. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-14
Chapter 2
General
Each filter body is provided with a drain plug (36) and an air vent (40) with isolating valves to drain and replace oil during filter maintenance. An equalizing line is provided with an equalizing valve (42) between the two filter element bodies to enable filling oil after maintenance, thereby avoiding a pressure drop during filter changeover. The equalizing valve is normally in the closed position and is opened only to fill the standby filter body. Inlet and outlet nozzles are cast integral with the body and are connected to the change over plug chamber through internal passages.
Return Oil Strainer Refer to Figure 2-21. The return oil strainer is of the vertical, cylindrical, basket type. The cylindrical strainer body is fabricated from steel SS400 and the filter element is wire gauze made from SUS304W. The strainer assembly consists of a cylindrical body (3) onto which a wire gauze set (10, 11) is secured using countersunk screws (12, 15) and bolts (13). The wire gauze set consists of an 80 mesh sandwiched between a 6 mesh and a 16 mesh for normal turbine operation. The strainer is also provided with an additional 100 wire mesh set to be used during turbine oil flushing. The return oil strainer is placed inside the return oil compartment within the main oil tank. The return oil enters through the inlet to the strainer and flows outwards thus retaining any debris contained in the returning oil. The main oil tank is provided with a hinged cover above the filter for periodical inspection and cleaning of the strainer.
2.4.7 Oil Cooler Refer to Figure 2-22. The main turbine lubricating oil system is provided with two plate type oil coolers for the temperature control of oil in the main oil tank. A transfer valve installed between the two oil coolers enables the selection of the oil cooler to be in service.
MM-M05.08
Rev.000
The oil cooler consists of several heat transfer plates (3) arranged in a line between a fixed S-frame (1) located at the front and a movable E-frame (2). The heat transfer plates are arranged in a line and held together by the E-frame. The E-frame is tightened uniformly by ten tightening bolts (7) and nuts (8) to provide a leak-tight joint between the adjacent heat transfer plates. The heat transfer plates and the E-frame are supported in a lower guide bar (4) at the bottom and guided by an upper guide bar (5) at the top. The lower guide bar and the upper guide bar are supported by the S-frame (1) at the front end and a guide bar support (6) at the rear end.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-15
Chapter 2
General
The entire cooler assembly is supported by the S-frame and the guide bar support by bolting them to the concrete foundation. The S-frame contains the supply and return nozzles for both lubricating oil and cooling water. Hot oil enters the bottom right nozzle (S4) and leaves the top right nozzle (S2) whereas the cooling water enters the top left nozzle (S1) and leaves the bottom left nozzle (S3).
MM-M05.08
Rev.000
For further details about the turbine oil cooler, refer to the vendor operation and maintenance manual No. OM – 02.01, Turbine Oil Cooler.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-16
Chapter 2
General
O IL LEVEL G AUG E
M AN HO LE CO VER
NO .2 O IL EJECTOR
MM-M05.08
Rev.000
SLID ING SU PPO RT
FIGURE 2-5 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
CUTAWAY VIEW OF THE MAIN OIL TANK 2-17
General
DRAIN GUARD PIPE 900A AIR VENT
MAIN BRG. OIL
MAIN OIL PUMP DISCHARGE
PRESSURE GAUGE PANEL
HP OIL
MAIN OIL PUMP SUCTION
Chapter 2
65A
8A
25A
OIL COOLER AIR VENT
25A B C
50A 100A
50A
100A
ANGLE TYPE CHECK VALVE
BFPT OIL INLET
100A
PURIFIED OIL INLET LUBE OIL STRAINER STRAINER (A) 25A
80A 80A
25A 20A
200A
B
250A
6-WAY VALVE
250A
200A
200A
(B) 80A
125A 200A
ORIFICE
ORIFICE
250A
OIL COOLER
250A
250A
MAIN OIL TANK INTERNAL PIPING DIAGRAM
200A
(A)
200A
200A
20A
MPTD-3-0484(B)
MM-M05.08
Rev.000
LUBE OIL STRAINER STRAINER (B)
250A
125A
No.2EJECTOR
250A
MOP
80A
200A
200A
NON-RETURN VALVE
No.1EJECTOR
200A 80A
250A
BRG
100A
80A
25A
250A
OIL COOLER
O10
TO OIL PURIFIER
15A
15A
15A
O5
15A
DRAIN BOX
50A
M
RELIEF VALVE
125A
M
STRAINER
100A
M
250A
AOP AC
250A
TOP AC
250A
EOP DC
8A
8A
8A
8A
MAIN OIL TANK
FIGURE 2-6 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
MAIN OIL TANK (INTERNAL PIPING) 2-18
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-7 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE AUXILIARY OIL PUMP 2-19
MM-M05.08
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi FIGURE 2-8 MPTD-3-0486
STRAINER
CASING (1st STAGE)
CASING (2nd STAGE)
AIR VENT
AIR VENT
CASING (3rd STAGE)
SLEEVE BEARING
OIL FLINGER
OIL SEAL
PUMP FRAME
SUCTION COVER (LP)
IMPELLER (1st STAGE)
SLEEVE BEARING
IMPELLER (2nd STAGE)
SLEEVE BEARING
IMPELLER (3rd STAGE)
COLUMN PIPE
SHAFT
THRUST BEARING
BEARING COVER
COUPLING
MOTOR
Chapter 2 General
CUTAWAY VIEW OF THE AUXILIARY OIL PUMP 2-20
MM-M05.08
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 37
52b
25
27
28
32
36
23
21
17
FIGURE 2-9
26
3
31
30
11
45
DETAIL OF "X"
48a 49a 50a 51a
12
4
14
15
48c 49c 50c 51c
53
18
48e 49e 50e 51e
40
41
44
43
Rev.000
8
13c
38
13a
22
24
52a
13b
56
1
47
49d 49e 49f
49a 49b 49c
DETAIL OF "Y"
50d 50e 50f
50a 50b 50c
48d 48e 48f
AIR VENT HEXAGONAL HEAD BOLT DRIVE MOTOR BOLTS, MOTOR TO FRAME BOLTS, FRAME TO M.O.T
SET SCREW
SET SCREW
IMPELLER RING
CASING RING
PUMP FRAME COLUMN PIPE SHAFT 1st STAGE CASING 1st STAGE IMPELLER SUCTION COVER STRAINER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER KEY HEXAGONAL HEAD BOLT SCREW SLEEVE BEARING SHAFT SLEEVE O-RING 2nd STAGE CASING SHAFT SLEEVE 2nd STAGE IMPELLER O-RING IMPELLER KEY SLEEVE BEARING HEXAGONAL HEAD BOLT O-RING IMPELLER KEY SLEEVE BEARING 3rd STAGE CASING HEXAGONAL HEAD BOLT 3rd STAGE IMPELLER THRUST (BALL) BEARING COLLAR BEARING NUT BEARING WASHER OIL FEED TUBE OIL FLINGER OIL SEAL HEXAGONAL HEAD BOLT KNOCK BOLT BEARING COVER V-RING COUPLING HALF (PUMP) COUPLING HALF (MOTOR) COUPLING BOLT & NUT COUPLING BUSH KEY COUPLING COVER HEXAGONAL HEAD BOLT
DESCRIPTION
51d 51e 51f
1 2 3 4 5 6 7 8 9 10 11 12 13a,b,c 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48a,b,c, d,e,f 49a,b,c, d,e,f 50a,b,c, d,e,f 51a,b,c, d,e,f 52 a,b 53 54 55 56
ITEM
48a 48b 48c
7
6
16
5
48b 49b 50b 51b
20
19
"X"
2
34
33
35
38
39
42
55
51a 51b 51c
10
9
"Y"
46
Chapter 2 General
SECTIONAL VIEW OF THE AUXILIARY OIL PUMP 2-21
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-10 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE TURNING OIL PUMP 2-22
MM-M05.08
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi FIGURE 2-11 MPTD-3-0489
PUMP CASING
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
OIL FLINGER
STRAINER
SUCTION COVER
IMPELLER
SLEEVE BEARING
BEARING COVER
Chapter 2 General
CUTAWAY VIEW OF THE TURNING OIL PUMP 2-23
Rev.000
MSD-3-0584
MM-M05.08
Y
DETAIL OF "X"
X
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 27
10
9
48
DESCRIPTION
29 33
PUMP FRAME COUPLING COVER (SAFETY) COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT HEX. BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR TUBE CONNECTOR OIL FEED TUBE HEX. HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEX. HEAD BOLT & LOCK WASHER HEX. HEAD BOLT & LOCK WASHER HEX. SOCKET SET SCREW HEX. SOCKET SET SCREW PUMP CASING SLEEVE BEARING PLUG TUBE CONNECTOR O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER HEX. SOCKET SET SCREW HEX. HEAD BOLT & LOCK WASHER DRIVE MOTOR BOLTS, FRAME TO M.O.T BOLTS, MOTOR TO FRAME
DETAIL OF "Y"
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
ITEM
Chapter 2 General
FIGURE 2-12 SECTIONAL VIEW OF THE TURNING OIL PUMP 2-24
General
MM-M05.08
Rev.000
OIL FEED TUBE
PUMP CASING
Chapter 2
FIGURE 2-13 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ISOMETRIC VIEW OF THE EMERGENCY OIL PUMP 2-25
PUMP CASING
STRAINER
SUCTION COVER
IMPELLER
PUMP DISCHARGE
AIR VENT
OIL FEED TUBE
SHAFT
General
MM-M05.08
Rev.000
OIL FLINGER
SLEEVE BEARING
BEARING COVER
Chapter 2
FIGURE 2-14 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
CUTAWAY VIEW OF THE EMERGENCY OIL PUMP 2-26
MM-M05.08
45
10
6
4
5
Rev.000
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi 18
20
29
21
19
22
33
28
31
32
36
41
42
15
14
12
14
2
DETAIL OF "X"
40
23
27
39
25
24
35
26
37
8
9
3
17
13
16
44
7
1
33
29
24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
27
20
33
