TG Lube Oil Flushing

Jindal Power Limited
O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department
Project OPJSTPP (4X600 MW), Tamnar

Procedure for Lube Oil & Jack Oil
Procedure
system flushing & commissioning
Purpose of Document For Execution/Information
Document No. JPL Reference No: Turbine/Comm./016
Prepared By - Reviewed By -
Rev No. 00
Dtd: Commissioning Commissioning Project
Name
Sign
Approved By :
HEAD – Steering Committee
Copy No:
Issued To:
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of
Stage II: (4X600 MW) Turbine/Comm./016
Plant Area: Turbine
Procedure for Lube Oil & Jacking Oil system flushing & Commissioning
SLNO
1.0 PLANT DETAILS

2.0 OBJECTIVE
3.0 PROPOSAL
4.0 SERVICES REQUIRED
5.0 SAFETY PERECAUTIONS
6.0 EMERGENCY PROCEDURE
7.0 STAE OF THE PLANT
8.0 TEST METHOD
9.0 COMPLETION CRITERIA
10.0 APPENDICES
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Plant Area: Turbine
SLNO STATUS
1.0 PLANT DETAILS:
1.1 a) BEARING OIL:
1.1.1 AOP 2 Nos. and EOP one No.
1.1.2 Oil Tank to hold the oil.
1.1.3 Coolers 2 Nos to cool the oil, one working and the other standby.
1.1.4 Duplex filter in the oil line to thrust bearing, one for service and the other
is standby.
1.1.5 Throttle to regulate the oil pressure in Lub oil header.
1.1.6 Throttles at the entry to each bearing, to regulate the oil flow to the
bearings.
1.1.7 Required instrumentation.
1.2 b) JACK OIL:
1.2.1 Jack oil pumps AC 2 Nos.
1.2.2 Jack oil pumps DC 1 No
1.2.3 Relief valves.
1.2.4 Pressure regulating valve
1.2.5 NRVS in lines going to the bearings, with isolating valves.

Required instrumentation.
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SLNO STATUS
2.0 OBJECTIVE:
To flush the complete lube oil and jacking oil system to remove
mechanical impurities, dirt, welding slag etc. by circulating
approximately 150% of service oil flow rate at an temperature
above the normal operating conditions of plant.
3.0 PROPOSAL:
To meet the above objective following techniques shall be

ensured.
a) Card Board Bursting of entire pipe lines.

b) High flow velocities during initial flushing cycles
achieved by removing orifices, filter elements &
bypassing coolers.
c) Heating up of oil: Oil is heated up to 65c-70c & it is

achieved by .
1) Pressure generations of the running pumps.

2) Flow resistance during flushing.
3) Switching on centrifuges
4) Switching on additional heaters if required.
d) Temperature change during flushing: By heating the

oil to 65 - 70c & then cooling the entire oil volume
to 40 c approx two to three times in 24 hours
operations.
e) Knocking at the pipe lines: By using suitable hammers
during flushing cycles.
f) Filtering out the impurities : With the help of strainers
provided in MOT ,duplex filters & operating centrifuges
Continuously.
4.0 SERVICES REQUIRED:
1. Manpower with required tools for attending to any leak, cleaning the
oil filter and to adjust throttles.
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2. Operating personnel to co-ordinate the activities.
3. Power supply for the pumps.
4. Lighting arrangement for oil tank and other operating floors.
5. Portable fire fighting equipments in all the floors.
6. Centrifuge for cleaning the oil.
7. Flushing oil quantity (estimated) =40 Cu.M.(tentative, actual

quantity will be estimated at site) Properties of oil should be
compatible with regular operation oil.
8. Availability of laboratory facilities for analysis of Oil samples.
9. Availability of service Air for filters cleaning.
10. Availability of Communication facility at flushing area.
11. The temporary pipes, which are included in the process, are of same
size as main pipes and are separately cleaned mechanically (using
wire brush and compressed air) before their installations.
12. Fabrication and erection of the system is completed as per drawing.
13. Cooling water to Oil cooler available for temperature
change.operation during Oil flushing.
14. Oil coolers inspected through oil line connection and, if required, the
same shall be cleaned before starting of flushing.
15. Temperature indicators before and after oil cooler are made
available for Oil as well as cooling water.
16. Before filling the oil in Main oil tank (MOT), the tank is cleaned
carefully.
17. All C&I installation and calibration of Oil tank level indicators,
level switches etc. completed before Oil filling.
18. Visual inspection carried out to check cleanliness of the interior
of the fire resistant oil tank.
19. Vapour extraction system with vapour extraction fan is available
for operation.
20. All the filter elements in the system, other than the tank filters are
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removed before initial flushing.

