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8/6/2019 INSTRUCTIONOF OIL PURIFIED TURBINEssFt+S++tFS1

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JHARSUGUDA 9x135MW

CAPTIVE POWER PLANT

OIL PURIFIER FOR GJZ-6 TURBINE

GJZ-6

PROJECT: JHARSUGUDA 9x135MWCAPTIVE POWER PLANT INDIA

JSG 9x135MW

OWNER: VEDANTA ALUMINA LTD.,INDIA

VEDANTA

CONSULTANT: TCE CONSULTING ENGINEERS LIMITED,MUMBAI

TCE

CONTRACTOR: SEPCO ELECTRIC POWER CONSTRUCTION CORP.,PRC

PROJECT CONTROL No. JSG-X-MZGGJ-EM-GJZ/6-A REV.No.A


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JHARSUGUDA 9x135MW CAPTIVE POWER PLANT

OIL PURIFIER FOR TURBINE EQUIPMENT Page2

ZIGONG HIGH PRECISION FILTER MANUFACTURING CO.LTD

1. APPLICATIONModel GJZ Oil Purifier for turbine can effectively remove moisture, gasses and particles from

various kinds of turbine oil and other oils with equal viscosity of turbine oil. In addition, it can remove

emulsions of said oils. Therefore, it is ideal for treating turbine oil of running units in power plant.

Model GJZ product is connected with oil system of units. Oil is obtained from main oil tank and

purified oil returns back main oil tank. It can operate together with oil system of unit to purify lube oil

or regulating system oil continuously. It can also operate individually to filter/purify oil of main tank.

2. SPECIFICATION AND PERFORMANCE2.1 Performance

Turbine oil to be purified treated by the machine several times can reach following index.

Emulsion: Transparent

Water content : 50ppm

Impurity : 5m

Noise :82dBA

2.2 Main specificationMain technical data for Modes GJZ Oil Purifier

NAME UNIT

MODEL

GJZ-3 GJZ-6 GJZ-9

Purification L/h 3000 6000 9000


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Capacity

Rated Operating

Pressure

Mpa 0.5 0.5 0.5

Power of Vacuum Pump KW 2.2 3 3

Power of Oil Inlet

Pump

KW 1.5 3 4

Power of Oil Drain

Pump

KW 1.1 3 4

Total Heating Power KW 18 24 48

Power V 3-phase 50HZ 415V

Operating Vacuum -Mpa 0.092-0.096

Total Power KW 22.8 33.09 59.09

Inlet/outlet Oil

Pipe Bore

mm DN25 DN32 DN40

Weight Kg 2500 3500 4000

Overall

Dimensions

L mm 2100 2150 2400

W mm 1650 2000 1950

H mm 1900 2070 2240

3. CONSTRUCTION3.1 Low temperature40-55aggregation technique and emulsion-removing technique under

vacuum operation condition is used to purify turbine oil with high efficiency ,time/power saving and

preventation of oil-ageing during purifying.


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3.2 Good suction, stable flow and low noise is ensured because adoption of specially-made oil pump.

3.3 High efficient de-watering and degassing is ensured by special dewatering/degassing parts in

vacuum purifying system.

3.4 Special aggregation filter cores can remove most moisture of oil.

3.5 Polymolecular absorption technique removes acid matter from oil.

3.6 High precision filter core ensures top quality filtration.

3.7 Control system is provided with inter-lock safety device so, operation is reliable.

3.8 Condensor utilizes separation cooling method without water-cooling. Therefore energy is saved.

4. CONSTRUCTION AND OPERATION PRINCIPLE4.1 Construction

Model GJZ Turbine Oil Purifier mainly consists of Coarse Strainer(2), Magnetic Filter(3), Heater(4),

Oil Inlet Pump(8),Vacuum Tank(21), Aggregation Filter System(9),Polymolecular

Absorption/Regeneration Tank(16), Condenser (24) , Vacuum Pump(28),Oil Drain Pump(29) and Fine

Filter (34),(35),etc(For details ,Please see Operation Principle Fig).

