SR-TG-08 油系统冲洗方案oil ing-5-8.docx

115MW SEMIRARA COAL FIREDPOWER PLANT PROJECTINSTRUCTIONSFOROIL FLUSHINGCBA0FIRST ISSUEREV.SIGNATUREDATEWRITTENDATECHECKEDDATEAPPROVEDDATEREVISION NO.: 0PAGE: 1 OF 13TITLE:油系统冲洗方案/ Instruction for Oil FlushingFILE NO.: SR-TG-08目 录Table of Contents1设备及概况Equipment and Overview12油循环前具备条件Conditions Provided before Oil Circulation13油循环步骤 Oil Circulating Steps44油系统冲洗的清洁度评定 Evaluation of Cleanliness of Flushed Oil System85 后续工作 Evaluation of Cleanliness of Flushed Oil System96安全施工 Safety Construction107 临时系统材料表 Material List of Temporary System111X15MW SEMIRARA CFB POWER PLANT PROJECTINSTRUCTIONS FOR OIL FLUSHINGOWNER: CNEECFILE NO.: SR-TG-8DOCUMENT NO.: SR-TG-8PAGE: 14 OF 161设备及概况Equipment and Overview菲律宾塞米拉拉项目115MW机组采用杭州汽轮机厂制造的NK40/56/25型汽轮机，南阳防爆集团股份有限公司生产的QFW-15-4型汽轮发电机，冲洗的范围包括：润滑油系统和部分控制油系统。THE 1X15MW SEMIRARA CFB POWER PLANT PROJECT uses NK40/56/25 steam turbine generators manufactured by HANGZHOU STEAM TURBINE CO., LTD, and QFW-15-4 steam turbine generators manufactured by NAN YANG EXPLOSION PROTECTION GROUP CO., LTD. of which the flushing scope includes: lubricating oil system and part of control oil system.2油循环前具备条件Conditions Provided before Oil Circulation1)所有碳钢材料的管道和管件，必须经过酸洗。辅助油箱打磨temperary tank 20 m31) All carbon steel pipes and fittings should be subjected to acid pickling.2)所有不锈钢材料的管道和管件，油循环之前，必须经过严格吹扫（最好蒸汽吹扫），且吹扫后采取特殊措施，用干净的绸布对管道内部进行擦洗。完成后对内壁进行检查。必须没有灰尘，管壁清洁2) All stainless steel pipes and fittings must be purged with compressed air prior to installation and protected by taking special measures after purging, while the inside of them must be cleaned by wiping with clean rag.3） 主油箱的清扫：把油箱内部彻底清扫干净，先用白布，然后再用面团。在油箱底部和回油的处加装磁棒。3) Main tank cleaning: the tank must be thoroughly cleaned inside with a white cloth first and then dough. The bar magnets must be installed at the tank bottom and the scavenge filter screen.4） 在汽机房安装二台 LY-150压力式滤油机（含5000张滤油纸300mm 300mm），进口接主油箱疏油口一次门门前，出口接在主油箱人孔门上并联在主油箱上。4) A LY-150 pressure oil filter (containing 5000 filter papers, 300mm x 300mm) is to be installed at 0m in the turbine generator room with the inlet connected to the main tank in front of the primary door of oleophobic outlet, and the outlet connected to the main tank manhole door and to the main tank in parallel.5） 汽轮机和发电机轴承：将所有支持轴承上半部均拆除，支撑轴承下半部不动，推力轴承的推力板拆除。5) Turbine and generator bearings: remove the upper halves of all support bearings with their lower halves remained in original positions, and remove the thrust plates of thrust bearings.6） 润滑油系统：将润滑油管道与轴承座脱开，将进回油管用临时短管连接起来,在主油泵吸入口和出口处加堵板。6) Lubricating oil system: the oil pipes are disconnected from the bearing seats, the inlet and return oil pipes are connected together with a temporary short tube. Add blind plate on suction inlet and outlet of main oil pump. 7） 控制油系统：速关组件进回油管用临时管道连接起来。7) Control oil system: the inlet and return pipes of quick closing assembly are connected together with a temporary tube.8） 上油前的系统检查：油箱上油前必须会同热工共同检查，确认系统连接正确无误，各热工测点安装正确无遗漏，油箱油位指示器灵活，其指示与油箱中的实际油位应相符合，做好防尘、防溅、防漏措施。除必要的压力、温度监测点外，油系统其它仪表点应隔离。8) System check before oil supply: the oil tank must be jointly checked with a I&C engineer before starting oil supply to confirm that the system connection is correct, the thermal measurement points are installed correctly and completely, and the tank oil level indicator is sensitive where the indication should be consistent with the actual oil level in the tank; the system should be protected by taking proper measures of dust, splash and leakage prevention. In addition to the necessary pressure and temperature monitoring points, the other instrument points of the oil system should be isolated.9） 各油泵的电动机及系统上的排烟风机经过空载试运行情况正常。9) The oil pump motors and the exhaust fan on the system are commissioned in normal test run.10） 确信事故排油系统连接正确，各放油门关闭严密并挂警告牌禁止操作。