Lubrication Academy - Bali 2018

Welcome to Bali,
Indonesia!
2 August, 2018
Jo Ameye
j.ameye@fluitec.com
© 2017 Fluitec International

Special thanks to:
Tekno Fluida
Indonesia

Fluitec’s Vision Bali, Indonesia Aug 2018

Course Overview Bali, Indonesia Aug 2018
1. Introduction
2. Turbines & Compressors
• Lubricants formulations
• Latest evolutions
3. Oil degradation
4. Condition Monitoring
5. Solutions & Case studies
• Extending Oil Life
• Varnish Control

A Few Acronyms that you may hear… Bali, Indonesia Aug 2018
Acronym Definition
R&O Rust & Oxidation
AW Antiwear
EP Extreme Pressure
PE Phosphate Ester
POE Polyol Ester
PAG Polyalkylene Glycol
PAO Polyalphaolefin
API American Petroleum Institute
TOST Turbine Oil Stability Test
VI Viscosity Index

A Few Acronyms that you may hear… Bali, Indonesia Aug 2018
Acronym Definition
OCM Oil
Condition Monitoring
CBM Condition Based Monitoring
CC Contamination Control
ESP Electrophysical Separation Process
AO Antioxidant
RULER Remaining Useful Life
MPC Membrane Patch Colorimetry
FTIR Fourier Transform Infrared

Introduction: Emerging
Lubrication Challenges

Chemistry vs Mechanical Bali, Indonesia Aug 2018
Chemical Mechanical
Changes Problems
In order to solve mechanical
problems it is important to first
understand chemical changes.

Why do we care about fluid degradation? Bali, Indonesia Aug 2018
1. Fluid degradation defines the failing point of the lubricant. Understanding why
the fluid is degrading allows us to take actions to prolong the fluid.
2. Understanding how a fluid degrades is critical in establishing a condition
monitoring program.
3. Oil Condition Monitoring is the foundation of Reliability Engineering.

How can lubrication impact a
plant’s bottom line?

Valve sticking is the highest profile problem with
varnish Bali, Indonesia Aug 2018
Varnish on bore of IGV Valve from Frame 7FA

Valve sticking is the highest profile problem with
varnish Bali, Indonesia Aug 2018
Typical Cost of a full load trip:

$30,000 - $200,000
Typical Cost of a Fail-to-Start Condition
$15,000 -$300,000
Varnish on bore of IGV Valve from Frame 7FA
African Power Plant - Catastrophic Failure Bali, Indonesia Aug 2018
• Coal Fired Power Plant in S. Africa had a

catastrophic failure Feb, 2011.
• Overspeed Trip Assembly failed to close resulting

in an “Overspeed to Failure”
African Power Plant - Catastrophic Failure Bali, Indonesia Aug 2018
• Flying Components flew out of the turbine building.

• Parts of the shaft were found throughout the plant.
• Company Press Release, “ST 4 was damaged in a
routine test.”

Varnish Problem in Australia Bali, Indonesia Aug 2018

Varnish Problem in Australia Bali, Indonesia Aug 2018
Emergency Trip Valve stuck,

causing turbine to rip apart.
2,000 people out of work.

Estimated Cost $15 Million

Hydro-electric turbine failure Bali, Indonesia Aug 2018

Costs to Change Wind Turbine Gearbox Bali, Indonesia Aug 2018

Costs to Change Wind Turbine Gearbox Bali, Indonesia Aug 2018
Up to $500,000 to change
gearbox.
Significantly impacts the Wind

Farms ROI and profitability

Turbines & Compressors

Turbine Lubrication had an Easy Century Bali, Indonesia Aug 2018
The 1900’s had few reported cases of lubrication related failures and problems
1927 (Roger, 1968 (ASLE) 1981 (Den Herder,

Miller; Standard Oxidation Amoco)
Oil) Oil quality problems not Reported quality
related to deposit present with gas turbine oils had
tendencies turbine oils minor degradation
1956 (Wilson) 1976 (Smith; GE)

3 Oil oxidation Relationship
problems; solved between AN/Vis &
by changing oil Deposits with oils
50-130,000 hours

Rotating Equipment has evolved Bali, Indonesia Aug 2018

What’s happened? Bali, Indonesia Aug 2018
GTs were increasingly used for peak power demands instead of base load
Stress on oil has increased by 400% Bali, Indonesia Aug 2018
Source: Shell Lubricants,

Feb. 24, 2015
Evolving fluid formulations Bali, Indonesia Aug 2018
Evolving conditions in turbine lube oil systems
• Changing operating conditions

(Baseload → Cycling)
• Lubricant may have multiple purposes
• Turbine oils have switched from Group I to
Group II basestocks and use different additive
systems
New formulations have generally resulted in higher performing oils, but they
may need to be monitored and maintained differently.
© 2017 Fluitec International Ref: Livingstone, Wooton
Confluence of Factors has created new challenges Bali, Indonesia Aug 2018
More sensitive Turbine

Controls
More thermal stress
New
Duty Cycle has Problems
changed
Oil has multiple

functions

Bali, Indonesia Aug 2018





The High Cost of Varnish Bali, Indonesia Aug 2018

Turbine Oils specs have evolved in response Bali, Indonesia Aug 2018
General Electric Specifications

GEK 46506D (1993) GEK 107395A (2001)
TOST (D943) >2000 hours >7000 hours
RPVOT (D2272) >250 mins >1000 mins
Mitsubishi Specifications

Turbine & Compressor Oil
Formulation

Turbine Oil Composition Bali, Indonesia Aug 2018
Base Oil
99%
Antioxidants (Primary & Secondary)

Rust Inhibitors
Foam Inhibitors

Base Oil Bali, Indonesia Aug 2018
• American Petroleum Institute (API)

categorizes base oils by:
• Viscosity Index
• Sulfur
• Saturates
• Chemistry
• Most of the turbine oils for sale today
are made with Group II products.

