220220en - Lube Oil System

Steam Turbine
Operation
Lube Oil System

Training Lesson
ALSTOM (Switzerland) Ltd
ABCD
ABCD
Steam Turbine
Operation
Lube Oil System
We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly
forbidden.
Copyright by ALSTOM (Switzerland) Ltd 2007
This is a training lesson. It provides overall information about the specific system
only.
To understand the operation concept in detail the project specific documents as
defined in the document reference section have to be included together with this
lesson.
All mentioned / attached values and settings are for information only. Typical
values are used to clarify particular subjects. Settings furthermore are subject to
change site specifically during commissioning.
For actual values please refer to the final plant specific
Operation & Maintenance Documentation.
Power Plant Training Center

CSXA220220en_
Page 2
ABCD
Steam Turbine
Operation
Lube Oil System
Table of Contents
Document Reference ........................................................................................................................... 5
Typical Documents ........................................................................................................................... 5
O&M Documentation ....................................................................................................................... 5
Lesson Objectives................................................................................................................................ 6
Overview ............................................................................................................................................ 7
System Function ............................................................................................................................... 7
Lube Oil Tank .................................................................................................................................. 8
Oil Vapor Extractor .......................................................................................................................... 9
Lube Oil Pumps ............................................................................................................................... 9
Lube Oil Pressure Control............................................................................................................... 12
Lube Oil Temperature Control ........................................................................................................ 13
Lube Oil Filter ................................................................................................................................ 14
Lube Oil Supervision ...................................................................................................................... 15
Lube Oil around the Bearings ......................................................................................................... 16
Lube Oil Purifier............................................................................................................................. 16
Lube Oil Block Diagram ................................................................................................................. 18
Operation and Supervision ................................................................................................................ 19
General......................................................................................................................................... 19
Preparation Prior to Start-up ........................................................................................................... 19
Start-up ......................................................................................................................................... 20
Normal Operation ......................................................................................................................... 21
Shut-down ..................................................................................................................................... 22
Emergency Operation .................................................................................................................... 22
Protection ...................................................................................................................................... 23
Trouble Shooting............................................................................................................................... 23
Routine Operation Maintenance......................................................................................................... 24
Exercises ........................................................................................................................................... 25
General......................................................................................................................................... 25
Overview ....................................................................................................................................... 25
Exercises Functionality, System Outline ............................................................................................ 26
Exercises Component Name, KKS Designation & Function................................................................ 27
Exercises System Instrumentation, KKS Designation, Indication, Set Point ........................................... 28
Exercises Operation & Routine Maintenance .................................................................................... 29
Exercises Trouble Shooting.............................................................................................................. 30
Exercises Routine Maintenance........................................................................................................ 31
Test Questions for Verification of Learning Progress ......................................................................... 32
Questions: ..................................................................................................................................... 32
Lesson Test Questions Solution Key ................................................................................................. 36
Summary .......................................................................................................................................... 37

CSXA220220en_
Page 3
ABCD
Steam Turbine
Operation
Lube Oil System
Table of Figures
Figure 1: Oil Tank for Steam Turbine Lube Oil System (Typical) ............................................................ 8
Figure 2: Oil Vapor Extractor, Butterfly Valve and Air Filter (Typical) ...................................................... 9
Figure 3: Gear Pump (Typical) .......................................................................................................... 10
Figure 4: Auxiliary Pump (View from Inside Lube Oil Tank) (Typical) .................................................... 10
Figure 5: Emergency Pump (Typical).................................................................................................. 11
Figure 6: Constant Pressure Valve (Typical) ........................................................................................ 12
Figure 7: Temperature Control Diagram (Typical) .............................................................................. 13
Figure 8: Tube and Shell Heat Exchanger, Control Valve (Typical)....................................................... 13
Figure 9: Lube Oil Twin Filter with Pressure Gauge (Typical) ............................................................... 14
Figure 10: Lube Oil Pressure Gauge (2 out of 3 Logic) (Typical) .......................................................... 15
Figure 11: Lube Oil Purifier (Typical) ................................................................................................. 17
Figure 12: Lube Oil Emergency Lube Oil System Block Diagram (Typical)............................................ 18

CSXA220220en_
Page 4
Steam Turbine
Operation
ABCD
Lube Oil System
Document Reference
Typical Documents
Typical documents are used to clarify aspects described in this lesson. These typical
documents may not show project specific contents, deviations are possible. All
typical documents are clearly identified.
O&M Documentation
O&M Documents are plant specific and form an important part of each training
course. A selection of the most relevant O&M Documents has been made and
included in the training course material. These documents provide a basis for
exercises and personal notes, markings, etc. The most relevant documents for the
operation training are:
P&IDs with legend
System descriptions
Operating instructions
Operating diagrams
Instrument lists
Set point lists
Maintenance instructions
The O&M Documents are separated into:
System specific documents
Overall plant specific documents

The system specific documents are attached to each specific lesson, whereas the
overall plant specific documents can be found in separate sections at the end of the
training manual.