21. The necessary by pass work as per scheme enclosed carried out
and the correctness of looping checked.
22. Insulation of Turbine & piping nearby pedestals shall be
completed and TG floor, Oil Tank & flushing area completely
cleaned
23. All pumps (AOPs & JOPs) shall be available.
\ 24. Oil in the tank is filled to the required level
25. All bearings are Boxed up.
5.0 SAFETY PRECAUTIONS:

1. Display of Board “No cutting / welding” at all floors and near Oil
Tank, Oil Coolers etc.
2. Debris in all the floors shall be removed.
3. Debris in and around oil systems and MOT (Main Oil Tank) floor
to be removed.
4. Approach / Stair Case / Platform wherever required are
made available.
5. Sign boards to be displayed at strategic location to indicate that
Oil System is charged and oil pumps are ‘ON’.
6. Welding / cutting shall not be carried out in flushing area.
Load on pumps shall not exceed full load current of the motor.
6.0 EMERGENCY PROCEDURE:

First Aid kit shall be made available.
The operating personnel shall know well about the procedure of pump and
the system.
They shall be in a position to intimate to shift In charge incase they are
unable to tackle any eventuality.
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SLNO STATUS
7.0 STATE OF THE PLANT:
1. All erection activities in lube oil, control oil, jacking oil, oil
purification circuit should be completed. CARD BOARD
BURSTING of oil lines have been completed as per
procedures annexed.
2. Temporary supports should be removed. & arrangements made
for knocking at the pipe lines in order to loosen the impurities
adhering to the walls & have them discharged with the flows
3. AOPs (Auxiliary Oil Pump) and jacking oil pumps are available
for running.
4. Oil Purification System should be available for operation.
5. Service air should be available near filters for cleaning of filters.
6. Cooling water at oil cooler should be available.
7. All temporary loops are made as per schemes given in this
procedure.
8. Waste oil system piping should be completed.
9. A telephone should be available near by and the telephone
numbers of hospital, ambulance and fire brigade is displayed.
10. Fire fighting equipments shall be made available.
11. The operating personnel shall be aware of the procedure.
12. Provision for emergency stopping of oil pumps from Local /
Main Control Room has to be made.
13. Sufficient quantity of safety appliances such as helmets, face
mark, hand gloves, Crum boots, Apron, nose breather are made
available for use at site.
14. The team for this operation shall be aware of this procedure for
oil flushing and shall act at the time of any emergency.
15. The team should be aware of first aid to be followed in case of
accident involving injury to personnel.
16. The team should be aware of operating procedures of fire
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extinguisher to be used for quenching minor oil fires.

17. The team should be aware of restarting the operation in case of
system stoppage due to failure of power supply.
METHOD:
8.0 Preparation
a. Oil throttle internals in oil supply line to bearings are to be removed
and are provided dummy plates on top of the throttle body. These
dummy plates are provided with oil flushing material.
b. Oil throttle before oil coolers need not to be removed, also provide a
temporary pipeline between inlet and outlet of the cooler.
c. Duplex filter elements provided in the supply line to thrust bearing are
to be removed. These elements are to be put back in position during
the final stage of flushing.
d. The regular adaptors in the bearing pedestals for supply are replaced
with flushing device so that oil is deflected to bearing-to-bearing
pedestal instead of going to the bearings.
e. MOP (Main Oil Pump) is to be completely removed and a flushing
device is to be placed in position.
f. Blind flange dummy is to be provided at flange as indicated in the
scheme in section 3.11.
g. The jacking oil pumps are disconnected at the discharge flanges of the
pumps and rotates as required and oil supply pipe to be connected
through a temporary valve (of high pressure duty) to the dummy flange
in the AOP discharge header.
h. The header of the jacking oil supply line has a dummy flange at the
exciter side. From this a temporary connection is run to the oil return
pipe blank flanges of flushing, with an isolating valve.
i. Pressure regulating valve of JOP (Jacking Oil Pump) discharge line to
be removed and spool piece to be erected for connecting JOP
discharge header and relief drains is to be blanked.
j. The hose connections of JOP lines inside the bearing pedestals are
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removed at the bearing end and left in the pedestals it.