10) Make sure that the emergency oil drain system is properly connected, the drainers are closed tightly and the warning signs “Operation is Prohibit” are attached.11） 确信直流电源能满足直流泵连续运行。11) Make sure that the DC power supply can meet the need for continuous operation of DC pump.12） 落实油箱加热装置，保证在连续冲洗过程中能把油从常温多次加热至75。油加热时，油温不得高于80，以免油变质。12) The oil tank heating device is well installed to ensure that the oil is repeatedly heated to 75C from room temperature during continuous flushing. The oil temperature shall not be higher than 80C when heating oil, to avoid the deterioration of oil.13） 冷油器放油口接临时管路，将油排至油箱，以免污积留在冷油器内。13) The oil drain of the oil cooler is connected to a temporary tube to drain the oil into the tank; to avoid the dirt accumulates in the oil cooler.14） 润滑油和调节油有各自的滤油器时，滤油器的滤芯拆出，在一个油冲洗循环周期后，再装入。14) When there are oil filters for lubricating oil and regulating oil, respectively, the oil filter element must be removed and then installed after a period of oil flushing cycle.15） 盘车油管路：采用液压直行程盘车机构的，盘车油泵的进油由临时管路接至回油。15) Barring oil pipe: as the hydraulic linear-motion barring mechanism is used, the inlet oil of the barring pump is connected to the return oil with a temporary tube.16） 电液转换器不参与油冲洗。装在速关组件上的电液转换器，闷板反装，有凹槽的一面朝向速关组件本体。16) The electro-hydraulic converter doesnt involve in the oil washing. The electro-hydraulic converter on the quick closing assembly is installed with the blanking flange mounted reversely and the grooved side facing the quick closing assembly body.3油循环步骤 Oil Circulating Steps1） 油箱上油 Tank Oil Supply油箱上油前，在确认油箱放油阀关闭正确，并采取了一定的防范措施，即可向油箱缓慢上油，上油时检查各管道连接处是否漏油，如有漏油修复后再继续上油，油箱距离油箱顶部约100mm时，停止上油,润滑油牌号ISO VG46汽轮机油，注油量约9m3。注油时用滤油机或经过滤网注入，禁止直接倒灌。灌油或放油时，储存汽轮机油的容器应清洁，不得使用盛过其它油品而未作彻底清理的容器，装油和运油时要防止与其它油品容器混淆。Make sure that the oil drain valve of the tank is properly closed and certain preventive measures are taken before starting oil supply. Start to fill oil tank slowly, check leakage of connecting pipes during filling, repair pipes if there is any leakage and then oil filling again. Stop filling as the oil in the tank is 100mm lower than top of tank; the oil filled should be turbine oil of ISO VG46, and the oil quantity should be about 9m3. The oil should be filled with an oil filter or through an oil filter screen; the direct pouring is prohibited. When filling or discharging oil, the turbine oil storage container should be clean; the use of a container that has been filled with other brand of oil and not thoroughly cleaned up is prohibited; the oil loading and transporting should prevent the oil container from mixing with others.2) 第一阶段油冲洗:润滑油管路 First phase of oil flushing: oil pipes流程为：主油箱辅助油泵（交、直流事故油泵可同时投入运行）双联冷油器双联滤油器（润滑油）润滑油进油母管各轴承处进油支管各轴承处进回油管路临时短接各轴承处回油支管回油母管主油箱Process: main tank auxiliary pumps (AC and DC emergency pumps can operate at the same time) double-connection oil cooler double-connection filter (oil) main oil inlet pipe oil inlet manifolds at bearings temporary short tubes for oil supply and return at bearings oil return manifolds at bearings main oil return pipe main oil tank启动辅助润滑油泵（交、直流事故油泵可同时投入运行），同时用透明夹丝软管将压榨式滤油机串联在主油箱上在线滤油，冲洗24小时，冲洗油压尽可能接近系统工作压力；冲洗油温，应使油温冷、热交替变化，以8小时为1个循环周期，期间低温约25，高温约75。Start the auxiliary oil pumps (AC and DC emergency pumps can start operating at the same time) while use a transparent wired hose to connect the press-type oil filter in series to the online oil filter in the main tank to flush for 24 hours with the flushing oil pressure as close to the system work pressure as possible; the flushing oil temperature should make the oil temperature alternate between cold and hot modes with an interval of 8 hours where the low temperature is approximately 25C and the high temperature is approximately 75C.停辅助润滑油泵和交、直流事故油泵，用压差式滤油机将主油箱的油倒入已清理干净的储备油箱，然后把油箱和润滑油滤网清理干净。这样进行反复冲洗，直到油质合格。