Chemical Structures Bali, Indonesia Aug 2018
Group IV R R
Paraffinic
MonoNaphthenic
R
Group II-III R R R
R Multi-Ring
naphthenic
Aromatic
R R R
R
R
Group I R R
0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Hydrocarbon type, m-%
Ref: Chevron

Manufacturing of Base-stocks Bali, Indonesia Aug 2018

Refining Treatment on Base-stocks Bali, Indonesia Aug 2018

Solubility Characteristics Bali, Indonesia Aug 2018
• Group I basestocks Type of Basestock Aniline Point (oC)

have greater
solubility Group I (Naphthenic) 56-59
Group I (Paraffinic) 99-102
• Additives stay in
Group II 114-118
solution more easily
Group III 124-126
• Group II, III, IV Group IV (PAO) 127
basestocks have to
formulated Group V (PE) -5 - 0
differently Group V (PAG) ~-20
Group V (Alkylated 32
Naphthalene)
© 2017 Fluitec International Ref: Livingstone, Wooton

Rust Inhibitors Bali, Indonesia Aug 2018
• Important ingredient for protecting metal surfaces in wet environments.

(i.e. Steam Turbines.)
• Can be basic or acidic in nature.
• Can assist in RPVOT values (i.e. fool the test).

Rust Inhibitor Depletion Bali, Indonesia Aug 2018
Typical turbine oil

additive depletion rates in
in a gas turbine
application.
Ref: Petro-Canada

Foam Inhibitors Bali, Indonesia Aug 2018
• Siloxanes Antifoam (insoluble and

filterable)
• Polyacrylates Antifoam (Turbine
Oils)
• Organo-modified Siloxanes
Ref: Evonik

Antioxidants Bali, Indonesia Aug 2018
• Main ingredient in turbine oil.

Largely determines the life and
performance.
• Usually consists of phenols or
amines (primary antioxidants).
• Sacrificial.
Antioxidants are also

essential in the body to resist
oxidation & disease
Ref: Livingstone, Ameye

Synergy of a Mixed AO package Bali, Indonesia Aug 2018
ROO. R
.
N R
.
O
H2
C OH
H
ROOH R N R H2
HO C OH
© 2017 Fluitec International Ref: Albemarle

Turbine & Compressor
Oil Failure

Valve Sticking is the biggest problem Bali, Indonesia Aug 2018
Ref:: Noria, Insight, Livingstone, Wooton

Valve Sticking is the biggest problem Bali, Indonesia Aug 2018

Bearing Deposits lead to increase wear and heat Bali, Indonesia Aug 2018

Varnish impact on bearing temperatures Bali, Indonesia Aug 2018
Bearing temperature increases from varnish

trend upwards in a saw-tooth pattern

Effect of Varnish on bearing temperatures Bali, Indonesia Aug 2018
Bearing 3 temp
The temperature increase Bearing 3

vibration
on bearing 3 has good
correlation to increased
vibration level and peaks
on bearing 2 (more rigid) Bearing 2
vibration

Hydrogen Seal Issues Bali, Indonesia Aug 2018

Crystalline deposits in low-flow oil line Bali, Indonesia Aug 2018
Deposits restricted oil flow during start-ups.

Heaters & coolers do not perform well when
insulated by varnish. Bali, Indonesia Aug 2018

Pumps are susceptible to failure Bali, Indonesia Aug 2018
High Pressure
Position
Oil out Low Pressure
of piston
in cycle
Drive
shaft
Oil flow
Oil flow
Valve
plate
Swash plate Piston Piston
shoe Piston
Oil in
Source: Lubrizol barrel
What time is it? Bali, Indonesia Aug 2018

Oil Degradation

The #1 Problematic Contaminant Bali, Indonesia Aug 2018
Dirt

Water
Air

Turbine Oil Degradation Bali, Indonesia Aug 2018
• Oxidation • Spark • Gas • Additive drop-

• Ultraviolet Discharge • Solid Particles out
• Microdieseling • Water • Incompatibility
• Hot Spots
Thermal External
Oxidation Other
Degradation Contaminants

Oxidation Propagation Cycle Bali, Indonesia Aug 2018
Termination
Chain breaking
RH Electron acceptor
Initiation O2
RH
R.
Antioxidants are
RO. + .OH Propagation responsible for stopping
the cycle of auto-
Termination
UV Absorber oxidation.
Propagation
Termination RO2.
Peroxide Decomposer
ROOH Termination
RH Chain breaking
Electron donor
Ref:: Wooton
Antioxidants are like an Apple’s skin Bali, Indonesia Aug 2018

Oxidized ISO VG 32 Turbine Oil Bali, Indonesia Aug 2018

Air Contamination Bali, Indonesia Aug 2018
Forms
• Free or emulsified air
• Dissolved air
Sources of Air Contamination
• Ingression through reservoir & system vents
• Change in fluid temperature/pressure in the
system
• Leakage through seals
• Fluid Top-off
Ref:: Livingstone, Wooton

UV Degradation Experiment Bali, Indonesia Aug 2018
A Split Sample that was stored in

the same location for 1-month.
One fluid had a towel on it and was
not exposed to the sun. The other
did not.
Ref: Livingstone, Wooton


• Hot Spots
Thermal External
Oxidation Other

We already know about ESD in fuels Bali, Indonesia Aug 2018

Primary Influences on Spark Discharge Bali, Indonesia Aug 2018
• Filter Design
• Temperature
• Oil Conductivity
• Flow Rates
Evidence of Spark Discharge Bali, Indonesia Aug 2018
Ref: Sasaki
Evidence of Spark Discharge Bali, Indonesia Aug 2018
Ref: Hydac
Thermoplastic deposits in filters Bali, Indonesia Aug 2018

Thermoplastic deposits on filters Bali, Indonesia Aug 2018

Case Study: Pictures of ESD products found in GT
lube oil reservoir Bali, Indonesia Aug 2018
Varnish-free lube oil

reservoir.
Does it look clean?