CSXA220220en_
Page 5
Steam Turbine
Operation
ABCD
Lube Oil System
Lesson Objectives
Upon completion of this lesson, the trainee is able to:
Explain the function of the system on a block diagram during start up, normal
operation and shut down.
To summarize the function of all components involved in the lube oil system.
Operate the function group according to the "starting & operating instruction of
steam turbine" during all operation situations.
Is able to trouble shoot the lube oil system according to "lubricating and
hydraulic oil system with integral jacking- and turning gear oil system".
To carry out a change over of the lube oil filter, from the in service unit to the
stand by unit, with the respective maintenance documentation.
Describe all maintenance checks to be carried out during regular operation.

CSXA220220en_
Page 6
Steam Turbine
Operation
ABCD
Lube Oil System
Overview
System Function
The turbine lubrication (lube oil) system performs the following function:
Lubricate the bearings of the generator and steam turbine.
Supply of lube oil to the jacking oil (shaft lifting) and electro hydraulic safety
system.
Removal of heat generated in the journal bearings by shaft rotation.
This is reached by the following:
Components
Maintaining a constant lube oil flow and pressure.
Maintaining sufficient lube oil flow during emergency situations.
Providing a specific lube oil flow to each bearing.
Maintaining a constant lube oil temperature to consumers.
Cleaning lube oil.
Guiding lube oil to consumers.
Returning lube oil from consumers.
Deaerating lube oil returning from the consumers.
Storage of lube oil at sufficient temperature.
Therefore the following components are needed as a minimum:
Lube oil tank
Vapor extractor
Pumps (main, auxiliary, emergency)
Constant pressure valve
Cooler
Temperature controller
Filter
Supply lines and orifices
Return lines
Oil purifier
Instrumentation and controls
Air filter

CSXA220220en_
Page 7
ABCD
Steam Turbine
Operation
Lube Oil System
Lube Oil Tank
The tank is mainly used to store the lube oil. Also most system components are
mounted on it. It is designed and sized to allow a sufficient deaeration (removing of
entrained air bubbles in the returning lube oil flow from the bearings).
Figure 1: Oil Tank for Steam Turbine Lube Oil System (Typical)

CSXA220220en_
Page 8
Steam Turbine
Operation
ABCD
Lube Oil System
Oil Vapor Extractor
The lube oil vapor extractor maintains a slight vacuum in the lube oil tank, oil drain
pipes and bearing pedestals. This not only removes oil vapor from the tank, but
also prevents oil from leaking through the oil scrapers of the bearing pedestal. A
butterfly valve upstream from the vapor extractor is used to adjust the vacuum in the
tank. Ventilation with fresh air is provided via the air filter.
Figure 2: Oil Vapor Extractor, Butterfly Valve and Air Filter (Typical)
Lube Oil Pumps
Redundancy
A total loss of lube oil during operation will damage the bearings of the turbo set.
Therefore three lube oil pumps are installed. Check valves after each pump ensure
that stand-by pumps do not reverse during operation and that the lube oil is not
discharged back into the tank. Pressure supervision transducers after each pump
indicate a malfunction of the pump and initiate an automatic change over from one
pump to the other.
(Continued next page)

CSXA220220en_
Page 9
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Pumps (continued)

Main Pump
The main lube oil pump is a gear pump (volumetric pump type), driven by the turbine
shaft. It provides oil as soon as the shaft begins to turn, but reaches its design data
already at approximately 80 % of nominal shaft speed.
CSXA401764.cdr
Figure 3: Gear Pump (Typical)
Auxiliary Pump
At low turning speeds during start-up,

shut-down and turning gear
operation, the main oil pump delivers
insufficient oil and the required lube
oil is then supplied by the auxiliary
lube oil pump (centrifugal pump with
AC motor). The auxiliary pump is
designed for the full pressure and a
flow rate of the required maximum
(100 %).
Check valve
Auxiliary pump
Suction cage
CSXA401756.cdr
Figure 4: Auxiliary Pump