4.2 Operation principle

4.2.1 In case that the machine operates together with the unit to filter/purify turbine oil in main oil

tank continuously, it works as follows (This system is called as aggregation/separation filter system):

Oil coming from oil tank of turbine passes through Inlet Ball Valve1 Coarse

Strainer2 Magnetic Filter3 Ball Valve7 Oil Inlet

Pump8 Aggregation/separation Filter 9

In case that oil needs acid matter removing Ball Valve 14


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No need for removing acid matter Ball Valve 15

Polymolecular Regeneration Tank (16) Ball Valve (17) Fine Filter34

Fine Filter35

Sampling Valve36 Outlet Ball Valve37 Main oil tank from the upper part

Aggregation/separation technique and polymolecular absorption tank filter cores can filter out

most of water, impurity and acid matter from oil. Separated water is discharged automatically by

means of interface meter and solenoid valve. Since this system has only one power source for oil

inlet pump, it is suitable for operating on-line with turbine for long period. During operation of

turbine, oil temperature of main oil tank is above 50. This oil system needs no heater of this

machine.

4.2.2 In case that shutdown needs to be made for service or high precision purification is needed,

another system of the machine (Vacuum film filtration/separation system) may be started.

Oil coming from the bottom of turbine main oil tank passes through Inlet Ball Valve(1)

Coarse Strainer(2) Magnetic Filter (3) Heater(4) Solenoid Valve(6) Ball Valve

(13) Float Ball Valve(19) Top of Vacuum Tank(21) Spec ial

Dewatering/Degassing Element(20)

After Passing Through Condenser(24), Separated gas, water is pumped out by Vacuum Pump(28).

Bottom of Vacuum Tank(21) Oil Drain Pump(28) One -way Valve(30)

In case that acid matter-removing is required


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No need for acid matter-removing

Ball Valve(18) polymdecular Regeneration Tank(16) Ball Valve(17)

Ball Valve(31)

Fine Filter(34)

Sampling Valve (36) Outlet Ball Valve(37)

Fine Filter(35)

Main oil Tank from upper part.

Water saturation temperature curve, vacuum film theory, polymolecular absorption regeneration

tank, deep-layer filter core can remove water, gas and impurity thoroughly from oil so that purified oil

meets new oil standard. Therefore, this system is applicable to high precision purification of oil

system. Since vacuum pump in this system is oil-immersed type spinning vacuum pump,it is not

suitable for long-time continuous running(continuos running cant exceed 4 working days).Otherwise,

overheat would be caused by friction. This system is not suitable for on-line operation with turbine for

a long period of time.

This machine not only has very good separation result, but also operates together with turbine for

long period of time.

5.ELECTRIC SYSTEM

This machine uses 3-phase,50Hz380V Power. Electric apparatus is provided with switching-off

protection and controller. Heaters are inter-locked with solenoid valve. Heaters can be started only

after solenoid valve is started. Heaters are devided into 2 groups :Group one for operation, Group

Two for standby. During operation, oil temperature is controlled by thermostat in heating system,


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with control range of40-80.When oil temperature thermostat in heating system is above rated

one, thermostat cuts-off henter power supply automatically. And when oil temperature is below rated

one, heater power supply is connected automatically. Temperature of heating system of oil filters

manufactured by our plant was set at 50normally when they left factory. Users may reset their

temperatures according to requirements. The machine is also provided with differential controller and

aggregation separator. When fine filter core is blocked, differential controller comes into action to

alarm by means of pilot lamp, indicating change of filter core (See Electric Operation Principle Fig.)

5. OPERATION6.1 Preparation

6.1.1 Open electric cabinet to check whether fuses are perfect, connections are loose and electric

elements are moistened or damaged. Remove foreign matters from the cabinet.

6.1.2 Check bolts and nuts for looseness. If so, tighten them.

6.1.3 Connect mains and grounding protection.

6.1.4 Check to see whether coarse strainer and fine filter is mounted with screens and cores according

to requirements.

6.1.5 Use transparent hose or steel tube to connect purifier with turbine main oil tank. Connection

hose or tube must be clean. Inlet of this machine should be connected with the bottom of turbine main

oil tank. And outlet of this machine should be connected with the top of turbine main oil tank(For

details, please see Installation sketch).

