Lube Oil Console by GPE

In rotary equipment, lubrication is one the most important factor. The lube oil system (console) is usually used to cool, lubricate the hydrodynamic bearings of the turbines, generators, pumps, gear boxes and the gear assembly of gear box. It is forced lubrication method. Its main function is to take lube oil from the tank, pump it to high pressure and send to the turbine, generator, pump and gear box. Lubrication reduces the friction during the operation results in higher efficiency, longer maintenance intervals and lower maintenance costs. The lube oil system (console) duty is to provide oil with the specified pressure, temperature, flow and quality to the bearings, gear, etc. In addition to lubrication some equipment’s needs additional requirement of hydrostatic starting aid (jacking oil system).

GPE meets specific requirement of customers for any application by customization and provides technical support for installation, commissioning, overhaul, repair and spares and services.

Lube oil system operation:

The return line from the gearbox is connected to the tank. The return oil from the lubricating components have high temperature and may contain some impurities. While oil is settling in the tank, some oil vapor and other gases will be vented by a fan to the atmosphere.
Heater immersed in the Lube oil tank are used to raise the oil temperature to permit pump operation. Once the pump is operating and oil temperature is above 40°C, the heaters are shut off. The heaters can be electrical or steam/hot water coils.
The pump sucks the oil and pushes it to the cooler; if the temperature is high, it enters the cooler; otherwise, the temperature control valve (TCV) operates and bypasses the oil and lets it go to the filter. Pressure control valve (PCV) are the automatic pressure-limiting device. PCV senses the pressure at the lube oil return line and controls that to required set pressure. If the pressure drop of filter exceeds the allowed magnitude, the filter element must be removed, cleaned, or replaced. After the filter, oil goes to the bearings, gearboxes, etc.
Some components may require high-pressure oil for lubrication, in such cases, gear pumps increase the oil pressure before entering the component.

GPE specializes in designing and manufacturing of consoles, including Lube Oil Systems, Cooling Water Consoles, Filtration Skids, and Pump Skids. We design systems in line with customers’ requirements, API guidelines, ASME standards etc. We offer robust engineering and advanced software to design consoles with precision. Our testing setups verify process parameters and validate it as per customer requirements. For Lube Oil Systems, we check pressure, flow, temperature, outlet oil cleanliness, two pump run test using same grade Oil which will be used at site.

GPE manufacture Consoles which can be skid mounted or tank-mounted as per customer’s requirement. These consoles consists of Base Plate, Tank, Heat Exchangers, Filters, Instruments, Control valves, and Piping – all pre-assembled and ready for transport as a single unit. We’ve successfully tested and dispatched Lube Oil Consoles, Cooling Water Consoles, and Pump Skids.

Lube Oil Consoles

  • We specialize in supplying Lube Oil Consoles as
    per API 614 5th and 6th Edition. Our design
    process adheres to HTRI, PV Elite, TEMA guidelines
    and ASME Section VIII for heat exchangers and vessels.
  • The consoles are skid mounted or tank mounted
    and designed to be shipped in fully assembled condition.
  • We provide customized designs to meet customer
    specifications, space constraints and terminal
    point location requirements. We create 3D models
    for accuracy and visualization.
  • In-house testing facilities: Flushing; Mechanical Run Test, 2 Pump run test, Vibration check, Pump Motor shaft Alignment, Pressure -Temperature & Flow check & all NDT requirements

Cooling Water Consoles

  • We design Cooling Water Consoles used in process control, temperature regulation, equipment protection from overheating, efficiency improvement and also as an utility water. 
  • We perform Staad analysis to confirm the selected base plate member size and lifting hook sizes are adequate.   
  • We provide customized designs to meet customer specifications and space constraints. 3D models for better understanding 
  • High efficiency Heat exchangers and Thermostatic TCV to control specified water temperature
  • In-house testing facilities: Noise & Vibration checks, Alignment, Pressure, Temperature & Flow measurement & all NDTs

Accessories

Jacking oil system –

A total package will be supplied as per customer requirement. Jacking Oil System can be mounted on the Main Lube Oil System or can be supplied as separate trolley mounted assembly. Due to Trolley mounting arrangement its is very easy to move the trolley anywhere. 

The jack oil pump is used before the startup time; it provides high-pressure oil to elevate the shaft from the bearing surfaces and provide initial lubrication

Rundown tank –

A Rundown Tank will be supplied as per customer requirement. Rundown Tanks are used to store oil at high level. When the Main Oil tank Oil level lowers below required level, run down tank valve opens and releases the required quantity of oil to make up the required level of oil in the main oil tank. 3. Perfect materials selection considering site conditions, available cooling water quality

Manufacturing and test facility :

Lube oil systems are tested throughout the manufacturing process in order to guarantee a perfect match to their design criteria and to assure long lasting, continuous operation. Intermittent inspection are done to ensure the quality and corrective-preventive actions if anything has gone wrong.  

The following tests are typically carried out at on components, subassemblies and final assembly. 

  1. Dye penetrant test on Root welding 
  2. Hydraulic pressure test on pipe line 
  3. Mechanical run test on complete assembly
  4. Two pump run test 
  5. Changeover test for cooler and filter
  6. Functional test on complete assembly
  7. Pump & Motor shaft alignment check for coaxially  
  8. Sound level and vibration measurement 
  9. Paint dry film thick check as per requirement

Benefits

  • Lube oil system reduces friction and wear – tear of bearing surfaces results in longer life of bearings.
  • Better equipment efficiency
  • The oil levels are continuously monitored by the instruments so no need to worry about less or no oil in the system.

Standard applications

  • Turbine bearing cooling & lubrication 
  • Generator bearing cooling & lubrication
  • Pump bearing cooling & lubrication
  • Gear box & its bearing cooling & lubrication
  • Cooling & lubrication of any other hydrodynamic bearing