Power (Hydro)
Lubrication
If it is large and rotates‚ it most certainly needs a pumped lubrication system. Pumps and engineered systems that supply lubrication oil to rotating equipment generally operate 24/7 making reliability of paramount importance.
On a typical lubrication oil skid‚ there are generally three pumps‚ a primary‚ a standby and an emergency backup pump. You may also find a seal oil pump included for the hydrogen cooled generators. These pumps and engineered system supply lubrication oil to the main journal bearings‚ generator bearings‚ reducing gear‚ accessory gear‚ high pressure hydraulic oil and generator seal oil.
The required flow rates depend on the size of the rotating equipment. In large steam and gas turbine applications flow rates as high as 2‚500GPM are required vs. stationary diesel applications where less than 500GPM required.
Users may have a choice between centrifugal and three screw pumps in these applications and there are trade offs between the technologies that engineers should be aware of. Centrifugal pumps typically have a lower initial cost; however‚ three screw pumps have a lower life cycle cost when you factor in operating efficiency and thus energy costs and maintenance costs.
CIRCOR also produces complete lubrication engineered systems for rotating equipment throughout the power plant. These applications include turbine‚ boiler feed‚ condensate‚ and recirculation pumps.
CIRCOR provides optimal pump technologies with three screw‚ two screw and centrifugal pumps.
| Flow Rates up to | Pressures to up to | Max Fluid Temperature | CIRCOR Brand, Series & Pump types |
|---|---|---|---|
|
2.7 m^3/h 12 GPM |
7 bar 101 psi |
90C 194F |
IMO AB ACD Three Screw |
|
11 m^3/h 48 GPM |
16 bar 232 psi |
155C 311F |
IMO AB ACE Three Screw |
|
28 m^3/h 125 GPM |
345 bar 5‚000 psi |
82C 180F |
IMO CIG Crescent Internal Gear |
|
48 m^3/h 210 GPM |
17 bar 250 psi |
107C 225F |
IMO 3G Three Screw |
|
51 m^3/h 225 GPM |
16 bar 232 psi |
120C 250F |
Allweiler ALLlub RUV Three Screw |
|
51 m^3/h 225 GPM |
16 bar 232 psi |
180C 356F |
IMO AB ACG Three Screw |
|
91 m^3/h 400 GPM |
34.5 bar 500 psi |
121C 250F |
IMO 3D Three Screw |
|
180 m^3/h 793 GPM |
16 bar 232 psi |
121C 250 F |
IMO AB ACF Three Screw |
|
450 m^3/h 1‚982 GPM |
16 bar 232 psi |
90C 194F |
IMO AB LPQ Three Screw |
|
453 m^3/h 2‚000 GPM |
16 bar 232 psi |
150C 356F |
Allweiler TriLub Three Screw |
|
490 m^3/h 2‚158 GPM |
16 bar 232 psi |
80C 176F |
Houttuin 215.10 Vertical Submersible Two Screw |
|
550 m^3/h 2‚500 GPM |
16 bar 232 psi |
120C 250F |
Allweiler NSSV Centrifugal |
|
600 m^3/h 2‚642 GPM |
16 bar 232 psi |
80C 176F |
Houttuin 211.10 Horizontal Two Screw |
|
750 m^3/h 3‚300 GPM |
21 bar 300 psi |
260C 500F |
IMO 323F Three Screw |
|
1‚100 m^3/h 4‚844 GPM |
16 bar 232 psi |
80C 176F |
Houttuin 216.10 Horizontal Two Screw |
Hydraulic Power to control the governor, wicket gates, or hydro properllers
Hydroelectric plants must control the amount of water allowed to reach the water turbine to maintain correct turbine speed under varying load demands. The opening position of large water gates (Wicket Gates) is controlled by hydraulic cylinders which are supplied with hydraulic oil in proportion to load demand on the turbine. This hydraulic system is also used to control the pitch of the turbine blades within the Hydro Turbine.