Stop the auxiliary oil pumps and AC & DC emergency oil pumps, use a differential pressure oil filter to pour the oil from the main tank into the reserve tank that has been thoroughly cleaned, and then clean the oil tank and oil filter screen. So repeatedly flush until the oil is qualified.3） 第二阶段油冲洗：控制油管道 Second phase of oil flushing: control oil pipes流程为：主油箱辅助油泵双联滤油器（控制油）速关组件前的进油母管速关组件进回油临时短接速关组件回油母管主油箱Process: main tank auxiliary pumps double-connection oil filter (control oil) main oil inlet pipe before quick closing assembly temporary short tubes for oil inlet and return of quick closing assembly main oil return pipe of quick closing assembly main oil tank启动辅助润滑油泵，同时用透明夹丝软管将压榨式滤油机串联在主油箱上在线滤油。冲洗24小时，冲洗油压尽可能接近系统工作压力；冲洗油温，应使油温冷、热交替变化，以8小时为1个循环周期，期间低温约25，高温约75。Start the auxiliary oil pumps while use a transparent wired hose to connect the press-type oil filter in series to the online oil filter in the main tank. Flush for 24 hours with the flushing oil pressure as close to the system work pressure as possible; the flushing oil temperature should make the oil temperature alternate between cold and hot modes with an interval of 8 hours where the low temperature is approximately 25C and the high temperature is approximately 75C.停辅助润滑油泵，用压差式滤油机将主油箱的油倒入已清理干净的储备油箱，然后把油箱和润滑油滤网清理干净。这样进行反复冲洗，直到油质合格。Stop the auxiliary oil pumps, use a differential pressure oil filter to pour the oil from the main tank into the reserve tank that has been thoroughly cleaned, and then clean the oil tank and the oil filter screen. So repeatedly flush until the oil is qualified.4） 第三阶段油冲洗：润滑油管路 Third phase of oil flushing: oil pipes第二阶段油循环结束后，润滑油系统，临时管道拆除，正式系统恢复，滤油器装入滤芯。After the second phase of oil circulation is completed, remove the temporary tubes from the lubricating system, restore the system operation and install the filter element into the oil filter.启动辅助润滑油泵（交、直流事故油泵可同时投入运行），同时用透明夹丝软管将压榨式滤油机串联在主油箱上在线滤油，冲洗24小时。滤油器滤芯定时清洗滤网，若规定时间未到，但进、出口油压差接近允许上限值时，应立即对滤油器进行切换清洗。 Start the auxiliary oil pumps (AC and DC emergency pumps can start operating at the same time) while use a transparent wired hose to connect the press-type oil filter in series to the online oil filter in the main tank to flush for 24 hours. The filter element cleans the filter screen regularly; if the specified time has not yet reached, but the difference between inlet and outlet oil pressures is close to the allowable upper limit value, the oil filter should be replaced and cleaned immediately.5） 第四阶段油冲洗：控制油管路 Fourth phase of oil flushing: control oil pipes第二阶段油循环结束后，控制油系统，临时管道拆除，滤油器装入滤芯，速关组件压力油进回油恢复正常连接（电液转换器不参加油循环，之间的闷板在油冲洗时使用）。危急遮断油门拔到倒钩位置并予以固定。速关组件的手动及遥控停机阀置于正常运行位置，定时轮换操作启动油及速关油控制阀（手动或电动），以使接到速阀的启动油和速关油管路得到冲洗，定期将速阀的试验阀置入试验位置，冲洗试验油管路。After the second phase of oil circulation is completed, remove the temporary tubes from the control oil system, install the filter element into the oil filter and restore the pressure oil inlet and outlet of quick closing assembly to normal connection (electro-hydraulic converter doesnt involve in the oil circulation, and the blanking plate between them is used in oil flushing). Place the emergency shutoff throttle to the barb position to be fixed. Set the manual and auto stop valves of quick closing assembly to normal operating position, regularly operate the start-up oil and quick closing oil control valves (manually or electrically) to receive the start-up oil from the quick valve and to have the quick closing oil pipes flushed; regularly set the test valve of quick valve into test position to flush the test oil pipes.启动辅助润滑油泵，同时用透明夹丝软管将压榨式滤油机串联在主油箱上在线滤油，冲洗24小时。滤油器滤芯定时清洗滤网，若规定时间未到，但进、出口油压差接近允许上限值时，应立即对滤油器进行切换清洗。Start the auxiliary oil pumps while use a transparent wired hose to connect the press-type oil filter in series to the online oil filter in the main tank to flush for 24 hours. The filter element cleans the filter screen regularly, if the specified time has not yet reached, but the difference between inlet and outlet oil pressures is close to the allowable upper limit value, the oil filter should be replaced and cleaned immediately.