NATIONAL THERMAL POWER CORPORATION

OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM

OPERATION GUIDANCE NOTE- OGN/OPS/CHEM/009

Issue No. : 1 Date :

THE EXAMINATION AND MAINTENANCE OF

TURBINE LUBRICATING OIL

Approved for
Implementation by .......................................................
Director (Operation)
Date :..........
Enquiries to : Executive Director, Operation Services.

THE EXAMINATION AND MAINTENANCE OF

TURBINE LUBRICATING OIL

CONTENTS
Page Nos.
1.0

Introduction

2.0

Superseded Documents

3.0

Scope

4.0

Safety

5.0

New Oil

6.0

Oil in Service

7.0

Condition Monitoring of oil in Service

8.0

Review

Table-I

BIS - 1012-1993

Table-II

Test Interpretation Chart

Table-III

IOC-Turbine Oil Limits for Fresh Oil

Page - 1
OGN/OPS/CHEM/009
Issue - 1

THE EXAMINATION AND MAINTENANCE OF

TURBINE LUBRICATING OIL
1.0

INTRODUCTION
Due to high specific loadings of bearings and peripheral speeds of
journals, the duty that turbine lubricating oil is required to perform is
arduous. It has to withstand continuous thermal cycling and a variable
degree of contamination by solid particles, sludge, water, hydrogen and
air. It is required to release readily such contaminants and retain its
lubricating and other properties over very long periods.
The purpose of this Guidance Note is to define the oil monitoring that is
necessary to ensure that appropriate lubricants are used and that any
degradation in service does not result in undue threat to the integrity of the
plant. Interpretation of reason of violation of recommended limits is
tabulated on Table No. II.

2.0

SUPERSEDED DOCUMENTS
Nil

3.0

Scope
The Operation Guidance Note covers the examination and maintenance of
turbine oils used in steam and gas turbines and their associated
generators or pumps. (Note: It is not intended to apply to those gas
generators which use a synthetic lubricant).
In order to provide assurance that the oil is being maintained in a
satisfactory condition, It is necessary to monitor selected properties of that
oil.

4.0

SAFETY

The procedures required by this Guidance necessitate handling/use of

lubricating oils and should be considered in conjunction with the Manual
on Analytical procedures for OIL-86 ZWOD 01003.

Page -2
OGN/OPS/CHEM/009
Issue - 1
5.0

NEW OIL

5.1

All new turbine lubricating oil should comply with above.

5.2

All supplies should either be delivered with a BIS with the procurement
specification or, if a BIS certificate is not available, samples, may be taken
and examined for appearance and viscosity. All samples should be within
the perimitted viscosity range and should appear clear and bright and
visually free from solid and liquid contaminants.

5.3

In the event of a disagreement over the appearance of the oil samples

the presence of contaminants shall be determined. Maximum
concentrations of 0.0007% (7mg/l) w/w insoluble inorganic material and
10mg/l w/w water are recommended (w/w means weight by weight), for
new oil.

6.0

OIL IN SERVICE

6.1

Turbine oils will gradually deteriorate in service due to oxidation and the
presence of water, corrosion and wear products. Purifying equipment is
provided to maintain the quality of the oil supplied to the bearings.
Sampling and monitoring should be carried out on a regular basis to
ascertain the rate of deterioration and to enable necessary corrective
measures to be taken.

6.2

Sampling and Testing of Oil

Representative samples of the oil being delivered to the machine should
be obtained from any convenient point whilst the oil is in circulation, and
tested as specified in Table 1. It may be desirable to obtain samples at
different positions in order to trace sources of contamination, etc.

6.3

Treatment and Maintenance

6.3.1

Water, dirt, hydrogen and air should be removed from the oil as efficiently
and as quickly as the system design allows using the installed purification

Page - 3
OGN/OPS/CHEM/009
Issue - 1
equipment. It is desirable to use condensate or demineralised water for sealing
centrifuges and operation of these at a temperature of at least 80 deg. C is
normally required to break oil/water emulsions. Wet and/or dirty oil returned to the
turbine will eventually manifest itself in corrosion, wear malfunctioning of the
equipment and biological growth.
6.3.2

Water and water/oil emulsion should be drained from the main oil tank drain at
intervals to ensure that a low level of water is maintained in the tank. The
necessary frequency of draining will be determined by local experience.

7.0

CONDITION MONITORING OF OIL IN SERVICE

Periodic monitoring of the condition of the turbine lubricating oil in each
operational unit should be carried out in accordance with Table 1. If parameters
are outside the recommended range, if possible. The reasons for this should be
sought and remedial action taken, if possible. The consequences of continued
operation with oil outside the specified condition should be considered and it may
be necessary to consult the oil supplier to discuss the need for an oil change or
refurbishment of the oil by the use of an additive package.

8.0

REVIEW
The Executive Director, Operation Service, will be responsible for reviewing this
document on two yearly basis or as necessary.

Page - 4
OGN/OPS/CHEM/009
Issue - 1
TABLE - 1, BIS - 1012-1993
RECOMMENDED RANGE
SL. CHARACTERISTIC
NO.