Case Study: Pictures of ESD products found in GT
lube oil reservoir Bali, Indonesia Aug 2018

Pictures of ESD on main lube oil filters Bali, Indonesia Aug 2018




• Hot Spots
Thermal External
Oxidation Other

The implosion of air bubbles causes micro-dieseling. Bali, Indonesia Aug 2018

Micro-Dieseling in a Compressor Bali, Indonesia Aug 2018
Crack Gas Compressor with

significant deposits throughout
the system. Micro-dieseling was
one of the modes of failure.

Micro-Dieseling in a Compressor Bali, Indonesia Aug 2018
Micro-dieseling derived deposits collected throughout the system.


• Hot Spots
Thermal External
Oxidation Other

Hot Spots can cause thermal degradation. Bali, Indonesia Aug 2018
Ref::Noria, Livingstone


• Hot Spots
Thermal External
Oxidation Other

Possible Impact from Water (video) Bali, Indonesia Aug 2018
Acids

Water may cause Microbial Growth Bali, Indonesia Aug 2018

Water may cause Microbial Growth Bali, Indonesia Aug 2018

Steam Turbine Tube Residue Bali, Indonesia Aug 2018
Acids Unsaturated Acid
Silica

Types of Gases that are often Compressed Bali, Indonesia Aug 2018
Chemically
Inert (Reducing) Hydrocarbon
Reactive
• Nitrogen • Methane • Oxygen
• Hydrogen • Ethane • Halogen
• Helium • Propane • Hydrogen
• Carbon • Butane Chloride
Monoxide • Ethylene • Hydrogen
• Carbon Dioxide • Propylene Sulfide
• Ammonia • Butylene • Nitrogen Oxide
• Natural Gas • Sulfur Dioxide
• Cracker-gas
Chemical Degradation Bali, Indonesia Aug 2018
“Inert and Hydrocarbon gases have no chemical effect on the oil.”

- Lubrication Engineers Handbook
Conventional Wisdom is NOT Correct. Inert &

Hydrocarbon gases can chemically react with the oil.
Turbine oils used in compressors often experience the most severe

degradation compared to power gen applications

Examples of “Inert” Gaseous Degradation Bali, Indonesia Aug 2018
• CO2 can react with water to form carbonic acid

• Oil has 8-12% air, 21% of which is oxygen
• Ammonia can react with the lubricant:
• It is a base it will act as a nucleophile and will interact with anything
acidic in the fluid such as Rust/Corrosion inhibitors. Transesterification
of any ester-containing compound will also react to make alcohol and
acids.
• Ammonia will react with oxygen to form NOX, a free radical initiator.

Sticking Valve Causes $1M Outage Bali, Indonesia Aug 2018
• FW Pump Valve Sticking

• Unit was shut-down for 30 hours to investigate
the problem
• Outage cost assessed at $1 million
• High profile root cause analysis performed to

determine/fix the cause
Case Study Overview
- Nuclear Power Plant
- 2,700 liters of ISO 32 TO
- MPC value: 16
- RULER Phenols: 75%

Investigation Bali, Indonesia Aug 2018
1. Removed & analyzed deposits 2. Concentrated and analyzed

from valve surface degradation products from the oil

Analytical Results Bali, Indonesia Aug 2018
Chemistry on the valve was the same

as that in the oil
Carboxylic acids were present as

well as primary amides
• Primary amides are
reactionary products produced
by ammonia & acids
Doublet indicate primary amides

Conclusion/Action Bali, Indonesia Aug 2018
• Ammonia was present in the plant’s steam.

Deposits
Carboxylic Acids Ammonia consisting
of Amides
• It was not feasible to remove sources of ammonia from entering the

system. The plant is installing a system to remove oil degradation
products (acids) so that the reaction cannot occur.
• In addition to MPC, plant is monitoring these oil systems with FTIR to
measure acidic content and amide production.


• Hot Spots
Thermal External
Oxidation Other

Incompatibility - Tenacious Deposits Bali, Indonesia Aug 2018
Very dark and wide bathtub ring, reservoir deposits and varnish through the inside of a 7FA gas turbine.

Incompatibility - Impossible to Wipe Bali, Indonesia Aug 2018
@#$&!!!
Ref: Livingstone,
Deposits due to oil mixtures Bali, Indonesia Aug 2018
A new generation of turbine oils from same oil supplier mixed with older formulation
Lube oil supplier confirmed 100 % compatibility
Applicable for the used oil or new oils??

Potential Impact of Incompatible Fluids Bali, Indonesia Aug 2018
Ref: Noria
Ref: Noria
Compatibility – A Growing Problem Bali, Indonesia Aug 2018
• New formulations with various basestocks and additive components.

• Most Group V basestocks are not compatible with mineral oils.
• Old foam inhibitors may not be compatible with new foam inhibitors
• Rust inhibitors may be incompatible
• Two new oils may be compatible, however may become incompatible if
one of the oils is mixed.
• Vapor Space Inhibitors in new components are not always compatible
with turbine oils
Critical to test. Do not assume compatibility.