These pumps operate in a pressure the 750-1250 PSIG range at high flow rates for hydraulic systems (300+ GPM) ‚ AC electric motor driven main and standbys.
| Flow Rates up to | Pressures to up to | Max Fluid Temperature | CIRCOR Brand & Series |
|---|---|---|---|
|
51 m^3/h 225 GPM |
100 bar 1‚450 psi |
90F 194C |
Imo AB E4 Three Screw |
|
51 m^3/h 225 GPM |
160 bar 2‚300 psi |
155F 311C |
Imo AB Dd Three Screw |
|
53 m^3/h 343 GPM |
120 bar 4‚061 psi |
150F 302C |
Allweiler VH Three Screw |
|
91 m^3/h 400 GPM |
103 bar 1‚500 psi |
121C 250F |
IMO 6D Three Screw |
|
91 m^3/h 400 GPM |
138 bar 2‚000 psi |
120C 250F |
IMO 12D Three Screw |
|
130 m^3/h 573 GPM |
120 bar 5‚061 psi |
250F 482C |
Allweiler SM Three Screw |
Bearing Lift
Bearing lift pumps provide the necessary high pressure “jacking oil” to lift the turbine generator shafts within the sleeve bearings on horizontal machines and to the lower thrust bearing of a vertical turbine prior to starting the rotation of the hydro turbines.
Crescent Internal Gears are a common choice here for their low initial cost and superb reliability.
| Flow Rates up to | Pressures to up to | Max Fluid Temperature | CIRCOR Brand & Series |
|---|---|---|---|
|
28 m^3/h 125 GPM |
345 bar 5‚000 psi |
82C 180F |
IMO CIG Crescent Internal Gear |
Oil Service
PurLube:
If you’ve worked in a power plant‚ you know how difficult it is to keep water out of your machinery and lubrication systems. When water finds its way into a lube oil system‚ it increases the risks of corrosion‚ wear and premature failure.
Commonly installed in a kidney loop off of the main lube oil console; the Purlube is able to pull lubrication oil from the system and return it after treatment. Inside the PurLube‚ oil is heated to 180F without causing thermal or oxidative stress to the oil. Next‚ a venture draws air into the oil creating small air bubbles. When the air bubbles mix with the heated stream of lube oil‚ the volume and surface area of the bubbles expand causing any moisture that contacts the bubbles’ surface to evaporate into the heated air inside the bubbles. The oil stream is them passed through a settling tray allowing the bubbles to come to the surface and break‚ allowing the formerly entrained water to simply escape as evaporating water vapor.
The PurLube system removes all three forms of water contamination in lubrication oil – free‚ emulsified and dissolved – to lower than 100ppm. Additionally‚ the discharge does not contain any oil or emulsion and maintenance is relatively low because the system only has one moving part‚ the oil recirculation pump.
Oil Mist:
Oil mist is a centralized lubrication system used to lubricate specific rolling element bearings‚ pump bearings‚ electric motor drivers‚ bearing housing of small steam turbines with sleeve bearings and purge gearboxes.
The LSC Oil Mist in the oil mist system uses compressed air to atomize oil into micro-size particles‚ which can be effectively moved to lubrication points up to 600 feet (180 meters)‚ through piping and tubing. The benefits of oil mist and lubrication are well documented. Providing the right amount of lubrication to your rotating equipment lowers the bearing temperature‚ reduces energy loss and extends the life of your equipment. Oil mist has reduced bearing failures in centrifugal pumps and electric motors by 90% and increased mean time between failure for mechanical seals by 100%.
Hydro Overview
How a hydro power Plant works:
Via gravity‚ water is channeled through a dam directly to a turbine‚ which then drives rotation of the turbine. The rotation of the turbine drives the rotation of a generator and ultimately production of electricity. After water is passed through the system‚ it continues downstream. The greater the difference between the top and bottom of the water levels‚ the greater the amount of electricity that can be produced. Hydro plants are some of the most efficient power plants in the industry.
One of the most famous dams in the world is the Three Gorges Dam in China. CIRCOR has supplied pumps for the lube oil package used on all 27 turbines as well as hydraulic pumps for the governors.
Circor Capabilities
CIRCOR brands Allweiler‚ IMO‚ IMO AB‚ provide pumping solutions for critical applications in hydro power plants with a product offering that includes three screw pumps‚ crescent internal gear pumps‚ and centrifugal pumps.
| Pump Applications | Engineered System Applications | Oil Service |
|---|---|---|
|
Lubrication |
Lubrication |
PurLube |
|
Hydraulic Power (Governor‚ Wicket Gates and Hydro Propellers) |
Hydraulic Support |
|
|
Bearing Lift |
|
|