NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A GOVERNMENT OF INDIA ENTERPRISE)

KUDANKULAM NUCLEAR POWER PROJECT NUCLEAR TRAINING CENTRE

TRAINING MANUAL ON
TURBINE LUBRICATION SYSTEM (MAV)

Document No: Prepared by Revised by Vivek Rathi Checked by

Rev number: Abid Hussain

Next rev due on Suresh Kumar

Issued By Rev date

CONTENTS
Sl No: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Index Introduction System Description List of Equipment Normal Operation of the System Operation Under Abnormal Conditions Backup System Requirements Technical Data Power Supplies Instrumentation Alarms And Actions Trouble Shooting Hazards And Precautions Maintenance References Page No: 1 1 2 2 2 3 4 4 4 6 7 7 7 7

1.

INTRODUCTION : The turbine generator lubrication system (MAV) is intended: To provide lubrication oil for turbine, generator and exciter bearings; For turbine generator emergency oil supply during failure of normal power supply; To prevent oil vapour egress from the oil tank and the bearing casings into the turbine hall.

2.

DESCRIPTION OF THE SYSTEM :

To supply oil to the turbine bearing lubrication system, two pumps driven by AC motors and one emergency pump driven by D.C. motor are installed. At normal operation one AC pump is running, the second pump is a stand-by. Oil is supplied by one pump from the oil tank through the oil coolers into the pressure header and from the header - to the bearings. Upstream of the discharge header there is a pressure regulating valve which maintains pressure at the level of the turbine axis as 0.12 MPa. Due to short-term operation (less than 1 hour) the emergency oil pump supplies oil to the oil pipeline downstream of the pressure regulating valve, i.e. downstream of the oil coolers, in order to reduce electric motor power consumption and capacity of the battery. After the bearings, oil flows by gravity to the discharge header and then into the oil tank. Cooling water is supplied to the oil coolers from the intermediate cooling loop system. To maintain constant temperature of oil supplied for lubrication, a control valve with control from the electronic temperature regulator (controller) is mounted at cooling water discharge from the oil coolers. Each oil cooler can be shut off from cooling water and oil supply lines for the purpose of cleaning and repair. For fire safety the fire-resistant oil is used in the system. Lube oil is purified by means of the following equipment: Two fine filters with continuous pumping through the filter (the second filter may be out of operation for cleaning) of a part of flow from the operating oil pump; or with pumping through by a special filtration pump (if the oil system is off) or when filling the lube oil tank; Two gauze rows mounted inside the lube oil tank; To diminish oil sludging in the pipes, oil supply and discharge headers are designed as filled with oil (not emptied when the lube oil system is stopped). Discharge header remains full at oil system shutdown due to hydraulic gate. Emptying the supply header is prevented by non-return valves (by two in series) installed at pressure side of each lube oil pump. For pump change-over (till the started pump reaches its full speed) and to prevent unfavourable consequences of the turbine running-down in case of total lube oil supply loss, each turbine set bearing is provided with an emergency reservoir with oil. The element MAV50001 in the lube oil system diagram is a hydraulic gate in the header of oil discharge from the bearings which prevents emptying the header and the delivery piping at shutdown (to exclude corrosion of the pipelines). To separate air dissolved in oil, an air separator is mounted in the tank. All equipment and piping, in which air may accumulate, have air release devices.

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The lines connecting the oil inlet header with the outlet header are just the small-diameter lines (NB 32), to which the transducers of the system of the lube oil standby pump automatic start-up and the transducers of turbine protection associated with lube oil pressure drop are connected. Closing the valve at oil inlet into this line and opening the outlet valve it is possible to decrease pressure to the transducers and to test the respective system by real pressure drop to make sure it is functioning properly. Oil vapours are removed from the bearing casings and the oil tank by a exhauster. Different to the other fire-resistant liquids used by other turbine manufacturers OMTI does not need regeneration during operation. 3. LIST OF EQUIPMENT Oil tank MAV10BB001; Oil pumps with AC motor MAV11AP001, MAV12AP001; Oil pump with DC motor MAV13AP001 (emergency); Oil pump for oil circulation and filtration MAV18AP001; Exhauster MAQ10AN001; Oil coolers MAV21AC001, MAV22AC001, MAV23AC001, MAV24AC001; Fine filters MAV16AT001, MAV17AT001; 4. NORMAL OPERATIN OF THE SYSTEM Lubrication oil system should be in operation from the beginning of the unit start-up to cooling-down of the turbine cylinders to 150C after the turbine trip (until the barring gear switch-off). During operation of the lubrication system one AC lubrication pump is switched on and delivers oil to the bearings. The other pumps are in reserve, they are ready to start. Oil vapour evacuation exhauster is also in operation. Operation without oil vapour exhauster is permitted for a limited time period required for its repair. In this case oil vapours are evacuated at the expense of natural draft in the vertical exhaust pipe. During start-up and shut-down of the Unit oil is supplied to the suction of rotor jacking oil pumps. In case of temperature rise of oil to the bearings up to 40C, a cooling water is supplied through the oil coolers. Oil temperature will be maintained automatically at this level by means of a control valve at cooling water discharge. At oil temperature in the tank of 60, as soon as water is lighter than OMTI, water will evaporate from the oil surface. In this connection short-duration water leakage in amount of 0.5 m3/h are permissible. However, for continuous operation it is not acceptable because ageing of oil will speed up. For continuous operation the leakage should not exceed 0.1 m3/h. 5. SYSTEM OPERATION UNDER ABNORMAL OPERATING CONDITIONS Pressure Drop in Lubrication System If oil pressure in the lubrication system drops down to the specified limit, a stand-by and an emergency lube oil pump come into operation automatically. If the reserve pump operates normally, the emergency pump is switched off by the operating personnel.

