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Introduction Basic turbine lubrication system Turbine lubrication requirements What is a turbine oil & what properties does it need? How do we test and evaluate these properties? Oil and oil system cleanliness Field cases Oil Condition Monitoring Questions
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Oil tank Oil pump Oil cooler Oil supply/return pipes Plain journal bearings Thrust bearing Turbine speed control system & valves Filters Gearbox in geared systems
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compressor
air out
Power turbine
Generator
oil demister
IGV
Oil reservoir Either combined for bearing and control system or separated (2 tanks: 1x bearing oil & 1x hydraulic oil for control system)
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2. Compressor
1. Air intake
Siemens SGT6-6000G Gas Turbine 300 MW to 500 MW for Combined Cycle Applications
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Main lube filter Main pump HP Thrust bearing Main lube oil tank Vacuum extract pump IP
To bearings Hydrogen sealing LP LP Jacking oil feed LP Generator and exciter Stator water cooling
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SWF File
Hydrodynamic
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As the journal begins to rotate, it tends to climb up the bearing and onto a layer of oil. This reduces friction and allows the journal to slide. Increase in rotational speed drawns oil into the wedge-shaped clearance space, and fluid pressure is developed between the journal and bearing. At full journal speed, the converging wedge exists under the journal, and a minimum film thickness exists to one side of the bearing: Hydrodynamic lubrication
PRESSURE FORCES DIAGRAM
BEARING
PRESSURE ZONE
Any Deposit will reduce running clearance and increase bearing temperature.
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SWF File
Hydrodynamic
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Steam turbines use a control system to operate the steam valves This is to control the turbine operational speed (governor) Hydraulic fluid is used to power this system High hydraulic pressures (possible leaks) Steam pipes are above auto-ignition temperature of mineral oils (<400C) Some studies show 2/3 turbo-generator fires due to control oil Less flammable fluids, based on phosphate esters, are very often used (autoignition temp ~600C) Shell product is Turbo Oil DR 46
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Gas turbines use a hydraulic control system to operate the fuel valves and the positioning of the inlet guide vanes This is to control the turbine operational speed (governor) and the air flow during start up The turbine oil is utilized as the hydraulic fluid Servo valves are used to control the hydraulic fluid flow to these operating components These control valves are sensitive to varnish (lacquering) forming insoluble materials that develop in gas turbine oils Varnish formation in a gas turbine oil is a significant characteristic of the operating fluid that affects the safety, start-up, reliability & operation of the turbine
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Magnet
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Typical valve dynamic clearances: Servo-valve Proportional valve Directional valve 1-4 m 1-6 m 2-8 m
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Lubrication requirements
Provide fluid film separation of bearing surfaces Remove heat generated in the bearing Provide protection against rust/corrosion Flush & remove wear debris from the bearing Long oil service life Reduced plant down-time / maintenance costs Trouble-free service
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Base fluid: type, quality & cleanliness Additives: type, concentration & synergy Resistance to oxidation: of the fluid & additive package Ability to prevent formation of varnishes, gums & deposits Air release, Water release & Filterability
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Lubricant
Air Release Emulsification
Energy Losses
Performance
Wear
Viscosity
Surface Activity Chemical Activity
Fatigue
Foaming
Corrosion
Oxidation Stability
Seal Compatibility
Oil Life
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Base Oil 98% Antioxidants Additives ~2% Rust Inhibitor Corrosion Inhibitor Others*
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Lubricant Feature
Viscosity, VI Anti-corrosion Oxidation stability EP Performance ARV, Foaming Filterability
Lubricant Technology
Base Oil Rust inhibitors Base Oil Base oil & AntiOxidants EP/AW Additives Base Oil Defoamer Base Oil/ Additive interactions
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Base oils on their own have limited lubricant performance and lifetimes Additives are used to
extend the base oils life and performance ensure the lubricant exceeds demanding application requirements protect the equipment for wear and protect the equipment from the effects of the process (i.e. water / steam contamination, high temperature etc.) improve surface properties (i.e. reduce foam, improve water separation etc.)