k. The internals of non-return valves provided in individuals jacking oil
line of the bearings may be removed. Internals of combined discharge
and non-return valve in the JOP discharge line is to be removed.
l. Remove the turning gear nozzle box and provide a flushing device in
its place before boxing up the pedestal.
m. Adequate quantity of cooling water must be available for oil coolers to
reduce oil temperature during the process of temperature change.
n. The necessary permanent dirty oil drain tank must be made available
for accepting the full charge of oil.
o. Arrangement for analysis of oil sample after the flushing must be
made. The sample may be taken for checking mechanical impulses.
Flushing Lube Oil Lines

a. Trial run of Vapour extraction fans should be completed.
b. First charging of oil system is to be done by running the EOP in order to
avoid any excessive oil spillage during first charging as discharge pressure
of EOP is lower than that of AOP. Ensure proper venting from all available
vents in the system.
c. For initial oil flushing the Lub oil cooler should be bypassed connection
provided for this purpose to be used. This will prevent the dirt of lines from
entering in the cooler. The duration of oil flushing can be decided
observing, the main oil tank filter. Normally 2-3 days flushing should be
sufficient, after these connections to be normalized (take oil cooler in
service
d. Once oil system in completely filled up and all leakages are attended, AOP
is to be run for further flushing operations.
e. Manual tapping / hammering of oil lines to be done continuously during the
heating / cooling periods. Hammering to be done on the complete length of
the pipes.
f. Filters in MOT are to be cleaned regularly, during the oil flushing.
g. Oil purification Unit is to be run continuously.
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h. After initial cleaning of oil lines, throttles in the oil supply line to bearings
are to be put in position. Oil flushing should then be continued for some
bearing at a time (keeping the throttles full open condition and closing the
throttles of the remaining bearings), therefore, ensuring flushing with
maximum possible flow in the oil return lines.
i. The flushing operation is to be continued by undertaking the above
exercise in rotation so that bearing oil supply lines are thoroughly flushed.
j. Turning gear line is to be flushed by opening the gate-gearing valve in such
a way that AOP motor does not get overloaded. This should be done daily
once for ½ hour.
Jacking Oil Lines:
a. The jacking oil system flushing can be started after initial dirt / muck
of Lube oil system is cleared.
b. Oil flushing is done by using the temporary connection from AOP
discharge header.
c. Initially the jacking oil header is to be flushed by using the
connection i.e. from header dead end to drain header.
d. After using above circuit for about sometimes the above connection
is to be closed and then the lines to the individual bearing are to be
flushed, say 2 or 3 lines at a time for effective flushing.
Restoration Of The System:
a. On completion of flushing, hydraulic test of the system is to be done.
Then the system is normalized.
b. When the oil is drained into the drain tanks provided, the drain tank,
which accepts oil, must be clean. The oil contained in the system,
main oil tank and oil coolers are to be completely drained using
purifier & MOT drain lines.
c. The MOT (Main Oil Tank) is carefully cleaned and inspected as
done earlier before flushing. Jacking oil lines are to be normalized.
d. The cooler tube nest should be withdrawn for inspection and
cleaning of the coolers should be done. Taking care so that O-rings
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are protected. It is done to remove entrapped dirt particles in tube

nest during flushing operation.
e. All bearing pedestals are to be cleaned thoroughly before boxing up
the pedestals.
f. All temporary arrangements must be removed / normalized.
g. All bearing pedestal connections should be normalized. Turbine
bearings should be normalized.
Normalization of Jacking Oil Lines
a. Check NRV flaps are back in position.
b. Normalize the pipelines with the jacking oil pump discharge
c. Check pressure-regulating valves has been serviced and it is in low-