(View from Inside Lube Oil Tank) (Typical)

CSXA220220en_
Page 10
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Pumps (continued)

Emergency
Pump
The emergency lube oil pump is a centrifugal, DC motor-driven back-up pump. It is

powered by batteries and runs only for test purposes or if the main and auxiliary
lube oil pumps fail. To limit the DC power consumption, the emergency oil pump is
designed with pressure and flow parameters below the required maximum at rated
speed. The capacity is sufficient to ensure safe rundown of the turboset and cooling
of the bearings if an AC power failure occurs. The discharge of the emergency oil
pump is located after the coolers and filters for two reasons:
Oil can be delivered to the system when these components are blocked.
Elimination of the pressure loss from these components allows the DC pump to
be designed for a lower discharge pressure and less power consumption.
Figure 5: Emergency Pump (Typical)

CSXA220220en_
Page 11
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Pressure Control
Operation of
Main and
Auxiliary Oil
Pumps
Constant
Pressure Valve
The oil supplied by the pumps during start-up and shut-down varies greatly, because
of two reasons:
The main lube oil pump is a volumetric pump type. The volume flow of such a
pump is proportional to the rotational speed and not depending on the back
pressure.
Initially only the AC pump, then the AC plus the main oil pump, finally only the
main oil pump is in operation.
To fit the oil supplied to the oil consumption of the bearings and to avoid an
overpressure in the system induced by the gear pump, a constant pressure valve is
installed, which guides the excessive oil before the filter back to the tank. To
compensate for the variable pressure loss depending on the cleanliness of the filter,
the pressure feedback signal for the valve is taken after the filter.
Screw
Spring
ine sure
el
s
uls pre
p
im tem
e
r
s
r
ssu d sy filte
Pre trolle am
re
n
co wnst
do
Piston
CSXA401766.cdr
Figure 6: Constant Pressure Valve (Typical)

CSXA220220en_
Page 12
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Temperature Control
Lube oil temperature is regulated by the inline lube oil cooler and a thermostatic
valve.
Downstream from the cooler, the thermostatic valve maintains the oil temperature at
a constant value by passing part of the oil around the cooler.
Hot oil from the pump and the cold oil from the cooler are mixed in the
internally-sensed thermostatic valve.
A cartridge with the expanding (controlling) medium moves the control cylinder
to open either the cold or hot oil supply.
Operating temperature
to oil system
Pump
Orifice
Thermostatic temperature
control valve
Hot oil
Oil cooler
Cooled oil
CSXA401765.cdr
Figure 7: Temperature Control Diagram (Typical)
Tube bundle
Heat exchanger
Thermostatic temperature
control valve
CSXA401865.cdr
Figure 8: Tube and Shell Heat Exchanger, Control Valve (Typical)

CSXA220220en_
Page 13
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Filter
The lube oil filter consists of two 100 % filters.Differential pressure over the filter (an
indication of the amount of dirt in the cartridge) is supervised continuously by a
differential pressure switch, with remote and local indication. The filters, which can
be changed over during operation, are equipped with vent valves.
2
8
10
Legend:
1
2
3
4
5
6
7
8
9
10
Oil inlet
Oil outlet (clean side)
Left side filter
Right side filter
Change-over handle
Filling handle (cross-over)
Vent handle
Vent sight glass
Overflow toward tank
Drain toward tank
CSXA403260.cdr
Figure 9: Lube Oil Twin Filter with Pressure Gauge (Typical)

CSXA220220en_
Page 14
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Supervision
Lube oil upstream from the bearings is supervised by three pressure transmitters whose
outputs are processed in a 2-out-of-3 logic for turbine safety purposes. If rated lube oil
pressure at the shaft level drops to below a minimum value, the turbine is tripped. The
lube oil pumps cannot be switched off until the shaft is at standstill.
Figure 10: Lube Oil Pressure Gauge (2 out of 3 Logic) (Typical)
The pressure transmitters are also used to automatically start the auxiliary and
emergency lube oil pumps.
If the lube oil pressure drops ca. 60 %, a trip signal is actuated, the auxiliary
lube oil pump is started immediately, and the emergency lube oil pump is
started after a 30s delay.
If the lube oil pressure continues to drop and reaches the 40 % set point, the
average value of the 3 pressure transducers is used to start both emergency and
auxiliary pumps without delay.
The transmitters can be tested one by one during operation by means of test valves.