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Frequently used
Anti-oxidants Anti-wear Anti-rust Metal passivators Demulsifiers Anti-foams
Occasionally used
Anti-static Pour point depressant Friction modifier
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Deposit formation
OIL OXIDATION
CONTAMINATION
Oil thickening Lacquering Acidity increase Insoluble deposits from oil External contamination
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Dissolved catalysts
The elimination or minimization of localized hot spots is critical to extended oil life
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All turbine oils will degrade in service with time, but the rate can be controlled with optimised base oil & additive chemistry
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Time
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Principle Accelerated ageing of small oil samples under conditions which attempt to simulate service conditions Methods 1. TOST 1000 hr sludging ASTM D 4310 2. TOST life ASTM D 934 3. RPVOT (incl. modified RPVOT) ASTM D 2272 4. FTM 791c-5308 (including modified FTM) 95 C 95 C 150 C 175 C
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Principle
Impact of temperature on the ageing of small oil samples under conditions which attempt to simulate service conditions
Methods
1. Cincinnati Machine Thermal Stability Test (D 2070) 2. Modified Wolf Strip Test ex DIN 51392 135C > 200C
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> 1 mm dia. air bubbles Rise rapidly to surface Burst or produce foam
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Oil condition invariably diagnosed as foaming problem Majority of cases actually caused by entrained air & poor ARV Addition of silicone anti-foamer seriously worsens aeration Silicones cannot be easily removed once added
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10 8 6 4 2 0 0 2 4 6 8 10
Anti-foam
zero
12
Time (minutes)
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Oil volume = constant Residence time = constant Bubble rise time (DEAERATION) @ depth d, d
x
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Excessive Foaming
Acceptable Foaming
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Local oxidation of oil Adiabatic compression of air bubbles Highly loaded areas e.g. thrust bearings Possible blackening of white metal bearings
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ARV
Foam
Probable cause of fault condition Excessive air entrainment Possible mechanical fault Contamination with silicones Contamination with basic metal salts e.g. engine oil, pipe lagging
Low High
Low Low
High
High
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Measuring Air Release and Foam Tendency, Air release ASTM D 3427, Foaming ASTM D 892
This test evaluates the oils capacity to release air, blown through the sample in a cylinder. The time required is reported The shorter the time the better the result, indicating good performance in the field Test conditions for air release: Temperature 50C reported as time for 0.2 % V/V of air to remain In this particular test the volume of foam, after air has been blown through the sample is measured. Lesser the foam, the better the oil. Test conditions for foam test: Temperature at 24C for 1st & 3rd test Temperature at 94C for 2nd test
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Key property #3: Minimizing the Effect of Water a) Water Separation (Demulsibility) b) Rust and Corrosion inhibition
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Steam leaking from shaft gland Water contamination of top-up oil Oil cooler leaks Condensation of ambient moisture Poor handling practises
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It should be removed as soon as possible It must remain as free water, rather than emulsified water Its source of ingression should be located and eliminated as soon as possible The amount of water in a turbine system should remain below 500 ppm If correctly applied, centrifugation or vacuum dehydration are affective ways to remove water
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Increased system wear break down of oil film Promote corrosion of metal parts Enhance oxidation of the lubricant Degrade filter performance Remove additives Fatigue life of ball bearings used in steam governors Microbial growth in static areas
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ASTM D 1401 40 ml oil, 40 ml water at 54C reported as time to 3 ml emulsion (nearest 5 min) e.g. 40 - 40 - 0 (5 min)
No Clear Separation
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Filterability
Oil filterability is quantified by the measuring the ease with which a volume of oil passes through a filter of known size, or the time taken to block the filter.
Finer filtration is increasingly common in turbines New oil vs. oil in service
Good quality new oil should never cause filter blockage >80% problems in service caused by contamination An oil with excellent filterability will allow the use of finer filtration which will help to improve contamination control
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Particulate contamination
Filter debris Rust and dirt
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Measuring Filterability
Filterability of Turbine Oils Contaminated with Water & Calcium, TMS 511 Hydraulic oil tests ISO, AFNOR, etc Shell uses own method (TMS 511), done wet, with calcium. Calcium additive is similar to the additive used in many motor oils
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Servo valves protected by 5- 10 m filters to achieve target cleanliness of 13/11 to 12/9 within the closed circuit
Oil must not block the servo final filters throughout service life
In service filterability of the oil determines the lifetime of the servo valve protection filters
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The same type MOOG servo final filters after 24000 running hours on SHELL TURBO GT 32
MOOG Servo valve final filter 10 m. Heavy sludge formation after 17000hr
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Relevant for turbines with reducing gear sets Some gearboxes require lubricant with enhanced anti-wear performance Poor load carrying capacity leads to accelerated wear
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Measuring Load Carrying Capacity FZG Spur Gear Test Rig DIN ISO 14635-1
1750 Load Clutch r/min Load Arm Test Gears
Lubricant
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Field cases
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General Electric Frame 9E A low quality mineral oil resulted in deposit formation on alternator bearing in this turbine
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General Electric Frame 9E Flevo 32 Centre bearing # 2 after 40,000 hours on Shell Turbo GT 32
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The same gear box thrust bearing, after 30,000 running hours on SHELL TURBO GT 32 JUNE 1993
Gear box thrust bearing after running on a mineral turbine oil before the swap to SHELL TURBO GT 32 JUNE 1988
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Why Flush?