pressure position (released condition).
Normalization of Lube oil & Control oil system
a. Put plugs in the relief holes of oil throttles and put the throttles in full
close position.
b. Provide dummy at the last flange joint available in the permanent
piping, before it is connected to the drain in the oil canal.
c. Make a connection from jacking oil header supply line to the Lube
oil circuit as marked in the drawing given in this procedure.
d. Close the valves wherever the valves are located at the end of
pipeline.
After hydraulic test drain the system & normalize system. On filling the
Fresh oil start system commissioning.
9.0 COMPLETION CRITERIA

a. The oil analysis of sample drawn from oil purifier inlet should not
have any mechanical impurities and moisture. Main oil tank bucket
filter should be in clean condition over a period of 24 hours.
b. Duplex filter element should be free from impurities such that no
chocking of filter should be experienced in duration of 24 hours.
c. Bearing Line filters are to be installed and flushing carried out for 24
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hours and no accumulation of dirt should be observed.

d. All criteria to be met for declaring the oil flushing completion.
A NOTE ON SYSTEM COMMISSIONING

On filling the Fresh oil start system commissioning.
1. Start main oil tank vapor fans from control system and record
observations
2. Commission Oil purifier and record observations
3. Before starting the Auxiliary Oil Pump, place persons in strategic
locations for observing leaks.
4. Start Auxiliary Oil Pump from control room and establish header
pressure.
5. Adjust lube oil throttles in the oil inlet lines as per design flow
requirements of individual bearing as per O&M instructions supplied
by designer.
6. Check for oil flow through the sight glass at all consumption points
7. Stop AOP
8. Start EOP from control system and establish header pressure Record
observations.
9. Check status of pressure switches.
10. Stop EOP and start AOP
11. Check Auto Start of EOP with interlock of pressure switches Check
feedback of thermocouples
12. Lube oil system ready and functional with AOP available for operation.
13. Control & signal cable loop checks completion done
14. Release JOP discharge header pressure relief valve completely
15. Run AC Jacking Oil Pump from control room
16. Adjust relief valve to establish Jacking Oil Pressure at 150 kg/cm2
17. Check status of pressure switches
18. Run the pump for 4hrs and record data
19. Stop AC Jacking oil pump
20. Start second Jacking Oil Pump from control room.
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21. Run the pump for 10 Minutes and record observations

22. During the first charging of oil system oil spill may happen due to
improperly tightened pipe joints, uncovered openings or flooding of
pedestal.
23. Before starting the oil pump, the system shall be checked for flange
tightness and correct valves line up.
24. Place persons in strategic locations for observing oil leakage before
starting the pump.
25. Funnels connected with hosepipes, empty buckets and empty drums
shall be used for collecting any drip.
26. Spraying fine sand over the spill and removing the sand after oil
absorption will clean oil drip on the floor.
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10.0 APPENDICES:
(a) Schemes
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OIL FLUSHING OF LUBRICATION AND CONTROL OIL SYSTEM
CONTROL OIL/PRIMARY OIL FLUSHING ARRANGEMENT
A-FLUSHING PIECE OF MOP

B-PEDESTAL ONE
C-CONTROL OIL TO RACK
D-PRIMARY OIL TO PEDESTAL
E-PRIMARY OIL FROM PEDESTAL
F- TEST OIL TO OS BOLTS
G-TEMPORARY PIECE
A H-BRG.1 LUBE OIL DRAIN LINE
J- RACK END
D
E F
J G
H
Sheet 2
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(b) WORK PLAN:
a. Commissioning of oil Vapour extraction fans

b. Commissioning of purifier
c. Commissioning of EOP
d. Commissioning of AOP 1&2.
e. Commissioning of JOP 1 & 2
f. Flushing through all loops as per enclosed sheets by passing coolers
g. Commissioning of the Lube oil system
h. Commissioning of the JOP system
(c) INPUTS SUMMARY TO START CYCLE
1. Completion of oil pipe lines maintaining cleanliness as per directives

