The Importance of Oil Cleanliness in

Turbine Reliability
Technical Specialist Group
 Presentation Outline
• Reliability Concept
• Turbine System Lubrication System Requirement
• Lube Oil System as Per API 614
• Basic of Lubricants
• Introduction to PERTAMINA Turbine Oil
• Measuring Oil Cleanliness With Condition Monitoring Program
• Contaminant Management and
 Lost of Usefulness

Obsolescence Surface Degradation Accidents

(15%) (70%) (15%)

Corrosion Mechanical Wear

(20%) (50%)

Abrasion Fatigue Adhesion

“6 – 7 % (over $1trillion) of The GNP is required just to repair the damage caused by mechanical wear”
Professor Ernest Rabinowicz (MIT)
 The Economic Analysis of Maintenance and Lubrication

Typical Cost of Causes of

Maintenance Budget Machine Failures Machine Failures
100%
Lubricants 3% Mechanical Fatigue
Cost of Repair
Misc. Supplies, 12% 15% 9%

Miscellaneous
21%

Maintenance Labor Incorrect Assembly

Addressable (70%)
45% and Misalignment
27%

Incorrect Lubricant,
Replacement Part Cost of Downtime Incorrect Application
40% 85% (Lubrications Issue)
43%

0%
References:
Practical Machinery Lubrication – NORIA
German Steel Industry Association, AIMAN, IRI, SKF, SAIT (2010), DuBois
 Reliability?
• The ability of a system or component to function under stated conditions for a
specified period of time.
 Common Reliability Methodology
RCM RIS RBI RCA

Reliability Centered Reliability Instrumented Risk Based Inspection Root Cause Analysis
Maintenance System
Usually used Rotating Equipment Electrical Static Equipment All, to prevent
for: Equipment failure from re-
occurence
TURBINE LUBRICATION SYSTEM REQUIREMENT
Lube Oil System (API 614)
Reference: API 614, NRD

Bearing Oil Pressure: 1.3 – 3.1 bar

Accumulator Response: < 4s
Oil filter new: < 0.3 bar
Oil filter element change:
DP > 1 – 1.5 bar
Filter Element: 10 -40 micron
Beta 200 minimum.
Oil Out Cooler: < 50 C
Water In Cooler: < 30 C
Oil Tank Temp: < 65 C
 QUIZ 01

https://bit.ly/3bgElwc
DEFINITION
Lubricant
Any material interposed between two surfaces that reduces the
friction or wear, or both, between them.

Lubrication
Lubrication is the process, or technique employed to reduce wear of
one or both surfaces in close proximity, and moving relative to each
another, by interposing a substance called lubricant between the
surfaces to carry or to help carry the load (pressure generated)
between the opposing surfaces

Reference:
ASTM D 4175: Standard Terminology Related to Petroleum, Petroleum Product and Lubricant
 FILM LUBRICATION THEORY
Sliding Mechanism Rotating Mechanism
T
dy dv

µ 
`


T

To

T : Shear Stress (N/m2)  =  dv/dy

m : viscosity (cp)
dv : velocity (m/s2)
dy : film thickness (m)
w : radian velocity (rad/s)
Reference: JW. Munson , “Fundamentals of Fluid Mechanics” – John Willey
To : operating temperature ( C )

To avoid “metal to metal contact”, lubricating system need a minimum dy thickness

 Lubrication Type

Elasto-Hydrodinamic

Film Thickness, Typical Contact AW = Anti Wear

micron Pressure, PSI EP = Extreme Pressure
Regime
Hydrodynamic 5 - 200 100 - 300
Elasto-Hydrodinamic <1 Up to 500,000
Stribeck Curve

Reference: 1. Three Bond – Technical News (Tokyo Institute of Technology)

2. NRD
 Lubricant Functions
Function Description
Friction Control  Make fluid film to avoid metal to metal contact
 Avoid Abrasions and severe wear

Chemical Control  Avoid corrosion

Temperature Control  Action as Heat Transfer

Contamination Control  Carrying contaminant particle to the filter

Reference: NRD
Turbine Lubricating Oil Formulation
• Antioxidants

• Rust Inhibitor

• Foam Inhibitor
Base Oil (Group II and
• Demulsifiers Group III is preferred)
Additive
• AW/EP