Critically important to minimise the harmful effects of material debris and chemical contamination on the turbine operation
Material Debris from assembly, transport, maintenance, wear, environment Chemical contaminants improper oils, chemical cleaners, corrosion preventives, water
Shortcuts here can cause problems later Flushing should be seen as an integral part of fluid and equipment life cycle.
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Principles of Flushing
Flushing normally requires: fast turbulent flow (often three times normal system velocity) to dislodge contaminants
the fast flow rate is one reason sensitive components must be blanked off turbulent flow rate
vibration/agitation
to dislodge contamination by mechanical vibration
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Siemens TLV 9013 04 supply <--/17/14 Solar require ISO 16/14/12 (ie <NAS 6) MHI Nagasaki Work ISO -/18/15 (<NAS 9) Toshiba NAS 7 max
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Have I the necessary fluids and filters on site to complete the flushing process? Have I arranged for used/flushing/replacement oil disposal? Have I allowed this downtime in the work schedule? Draining the contaminated fluid from the system whilst still hot aids removal of contaminants from the system.
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Outline procedure
Appropriate fluid Fast turbulent flow Hot fluid Vibration Filtration Analysis of cleanliness levels
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Summary
Turbine fluid base oil performance is intimately linked the quality of the base oil and the additives used Oil oxidation is the main cause of unplanned downtime (excluding external contamination) Specific oxidation tests support oil life estimation Oil condition monitoring is a pro-active maintenance tool that helps to reduce turbine outages Sample quality is essential for reliable analyses results Flushing maximises turbine oil life and minimises outages
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Machine failures contamination, particles, moisture, chemicals, air, heat, deterioration products influences oil properties: viscosity, additives, lubricity resulting wear debris: metal particles, corrosion products corrective pro-active
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Sampling frequency see later slide Identify appropriate oil tests and limits see later slide Interpretation of data trend analysis, baseline is new oil
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ASTM D4378-03 Standard Practice for In-Service Monitoring of Mineral Turbine Oils for Steam & Gas Turbines OEM guidelines: GE, Alstom Power, Siemens, Solar Operational factors affecting service life
Type & design of system Condition of system at start-up Original oil quality System operating conditions Contamination Oil make-up rate
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Property
Method
New fluid
1 week
1 month
3 months
Subsequent operation
Appearance / colour
ASTM D 1500 Y Y Y Y Y Y Y Y Y Y Y Y Y Every month Every 3 months Every 3 months Every 3 months Every 3 month
Y Y Y Y
ASTM D 6304 ASTM D 2272 In house ASTM D 3427 ASTM D 1401 ASTM D 892
Y Y Y
Y Y
Troubleshoot only
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Appearance/colour Viscosity at 40 C Wear metals analysis Acid number Cleanliness Water RPVOT Sludge
look for rapid colour changes consider oil change if +/- 10 % of original investigate possible causes if any significant increase consider oil change if increase over new oil 0.3 to 0.4, check RPVOT, and Millipore filtration inspect oil and breather filters in case of increase if greater than 0.05 % if less than 25% of original consider oil change if more than 3 mg/100ml investigate further
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25% of initial RBOT of Turbo CC 32 Traditional turbine oil initial RBOT <500 mins
5000
10000
15000
20000 25000
30000
35000
40000
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Phenolic antioxidant Phenolic Intermediate A formed by reaction with radicals Phenolic Intermediate B formed by reaction with radicals
species concentration
Time
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500 450
RPVOT NORM Colour
12
Ref.
RBOT in minutes
400 350 300 250 200 150 100 50 0 0 20000 40000 60000
10 8 6 4 2 0
Ref. NORM
80000
100000
120000
Running hours
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Colour
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Sampling
WHERE
HOW
On the same spot Halfway down oil tank In oil feed (high pressure) In return line (low pressure)
BY WHOM
WHEN
SAFETY MEASURES
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Summary
Base oil performance is very important because of low turbine oil additive treat rate Oil oxidation is the main cause of unplanned downtime (excluding external contamination) Specific oxidation tests support oil life estimation Oil condition monitoring is a pro-active maintenance tool that helps to reduce turbine outages Sample quality is essential for reliable analyses results
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