CSXA220220en_
Page 15
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil around the Bearings
To adjust the flow rate separately for each bearing, individual supply lines from the
lube oil supply header feed the bearings through orifices. Oil enters the bearing shell
and drains into the bearing pedestal. To verify oil flow, sight glasses are installed in the
individual return lines. Temperature indicators are installed in the return lines to
supervise heat development in the bearings. The individual return lines merge into a
return header leading to the tank.
Lube Oil Purifier
Purpose
Function
The function of the lube oil purifier is to eliminate:
Dirt sucked into the bearing pedestal.
Water from the gland seals.
Particles from erection or overhaul.
Sludge from erosion of materials.
When two fluids are being separated, the heavier part collects at the periphery of
the bowl and the lighter part near the center. Each fluid leaves the separator
through its own outlet. The outlet of the heavier liquid is at a somewhat greater
radius than the outlet for the lighter fluid. The more or less cylindrical division
between the fluids is known as the interface. Its location is fixed by gravity disks of
different diameters in the heavy-liquid outlet. The degree of separation obtained
depends on the diameter of the gravity disks. A siphon in the inlet to the oil purifier
unit protects the lube oil tank from being emptied by the purifier.

CSXA220220en_
Page 16
Steam Turbine
Operation
ABCD
Lube Oil System
Lube Oil Purifier (continued)
Figure 11: Lube Oil Purifier (Typical)

CSXA220220en_
Page 17
CSXA220220en_
Auxiliary
lube oil
oump
Main
lube oil
pump
Constant
pressure
control valve
Temperature
control
valve
Lube oil tank
Lube oil
cooler
Filter
To power oil pump
To jacking oil pump
To bearing
Emergency
lube oil
pump
Oil vapor
extractor
To atmosphere
Breathing
gilter
Oil sludge, silt
Ambient air
Oil
purifier
Steam Turbine
Operation
CSXA401724.cdr
Waste water
Water
ABCD
Lube Oil System
Lube Oil Block Diagram
Figure 12: Lube Oil Emergency Lube Oil System Block Diagram (Typical)
Page 18
Steam Turbine
Operation
ABCD
Lube Oil System
Operation and Supervision

General
The operation is fully described in the operation manual, which should be read
carefully. Nevertheless, the most important facts are listed in this section.
Preparation Prior to Start-up
Operating
Method
The system may be operated using the following methods:
Manual operation from the control room via operator station and function
group controller.
Automatic operation by automatic start-up and shut-down sequencer.

Normally the system will be operated using the automatic sequencer. However,
during system checks or maintenance, the system has to be operated manually.
Proper walk-down procedures and valve selection check lists are mandatory for a
safe operation of the system.
(See O&M Steam Turbine Maintenance Manual, section "Inspection")
System Start-up
Sequence
Before any operation may take place, the following systems have to be in
operation:
Lube oil cooling system, i.e. closed cooling water system.
For system start-up, the following has to be fulfilled:
Lube oil level in the tank just below the maximum level (no oil in system yet, oil
level is going to drop during start-up and filling of system).
Lube oil temperature above minimum temperature (to avoid cavitation of lube
oil pumps), normally > 25 C (alarm > 20 C).
Emergency DC pump not in manual operation.

There are no interlocks for these conditions, therefore operation has to prepare the
system according to the specific operating procedure.

CSXA220220en_
Page 19
Steam Turbine
Operation
ABCD
Lube Oil System
Start-up
Procedure
When the function group is placed in operation, lube oil pressure is low because no
pump is on. Since pressure supervision shows low pressure, the auxiliary oil AC
pump will start. Pressure will remain low for a few seconds while the piping fills, but
this will not start the DC pump because of a time delay at start-up of the function
group. After a few seconds, pressure will rise and pressure supervision will indicate
normal pressure. The DC pump will not start when it is released because pressure is
now normal (above 40 % and 60 % respectively). The lube oil vapor extractor is
started immediately at function group start-up.
Pressure and temperature control as well as filtering are automatic and need no
attention other than periodic checks.
During steam turbine start-up, the main lube oil pump will increase the flow of oil
proportionately with speed. At 90 % of rated turbine speed the auxiliary oil pump is
automatically switched off as its operation is no longer necessary to maintain
system pressure. When the auxiliary oil pump is switched off, the reduced oil supply
is compensated by the constant pressure valve. Lube oil is then supplied only by the
main oil pump, which is driven directly by the turbine.
Supervision
During start-up check for the following:
Auxiliary lube oil pump start.
Oil vapour extractor start.
Lube oil pressure, acknowledge MIN1 and MIN2 alarms.
Emergency lube oil pump does not start.
Manually switch ON/OFF emergency lube oil pump, supervise discharge

pressure.
Oil flows in sight-glasses on all automatic cooler and filter vents.
Lube oil pressure upstream of bearing feed orifices between 1.5 to 1.7 barg
(21.75 to 24.65 psig) at shaft level.
Unobstructed lube oil flow through drain sight glasses at each bearing.