2. Completion of temporary pipe loops as per flushing scheme
3. Preparedness of brg. Pedestals for oil flushing
4. Completion of filling as per scheme
5. Completion of C & I tapping points (TWs, ROOT VALVES ETC.)
6. Availability of power for AOP1, AOP2, JOP1, JOP2, EOP, Oil Vapour fan 1& 2, purifier.
7. Availability of aux. Stem
8. Availability of cooling water to cold water cooler with design flow /temp
9. Availability of pressure & temp. Gauges as per scheme
(d) Other plans:

1. Oil draining arrangement
2. Proper gangs distribution & availability
(MOT, Piping, Pedestal work C&I WORK).
3. Sequential erection of activities as per agreed schedule for –
a. Bearing Bottom halves work completion
b. Rotor zero position
c. MOP work
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d. Bearing Top halves work & pedestals box-up

e. SOP system readiness.
f. End shield mounting
g. MOT work
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(e) Test report format
Schedule of Check Lists for Lube Oil System and jacking oil system
Sl. Check list Description

No.
1 STG-LO-01 Installation of orifices
2 STG-LO-02 Installation of devices
3 STG-LO-03 Calibration of devices
4 STG-LO-04 Main Oil Tank Readiness
5 STG-LO-05 Turbine Oil Sample Results
6 STG-LO-06 Oil vapor fan commissioning
7 STG-LO-07 Oil Purifier Commissioning
8 STG-LO-08 Auxiliary Oil Pumps commissioning
9 STG-LO-09 Oil flow through sight glasses
10 STG-LO-10 Oil System Alarm Schedule
11 STG-LO-11 EOP (Emergency Oil Pump)
12 STG-LO-12 Feed back of thermocouples
13 STG-LO-13 Temperature control valve
14 STG-JO-01 Installation of devices
15 STG-JO-02 Calibration of devices
16 STG-JO-03 AC JOP Motor commissioning
17 STG-JO-04 AC JOP commissioning
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Checklist STG-LO-01
INSTALLATION OF ORIFICES
Date:
SL Orifice Identification Orifice Diameter. Orifice Installed
No (Yes/No)
1
2
3
4
(Pl refer PIDs oil system supplied by HWR)
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Checklist STG-LO-02
INSTALLATION OF DEVICES
Date:
SL. Tag No Description Installed
No. Yes/No
1. 37 micron filter cartridges in LO
2. 37micron filter cartridges IN JO
3. MOT level indicator
4. MOT level high switch
5. MOT level low switch
6. AOP discharge pressure indicators
7. DC LOP discharge pressure indicator
8. Lube oil inlet to cooler1 local temperature indicator.
9. Lube oil inlet to cooler 2 local temperature indicators.
10. Lube oil outlet from cooler 1 local temperature indicator.
11. Lube oil outlet from cooler 2 local temperature indicators.
12. Lube oil temperature after cooler - temperature element
13. Differential pressure indicator for lube oil filters
14. Differential pressure switch for lube oil filters
15. Lube oil header pressure indicator
16. Lube oil header pressure transmitter
17. Lube oil header pressure low – switch
18. Lube oil header pressure low-low – switch
19. Lube oil header pressure low-low switch
23. MOP discharge header pressure low - switch
24. MOP discharge header pressure indicator
25. MOP suction pressure – indicator
26. Lube oil pressure to thrust bearing - indicator
27. Lube oil pressure to turbine bearing 1 – test indicator
28. Lube oil pressure to turbine bearing 2- test indicator
31. Return oil temperature indicator – bearing 1 pedestal
38. Lube oil pressure test indicator exciter rear bearing
Refer for Tag no, set points & other details :INSTRUMENT LIST
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Checklist STG-LO-03
ON SITE CALIBRATION OF DEVICES
Date:
Sl. no. Device Tag no Range / Set Checked OK /
Point NOT OK
1. MOT level indicator
2. MOT level high switch
3. MOT level low switch
4. AOP discharge pressure indicators
5. DC LOP discharge pressure indicator
6. Lube oil inlet to cooler local temperature
indicator.
7. Lube oil inlet to cooler local temperature
indicator.
8. Lube oil outlet from cooler local
temperature indicator.
9. Lube oil outlet from cooler local
temperature indicator.
10. Lube oil temperature after cooler -
temperature element
11. Differential pressure indicator for lube oil
filters
12. Differential pressure switch for lube oil
filters
13. Lube oil header pressure indicator
14. Lube oil header pressure transmitter
15. Lube oil header pressure low – switch
21. MOP discharge header pressure low –
switch
22. MOP discharge header pressure indicator
23. MOP suction pressure - indicator
24. Lube oil pressure to thrust bearing –
indicator
25. Return oil temperature indicators
26. Oil pressure to barring gear – indicator
27. Oil pressure to barring gear low – switch
Refer for Tag no, set points & other details :INSTRUMENT LIST
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Checklist STG-LO-04
MAIN OIL TANK READINESS
Tank Description: Main Oil Tank

