encl03 lubricating and control oils for turbines
DESCRIPTION
Lubricating and Control Oils for TurbinesTRANSCRIPT
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Lubricating and Control Oilsfor Turbines
Specification and supervision
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Revision History
Revision Content of Change Document Pagestotal :
N 97-10-21, Extension of content, re-structuring of the text 18P 98-02-11, Oil designations from Castrol have been changedQ 99-06-16, Additional requirements and oil brandsR 00-05-17, Cleanliness class ISO 4406 changed to new standard,
div. Oil suppliers added
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Contents
1 GENERAL .....................................................................................................................5
2 SCOPE OF APPLICATION...........................................................................................5
2.1 Exceptions.............................................................................................................5
2.2 Viscosity classes ..................................................................................................5
2.3 Terms of delivery...................................................................................................6
2.4 Notes on acceptance and first filling of the lube oil tank ..................................6
2.5 References.............................................................................................................6
2.6 Properties ..............................................................................................................7
3 SUPERVISION ............................................................................................................11
3.1 Sampling..............................................................................................................12
3.2 Explanatory notes on the tables ........................................................................12
4 REFILLING THE OIL TANK........................................................................................14
5 SELECTION OF THE OIL SUPPLIER ........................................................................15
5.1 Tested lube and control oils ..............................................................................15
5.2 Untested lube and control oils...........................................................................18
Figures
Fig. 1 Specification table ..................................................................................................8
Fig. 2 Viscosity characteristics........................................................................................10
Fig. 3 Supervision...........................................................................................................11
Fig. 4 Purity classes as per ISO 4406 ............................................................................13
Fig. 5 Purity classes as per NAS 1638 ...........................................................................13
Fig. 6 Purity classes as per SAE 749 .............................................................................14
Fig. 7 ABB ALSTOM POWER-tested lube and control oils ............................................17
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Additional documents
Check list ......................................................................................... HTGD 90 117 D0001
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1 GENERAL
This specification stipulates the requirements, test methods and terms of de-livery for lubricating (lube) and control oils, which ABB ALSTOM POWERuses in steam and gas turbines.
2 SCOPE OF APPLICATION
The mineral oils in accordance with this specification are refined mineral oilswith additives which increase the resistance to ageing and improve the pro-tection against corrosion. Small quantities of other additives can also beadded to achieve the required properties.
The mineral oils in accordance with this specification can be used in the lubeand control oil systems of turbomachinery.
)It is usually not permitted to use mineral oil as control oil inhydraulic systems with a pressure > 120 bar!
2.1 Exceptions
)Mineral oils and additions of metal-organic compound (e.g.zinc-dialkyldithiophosphate) are not permitted!
2.2 Viscosity classes
Mineral oils of viscosity classes ISO VG 32 and 46 are usually used for steamor gas turbines.
ABB ALSTOM POWER uses normally the viscosity class ISO VG 46 if thebearing oil inlet temperature is between 40 °C and 50 °C (104 °F to 122°F).
Mineral oils of viscosity class ISO VG 32 can be used without problems up toa bearing oil inlet temperature of 45°C (113°F). These mineral oils are lesssuitable for turbosets with higher bearing oil inlet temperatures.
Mineral oil of viscosity class ISO VG 68 can possibly be used with very highbearing oil inlet temperatures.
The ABB ALSTOM POWER Engineering Department responsible must prin-cipally be consulted for approving the viscosity class.
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2.3 Terms of delivery
As agreed between supplier and customer, the oil is supplied in tank lorries orin clean, firm and dry barrels. The following minimum information must beprovided in a legible and durable manner on each barrel:
• Designation of the type and viscosity class
• Identification of the product and supplier
• Charge or delivery number
)When placing the order, a test certificate must be re-quested from the supplier for the supplied mineral oil.
The delivery may not be accepted if this condition is notfulfilled.
2.4 Notes on acceptance and first filling of the lube oil tank
The check and procedure for the acceptance on delivery and first filling of thelube oil tank are laid down in the check list to be completed.
A copy of this check list must always be sent to the Project Manager of ABBALSTOM POWER.