Reference: ESB,
NRD
Target : Key Performance Features of Turbine Oils

Reference: ESB
 Non-EP Oils EP Oils
Performance Characteristics BS 489 British
DIN 51515 G.E GEK 32568A US Steel 120 AB8 HTGD 90117
Standard
Viscosity index Minimum 80 - - 100 90
Flash Point (°C),
168 160-215 1 215 190 185
Minimum
Pour Point (°C), Minimum -6 -6 -12 -6 -6
Acid Number 0,2 Report - Report Report

Air Release (DIN 51318, ASTM D327),time (min) 5-10 1 5-6 1 - - 5

Foam Tendency / Stability ASTM D892

Sequence 1 450/2 2 - 10/0 - 450/10
Sequence 2 50/0 - 20/0 - 10/0
Sequence 3 450/10 - 50/0 - 450/0
Demulsibility Steams (S)max 300 300 - - 5

Turbine oil demulsibility ASTM D1401 Minutes - - - 40/37/3 (20) 30

Oxidation Stability
ASTM D943 time to 2.0 AN (h) - 2000 2000 3 1.0 in 1000 2000
ASTM D4310 Sludge (mg), max - - - - 100
IP280 TOP,max 1.0 - - - 1.8
IP280 Sludge %,max 0.4 - - - 0.4
ASTM 2272 Time to 25 PSI Loss (min) - - 450 - -
Cooper strip corrosion ASTM D130, 3h 100°C 2 max 2 max 2 max - 2 max
Rust ASTM D665
A-Distiled Water - Pass Pass Pass -
B-Synthetic Sea Water Pass 4 - - - Pass 4
FZG (A/8,3/90)
Pass Load stage, Minimum - - - - 6-7 1
1
2
Depends on viscosity grade
ISO VG 68/100 requirements sequence I 450/40, Sequence II 100/10, sequence III 450/40 Various Turbine Oil Specification
3
4
Additional oxidation rest FTMS 5308,6 : -5 to +20% viscosity change , 3.0 AN increase
Modified Procedure (OEM and Standard)
PERTAMINA Turbine Oil
 PERTAMINA Turbolube Specification Meet
Turbine
• German Standard DIN 51515
• British Standard BS489:1983
• US Military MIL-L-17672D
• Solar Turbine ES 9-224
• Alsthom Atlantique NBA P50001
• Alsthom HTGD 90 117 V0001S
• General Electric GEK 32568E
• General Electric GEK 101941A
PERTAMINA Turbolube XT Specification Meet
Turbine
• British Standard BS489 (CIGRE)
• Solar Turbine ES 9-224 U
• ABB Stal VTI 3200-3
• Alsthom HTGD 90 117 V0001R117
• General Electric GEK 32568C,F
• General Electric GEK 101941A
• General Electric GEK 107395A
• General Electric GEK 28143A
• General Electric GEK 46506D
• SIEMENS AG TLV 9013 04/01
• MHI E00-87182
• WESTINGHOUSE 21T0591,55125Z3
Hydraulic Gear
• German Standard DIN 51524 Part • German Standard DIN 51517
I Part I and II
• Denison HF-1 • AGMA 9005-D94 (R&O)
• Cincinnati Milacron P-38, P-54, P-
55 and P-57
• Asle 64-1, 64-2, 64-3, 64-4
Hydraulic Gear
• DIN 51524 Part I (HL) • DIN 51517 Part I and II
• DIN 51515 Part I (L-TD) • AGMA 9005-D94 (R&O)
• DIN 51515 Part II (L-TG) • US Steel 120,126
• Cincinnati Milacron P-38, P-45, P- • ASTM D 4304 Type II (EP)
54, P-55
• US Mill MIL-L-17672D
• MIL –L-17331-G
• MIL-17331B
• AFNOR E-48600HL
Approval
Approval
 QUIZ 02

https://bit.ly/3fBmQtL
Measuring Oil Cleanliness With
Condition Monitoring Program
 Lubrication Condition Monitoring for Turbine
(ASTM D4378 / ASTM D6224)