CSXA220220en_
Page 20
Steam Turbine
Operation
ABCD
Lube Oil System
Normal Operation
Procedure
The lube oil function group is in operation and the turbine controller regulates the
process.
The AC auxiliary and DC emergency pumps are on stand-by and are started-up in
case the lube oil pressure drops below 60 % and 40 % respectively for any reason.
Supervision
Once per shift walk down the system, checking for the following:
Local instrumentation for deviations from normal values.
Tank level at local level indicators.
Oil temperature after the cooler.
Lube oil system pressure.
Differential pressure across the filter.
Oil leaks.
Abnormal sounds or noises as well as vibrations from the pumps and piping.
In case of dirty filter elements the lube oil filter has to be changed over to the stand
by filter.
Filter
Change-over
Change-over to the stand by filter element is a simple manual action. With one
lever or hand wheel both 2-way valves at the inlet- and outlet side can be changed
at once.
The standby filter must be filled and properly vented!
Air can destroy both the jacking- and turning gear pump immediately.
Larger air pockets destroy the bearings.

The procedure for changing the lube oil filter during normal operation is described
in detail in the maintenance manuals supplied with the unit. The documentation
must be consulted when a change-over is required.
Oil Cooler
Increased pressure drop in the cooler or temperature rise can be caused by

contamination of the oil cooler. In normal cases this contamination appears only at
the water side while the oil side shows just little changes even after years. To
achieve a long lifetime of the cooler the water side should be inspected at least
once a year.

CSXA220220en_
Page 21
Steam Turbine
Operation
ABCD
Lube Oil System
Shut-down
Procedure
When the turbine has coasted down to 90 % of rated speed, the AC auxiliary oil
pump is automatically started to supply oil during run-down.
As a rule the lube oil system is shut down only if the average rotor metal
temperature is <150 C / 302 F.
In case of an emergency the lube oil system may be switched off for a short time at
a metal temperature of max. 200 C / 392 F. However, under no circumstances
and white metal temperature in the various bearings exceed 100 C / 212 F.
When the lube oil function group is removed from service, the vapor extractor fan
remains in operation for another 20 minutes. During this time the oil sticking to the
fan's rotating parts is removed, therefore no excessive fan vibration will occur
during the next start-up.
Supervision
During shut-down the following has to be supervised:
Auxiliary lube oil pump starts at 90 % rated speed.
White metal temperatures in each bearing.
Emergency Operation
Automatic
Operation
Failure
All emergency situations are handled by the control system if the instrumentation
and hardware are working properly and function group is On. If there is a
malfunction in any of these devices, the pumps can be switched on manually at the
single drive level. The DC emergency pump can also be switched on at the switch
gear level.
If no AC or DC power is available, or if the electric pumps fail, the main lube oil
pump will continue to provide lubrication at low turbine speed because it is a
volumetric type pump.
In most cases this oil supply will save the bearings or will at least minimize damage.

CSXA220220en_
Page 22
Steam Turbine
Operation
ABCD
Lube Oil System
Protection
Emergency
Shut-down
In case of an emergency the steam turbine can be tripped immediately by actuating

the emergency push button in the control room or at the turbine. The shutdown
sequence for the steam turbine systems is the same as during a normal shut-down.
Lube Oil Supply

to the Bearings
The lube oil system is one of the most important auxiliary systems for the steam
turbine. Without a sufficient supply of lube oil to the bearings, the machine will be
seriously damaged and may be out of service for weeks. Therefore the supply
pressure (2 out of 3 pressure measurement) in the distribution system is ensured as
follows:
AC auxiliary lube oil pump starts below 90 % nominal rotor speed.
AC auxiliary lube oil pump starts below 60 % nominal lube oil pressure without
delay.
DC emergency lube oil pump starts below 60 % nominal lube oil pressure with
a delay of 15 seconds.
DC emergency lube oil pump starts below 40 % nominal lube oil pressure
without delay.
Trouble Shooting
General Remark
System
Troubleshooting has the goal to quickly return the equipment back to normal
operation or full availability for operation. For fast and successful troubleshooting
the following points are very important:
Accurate and up-to-date logbooks (see section routine maintenance below).
Main machine and system functionality know-how.
Abnormal and emergency operating procedures.
Troubleshooting procedures.
Good teamwork between operating and maintenance staff.
The system specific troubleshooting procedures are described in the following

document:
Maintenance description of lube oil system.