• ASTM D-7155: Standard Practice for Evaluating Compatibility of Mixtures of
Turbine Lubricating Oils

Results of Incompatibilities Bali, Indonesia Aug 2018
The first sign of fluid incompatibility is the fluid’s intolerance to contaminants. These tests
provide the earliest detection:
Test
Air Foam, Air Release, Visual
Water Demulsibility, Visual
Solids MPC, UC, Visual
Storing the mixed fluid for 1 week at room temperature may also show signs of problems


Condition Monitoring
Measuring Oil Degradation

Condition Monitoring Improves Sustainability

In 2017, 85% of S&P Companies
reported their Sustainability and Bali, Indonesia Aug 2018
Corporate Social Responsibility Results

- GOVERNANCE & ACCOUNTABILITY INSTITUTE, INC.
Companies with the highest

ratings had the highest
financial performance
- CSRHub

Contam- Bali, Indonesia Aug 2018
ination
• Enhance
Equipment Life
and Reliability
Oil
Health
• Reduce Equipment
Downtime
• Lower
Machine Health Maintenance

The Value of Oil Condition Monitoring
Oil Analysis Improves Sustainability
• Extends the Life of Hazardous
Fluids Bali, Indonesia Aug 2018
• Makes Sustainable Energy
more sustainable
• Enables Energy Efficiency

Improvements
• Helps implement bio-lubricants
• Extends component life
• Improves manufacturing
automation
• Decreases fuel usage
• Reduces equipment
replacement

Conventional Analysis Devices Bali, Indonesia Aug 2018
Elements by ICP
Viscosity
PQ Index Fuel by GC /FT-IR)
FT-IR Spectroscopy BN, AN, ipH by Titration

What do you see?

Tests for measuring fluid degradation Bali, Indonesia Aug 2018
Compatibility
Soft Fluid
with
Contaminants Degradation
Contaminants
The MPC Test (ASTM D7843) is MPC Air (Foam, Air

the most widely used test for AO Health (RULER)
Release)
identifying varnish potential.
Ultracentrifuge
RULER (ASTM D6971) is the
preferred method for
determining antioxidant life. Degradation Water
Gravimetric Patch Products (FTIR) (Demulsibility)
Test

Membrane Patch Colorimetry (D7843) Bali, Indonesia Aug 2018

An Example of MPC Values Bali, Indonesia Aug 2018
© 2017 Fluitec International Ref:: Livingstone, Wooton

Oil Color is not related to the MPC Value Bali, Indonesia Aug 2018
All MPC patches are

diagnosed as “Critical”
and have similar hues,
even though the color of
the oil samples are quite
different.

Strange colors indicate different chemistries Bali, Indonesia Aug 2018

Interpretation of MPC Results is Application Specific Bali, Indonesia Aug 2018
The controls on a GE 9/7FA unit are much more sensitive than a GE 9/7EA unit
Critical Results
for GE 9FA
Abnormal Results
for GE 9EA

Benefits of MPC + RULER Bali, Indonesia Aug 2018
Sample: A T0 Sample: A T1 Sample: A T2 Sample: A T3 Sample: A T4 Sample: A T6
1300
1200
1100
1000
900
800
700
600
500
400
300
200
100
5.2 12.812.8 15.6

0
0 2 4 6 8 10 12 14 16

Benefits of MPC + RULER Bali, Indonesia Aug 2018
Sample: A T0 Sample: A T1 Sample: A T2 Sample: A T3 Sample: A T4 Sample: A T6
1300
1200
1100
1000
900
800
700
600
500
400
300
200
100
5.2 12.812.8 15.6

0
0 2 4 6 8 10 12 14 16

Cleanliness standards – to be or not to be! Bali, Indonesia Aug 2018

Soft Compatibility with

Fluid Degradation
Contaminants Contaminants
MPC
AO Health (RULER) Air (Foam, Air Release)
Ultracentrifuge
Gravimetric Patch Test

Degradation Products
Water (Demulsibility)
(FTIR)
Particle Counting (Laser)

Antioxidants vs. RUL% Bali, Indonesia Aug 2018
A O
N First degradation XI
Antioxidant level starts to be too low
TI PROACTIVE
to control the C-radical
D
O Second degradation
A
XI REACTIVE TI
D O
A N
N
T
OPERATING TIME

Antioxidant 1 Antioxidant 2

The Mechanics of a Mixed AO Package Bali, Indonesia Aug 2018
Good solubility
ROO . R
.
N R
.
O
H2
C OH
H
ROOH R N R H2
HO C OH
Source:
© Albemarle
2017 Fluitec International
SIEMENS Power Generation Bali, Indonesia Aug 2018

Types of antioxidants Bali, Indonesia Aug 2018
• Primary antioxidants
• (radical) Chain-breaking reaction
• Go to the root of the problem
• “Green” type – ashless/metal free additives
• Amines and Phenols
• Secondary antioxidants
• Peroxide catchers
• ZincDithioPhosphates, carbamates etc…

RULER Technology
Antioxidant 1 Antioxidant 2 Bali, Indonesia Aug 2018
T
E
S
T

RULER Technology
Antioxidant 1 Antioxidant 2 Bali, Indonesia Aug 2018
T
E
S
T
In service turbine oil – 55775 hours

RULER Technology benefits Bali, Indonesia Aug 2018
On-site
portable
Small Standardi
Sample zed
size Test
RUL %
AO
Maintenan
Exchange
ce
data
tool

RULER & Oil Condition Monitoring Bali, Indonesia Aug 2018
FRESH OIL REPLENISHMENT
NORMAL TRENDING
RUL (%)
CHANGE IN OPERATING
CONDITIONS
Operating time
FLUID & MACHINE CONDITION MONITORING
Linear Sweep Voltammetry, RULER (ASTM D6971) Bali, Indonesia Aug 2018

Determining Remaining Useful Life Bali, Indonesia Aug 2018
• MPC is not directly

correlated with RULER.
• In phenol-only
formulations, the
condemning limit is when
the phenols are at 25%.
• In mixed AO systems, the
condemning limit is when
the amines reach 25%.

Soft Compatibility with

Fluid Degradation
Contaminants Contaminants
MPC
AO Health (RULER) Air (Foam, Air Release)
Ultracentrifuge
Gravimetric Patch Test

Degradation Products
Water (Demulsibility)
(FTIR)
Particle Counting (Laser)

Foam Test (D892) Bali, Indonesia Aug 2018

Air Release (ASTM D3427) Bali, Indonesia Aug 2018

Foam vs Air Release Bali, Indonesia Aug 2018
Source: Evonik
Demulsibility Test (D1401) Bali, Indonesia Aug 2018

Demulsibility Test (D1401) Bali, Indonesia Aug 2018
Demulsibility may be caused by polar contamination or

polar degradation by-products
What do you do if you’re failing Demulsibility?

