Professional Documents
Culture Documents
MaintenanceandAnalysis
Copyright20052012,EPT
LocatedinCalgary,Canada
Specialistsin
TurbineVarnishprevention
EHCfluidmaintenance
Onsitelubricantflushing
OilTestingServices
Operatingin20countries
Installedonlargestplantsin
Asia,Europe,MiddleEastand
NorthAmerica
PartneredwithHypro 2
Filtration
www.filterelement.com
3
5
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TURBINEOIL
CONDITIONMONITORING
Copyright EPT 2012, All rights Reserved Copyright EPT 2012, All rights Reserved 10
Establishingorupdatingan
OilAnalysisProgram
Oiltestingguidelinesforauxiliarypowerplant
equipmentareestablishedandpublishedin
ASTMD622402
Copyright EPT 2012, All rights Reserved Copyright EPT 2012, All rights Reserved 11
TurbineOilAnalyses
SuggestedFrequency:
Testingfrequencydependson:
Unitcriticality:criticalsystemsshouldbetestedmoreoften.
Unitage:newunitsshouldbetestedmorefrequentlyduringbreakin
(first6months).
Fluidage:fluidsshouldbetestedmorefrequentlywhentheybeginto
approachtheendoftheirlifetime(RPVOT<50%newoilvalue).
Testingshouldalsobecompleted24hoursafteranyoilchange.
AnalysesRecommendedforGasandSteamTurbineUsers:
ISOParticleCount(ISO4406) AirRelease(ASTMD3427)
MPC(ASTMD7843) Demulsibility(ASTMD1401)
Appearance:
Uservisualcheck quickandefficient.
Frequency:atleastweekly.
Appearanceshouldbecleanand
bright.
Hazinessindicates>100ppm
water.
Turbineoilsoftendarkenslowly
overyearsofservice,however,
rapidchangesincolormaybedue
tocontaminationoraccelerated
degradationandshouldbe
investigated.
Viscosityat40C(100F):
ASTMD445
Frequency:Every1 3months.
Warninglimit: 10%newoil.
Mostimportantcharacteristic:dictates
thicknessoflubricatingfilm.
Verysensitivetocontaminationor
severeoildegradation.
Increase:incorrectoilorformation
ofawateremulsion.
Decrease:incorrectoilor
contaminationwithsolvent.
ISOParticleCount:
ISO11500and4406
Frequency:Every1 3months.
Warninglimit:>18/16/13.
Quantifiesparticlesproducedbywear
orcontamination.
Oncepresent,particlescontribute
toacceleratedwear.
Asuddenincreaseof2codesis
causeforconcern.
Strongcorrelationbetweenlower
ISOcodeandincreasedequipment
reliabilityandlifetime.
100000
10000
Particle Count (per mL)
1000
100
ISO(4)
ISO(6)
ISO(14)
10 Servo Failure
Filter Change
Polishing Filter
Conditioning Filter
Fluid change
1
12/10/02 6/28/03 1/14/04 8/01/04 2/17/05 9/05/05 3/24/06 10/10/06 4/28/07
Date (dd/mm/yy)
Copyright EPT 2012, All rights Reserved Copyright EPT 2012, All rights Reserved
RegularTurbineOilAnalyses
VarnishPotential(MPC):
ASTMD7843
Frequency:Every1 3months.
Warninglimit:30 40.
Fluiddegradationleadstothe
formationofcompoundsthatare
precursorstoinsolublevarnishes.
Fluidspotentialtoformvarnishes
quantifiedonascaleof0 100.
0 15:lowvarnishpotential.
16 30:possiblevarnishing.
31 40:probablevarnishing.
>41:currentleveloffluid
degradationwillleadtovarnish.
Unittripslikely.
30
20
10
0
Date
Copyright EPT 2012, All rights Reserved Copyright EPT 2012, All rights Reserved
RegularTurbineOilAnalyses
Moisture
ASTMD6304/D7546
Frequency:Every1 3months.
Warninglimit (ppm):GT=100,ST=200
Waterhinderslubricatingabilityoffluid
whilepromotingacceleratedfluid
degradationandequipmentcorrosion.
Quickcheckoffluidappearanceis
ausefulscreeningtest.
Moisturesources:leakingseals
(ST),leakingheatexchangers
and/oratmosphericcondensation.
