20 Lubrication

Lubrication of rotating equipment
Oil characteristics and more
Ronald Bakker Shell Global Solutions
Shell Global Solutions International B.V., 2010. All rights reserved.
Contents
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
Shell Global Solutions International B.V., 2008. All rights rights reserved. Shell Global Solutions International B.V., 2010. All reserved.
Common Turbine Lubrication System Features
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
Typical Gas Turbine Lubrication System

cooling air
compressor
air out
Power turbine
Generator
oil demister
IGV
duplex filter lube oil pump hydraulic oil pump
MOOG valves servo protection filters
extra by pass filter
Oil reservoir Either combined for bearing and control system or separated (2 tanks: 1x bearing oil & 1x hydraulic oil for control system)
Industrial Steam Turbine - working
Industrial Gas Turbine
Simplified turbine schematic

3. Combustion chamber 4. Expansion turbine 6. Exhaust
5. Turbine outer casing
2. Compressor
1. Air intake
Siemens SGT6-6000G Gas Turbine 300 MW to 500 MW for Combined Cycle Applications
Picture courtesy of Siemens web site
Industrial Gas Turbine - working
Schematic of Steam Turbine Lube System
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
Purifier Stages (HP, IP, LP) Bearings

Lube oil purifier
Control system not shown
Turbine Components Requiring Lubrication

Journal bearings (Hydrodynamic)
Used to support the weight of the turbine rotors. A journal bearing consists of two half-cylinders that enclose the shaft and are internally lined with Babbitt, a metal alloy usually consisting of tin, copper and antimony
Thrust bearings (Hydrodynamic)

Axially locate the turbine rotors. A thrust bearing is made up of a series of Babbitt lined pads that run against a locating disk attached to the turbine rotor
Turbine Components Requiring Lubrication
Pocket type bearing (jacking hole in centre)
3 wedge bearing (jacking hole off centre)
Tilting pad thrust bearing Tilting pad journal bearing
Typical Turbine and Bearing Oil Flow
SWF File
Hydrodynamic
Hydrodynamic Oil Wedge Principle

At rest, metal-to-metal contact, no oil film layer is present.
JOURNAL
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
HIGH PRESSURES ZONES
Any Deposit will reduce running clearance and increase bearing temperature.
Picture courtesy of PALL
Turbine Components Requiring Lubrication (cont.) Jacking Oil System:

During turning, high pressure jacking oil is used to increase oil film thickness. Also to float the shaft before starting rotation from rest During start-up and shut down the rotor must be rotated slowly (barred) to avoid uneven heating or cooling which would distort or bow the shaft & to prevent them settling in the bearings, due to weight resting on one spot A barring mechanism or turning gear is used to do this
Jacking oil creates hydrostatic lubrication during turning
SWF File
Hydrodynamic
Steam Turbine - Control system
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
Gas Turbine - Control system
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
MOOG Servo Valve
Magnet
Upper pole piece
Flapper Nozzle Spool Feedback spring
Valve - Wear and Sticking

SILT SIZED CRITICAL PARTICLES
Typical valve dynamic clearances: Servo-valve Proportional valve Directional valve 1-4 m 1-6 m 2-8 m
Rotating Equipment Lubricant Requirements
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
Factors affecting fluid performance
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
10
Base oil evaluation
Lubricant
Air Release Emulsification
Energy Losses
Low Temperature Performance
Performance
Wear
Viscosity
Surface Activity Chemical Activity
Fatigue
Foaming
Base Oil Properties

Solvency
Corrosion
Oxidation Stability
Seal Compatibility
Volatility Storage Stability Deposit Formation Electrical Properties
Oil Life
Typical Turbine Oil Composition
Base Oil 98% Antioxidants Additives ~2% Rust Inhibitor Corrosion Inhibitor Others*
Turbine Oil Additive Package * Defoamer, demulsifier, AW/EP Additives, etc.
11
Turbine Lubrication Requirements

Turbine Feature Bearings Lubricant Performance
Hydrodynamic Lubrication Water shedding
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
Steam/H2O Corrosion Resistance Heat Gears Design Hydraulics