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Oil Temperature Rise In case of oil temperature rise above the specified limit, the temperature regulator is automatically disconnected from the control valve at cooling water line and the latter gets fully open. Oil Level Drop in the Oil Tank If the level of the oil in the tank drops, the system should be checked for leaks, and after attending the leaks when there is no oil leakage from the system, lubrication oil should be added into the tank during unit operation so that normal level is maintained. Clogging of Filter In case of differential pressure rise in the fine filters or at the gauzes inside the oil tank, the respective filter should be cleaned. Failure at Oil Pump Start-up If the operating pump is switched off and the reserve pump fails to start, the Unit is shut down. Loss in power supply to the reserve pumps with the running emergency pump should not exceed the specified time (20 s) in order to maintain capacity of the battery for turbine generator normal running-down. If the emergency pump also failed to start, automatic protection will trip the turbine with a time delay of 3s. Break of Lube Oil Piping Owing to usage of fire-resistant oil of OMTI type in the lubrication system, break of lube oil discharge piping does not result in intensive ignition and fire. Due to individual emergency reservoirs located in bearing covers, oil wedge pressure in bearings will not fall during turbine rotor running-down. Failure of Lubrication System Exhauster Start-up Operation without the exhauster is permitted during the limited time period required for repair. 6. BACK UP SYSTEM REQUIREMENT In case of failure of lube oil supply to bearings, emergency reservoirs located on the bearings supply oil to bearings.

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TECHNICAL DATA KKS code MAV10BB001 Name of equipment Lube oil tank Type, technical data V=70 m3 Qnty 1 Material Two-ply corrosionresistant steel Carbon steel, stainless steel, alloyed steel Carbon steel, stainless steel, alloyed steel Carbon steel, alloyed steel Mass of one piece, kg 16000

MAV11AP001 MAV12AP001

Oil pump with AC electric motor Oil pump with DC electric motor Oil filtration and circulation pump Exhauster

AMKB-500-35 Q=500 m3/h H=34 m w.c. AMKB-500-35 Q=430 m3/h H=20 m w.c. -40-4.1-19.5 Q=19.5 m3/h H=40 m w.c. B-14-46-4 Q=7000 m3/h H=150 mm w.c. M330-300-1 F=440 m2 Qw=300 m3/h Qoil=330 m3/h F=3.5 m2 Qw=20 m3/h

1460

MAV13AP001

1360

MAV18AP001

220

MAQ10AN001

Carbon steel, alloyed steel Carbon steel (shell), stainless steel (tubes) Carbon steel

90

MAV21AC001 MAV22AC001 MAV23AC001 MAV24AC001 MAV16AT001 MAV17AT001 7.

Oil cooler

4500

Fine filter

350

POWER SUPPLIES

Electrically (AC) driven components of MAV system receive power from the normal operation power supply system under all design operating conditions. In case of loss of normal operation power supply the lube oil pump AC motors (MAV11P001 and MAV12P001) get connected to the normal operation reliable (from the diesel-generator of the turbine hall) power supply system. The electric motor of the emergency lubrication pump (MAV13P001) is powered from the battery. 8. INSTRUMENTATION Control over motor-driven equipment and valves, supervision over position (status) of elements, monitoring process parameters, alarm and warning signalling as well as recording the parameters and events in the full scope for all operating modes are envisaged to be executed at Main Control Room.

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9.