PUMP FRAME COUPLING COVER COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR TUBE CONNECTOR OIL FEED TUBE HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEAD BOLT & LOCK WASHER HEAD BOLT & LOCK WASHER SOCKET SET SCREW SOCKET SET SCREW PUMP CASING SLEEVE BEARING PLUG TUBE CONNECTOR O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER SOCKET SET SCREW HEAD BOLT & LOCK WASHER
DESCRIPTION
DETAIL OF "Y"
ITEM
Chapter 2 General
FIGURE 2-15 SECTIONAL VIEW OF THE EMERGENCY OIL PUMP 2-27
Chapter 2
3
General
15
17
9 19 10 8
7
VIEW A - A 4
21 20
DETAIL OF SHAFT SEAL
24 1
6 2 24
14
A
A
15
20
11
23 5 18
12
Rev.000 MM-M05.08
16
16
22
13 MPTD-3-0494
FIGURE 2-16 SECTIONAL VIEW OF THE VAPOR EXTRACTION FAN Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
2-28
Chapter 2
A
"C"
General
19 20 21 1
2 6
15
8
16
7
1
23
VIEW A
5 14
18 3 3 14
B
B
17
13 4 4
22
B-B
10 12
9
2 3
11
MM-M05.08
Rev.000
DETAIL "C"
MPTD-4-1089
FIGURE 2-17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
COVER SHELL FLANGE SHELL END PLATE DEMISTER CARTRIDGE ELEMENT HOLDER TIE BOLT NUT O-RING BOLT NUT PLAIN WASHER FLANGE NOZZLE PIPE FLANGE NOZZLE PIPE DRAIN CONNECTION NAME PLATE EYE NUT BOLT PLAIN WASHER INLET COMPARTMENT OULET COMPARTMENT
OIL MIST SEPARATOR
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-29
General
MM-M05.08
Rev.000
Chapter 2
FIGURE 2-18 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
ARRANGEMENT OF NO. 1 & 2 OIL EJECTOR
2-30
Chapter 2
General
11
13
12 8
7
6
4
14 15
3
17
2
1 150
HIGH ALARM OIL LEVEL
150
NORMAL WORKING LEVEL 16
MM-M05.08
Rev.000
LOW ALARM OIL LEVEL
MPTD-4-0499
FIGURE 2-19
MAIN OIL TANK LEVEL GAUGE ASSEMBLY
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-31
Chapter 2 41
42
General
45 44
34
43
UP S
O
32
30
VIEW B - B
9
23 18
12
20
38
17
13 24
10
16
15
A
2 19
22
B
3
21
14 11
35
28
24
B
DETAIL "C"
27 29 2
26
8
9
25
40 39
37
46 34
A 19
"C"
7
32
8 16
35 1
31
19
MM-M05.08
Rev.000
8 36 5
MPTD-3-0496
33
4
6
16
19
VIEW A - A FIGURE 2-20
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
LUBRICATING OIL STRAINER ASSEMBLY 2-32
Chapter 2
5
General
10 14
1
6
12 7
16 O MESH 80 O MESH
DETAIL "A"
5
16O MESH 1 DETAIL "A"
10 3
8
14 11
6 17 7 9 16 O MESH
12
80 O MESH
3
10
16 O MESH 15
4 8 9
13 4
MM-M05.03
Rev.000
2
11
16 2
DETAIL "B"
DETAIL "B"
MPTD-3-0497
FIGURE 2-21 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
RETURN OIL STRAINER 2-33
Chapter 2
CW INLET
1 2 3 4 5 6 7 8 9 10 11 12
OIL OUTLET
S- FRAME E- FRAME HEAT TRANSFER PLATE LOWER GUDE BAR UPPER GUDE BAR GUIDE BAR SUPPORT TIGHTENING BOLT NUT S1-NOZZLE (CW INLET) S3- NOZZLE (CW OUTLET) S4-NOZZLE (OIL INLET) S2- NOZZLE (OIL OUTLET)
LUBE OIL O UTLET
CW O UTLET
LUBE O IL INLET
PLATE NO. 1 3
CW OUTLET
CW INLET
A SIDE
S
6
General
B SIDE
D1234
PLATE NO. 2 4
OIL INLET
179
178
E 0000 E
PLATE ARRANGEMENT
(B) SIDE 1234 89 0234 1034 1204 1230 0034 1200 0230 1004
Rev.000
6
MM-M05.08
TOTAL
89
(A) SIDE 1234 88 1230 1204 1034 0234 1200 0034 0230 1004
THE POSITIONS OF HOLE ARE CALLED 1,2,3 AND 4. THE PART HAVING NO HOLE IS INDICATED BY 0 INSTEAD OF 1,2,3, AND 4. * SHOWS DRAIN HOLES AND AIR VENT. 1
0
1O
2
O4
3O
4
D1234 E000
1 1
*
TOTAL
90
B10*4
A1234
MPTD-3-1090
FIGURE 2-22 TURBINE OIL COOLER Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
2-34
Chapter 2
A
General
A
14
10
19
23
18 2
20
A-A
MM-M05.08
Rev.000
MPTD-4-0498
FIGURE 2-23
BEARING OIL PRESSURE ADJUSTING VALVE
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP, EOP) Mitsubishi
2-35
Chapter 3
Specifications
Chapter
3 Specifications TABLE 3-1
MAIN OIL TANK
Description
Details
Equipment Number
03MAV01BB101
Quantity
1 set
Manufacturer
Mitsubishi Heavy Industries Limited
Type
Horizontal, cylindrical
Capacity at NWL
36,800 liters
Capacity at High level
40,180 liters
Capacity at Low level
33310 liters
Fluid
Turbine Oil (ISO VG32)
Tank Dimensions
8140mm x 3050mm
Weight
Empty
23.5 ton
Full
71.8 ton
TABLE 3-2
AUXILIARY OIL PUMP
Description
Details
Equipment Number
03MAV03AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
3DVCW-50B-NA
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
100 L/min
Discharge pressure
1.08 MPa
Suction pressure
0
Rotation
View from driver - CW
MM-M05.08
Rev.000
Material Discharge bore rating
ANSI 300LB-50A-FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
22kW, 380V, 3Ø,50Hz,
Speed (synchronous)
3000 min
Weight (Pump + Motor)
(310 kg + 181kg)
-1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-1
Chapter 3
TABLE 3-3
Specifications
TURNING OIL PUMP
Description
Details
Equipment Number
03MAV04AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
DVC-200E-NE
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
6100 L/min
Discharge pressure
0.34 MPa
Suction pressure
0
Rotation
View from driver - CW
Construction Discharge bore rating
ANSI 150LB-200A.FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
65kW, 380V, 3Ø,50Hz
Speed (synchronous)
1500 min-1
Weight (Pump + Motor)
(700 kg + 560kg)
TABLE 3-4
EMERGENCY OIL PUMP
Description
Details
Equipment Number
03MAV05AP101
Quantity
1 set
Manufacturer
Taiko Kikai Industries Co., Ltd.
Type
DVC-200E-NE
Operating condition Liquid name
Turbine oil ISO VG 32
Capacity
5800 L/min
Discharge pressure
0.35 MPa
Suction pressure
0
Rotation
View from driver - CW
MM-M05.08
Rev.000
Construction Discharge bore rating
ANSI 150LB-200A.FF
Bearing Type
Ball & bearing metal
Bearing lubrication
Pump liquid
Shaft seal
Oil seal
Coupling
Flexible Coupling
Motor Specifications
65kW, 250VDC, 3Ø, 50Hz,
Speed
1500 min-1
Weight (Pump + Motor)
(700 kg. +
1465kg)
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-2
Chapter 3
TABLE 3-5
MAIN OIL TANK VAPOR EXTRACTOR FAN
Description
Details
Equipment number
03MAV07AN101/102
Quantity
2
Fan
Manufacturer
Azuma Sofuki Co. Ltd.
Model
CTB-E-MD/6-75 Turbo Blower
Type
Single stage, horizontal, centrifugal type
Motor Rating
7.5 kW, 2P, 380 V AC, 3-Ø, 50 Hz
Rotating speed
2900 rpm
Direction of rotation
Clockwise (viewed from motor end)
Capacity
17 m3/min
Static pressure
6.86 kPa at 60ºC
Inlet pressure
– 1.47 kPa
Outlet pressure
5.39 kPa
Fluid
Oil vapor
Fluid temperature (design)
60°C
Major material
Impeller
SS400
Impeller hub
S45C
Casing
SS400
Blower
300 kg
Motor
62 kg
MM-M05.08
Rev.000
Weight
Specifications
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-3
Chapter 3
TABLE 3-6
Specifications
OIL MIST SEPARATOR
Description
Details
Equipment number
03MAV07AT101
Quantity
1 set
Manufacturer
Taiyo Techno Ltd.
Model
ME6-839-150/250A-V
Fluid
Air + Oil mist (ISO VG32)
Flow rate
17 m3/min
Design pressure
0.1 barg
Design temperature
80°C
Operating pressure
450 mmAq (0.044 barg)
Operating temperature
60°C
Differential pressure
Less than 150 mmAq (0.0147 bar) @ Normal flow
Maximum allowable differential pressure
750 mmAq (0.074 bar)
Major material
Shell
SUS304TP-A
Cover
SS304
Cartridge
Fiber glass
Oil mist separator
330 kg
Cartridge
5.5 kg x 6
Weight
TABLE 3-7
MAIN OIL TANK LEVEL GAUGE
Description
Details
Equipment number
03MAV01CL101
Quantity
1 set
Manufacturer
Demper Kogyo Co, Ltd.
Type
Float type
Fluid
Turbine Oil (ISO VG32)
Specific gravity
0.845
Range
L200-NO-H600 Float
Polypropylene
Float rod
SUS304
Gasket
V#6500
MM-M05.08
Rev.000
Major material
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-4
Chapter 3
TABLE 3-8
LUBE OIL STRAINER
Description
Details
Equipment number
03MAV10AT501/502
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Duplex
Fluid
Turbine Oil (ISO VG32)
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
Wire mesh size
P x 16 x 150 x 16
Effective filter passage area
6243 cm2
Max. allowable differential pressure (at 59ºC and 2800 l/min)
0.122 bar
Major material
Body
FCD450
Filter cylinder
SUS304
Wire mesh (filter element)
SUS304
Weight
2540 kg
TABLE 3-9
RETURN OIL STRAINER
Description
Details
Equipment number
03MAV01AT501
Quantity
1 set
Manufacturer
Misuzu Seiko Co. Ltd.
Type
Basket type
Fluid
Turbine Oil (ISO VG32)
Diameter of filter cylinder holes
12 mm
Pitch of holes
15 mm
No. of holes
6415
Wire mesh size
80 mesh, 16 mesh, 6 mesh
Effective passage area
2474 cm2
Max. allowable differential pressure
0.03 MPa
Major material
Filter cylinder
SS400
Wire mesh (filter element)
SUS304
Under cylinder bush
SS400
Upper cylinder bush
SS400
Weight (Approx.)
43 kg
MM-M05.08
Rev.000
Specifications
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-5
Chapter 3
TABLE 3-10
TURBINE OIL COOLER
Description
Details
Equipment number
03MAV08AC101/102
Quantity
2
Manufacturer
Hisaka Works, Ltd.