2.5 References
ISO 6743 part 5 Lubricants, industrial oils and related productsClass L-Classification-Part 5-Family T (Turbines)
ISO 3448 Industrial liquid lubricants-ISO
ISO 4406 Hydraulic fluid Power-Fluids-Method for codinglevel of contamination by solid particles
ISO 8068 Petroleum products and lubricants - Petroleumlubricating oils for turbines, categories ISO-L-TSA and ISO-L-TGA-Specifications
DIN 51519 ISO-Viscosity classification for liquid industriallubricants
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2.6 Properties
When checking a 10 cm thick oil layer in transilluminating light, the oil shall bebright and clear and free of visible foreign matter. The additives may not havenegative effects on the materials of the oil system.
Fig. 1 lists the limit values for the most important oil quality requirements andthe approved testing methods.
The viscosity/temperature relationship is shown by the viscosity characteris-tics in the graph in Fig. 2.
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Requirements ISO viscosity class 6) Test methods as per
ISOVG32 ISOVG46 ISOVG68 ISO ASTM DIN
Viscosity at 40°C mm2/s 32 ± 10% 46 ± 10% 68 ± 10% 3104 D 445 51 55051 562
Viscosity index 1) ≥ 90 2909 D 2270
Density at 15 °C ≤ 0.90 g/cm3 3675 D 941 51 757
Flash point C.O.C. ≥ 185 °C ≥ 205 °C 2592 D 92 51 376
Pour point Below – 6 °C 3016 D 97 ISO3016
Zinc content ≤ 2 ppm Optional
Neutralisation value max. 0.3 mg KOH/g 6618 D 664D 974
51 558
Air release at 50 °C ≤ 4 min. ≤ 7 min 9120 3427 51 381
Foaming characteristic Foam tendency at 24/93.5/24 °Cmax. 450/50/450 mlFoam tendency at 24/93.5/24°Cafter 10 minutes. 0/0/0 ml
DP 6247 D 892
Demulsibility 3) after Steam treatment ≤ 5 min.4) 51 589
Emulsion characteristic 3) ≤ 30 min. 6614 D 1401 51 599
Ageing stability 5) Increase of neutralisation valueafter 2000 h max. 2.0 mg KOH/g
4263-2 D 943 51 587
Neutralisation value < 1.8 mg KOH/gSludge content < 0.4 %
DP 7624
Copper corrosion Max. degree of corrosion 2(at 100 °C / 3 h)
2160 D 130 51 759
Rust preventing characteristic Free from corrosion using artificialseawater
7120 D 665 51 585
Load stage without gear at least
VG 32 : 5 VG 46 : 6 VG 68 : 7
Load stage with gear at least
Load carrying capacity 2)FZG-Normaltest A/ 8.3/ 90
VG 32 : 9 VG 46 : 9 VG 68 : 9 51 354
Oxidation stability RBOT 7) Requirements not definedaccord. to experience > 300 min
2272
Purity --/18/15 4406
Fig. 1 Specification table
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Notes on the table, Fig. 1
1) The viscosity index (VI) is a measure for the viscosity-temperature rela-tionship. The requirement for the index is fulfilled if all viscosity valuesmeasured for temperatures between 20 °C and 100 °C (68 °F and212 °F) or determined by extrapolation are within the range correspond-ing to this viscosity class (see graph, Fig 2).
2) For turbines with gear a FZG load stage of at least 9 is required (mineraloils with EP additives). Depending on the plant, the gear manufacturermay require other FZG load stages.
3) There is no sufficiently reliable correlation between the water separationability according to DIN and the demulsification capacity according toISO. It depends on the national regulation of the country where the oil isused which of the two criteria must be fulfilled.
4) An English standard IP19, corresponding to DIN 51589, is contained in avolume of the English “Institute of Petroleum”.
5) Supplier and customer decide which test method is used.
6) The viscosity class has to be selected plant-specifically.
7) The limit value for new oil is not defined. The measurement is importantas a basis.
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Comparison
Fig. 2 Viscosity characteristics
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3 SUPERVISION
Periodic supervision of the lube oil condition permits assessment of theproper functioning of the system and early action in the case of malfunction-ing.
Fig. 3 specifies the recommended periodic checks, approximate values andcorrective actions.
