MAN Turbo

Product Training

Lube Oil
System

MAN Turbo AG

GF14

16-Jun-09

< 1 >

Lube oil system

Location

On / in GT
baseframe
Within enclosure
on the suctionside
z exception:
oil cooler

MAN Turbo AG

GF14

16-Jun-09

< 2 >

Lube oil system

Function

Lubricate and cool

z GG and PT plain
bearings
z bearings of the
power consuming
machine

MAN Turbo AG

GF14

16-Jun-09

< 3 >

Lube oil system

Lube oil requirements

Exclusively mineral oil

Initial filling of the lube
oil tank by MAN Turbo
AG with Mobil DTE 846
ISO VG46

Warning

Observe always our lube

oil specification
Any variation of the type
of oil used must first be
agreed with MAN Turbo
AG.
Observe preservation
measures in case of
longer shutdowns
MAN Turbo AG

GF14

16-Jun-09

< 4 >

Lube oil system

Main components

Oil tank integrated in

the GT baseframe
Three lube oil
pumps
One oil cooler

One dual oil filter

One oil demister
One temperature
control valve
Two pressure
control valves

Components of the lube oil system

1 Dual oil filter
4 Filler nozzle

2 Lube oil pumps

5 Lube oil heaters

3 Oil demister

Instruments for
monitoring pressure,
level, temperature
MAN Turbo AG

GF14

16-Jun-09

< 5 >

Lube oil tank

Location
z integrated in the
GT baseframe
Function
z total volume
greater than the
permissible
volume of oil
charge
to permit the
oil to expand
during
operation,
to ensure
effective
degassing

Components of the lube oil system

1 Dual oil filter
4 Filler nozzle

MAN Turbo AG

2 Lube oil pumps

5 Lube oil heaters

GF14

3 Oil demister

16-Jun-09

< 6 >

Lube oil tank

Technical data

Max. Operating Capacity:

z 8,5 m3
Normal Operating Capacity:
z 7,5 m3
Min. Operating Capacity:
z 6,5 m3

MAN Turbo AG

GF14

16-Jun-09

< 7 >

Lube oil tank

Operation
z inside the tank
perforated sheets
to remove the air
trapped in the oil
arranged at oil
return line.
z baffle plates
welded inside
increase dwell
time of the
returned oil
z guarantee that
the total volume
of oil is used for
lubrication.

Components of the lube oil system

1 Dual oil filter
4 Filler nozzle

MAN Turbo AG

2 Lube oil pumps

5 Lube oil heaters

GF14

3 Oil demister

16-Jun-09

< 8 >

Lube oil tank

Operation
z manholes used for
inspecting or
cleaning
z filler nozzle
also to take oil
samples,
z nozzles for measuring
oil temperature and
oil pressure and for
checking the level,
z boreholes for

accommodating pumps.
z oil drain connection in
the lower part of the
tank.
MAN Turbo AG

GF14

16-Jun-09

< 9 >

Lube oil heaters

Location
z electrical
heaters
installed
horizontally
in the GT
baseframe or
lube oil tank
Function
z heat oil to
required
minimum
temperature
before start
up

Components of the lube oil system

1 Dual oil filter
4 Filler nozzle

2 Lube oil pumps

5 Lube oil heaters

MAN Turbo AG

GF14

3 Oil demister

16-Jun-09

< 10 >

Lube oil heaters

Main parts
z connection head with integrated
temperature controller and limiter,
z heating bundle with flange.
Operation
z to inspect the heating bundle for deposits,
heating bundle can be removed from the

Tank heater wiring diagram

TB = temperature limiter

TR = temperature controller

casing without having to drain off the oil.

z temperature sensor can be removed
from the protective tube
extends into the heating bundle
without having to dismantle the heater.

Tank heater terminal housing

1 Power terminal
3 Temperature limiter

MAN Turbo AG

GF14

2 Temperature controller
4 Control terminal

16-Jun-09

< 11 >

Lube oil heaters

Operation
z temperature controller in connection
head of the heater
to heat the oil to the start-up
temperature
z temperature limiter
to switchoff when at maximum
permissible oil temperature

Tank heater wiring diagram

TB = temperature limiter

TR = temperature controller

Tank heater terminal housing

1 Power terminal
3 Temperature limiter

MAN Turbo AG

GF14

2 Temperature controller
4 Control terminal

16-Jun-09

< 12 >

Lube oil heaters

Note

Temperature limiter is not re-activated

automatically
z after being triggered as a result of over
heating
Tank heater wiring diagram

Do

TB = temperature limiter

TR = temperature controller

z reduce average temperature by

approx. 10 C
z eliminate the cause of the fault,
z re-activate limiter manually by pressing
limiter button

Tank heater terminal housing

1 Power terminal
3 Temperature limiter

MAN Turbo AG

GF14

2 Temperature controller
4 Control terminal

16-Jun-09

< 13 >

Lube oil heaters

Warning

Heaters may only be operated with a full tank

To avoid overheating and damage to the heating element
Do not
z temperature controller turn beyond scale range
to prevent the release of the temperature limiter.