Type
Horizontal, Plate type
Model
UX-915-KNHP-179
Relative direction of fluids
Counter current
No. of plates
179
Heat transfer area (m2)
322.14
Heat exchanged (kW)
3694
No of passes
Specifications
Cold Side
Hot Side
1
1
Cooling Water
Oil ISO VG32
Flow rate (m /h)
600
366
Inlet temperature (ºC)
38.0
67.6
Outlet temperature (ºC)
43.3
46.0
Pressure drop (MPa)
0.068
0.042
Design pressure (MPag)
1.00
0.41
Design temperature (ºC)
80
80
89 x 1
89 x 1
Fluid 3
Plate arrangement Material
SA-240-304
Plate gasket
G-NBR
Frame
SA-516 Gr60
Nozzle
SA-240-316L
Empty
5390 kg
Flooded
7330 kg
MM-M05.08
Rev.000
Weight (approx.)
Plate
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
3-6
Chapter 4
Preventive Maintenance
Chapter
4 Preventive Maintenance Preventive maintenance is performed to avoid or minimize the possibility of failure or deterioration of equipment performance. This requires a constant effort from maintenance staff to ensure that the equipment is available on demand. There are two categories of preventive maintenance, Routine Maintenance and Annual Outage Maintenance. Routine maintenance helps to reduce the possibility of outage and hence the downtime of machinery. Annual outage maintenance is required to maintain the internal components of the installed equipment. Though vendor/manufacturer’s recommendations provide a good basis for the provision of a preventive maintenance schedule, the frequency and other details should be updated from time to time based on practical experience and actual feedback gathered through inspection and normal operation of the equipment/plant. Consideration of these site related specific issues will make the preventive maintenance more effective.
4.1
Prerequisites The necessary prerequisites for the preventive maintenance of the Main Oil Tank, Auxiliary oil Pumps and Vapor Extractor Fan are as follows:
Scheduling is the first activity in the preparation of a preventive maintenance program; the schedule is to include planning to attend all operating equipment on a fixed regular basis. Initially, schedules will be prepared based on vendor/manufacturer’s generic instructions, the schedules will however be updated (frequency, nature of inspection etc.) as site-specific data becomes available. Preventive maintenance is to be coordinated with other concerned departments. In the case of a major scheduled outage, maintenance personnel and other concerned departments should jointly produce a plan of activities, well in advance, to decide the inspection activities and other logistics (such as availability and supply of required equipment, spare parts, tools and tackle, etc.). The schedule should clearly identify the critical path. Priority is to be assigned to specific tasks that also involve parallel activities to reduce the equipment downtime and to complete the work within scheduled time.
MM-M05.08
Rev.000
4.1.1 Scheduling
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--1
Chapter 4
Preventive Maintenance
4.1.2 Department Interface/Notification Departmental communication is essential and interfacing between departments is to be maintained to avoid any lack of communication that may arise and adversely affect routine or annual outage maintenance work. Prior to commencing preventive maintenance all concerned persons (shift supervisor, operators, etc.) are to be made aware of the schedule and the nature of the activities that are to take place. If it becomes clear that there is a problem or a conflict of interests in the schedule (e.g. the maintenance schedule interferes with another group’s work), this is to be resolved by mutual agreement between the parties involved.
4.1.3 Isolation of Equipment It is important that isolations are agreed and valid clearances and work permits are obtained before any maintenance work is performed. The isolation boundaries of the particular equipment to be taken under maintenance are to be clearly identified. In the case of an electrical isolation the power supply shall be disconnected and/or the fuses removed. In the case of mechanical isolations, the valves or other mechanical means of isolation, at the isolation boundaries are to be closed and if possible locked closed. The system within the isolation boundaries is to be de-pressurized.
4.1.4 Safety Precautions
Prior to commencement of actual work the person carrying out the work is to make a safety check based on the above method statement and also use his own judgment to ensure that the equipment and the prevailing working conditions are safe. During maintenance work, every employee should follow the safe working procedures detailed in the method statement.
MM-M05.08
Rev.000
Before the commencement of any maintenance work, the person in charge of the work site is to perform a risk assessment and method statement for the safe execution of the job scope activities, described within the work permit. Risk assessment includes identifying, recognizing and understanding the potential hazards associated with the work. The method statement is to illustrate the safe working practices in accordance with the safety manual and manufacturer’s instruction manual to prevent personal injury and/or equipment damage.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--2
Chapter 4
4.2
Preventive Maintenance
Routine Maintenance The purpose of routine maintenance is the implementation of the preventive maintenance program on a day-to-day basis through a planned and correctly executed inspection. The routine maintenance activities are very important in that if they are properly carried out, they will enhance equipment reliability. As a result, good routine maintenance activities may help in cost reduction in the long run through minimization of equipment downtime. Cleaning is an important and necessary maintenance activity to prevent the ingress of foreign material. Other major points are as follows: (Summarized major routine activities are also shown in Table 4-1.)
4.2.1 Preparation a)
Parts, Tools and Equipment It is important to prepare the necessary parts, tools and equipment before commencing actual work. Routine maintenance generally requires a standard mechanical toolkit, consumables, cleaning materials etc. Any shortages of these items will affect the maintenance activity and may delay the schedule. Personal Protective Equipment (PPE) is necessary for maintenance staff at all times. Upon completion of work, all tools and equipment should be serviced and stored correctly to ensure availability for further use.
b)
Documentation
MM-M05.08
Rev.000
Documentation is an important part of any maintenance duty. All findings should be noted on a comprehensive log sheet, reporting all aspects of the equipment observed during the routine inspection. The data recorded in these documents will be useful in determining the root cause of equipment failure found during the annual outage/corrective maintenance work. Any abnormalities, if observed, are to be immediately communicated to the concerned department/personnel for rectification and are to be detailed in the report.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--3
Chapter 4
Preventive Maintenance
4.2.2 Inspection and Maintenance a)
Main Oil Tank Visually check the external surfaces of the tank for signs of leakage, corrosion or damage (any damage should immediately be reported to the supervisor). Monitor the oil level in the main oil tank and ensure that a continuous oil circulation is maintained through the oil purifier. Also ensure that the tank oil level is maintained nearer to the NWL and below the maximum oil level to accommodate the flow-back oil quantity expected on Unit shutdown. The minimal-optimum vacuum is to be maintained to prevent oil and/or vapor leakage. All bolts and nuts securing manhole and tank nozzle connections are to be checked for tightness. Check the position of vapor extractor fan suction damper and readjust to achieve the required vacuum. Lock the damper handle after vacuum adjustment. Monitor the running pump for discharge pressure and for signs of abnormal vibration and temperature. If any abnormality is observed, take remedial measures as indicated in this manual, if the trouble still exists advise your supervisor. Monitor the lube oil filter differential pressure at regular intervals and changeover to the standby filter when blockage is indicated. After changeover, clean or replace the blocked filter and place it in standby mode. Check the return oil strainer regularly to prevent any accumulation of debris. Clean the strainer and remove any foreign matter. Check the strainer for any signs of damage that could occur with prolonged use. Monitor the E/H oil pump suction and discharge filters differential pressures at regular intervals. Clean or replace the filters as necessary when blockage is indicated.
MM-M05.08
Rev.000
Collect periodic oil sample from the tank overflow line and analyze the sample for oil properties in a laboratory. Ensure the oil sample results are within permissible limits.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--4
Chapter 4
b)
Preventive Maintenance
Auxiliary Oil Pumps Auxiliary oil pumps to be monitored for vibration. Check for any loose motor holding bolts and tightened them if vibration is observed. Another area that deserves attention is the identification of any abnormal noise. Any abnormal noise generated should be investigated and the source must be identified.
c)
Vapor Extractor Fan
DANGER Take care near rotating machinery, hands and clothing can be drawn into machinery. Always check that all guards are in place before starting any rotating machinery. The vapor extractor fan is to be monitored for vibration. Check for any loose motor holding bolts and tighten them if vibration is observed. Perform an alignment check and correct if any misalignment is observed. Vibration may also be generated by an imbalance of the impeller wheel resulting from corrosion or deposit of impurities on the impeller or accumulation of oil in the fan casing. Check for any accumulated oil in the fan casing and blockage in the casing drain if vibration is apparent. If records indicate an increased vibration level, the fan should be monitored closely and if the increase persists, inspection and rectification should be arranged.
MM-M05.08
Rev.000
The vapor extractor fan motor and seals are to be checked for any abnormal increase in temperature. Inject fresh grease into the seal housing and/or the motor bearings through the grease nipples provided and if an increase in temperature is observed. Remove the spent grease through the drain cock while greasing. Observe the performance of the bearings and/or seals after greasing and if higher temperature persists, inspection and replacement should be arranged. Another area that deserves attention is the identification of any abnormal noise. Any abnormal noise generated should be investigated and the source identified. Visually inspect the extractor fan for any leakage or damage and rectify as required.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4--5
Chapter 4
TABLE 4-1
No.
1
Description
Main oil tank
Major Check Item
Preventive Maintenance
ROUTINE MAINTENANCE CHECKLIST
Check Method
Check Reference
Action to be Taken (if beyond acceptable limit)
Leakage, corrosion Visual or damage
No leakage, corrosion or damage
Isolate and repair as necessary
Oil level
Level gauge
NWL
Add fresh oil if level is low and transfer oil if level is high
Vacuum inside the tank
Installed instrument
-0.5 ~ -1 kPa(g)
Check manhole doors and adjust extractor fan suction damper
Oil quality
Lab analysis
No trace of oil contamination
Check oil purifier operation
Remarks
Recommended Maintenance Frequency
Daily
Daily Daily
Monthly
2
Oil pumps
Running oil pump pressure, vibration and overheating
Portable testing instruments and installed instrument
Normal pressure, vibration and temperature
Analyze and rectify causes for low discharge pressure, high vibration and overheating
Daily
3
Lube oil pressure
Differential pressure
Installed instrument
<0..5 bar
Changeover to the standby filter and clean or replace the blocked filter
Daily
5
Return oil strainer
Blockage
Visual
No blockage
Clean the filter element
MM-M05.09
Rev.000
Monthly
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4--6
Chapter 4
Preventive Maintenance
Continued from previous page. TABLE 4-1 No.
6
Description
Vapor extractor fan
Major Check Item
Vibration
ROUTINE MAINTENANCE CHECKLIST
Check Method
Portable vibration meter
Check Reference
Action to be Taken (if beyond acceptable limit)
Remarks
Recommended Maintenance Frequency
No tangible vibration Check and tighten motor holding
bolts Shut down and check the impeller wheel balance
Daily
Perform alignment check Motor bearing and seal Portable temperature thermometer
Allowable Inject fresh grease. If the temperature temperature of 750C is still high, stop the fan and investigate or ambient plus 400C the cause of overheating whichever is less
Abnormal noise
Audible
No abnormal noise
Check for internal rubbing
Daily
Vapor leakage
Visual, audible and by touch
No tangible vapor leakage
Shutdown and rectify the leakage
Daily
MM-M05.09
Rev.000
Daily
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4--7
Chapter 4
4.3
Preventive Maintenance
Annual Outage Maintenance The purpose of annual outage maintenance is the implementation of a preventive maintenance program on a yearly (or some multiple) basis through a planned and correctly executed maintenance work program accompanying necessary inspections. Such outage maintenance activities are very important in the sense that if properly undertaken these enhance the life and reliability of the equipment. The turbine manufacturer/vendor has a recommended interval for inspection and maintenance of the lubrication system in general it is two years. A two year interval is defined by the turbine manufacturer/vendor as a minor overhaul interval. The turbine major overhaul interval is four years. However, some of the lubrication equipment may have maintenance requirements outside this framework. These situations are indicated in the text. Major activities related to annual outage maintenance are as follows: (Summarized major activities for outage maintenance are also shown in Table 4-2).