6.1.6 Close all valves

6.2 Operation

In case of starting vacuum film filtration/separation oil system:

a. Power on


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b. Start vacuum pump (28).c. Open Inlet Valve (1), Ball Valve(13),(31) and Outlet Valve(37).Start Solenoid Valve(6).When oil

level of vacuum tank reaches or exceeds 3/4 of visual hole, start Oil Drain Pump(29).

d. When oil level of vacuum tank is almost stable, start heaters. Now, the machine is in operationmode.

In case of starting aggregation separation/filtration system:

a. Power onb. Open Inlet Ball Valve(1),Ball Valve(7),(15)and Outlet Ball Valve(37).c. Start oil Inlet Pump(8).6.3 Precautions

6.3.1 Sampling should be made from Sampling Valve (37) and done strictly according to sampling

procedures or sampling precision will be affected.

6.3.2 Temperature rise of motors for vacuum pump and oil inlet pump cant exceed 40.

6.3.3 Vacuum pump oil level should be always maintained at oil marks.

6.3.4 In case that vacuum tank has too much foam, slightly open Vacuum Charge Valve (23) to reduce

vacuum (Removing foam).When reduced foam is obtained, close said valve.

6.3.5 In case that flow is remarkably reduced, check to see whether coarse strainer is blocked and fine

filter is dirty.

6.3.6 Discharge oil/water in water tank in time.

6.3.7 Before starting heaters, pay special attention to whether oil flows into heaters. Never start

heaters until oil enters into heaters. Lit pilot lamp indicates that heaters are in operation mode. Never

start heaters at random in order to avoid burn of heaters and electric accident.

6.3.8 When aggregation filter core differential alarm and fine filter core differential alarm occurs,


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shutdown should be made for changing aggregation core or fine filter core.

6.3.9 Keep an eye to balancing oil level of vacuum tank. Keep oil level at 3/4 of visual glass at the

lower part as much as possible. Stop oil drain pump if oil level exceeds above mentioned position.

Otherwise, start oil drain pump.

6.4 Precautions for shutdown

Firstly turn off heaters and then close inlet ball valve and solenoid valve. After oil in vacuum tank is

drained off by oil drain pump, turn off oil drain pump and close outlet ball valve. When readings of

vacuum-meter is above operating vacuum (higher vacuum, the better), stop vacuum pump. Let out

oil/water in condenser. Close rest valves and cut off power supply.

6.5Operating Conditions of Model GJZ Turbine Oil Purifier:

a. Ambient temperature: Below 50b. If oil temperature is below-15,vacuum pump oil should be heated to 15 or so.c. If oil to be purified is too dirty (Containing too much water, gas and particles), pretreating is

recommended (Treated with clarification method or Model LY Board Frame Press Oil Filter).

Otherwise, purification result will be affected.

d. Site elevation will affect vacuum and purification. In this case ,oil temperature may be increasedto compensate.

e. Relationship Between Water Vaporizing Temperature, Oil Temperature and Vacuum

VACUUMmm Hg Column WATER VAPOURIZING TEMP OILTEMPERATURE

-750 100C 200C

-742 200C 300C


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-727 300C 400C

-714 350C 450C

f. CONVERSION BETWEEN ELEVATON AND VACUUMVACUUM ELEVATIONm

m-Mpa mmHg

0.1013 760 0

0.0990 742.7 200

0.0968 726.2 400

0.0957 717.9 500

0.0902 676.7 1000

0.0846 634.7 1500

0.07908 593.3 2000

7.MAINTENANCE AND SERVICE

7.1 Often add No1 vacuum pump oil to oil tank to keep oil level at oil mark (For details, please see its

Operation Instruction).

7.2 Every 3000 hours running of motor bearings, add No.2 or No.3 calcium-based grease to them

(General speaking, addition should be made when maintenance or service is carried out).

7.3 Drain oil from vacuum pump every 6 months. And fill small quantity of fresh No.1 vacuum pump

oil. Move pulley by hand to make fresh oil wash internals of the pump. Then let out filled oil. This

rinsing should be done twice. Finally, add enough fresh oil.