• Depends on application
• Depends on what water control technologies are
available

CM CASE STUDY 1 Bali, Indonesia Aug 2018
Parameter Analysis value Units

AN 0.3 mg KOH/g
VISCOSITY (40° C) 44.6 cSt
WATER 35 ppm
COLOUR 6
Group I AIR RELEASE 5 min
ISO VG 46 DEMULS 350 ml
ISO P.C. 19/16/14
15,000 liters
MPC 18 d-E
Steam Turbine RUL PHENOLS <10% %
90,000 operating hours RUL AMINES 20% %
ICP
Zn 5 ppm
Ca 0 ppm
P 85 ppm
S 125 ppm
Si 12 ppm


AN 0.3 mg KOH/g
WATER 35 ppm
COLOUR 6
ISO P.C. 19/16/14
15,000 liters
MPC 18 d-E
ICP
Zn 5 ppm
Ca 0 ppm
P 85 ppm
S 125 ppm
Si 12 ppm


AN 0.3 mg KOH/g
WATER 35 ppm
COLOUR 6
ISO P.C. 19/16/14
15,000 liters
MPC 18 d-E
ICP
Zn 5 ppm
Ca 0 ppm
P 85 ppm
S 125 ppm
Si 12 ppm


AN 0.1 mg KOH/g
VISCOSITY (40° C) 32 cSt
WATER <10 ppm
COLOUR 4
Group II AIR RELEASE 7 min
ISO VG 32 DEMULS 450/0/125 ml
ISO P.C. 22/17/13
8,000 liters
MPC 35 d-E
Gas Turbine RUL PHENOLS <10% %
ICP
Zn 0 ppm
Ca 0 ppm
P 125 ppm
S 35 ppm
Si 2 ppm


AN 0.1 mg KOH/g
WATER <10 ppm
COLOUR 4
ISO VG 32 FOAM 450/0/125 ml
ISO P.C. 22/17/13
8,000 liters
MPC 35 d-E
ICP
Zn 0 ppm
Ca 0 ppm
P 125 ppm
S 35 ppm
Si 2 ppm


AN 0.1 mg KOH/g
WATER <10 ppm
COLOUR 4
ISO VG 32 DEMULS 450/0/125 ml
ISO P.C. 22/17/13
8,000 liters
MPC 35 d-E
ICP
Zn 0 ppm
Ca 0 ppm
P 125 ppm
S 35 ppm
Si 2 ppm

This is also condition monitoring Bali, Indonesia Aug 2018

Contributing to Reliability Strategies Bali, Indonesia Aug 2018

Solutions
Mitigate Varnish and Extend Lube Oil Life

The Deposition Process Bali, Indonesia Aug 2018
The two key variables that drive the varnish deposition process are:
1. Temperature
• High Temperature can cause rapid oxidation or coking,
burning the deposits onto the surface
• Low Temperature will impact the solubility of the
contaminants
2. Pressure
• Elevated pressure will drive deposits out of solution
Ref: Noria

Varnish is Soluble Bali, Indonesia Aug 2018

Varnish Removal Technologies Bali, Indonesia Aug 2018
Depth Media Electrostatic Charged ESP: Chemical

Filters Oil Cleaners Agglomeration Filtration
Technologies that can remove soft contaminants under the right conditions.

Depth Media Filtration Bali, Indonesia Aug 2018
Pros Cons
1. Simple and 1. Only removes
economical to soluble soft
operate contaminants that
2. High dirt holding are in suspension.
capacity and For varnish
efficiently filters to removal, ideally
as low as 3mm. suited for
3. Adsorbs soft reservoirs
contaminants operating <40C.
Source: CC Jensen,
4. Adsorbs moisture

Electrostatic Oil Cleaning Bali, Indonesia Aug 2018
Pros Cons
1. Efficiently removes all 1. Only removes soluble
suspended soft contaminants that
contaminants down to are in suspension. For
0.01mm in size. varnish removal, ideally
2. Successfully removes suited for reservoirs
inorganic, insoluble operating <40C.
degradation products 2. Sensitive to water and
3. Removes soot-type other conductive
carbonaceous particles contaminants/fluids
3. Complex controls can
be sensitive

ESP: Chemical Filtration Bali, Indonesia Aug 2018
Pros Cons
1. Removes soft Only removes organic

contaminants that are soft contaminants. Has
both in suspension and no impact on dirt and
in solution wear metals (inorganic
2. Has a wide range of contaminants).
temperature
effectiveness from
10oC – 70oC.
3. Simple design allows
for easy operation

ESP resins in action Bali, Indonesia Aug 2018

ESP resins in action Bali, Indonesia Aug 2018

Contamination Control, and the varnish life cycle Bali, Indonesia Aug 2018
ESP

Long term results of ESP at the plant Bali, Indonesia Aug 2018
• New oil condition monitoring parameters leads to

more proactive health monitoring
• Distinct Increased equipment reliability & availability
• Contamination control for turbine oils
• a matter of stabilizing oil quality and degradation
patterns
• through installation and usage of ESP technology

ESP products available in many formats Bali, Indonesia Aug 2018
VITA II standard VITA II Air driven VITA II ATEX

ESP products available in many formats Bali, Indonesia Aug 2018
VITA III standard VITA III Air driven VITA III ATEX

Question:
How do you get rid of
VARNISH
Answer:
Remove the R!
VARNISH By Violeta Soto

Age 10

ESP Case study – gas separation Bali, Indonesia Aug 2018
Case study ESP - https://youtu.be/BLa186Q95WQ

Safely Cleaning System
Deposits

Boost VR Process Bali, Indonesia Aug 2018
Boost VR works by increasing the solubility of the

oil, allowing stubborn deposits to be dissolved.