Sampling Frequency Sampling Frequency

Test
(STEAM) (GAS)
Viscosities 3-6 months 500 h
TAN 1-3 months 500-1000 h
Appearance Daily 100 h
Water content 1-3 months --
Color Weekly 200 h
Rust test Yearly --
Cleanliness 1-3 months 1000 h
RBOT/RPVOT 6-12 months 1500-2000 h
 Condemning Limit
 ASTM D 4378 is general guidance for turbine lubrication condition monitoring
It is mentioning Condemning Limit also
 OEM may publish their own condemning limit

GEK 32568F
Viscosity @ 40oC (104oF) 41 cSt (max)
25 cSt (min)
Total Acid Number 0,4 mg KOH/g (max)

Rotating Bomb Oxidation Test (RBOT)/RPVOT 25% (min) of value for new oil

Reference: ESB
 Condemning Limit (Cont’d)
SOLAR TURBIN ES 9-224
Property Test Method Limiting Condition
Color Visual observation Rapid darkening, haziness
Odor Olfactory observation Strong odor
Viscosity @ 40oC ASTM D 445 + 20% / - 10%
Water Content ASTM D 1744 max 2000 ppmw

Particle Contamination ISO 4406 Code abrupt increase in particle count

TAN ASTM D 664 or 0,6 mg KOH/gr
ASTM D 974
RBOT/RPVOT ASTM D 2272 25% of original (new oil) v
Foaming test ASTM D 892 Seq. I - 300/10
Seq. II - 300/10
Air release at 50oC ASTM D 3427 10 minutes (max)
 ASTM D4378 – Condemning Limit and Recommendation

Steam (S) or Oil Life (Running

Test Warning Limit Interpretation Action Steps
gas Turbine (G) Hours)

Total Acid No. 0.1 to 0.2 mg S Up to 20 000 h This represent above Investigate cause.
Increase Over KOH / gm G Up to 3000 h normal deterioration. Increase frequency of
New Oil Possible causes are: testing-compare with
(a) System very severe; RBOT data. Consult
(b) anti-oxidant depleted; with oil supplier for
(c) wrong oil used; possible reinhibition.
(d) oil contaminated.

Total Acid No. 0.3 to 0.4 mg S,G At any time during Oil at or approaching end Look for signs of
Increase Over KOH / gm life of oil charge of service life, (c) or (d) increased sediment
New Oil above may apply. on filters and
centrifuge. Check
RBOT. If RBOT less
than 25% of original,
review status oil with
oil supplier and
consider oil change.
Increase test
frequency if left in
system.
 Steam (S) or Oil Life (Running
Test Warning Limit Interpretation Action Steps
gas Turbine (G) Hours)

RBOT less than half value on S Up to 20 000 h Above normal Investigate cause. Increase
original oil G Up to 3000 h degradation. frequency of testing.

RBOT less than 25% of original. S,G At any time Together with high Resample and retest. If
TAN indicates oil same, consider oil change.
at or approaching
end of service life.

Water Exceeds 0.2% S At any time Oil contaminated. Investigate and remedy
Content Potential water cause.
leak. Clean system by
centrifugation. If still
unsatisfactory. Consider oil
change or consult oil
supplier.
 Steam (S) or
Oil Life (Running
Test Warning Limit gas Turbine Intrepretation Action Steps
Hours)
(G)
Cleanliness Exceeds S, G At any time Source of particulates may Locate and eliminate
accepted limits be: source of
(Note 1) particulates. Clean
(a) make-up oil; system oil by filtration
(b) dust or ash entering and/or centrifuging.
system;
(c) wear condition in
system.