Cooling Anti-wear Release trapped air Low foaming Filter compatibility
Shell Global Solutions International B.V., 2010. All reserved. Shell Global Solutions International B.V., 2008. All rights rights reserved.
Additives for Lubricants

Why do lubricating oils contain additives?
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.)
12
Typical turbine oil additives may include
Frequently used
Anti-oxidants Anti-wear Anti-rust Metal passivators Demulsifiers Anti-foams
Occasionally used
Anti-static Pour point depressant Friction modifier
Important Performance Properties of Fresh Turbine Oil
13
Key property #1: Oxidation and Thermal Stability
Effects of turbine oil oxidation
Deposit formation
OIL OXIDATION
CONTAMINATION
Oil thickening Lacquering Acidity increase Insoluble deposits from oil External contamination
Reduced oil life
Blocked filters and valves
14
Basic Lubricant Oxidation Mechanism
Varnish Fresh Oil
Soluble organic acids, plus Soluble polymeric material
Insoluble oxidation products Reduced Oil Life

Two types of oil oxidation
Bulk Oil Oxidation Temperature of bulk oil

Overall heat output Rate of cooling
Thin Film Oxidation
Local hot spots

Distribution of heat

Dissolved catalysts
Oil flow rate Residence time
Excessive aeration Hot sealing air
The elimination or minimization of localized hot spots is critical to extended oil life
15
If a Turbine Oil is Not Sufficiently Stable

In service rapid & extensive oxidation oil insoluble oxidation products
All turbine oils will degrade in service with time, but the rate can be controlled with optimised base oil & additive chemistry
Poor oxidation resistance
16
How Anti-Oxidants Work

Anti-oxidants present to protect the base oil and extend the oil life Anti-oxidants are consumed in service Typically phenolic and/or aminic or combinations of these Primary antioxidants remove radicals but dont remove peroxides Their effect is greatly enhanced when combined with secondary antioxidant to deal with the peroxides
No Anti-Oxidant Primary AO Oxidation or Fluid Life Secondary AO Primary + Secondary SYNERGY
Time
Assessing Oxidative Stability
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
17
Assessing Thermal Stability
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
Key property #2: Air Separation and Foaming
18
Aeration and Foaming
Foaming Oil surface
> 1 mm dia. air bubbles Rise rapidly to surface Burst or produce foam
Aeration Oil Reservoir
10-3 to 1 mm air bubbles Entrained in oil Slow to rise to surface
Aeration and foaming
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
REPLACE ENTIRE OIL CHARGE

19
Effect of silicone anti-foam agents on ARV
Air content (% vol)
10 8 6 4 2 0 0 2 4 6 8 10
Anti-foam
zero
0.2 ppm 2.0 ppm
12
Time (minutes)
Effect of oil reservoir design on deaeration
Oil volume = constant Residence time = constant Bubble rise time (DEAERATION) @ depth d, d
x
20
Dangers of Excessive Aeration and Foam

Loss of oil pressure Reduced oil flow Increased oil compressibility Failure to reach minimum pressure Poor response in high pressure servos Local oxidation of oil Adiabatic compression of air bubbles Highly loaded areas e.g. thrust bearings Possible blackening of white metal bearings Filter blocking Excessive pressure drop associated with no apparent contamination
Visible Foam in Oil Reservoir
Breaks in foam layer
Excessive Foaming
Acceptable Foaming
21
Principle Causes of Excessive Aeration

Inadequately specified new oil Presence of silicone anti-foam agents System design and/or operation
Excessive oil circulation rate Vertical section in oil return line Oil cascading down from excessive height Highly aerated oil fed too close to suction strainer Air leaks in pump suction system Oil pressure too high Vacuum entrainment on high speed plain bearings
Excessive build up of oxidation products Basic metal salts and/or greases
Aeration and foaming: equipment and operation

Excessive oil circulation rate Vertical section in oil return line Oil cascading down from excessive height Highly aerated oil fed too close to suction strainer Air leaks in pump suction system Oil pressure too high Vacuum entrainment on high speed plain bearings
22
Dangers of excessive aeration