Varnish is removed one layer at a time is removed.

No sudden “dump” of contaminants occurs.
Boost chemistry is 100% compatible with the in-

service lubricant.


Varnish is removed one layer at a time is removed.

No sudden “dump” of contaminants occurs.
Boost chemistry is 100% compatible with the in-

service lubricant.
In combination with ESP, the system is

decontaminated in approximately 3-months.
No Flushing – No Downtime – No Risk

Boost VR Competition Bali, Indonesia Aug 2018
Most competitive processes use surface active

chemistries to remove deposits as part of a
“chemical” or “varnish” flush. An outage is
required to perform this service.

Boost VR Competition Bali, Indonesia Aug 2018

They lift and suspend lube deposits into the fluid,

resulting in significant pollution throughout the
internals of the lube oil system. Supplemental
filtration is required.

Boost VR vs The Competition Bali, Indonesia Aug 2018

They lift and suspend lube deposits into the fluid,

resulting in significant pollution throughout the
internals of the lube oil system. Supplemental
filtration is required.
Remnants of the incompatible surface active

chemistry remains, contaminating the new
charge of turbine oil. Even after a sacrificial rinse.
The use of surface active cleaners is considered

risky and expensive.

Effect of BVR on Compressor High Bearing
Temperatures Bali, Indonesia Aug 2018
• In October 2017, machine operating data

show that thrust bearing temperature
approaching 110 deg C (normal 75-90 deg C).
• This had the potential to trip the Recycle

compressor as there is temperature
protection on the bearings to protect the
machine from abnormal operating
conditions.
• Lube oil analysis plus known varnish issues
(hard deposits formed from oil degradation
forming ‘hot spots’) helped Machinery Team
diagnose problem and determine a course of
action.

Effect of BVR on Compressor High Bearing
Temperatures Bali, Indonesia Aug 2018
Boost VR
added
• Boost VR oil was mixed with the in-

service lube oil.
• Following 2 weeks operation,
bearing temperatures returned to
‘normal’ state.
• In the past this issues would have
resulted in a machine/unit outage
with consequent revenue loss.


What is the End of Life? Bali, Indonesia Aug 2018
• ASTM D4378 suggests the end of turbine oil life is when there are 25%
remaining antioxidants.
• RULER (ASTM D6971) is the preferred test for this, however RPVOT (ASTM
D2272) is still commonly used.
• Accelerated antioxidant depletion occurs under thermally stressful
conditions or water ingression.
• Time impact for oil change out during revision
• To change or not to change
• Take alternative and less time consuming actions

Options for oils with low AO levels Bali, Indonesia Aug 2018
Bleed &
Feed
Low Dump,
Costs
Flush &
AO Recharge
Replenish
Additives

Bleed & Feed Bali, Indonesia Aug 2018
A common practice for maintaining additive levels is “bleed

and feed”
• Up to 30% of in-service turbine oil is drained and refilled

with new turbine oil.
• This practice has yielded mixed results in the field.

Data from several bleed & feed operations Bali, Indonesia Aug 2018
100%
1 2 3 4 5 6 7 90%
80%
70%
Phenols Before 20% 41% 32% 5% 24% 55% 12%
Effectiveness
60%
50%
Bleed & Feed % 10% 12% 14% 15% 25% 27% 30%
40%
Estimated 30%
Result 28% 48% 42% 19% 43% 67% 38% 20%
10%
Phenols After 21% 44% 37% 16% 41% 65% 37% 0%
0% 5% 10% 15% 20% 25% 30% 35%
Bleed & Feed Rate
Effectiveness 13% 43% 50% 79% 89% 83% 96%

Bleed & Feed is Costly Bali, Indonesia Aug 2018
• Many bleed and feed examples indicate a lower additive treat rate than
expected.
• We believe that fresh antioxidants are immediately consumed when first

introduced into the system.
• This lowers the economics of bleed & feed and additive replenishment.

Additive Replenishment is not a new idea Bali, Indonesia Aug 2018
“Oil Reconditioning, Reclaiming, and Recycling-Understanding the

Processes and the Role of Oil Analysis in Each”
- Greg Livingstone, Practicing Oil Analysis 1999
Additive Replenishment Case Study from Hoover Dam

Key learnings about antioxidant replenishment Bali, Indonesia Aug 2018
• Not all turbine oils are compatible, therefore there’s not a one-size-fits all AO
package for in-service oils
• Every in-service sample has to be individually qualified, following ASTM
procedures
• Oils are more likely to be suitable if:
• The in-service oil hasn’t degraded to the
point that the base has undergone
significant deterioration.
• The in-service oil doesn’t have a high
varnish potential and is being maintained
with a suitable varnish mitigation system

Qualification Process Bali, Indonesia Aug 2018
Compatibility testing (ASTM D7155) is conducted with the

proposed AO formulation to qualify the oil.