Rust Test D665A Light fail S Up to 20 000 h (a) The system is wet Investigate cause and
and/or dirty. make necessary
(b) The system is not maintenance and
maintained properly operating changes.
(e.g water drainage Check Rust Test.
neglected, centrifuge Consult oil supplier
not operating.) regarding
reinhibation if test
result unchanged

Rust Test D665A Light fail S, G After 20 000 h Normal additive depletion Consult oil supplier
during life of oil in wet system. regarding re-
charge inhibition.
 Steam (S) or gas Oil Life (Running
Test Warning Limit Interpretation Action Steps
Turbine (G) Hours)

Appearance Hazy S, G At any time Oil contains water Investigate cause and
and/or solids. remedy.
Filter and/or
centrifuge oil.

Color Unusual and S,G At any time This is indicative of: Determine cause and
rapid darkening rectify.
(a) contamination
or
(b) excessive
degradation.

Viscosity ± 20% from S,G At any time (a) Oil is Determine cause. If
original oil contaminated viscosity is low
viscosity. or determine flash point.
(b) Oil is severely Change oil, if
degraded. necessary.
 Oil Life
Steam (S) or gas
Test Warning Limit (Running Interpretation Action Steps
Turbine (G)
Hours)

Flash Point Drop 30°F or S,G At any time Probably Determine cause. If
more compared contamination. viscosity is low
to new oil. determine flash point.
Change oil, if necessary.

Foam test D892 Exceeds S,G At any time Possibly contamination Rectify cause. Check with
Sequence I following limits or antifoam depletion. oil supplier regarding
Tendency-450 In new turbines residual inhibition.
Stability-10 rust preventives Note: Plant problems
absorbed by oil may often mechanical in
cause problem. origin.
Contaminant Management
 Classification of In-Service Lubricating Oil
Purification Technology

Particle / Debris Varnish

Water Contamination
Contamination Contamination

External and/or External Source Internal Source

Internal Source
No chemically Oil Molecule may Oil Molecule is
changed in oil chemically changed chemically changed
molecule

Reference: NRD
Schematic Diagram, How Oil Purification Shall Done

Reference:
• API 614 – Lube Oil System, Control System and Sealing System
• ASTM D4248 – Lube Oil System of Steam Turbine
• ASTM D4241 – Lube Oil System of Gas Turbine
 General Acceptance Criteria
Varnish Potential
EQUIPMENT Clean Dirty Water Rating
Piston (Reciprocating)
17/14 20/17 < 500 ppm < 20
Compressor

Screw Compressor 16/13 18/15 < 500 ppm < 20

Turbo / Rotary Compressor 15/12 17/14 < 500 ppm < 20

Turbine 15/12 17/14 < 100 ppm < 15

Gearbox System 18/15 22/18 < 500 ppm N/A

Bearing System 15/12 17/14 < 500 ppm < 20

Hydraulic System 13/10 17/14 < 500 ppm < 15

Reference:
• ASTM D 6224 - “In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant Equipment”
• ASTM D 4378 - “Standard Practice for In-Service Monitoring of Mineral Turbine Oils for Steam and Gas Turbines”
• ASTM D 7843 – “Test Method for Varnish Potential Rating by Membrane Patch Test Colorimetry (MPC).
• NORIA
• Various OEMs
 QUIZ 03

https://bit.ly/2SVTDQx
Introduction to
Debris / Particle Contamination Removal
 Important Article for Filtration System Design in API 614

• 1.6.1 Twin full-flow filters with replaceable elements or cartridges shall be provided. Filters
shall provide a minimum particle removal efficiency (PRE) of 90 percent for 10 micron
particles (ß10 > 10) and a minimum PRE of 99.5 percent for 15 micron particles (ß15 > 200),
both per ISO 4572 when tested to a minimum terminal (end of test run) differential pressure
of 3.5 bar (50 PSID).

• 1.6.4 Filter cartridge materials shall be water and corrosion resistant.

• 1.6.4.1 Water-resistant filter cartridges shall not deteriorate if water contamination in the oil
reaches 5% by volume and an operating temperature as high as 70°C (160°F).

• 1.6.5 The pressure drop for clean filter elements or cartridges shall not exceed 30 kPa (5 psi)
at an operating temperature of 40°C (100°F) and normal flow.

• 1.6.6 Elements or cartridges shall have a minimum collapsing differential pressure of 500 kPa
(70 psi).