MAN Turbo AG

GF14

16-Jun-09

< 14 >

Pumps
Main lube oil

Location
z mounted in the front region of
GT baseframe and feed the
oil through a suction pipe out
of the tank to the bearings.

Function
z displacement screw pumps
z feed oil through a suction
pipe out of the tank into the
supply line

Main lube oil pumps P121 and P122

MAN Turbo AG

GF14

16-Jun-09

< 15 >

Pumps
Main lube oil

Operation
z during various operating phases only
one pump is running
start-up,
shutdown,
load operation,
re-lubrication phase,
z pumps used alternately
with next start the previously not

used pump will be switched on

MAN Turbo AG

GF14

16-Jun-09

< 16 >

Pumps
Main lube oil

If pressure drops
z second main lube oil pump is automatically activated
z originally operating pump is switched off
If AC supply fails
z emergency lube oil pump is switched on
z to guarantee oil supply during the subsequent automatic
shutdown process.
z load operation with emergency lube oil pump is not
possible.
Safety valve at each pump.
z if pressure too high,
z returns lube oil to lube oil tank to protect the pump.

MAN Turbo AG

GF14

16-Jun-09

< 17 >

Motors
Main lube oil pumps drive

Operation
z three-phase AC motors
z connected to pump via
elastic coupling

MAN Turbo AG

GF14

16-Jun-09

< 18 >

Pump
Emergency Lube oil supply

Location
z installed at the front baseframe
Function
z if main lube oil pumps or AC supply
fails
supplies oil through suction pipe
out of the tank and into supply line
protects the bearings against
damage

Operation
z displacement screw pump
z fed from a reliable electricity supply
z safety valve at the pump
if pressure is too high lube oil is
returned into lube oil tank
MAN Turbo AG

GF14

16-Jun-09

< 19 >

Motor
Emergency Lube oil pump drive

Operation
z connected to pump via an
elastic coupling.

MAN Turbo AG

GF14

16-Jun-09

< 20 >

Cooler

Location
z piping to the oil
cooler at front side
of baseframe
Function
z installed upstream
of the dual oil filter
z cools the oil
supplied via the
temperature control
valve
Main components
z heat exchanger and
z AC fans
fans individually
switched on
MAN Turbo AG

GF14

16-Jun-09

< 21 >

Motors
Oil cooler fans drive

Location
z outside sound enclosure

MAN Turbo AG

GF14

16-Jun-09

< 22 >

Dual oil filter

Location
z behind the temperature
control valve in the supply
line
z in the front area of the GT
baseframe
z access through door in the
acoustic enclosure

MAN Turbo AG

GF14

16-Jun-09

< 23 >

Dual oil filter

Function
z guarantees that only
filtered oil enters the
bearing regions
z dual oil filter is installed
In order to change the
filter
z differential pressure
monitored by
differential pressure

manometer
differential pressure
sensor.

Dual oil filter

1
3
5
7

Pressure equalisation valve

Ventilation
Change-over lever
Clean oil discharge

MAN Turbo AG

GF14

2 Manometer
4 Filter cartridge
6 Contaminated oil discharge

16-Jun-09

< 24 >

Dual oil filter

Operation
z without interrupting through
change-over valve
z filter change during operation
vent valve at each filter

and
drainage valve.
pressure equalization
after filter change

Dual oil filter

1
3
5
7

Pressure equalisation valve

Ventilation
Change-over lever
Clean oil discharge

MAN Turbo AG

GF14

2 Manometer
4 Filter cartridge
6 Contaminated oil discharge

16-Jun-09

< 25 >

Oil demister

Location
z within the GT
enclosure
z on the left-hand
side in the area
of the power
turbine
Main components
z side-channel fan
z filter casing
z filter cartridge.

MAN Turbo AG

GF14

16-Jun-09

< 26 >

Oil demister
Function

Side-channel fan generates

vacuum in filter housing

Air containing oil mist sucked in

from oil tank.