P&ID Number:
Fluid Stored: Turbine Oil
Capacity: --m3 Date:
No Description Result Remarks
1. Check identification agrees with details on drawing no.

Tag Number
Title
Capacity
2. Check that access is safe for operational purposes.
3. Check that tank and nozzles correctly fabricated as per
approved drawing
4. All appurtenances (such as strainers, level gauges, valves,
vents and drains) are connected properly.
5. The interior of tank is clean and free from all loose scale,
sand and debris.
6. Tank painted internally and externally as per specifications
7. Ladder is installed- if applicable
8. All manhole covers and flanged joints are made up complete
with gaskets and bolts tightened.
9. Commissioning of Level instruments including Indicators as
per check list
10. Tanks drain valve locked / closed.
11. Fire detection & Protection system for the Tank ready – if
applicable
12. Earthling Connection for tank done
Tank is ready for receiving the fluid
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Checklist STG-LO-05
LUBE OIL SAMPLE TEST RESULTS

Grade: Servo prime 46 or Turbine oil 46
Sample taken on:
Sample taken from:
Size of sample:
Tested at:
Results received on date:
Sl No Test Unit Desired value Test Value Remarks
1 Kinematic viscosity at CST 41.4 – 50.6

40degC
2 Water Content Gm/100 gm 0.1
3 Solid content gm/100gm 0.05
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Checklist STG-LO-06
OIL VAPOUR FANS COMMISSIONING
Equipment tag number. ……………………………

System Description………………………….
P&ID No………………………..
Manufacturer’s Name. ………………………………
Name Plate details ……………………………………
Date
Sl. No Description Remarks
1 Bearing lubricated as recommended

2 Rotor free in its bearings
3 Review motor winding insulation resistance values
4 Check Motor earthling
5 Power supply switchgear checked and ready for
charging
6 Cabling completed
7 Fan bumped and rotation proved
8 Instrumentation & protection devices checked
9 Holding-down bolts fitted securely
10 Demister drain provided (Yes/No)
Fan is ready for commissioning

Oil Vapor Fan Trial Data
TIME
DATA UNIT
Motor Current Amps
Vibration at Microns /
Motor CE mm/sec
Motor FE mm/sec
Legend: CE – Coupling End, FE- Free End
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Checklist STG-LO-07
OIL PURIFIER COMMISSIONING
Ref: Vendor drg No.

Sl No Activity Checked OK / Not Remarks
OK
1. Components and instrumentation
checked as per drawings
2. control panel charged
3. All alarms, interlocks & protections
checked as per Vendor drg No.
SEN003880
4. Purifier trial run for 4 hours completed
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Checklist STG-LO-08
AUXILIARY OIL PUMPs COMMISSIONING
Equipment tag number …………………………….
P&ID Number ……………………………….
Manufacturer’s Name ……………………………….
Date
SLNo Description Remarks
3 Review motor winding insulation resistance values
4 Check Motor earthing
5 Power supply switchgear checked and ready for
charging
6 Pump bumped and rotation proved
Pump set is ready for trial run.