Test Procedure Fre-quency
Set value Limit value Corrective action
Appearance seechapter 3.2
Visualinspection
Clear, light-yellowor coloured liquid
Cloudiness, darkdiscoloration
Analyse inlaboratory
Water content in oilsample
Visualinspection
MonthlyClear liquid Cloudiness
(no free water)Drain(centrifuge)
Water content acc.to K. Fischer
DIN 51777ASTM D1744ISO 12937
Yearly100 mg/kg 500 mg/kg Drain
Solidimpurities
SAE 749 DISO 4406NAS
Class 4Class 16/13Class 7
Class 51)
Class --/17/141)
Class 81)
FilterReplace filter
Neutralisation value ASTM D664/D974DIN 51558ISO 3104
Acc. to original condi-tion analysis
max. 0.4 mg KOH/gabove original value
Contact oilsupplier
Viscosity ASTM D445DIN 51550/62ISO 3104
Acc. toISO VG-class
ExceedingISO VG
E.g. check refill oilFind out reason
Air releaseat 50°C
DIN 51381ASTM 3427
4 min.ISO VG32/467 min. ISO VG68
8 min. ISO VG32/4610 min. ISO VG68
Contact oilsupplier
Emulsioncharacteristic
ASTM D1401DIN 51599ISO 6614
max. 30 min. max. 30 min. Observe carefully,refill in the case ofpoor oxidation stability
Demulsibility DIN 51589 max. 5 min. max. 6 min Find out reason
Copper content(solved in oil)
Optional < 10 ppm exceeding15 – 25 ppm
Observe carefully
> 30 ppm Extreme case:new filling
Oxidation stabilityRBOT
ASTM D2272 > 25% of new oil or> 100 min. if initialvalue is unknown
25% of new oil or 70min. if initial value isunknown
New filling
1) For control oil class 4 SAE4, ISO 4406 --/16/13, NAS 7
Fig. 3 Supervision
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3.1 Sampling
Take the oil samples from the lower third of the oil tank for the monthly checkof the appearance and water content
)Take the oil sample from the pressure line downstream of thefilter for the quantitative determination of impurities or for theyearly check of the overall condition!
)The oil system must have been in operation for at least 12hours before taking the sample!
Prior to the actual sampling (approx. 1 litre) discharge approx. 3 to 4 l flushingoil for flushing the valves. Rinse the clean test receptacle three times with oil.
The valve may not be fully closed between flushing and sampling. If the testis not carried out in the plant’s own laboratory, the receptacle must bear thefollowing information:
• plant name
• oil brand
• point of sampling
• date and operating hours of oil filling
• Quantity refilled since last oil analysis
• total refill quantity since last oil filling
3.2 Explanatory notes on the tables
Appearance
When checking a 10 cm thick oil layer in transilluminating light, the oil shall beclear and free of visible foreign matter after settling down for 10 minutes.
Solid impurities
The solid impurities are classified in the following purity classes in accor-dance with their number and size per volume unit.
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ISO 4406 (excerpt from ISO standard)
Number of particles per 100 millilitre greater than
Class > 6 µm 14 µm
more than up to and incl. more than up to and incl.
--/20/17--/19/16--/18/15--/17/14--/16/13--/15/12--/14/11--/13/10
500’000250’000130’000 64’000 32’000 16’000 8’000 4’000
1’000’000500’000250’000130’00064’00032’00016’0008’000
64’00032’00016’0008’0004’000
12’0001’000500
130’00064’00032’00016’0008’0004’0002’0001’000
Fig. 4 Purity classes as per ISO 4406
NAS 1638
Number of particles per 100 millilitre
Class 5-15 µm 15-25 µm 25-50 µm 50-100 µm > 100 µm
4 5 6 7 8 91011
4’0008’000
16’00032’00064’000
128’000256’000512’000
7121’4252’8505’700
11’40022’80045’60091’200
126253506
1’0122’0254’0508’100
16’200
224590
180360720
1’4402’880
48
163264
128256512
Fig. 5 Purity classes as per NAS 1638
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SAE 749
Particlesize
Purity classNumber of particles per 100 millilitre
µm Class 4 Class 5 5 - 1010 - 2525 - 5050 - 100 > 100
32’00010’700 1’510 225 21
87’00021’000
3’310430
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Fig. 6 Purity classes as per SAE 749
)Solid particles larger than 150 microns are not permitted!
If the lube oil is also used as control oil, it must have the pu-rity SAE class 4 or ISO class --/16/13!
4 REFILLING THE OIL TANKThe oil tank shall principally be refilled with oil of the same brand and viscos-ity class.
Refill the clean lube oil system principally via a filter with a mesh size of 10µm in order to filter out impurities.
)Mixing of different oils may cause accelerated ageing andprecipitation of additives!
