Analysis of the advantages and disadvantages of two different designs for the steam turbine safety and lubrication systems. One key advantage of the main oil pump without a spindle drive is energy efficiency. Normally, the lubricating oil supply in steam turbines is provided by the main oil pump through an oil injector, which has very low efficiency. The power required by the main oil pump is usually much higher than that of the electric lubricating oil pump, and the inefficiency of the oil injector is one of the main reasons. Currently, most domestic units above 100MW have undergone DEH system upgrades. For these units, the main oil pump often has excess capacity because it no longer needs to supply control oil to the speed control system, offering significant energy-saving potential. According to initial estimates, a 200MW unit can save around 100,000 yuan in electricity costs per year.
Reducing failure risks is another benefit. The main oil pump driven by the main shaft is mounted on the short shaft of the steam turbine, which requires precise installation and often leads to malfunctions. For example, the main oil pump in a 300MW unit frequently causes high thrust bearing temperatures. In a 125MW and 100MW unit, abnormal operation has occurred due to foreign matter blocking the main oil pump inlet. Some 125MW units experience issues with porous injectors that cannot withstand the oil flow erosion, leading to frequent part replacements. Moreover, the small shaft of the steam turbine is often subjected to large variable torques, which may cause the bolts to break—resulting in serious consequences. In one case, the small shaft of a 200MW unit broke, causing the control system to lose speed feedback and resulting in overspeed. Similarly, a 300MW unit in Shandong experienced near-disaster conditions when its small shaft was almost broken.
Additionally, the new design system is simpler, more reliable, and significantly reduces maintenance workload. With fewer components and less complexity, the failure rate is lower, making the system easier to maintain and operate over time. This improvement not only enhances system stability but also contributes to long-term cost savings and operational efficiency.
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