CSXA220220en_
Page 23
Steam Turbine
Operation
ABCD
Lube Oil System
Routine Operation Maintenance

General Remark
When the automatic control and protection systems are working properly, any
particular attendance is not needed. Abnormalities will be alarmed and signalized.
However, in order to prevent unprepared shutdowns by any safety device, regular
routine maintenance is recommended.
Logbook
A logbook with all readings of measurements as well as any observation regarding

operation, starting and shutdown times should be kept. Overhauls and adjustments
carried out should be recorded. The variation of values provides a picture of the
system performance and allows quick and accurate identification of any
abnormality.
Documents
In detail the following documents describe the necessary actions:
Starting & operating instruction of the steam turbine.
Maintenance description of lube oil system.

CSXA220220en_
Page 24
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises
General
To be able to understand the exercises the relevant chapter of the following project
specific documents must be studied carefully:
P&ID incl. legend
Description of Steam Turbine Systems
Starting and Operating Instructions of Steam Turbine
Instrument List
Set Point List
Overview
System &
Components
Operation &
Routine
Maintenance
This section contains the following exercises:
System Outline
Component Name, KKS Designation & Function
System Instrumentation
This section contains the following exercises:
Operation
Trouble Shooting
Routine Maintenance

CSXA220220en_
Page 25
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises Functionality, System Outline
Exercise Task
Mark (with color pens) all media lines which belong to the lube oil system in your
P&ID as follows:
Lube oil tank and supply to oil pump suction side
Lube oil discharge and distribution lines to the bearings
Lube oil drain lines
Exercise Aids
Plant specific P&ID and legend to P&ID
Group
Time Frame
Presentation
Each trainee for himself
10 minutes
Discussion in classroom

CSXA220220en_
Page 26
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises Component Name, KKS Designation & Function
Exercise Task
Fill-in the table below with the following information according to the example
given in the first line:
Major components name
KKS number
Short functional description
Mark all the major components listed on the following drawing:
Exercise Aids
Group
Time Frame
Presentation
Lube oil skid outline drawing
Lube oil skid outline drawing
Each trainee for himself
15 minutes
Discussion in classroom
Component Name
KKS - Number
Component Function

CSXA220220en_
Page 27
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises System Instrumentation, KKS Designation, Indication,

Set Point
Exercise Task
Exercise Aids
Group
Time Frame
Presentation
Fill-in the table below with the following information according to the example
given in the first line:
Instrument type
KKS number
Function code
Indication type
Set points for switching alarm or trip
Instrumentation list
Set point list steam turbine
Group work with max. 4 trainees per group
15 minutes
Group presentation in front of class
Instrument Type
KKS - Number
F-Code
Incic
Switch
Alarm
Trip
P-Gauge
MAV21 CP001
PI
Local

CSXA220220en_
Page 28
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises Operation & Routine Maintenance
Exercise Task
List all major operation steps concerning lube oil system with relevant set points, i.e.
above 90 % shaft speed switch-off auxiliary oil pump.
Exercise Aids
Starting and operating instructions of steam turbines
20 minutes
Group
Time Frame
Presentation
Set Point (Speed, Load, etc.)
Operation Step

CSXA220220en_
Page 29
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises Trouble Shooting
Exercise Task
List all alarms concerning the lube oil systems as well as the possible causes of
them.
Exercise Aids
20 minutes
Group
Time Frame
Presentation
Alarm
Possible Causes
Action Required

CSXA220220en_
Page 30
Steam Turbine
Operation
ABCD
Lube Oil System
Exercises Routine Maintenance
Exercise Task
List all major actions required for routine maintenance of the lube oil system.
Exercise Aids
Maintenance description of lube oil system
20 minutes

Site visited with hands-on dry-exercise
Group presentation in the field
Group
Time Frame
Presentation
Schedule
Action Required

CSXA220220en_
Page 31
Steam Turbine
Operation
ABCD
Lube Oil System
Test Questions for Verification of Learning Progress
General
The following points are important and shall be taken into account:
The training manual may be used (open book), but first try without looking up in
the manual.
Mark the box in front of each correct statement with a diagonal cross.
One or more or all statements may be correct.