Qualification Test Slate Bali, Indonesia Aug 2018
Aging &
Used Oil Blending with Compatibility Post-Aging
Analysis AO Testing Analysis
(ASTM D7155)
Ruler Ruler
MPC MPC
Demulsibility Demulsibility
Foam Foam
Viscosity Viscosity
TAN TAN
RPVOT RPVOT
FTIR FTIR
Air release Air Release

Qualification Test Slate Bali, Indonesia Aug 2018
Aging &
Used Oil Blending with Compatibility Post-Aging
Analysis AO Testing Analysis
(ASTM D7155)
Ruler Ruler
MPC MPC
Demulsibility Demulsibility
Foam Foam
Viscosity 1. No Negative Impacts Viscosity
TAN 2. Significant AO response TAN
RPVOT RPVOT
FTIR FTIR
Air release Air Release

Long-Term Performance
of Boost AO
Laboratory Simulations & Field Performance

Determining Long-Term Performance Bali, Indonesia Aug 2018
There are two ways of measuring long-term performance of Boost AO

1. Lab Simulations → TOPP testing
2. Field Trials

Lab Tests: TOPP Testing Bali, Indonesia Aug 2018
Turbine Oil Performance Prediction (TOPP) Testing

Test Parameters
Turbine oil is maintained in a bath at 120oC with
catalysts for 6 weeks.
Common weekly tests are:
• MPC
• RULER
• RPVOT
• FTIR

TOPP Testing on Boost-treated samples Bali, Indonesia Aug 2018
100
New Oil
35
Used Oil Condemning Limit

60 Before TOPP
After TOPP
165
Used Oil + AO
112
0 50 100 150 200

AO %
0 3 6 9 12
Estimated Life (Years)
Only 13% Life Left in New Oil after

100
New Oil TOPP test. This oil would last for ~7
35 years in a Gas Turbine.
Used Oil
60 Before TOPP
After TOPP
165
Used Oil + AO
112
0 50 100 150 200

AO %

Used Oil <50% remaining life or <3.5

100
New Oil years.
35
60
Used Oil
Before TOPP
After TOPP
165
Used Oil + AO
112
0 50 100 150 200

AO %

Used Oil’s AO levels increased to

100
New Oil 165% of new with addition of AO.
35
60
Used Oil
Before TOPP
After TOPP
165
Used Oil + AO
112
0 50 100 150 200

AO %

After TOPP Test, used oil still had

100
New Oil more AO than new oil. Estimated Life
35 after test is approximately 8 years.
60
Used Oil
Before TOPP
After TOPP
165
Used Oil + AO
112
0 50 100 150 200

AO %

100
New Oil Lost 65% of AO
35
60
Used Oil
Before TOPP
After TOPP
165
Used Oil + AO Lost 53% of AO
112
0 50 100 150 200

AO %

TOPP Testing on Boost-treated samples - RPVOT Bali, Indonesia Aug 2018
It is well accepted that initial RPVOT values do not correlate to

550
New Oil the life and performance
1250
of turbine oils.
“RPVOT retention” is a more important consideration.

Used Oil
475 Before TOPP
After TOPP
812
Used Oil + AO
845
0 200 400 600 800 1000 1200 1400

RPVOT Values

Results of TOPP Testing Bali, Indonesia Aug 2018
1250
New Oil
550
475
Used Oil
Before TOPP
After TOPP
812
Used Oil + AO
845
0 200 400 600 800 1000 1200 1400

RPVOT Values

Field Performance
1250 MW Combined Cycle Plant
GT Reservoir Size: 23,400 liters

GE 7FA Combined Cycle Plant – GT1 Bali, Indonesia Aug 2018
1400 250
1200
200
1000
RPVOT (mins)
150
800
Amines (%)
600 100
400
50
200
0 0
2011 2012B 2012A 2013 2014 2015 2016 2017

RPVOT Antioxidants
GE 7FA Combined Cycle Plant – GT2 Bali, Indonesia Aug 2018
1400 200
180
1200
160
1000 140
RPVOT (mins)
120
800
Amines (%)
100
600 80
60
400
40
200
20
0 0
2011 2012B 2012A 2013 2014 2015 2016 2017

RPVOT Antioxidants
SRP – BOOST AO real life case study Bali, Indonesia Aug 2018
• Mesquite Power plant

Avoiding Varnish requires a holistic perspective Bali, Indonesia Aug 2018
Fluid Selection
Maintenance Condition
Practices Monitoring
Contamination Avoid
Control Degradation

New Generation Turbine Oils may solve varnish
issues Bali, Indonesia Aug 2018
Varnish Potential (MPC) after TOPP test TOPP

74
70 71
63
MPC (de)
43
40
35
20
OIL 1 OIL 2 OIL 3 OIL 4 OIL 5 OIL 6 INFINITY

OILTO
7 32 OIL 8 OIL 9

New Generation Turbine Oils may solve varnish
issues – INFINITY TO 32 & 46 Bali, Indonesia Aug 2018
Varnish Potential (MPC) after TOPP test TOPP

74
70 71
Best-in-class Deposit Control
63
MPC (de)
43
40
35
20
OIL 1 OIL 2 OIL 3 OIL 4 OIL 5 OIL 6 INFINITY TO 32 OIL 8 OIL 9

Best in Class Deposit Control Bali, Indonesia Aug 2018

Varnish Conclusions Bali, Indonesia Aug 2018
• Varnish is complex!
• There is not necessarily one solution to solve oil degradation.

Final thoughts: your oil is an asset! Bali, Indonesia Aug 2018

Fluitec Case studies
Reliability Centered Strategies

Case #1 : Waste Energy Plant treatment Bali, Indonesia Aug 2018
• MVA Hamm - Mid of 2010

• First issues @ Turbine 3
• Based on Siemens oil analysis report
• Servo valves sticking
• Dark brown deposits noted on valve internals
• Radial bearings also reported brown deposits
• Oil cooler deposits
• Needed mechanical action to remove varnish

ISO VG 46 turbine oil – MVA HAMM DT2 Results Recommend values

Oil analysis parameter- Sept’ 2011
Viscosity 43.6 41 - 51
Water 0.01% < 0.02%
Acid Number 0.37 < 0.3
MPC – ASTM D7843 39 < 15
RULER – ASTM D6971 <10% RUL for amines > 25
and phenols
Air Release 6 min < 4 min
Demulsibility 200 sec < 300 sec
ISO Particle Count 22/22/21 20/17/14
Overall condition Critical
Table 1: oil analysis parameters DT2 – September 2011
• Germany plant - Deposits on servo valves and bearings turbine 3