Loss of oil pressure Reduced oil flow Increased oil compressibility Failure to reach minimum pressure Poor response in high pressure servos
Local oxidation of oil Adiabatic compression of air bubbles Highly loaded areas e.g. thrust bearings Possible blackening of white metal bearings
Filter blocking Excessive pressure drop associated with no apparent contamination
Diagnosis of aeration / foaming problems
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
23
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
Key property #3: Minimizing the Effect of Water a) Water Separation (Demulsibility) b) Rust and Corrosion inhibition
24
Sources of Water Contamination
Steam leaking from shaft gland Water contamination of top-up oil Oil cooler leaks Condensation of ambient moisture Poor handling practises
When Water is Present in a Turbine System
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
25
Excesses Amount of Water can Cause:
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
Causes of Reduced Demulsibility

Turbine oils are formulated with excellent water separation properties. However the following can degrade performance: Solids: Carbon residue, rust, fly ash and fine particulates, these can be removed by filtration Liquids: Engine Oils (1 part in 1000 is sufficient) Oil soluble materials cannot be removed by filtration, i.e other lubricant, greases, etc. Surface active additives can be removed by excessive water contamination Other: Oxidation by-products Contamination with other fluids containing emulsifiers, metal protective oils, etc. Formation of soaps with rust inhibitors and acidic oxidation products
26
Measuring Water Separation ASTM D 1401, Demulsibility Characteristics
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)
Clear Oil Layer
No Clear Separation
Clear Water Layer
Measuring Water Separation Steam Demulsibility (IP 19)

This method gives a measure of the oils ability to separate from an emulsion with steam. As the oil gets contaminated with fine dispersed water droplets at high temperature this test method is regarded to be much more severe than ASTM D1401 Demulsibility Test (where a 50/50 water/oil mixture is placed at 54 C (130 F) The time for 20 ml of oil to separate is recorded (in seconds) The shorter the time, the better the oil performance Test conditions: 20 ml of oil is violently emulsified with steam at about 90 C (194F) The emulsified test oil is placed in a bath at about 94 C (201F) The time to separate condensed steam (water) is measured
AP/Wide World Photo, www.state.gov
27
Measuring Corrosion Protection Rust test ASTM D 665 / IP 135

To evaluate the ability of oils to prevent the rusting of ferrous parts should water become mixed with the oil. Procedure A= distilled water Procedure B= synthetic sea water The specimens are inspected after the test and are classified as follows: A) B) C) D) E) F) Pass Fail- Dark grey staining noted Fail Light Fail Moderate Fail Severe Fail Severe
Key property #4: Filterability
28
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
Causes of Poor Turbine Oil Filterability

Contamination
A mixture with engine oils Solid, liquid or gaseous (eg process gases like ammonia) contaminant reacts with the additives Water
Oxidation products from oil

Insoluble oxidation products (sludge) Organic acids form soaps with metal salt contaminants
Particulate contamination
Filter debris Rust and dirt
29
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
Blank Filter Membrane (0.8m)
Oil with Acidic Components
High quality turbine oil
SEM Images of filter Elements
Filterability and cleanliness of turbine oils
Protection of control system servo valves

Hydraulic component clearance: up to 5 m high pressure up to 20 m low pressure
Servo valves protected by 5- 10 m filters to achieve target cleanliness of 13/11 to 12/9 within the closed circuit
Service life of filters
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
30
Filterability of fluids important
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
Key property #5: Extra load carrying capacity
31
Extra Load Carrying Capacity
Relevant for turbines with reducing gear sets Some gearboxes require lubricant with enhanced anti-wear performance Poor load carrying capacity leads to accelerated wear
Measuring Load Carrying Capacity FZG Spur Gear Test Rig DIN ISO 14635-1
1750 Load Clutch r/min Load Arm Test Gears
Lubricant
load is raised in stages, inspecting gears at end of each load stage
Failure load stage is when total scouring /scuffing exceeds limits
32
Some examples of high and low quality oils
Field cases
Some examples of high and low quality oils
33
Low quality oils
General Electric Frame 9E A low quality mineral oil resulted in deposit formation on alternator bearing in this turbine
Low quality oils