Use this section to verify your learning progress! Review subjects, which are not
clearly understood.
Questions:
Question 01:
Question 02:
The turbine lubrication system supplies oil to the following consumers:

A
Journal and axial bearings of the steam turbine
Turning gear system
Hydraulic oil system
Jacking oil system
Sealing oil system of the generator
The temperature of the lube oil is maintained to be not less than 45 C

during normal load operation of the steam turbine by the following:
A
Lube oil cooler
Lube oil temperature control valve
Lube oil mass flow control through the lube oil cooler
Lube oil tank heater
Cooling water mass flow control through the lube oil cooler

CSXA220220en_
Page 32
Steam Turbine
Operation
ABCD
Lube Oil System
Questions (continued):
Question 03:
Question 04:
Question 05:
During operation, the shaft driven main lube oil pump supplies the
steam turbo set with the lube oil required. What happens if the pump
fails?
A
The auxiliary lube oil pump is immediately added into service
The emergency lube oil pump is automatically added into service
The service is switched over to the auxiliary lube oil pump
The steam turbine trips
The pressure accumulator supplies oil while the auxiliary pump is running
What happens in case of an AC loss?

A
The pressure in the lube oil system collapses
The steam turbine goes into a trip
The emergency lube oil pump is automatically switched on
The emergency lube oil pump will carry the supply of the lube oil to
prevent damage to the unit from lack of lube oil during shut-down
The pressure accumulator supplies oil while the auxiliary pump is running
up
What happens when the lube oil temperature downstream of the

twin filter exceeds the pre-set maximum level?
A
An alarm is issued. The operator has to take the action necessary to

return the unit to normal operation
An alarm is issued. If the temperature exceeds the pre-set max. level, the
steam turbine goes into a trip
An alarm is issued. The operator has to investigate until the source of the
problem is found
An alarm is issued. The operator has to investigate until the source of the
problem is found and has to take the action necessary to return the unit to
normal operation

CSXA220220en_
Page 33
Steam Turbine
Operation
ABCD
Lube Oil System
Question 06:
Question 07:
Question 08:
What happens when the bearing metal temperature exceeds the

pre-set maximum level?
A
The steam turbine goes into a trip
Sequential initiation of an alarm and a trip of the steam turbine
Automatic change-over to standby oil cooler
How Is operational readiness of the auxiliary and the emergency

lube oil pump during normal operation of the steam turbine
tested?
A
The lube oil supply is switched over to the auxiliary pump
The auxiliary and the emergency lube oil pumps are started automatically
during each FG start-up. When the pre-set pressure level after each
pump is reached, it is switched off
The shaft driven main lube oil pump and the auxiliary or the emergency
lube oil pump may be operated simultaneously, therefore the pump to be
tested shall be switched-on manually for a brief time
TURBOTROL features a lube oil pump test program, which can be

activated during operation
For how long has the FG lube oil supply to remain in operation after a
shut-down of the steam turbine?
A
For 72 hours
Until the steam turbine metal temperature is <154 C and FG

turning gear can be shut-down
Until the FG lube oil supply is shut-off
Until the FG jacking oil is shut-off


CSXA220220en_
Page 34
Steam Turbine
Operation
ABCD
Lube Oil System
Question 09:
Question 10:
Question 11:
What has to be checked specially during a "once a shift" walk down on

the turbine lubrication system?
A
Watch out for leaks because they will lead to fires where hot surfaces are
present
Proper lube oil forward and return temperature
Lube oil level in the tank
Pressure drop across twin filter
What is important when switching over from the service to the standby side of the twin filter?
A
Proper venting of the stand-by side before switchover
Replace the dirty filter elements with new elements
Discard the used elements
Wash dirty filter elements for re-assembly
Check the system for leaks after re-assembly
Define the following process parameters:

A
Lube oil pressure at the inlet to the bearings:
............ barg
Lube oil pressure at the discharge of the shaft driven

lube oil pump:
............ barg
Minimal lube oil temperature for steam turbine

run-up:
............
Maximal lube oil temperature in the distribution

system (alarm):
............
Maximal pressure drop across twin filter (alarm):
............ barg
C
C