LIGHT
TURBINE
OIL

MEDIUM
TURBINE
OIL

HEAVY
TURBINE
OIL

EXTRA
HEAVY
TURBINE OIL

TEST
METHOD
NTPC

1.

Appearance

Note (3)

Note (3)

Note (3)

Note (3)

2.

*Moisture Content
mg/l w/w

<500
(Note 4)

<500
(Note 4)

<500
(Note 4)

<500
(Note 4)

No.0114-84 Monthly
(Note 2)
No.0.129-84 Once a week
(Note 2)

3.

Kinematic Vicosity
at 37.8 deg. C.,
centistokes (CST)

31-33

45-49

62-69

86-95

No.0106-84 Monthly

4.

Viscosity index, min

100

98

95

95

**

Monthly

5.

Acidity inorganic
mg KOH/gm.

Nil

Nil

Nil

Nil

**

Monthly

6.

Flash point (cleavland

open cup.)0 C min.

200

200

200

200

**

monthly

7.

Copper strip corrosion at 100 deg.C

for three hours.

Not
worse
than 1

Not
worse
than 1

Not
worse
than 1

Not
worse
than 1

**

Annual

8.

Rust preventive
characteristics

Shall
Pass
with artificial
sea water

Shall
Pass
with artificial
sea water

Shall
Pass
with artificial
sea water

Shall
Pass
with artificial
sea water

**

Annual

9.

Emulsion characteristics

40-40-0
(20 min.)

.........

40.40-0
(20 min.)

........

**

Annual

2.0
(after
2500 hrs.)

2.0
(after
2000 hrs.)

2.0
(after
1500 hrs.)

2.0
(after
1000 hrs.)

**

Optional

10. Total acidity after

oxidation, Max.
mg. of KOH per gm
of the oil

RECOMMENDED
FREQUENCY
(NOTE-1)

REMARKS

11. Foaming stability after

10 minutes, max.

Nil

Nil

Nil

Nil

**

Annual

Table-I Contd........

Page - 5
OGN/OPS/CHEM/009
Issue - 1
RECOMMENDED RANGE
SL. CHARACTERISTIC
NO.

LIGHT
TURBINE
OIL

MEDIUM
TURBINE
OIL

HEAVY
TURBINE
OIL

EXTRA
HEAVY
TURBINE OIL

TEST
METHOD
NTPC

RECOMMENDED
FREQUENCY
(NOTE-1)

12. Air release value,

Minutes 0.290 air
content at 50 deg. C.
Max.

11

17

**

Monthly

13. *Mechanical
impurities %

<0.005
(Note-7)

<0.005
(Note-7)

<0.005
(Note-7)

<0.005
(Note-7)

**

Weekly

REMARKS

a) at 24 deg. C
b) at 23.5 deg. C
c) at 24 deg. C
after testing
at 93.5 deg. C.

These are the limits for guideline but it is not given in BIS. These are the limits given on the basis of BS &
DIN.

**

As per NTPC test methods mentioned in Manual on Analytical test procedures for oil, No 86, ZWOD- 01003.

Page - 6
OGN/OPS/CHEM/009
Issue -1
NOTES TO BE USED WITH THE TABLE NO. 1
1.

The recommended frequency of all above tests may be increased if problems

with the plant or the lubricating oil are being experienced.

2.

The recommended frequency of these tests may be decided in the light of local
operating experience and conditions on the plant or as per manufacturers
recommendations.

3.

The requirement of IS-1012-1987 (reaffirmed 1993) is that oil should be

visually clear and free from water, suspended matter, dirt and sediment. Some
darkening with age is to be expected which is not detrimental to the
performance of the oil.

4.

The moisture content of turbine lubricating oil varies widely with plant design
and operational practices, although, it is desirable to keep the moisture content
as low as practicable and below 100mg/l. If this is not achievable with some
plant, excursions above 500 mg/l may be experienced. The reasons for such
excursions should be sought and remedial action taken. More frequent
monitoring may be necessary under these conditions.

5.

These tests may be used for diagnostic purposes, if for example, rapid
darkening or other visual changes occur in the oil.

6.

All test methods are given in manual on analytical procedures for oil no-86
ZWOD 01003.

*7.

Insolubles normal level would be organic insoluble below 20 ppm and inorganic
insoluble below 20 ppm. Thus, attempts should be made in day-to-day practice
to maintain total insolubles below 50 ppm and under extreme conditions, it
should not be allowed to increase above 100 ppm.

Page - 7
OGN/OPS/CHEM/009
Issue -1
TABLE-II, TEST INTERPRETATION CHART
(This table proposes test Limits at which action should be taken, Interpretation of these
limits, and the Action to be taken)
Sl.No. Test
(1)
(2)
1.
2.

3.

4.

5.

Appearance
Moisture

Viscosity

Acidity

Flash point

Limits
(3)

Interpretation
(4)

Action
(5)

As per
Table-1.

1)

More susceptiable to
oxidise and degrade.