4.3.1 Preparation a)
Parts Tools and Equipment Refer to Subsection 4.2.1 a), Parts Tools and Equipment. In addition, it will be necessary to identify and request the provision of any spare part requirements. Annual outage will, in certain cases, require the use of material handling equipment. Unused spare parts are to be returned for correct storage and used spare parts are to be replaced.
b)
Documentation Refer to Subsection 4.2.1 b), Documentation.
On completion of annual outage maintenance work, the equipment is to be monitored for correct operation and maintenance data logging. This will help to determine the correct intervals of preventive maintenance activities to ensure optimum plant availability. The correct recording of the findings during inspection will build a valuable document for future reference.
MM-M05.08
Rev.000
Records are to be maintained to record information regarding spares and consumables used. These records will be used for future reference and spare parts replacement.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-8
Chapter 4
Preventive Maintenance
4.3.2 Inspection and Maintenance Normal run down, cooling and isolation procedures are to be followed. It should be noted that there is a manufacturer/vendor statement of preference to keep the turning gear in operation whenever possible, between shut down and start up. If access to equipment that affects the turbine rotating parts is required quickly from operating conditions, there are clear procedures that must be followed. Loss of availability of lubrication and conditioning equipment will normally affect turbine operation. The procedures for various shutdown situations are provided in Appendix F, Turning Gear Operation During Shutdown. Operations personnel are to carry out the turbine shutdown with due regard to these procedures. These are standard procedures for various shutdown situations but dependent on the work content and the intended duration of the outage it is normal that the actual stoppage of the turning gear, lubricating oil, seal oil pumps, etc. is a joint operational and maintenance department decision. Limited access to the lubricating oil system for maintenance may be possible with the Unit in operation. However, the annual outage inspection and maintenance of the lubricating oil pumps requires entry into the MOT to disconnect and secure the discharge piping, and the subsequent pump removal. These situations are assessed by the Operations personnel and, due to the nature of this equipment, will depend in part on local conditions at the time. For this reason, it is not possible to outline the possibilities/restrictions in this manual.
MM-M05.08
Rev.000
A safety document detailing the precautions to be observed while working inside the main oil tank is to be obtained. Rules relating to work in confined spaces are to be followed.
The manufacturer/vendor recommends overhaul of the pump annually. However, some components only require inspection every two or four years. These are identified in the text. Inspections and checks should be carried out on the pump internal components. Suitability for further service is determined by comparing inspection results with the reference information in Table 4-2.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-9
Chapter 4
Preventive Maintenance
The pre-outage records for vibration and noise levels should also be consulted. The manufacturer/vendor recommends that the pump bearings are changed automatically if there has been any irregularity in the recorded vibration and noise levels.
a)
Casing and Casing Wear Rings Pump casings and discharge casing are to be inspected for wear, crack or damage. The mating surfaces of the casings with their suction covers and the guide bearings are to be inspected for any flow erosion damage. Damaged components are to be repaired or replaced as required. The column pipe and the casing air vent holes are to be checked for blockage and cleared, if necessary. The casing wear rings are to be inspected while remaining attached to their casings. Examine the bore of each casing wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance between the casing and impeller wear rings exceeds the maximum allowable limit, the wear rings should be replaced with new.
b)
Impeller and Impeller Wear rings The impellers are to be inspected for damage to the keyways or to the bores which may have occurred during operation or dismantling. Ensure that the impeller bores are perfectly smooth and free from distortion. Inspect the impeller necks for damage or excessive wear. Light radial scoring is acceptable provided the clearance to the casing wear ring is within tolerance. If the wear ring requires replacement, the opportunity is to be taken to restore the impeller neck surface by machining if this is required.
Perform dimensional checks on the impeller wear rings while remaining attached to their impellers and ensure that they are within tolerance. Examine the surface of each impeller wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance or dimension exceeds the maximum allowable limit, the wear rings should be replaced with new.
MM-M05.08
Rev.000
Restore the bore of any impeller which reveals damage and remove any burrs. If an impeller cannot be brought to a satisfactory condition, it is to be replaced with new.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-10
Chapter 4
c)
Preventive Maintenance
Suction Covers and Strainers The suction covers are to be inspected for damage or wear. Inspect for evidence of rubbing by the rotating components and replace damaged suction covers with new. The wear rings installed in the suction covers are to be inspected while remaining attached to their suction covers. Examine the bore of each wear ring for damage or excessive wear. Light radial scoring is acceptable but axial grooves will affect pump performance. If axial grooves are revealed, or if the clearance between the suction cover wear ring and impeller wear ring exceeds the maximum allowable limit, the wear rings should be replaced with new. The suction strainers are to be inspected for accumulation of debris and for crack or damage. Accumulated debris is to be removed and a damaged filter assembly should be repaired or replaced.
d)
Column Pipe The column pipe is to be inspected for the presence of any weld crack or damage and repaired as required. The thrust bearing housing is to be checked for weld crack or damage to the bearing seating surface and repaired as required. The lubricating oil supply port in the bearing housing is to be inspected for blockage and cleared if blockage is observed.
e)
Shaft and Shaft Sleeve The pump shaft is to be removed and checked for run-out using V-blocks. If the shaft exceeds the maximum allowable run-out, the shaft is to be changed for new.
MM-M05.08
Rev.000
The shaft is to be checked for surface roughness or scoring in the areas where the sleeve bearings and the oil seal are located. Minor scoring marks are to be polished with an oil stone and more severe scoring is to be machined. If the damage is beyond repair, the shaft is to be replaced with new. The keys, keyways and threads on the shaft are to be checked for any damage. Damaged keyway and threads are to be repaired as found necessary. Any key which is a loose fit in its shaft keyway or in the impeller/coupling keyway is to be replaced with new. Any burrs raised during removal of the keys are to be removed using an oil stone.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-11
Chapter 4
Preventive Maintenance
The shaft sleeve is to be checked for surface roughness or scoring in the areas where the sleeve bearings are located. If the shaft sleeve has scoring marks or excessive wear, it is to be replaced with new.
f)
Bearings The thrust bearing is to be inspected for any signs of damage and pitting marks on the balls and the inner & outer races. A damaged or pitted bearing is to be replaced with new. The sleeve bearings are to be examined for any damage, scratches or excessive wear on the white metal lining. Minor scratches or damage on the white metal can be removed with a metal scraper. Replace any bearing which reveals excessive damage or wear. Perform a dimensional check on the inside diameter (ID) of the sleeve bearings and calculate the clearance between each bearing and its respective shaft/sleeve. If the clearance exceeds the maximum allowable limit, the bearing should be replaced and the clearance adjusted as required. The original bearing should be re-metalled and machined for future use.
g)
Coupling The coupling bolts and the rubber bushes are to be inspected for damage or excessive wear. The coupling bolts exhibiting wear or damage are to be replaced with new and the rubber bushes exhibiting excessive wear or damage are to be replaced as a set.
h)
Oil Seal The oil seal is to be replaced with new if leakage was observed during operation or if seal replacement is due as per the recommended maintenance schedule. Inspect the oil flinger for any signs of contact with the bearing cover. If contact is apparent, polish the damaged surface and readjust the clearance during reassembly.
MM-M05.08
Rev.000
i)
Piping and Discharge Valves The discharge pipe flange gaskets, once removed, must be replaced with new. The flanges are to be thoroughly cleaned, and any old adhered gasket material is to be removed prior to replacement. The disc/flap and the seat of the discharge check valves are to be inspected for any dents, scratches or damage. The disc/flap is to be rectified by lapping with the respective valve seat.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-12
Chapter 4
Preventive Maintenance
The orifices in the air vents of the discharge pipes are to be inspected and cleared if any blockage is observed.
MM-M05.08
Rev.000
The thrust bearing lubricating oil pipe supports are to be inspected for their integrity and rigidity. Loose supports are to be tightened as required. Oil pipe without support may result in breakage of the line causing damage to the bearing.
Turbine Oil Pumps (AOP, TOP, EOP) Mitsubishi
4-13
Chapter 4
TABLE 4-2 No 1
2
Description Main oil tank
Major Check Item Corrosion, damage or leakage
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Visual and by No corrosion, touch damage or leakage
Action to be Taken (if beyond acceptable limit)
No damage or defective weld
Repair or replace
Oil separator drain blockage
Visual
No blockage
Clear blockage
Visual
No blockage
Clear accumulated debris
Visual
No wear or damage
Repair or replace defective components Repair or replace
AOP, TOP, EOP Suction strainer
3
Check valve
Wear or damage Visual on disc/flap and seat
No wear or damage
4
Oil ejector
Nozzle wear or blockage
Visual
No abnormal wear or Clean or replace blockage
Check plate
Visual
Freedom for movement
Repair or replace
Strainer
Visual
No clogging
Clean the strainer
Strainer condition
Visual
No damage
Replace the strainer
No clogging
Clean the strainer
Return oil strainer
Inspection Date
Inspector
Results
MM-M05.08
5
Remarks
Repair and apply preservative paint
Baffle plates and Visual supports
Pump internal components
Rev.000
Check Method
Preventive Maintenance
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4-14
Chapter 4
Preventive Maintenance
Continued from previous page. TABLE 4-2 No 6
7
Description Oil level gauge
Vapor extractor fan
Major Check Item
Check Method
ANNUAL OUTAGE MAINTENANCE CHECKLIST
Check Reference
Action to be Taken (if beyond acceptable limit)
Damage to float Visual
No damage
Repair or replace
Accumulation of Visual debris
No debris
Clean
Wear, crack or Visual damage and deposit of debris
No dust build up
Replace the impeller wheel
Wear, crack or Visual damage to rotor shaft
No wear, crack or damage
Repair the shaft
Corrosion, Visual debris deposit in casing
No corrosion or debris deposit
Remove corrosion and debris.