Power turbine thrust bearing pads: General varnish deposition
34
Low quality oils

Generally bearing in good condition, however black carbonaceous deposits formed after relatively low hours of operation
Low quality oils

Bearing housing cover: Heavy varnish/ carbon deposits, labyrinth seal wear
35
Low quality oils

Very heavy deposition, overlay loss, less than 1 year operation
The right oil makes all the difference
MAAG GEAR BOX, ABB GASTURBINE TYPE 9D

AFTER 24000 HOURS ON A NORMAL TYPE STEAM TURBINEOIL ISO VG 46 SAME GEAR BOX AFTER 35000 HOURS ON SHELL TURBO GT 32
36
High quality oils
35,000 Hrs Turbo GT32 oil service life
Number 9 bearing - right hand of pinion
High quality oils
General Electric Frame 9E Flevo 32 Centre bearing # 2 after 40,000 hours on Shell Turbo GT 32
No deposit formation Absolutely clean labyrinths
37
High quality oils
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
Flushing and Filling
38
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
Proper flushing and filling at the turbine commissioning step will

maximise the turbine oils lifetime minimise turbine outages reduce costs
Shortcuts here can cause problems later Flushing should be seen as an integral part of fluid and equipment life cycle.
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
hot fluid, thermo shock

to expand components of the system and further dislodge contaminants heat also increases the solvency power of the fluid
vibration/agitation
to dislodge contamination by mechanical vibration
efficient filtration to remove the contamination
39
Requirements of a flushing fluid

A flushing fluid must:
be unaffected by the thermal stress of operating at the flushing temperature for a period of hours solvate sludge and oil deposits not remove anti-rust coating from tanks be compatible with all system components and coatings possess good filterability possess anti-rust properties be compatible with the current or previous fill, particularly is a flying flush is being performed Consider the use of a lower viscosity to reach turbulent flow With Shell products it is normally recommended to flush with a charge of the fresh product
Turbine oil flushing and filling

OEM requirement
GE Lubricating oil recommendations (GEK..) refers to

ASTM D6439 flushing & filling, & ASTM D4378 monitoring,
Alstom HTGD 90117 supply --/18/15 or NAS 9, if EHC --/16/13

Service --/16/13 or NAS 7, limit --/17/14 or NAS 8
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
40
Checklist & Tips - some points to consider

Have I a written procedure detailing each step for my system? Have I consulted OEM - procedures on flushing the system (pump speeds, insertion of blanking flanges)? the operator - familiar with the written procedure? fluid supplier (fluid compatibility, flushing temperature, solvency)? Do I have all the appropriate manuals and information to hand? Have I performed analysis of the current fluid in service? What is this telling me?
Is the fluid contamination due to service or a malfunction which flushing will not solve?
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.
Outline procedure
Appropriate fluid Fast turbulent flow Hot fluid Vibration Filtration Analysis of cleanliness levels
41
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
Oil Condition Monitoring
42
Oil condition monitoring
What does it tell us?

Oil properties & condition performance, physical properties Contamination destructive contaminants to oil and machinery Wear debris
All important to reduce machine outages
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
via oil analysis
43
Oil condition monitoring - implementation
Identify oil sampling points

Critical to obtain sample representative of oil condition Turbulent flow area such as turbine bearing return lines, not reservoir Flush sample point Well labelled clean container
Sampling frequency see later slide Identify appropriate oil tests and limits see later slide Interpretation of data trend analysis, baseline is new oil
Guidelines for in service monitoring of RE oils
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
44
Suggested turbine oil condition monitoring

(broadly based upon ASTM D4378)
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
Viscosity 40 C Metals ICP TAN Cleanliness
ASTM D 445 In house ASTM D 664 ISO 4406 / NAS
Y Y Y Y
Water content RPVOT Millipore sludge Air release - Water separationFoaming
ASTM D 6304 ASTM D 2272 In house ASTM D 3427 ASTM D 1401 ASTM D 892
Y Y Y
Y Y
Every 3 month Every 6 months Every 3 months
Troubleshoot only
Microsoft Word Document
Monitoring tests and alert levels (mainly from D4378)
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
45
Oil Condition Monitoring field cases
Estimated oil life