RULER
ASTMD6971
Frequency:Every3 6months.
Warninglimit:50%ofnewoilamines.
Determineslevelsofantioxidants
(generallyphenolsandamines)
remainingintheoil.
Oxidationistheprimary
degradationrouteforturbineoils.
Antioxidantscontroltherateof
oxidativedegradation.
Whenantioxidantsaredepleted,
rapiddegradationcanoccur.
RPVOT
ASTMD2272
Frequency:Every6 12months.
Warninglimit:50%ofnewoil.
Determinesoxidativeresistance.
TestmorefrequentlyonceRPVOT
valuefallsbelow50%ofnewoil.
ReplaceoilonceRPVOTvaluefalls
below25%ofnewoil.
ConditionMonitoringbyFTIR
ASTME2412
Frequency:Asneeded.
Warninglimit:statisticallydetermined.
Usedtomonitoroxidativedegradation
ofoilsbyspectralsubtractionordirect
trendingmethods.
Spectralsubtractionmethodoffers
simplifiedinterpretationbut
requiresavalidnewoilsample.
Dataprovidediscomplimentarytothat Source: Noria.
obtainedfrom:
Acidnumber,MPCandRULERtests.
FoamTest
ASTMD892
Frequency:Asneeded.
Warninglimit:450mLtendency,10mL
stability.
Foamingisoftenmechanicalinorigin,
however,itcanalsobecausedbyanti
foamingadditivedepletionoroil
degradation.
Somefoamingisnormal.
Testiffoamingisexcessive.
Excessivefoamingcanleadtorapid
fluiddegradationbymicro
dieseling.
AirRelease
ASTMD3427.
Frequency:Asneeded.
Warninglimit:airrelease<reservoir
residencetime.
Thefollowingissuescanariseifoilis
notgivensufficientresidencetimein
thereservoirtoreleaseentrainedair:
Poorlubrication.
Poorhydraulicperformance.
Inabilitytomaintainoilpressure.
Degradationduetomicro
dieseling.
Wearduetocavitation.
Demulsibility/WaterSeperability
ASTMD1401
Frequency:Asneeded.
Warninglimit:15mLemulsionafter30
minutes.
InGTs,heatdrivesofffreewaterwhile
inSTs,freewatercanbedrainedoff.
IfthefluidhaspoorDemulsibility,
watercanformstableemulsions.
Emulsionshinderthelubricating
abilityofthefluidandexposeboth
equipmentandfluidtothe
damagingeffectsofwater.
InsolublesbyUltraCentrifuge
ASTMD2273
Frequency:Asneeded.
Warninglimit:UCratingof4 6.
Usedtodetectfinelysuspended
insolublesforpoorlysolublesludge
precursors.
ComplimentarytoISOparticle
countandMPC.
FlashPoint
ASTMD92
Frequency:Asneeded.
Warninglimit:17C(30F)decrease
fromnewoil.
Degradationhaslittleeffectuponflash
point,however,contaminationby
lowerboilingsolventslowersflash
point.
Suchcontaminationmayalsolead
toadecreaseinoilviscositywhich
canimpedelubricatingability.
Summary:
Performevery1 3 Performevery3 6 Performevery6 12 Perform asneeded:
months: months: months:
Viscosityat40C(ASTM RULER(ASTMD6971) RPVOT(ASTMD2272) RustTest forGT
D445) (ASTMD664)
TotalAcid Number RustTest forST (ASTM Foaming(ASTMD892)
(ASTMD664) D664)
ISOParticleCount(ISO AirRelease(ASTM
4406) D3427)
MPC(ASTMD7843) Demulsibility(ASTM
D1401)
Moisture(ASTMD6304 Insolubles (ASTM
/D7546) D2273)
Metals(ASTMD5185) FlashPoint(ASTM D92)
Note:Checkappearanceofthe turbineoilforcolorandhazinessfrequently(atleastweekly).
33
Copyright EPT 2012, All rights Reserved
Age of RPVOT Amine Phenol MPC Loss Loss Loss Increase
Oil Rate Rate Rate Rate
Months RPVOT Amine Phenol MPC
Commonquestion.Willmyoillastuntilthe
nextchangeoutintervalin18months?