Reliability Issues Bali, Indonesia Aug 2018
• Deposits

Start-Up ESP

Case # 2: Oil Treatment through ESP
• Short description
At 2 power plants, the front bearings of the gearbox suffered regularly from temperature
increase. After research this temperature increased was found to be a result from varnish
deposits. This deposits resulted in a lower oil flow at the bearings as well a reduced heat
dissipation. The deposits were characterized through analysis as being organic type of
varnish.
24 01.08.2018 Ölaufbereitung ESP Anlagen

1 International
© 2017 Fluitec
Case # 2: Oil Treatment through ESP
Due to the high load factors on this bearing the plant was used to a 2-yearly revision, to
clean up the bearings and internals.
But when the lifetime of the bearings from these turbines were reduced to approximately
2 months time, the plant had to go over to specific actions.
During the spring of 2015 the power plant decided to purchase the Fluitec ESP units, for
installation on the 2 turbine units where a increasing temperature effect is noticed on the
bearings from the gearbox..

2 International
© 2017 Fluitec
Case # 2: Oil Treatment through ESP Bali, Indonesia Aug 2018
• First the power plant tried to identify the bearing temperature behavior as a way to
define the varnish deposit tendency. As a possibility to meet the temperatures, the load
factors of the bearings (power plant efficiency, flow steam inlet) had to be reduced
• This reference value is identified as „Temperature vs. Load factor“ tendency.
3 International
© 2017 Fluitec
These are the graphs for Block 4,

where before the use of ESP the
lifetime of the bearings was
getting shorter and shorter.
Temperature evolution vs. load
Bearing temperatur 1
Temperaturs achieve maximum in

less than 8h
4 International
© 2017 Fluitec
This the trend for Block 5, where

before the use of ESP the bearing
temperature did not increase with
higher load factors
Temperature evolution vs. load
Temperature increase in less than

8h
5 International
© 2017 Fluitec
• Air Liquide Industry Belgium

• ATLAS COPCO compressor on CO-gas
• 1,200 liters mineral oil
• Root cause of varnish defined : oil mixtures


0 months 2 years 5 years





Australian Case Studies Bali, Indonesia Aug 2018

• Solar Turbines running Castrol Perfecto T.

• The historical below, I have removed the customer name, but you can see 2 cases below
• ESP installed 1st June 2016
• Only ESP up until August 19th got the MPC down from 66 to 44
• Adding Boost VR on 19th August saw MPC drop to 16 (29th Aug), 13 (5th Sept) and 7 (18th
Sep)
• Since then the customer replaced the oil and new oil solvency has dissolved more
contaminant and ESP will be reinstalled on this GT

Gas Turbine – Natural Gas Compressor
ESP \ Boost VR \ Boost AO Bali, Indonesia Aug 2018
• Gas turbine / Compressor - Solar Centaur 50 (GT)

• Oil reservoir: 3,000 litres turbine oil

Gas Turbine – Co-Gen Plant Bali, Indonesia Aug 2018
• Oil reservoir: 12,000 litres

• 3 gear box replacements - May 2013 – Sept 2014
• Initial MPC level 65
• ESP136 installed May 2015
• Boost VR added
July + Sept 2015
• System cleaned prior

to oil replacement in
October 2015
• New Oil dissolved

contaminants
• ESP permanent
installed and continues
to remove degradation
products

Steam Turbine – Air Compressor – Refinery Bali, Indonesia Aug 2018
• Oil reservoir: 24,000 litres turbine oil - Initial MPC level 29-33
• 2 trips in 6 months before ESP
• “Entire management used to worry about trips, now only I do”

Case study Australia GT 1 Bali, Indonesia Aug 2018
• 2015 till 2018

• Long term cleaning
Effect of ESP

Steam Turbine Ammonia Refrigeration
Compressor Bali, Indonesia Aug 2018
Bearing and seal varnish as found November 2014 after 8 months operation
Bearing as found 2012

Steam Turbine Ammonia
Refrigeration Compressor Bali, Indonesia Aug 2018
Bearing as found March 2016

China – Petrochemical - Compressor Bali, Indonesia Aug 2018

2 August, 2018
Any questions?
j.ameye@fluitec.com

Lubrication Academy - Bali 2018

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Varnish on bore of IGV Valve from Frame 7FA

Typical Cost of a full load trip:

• Coal Fired Power Plant in S. Africa had a

• Overspeed Trip Assembly failed to close resulting

• Flying Components flew out of the turbine building.

© 2017 Fluitec International

© 2017 Fluitec International

Emergency Trip Valve stuck,

2,000 people out of work.

© 2017 Fluitec International

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Significantly impacts the Wind

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© 2017 Fluitec International

1927 (Roger, 1968 (ASLE) 1981 (Den Herder,

1956 (Wilson) 1976 (Smith; GE)

© 2017 Fluitec International

© 2017 Fluitec International

Source: Shell Lubricants,

Evolving conditions in turbine lube oil systems

• Changing operating conditions

More sensitive Turbine

More thermal stress

Oil has multiple

© 2017 Fluitec International

© 2017 Fluitec International

© 2017 Fluitec International

© 2017 Fluitec International

© 2017 Fluitec International

© 2017 Fluitec International

© 2017 Fluitec International

General Electric Specifications

© 2017 Fluitec International

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Antioxidants (Primary & Secondary)

© 2017 Fluitec International

• American Petroleum Institute (API)

© 2017 Fluitec International

© 2017 Fluitec International

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© 2017 Fluitec International

• Group I basestocks Type of Basestock Aniline Point (oC)

© 2017 Fluitec International Ref: Livingstone, Wooton

• Important ingredient for protecting metal surfaces in wet environments.

© 2017 Fluitec International

Typical turbine oil

© 2017 Fluitec International

• Siloxanes Antifoam (insoluble and

© 2017 Fluitec International

• Main ingredient in turbine oil.

Antioxidants are also

Ref: Livingstone, Ameye