Rolls-Royce Power Engineering plc Technical Support Warwick, Coventry CV34 6DA, England Telephone:+44 (0)1926 3 07700

Fax: +44 (0)1926 3 07987 www.energymanager-online.com

®

ro
Model: AVON SB No. 0122 Page 1 of 9

®

S E R V I C E

B U L L E T I N

© Rolls-Royce Power Engineering plc (Date as shown) The information in this document is the property of Rolls-Royce Power Engineering plc and is confidential. The information may not be copied, or communicated to a third party, or used for any purpose other than that for which it is supplied, without the prior written consent of Rolls-Royce Power Engineering plc.

Date: November 2011 GAS GENERATOR LUBRICATING OIL SPECIFICATION APPLICABILITY This Service Bulletin is applicable to all Industrial Avon gas generators and replaces Service Bulletin Nos.85, 113 and 116. EFFECT ON SAFETY This Service Bulletin affects the safe operation of the equipment and it is important that you comply with its instructions. REASON The purpose of this Bulletin is to provide a single Service Bulletin to reference Avon Gas Generator Lubricating Oil Requirement for operators, and includes the following: (1) (2) (3) (4) An update to the list of approved oils. Acceptable method of changing/intermixing lubricating oils. Monitoring of the oil supply temperature. Acceptance levels for oil acidity and the associated corrective action if the acidity is unacceptable. This includes oil quality limits and recommended test methods. Best practice for testing for wear metal contaminants. Preventative measures to avoid oil system contamination. Inform operators that lubricating oil drained from demisters can be re-used provided the oil quality is within the acceptance limits specified here.

(5) (6) (7)

Whilst this information is given in good faith, based on the latest information available to Rolls-Royce Power Engineering plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce Power Engineering plc or any of its subsidiary or associated companies. Rolls-Royce Power Engineering plc, Registered office: Moor Lane, Derby DE24 8BJ Company number: 1305027, Registered in England Produced in Great Britain

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 2 of 9

ACTION (1) Table 1 gives a list of currently approved lubricating oils. Approval is granted by Rolls-Royce solely on the basis that oil will not adversely affect the gas generator components, seals and coating. TABLE 1 - APPROVED LUBRICATING OILS Lubricating Oil BP Turbo Oil 2389 Aeroshell turbine Oil 390 Castrol Perfecto GT5 Castrol Aero 5000 Castrol 580 Caltex Regal SGT22 Chevron Synthetic Oil SGT Aeroshell Turbine Oil 500 (ASTO 500) Aeroshell Turbine Oil (ASTO 560) Mobil Jet Oil II BP Turbo Oil 2380 (BPTO 2380) Turbo Nycoil 600 Total Preslia SE Jet (Total Jet Turbine 530) Texaco Regal SGT22 Petronas Jenteram Syn AE Viscosity (centistoke) 3cSt 3cSt 4.5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt 5cSt

NOTE 1 NOTE 2
(2)

Castrol Perfecto GT3000 has been discontinued. Any existing stocks of this brand may be consumed. BP Turbo Oil 2389 has now been approved for use in the Industrial Avon.

Intermixing of Lubricating Oils.

CAUTION IT IS CRITICAL THAT ONLY OILS FROM WITHIN THE SAME
VISCOSITY GROUPING AND SPECIFICATION ARE MIXED TOGETHER. It is advised where Operators are using 3cSt gas generator lubricating oils, consideration should be given to changing over to a higher viscosity oil, i.e. 4.5 or 5cSt. A list of approved oils is given above in Table 1.

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 3 of 9

Due to the different swell characteristics of the internal ‘O’ seals, in response to changes in oil types, oils should only be changed by the following methods to prevent oil leakage.

CAUTION THIS PROCEDURE SHALL ONLY BE CARRIED OUT WITH NEW
OR OVERHAULED ENGINES, WHEN IT IS KNOWN THAT ALL THE ‘O’ SEALS HAVE BEEN REPLACED WITH NEW SEALS. (a) When changing to a higher grade oil i.e. 3cSt to 4.5 or 5cSt, drain the complete lubricating oil system, flush with clean oil to the higher grade and replenish with new oil.

CAUTION IT IS CRITICAL THAT ONLY OILS FROM WITHIN THE SAME
VISCOSITY GROUPING ARE MIXED TOGETHER. (b) Approved oils within the same viscosity grade can be changed by topping up the oil tank. As the level in the oil tank decreases replenish with the new oil.

(3)

Operators should monitor the oil supply temperature, as close to the gas generator oil inlet position as possible, ‘on a daily basis and take remedial action if the temperature is in excess of the limits below. Oil supply temperature instrumentation should be regularly calibrated. The recommended temperature limits are as follows:Normal operating temperature = 60 deg.C. Alarm set point = 70 deg.C. Trip set point = 90 deg.C.