7.4 In case that shutdown would last more than one months, the machine should be stored in dry place,

with electric cabinet door closed and machine housed.


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8. TROUBLE SHOOTING AND REMEDY

FAILURE CAUSE REMEDY

A.Vacuum

decreases and

fails to reach

rated value

1.Pipe connections or joints are

leaky.

2.Insuffiecint oil in vacuum pump oil

tank.

3.Oil in vacuum pump oil tank is

dirty.

4.Exhaust valve or other parts of

vacuum pump damaged.

5.Gas pumped contains much

condensational gas.

1.Service

2.Add oil to vacuum pump oil

tank.

3.Change with fresh oil.

4.Change

5.Discharge water and oil

through oil drain valve of

condenser.

B. Filtered oil

quantity reduced.

1.Oil drain pump damaged.

2.Filter has excessive pressure due

to too much filtered things.

1.Service.

2.Rinse or change filter

core/screen.


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3.The system blocked.

4.Too much filtered things on coarse

strainer screen.

5.Sealing ring of oil drain pump

damaged.

6.Oil suction pipe is too long or

suction head is too high.

3.Remove.

4.Rinse.

5.Change

6.Shorten.

C. Abnormal noise

of oil drain pump.

1.Fastening bolts of pump motor are

loose.

2.Internal parts damaged.

3.Insufficient oil.

1.Tighten

2.Change.

3.Compensate or filter out.

D. Abnormal noise

of vacuum pump.

1.Fastening blots of pump or motor are

loose.

2.Impeller or exhaust valve vane or

internal parts damaged.

1.Fasten.

2.Change.

E. Vacuum tank has

too much foam.

1.Oil to be purified contains gas and

water.

2.Tank has highvacuum.

3.Level valve is out of order, causing

high level.

1.Pre-treat.

2.Slightly open charge

valve.

3.Change.

F. Oil temperature

fail to go up or go

up slightly after

1.Thermostat is out of action.

2.Wiring disconnected or burn of

heaters.

1.Change thermostat

2.Repair connection or

change heater.


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heaters are

started.

G. Sampling fails

to meet

requirement.

1.Oil to be purified contains much

water, gas or impurities.

2.Filter core damaged.

3.Sampling method is incorrect or

sampling bottle is not clean.

4.Too Much foam in vacuum tank.

5.Vacuum is low.

1.Pro-treat.

2.Change.

3.Sample with clean bottle

according to standard.

4.Handle according as E.

5.Handle according as A.

GJZ

GJZ


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mm 1650 2000 1950

mm 1900 2070 2240

1400C-550C

2

3

4

5

6

7

8

GJZ 2348

219162428

293435


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1 2 3

7 8 9

14 16 17

15

34

36 37

35

50

:

1 2 3

4 6 13 19 21

20

2428

21 28 30


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18 16 17 34

36

31 35

37

,,,

()

4

50HZ380V

40-80

500C


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1.

2.

3.

4.

5.

6.

()

1.

2.28

3.11331376

3/429

4.

:

1.

2.(1)71537


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3.8

1.37

2. 40

3.

4.23

5.

6.

7.

8.

9 3/4

GJZ

1 50

2-150C 150C


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3

LY

4

(5)

-750 100C 200C

-742 200C 300C

-727 300C 400C

-714 350C 450C

(6)

m

m-MPa mmHg

0.1013 760 0

0.0990 742.7 200

0.0968 726.2 400

0.0957 717.9 500

0.0902 676.7 1000

0.0846 634.7 1500

0.07908 593.3 2000


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1. 1

2. 3000h 2 3

3. 1

4.

A.

1.

2.

3.

4.

5.

1.

2.

3.

4.

5.

B.

1.

2.

3.

4.

5.

1.

2.

3.

4.


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6. 5.

6.

C.

1.

2.

3.

1.

2.

3.

D.

1.

2.

1.

2.

E.

1.

2.

3.

1.

2.

3.

F.

1.

2.

1.

2.

G.

1.

2.

3.

4.

5.

1.

2.

3.

4. E

5. A

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