Challenges in Power Plant Lubrication

Contents
Power Plant Customers

Critical Mobil Range of

Applications Turbine Oils

Turbine Oil Quality Checks

2
 Power Plant Customers

3
 Customer Expectations

Economics Quality Products

Service

4
 Power Plant Metrics
Capacity factor
Life Cycle & First-cost Availability
Economics

Unscheduled outages
Maintenance cost
Overtime cost

Grid penalties
Lost revenue...

5
 Lost Revenue Example

500 MW Coal-fired Steam Plant

RMB X /kW-hr - Nominal
Nominal

6
 Power Generation Customers – Facility Types

Fossil-fired steam generation - coal, oil & natural gas

Large oil reservoirs (12,000 - 80,000 liter)

Turbine oils can last >20 years – rejuvenate with make-up

Conversions usually via make-up / top-add
 Turbine Oil Compatibility Studies (ASTM D 7155)
Plant may have over 1,000 lube points

Nuclear generation
Faces many similar issues as fossil-fired steam generation

Paperwork for product conversions

Paperwork for product delivery

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 Power Generation Customers – Facility Types

Simple & combined cycle gas turbine

Oil reservoirs (8,000 – 28,000 liters)

Turbine oils can last 3 - 10 years

OEM approvals / specifications

Limited auxiliary lubricant consumption

Hydro electric turbines

Oil reservoirs (4,000 - 40,000 liters)

ISO 46 or 68 R&O

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 Power Generation Customers - Consumption

Rough consumption estimates

Initial fill = 136 liters per MW

Annual make-up = 1.4 liters per MW

Replenishment forms
 Straight make-up
 Bleed & Feed
 Change-out
 Drain & fill ~ 10% holdback
 Displacement flush ~ 1% holdback
 High velocity flush with purge <1% holdback

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 Power Generation Customers – Business Barriers

Right people Product compatibility

 Generally comprises – ASTM D 7155
team of Purchasing,  Run equipment-specific
Operations & compatibility tests to include :
Maintenance  Tier 1 – Visual: freeze / oven /
 Work primarily through ultra-violet
operations and  Tier 2 – Physical tests:
demulsibility, foam, RPVOT
maintenance

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 Power Generation Customers – Business Barriers

Implementation
time frame
 Gant Chart by weeks to Product pricing
include:  Total cost of ownership ~
 Product compatibility
determine lost revenue,
testing, rough lube
crossover, lube charting, grid penalties
product stocking  Probe for suffering points
recommendations – onsite
and at distributor, training,
maintenance programs
such as oil analysis

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 Critical Applications

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 Steam Turbine

Suffering points

 Water contamination – gland seals, water coolers, house-keeping

 Rust / bacteria / reduced oil life / reduced filter life

Solutions

Oil demulsibility, water removal systems

Key products

Main reservoir –
DTE 700, DTE 800

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 Steam Turbine Overhaul

Suffering points

Oil cleanliness & storage

Solutions

Flushing, filtration & storage

service

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 Steam Turbines

Suffering points

Failed filtration & water removal

Solutions

Test for ISO cleanliness, water

content & demulsibility at filter /
coalescer / centrifuge

Key products
Steam turbine lube system
Mobil DTE 732, Mobil DTE 832

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 Gas Turbines
Pencil filter

Suffering points

Varnish formations on moog valves &

pencil filters

Solutions

 Upgrade to high quality Mobil

turbine oils
 Improve maintenance ~ Moog Inlet guide
valve change outs, full-flow filter Vane Servo
upgrade

Key product
Mobil DTE 832

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 Gas Turbines

Suffering point

Varnish on bearing surfaces

Solutions

 Upgrade to high quality Mobil products

 Utilise oil analysis ultra centrifuge testing

Key product

Mobil DTE 832

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 Hydro Turbines

Suffering point

Varnish on Kingsbury thrust bearing

Solution

High quality turbine oils & Oil

analysis - UC

Key product
Mobil DTE 746

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 Boiler Feedwater Pump

Suffering point

Water contamination

Solutions

Oil demulsiblity, water removal

systems

Key products

Mobil DTE 732, DTE 832

Electric – Boiler feedwater pump,
will also see steam turbine driven

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 Coal Pulverizers
Suffering points
 Coal dust contamination in main gear reducers
 Elevated gear wear
 Foam

Solutions

 Kidney loop filtration cart ~ 10 micron abs.

 Upgrade breathers
 Synthetics

Key products

B&W MPS
 Main gear reducer – Mobilgear 600 XP 460, Mobil SHC 634, Mobilgear SHC 460
 Roll wheel assembly – Mobilgear 600 XP 680
 Rotating classifier drive – Mobilgear SHC 460

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 Fire Resistant EHC (Phosphate Ester)

Suffering point Key products

Sludge / varnish Mobil Pyrotec HFD 46

Solutions

 High quality phosphate ester

 Contamination control
 Fullers Earth or Activated Alumina
or Ion Exchange (electrostatic)
 Vacuum dehydrators
 Desicant breathers
 Filtration – 2 micron, Beta 75
 Oil analysis – key tests
 Water < .05%
 TAN < .2 mg KOH/g
 Resistivity < 5x10^9 ohm cm
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 Ljungstrom Air Pre-heater