Visual and physical check
Inspection Date
Inspector
Results
No wear or cracks
Flange bolts properly Retighten the flange bolts tightened
MM-M05.08
Rev.000
Tightness of flange bolts
Remarks
Main Oil Tank and Vapor Extractor Fan Mitsubishi
4-15
Chapter 4
Preventive Maintenance
SLEEVE BEARING
IM PELLER RING
IM PELLER RING
IM PELLER RING
SHAFT SHAFT SLEEVE
CASING RING
A
CASING RING
MM-M05.08
Rev.000
CASING (1st STAGE)
FIGURE 4-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
AUXILIARY OIL PUMP CLEARANCE DRAWING 4-16
Chapter 4
Preventive Maintenance
MM-M05.03
Rev.000
SHAFT
FIGURE 4-2 TURNING OIL PUMP CLEARANCE DRAWING Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4-17
Chapter 4
Preventive Maintenance
MM-M05.03
Rev.000
SHAFT
FIGURE 4-3 EMERGENCY OIL PUMP CLEARANCE DRAWING Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
4-18
Chapter 5
Disassembly and Reassembly
Chapter
5 Disassembly and Reassembly Disassembly and reassembly are the activities to be conducted when internal parts of the equipment are required to be accessed. An important part of the activities is the preparatory work. This should identify the manpower, spares and tools that may be required during the maintenance work. A shortfall of any of these may affect the schedule and the operational status of the plant. The major steps associated with disassembly and reassembly are as follows.
5.1
Main Oil Tank Disassembly and Reassembly
CAUTION Prior to carrying out any maintenance, confirm the equipment is shut down and all isolations are in place. Disassembly and reassembly of the main oil tank is limited to the opening and closing of manholes.
a)
Preparation If main oil tank disassembly becomes necessary, all associated internal and external equipment is to be mechanically and electrically isolated and the tank is to be drained and an oil free certificate issued. An authorized clearance and work permit shall be in place prior to the commencement of work. The following points are also to be considered when preparing for inspection: •
b)
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to start of work.
Disassembly
CAUTION
MM-M05.08
Rev.000
When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-1
Chapter 5
Disassembly and Reassembly
Refer to Figures 2-2 to 2-5A/B. 1
Ensure that the main oil tank is drained fully, vented and purged with nitrogen gas.
2
Remove the fasteners securing the manhole cover and then remove the manhole cover.
CAUTION If weld repairs are necessary, arrange for the appropriate gas and oil free certification and for the appropriate ventilation facilities, before commencing any welding work, on, within, or in the vicinity of the oil tank.
Note During the inspection always use the low voltage safety lamps.
c)
3
Visually inspect the internal tank welds for signs of cracking. Repair if cracks are found.
4
Inspect the inside and outside surfaces of the tank for any signs of corrosion. If corrosion is found, clean off the affected area, repair as necessary and treat with a suitable preservative.
5
Visually inspect the instrument pockets for blockage or cracking. Repair to the approved procedure if cracks are found.
6
Visually inspect the pipes, valves and the pipe supports inside the tank for corrosion or damage. Repair or replace, as applicable, if corrosion or damage is apparent.
7
Visually inspect the flange joints inside the main oil tank for loose bolts and tighten them as necessary.
Reassembly The reassembly procedure is carried out in the reverse sequence to that of the disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified. Before closing the main oil tank ensure that all parts are in position and securely attached. Ensure that all tools and equipment are removed and accounted for.
2
Using a new gasket replace and secure the manhole cover.
MM-M05.08
Rev.000
1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-2
Chapter 5
5.2
Disassembly and Reassembly
Disassembly and Reassembly of the Auxiliary Oil Pump
CAUTION Prior to carrying out any maintenance, confirm all isolations are in place and the equipment is shutdown.
a)
Preparation If AOP disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized clearance and work permit is to be in place prior to the commencement of work. The following points are also to be considered when preparing for disassembly and reassembly: •
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to the start of work.
•
Prepare the necessary handling facilities to remove and store the various parts of the equipment.
•
Prepare separate temporary structures of adequate height and strength, to receive the motor and the complete pump as they are removed from the tank. The structure for the pump should be high enough and strong enough to support the pump in both the vertical position and the horizontal position.
•
Co-ordinate with the Instrument and Control (I&C) Department to remove all the attached instrumentation such as pressure indicators before starting disassembly work.
•
Co-ordinate with the Electrical Department to disconnect and remove the motor power cable before starting disassembly work.
Note
MM-M05.08
Rev.000
Work on the oil pumps requires entry into the main oil tank, which must be emptied, cleaned and pronounced safe for entry, by a competent person who should issue a relevant safety document before work commences.
A safety document detailing the precautions to be observed while working inside the main oil tank is to be obtained. Any national or local rules relating to work in confined spaces are to be followed.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-3
Chapter 5
b)
Disassembly and Reassembly
Disassembly Refer to Figure 2-9 and 5-1. Before starting disassembly, prepare a laydown area where equipment can be stored and worked on without undue risk of contamination or damage. Before removing the pumping unit, make sure the pump is isolated then make suitable arrangements for the following: (i)
Removal of the motor. The coupling is designed such that the motor can be lifted off after the coupling bolts (43), and the bolts securing the motor to the pump frame (55) are removed.
(ii)
During disassembly, tag all components for identification purposes and, if necessary, bag or wrap to prevent miscellaneous losses and ensure adequate protection.
CAUTION When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows:
MM-M05.08
Rev.000
Removal of the Motor 1
Unbolt and remove the safety covers from the pump frame (1).
2
Ensure that match marks are clearly visible on the pump frame, and on the oil tank mounting location.
3
Loosen and remove the coupling bolts and nuts (43) and the coupling bushes (44) from the coupling.
4
Refer to Chapter 3 for the weight of the motor then attach suitable slings from the crane hook to the eyebolts provided on the motor and remove the slackness from the slings.
5
Check the supports arranged in the laydown area to ensure that the motor will be supported without the protruding coupling contacting the floor.
6
Remove the fasteners (55) securing the motor to the pump frame (1).
7
Lift the motor, transport it to the laydown area and protect it with a secured plastic cover.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-4
Chapter 5
Disassembly and Reassembly
Removal of the Auxiliary Oil Pump Assembly from the Main Oil Tank 8
Confirm that all tank entry precautions have been implemented. The outlet surface of all motor operated pumps should be cleaned, and all available to be worked on. The oil tank manhole cover and the return oil filter should be removed to ensure air circulation. When safety has been assured personnel may enter the tank with one additional person always stationed at the tank entry to assist in any emergency.
9
Remove the nuts and bolts securing the discharge pipes to the respective pumps, securely supporting the connected valves and piping, within the tank, to facilitate the removal of the complete pump assembly from the tank.
10
Remove the hexagon head bolts (56) securing the pump frame (1) to the main oil tank. (Store these bolts for use during reassembly)
CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Special consideration is to be given to the center of gravity of the assembly. Refer to Section 3 for the weight of the pump. 11
Attach suitable lifting equipment to the pump frame and make a trial lift to ensure a smooth lift of the pump assembly. Readjust slings as required.
Note Special care should be taken while lifting the pump assembly. Use additional chain blocks, if necessary, to ensure a smooth lift.
CAUTION
MM-M05.08
Rev.000
Oil will drain from the pump as it is raised from the main oil tank. If cleaning materials or fluids are used to clean the pump prior to transporting it to the laydown area, care must be taken that they do not enter the main oil tank. 12
Transport the removed pump to the laydown area and locate it vertically or horizontally as decided by the Maintenance Engineer on the pre-arranged supports. In this manual, we have the pump arranged with the frame horizontal on the prepared structure so the shaft (3) can be removed vertically.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-5
Chapter 5
Disassembly and Reassembly
CAUTION During the pump disassembly care must be taken when removing the strainers, suction covers, impellers, pump casings, etc. They are moderately heavy and will be oil soaked. The individual parts should be placed on stacked timbers, wooden frame or a low wheeled bogie, then removed from the area for cleaning and inspection.
Disassembly of the Auxiliary Oil Pump Refer to Figures 2-9 and 5-1 and follow the removal system in the description column starting at the suction side of the pump. 13
Disconnect and remove the oil feed tube (34) between the 1st stage casing (4) and the column pipe (2).
14
Provide a suitable support for the suction strainer (7), remove the hexagonal head bolts and lock washers (12) and then remove the suction strainer and the pump suction cover (6). Remove the O-ring (16) between the suction cover (6) and the 1st stage pump casing (4).
15
Check the clearance between the casing wear ring (48) and the impeller wear ring (49). If the clearance check indicates that the disassembly of the casing and the impeller wear rings is necessary remove the set screws (50) & (51) to release casing and the impeller wear rings.
16
Straighten the bent tongue of the lock plate and then remove the impeller nut (8), the lock plate (10) and the impeller washer (9).
17
Remove the 1st. stage pump impeller (5) clean, and then examine the impeller to remove any defects.
Wear suitable protective clothing when handling heated components.
MM-M05.08
Rev.000
Note If difficulty is experienced when attempting to remove the impeller, apply heat around the periphery, working slowly towards the hub. Do not initially heat the hub as this will cause the impeller to grip tighter on the shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-6
Chapter 5
Disassembly and Reassembly
18
Recover the impeller key (11) from the shaft (3). Check the oil clearance between the sleeve bearing (14) and the shaft sleeve (15), if the clearance is excessive change the shaft sleeve or the sleeve bearing whichever has worn the most, or if necessary change them both.
19
Remove the hexagon head bolts 23) to release the 1st stage casing (4). Recover the ‘O’ ring (20) and remove the shaft sleeve (15).
20
Remove the 2nd stage impeller (19). After checking the clearance between the casing and the impeller wear rings and if the wear ring clearances need adjustment remove the set screws provided in (50a-f) and (51a-f).
21
Remove the impeller key (21). Check the oil clearance between the sleeve bearing (22) and the shaft sleeve (18), and if the clearance is excessive, change the shaft sleeve or the sleeve bearing which ever has worn the most, or if necessary change them both.
22
Clean and remove any defects noted on the impeller.
23
Remove the hexagon head bolts (53) to release the second stage casing (17) and to recover the ‘O’ ring (24). Remove the shaft sleeve (18).
24
Remove the 3rd stage impeller (29), check the clearance between the casing and the impeller wear rings and if any clearance changes are required this can be done after removing the set screws provided (50a-f) and (51a-f).
25
Remove the impeller key (25). Check the oil clearance between the sleeve bearing (26) and the shaft (3), any change in the oil clearances can be made by replacing the sleeve bearing (26) using the securing screws (13c).
Note From this position with the 3rd stage impeller removed, please check the shaft (3) and the column pipe (2), and please make and record any changes made, and also make the changes made apparent during the checks made during the pump disassembly.
Inspection and check on the Thrust Bearing.
MM-M05.08
Rev.000
Refer to Figure 2-9 and 5-1. 1
Using a suitable bearing puller remove the coupling half (41) from the pump shaft (3) and recover the coupling key (45).
2
Remove the V-ring (40) from the shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-7
Chapter 5
Disassembly and Reassembly
3
Remove the bolts (47) and then remove the bearing cover (39). Remove the oil seal (36) from the bearing cover, inspect the oil seal and replace it if wear or damage is apparent.
4
Remove the securing screw and the remove the oil flinger (35) from the shaft.