Air flows through the standpipe

in the intermediate area of the
filter casing

Through the filter cartridges

from inside to outside

Separated oil is drained out

z along the outer surface of the
filter cartridge
z flows back into tank

Oil demister
1 Motor
4 O-ring
7 Drain

MAN Turbo AG

GF14

2 Manual inlet valve 3 Side-channel fan

5 Filter casing
6 Filter cartridge
8 Manometer
9 Stand pipe

16-Jun-09

< 27 >

Oil demister
Function

Manually operated valve to control the

inlet air is
z fully open
z cannot be adjusted.
!

Warning

Inlet valve position is set during

commissioning

Do not
z change to prevent switch-off of the
installation
z as a result of a non-permissible tank
vacuum.

Oil demister
1 Motor
4 O-ring
7 Drain

MAN Turbo AG

GF14

2 Manual inlet valve 3 Side-channel fan

5 Filter casing
6 Filter cartridge
8 Manometer
9 Stand pipe

16-Jun-09

< 28 >

Motor
Oil demister fan drive

Location
z installed on filter
housing cover of
demister

Operation
z AC motor for
side-channel
fan.

Components of the lube oil system

1 Dual oil filter
4 Filler nozzle

2 Lube oil pumps

5 Lube oil heaters

MAN Turbo AG

GF14

3 Oil demister

16-Jun-09

< 29 >

Temperature control valve

Oil header temperature

Location
z outside the enclosure
z in supply line in front of
oil cooler

Function
z the 3-way valve

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 30 >

Temperature control valve

Oil header temperature

Operation
z rapid heating
during the first

minutes of operation
through cooler
bypass function.
z constant oil temperature
during operation
by conveying oil
through cooler

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 31 >

Temperature control valve

Oil header temperature

Operation principle
z with wax expansion
elements and
z exhibits a proportional
control action.
z temperature range of
control element is
selected in accordance
with ambient
temperature in the place
of installation

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 32 >

Temperature control valve

Oil header temperature

Operation details
z if oil temperature is
above temperature
range
connection marked
B fully is closed
connection marked
C is opened
total oil volume
passes through oil
cooler.

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 33 >

Temperature control valve

Oil header temperature

Operation details
z if oil temperature is
below temperature
range
connection marked
C is fully opened
connection marked
B is closed.
total oil volume does
not pass through oil
cooler,
but directly to dual
oil filter

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 34 >

Temperature control valve

Oil header temperature

Operation details
z if oil temperature is
within temperature range
connection marked
C opens to the
same extent as
connection B
closes
uncooled oil is mixed
with the cooled oil

T e m p e r a t u r e c o n t r o l v a lv e
A to o il filte r
1 C o n tr o lle r e le m e n t

MAN Turbo AG

GF14

B fr o m p u m p
2 C o n tr o lle r e le m e n t

C v o m K h le r

16-Jun-09

< 35 >

Lube oil system

Operation

Check of oil temperature in the

tank during start-up sequence
z if temperature too low, the
lube oil heaters activated
and
z start-up sequence
interrupted
z heating up the large oil
volume can take a few
hours
Testing of pumps and switch
on main lube oil pump
z that was not in operation
during the previous
operating phase.
Temperature control valve TCV
Dual oil filter
MAN Turbo AG

GF14

16-Jun-09

< 36 >

Lube oil system

Operation

Two oil pressure control

valves PCV
z normal operation PCV127
continuously reduce
approx. 25% of oil volume.
z during the re-lubrication
phase or in the event of the
failure of the AC voltage
supply PCV124 activated,
lower lube oil header
pressure is sufficient.

MAN Turbo AG

GF14

16-Jun-09

< 37 >

Lube oil system

Operation

Lube oil return

z Under gravity
back into the
lube oil tank
z Through a
common
header
manifold
z Oil demister
filters out large
amount of air

MAN Turbo AG

GF14

16-Jun-09

< 38 >

Lube oil system

Post-lubrication phase

After switching off lube

oil is fed to the
bearings for several
hours in order to
dissipate the heat.
Prevents a
carbonization of the oil
in the area around the
bearings.

MAN Turbo AG

GF14

16-Jun-09

< 39 >

Lube oil system

Instrument frame

Monitoring instruments
z manometer,
z pressure switch and
z pressure sensor
Housed at the front
right-hand side of a
frame within enclosure.
Manometers can be read
off through the glass
panel of the enclosure
door

MAN Turbo AG

GF14

16-Jun-09

< 40 >