(4)

Gas Generator Oil Degradation. Gas generator synthetic lubricating oil undergoes a process of oxidation and thermal breakdown during normal service operation. In healthy oil systems the rate of oil replenishment through tank top up prevents significant degradation of the oil. However, degradation has affected some operations, with a steady increase in acidity re-occurring despite oil replacement being undertaken. This high level of acidity has led to ‘O’ seal failure and associated oil leakage requiring removal of the gas generator for repair causing loss of availability and increased downtime. This section defines the necessary corrective action to restore the oil system to an acceptable condition when acidity levels exceed a TAN of 2. This is required as the residual high TAN oil in the system contaminates the new oil leading to continued degradation.

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 4 of 9

Rolls-Royce recommends regular oil sampling to maintain oil health and hence gas generator health. Normally regular oil sampling should be undertaken quarterly, after 2,000 running hours or at the same interval as oil filter replacement, whichever is the sooner. Where a reading higher than 1 is found then a reduced sampling interval is recommended, monthly for example. The maximum TAN should not exceed 2. Table 2 defines the acceptance levels for oil acidity and the necessary corrective action for an oil change, if the acidity is unacceptable. In extreme cases this may include an oil system drain and flush. These corrective actions reflect service experience with degradation of synthetic oils not only from the Industrial engines but also from the aero engine fleet.

NOTE

Before flushing a system, or even earlier when TAN levels start to increase, every effort should be made to ensure that the source of acidity increase is resolved. This may be caused by water entering the system, due to condensation or leakage. TABLE 2 - ACCEPTANCE LEVELS Oil Sample TAN (Total acidity number mg KOH/g) 1 or less 1-2 2-5 Action No action required Increase sampling frequency Drain oil system Clean tank and refill with fresh oil 5 or more Drain oil system Clean tank Flush system with fresh oil Drain Replace filters and refill

WARNING IF SYNTHETIC OIL COMES INTO CONTACT WITH THE SKIN IT
MAY BE ABSORBED INTO THE BODY. THEREFORE, OIL CONTACT WITH SKIN SHOULD BE AVOIDED. IF CONTACT OCCURS FLUSH THE OIL FROM THE SKIN WITH WATER. FOR FURTHER INFORMATION REFER TO THE APPROPRIATE MANUFACTURER’S SAFETY DATA SHEETS.

November 2011 © Rolls-Royce Power Engineering plc

r
Check

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 5 of 9

The analysis of gas generator lubrication oil to check for acidity shall be to the test methods and acceptance limits specified in Table 3 in this Service Bulletin. TABLE 3 - OIL ACCEPTANCE LEVELS Maximum Approved 5 cSt Lubricant 15 ASTMD445 2.0 0.06* 240 Minimum ASTMD92 Insoluble Material - % Weight Metals 0.1 See para.(4) Defence Standard 05-50 (Part 61) Method 12 AA/ICP SAE ARP 5088 ASTMD6304 IP36 Flash Point (COC) deg.C. Test Method IP71

*Property Change over New Oil Value Absolute limit as a rejection level

Kinematic Viscosity Increased at 100 deg.C. - % Total Acidity Number (TAN) mg KOH/g

Total Water Content - % Volume

* The decrease in water content limit from 0.1% to 0.06% by volume is due to in-service experience where water contents higher than 0.06% have led to rapid increase in TAN (acidity) levels (5) Testing for Wear Metal Contamination. Wear metal elemental analysis provides a measure of the overall "health" of the operating unit. The presence of trace metals in the oil is expected and most do not substantially change the performance of the oil, but do indicate wear and potential damage to the unit.

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 6 of 9

The following are common wear metals or contaminants for rotating equipment: • Chromium • Aluminium • Iron • Nickel • Copper • Lead • Tin • Silver • Antimony • Sodium • Zinc Periodic oil analysis and charting of the results provide an effective means of monitoring unit health through incremental change in wear metal content. Such trend analysis is recommended rather than establishing conditional limitations on wear metal content. Rolls-Royce advises operators to obtain monthly oil analyses using the test method as per Table 3, study the results, and make decisions based on incremental changes for each unit. For example, a significant increase in wear metal content is an indicator that something is going wrong. Waiting until the end of major maintenance cycles, e.g., at 2-years or 5-years, to increase oil analysis frequency, is not recommended. Gas Generator engines operating in particularly harsh environments should consider more frequent sampling to prevent a situation deteriorating.

