Turbine oil

Viscosity

 Viscosity is the primary requirement for selecting a steam

turbine oil. Using a product that has the correct viscosity
will provide the necessary film thickness to reduce
friction between moving parts.
 Different types of turbines may require oils with different
viscosity ranges to promote optimum film thicknesses.
Generally, smaller turbines and marine power propulsion
turbines, which rotate at speeds greater than 3,000 rpm,
require an oil with a viscosity of ISO VG 22-32.
Viscosity Index (Thermal resistance)

 The viscosity index (V.I.) indicates the effects that

temperature change can have on a lubricant’s viscosity.
The V.I. value is calculated from a fluid’s viscosity at two
temperatures; 100 F and 212 F (40 C and 100 C). The
higher the V.I. value, the less the oil’s viscosity changes
with temperature. Fluids generally become less viscous as
temperatures increase; this is almost always the case with
oils. Thus, an oil’s formulation is less likely to be
compromised under drastic changes in temperature if its
V.I. is high enough for the application. Quality turbine oils
frequently will have a V.I. of at least 95. Many
commercially available turbine oils can have V.I.s higher
than 115.
Good Demulsibility
 Demulsibility is an oil’s ability to separate from water.
Water can appear in solution, free or emulsified form in
oil. All three forms of water are undesirable and must be
controlled.
 Water contamination promotes oil degradation, chemical
corrosion and bearing fatigue. Each condition
compromises a lubricant’s capability to perform properly.
Many different sources of water contamination exist in a
steam turbine.
 Examples can include condensation of humid air in
reservoirs,
 steam leaks through the turbine gland seals
 faulty oil coolers.
Demulsibility

 The demulsibility of an oil in service can be affected by

the presence of contaminants, such as mineral sediments
like rust, paint or dust, and by polar organic compounds
formed due to oil degradation.
 Additionally, mixing turbine oils with other lubricants
containing high concentrations of detergents and
dispersants commonly found in engine oils must be
avoided to preserve the oil’s ability to readily separate
from water. A small amount of engine oil in some cases
can completely destroy a turbine oil’s demulsiblity
properties.
Foam Resistance

 The presence of foam entrained in the turbine reservoir is

not unusual and is generally of little concern. However,
when excessive amounts of entrained air and stable foam
accumulate in the oil, foam can overflow on top of the
reservoir. And foam introduced into the circulating system
can damage pumps and bearings or cause sluggish
operation of hydraulic control systems.
Foam - Reasons
 Main causes leading to excessive air entrainment and foam
include:
 Air intake in suction side of the pump
 Low oil level in reservoir
 Excessive splashing of oil returning to the main reservoir
 Insufficient size of oil return lines
 High temperature differences between the oil that is
replaced and the one that is in service
 Excessive pressure changes that allow dissolved air to
release from the oil.
Foam Resistance

 Turbine oils typically have an anti-foam additive package

that assists with the breakdown of foam.

 A lubricant with the right balance of base stocks and

additives helps avoid these types of problems.
Rust and Corrosion
 Chemical corrosion and rust formation are mentioned
together, but they actually represent two different
mechanisms of metal degradation.
 Chemical corrosion occurs when strong acids or bases
attack metal surfaces.
 Rust is a metallic oxide formation that appears when
oxygen, usually in the presence of water, comes into
contact with a metal for prolonged periods.
 To prevent both from forming, rust preventive and metal
passivating additives are typically added to properly
formulated turbine oils. These are the “R” in the R&O
additive system, for rust and oxidation. These agents act
by preferentially attaching themselves to the metal
surface, forming a protective coating.
Oxidation Stability
 Steam turbine oil resides in the machine’s reservoir for
extended periods where it is exposed to oxygen, which
can have a deleterious effect on a lubricant’s
performance capabilities. Thus, oxidation resistance is a
vital property to look for when selecting a steam turbine
oil.
 Oxidation is the reaction of hydrocarbon molecules that
form when oxygen is introduced to the base fluid of an
oil. The rate of oxidation increases exponentially as
temperature rises and with the presence of metallic
contaminants. An increase of around 10 C in the oil’s
temperature effectively doubles the oxidation rate.
Copper, bronze, brass and iron contaminants are typical
materials that catalyze the oxidation reaction.
Oxidation Stability

 From a practical standpoint, poor oxidation resistance

shortens the oil’s service life. Additionally, as the oil
oxidizes, foam control, demulsibility and air release will
likely be compromised. Sludge and deposits can form in
more severe cases, impeding proper lubrication and
hydraulic control of the turbine.
Stability in long-term storage

 Taking into account the long life of these oils, they must
be stable and maintain their properties for long periods of
time.
Testing Oil condition

Oil cleanliness

Machine Wear
Oil Condition

 The assessment of the lubricant condition reveals whether

the system fluid is healthy and fit for further service or
needs changing.
 This category includes the following tests to determine
the physical and chemical properties of the lubricant:
 Oil condition
 Color, Appearance
 Viscosity @ 40°C and 100°C
 Viscosity Index (VI)
 Atomic Emission Spectroscopy (by Rotating disc electrode) to
monitor for wear metals,contaminants and additives
 FTIR Spectroscopy - Fourier Transform Infra-Red Analyzer
Spectrometer to monitor for Oxidation, Nitration, Sulphation,
Water, Fuel Dilution. Antiwear Additives and insolubles.
 Oxidation Stability through Rotating Pressure Vessel
Oxidation Test (RPVOT) & Total Acid Number (TAN)
 Demulsibility & Foaming
Oil cleanliness

 Ingressed contaminants from the surrounding environment

in the form of dirt, water and process contamination are
the leading cause of machine degradation and failure.
Increased contamination can provide the necessary alerts
to take action in order to save the oil and avoid
unnecessary machine wear
Oil cleanliness

 Water Content
 Particle Count
 Rust
Machine wear

 An unhealthy machine generates wear particles at an

exponential rate. The detection and analysis of these
particles assist in making critical maintenance decisions.
 Machine failure due to worn out components can be
avoided through the utilization of healthy and clean oil.
Machine wear

 Direct-Reading Ferrography
 Analytical Ferrography
Demulsibility test

 Good demulsibility is critical to an oil’s success. ASTM D-1401 is used to

measure demulsibility. The test requires a mixture of 40 millileters (ml) of
distilled water with 40 ml of oil to be stirred for 5 minutes at 54 C. The time
for the emulsion to separate to 3 ml of emulsion remaining is recorded. A
typical passing result for a new turbine oil is 15 minutes.