CSXA220220en_
Page 35
ABCD
Steam Turbine
Operation
Lube Oil System
Lesson Test Questions Solution Key
The correct answers for each question are as follows:

01: A, B, D
02: B, C, E
03: A, B
04: B, C, D
05: D
06: B
07: C
08: B
09: A, B, C, D
10: A, B, C, E
11: 1.5barg, 5.5 barg, > 20 C, < 70 C, 0.8 barg

CSXA220220en_
Page 36
ABCD
Steam Turbine
Operation
Lube Oil System
Summary
The purpose of the lube oil system is to lubricate the bearings of the steam turbine
and the generator. Additionally, the heat transferred to the rotor by the steam,
which is conducted to the journals, is transferred to the lube oil together with the
friction heat generated in the bearings. The lube oil system supplies also a variety of
other systems, such as the power oil-, the jacking oil- and the turning gear system.
The main lube oil pump, driven by the turbine shaft, supplies the lube oil system.
The lube oil is partly passed through the lube oil cooler. The temperature is
maintained by the temperature controller, which mixes the warm oil from the tank
with the required amount of cooled oil. A pressure control valve maintains the
system pressure under all operating conditions. The oil passes then through a twin
lube oil filter, before it enters the bearings. Each bearing is equipped with an
orifice, thus preventing a total pressure loss in the system in case of a system leak.
An oil vapor extractor maintains a slight vacuum in the system, thus preventing oil
leaks on the bearing pedestals.
An auxiliary lube oil pump is required for start up, since the main lube oil pump
delivers an insufficient quantity of oil during low speed operation. The auxiliary lube
oil pump, together with the emergency lube oil pump, is switched on, when the lube
oil pressure drops below a defined minimum.
The electronic control system supervises pressure and temperature and provides the
necessary alarms or actions.
The lube oil system requires only little maintenance during regular operation. The
operator should always check for leaks on all components involved in the system.
Particular attention is required for the filter, since the filter in operation may clog up
over a period of time.
Severe damage results when changing-over the oil filter or oil coolers without
proper filling venting!

CSXA220220en_
Page 37
ABCD
Steam Turbine
Operation
Lube Oil System
Blank Page

CSXA220220en_
Page 38

220220en - Lube Oil System

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

220220en - Lube Oil System

Diunggah oleh

Hak Cipta:

Format Tersedia

Steam Turbine

Lube Oil System

ALSTOM (Switzerland) Ltd

Lube Oil System

Power Plant Training Center

Lube Oil System

Power Plant Training Center

Lube Oil System

Power Plant Training Center

Lube Oil System

P&IDs with legend

Set point lists

The O&M Documents are separated into:

System specific documents

Overall plant specific documents

Power Plant Training Center

Lube Oil System

Describe all maintenance checks to be carried out during regular operation.

Power Plant Training Center

Lube Oil System

Lubricate the bearings of the generator and steam turbine.

Removal of heat generated in the journal bearings by shaft rotation.

This is reached by the following:

Maintaining a constant lube oil flow and pressure.

Maintaining sufficient lube oil flow during emergency situations.

Providing a specific lube oil flow to each bearing.

Maintaining a constant lube oil temperature to consumers.

Cleaning lube oil.

Guiding lube oil to consumers.

Returning lube oil from consumers.

Deaerating lube oil returning from the consumers.

Storage of lube oil at sufficient temperature.

Therefore the following components are needed as a minimum:

Lube oil tank

Pumps (main, auxiliary, emergency)

Constant pressure valve

Supply lines and orifices

Instrumentation and controls

Power Plant Training Center

Lube Oil System

Lube Oil Tank

Power Plant Training Center

Lube Oil System

Oil Vapor Extractor

Lube Oil Pumps

Power Plant Training Center

Lube Oil System

Lube Oil Pumps (continued)

Figure 3: Gear Pump (Typical)

At low turning speeds during start-up,

Figure 4: Auxiliary Pump

Power Plant Training Center

Lube Oil System

Lube Oil Pumps (continued)

The emergency lube oil pump is a centrifugal, DC motor-driven back-up pump. It is

Figure 5: Emergency Pump (Typical)

Power Plant Training Center

Lube Oil System

Lube Oil Pressure Control

Figure 6: Constant Pressure Valve (Typical)

Power Plant Training Center

Lube Oil System

Lube Oil Temperature Control