NOTE

Engines equipped with QDMs (Quantitative Debris Monitors) are not exempt from these requirements. Oil samples and analysis are still essential for optimum equipment life.

Rolls-Royce would welcome copies of the reported analysis to provide assistance in this study. Alternatively, oil samples may be sent to Rolls-Royce for analysis. For this option, please contact your local Rolls-Royce Customer Service Centre to make arrangements. Preventative measures should also be taken to prevent wear metal contamination. These recommendations are made in para.(6).

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 7 of 9

(6)

Preventing Gas Generator Oil System Contamination. There have been incidents of carbon formation in oil pipes. In extreme cases this could lead to pipe blockages and inadequate oil scavenging, with the possibility of an internal oil fire. Investigations have found that this may be caused by zinc contamination of the synthetic oil. It is often very difficult to trace the source of the contamination but one source identified is the use of galvanized containers for filling and topping up of oil systems. The following metals have a catalytic reaction with synthetic oil and must not be used in oil systems, or for the storage or transportation of synthetic oil, particularly during filling and topping up of oil systems. These are zinc, copper, cadmium and lead. Wherever an operator undertakes maintenance on an oil system, refills or tops up the system or needs to modify or add components to an oil system, the following materials must not be used, or the oil allowed to come into contact with these materials. (a) (b) (c) Zinc, zinc alloy die casting or zinc protective coatings (e.g. galvanizing). Nominally pure copper including copper coated materials. Cadmium in any form (e.g. cadmium plating or brazing alloys containing cadmium). Nominally pure lead or alloys containing lead (e.g. white metal bearings and solder).

(d)

NOTE

An exception to (d) is the use of lead bronze bearings where a maximum lead content of 3% is permissible.

For topping up of oil systems, ideally the oil should be added directly from the supplier’s container, but if an intermediate container is to be used then ideally it should be clean stainless steel or plastic.

NOTE

If using plastic containers, care should be taken to make sure compatibility with synthetic oil. The oil manufacturers guidelines will be able to advise on compatibilities with plastic.

The test method to check for metal contamination in gas turbine lubricants are specified in the acceptance criteria shown in Table 3 with recommended best practice in para.(4).

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 8 of 9

(7)

Lubricating Oil Console Demister Oil. This action is applicable to lubricating oil consoles fitted with a lube oil tank demister system where the demister oil is not automatically returned to tank.

WARNING 1 OBSERVE ALL HEALTH AND SAFETY PRECAUTIONS WHEN
HANDLING SYNTHETIC OIL. CONTACT OIL MANUFACTURER FOR SAFETY DATA SHEETS.

WARNING 2 AVOID CONTACT WITH HOT OIL.
(a) Oil should be drained from the demister into a clean container, following an engine shutdown or on a monthly basis, to minimise acidic vapour condensation. The container should not be used for any other liquids/substances to avoid contamination of the oil. Record the quantity of oil drained from the demister. (b) Analyse the collected oil as specified in Table 3. Subject to satisfactory conditions, the collected oil may be returned to tank for re-use. If the oil is outside of the specified limits then it should be disposed of subject to local legislations. On a unit by unit basis, operators may establish that the procedure can be carried out less frequently once they have accumulated enough analytical results. Rolls-Royce would welcome copies of the reported analysis. Alternatively, oil samples may be sent to Rolls-Royce for analysis. For this option, please contact your local Rolls-Royce Customer Service Centre to make arrangements.

(c)

(d)

November 2011 © Rolls-Royce Power Engineering plc

r

AVON
INDUSTRIAL APPLICATIONS SERVICE BULLETIN SB No.0122 Page 9 of 9

COMMUNICATION If you have any queries all communication should be addressed to: Customer Business Rolls-Royce Power Engineering plc The Iceni Centre Warwick Technology Park Warwick CV34 6DA Tel: +44 (0)1926 3 07700 or 07701 Fax: +44 (0)1926 3 07987 Customer Business Rolls-Royce Energy 8303 McHard Road Houston TX 77053 USA Tel: +1 281 436 6700 Fax: +1 281 436 6777 Customer Business Rolls-Royce Industrial Power Engineering (Overseas Projects) Limited HQ Building, 7th Floor, SW Raha Beach PO Box 144294 Abu Dhabi UAE Tel: +971 2 616 9000 Fax: +971 2 616 9051 Customer Business Rolls-Royce Brasil Ltda. Av. Almirante Barroso, 52 - sala 2001 20031-000 - Rio de Janeiro Rio de Janeiro Brazil Tel: +55 21 2277 0100 Please remember to use the international dialling codes. Customer Business Rolls-Royce Singapore Pte Limited 6 Seletar Aerospace Rise Singapore 797575 Tel: +65 6240 3333