注：油循环冲洗工艺要求Note: Oil circulation flushing process requirements在冲洗过程中，利用油箱加热装置及冷油器进行冷热交替冲洗，冲洗时用压差式滤油机滤油，油温最高不超过75，并经常用木锤或铜棒敲打管道焊缝，在初次冲洗各系统时，必须配备足够人员监视各轴承箱和有关系统接口处，防止跑、冒油。The oil tank heating device and oil cooler are used to flush alternately in cold and hot modes during flushing and the differential pressure oil filter is used to filter the oil in flushing with oil temperature not higher than 75C maximum, and at the same time, a wooden hammer or copper rod should be often used to knock the pipe welding joints; when the systems are flushed for the first time, adequate personnel must be staffed to monitor the bearing housing and the relevant system interfaces to prevent oil escaping and flowing out.4油系统冲洗的清洁度评定 Evaluation of Cleanliness of Flushed Oil System在油循环各周期后，清洁滤油器滤网时，凭目测和手感，在滤网上未发现明显的硬质颗粒杂质时，可着手油系统清洁度的检查。在油箱底部疏油口处，取油样进行定量分析，其结果应符合下表标准。When cleaning the oil filter screens after all periods of oil circulating cycle, if no impurities of obviously hard particles are found visually or felt by hand on the filter screen, proceed with the oil system cleanliness inspection. The oil sample is taken from the oleophobic outlet at the tank bottom for quantitative analysis, and the results should meet the following criteria:杂质颗粒尺寸（mm） Impurity Particle Size (mm)数量（颗） Quantity (grain)0.25无None0.130.2555 后续工作 Evaluation of Cleanliness of Flushed Oil System1）换油Oil replacement经油冲洗系统清洁度符合要求后，放出冲洗油，排尽系统中的残油，清理油箱、轴承座及齿轮箱、滤油器内部，清洗滤网，然后向油箱注入合格的ISO VG46汽轮机油，油量为运行油量，油箱第一次的加油量应高于最高油位，但低于油箱上面板100mm左右，初始装油量约为9m3。As the system cleanliness complies with the requirement after oil flushing, discharge the flushing oil and drain the system dry with no residual oil left, clean the oil tank, bearing seat and gearbox, inside of the oil filter and filter screen, and then fill the tank with qualified turbine oil ISO VG46 with an operating oil quantity; the oil quantity filled in the tank for the first time should be higher than the maximum oil level, but about 100mm below the upper panel of the oil tank; the initial oil loading is about 9m3.2）油质检验Oil quality Inspection每次新加油或换油时，事先应对加油的油质进行检验，需取双份油样，一份用于化验，另一份密封避光保存，作为以后油质检测的比照样品。Each time filling oil or changing oil, the oil quality filled should be inspected in advance by taking two oil samples: one is for analysis and the other is stored in a container sealed from light as check sample for future oil quality test.6安全施工 Safety Construction6.1在顶轴油冲洗及耐压试验前、主油箱清理前、储油箱清理前以及油冲洗开始前均需办理安全签证。 6.1 Safety papers must be assigned before starting technical process including jacking oil flushing and pressure-tight test, cleaning main tank& oil tank and oil flushing.6.2严格执行安全规程、消防制度及工作票制度。 6.2 Strictly follow safety regulation, firefighting system and working permit system6.3冲洗过程中对冲洗涉及的设备及管路设置安全区域，项目安保部派专人进行监护，消防人员到施工区域进行督促检查措施实施情况。 6.3 Assign security and fireman in construction area to inspect and check safety area of equipments and pipe arrangement during oil flushing. 6.4进油前，清除冲洗涉及的设备及管路区域周围的已燃物品，做好防火隔离措施，同时悬挂警示牌并布置消防器材。6.4 Before feeding oil, clean all combustibles around oil flushing equipments and oil pipe area and take actions of fire resistance and isolation at the same time warning signs and extinguishers must be prepared. 7 临时系统材料表 Material List of oil flushing Temporary System名称 Name规格Specification数量Quantity备注 Remarks夹丝透明软管 Wired transparent hoses2” 、1.5”各50米50m each软管管卡2” 、1.5”30个 30pcs压榨式滤油机 Press-type oil filterLY-1502台 2 set采用卡拉卡项目的滤油机， the oil filter will be borrowed from Calaca by CNEEC, 滤油纸300mm300mm5000张 pcs磁棒 Bar magnets600800mm 长length约10个About 10 pcs放置于油箱底部，吸附铁质杂质To put inside the oil tank to attracts iron in the oil 临时阀门 Temporary valves1.25 or 1.5 or 1球阀 ball valve4个4 pcs安装在滤油机的进口To be in