5
Withdraw the shaft (3) with the thrust ball bearing (30) still in position in the column pipe (2) through the coupling end of the pump.
6
If the thrust bearing replacement is necessary, straighten the bent tongue of the bearing washer (33), unscrew and remove the bearing nut (32). Using a bearing puller, remove the thrust bearing (30). Check the collar (31) for inspection and./or replacement.
Installation of the Thrust Bearing when the change is required 7
Confirm that the collar (31) is in position on the shaft, that it is undamaged and is full contact with the step provided on the pump shaft.
Wear suitable protective clothing when handling heated components. 8
Heat the thrust ball bearing (30) to about 100ºC in an electric oven and insert it over the shaft and butt it against the collar (31).
9
Immediately after installation of the bearing, install the bearing washer and the bearing nut, and hand tighten the bearing nut to apply a small force to locate the bearings in position while cooling.
Note
MM-M05.08
Rev.000
This activity should be performed quickly as any delay could cool the bearings, and this may lead to incorrect positioning of the bearings and subsequent dismantling and reinstallation.
10
Tighten the bearing nut (32), fully after the bearings have cooled to near ambient temperature. Bend the tongue of the bearing washer to lock the bearing nut.
11
Install the oil flinger (35) onto the shaft and secure it using the set screw.
12
Ensure that the pump frame (1) with column pipe (2) is supported vertically on a suitable support and that the column pipe is located correctly below the pump frame.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-8
Chapter 5
Disassembly and Reassembly
13
Insert the shaft assembly into the column pipe (2) such that the thrust bearing (30) slide smoothly into the thrust bearing housing in the column pipe. Ensure that the thrust bearing seats correctly in the thrust bearing housing.
14
Install the oil seal (36) into the groove provided in the bearing cover (39). Insert the bearing cover over the shaft (3) from the pump coupling end such that the oil seal slides smoothly over the shaft.
15
After ensuring that the bearing cover is properly seated on the pump frame (1), secure it to the pump frame using the fixing bolts (47).
16
Replace and secure the V-ring (40) to the shaft.
With a new thrust bearing installed we can return to the re-assembly of the Auxiliary oil pump.
MM-M05.08
Rev.000
Reassembly of the AOP 17
Clean the lower flange of the column pipe, and replace the 3rd stage casing (27), checking that the air vent (52a/b) is correctly located, install all hexagon bolts (28) and knock bolts (38).
18
Install the sleeve bearing (26) using the securing screws (13c).
19
Install the 3rd stage impeller upper casing ring and secure using the set screws.
20
Install the 3rd stage impeller key.
21
Replace the 3rd stage impeller, upper and lower rings and secure using set screws.
22
Replace the 3rd stage impeller (29) in its position.
23
Apply lubricating oil into the location of the 3rd stage impeller.
24
Prepare to make the 2nd stage casing (17) ready for installation. Shaft sleeve (18) is to be installed on the shaft (3) and the sleeve bearing (22) must be installed over the shaft sleeve (18), and secure using the securing screws (13b).
25
Install the ‘O’ ring (24), replace the casing (17) and secure it using the hexagonal head bolts (53).
26
Confirm that the impeller upper casing ring is located correctly in its position with set screws already installed.
27
Replace the impeller key (21), and install the No. 2 impeller (19) with the impeller rings already installed.
28
Apply lubricating oil onto the locations of the 2nd stage impeller.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-9
Chapter 5
Disassembly and Reassembly
To prepare the 1st stage casing for installation, install the shaft sleeve (15) and then install the sleeve bearing (14) held in position with securing screws (13a).
30
Replace the ‘O’ ring (20), then install the 1st stage casing, using the hexagon head screws (23), and also install the upper and the lower impeller rings.
31
In the 1st stage casing, we must install the upper casing ring, using the hexagon head screws, and we also install the upper and the lower impeller rings.
32
Install the impeller key (11), and install the 1st stage impeller.
32
Check that all 1st stage casing rings and impeller rings are secure, then install the impeller washer (9), the lock plate (10) and the impeller nut (8).
33
Apply lubrication oil onto the location of the 1st stage impeller.
34
Restore the suction cover (6), the strainer (7) and the ‘O’ ring (16) using the hexagon head bolts (12).
35
Replace the oil feed tube (34) connected between the 1st stage casing (4) and the column pipe (2).
MM-M05.08
Rev.000
29
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-10
Chapter 5
Disassembly and Reassembly
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13a,b,c 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48a,b,c, d,e,f 49a,b,c, d,e,f 50a,b,c, d,e,f 51a,b,c, d,e,f 52 a,b 53 54 55 56
40 55
47 39
35 36
32 33 30
2 1
31 38
38 37 28 38
CASING RING IMPELLER RING SET SCREW SET SCREW AIR VENT HEXAGONAL HEAD BOLT DRIVE MOTOR BOLTS, MOTOR TO FRAME BOLTS, FRAME TO M.O.T
MM-M05.08
Rev.000
34
DESCRIPTION PUMP FRAME COLUMN PIPE SHAFT 1st STAGE CASING 1st STAGE IMPELLER SUCTION COVER STRAINER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER KEY HEXAGONAL HEAD BOLT SCREW SLEEVE BEARING SHAFT SLEEVE O-RING 2nd STAGE CASING SHAFT SLEEVE 2nd STAGE IMPELLER O-RING IMPELLER KEY SLEEVE BEARING HEXAGONAL HEAD BOLT O-RING IMPELLER KEY SLEEVE BEARING 3rd STAGE CASING HEXAGONAL HEAD BOLT 3rd STAGE IMPELLER THRUST (BALL) BEARING COLLAR BEARING NUT BEARING WASHER OIL FEED TUBE OIL FLINGER OIL SEAL HEXAGONAL HEAD BOLT KNOCK BOLT BEARING COVER V-RING COUPLING HALF (PUMP) COUPLING HALF (MOTOR) COUPLING BOLT & NUTS COUPLING BUSH KEY COUPLING COVER HEXAGONAL HEAD BOLT
FIGURE 5-1 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
EXPLODED VIEW OF THE AUXILIARY OIL PUMP 5-11
Chapter 5
5.3
Disassembly and Reassembly
Disassembly and Reassembly of Turning Oil Pump a) Preparation If Turning Oil Pump disassembly becomes necessary, all associated equipment shall be mechanically and electrically isolated and an authorized clearance and work permit shall be in place prior to the commencement of work. The permit should include entry into the main oil tank. The following points are also to be considered when preparing for disassembly and reassembly. •
Have all necessary drawings (assembly drawings, sectional drawings, part details, etc.) and documents (log sheets, field record book, etc.) ready prior to start of work.
•
Prepare the necessary handling facilities (e.g. crane facilities, temporary supports, etc.) to remove and store the various parts of the equipment.
•
Prepare separate temporary structures of adequate height and strength, to receive first the motor, and then the complete pump as they are removed from the tank.
•
Co-ordinate with the I&C Department to remove all instrumentation from the equipment before starting disassembly work.
•
Coordinate with Electrical department to have the power cable removed from the motor.
b) Disassembly Before starting disassembly, prepare a laydown area where equipment can be stored and worked on without undue risk of contamination or damage.
MM-M05.08
Rev.000
Before removing the pumping unit, make suitable arrangements for the following: (i)
Removal of the motor. The coupling is designed such that the motor can be lifted off after the coupling bolts (6) and the bolts securing the motor to the pump frame (49) are removed.
(ii)
Lifting of the pump and containment of the oil which will drain from the pump after it has been removed from the MOT. If cleaning materials or fluids are used for cleaning the pumping unit prior to transporting it to the laydown area, they should not be allowed to enter the MOT.
During disassembly, tag all components for identification purposes and, if necessary, bag or wrap to prevent miscellaneous losses and ensure adequate protection.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-12
Chapter 5
Disassembly and Reassembly
CAUTION When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for ease of identification during reassembly. The disassembly procedure is described as follows: Refer to Figures 2-12 and 5-2.
Removal of the Motor 1
Unbolt and remove the safety covers (2) from the pump frame (1).
2
Ensure that match marks are clearly visible on the motor (47), the pump frame (1), and on the main oil tank mounting flange.
3
Loosen and remove the coupling bolts and nuts (6) from the coupling.
4
Refer to Chapter 3 for the weight of the motor, then attach suitable slings from the crane hook to the eyebolts provided on the motor and remove the slackness from the slings.
5
Check the supports arranged in the laydown area to ensure that the motor will be supported without the protruding coupling contacting the floor.
6
Remove the bolts (49) securing the motor to the pump frame.
7
Lift the motor, transport it to the prepared laydown area and protect it with a secured plastic cover.
MM-M05.08
Rev.000
Removal of the Pump 8
Confirm that the Permit to work (PTW) covers entry into the MOT, that the MOT has been cleaned, is gas free, and ventilated. Maintenance personnel can then enter the MOT to remove the pump discharge flange bolts, and to secure the discharge piping within the MOT.
9
Remove the bolts (48) securing the pump frame (1) to the MOT, then using the appropriate lifting gear, lift the complete pump assembly from the MOT. Transport the removed pump assembly to the laydown area and locate it vertically on the pre-arranged supports.
10 Confirm that there is sufficient working area directly above the pump for the withdrawal of the pump shaft. 11 Using a suitable bearing puller, remove the pump side coupling half (4) and recover the key (40) from the pump shaft (41). 12 Remove the ‘V’ ring (9) from the pump shaft. Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-13
Chapter 5
Disassembly and Reassembly
13 Remove the bolts and washers (7) and then remove the bearing cover (8) from the pump frame (1). 14 Remove the oil seal (10) from the bearing cover. 15 Remove the set screws (45) and then remove the oil flinger (11) from the pump shaft. 16 Remove the oil feed tube (17), and seal the open ends to prevent the entry of dust or debris.
CAUTION During the pump disassembly care should be taken when removing the strainer, suction cover, impeller and pump casing. They are moderately heavy and will be oil soaked. The individual parts should be lowered onto stacked timbers (wood) or a low wheeled bogie, then removed from under the pump for inspection. 17 Straighten the bent tongue of the lock washers, remove the bolts and the lock washers (18) and then remove the strainer (19) and the suction cover (20). Remove the O-ring (39) between the suction cover (20) and the pump casing (35). 18 Straighten the bent tongue of the lock plate (23) and then loosen and remove the impeller nut (21), the lock plate (23) and the impeller washer (22). 19 Withdraw the impeller (24) from the impeller end of the shaft and recover the impeller key (25) from the shaft (41).
Wear suitable protective clothing when handling heated components.