Age of RPVOT Amine Phenol MPC Loss Loss Loss Increase
Oil Rate Rate Rate Rate
Months RPVOT Amine Phenol MPC
Copyright EPT 2012, All rights Reserved Copyright EPT 2012, All rights Reserved 35
KNOWLEDGEREVIEW
LUBRICANTCOMPOSITIONAND
FORMULATION
36
37
Themajorityofturbinefluidisbaseoil(approximately99%)
blendedwithaboutonepercentadditive.
Theseadditivesmayconsistofantioxidants,rustinhibitors,
foaminhibitors,demulsifiers,antiwearand/orextreme
pressurecompounds. 38
Anti-oxidants
Mainadditiveinturbineoil(90%)
usuallyconsistsofphenolderivatives
&aminederivatives.
39
Amine and Phenol Anti oxidants
Appliedvoltageincreasedovertimeandthecorresponding
currentismeasured.Allmoleculesrespondtodifferent
voltages 40
MitsubishiHeavyIndustries(MHI
developedatesttostudy
sludgeformationinturbine
oils,ModifiedTOSTtest(D
943)
Runat120C,withoutwater
Tested20commercially
availableturbineoils
Passinglimit:<100mg/kg@
25%residualRPVOT
41
FormulationComparison
6DifferentTurbineLubes
1600
1400
ArbitraryRULERNumber
1200
1000
800
600
400
200
Time(s)
42
OilFormulationTrends
Formulationchemistryplaysasignificantroleinthe
varnishtendenciesofthelubricant
Oilswithamixedantioxidantsystemappearto
performbetterthanoilswithanamineorPhenol
onlysystems.
Phenylalphanapthylamine(PANA)isacommonly
usedantioxidant.Upondepletion,PANAcancause
significantdeposits.
LubeOilVarnish
What is Varnish? A thin, hard, lustrous, oil-insoluble deposit, composed primarily of
organic residue, & most readily definable by color intensity. It is not easily removed by wiping
with a clean, dry, soft, lint-free wiping material and is resistant to saturated [light hydrocarbon]
solvents. Its color may vary, but it usually appears in gray, brown or amber hues.
ASTM.D02C.01 definition
Varnish can be soft Varnish can be hard Varnish on reservoir Varnish deposits on
and gooey (Sludge) and brittle (Lacquer) ceiling (Stalactites) reservoir floor (Plated)
Thermal
Oxidation
Degradation
Spark
Water
Discharge
Micro
Oxygen dieseling
Metals HotSpots
46
Sparksonthereturnlineina
steamturbine.
A video of spark events from the return line in a steam turbine lube system.
LubeOilVarnish
Varnish Formation Step 1: Lubricant Upset
Oxidation
#1 cause of fluid breakdown by water,
entrained air, and heat.
Oxidation
loss of electron = polar free radical
Oxidation byproducts (free radical)
Acids
Alcohols
Lactones
Esters
Oxidation byproducts
attack hydrocarbons
Anti-oxidant additives
Oxidation inhibitor = arrest free radicals
Sacrificial (depletes)
Copyright EPT 2012, All rights Reserved 48
LubeOilVarnish
Varnish Formation Step 2: Soluble
Impurities
Soluble oxidation byproducts
Absorbed in oil as byproduct is created
Polar
Oxidation byproducts
no longer absorbed in oil
Affects on oil
Additive package depletes rapidly
AN increases
Viscosity increases
Sludge & sediment build-up
Patch test & analysis determine the potential of a fluid to form varnish
QSA Quantitative Spectro Analysis (Analysts, Inc.)
MPC Membrane Patch Colorimetric (ASTM standard, Insight Services)
Others Some independent labs have their own patch method
Polar soluble oxidation byproducts must be removed before oil saturation point is
reached. Not doing so leads to insoluble molecules and varnish
formation
Ion Charge Bonding (ICB) is the only technology that can remove the soluble impurities
1. Eliminates varnish forming insoluble oxidation byproducts
2. Restores oil solubility (health), allowing the oil to clean the system
3. Varnish deposits dissolved back into the oil and removed by ICB element
Evidence of sparking
RichardTrent
Richard.Trent@hyprofiltration.com
www.hyprofiltration.com
+2054926666
PeterDufresne
pdufresne@cleanoil.com
www.cleanoil.com
4034501755
4033894104Cell
Copyright EPT 2012, All rights Reserved 75