RVPOT Performance of Turbo CC 32 in GE Alstom Frame 6 gas turbine
2000 R B O T , m in s 1500 1000 500 0 0
Best fit curve through RBOT data
25% of initial RBOT of Turbo CC 32 Traditional turbine oil initial RBOT <500 mins
5000
10000
15000
20000 25000
30000
35000
40000
gas turbine service hrs

46
Why RPVOT test ?
Phenolic antioxidant Phenolic Intermediate A formed by reaction with radicals Phenolic Intermediate B formed by reaction with radicals
species concentration
sum of concentration of all antioxidant species
Time
OCM Turbo T in steam turbine application
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
Colour
47
OCM Turbo GT, GE Fr 6B gas turbine

1600 1400 1200 1000 RBOT 800 600 400 200 0 Jan-95
Oil monitoring Turbo GT, GE FS 6 gas turbine

1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 May-95 Jun-97 Aug-98 datum Nov-98 Jun-99 0 Feb-00 visco 40 RBOT TAN
Sampling
WHERE

HOW

On the same spot Halfway down oil tank In oil feed (high pressure) In return line (low pressure)
In the same way With proper/clean equipment
BY WHOM
The same person(s)
WHEN

At the same point of time Warm installation
SAFETY MEASURES

High pressure lines Running equipment
48
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
End of Presentation Thank you for your kind attention
49

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20 Lubrication

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Lubrication of rotating equipment

Oil characteristics and more

Ronald Bakker Shell Global Solutions

Shell Global Solutions International B.V., 2010. All rights reserved.

Common Turbine Lubrication System Features

Typical Gas Turbine Lubrication System

duplex filter lube oil pump hydraulic oil pump

MOOG valves servo protection filters

extra by pass filter

Industrial Steam Turbine - working

Industrial Gas Turbine

Simplified turbine schematic

5. Turbine outer casing

Picture courtesy of Siemens web site

Industrial Gas Turbine - working

Schematic of Steam Turbine Lube System

Purifier Stages (HP, IP, LP) Bearings

Control system not shown

Turbine Components Requiring Lubrication

Thrust bearings (Hydrodynamic)

Turbine Components Requiring Lubrication

Pocket type bearing (jacking hole in centre)

3 wedge bearing (jacking hole off centre)

Tilting pad thrust bearing Tilting pad journal bearing

Typical Turbine and Bearing Oil Flow

Hydrodynamic Oil Wedge Principle

HIGH PRESSURES ZONES

Picture courtesy of PALL

Turbine Components Requiring Lubrication (cont.) Jacking Oil System:

Jacking oil creates hydrostatic lubrication during turning

Steam Turbine - Control system

Gas Turbine - Control system

MOOG Servo Valve

Upper pole piece

Flapper Nozzle Spool Feedback spring

Valve - Wear and Sticking

Rotating Equipment Lubricant Requirements

Shell Global Solutions International B.V., 2010. All rights reserved.

Factors affecting fluid performance

Base oil evaluation

Low Temperature Performance

Base Oil Properties

Volatility Storage Stability Deposit Formation Electrical Properties

Typical Turbine Oil Composition

Turbine Oil Additive Package * Defoamer, demulsifier, AW/EP Additives, etc.

Turbine Lubrication Requirements

Steam/H2O Corrosion Resistance Heat Gears Design Hydraulics

Additives for Lubricants

Typical turbine oil additives may include

Important Performance Properties of Fresh Turbine Oil

Key property #1: Oxidation and Thermal Stability

Effects of turbine oil oxidation

Reduced oil life

Blocked filters and valves

Basic Lubricant Oxidation Mechanism

Varnish Fresh Oil

Soluble organic acids, plus Soluble polymeric material

Insoluble oxidation products Reduced Oil Life

Two types of oil oxidation

Bulk Oil Oxidation Temperature of bulk oil

Thin Film Oxidation

Local hot spots

Oil flow rate Residence time