PROTECTIONS AND INTERLOCKS

Interlock Description of interlocks and protections No.
MAV 1.1 MAV 1.2 Electric motor of the pump is powered from normal power supply with change-over to the diesel-generator in case of loss of normal power supply. The pump is started automatically: in case of pump MAV12AP001 trips either spontaneous or under action of motor protection, or in result of power supply loss. if pressure of oil for lubrication MAV30CP002 falls to limit 1 and with this either pump MAV12AP001 is in operation and the preset time has passed from the moment of its switching on (no more than 60 s), or any of the conditions listed in MAV 1.3. is available. BG motor is switched on; or there is no signal about closure of more than one HP stop valve; or the temperature of HPC outer surface at steam admission MAA10CT011 exceeds the preset value; or turbine speed MAX51CS001 is not equal to zero. From CCR it is possible to switch on the pump at any time and to switch it off if pump MAV12AP001 is in operation or if none of conditions of MAV 1.3. is available (i.e. at stand-still cold turbine). At short loss of AC power supply (no more than 3 s) automatic restarting (self start-up) of operating lubrication pump should take place. Power supply and control conditions are absolutely similar to those of pump MAV11AP001. To realize an interlock associated with pressure drop in lubrication system down to limit 1, a signal from pressure relay MAV30CP003 is used. Electric motor of the pump is powered from battery. The pump is started automatically if lube oil pressure falls to limit II MAV30CP004 and with this one of AC pumps (MAV11AP001 or MAV12AP001) is in operation or any of the conditions of MAV 1.3. is available. From CCR it is possible to switch on the pump at any time or to switch it off if none of above mentioned conditions (MAV 1.3) is available. If any of conditions of MAV 1.3. is available, the pump is allowed to be switched off manually provided that any one of AC pumps is in operation. If more than 20 sec have been passed from the moment of the pump switching on and any HP stop valve is not closed, the alarm at the CCR appears Electric motor of the exhauster is powered from power lines of normal power supplies Exhauster is switched on when switching on any of lubrication pumps and is switched off with a lag time of 15 min after all lubrication pumps have switched off (it is possible to take into account only AC oil pumps). Automatic commands for switching on/off are of pulse type, they do not prevent switching the pump on/off manually. If interlock of MAV 4.2.is enabled, operator's control over the exhauster from CCR is not provided. If control from CCR is provided, it should be possible to switch off/on the exhauster at any time. Electric motor of the exhauster is fed from normal power supplies At turbine operation the pump is used for periodical pumping of oil through the filter. Does not have control from CCR.

Equipment
Lubrication pump MAV11AP001

MAV 1.3

MAV 1.4

MAV 1.5 Lubrication pump MAV12AP001 Lubrication pump MVB13AP001 MAV 2.1

MAV 3.1 MAV 3.2

MAV 3.3

MAV 3.4

Exhauster of MAV 4.1 lubrication system MAVQ10AN00 MAV 4.2 1

MAV 4.3

Pump to fill MAV 5.1 and empty the oil tank MAV 5.2 MAV18AP001

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10.

ALARMS AND ACTIONS

Value and measur. unit Oper. Max Min. INFORMATION Indicat. Signalling. Place Mode Mode Preset (SCR, (ind., (ind., value & MCR, ICS, call) light directio etc) annum. n or ICS)
CCR Local Local CCR Local Local Local Local Local CCR CCR CCR Call ICS ICS ICS ICS ICS Ind. light (com.) Emerg. ICS 400 mm raise 0.07 MPa fall 0.03 MPa fall 45 raise 45 raise -

Parameter name

Marking

D at oil tank gauze of oil at lube oil pump discharge

400 mm 0 mm MAV11CP501 0.4 MPa 0.44 MPa MAV12CP501 0 MPa MAV13CP501 of oil ahead of oil MAV20CP501 0.4 MPa 0.44 MPa cooler 0 MPa of oil for MAV30CP001 0.12 0.13 MPa lubrication MPa 0 MPa P of oil for MAV30CP051 0.12 0.13 MPa lubrication MPa 0 MPa P of oil for MAV30CP002 0.12 0.13 MPa lubrication MAV30CP003 MPa 0 MPa MAV30CP004 of oil for MAV30CP502 0.12 0.13 MPa lubrication MPa 0 MPa of oil in lines to MAV30CP503 0.12 0.13 MPa pressure relays MAV30CP504 MPa 0 MPa MAV30CP504 of oil ahead of MAV30CP501 0.4 MPa 0.44 MPa reduction valve 0 MPa of oil ahead of MAV17CP501 0.4 MPa 0.44 MPa fine filter MAV18CP501 0 MPa P of cooling water PGB10CP501 0.5 MPa 0.55 MPa 0 MPa H of cooling water PGB20CG201 70% 100% control valve 0% of oil ahead of oil MAV20CT001 60 75 coolers 15 of oil after oil MAV21CT001 40 55 coolere MAV22CT001 15 MAV23CT001 MAV24CT001 of oil for MAV30CT001 40 50 lubrication 20 T of cooling water PGB10CT001 35 39 ahead of oil coolers 20 T of cooling water PGB11CT001 39 45 after of oil coolers PGB12CT001 20 PGB13CT001 PGB14CT001 L of oil in oil tank MAV10CL001 300 mm 1000 mm 0 mm L of oil in oil tank MAV10CL501 200 mm 1000 mm 0 mm

MAV10CP001 200 mm

CCR CCR CCR

ICS ICS ICS

ICS -

CCR Local

ICS -

ICS -

900 mm raise 100 mm fall -

11.

TROUBLE SHOOTING : Page 6 of 7

12. 13. 14.

HAZARDS AND PRECAUTIONS : MAINTENANCE : REFERENCE : DPR\3_1.10

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