Auxiliary Oil pump Trial Data
TIME
DATA UNIT
Motor Current Amps
Pump discharge pressure Kg/cm2
Vibration at Motor CE Microns /
mm/sec
Vibration at Motor FE Microns /
mm/sec
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Checklist STG-LO-09
OIL FLOW THROUGH SIGHT GLASS

Date:
SL Sight Glass location Flow Observed

No Yes/No
1. Pedestal 1
2. Pedestal 2
3. Pedestal 3
4. Pedestal 4
5. Pedestal 5
6. Pedestal 6
7. Pedestal 7
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Checklist STG-LO-10
OIL SYSTEM ALARM SCHEDULE
Date:
Ref: BHEL SOE List :
Sl Tag No Service Status Set Point Remark Checked

No OK/NOT
OK
1. LO main tank level High Alarm
2. LO main tank level Low Alarm
3. LO Pr across filter High Alarm
4. MOP/AOP Low Standby AOP start

Discharge Pr
5. LO Header Pr Low Alarm
6. L.O. Header Pr V Low AC EOP Start
7. LO Header Pr Low AOP start
8. Jacking Oil Pr Low Alarm
9. Lub. oil after cooler Hi Alarm
10. Turbine TB Non- Hi Alarm

active temp

active temp

active temp

active temp
14. Turbine TB active Hi Alarm
temp
temp
temp
temp
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18. Turbine FJB temp Hi Alarm
19. Turbine Bearing Hi Alarm

1temp
20. Turbine Bearing Hi Alarm
2temp
21. Turbine Bearing 3 Hi Alarm
temp
temp
temp
temp
temp
26. Turbine axial Hi Alarm
displacement
27. Turbine axial Hi Alarm
displacement
28. AOP not on Auto Alarm
Refer for Tag no , set points & other details :INSTRUMENT LIST
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Checklist STG-LO-11
EMERGENCY OIL PUMP

Date:
SL Pump in Operation Value Unit

No
1 Emergency Oil Pump discharge Kg/cm2
pressure set at
2 Voltage Volts
3 Current drawn Amps
4 Pump speed rpm
5 Field resistance value Ohms
6 Armature resistance value Ohms
Status of pressure switches
7 OK / NOT OK
8 OK / NOT OK
Auto start of EOP
9 OK / NOT OK
10 OK / NOT OK
Checklist STG-LO-12
FEEDBACK OF THERMOCOUPLES AND PRESSURE TRANSMITTERS
SL NO Device Status in STG control system

1
2
Checklist STG-LO-13
TEMPERATURE CONTROL VALVE
SL NO Activity Remarks
1 Valve operation OK / NOT OK
2 Temperature control setting 45 degC
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Checklist STG-JO-01
INSTALLATION OF DEVICES
Date:
SL Tag No Description Installed

No Yes/No
1 AC JOP 1 discharge pressure
2 AC JOP 2 discharge pressure
3 JOP discharge header pressure transmitter
4 JOP header pressure low - switch
5 JOP header pressure low - switch
6 JOP pressure at bearing 1
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Checklist STG-JO-02
ON SITE CALIBRATION OF DEVICES
Date:
Sl Tag no Device Range / set Calibrated
no point yes/no
1 JOP discharge header transmitter
2 JOP discharge header pressure low
3 JOP Discharge header to Turning gear
interlock
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Checklist STG-JO-03
JACKING OIL PUMPs MOTOR

P&ID Number ……………………………….
Date:
SL Description Remarks
No
1 Foundation bolts tightened

2 Check driven equipment fitted in right direction
3 Bearing lubricated with specified lubricant
4 Check free rotation of the shaft manually in
uncoupled condition
5 Verify winding insulation resistance value
6 Check Motor earthing
7 Power supply switchgear ready for charging
8 Verify cabling completion
9 Protective devices checked
10 Local start-stop push buttons provided (if applicable)
11 Motor coupling guard provided
12 Set up temporary instrumentation for recording of
no-load running current
13 Start motor (bump test) and confirm the direction of
rotation
14 Run motor for 4 hrs. Note the readings of motor
current
Motor is ready for coupling with the driven equipment.
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
JOP Motor Trial Data
TIME
DATA UNIT
Motor Current Amps
Motor CE mm/sec
Motor FE mm/sec
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Checklist STG-JO-04 Date:

JACKING OIL PUMP COMMISSIONING
P&ID Number ……………………………….
No Description Remarks
3 Pump bumped and rotation confirmed
6 Piping connection checked
7 Relief valve released completely
Pump set is ready for trial run.. Set Jacking Oil Header Pressure at 150 kg/cm2.
Jacking Oil pumps Trial Data
Relief valve set value after pump starting Kg/cm2

TIME
DATA UNIT
Motor Current Amps
Pump disch. Pressure Kg/cm2
JOP header pressure Kg/cm2
Vibration at Motor CE Microns /
mm/sec
Vibration at Motor FE Microns /
mm/sec
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
Status of Jacking Oil System devices

Sl Tag no Device Set Point Status in
no STG control
system
1 JOP discharge header pressure –switch
2 JOP Discharge header to Turning gear
interlock
Signatures
JPL BHEL
Sheet 1 of
Plant Area: Turbine
PROCEDURE FOR TURBINE LUBE OIL AND JACKING

OIL FLUSHING & COMMISSIONING
4X600MW, JPL, TAMNAR
Signatures
JPL BHEL

TG Lube Oil Flushing

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Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Project OPJSTPP (4X600 MW), Tamnar

1.0 PLANT DETAILS

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STAE OF THE PLANT

8.0 TEST METHOD

9.0 COMPLETION CRITERIA

1.1 a) BEARING OIL:

1.1.1 AOP 2 Nos. and EOP one No.

1.1.2 Oil Tank to hold the oil.

1.1.5 Throttle to regulate the oil pressure in Lub oil header.

1.2 b) JACK OIL:

1.2.1 Jack oil pumps AC 2 Nos.

1.2.2 Jack oil pumps DC 1 No

1.2.3 Relief valves.

1.2.4 Pressure regulating valve

1.2.5 NRVS in lines going to the bearings, with isolating valves.

To meet the above objective following techniques shall be

a) Card Board Bursting of entire pipe lines.

c) Heating up of oil: Oil is heated up to 65c-70c & it is

1) Pressure generations of the running pumps.

d) Temperature change during flushing: By heating the

2. Operating personnel to co-ordinate the activities.

3. Power supply for the pumps.

4. Lighting arrangement for oil tank and other operating floors.

5. Portable fire fighting equipments in all the floors.

6. Centrifuge for cleaning the oil.

7. Flushing oil quantity (estimated) =40 Cu.M.(tentative, actual

removed before initial flushing.

\ 24. Oil in the tank is filled to the required level

25. All bearings are Boxed up.

5.0 SAFETY PRECAUTIONS:

6.0 EMERGENCY PROCEDURE:

extinguisher to be used for quenching minor oil fires.

removed at the bearing end and left in the pedestals it.

Flushing Lube Oil Lines

are protected. It is done to remove entrapped dirt particles in tube

c. Check pressure-regulating valves has been serviced and it is in low-

9.0 COMPLETION CRITERIA

hours and no accumulation of dirt should be observed.

A NOTE ON SYSTEM COMMISSIONING

21. Run the pump for 10 Minutes and record observations

OIL FLUSHING OF LUBRICATION AND CONTROL OIL SYSTEM

CONTROL OIL/PRIMARY OIL FLUSHING ARRANGEMENT

A-FLUSHING PIECE OF MOP

(b) WORK PLAN:

a. Commissioning of oil Vapour extraction fans

(c) INPUTS SUMMARY TO START CYCLE

1. Completion of oil pipe lines maintaining cleanliness as per directives

(d) Other plans:

d. Bearing Top halves work & pedestals box-up

(e) Test report format

Sl. Check list Description

(Pl refer PIDs oil system supplied by HWR)

Tank Description: Main Oil Tank

1. Check identification agrees with details on drawing no.

Tank is ready for receiving the fluid

LUBE OIL SAMPLE TEST RESULTS

Sl No Test Unit Desired value Test Value Remarks

1 Kinematic viscosity at CST 41.4 – 50.6