Vanquishing Varnish Part 1

Jim Hannon, Product Technical Engineer, ExxonMobil Fuels and Lubricants

One common problem that operators in the power industry are consistently facing is the
formation of varnish. Varnish has historically been used as a catch all term for oil
deposits, but specifically refers to the hard, oil insoluble organic residue that cannot be
easily removed from mechanical components by wiping away.
Varnish and sludge, the soft, pliable, organic residue that can be easily removed from
components, form in different ways and there are many factors that contribute to their
formation:
There are three main mechanisms of varnish formation:
! thermal degradation of oil which can take place at temperatures above 300C,
! oxidation, a reaction that acts to decompose the oil,
! and contamination of the oil, through either internal or external sources

Comparison of a new servo valve filter to in-service oil with varnish/sludge.

According to a recent ExxonMobil Fuels & Lubricants survey of 192 gas turbine power
plants, running a combined 626 gas turbines, approximately 40 percent of turbine
operators report current or historical issues with varnish within six years of oil service
life.
Turbines with common hydraulic and bearing reservoirs are far more susceptible to unit
trips or no-starts related to varnish than are turbines with segregated reservoirs.
Additionally, mild varnish can build on journal and thrust bearings with little-to-no
impact on bearing temperatures or shaft rotations. For this reason, early varnish


detection and prevention is incredibly important for common hydraulic/turbine
reservoirs, compared to turbines with separate hydraulic and turbine reservoirs.
Mild varnish can build on journal and thrust bearings with little or no impact on bearing
temperatures or shaft rotations and unit trips or no-starts are rarely, if ever, reported
due to varnish in turbine bearings. For this reason, I want to stress that practices to
encourage varnish detection and prevention should be emphasized on turbines with
common hydraulic and turbine oil reservoirs.
Varnish Theory
While treating the symptoms of varnish with mitigation technologies may extend service
life, for reliable operation it is important to begin with a clean system and use turbine oil
designed to prevent varnish from forming. A well-balanced formulation that utilizes
high-performance base stocks and advanced technology additives will be your first line
of defense against the formation of sludge and varnish. In general, higher group base
stocks blended with advanced technology additives offer the best protection against
varnish.
In my next post, I will provide a number of tips for selecting a well-balanced gas turbine
lubricant to help mitigate the formation of varnish.

Vanquishing Varnish Part 2

Jim Hannon, Product Technical Engineer, ExxonMobil Fuels and Lubricants

In my last post, I provided a brief introduction into the formation of varnish in gas
turbines. In this post, I will provide some insight into the considerations that should be
taken into account when selecting a well-balanced gas turbine lubricant.
The first area of consideration is the turbine oils ability to control deposits. Some oils
generate more deposits than others, but choosing an advanced turbine oil, formulated
to limit the generation of sludge and varnish and keep deposits in suspension, will
greatly reduce the risk of varnish formation.
Varnish Examples from Test Rig

Oil A
1008 hrs

Oil B
1008 hrs

Oil C
672 hrs

Oil D
336 hrs

Some oils generate varnish more than others.

"The above photos show varnish formation of four market available oils from test
rig inspections."
| Proprietary


The second area to consider is an oils oxidation stability.
Turbine bearing temperatures approaching 120C, in combination with equipment
metals, contaminants and entrained air, contributes to the oxidation process that
precedes the formation of varnish. To combat this reaction, opt for lubricants that
feature higher level turbine oil base stocks and carefully selected additives and
antioxidants.
Next, consider air release and foam control.
In an oil with poor air release performance, entrained air can be compressed in turbine
bearings or high pressure hydraulics, which will cause adiabatic compression (a.k.a.
micro dieseling). Adiabatic compression can cause localized elevated oil
temperatures, which may facilitate the formation of varnish.
Excessive surface-level foaming can accelerate the process of oxidation and lead to
operational issues, such as the inability properly measure lubricant levels or the
overflow of oil reservoirs through vents. Oils formulated to promote rapid air release
and minimal foam formation will provide superior protection against the formation of
varnish.
Filterability of a fluid, or the ability to pass through a filter with minimal pressure drop, is
another performance consideration that will contribute to varnish formation. Oils with
poor filterability will pollute filters faster that those with good filterability, which can often
translate into more frequent filter changes.
You should next consider anti-rust and corrosion protection, as rust and corrosion can
also contribute to oxidation and the formation of contaminant-based varnish. For this
reason, you should look for oils formulated to minimize rust and corrosion.
Finally, consider the oils ability to protect against wear.
Wear on high pressure hydraulics, the gears of the accessory gearbox, generator
reduction gear or turning gear, can directly impact on gas turbine performance. Any
wear material resulting from these components can indirectly be a source of varnish
formation, as the wear metals can act as an oxidation catalyst.

Vanquishing Varnish series by Jim Hannon reprinted with permission of the Mobil SHC Club. All Rights Reserved.