2)

Enhance corrosion

Investigate/
check functioning of
centrifuge
equipment.

3)
4)

Deplete additives.
Risk of bacterial/
fungal growth.

5)

Increase moisture in
Hydrogen used for
generator coolant

1)

Oil contaminated

2)

Oil severely degrated.

1)

Oil degraded.

Increase frequency of
testing & investigate
cause.

2)

Oil contaminated

Consider oil change

3)

High acidity will increase

corrosion potential.

4)

Catalyse further
degradation reactions.

1)

Oil contaminated.

-do-

-do-

-do-

2) Oil severely degrated.

Remarks
(6)

Consider for
oil change.

Increase frequency of
testing & investigate
cause.
Consider oil change

Table-II Contd......

PS/CHEM/009
Issue -1
Sl.No. Test
(1)
(2)

Limits
(3)

Interpretation
(4)

Action
(5)

6.

As per
Table-1

1)

The system is very severe

on oil, i.e. it is very
wet and/or dirty.

Investigate
cause immediately and
rectify.

2)

The system is incorrectly

maintained, i.e. water
drainage neglected and/
or centrifuge not operating satisfactorily.

Recheck oil
and consult
oil company
regarding reinhibition if
test result is
unchanged.

3)

Normal inhibitor depletion

in wet system.

1)

Oil degraded.

2)

Oil contaminated.

3)

Oil coolers leakage.

7.

Rust Preventive characterstics

Emulsion
Charateristics

As per
Table-1

1) Investigate
functioning
of purification
equipment/
centrifuge.
2) Check oxidation stability.
3) Check rusting characteristics.

8.

Mechanical
impurities

As per
Table-1

1)

Purification equipment
not functioning correctly.

2)

Severe oil degradation is occuring.

3)

Oil contamination is
occuring.

4)

Additive Precipitation is
occuring.

5)

Due to presence of
Corrosion and/or debris.

Centrifuge
bowl cleaning.

Remarks
(6)

Page - 9
OGN/OPS/CHEM/009
Issue -1
ON REFRERRING, M/S. INDIAN OIL CORPORATION HAS GIVEN LIMITS
OF USED UP AND FRESH TURBINE OIL. REFER TABLE NO. III

Table-III
TURBINE OIL LIMITS FOR FRESH OIL, I.O.C.
CHARACTERISTIC

SERVOPRIME
57
68

32

46

ISD VG

32

46

68

Kinematic Viscosity, cST at 40 deg. C

29-33

43-48

55-60

64-72

74-80

Viscosity Index, Min.

100

98

95

95

95

Flash Point (COC), deg. C, Min.

200

200

210

210

220

Pour Point, deg. C. Max.

(-)6

(-)6

(-)6

(-)6

(-)6

Neutralisation no. mg KOH/gm

0.2

0.2

0.2

0.2

0.2

Rust Test, (D-665 A&B, 24 hrs)

Pass

Pass

Pass

Pass

Pass

Emulsion Characteristics, (D-1401)

20

20

20

20

20

minutes to complete separation, Max.

76

DOCUMENT FOR DISTRIBUTION TO

I.

II.

Power Stations
1.

General Manager

SSTPS

2.

General Manager

KSTPS

3.

General Manager

RSTPS

4.

General Manager

FSTPP

5.

General Manager

RhSTPP

6.

General Manager

VSTPP

7.

General Manager

NCTPP

8.

General Manager

BTPS

9.

General Manager

KhSTPP

10.

General Manager

TSTPP

11.

Addl. General Manager

FCUTPP

12.

Addl. General Manager

BCPP

13.

Addl. General Manager

An. GPP

14.

Addl. General Manager

Au. GPP

15.

Addl. General Manager

D.a GPP

16.

Addl. General Manager

Kw. GPP

17.

Dy General Manger (I/C)

JG. GPP

18.

Dy. General Manager (I/C)

TTPS

Regional Head Quarters

19.

Executive Director (NR)

Allahabad

20.

Executive Director (SR)

Hyderabad

III

21.

Executive Director (WR)

Nagpur

22.

Executive Director (ER)

Patna

23.

Executive Director (NCR)

New Delhi

Corporate Head Quarters

24.

Chairman & Managing Director

New Delhi

25.

Director (Technical)

-do-

26.

Director (Operations)

-do-

27.

Director (Projects)

-do-

28.

Executive Director (OS)

-do-

29.

Executive Director (Engg)

-do-

30.

General Manager (R&D)

-do-

31.

Group Heads in Operation Services

-do-

i)

HOD Group-II

Gas Turbine & Spare Parts

ii)

HOD Group-III

Steam Turbine & Auxiliaries

iii)

HOD Group-IV

CHP, AHP & Offsite

iv)

HOD Group-V

Boiler & Auxiliaries, PBLE

V)

HOD Group-VI

Electrical

VI)

HOD Group-VII

C&L and Technical Compliance

VII)

HOD Group-VII

Chemistry, O/H & Efficiency

VIII)

DGM (OS-ER)