Note
MM-M05.08
Rev.000
If difficulty is experienced when attempting to remove the impeller, apply heat around the periphery, working slowly towards the hub. Do not initially heat the hub as this will cause the impeller to grip tighter on the shaft. 20 Remove the knock bolts (30) which locate the pump casing (35) and the column pipe (42).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-14
Chapter 5
Disassembly and Reassembly
21 Remove the bolts and lock washers (31) and then withdraw the pump casing (35). 22 The pump casing should be examined for signs of wear and reference should be made to the manufacturer if wear is apparent. 23 Remove the bolts and washers (32) and then remove the sleeve bearing (36) from inside the pump casing. 24 Inspect the impeller (24) for wear or damage, paying particular attention to the suction entry blade tips, the impeller rings (28, 29) and the casing rings (26, 27). 25 Measure the bore of the casing wear rings and the OD of the impeller wear rings and calculate the wear. If the wear ring clearances are beyond the tolerance limit, remove the casing and impeller wear rings.
Note The above wear rings are located in both the suction and discharge sides of the pump. The casing wear rings are retained by set screws or peening and the impeller wear rings by set screws. It is not necessary for the rings to be removed from the casing and the impeller unless damaged, worn, or due for replacement.
26 Replace excessively worn casing rings, impeller rings and any other component which fails to meet the acceptance criteria. 27 Inspect the sleeve bearing (36) for wear or damage. Measure the clearance between the sleeve bearing and the shaft. Replace the bearing with a new one if the clearance exceeds the acceptable limit. 28 The pump shaft assembly containing the shaft, bearing nut, bearing washer and thrust bearing can now be removed through the motor end of the pump frame. Timber and a hydraulic jack should be available to raise the shaft assembly. 29 Straighten the bent tongue of the bearing washer and then remove the bearing nut (12) and the bearing washer (13).
MM-M05.08
Rev.000
30 Using a suitable bearing puller, withdraw the thrust bearing (14) from the pump shaft. 31 The thrust bearing should be inspected for ball or ball race damage and the bearing should be replaced if damage is apparent. 32 If there are doubts regarding the shaft concentricity, a shaft run-out check should be performed to confirm that the acceptable limit of 0.05 mm at the shaft journals is not exceeded.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-15
Chapter 5
c)
Disassembly and Reassembly
Reassembly Refer to Figure 5-2. 1
Before reassembly, ensure that all components have been cleaned thoroughly.
2
Lubricate the internal pump parts with clean turbine oil where necessary.
3
Confirm that the collar (15) is in its original location on the pump shaft (41). And if the thrust bearing is to be changed proceed as follows:
Wear suitable protective clothing when handling heated components. 4
Heat the thrust bearing (14) to about 100°C in an electric oven and insert it over the shaft and butt it against the collar (15).
5
Immediately after installation of the bearing, install the bearing washer (13) and the bearing nut (12), and hand tighten the bearing nut to apply a small force to locate the bearing in position while cooling.
Note This activity should be performed quickly as any delay could cool the bearing, and this may lead to incorrect positioning of the bearing and subsequent dismantling and reinstallation.
6
Tighten the bearing nut fully after the bearing has cooled to near ambient temperature. Bend the tongue of the bearing washer to lock the bearing nut.
7
Install the pump frame and column pipe assembly vertically on the prepared support such that the pump frame is located above the column pipe.
8
Replace the shaft with the assembled thrust bearing into the column pipe (42) confirming that the collar (15) and the thrust bearing (14) are correctly located.
9
Install the oil flinger (11) and secure it with the set screws (45).
11 Replace the bearing cover (8) (with oil seal) into the pump frame (1) and secure it with the hexagonal head bolts and spring washers (7).
MM-M05.08
Rev.000
10 Replace the oil seal (10) in the slot provided in the bearing cover (8).
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-16
Chapter 5
Disassembly and Reassembly
12 Install the ‘V’ ring (9) onto the pump shaft. 13 Replace the key (40) in the slot on the shaft.
Wear suitable protective clothing when handling heated components. 14 Heat the pump coupling half (4) in an electric oven and then ensuring that the coupling keyway aligns with the shaft key (40), insert the coupling half over the pump shaft until it comes into contact with the step on the shaft. 15 Rotate the shaft by hand and ensure the shaft is free to rotate. 16 Replace the casing wear ring (26) in the pump casing (35) and the casing wear ring (27) on the suction cover (20) and secure them. 17 Replace the impeller wear rings (28 and 29) on the impeller (24) and secure them with the set screws (33 and 34). 18 Confirm that the wear ring clearances are within tolerance. 19 Rotate and support the pump frame and column pipe assembly on the prepared support such that the column pipe is located above the pump frame. Provide suitable temporary side-supports for the shaft from the column pipe, if required. 20 Check the pump casing flanges for bumps or burrs and remove any, using emery cloth or a smooth file. Check for cleanliness and locate the casing (35) on the column pipe (42) using the knock bolts and nuts (30). 21 Secure the casing to the column pipe using the lock washers and bolts (31). 22 Check the condition of the sleeve bearing (36) and remove any burrs. Apply a coating of oil and install it in the pump casing using the hexagonal head bolts (32).
24 Install the impeller (24) ensuring that it locates correctly on the shaft key.
MM-M05.08
Rev.000
23 Check the impeller key (25), then insert it in the keyway on the pump shaft.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-17
Chapter 5
Disassembly and Reassembly
Note The bore of the impeller is machined to the same size as the diameter of the shaft with a small tolerance. It may or may not be possible to slide the impeller onto the shaft. Try to install the impeller on the shaft by hand. If the impeller will not slide onto the shaft, heat may be applied evenly around the hub and then installed.
CAUTION Force must not be used when installing the impeller. If the impeller fails to butt against the shaft shoulder, remove the impeller and check for any burrs or dirt which may have been overlooked during inspection. Clean up as necessary. Do not attempt to install the impeller if the shaft temperature is above ambient.
Wear suitable protective clothing when handling heated components. 25 Replace the impeller washer (22) and the lock plate (23) and then tighten them with the impeller nut (21).The tongue of the lock plate should be bent after fully tightening the impeller nut to prevent loosening. 26 Clean and check the condition of the suction cover (20), smear oil over the internal surfaces and replace the O-ring (39). 27 Replace the suction cover (20) and the suction strainer (19) onto the pump casing and secure them using the hexagonal head bolts and lock washers (18). 28 Replace the oil feed tube (17) between the pump casing and the column pipe, and secure it with the removed supports.
Replacement of the Turning Oil Pump Assembly
MM-M05.08
Rev.000
CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Special consideration is to be given to the center of gravity of the assembly.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-18
Chapter 5
Disassembly and Reassembly
29 Carefully transport the pump frame/pump assembly from the laydown area to the location of the MOT and align it above the respective opening on the MOT. 30 Confirm that the mating flange faces are clean and smooth, then slowly lower the oil pump assembly into the tank until the pump frame (1) is located properly on the mounting flange. 31 Secure the pump frame to the MOT using the fasteners (48). 32 Using new gaskets, replace the pump discharge pipes inside the main oil tank. 33 Replace new rubber coupling bushes (5) into the coupling flange (3) on the motor shaft if the inspection or the maintenance schedules necessitates their replacement. 34 Using the lifting equipment, lift the motor onto the pump frame and secure it with the fixing bolts and nuts (49). 35 Perform an alignment check as per the procedure indicated in Appendix D. 36 When the coupling alignment is completed, replace the coupling bolts and nuts (6) and tighten them in sequence. 37 Replace the safety covers (2) onto the motor frame. 38 Reinstall the removed instrumentation and reconnect the electrical power cable removed during disassembly. 39 Clean the main oil tank thoroughly and refill with the recommended oil to the required operating level. 40 Start the pump as per the recommended starting procedure and ensure that the pump operates satisfactory without any oil leakage.
5.4
Disassembly and Reassembly of the Emergency Oil Pump
MM-M05.08
Rev.000
Although, as their titles suggest, the EOP and the TOP have different (motor) drives, the pumping units are the same. If disassembly of the EOP becomes necessary, refer to Section 5.2, Turning Oil Pump Disassembly and Reassembly and follow the same procedure.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
5-19
Chapter 5
ITEM
DESCRIPTION PUMP FRAME COUPLING COVER (SAFETY) COUPLING HALF (MOTOR) COUPLING HALF (PUMP) COUPLING BUSH COUPLING BOLT & NUT HEX. BOLT / SPRING WASHER BEARING COVER V. RING OIL SEAL OIL FLINGER BEARING NUT BEARING WASHER THRUST BEARING COLLAR OIL FEED TUBE HEX. HEAD BOLT & WASHER SUCTION STRAINER SUCTION COVER IMPELLER NUT IMPELLER WASHER LOCK PLATE IMPELLER IMPELLER KEY CASING RING CASING RING IMPELLER RING IMPELLER RING KNOCK BOLT, NUT, WASHER HEX. HEAD BOLT & LOCK WASHER HEX. HEAD BOLT & LOCK WASHER HEX. SOCKET SET SCREW HEX. SOCKET SET SCREW PUMP CASING SLEEVE BEARING O-RING KEY (COUPLING) SHAFT COLUMN PIPE AIR VENT PLUG KNOCK BOLT, NUT, WASHER SET SCREW HEX. HEAD BOLT & LOCK WASHER DRIVE MOTOR BOLTS, FRAME TO M.O.T BOLTS, MOTOR TO FRAME
MM-M05.08
Rev.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 39 40 41 42 43 44 45 46 47 48 49
Disassembly and Reassembly
FIGURE 5-2 Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
EXPLODED VIEW OF TURNING OIL PUMP 5-20
Chapter-6
Corrective Maintenance
Chapter
6 Corrective Maintenance Corrective maintenance is the repair or replacement work undertaken for sudden failure of any part or component of the equipment. Though a well-planned preventive maintenance program tries to minimize the probability of occurrence of sudden failure of equipment, provision for attending these unscheduled maintenance requirements should be made. Corrective maintenance work is to be given priority depending on the seriousness of the problem faced and the impact on plant operations. The schedule for repair of any equipment should be carefully planned to keep outage time to a minimum. During such repair or replacement work, inspection should be conducted carefully to determine why the equipment has failed. Good corrective maintenance requires, not only quick restoration of the failed equipment back into service but also demands every effort to identify and record the root cause of the failure. The inspection results can be of significant help in exploring the exact reason for the failure. The findings along with possible rectification proposals are to be used as a feedback to update the preventive maintenance procedures.
6.1
Prerequisites The necessary prerequisites for the corrective maintenance of the main oil tank and the vapor extractor fan are as follows:
a)
Scheduling Unlike preventive maintenance, scheduling activity only starts after failure of the equipment. Depending on the severity of the problem, the importance of the service provided by the failed equipment and availability of manpower to attend to the problem, a contingency schedule is to be prepared to solve the problem at the earliest opportunity. The schedule should clearly indicate the critical path activity and assign the priority for different parallel activities. Finally, once the schedule is agreed, strict adherence to it is to be maintained to ensure timely completion of the maintenance activity.
b)
Inter Departmental Cooperation/Communication Refer to Section 4.1.2, Departmental Interface/Notification.
c)
Isolation of Equipment
d)
Safety Precautions Refer to Section 4.1.4, Safety Precautions.