Source: API 614

 Vendor Responsibility

• Required pump flow

• Port / Valve Connection
• Electricity Connection
• Filter element selection
• Filter Sizing
• Filter Configuration
• Estimated number of utilized filter element

Source: NRD
Beta Ratio Rating (ISO 16889)
The efficiency of the filter can be calculated
directly from the beta ratio because the
percent capture efficiency is ((beta-1)/beta) x
100. A filter with a beta of 10 at five microns is
thus said to be 90 percent efficient at
removing particles five microns and larger.

Source: www.machinerylubrication.com

39
 Things shall be Considered During Purification Activity

• Define proper sampling point location which is suitable to evaluate the purification
activity
• During filtration activity, ensure that the filter housing is grounded properly, to
prevent the accumulation of electro static current.
• It is strongly recommended to use filter element which having Beta Ratio = 1000
• It is recommended that the minimum cycle of oil filtration is 6.
example :
Pump flow rate = 20 L/minutes
Oil Reservoir Volume = 2,000 L
1 Cycle Time = 2,000 / 20 = 100 minutes
6 Cycle Time = 100 x 6 = 600 minutes or 10 hours minimum.

• To make effectiveness in oil filter element utilization, Filter Stepping is strongly

recommended, i.e:
22 – 10 – 5
use 22 micron first, then 10 micron, then 5 micron.
Introduction to
Water Contamination Removal
Water Removal Technologies

Source: www.machinerylubrication.com

42
 Centrifuge Water-Oil Separator

centrifugation, n—the use of centrifugal force to separate contaminants from oils.

Contaminants such as water and particulate are generally more dense than the oil and
migrate to the outside of the centrifuge because of centrifugal force

Source: Alfa Laval

Coalescer Element Water Removal

Source: PALL FIltration

Vacuum Dehydration

Source: HY-PRO Filtration

Water Boiling Point Temperature VS Vacuum

Source: NRD
Air Stripping Unit

Source: HydroVac and ThermoJet

 QUIZ 04

https://bit.ly/2WntJHO
Introduction to
Varnish Contamination Removal
 When varnish come…
• Oxidation --- Varnish --- Sticky deposit adhere to metal surface ---
build up particulate --- abrasive destructive surface.
Some of potential problem:
• Restriction and sticking of moving mechanical parts, such as servo
or directional valves
• Increased component wear due to varnish attracting dirt and solid
particle contaminants
• Loss of heat transfer in heat exchangers; increased friction, heat and
energy due to varnish's thermal insulation effect
• Autocatalytic deterioration of the lubricant
• Plugging of small oil flow orifices and oil strainers
• Reduction in filter efficiency and potential filter plugging
• Journal bearing failure
• Increased maintenance costs due to cleanup and disposal of oil
 Controlling varnish in oil
• Use root cause for every case to determine varnish build up problem.
• However, there are numerous other causes. These include hydrolysis, mixing of incompatible
fluids/additives, additive precipitation, microbial contamination, radiation, and chemical
interactions with sealants, hoses, elastomers, surface coatings, etc.
 Electrostatic Particle Removal

Electrophoresis (removal of naturally charged particles by electrostatic force)

Dielectrophoresis (removal of a charge-neutral particle by gradient voltage field force).

Source: Kleentex Oil Filtration

Balance Charged Aglomeration

Source: ISOPUR FIltration

Varnish Removal Filter(Cellulose-Resin Technology)
Physisorption, also called physical adsorption, is a
process in which the adsorbent material and the
adsorbate molecules (varnish precursors) do not
form chemical bonds arising from a chemical
reaction but are bonded by weak electrostatic
forces arising from induced dipole moments such as
van der Waals forces. The electronic structure of
the adsorbate does not change upon adsorption.

A filtration medium based on physisorption, called a

Varnish Removal Filter (VRF), has been
developed. This filtration medium is a composite
consisting of a cellulose fiber matrix and other
materials that give it a high-void volume and an
open-fiber matrix. The resin-bonded, open-fiber
matrix provides high permeability, which is
necessary for the fluid to come in contact with the
large fiber surface area for the absorption of the
varnish precursors.
Source: http://www.machinerylubrication.com/