The mixing of oils is only permitted after consulting the turbine and oil suppli-ers.
The oil supplier must also be consulted if other measures are required, suchas re-inhibiting the oil. Such action is, however, only useful if previously test-ed with success in the laboratory.
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)It is recommended to record all refillings to permit a correctassessment of changes in the oil.
5 SELECTION OF THE OIL SUPPLIERPrincipally, only those mineral oils are permitted that meet the requirementsof the specification given in Fig. 1.
5.1 Tested lube and control oilsThe lube and control oils, tested and approved by ABB ALSTOM POWER onthe basis of the specification given in Fig. 1, are mentioned in Fig. 7.
The ABB ALSTOM POWER approval does not exonerate the supplier fromhis responsibility for the quality of the product.
The supplier must immediately inform ABB ALSTOM POWER if he changesthe name of the product, its composition or the name of his company.
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With EPAdditive FZG
at least 9Brand Desigantion
Date of lastoil test
no yes
ADDINOL Turbinenöl TL 32 X
Turbinenöl TL 46 May 1994 X
AGIP OTE 46 May 1992 X
Aseol Dawatur 16-403-ISO VG32 X
Dawatur 16-404-ISO VG46 X
BASF Wintershall Wiolan DW32 X
Wintershall Wiolan DW46 X
BP Turbinol 32 X
Turbinol 46 January 1992 X
Energol TH-HT 32 X
Energol TH-HT 46 X
Turbinol X32 October 1999 X
Turbinol X46 October 1999 X
Turbinol EPX32 October 1999 X
Turbinol EPX46 October 1999 X
Caltex Regal Oil R& O 32 X
Regal Oil R & O 46 June 1989 X
Regal EP 32 X
Regal EP 46 X
Regal Premium EP 32 August 1999 X
Regal Premium EP 46 August 1999 X
Castrol Perfecto T32 X
Perfecto T46 X
Perfecto HPT46 May 1995 X
Perfecto AWT 46 March 2000 X
Cepsa ODIEL EP46 1989 X
ODIEL EP 32 X
Chevron GST Oil 32 January 1990 X
GST Oil 46 March 2000 X
Conoco Hydroclear Multipurpose R&O Oil 46 April 2000 X
Fuchs/DEA Renolin Eterna 32 X
Renolin Eterna 46 June 1989 X
Elf France Turbelf SA32 X
Turbelf SA46 X
Esso Teresso 32 X
Teresso 46 X
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With EPAdditive FZG
at least 9Brand Designation
Date of lastoil test
no yes
Fina Bakola 46 June 1989 X
Kuwait Oil Turbine Oil 32 X
Turbine Oil 46 X
Mobil Turbine Oil Light (ISO VG32)1) X
Turbine Oil Medium (ISO GV46)1) X
DTE797 (ISO VG32) X
DTE798 (ISO VG46) X
DTE 832 October 1997 X
DTE 846 November 1996 X
Turbine Oil 32 October 1997 X
Turbine Oil 46 November 1996 X
Mol HungarianOil & Gas Co.
Carrier Turbokomol 32 K September 1997 X
Carrier Turbokomol 46 K X
Petrogal Galp Turbinoil C32 X
Galp Turbinoil C46 X
Shell Turbo Oil T32 X
Turbo Oil T46 X
Turbo CC 32 September 1999 X
Turbo CC 46 September 1999 X
Texaco Regal X46 2) June 1989 X
Regal EP 32 X
Regal EP 46 July 1995 X
Regal Premium EP32 August 1999 X
Regal Premium EP46 August 1999 X
Total Preslia 32 X
Preslia 46 March 1987 X1) According to Mobil the lube oils “Turbine Oil light/medium” are no longer supplied (since 1995).2) No longer supplied (since 1999)
Most of the oils are also available in ISO VG 68. State: May 2000
Fig. 7 ABB ALSTOM POWER-tested lube and control oils
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5.2 Untested lube and control oils
The following possibilities exist if a plant operator wants to use a mineral oilthat has not been tested by ABB ALSTOM POWER:
• The oil is tested in the ABB ALSTOM POWER laboratory in accordancewith the specification list in Fig. 1 and at the expense of the oil supplier. Itis approved if all requirements are met. The test requires approximately 4months because of the aging test (2’000 hours).
• If ABB ALSTOM POWER agrees, individual tests can be carried out incertified laboratories.
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