MM-M05.08
Rev.000
Refer to Section 4.1.3, Isolation of Equipment.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-1
Chapter-6
6.2
Corrective Maintenance
Preparation a)
Parts, Tools and Equipment Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.
b)
Documentation Refer to Subsection 4.2.1 b), Documentation.
6.3
Troubleshooting
MM-M05.08
Rev.000
This section provides information about carrying out troubleshooting and servicing for the main oil tank and vapor extractor fan, pertaining to the mechanical maintenance staff. A table of Faults, Possible Causes and Remedies has been provided to assist in troubleshooting by qualified users. If any new kind of problem is encountered which is not listed in the following table, contact the manufacturer for assistance.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-2
Chapter-6
TABLE 6-1
Corrective Maintenance
TROUBLESHOOTING – MAIN OIL TANK AND VAPOR EXTRACTOR FAN Fault
Abnormal decrease of oil level in the tank
Possible Cause
Remedy
Loose flange connection
Retighten the connection
Oil emission through the mist separator
Adjust vapor extractor fan suction damper
Failure of oil purifier seal
Correct oil purifier
Evaporation loss
Top-up with fresh oil
Manhole cover left open or loose
Close cover securely
Loose inspection covers
Tighten the inspection covers properly
Vapor extractor fan suction closed or throttled
Readjust the suction damper
Steam ingress from turbine glands
Check and correct gland sealing pressure and gland steam condenser vacuum
Improper oil purifier water separation
Check and correct the oil purifier
Main oil pump suction oil pressure low
Faulty No. 1 ejector
Shutdown and rectify No. 1 ejector
AOP/TOP/EOP discharge pressure low
Suction strainer blocked
Shutdown and clean suction strainer
Oil piping leakage
Rectify oil leakage
Relief valve seat leakage due to debris
Clean and remove debris/foreign matter
Oil piping leakage
Rectify oil leakage
Increase in MOP internal clearances
Shutdown and correct MOP internal clearances
Internal leakage in the discharge check valve of the standby pump (AOP/TOP/EOP)
Rectify the check valve internal leakage
High oil temperature
Check and rectify problems of oil cooler
Standby pump rotating in reverse direction (AOP/TOP/EOP)
Internal leakage in the discharge check valve of the standby pump
Rectify the check valve internal leakage
High oil temperature
Malfunctioning of oil cooler
Check and rectify problems of oil cooler
Loss of vacuum in the oil tank
High water content in oil
MM-M05.08
Rev.000
Reduction of lube / HP oil pressure
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
6-3
Chapter-7
Recommended Lubrication
Chapter
MM-M05.08
Rev.000
7 Recommended Lubrication
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-1
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1069
FIGURE 7-1
RECOMMENDED LUBRICANTS LIST FOR MAIN OIL TANK
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-2
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1070
FIGURE 7-2
RECOMMENDED LUBRICANTS LIST FOR AOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-3
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1071
FIGURE 7-3
RECOMMENDED LUBRICANTS LIST FOR TOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-4
Recommended Lubrication
MM-M05.08
Rev.000
Chapter-7
MPTD-4-1072
FIGURE 7-4
RECOMMENDED LUBRICANTS LIST FOR EOP
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-5
MM-M05.08
Rev.000
Chapter-7
Recommended Lubrication
MPTD-4-1073
FIGURE 7-5
RECOMMENDED LUBRICANTS LIST FOR VAPOR EXTRACTOR FAN
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
7-6
Appendix A
Appendix
A Torque Chart TABLE A-1
TORQUE CHART
Bolt Size
Tightening Torque (Nm)
M6
4
M7
10
M10
20
M12
35
M16
80 – 90
M20
155 – 175
M24
275 – 305
M30
545 – 605
M36
950 – 1050
M42
1520 – 1680
M48
2300 – 2520
M56
3690 – 4070
M64
5560 – 6150
Note This table is to be used in absence of torque value recommended by the vendor.
(1)
Apply anti-seize compound to bolts.
(2)
Tighten nuts 20% of the calculated torque in a cross-diagonal sequence.
(3)
Following the sequence, tighten the nuts to 80% of calculated torque.
(4)
Following the sequence, tighten the nuts to 100% of calculated torque.
MM-M05.08
Rev.000
Perform the following steps in sequence:
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
A-1
Appendix B
Recommended B Spare Parts
MM-M05.08
Rev.000
Appendix
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-1
MM-M05.08
Rev.000
Appendix B
MPTD-4-0776
FIGURE B-1
OPERATING SPARE PARTS LIST FOR AUXILIARY OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-2
Rev.000
Appendix B
MM-M05.08
MPTD-4-0777
FIGURE B-2
OPERATING SPARE PARTS LIST FOR TURNING OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-3
Rev.000
Appendix B
MM-M05.08
MPTD-4-0778
FIGURE B-3
OPERATING SPARE PARTS LIST FOR EMERGENCY OIL PUMP
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-4
MM-M05.08
Rev.000
Appendix B
MPTD-4-1130
FIGURE B-4
OPERATING SPARE PARTS FOR MOT VAPOR EXTRACTOR
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-5
MM-M05.08
Rev.000
Appendix B
MPTD-4-1131
FIGURE B-5
OPERATING SPARE PARTS FOR MIST SEPARATOR
Turbine Main Oil Tank & Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
B-6
Appendix C
Appendix
C Special Tools
MM-M05.08
Rev.000
The manufacturer of these pumps does not recommend any special tools for maintenance work.
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
C-1
Appendix D
Appendix
D Coupling Alignment The following basic alignment procedure is suitable for most motor to driven machine couplings. However, if additional details are required, reference should be made to the manufacturers instructions. Peripheral Alignment Using a Dial Test Indicator (DTI): Match mark the coupling halves.
With both match marks at the top: Check DTI reading at zero.
2
Turn both shafts 90°, check DTI reading at 90°.
3
Turn both shafts a further 90°, check DTI reading at 180°.
4
Turn both shafts a further 90°, check DTI reading at 270°.
5
Turn both shafts to zero, recheck DTI reading at zero.
MM-M05.08
Rev.000
1
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
D-1
Appendix D
Axial Alignment An inside micrometer or a tapered gap gauge can be used dependent upon the size of the gap between the coupling faces. This example uses an inside micrometer. Ensure both match marks at the top: 1
With shafts stationary, measure a, b, c, d.
2
Turn both shafts 180° (match marks at the bottom).
3
With shafts stationary, measure c, d, a, b.
From the readings obtained, adjustments can be made to the liners (shims) installed under the feet of the driving/driven equipment. Allowable tolerances are as follows: Flexible Couplings
Rigid Couplings
0.05 mm
Peripheral
0.03 mm
Axial
0.03 mm
Axial
0.02 mm
MM-M05.08
Rev.000
Peripheral
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
D-2
Appendix E
Applicable E Reference Drawings
MM-M05.08
Rev.000
Appendix
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-1
MM-M05.08
Rev.000
Appendix E
MPTD-3-0754
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
FIGURE E-1
ARRANGEMENT DRAWING OF MAIN OIL TANK E-2
MM-M05.08
Rev.000
Appendix E
MPTD-4-0755
FIGURE E-2
OUTLINE DRAWING OF AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-3
MM-M05.08
Rev.000
Appendix E
MPTD-4-0756
FIGURE E-3
ASSEMBLY DRAWING OF AOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-4
MM-M05.08
Rev.000
Appendix E
MPTD-4-0757
FIGURE E-4
ASSEMBLY DRAWING OF AOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-5
MM-M05.08
Rev.000
Appendix E
MPTD-4-0758
FIGURE E-5
ASSEMBLY DRAWING OF AOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-6
MM-M05.08
Rev.000
Appendix E
MPTD-4-0759
FIGURE E-6
EXPECTED PERFORMANCE CURVES FOR AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-7
MM-M05.08
Rev.000
Appendix E
MPTD-4-0760
FIGURE E-7
TORQUE CHARACTERISTIC CURVES FOR AOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-8
MM-M05.08
Rev.000
Appendix E
MPTD-4-0761
FIGURE E-8
OUTLINE DRAWING OF AOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-9
MM-M05.08
Rev.000
Appendix E
MPTD-4-0762
FIGURE E-9
OUTLINE DRAWING OF TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-10
MM-M05.08
Rev.000
Appendix E
MPTD-4-0763
FIGURE E-10
ASSEMBLY DRAWING OF TOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-11
MM-M05.08
Rev.000
Appendix E
MPTD-4-0764
FIGURE E-11
ASSEMBLY DRAWING OF TOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-12
MM-M05.08
Rev.000
Appendix E
MPTD-4-0765
FIGURE E-12
ASSEMBLY DRAWING OF TOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-13
MM-M05.08
Rev.000
Appendix E
MPTD-4-0766
FIGURE E-13
EXPECTED PERFORMANCE CURVES FOR TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-14
MM-M05.08
Rev.000
Appendix E
MPTD-4-0767
FIGURE E-14
TORQUE CHARACTERISTIC CURVES FOR TOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-15
MM-M05.08
Rev.000
Appendix E
MPTD-4-0768
FIGURE E-15
OUTLINE DRAWING OF TOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-16
MM-M05.08
Rev.000
Appendix E
MPTD-4-0769
FIGURE E-16
OUTLINE DRAWING OF EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-17
MM-M05.08
Rev.000
Appendix E
MPTD-4-0770
FIGURE E-17
ASSEMBLY DRAWING OF EOP (1/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-18
MM-M05.08
Rev.000
Appendix E
MPTD-4-0771
FIGURE E-18
ASSEMBLY DRAWING OF EOP (2/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-19
MM-M05.08
Rev.000
Appendix E
MPTD-4-0772
FIGURE E-19
ASSEMBLY DRAWING OF EOP (3/3)
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-20
MM-M05.08
Rev.000
Appendix E
MPTD-4-0773
FIGURE E-20
EXPECTED PERFORMANCE CURVES FOR EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-21
MM-M05.08
Rev.000
Appendix E
MPTD-4-0774
FIGURE E-21
TORQUE CHARACTERISTIC CURVES FOR EOP
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-22
MM-M05.08
Rev.000
Appendix E
MPTD-4-0775
FIGURE E-22
OUTLINE DRAWING OF EOP MOTOR
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-23
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-24
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-25
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-26
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-27
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-28
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-29
MM-M05.08
Rev.000
Appendix E
MPTD-3-1038
Turbine Main Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
FIGURE E-29
LUBRICATING OIL STRAINER E-30
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-31
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-32
MM-M05.08
Rev.000
Appendix E
Turbine Oil Tank and Auxiliary Oil Pumps (AOP, TOP & EOP) Mitsubishi
E-33