Suffering point

Hot and cold temps from start-up

to operation

Solution

Synthetics

Key products

Mobilgear 600 XP 680, Mobil SHC 636

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 Induced Draft and Forced Draft Fans

Suffering point Induced draft / Forced draft fans

Foam in fan bearings

Solutions

 Test for ISO cleanliness, filter oil

 Oil level check
 Confirm proper lubricant usage

Key products

 Electric motor or steam turbine – Mobil DTE

732, Mobil DTE 832
 Fan bearings – Mobil DTE heavy medium

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 Soot Blowers

Suffering point

Hot & cold temperature issues

Solutions

 Multi-weight gear oils

 Synthetics

Key products

 Gear case – Mobil SHC 634 or

Delvac Synthetic Gear Oil
 Grease Points – Unirex S2,
Mobilith SHC 220

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 Cooling Tower

Suffering points
Remote access for check / change, wide
temperature range, water contamination

Solutions

 With quarterly sampling, upgrade to synthetic

 Install Bladder Breathers

Key product

Mobil SHC 630 or Mobil DTE AA

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 Air Compressors

Suffering points

Oil oxidation due to harsh, warm &

humid conditions
Solution

High quality product with quarterly

oil analysis

Key product

Mobil DTE 832

Ingersoll-Rand Centec
centrifugal compressor

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 Turbine Oil Quality Checks

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 Turbine Oil Deliveries

 ISO 9001 blending & refining

facilities
 Plant retains – 3 months
 Distributor retains – 3 months
 Detailed prior cargo guidelines
 Certificate of analysis –
available
 Sales engineer / DSR delivery
inspections

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 Turbine Oil Quality Checks

On-site checks
Viscosity, visc gauge /
Water
flow stick
Colour Foam

Odour Solid

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 Turbine Oil Quality Checks

Suitability for continued use

Viscosity, ASTM D445 ISO Cleanliness Code 4406

RPVOT, ASTM D 2272 Demulsibility ASTM D 1401

Water, ATSM D 1744 ICP Metals

Acid Number, ASTM D 664 Foam D-892, if necessary

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 Turbine Oil Quality Checks

Regular trend analysis

Viscosity, ASTM D445 Acid Number, ASTM D 664

Water, ATSM D 1744 ISO Cleanliness Code 4406

ICP Metals

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 Services
 Bearing & gear inspections
 Plant equipment inspections
 Infrared camera studies
 Excel-based lubrication charts
 RCM programme development
 Product recommendations
 Product consolidation
 Flush & filtration recommendations
 Lube tags
Planned  Failure analysis
 On-site oil checks – Tool box
Engineering  Oil analysis interpretation
 Training clinics
 Written documentation
Services  Best practice sharing
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 Mobil Range of Turbine Oils

Balanced formulations For desired application

Right base-oils & additives

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 Key Turbine Oil Performance Tests

 TOST (D943), RPVOT (D2272), CIGRE (ISO DIS 4263/M1297))

Oxidation
 EM Property Retention Test (PRT, 71° or 90°C), Oven Color
stability
Stability Test - OCST (M1568/P10)
Multi-metal  ASTM Rust (D665B, sea water)
corrosion and  Copper corrosion (D130)
antirust protection
Air & water  ASTM Foam (D892)  Demulsibility (D1401)
separability,  Air release (D3427)  Filterability (M1082)
filterability
 100°C oven storage test (P26)
Deposit control
(additive & oxidation  EM Property Retention Test (PRT) - overall oil durability
product solubility)  Antiwear performance (for geared systems)

Antiwear  FZG gear test (DIN 51354)

Performance (for
geared systems)

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 Performance Balance
Performance criteria
for desired application
ExxonMobil’s
 Air release / foam
Approach  D3427 / D892
Air Release/Foam  Antirust / corrosion
10
 D665 / D130 / PRT Catalyst
 Antiwear (for gear systems)
B

Oxidation Stability Antirust/Corrosion

10
B B
10
 FZG gear scuffing test
 Color stability
 OCST
 Demulsibility / filterability
 D1401 / M1082
B
B
10 10
Deposit Control Antiwear

 Deposit control
 Mobil PRT rig test
 Oxidation / thermal stability
B B

10 10
Demulsibility/Filterability Color Stability
 D943TOST / D2272RPVOT
Balanced Oil

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 Performance Balance
Performance criteria
Competitor’s for desired application
approach  Air release / foam
 D3427 / D892
Air Release/Foam  Antirust / corrosion
10
 D665/D130 / PRT Catalyst
Oxidation Stability
B

Antirust/Corrosion
 Antiwear (for gear systems)
10 B B
10
 FZG gear scuffing test
 Color stability
 OCST
B
 Demulsibility / filterability
Deposit Control 10
B
10
Antiwear  D1401 / M1082
B B
 Deposit control
 Mobil PRT rig test
10 10
 Oxidation / thermal stability
Demulsibility/Filterability Color Stability  D2272 RPVOT / D943 TOST

Unbalanced Oil

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 Customer Expectations

Economics

Service

Product Quality

WE HOPE THAT YOU AGREE

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