Advances in Turbine Lubricant Maintenance

Copyright © EPT 2017, All rights Reserved
Advances in Turbine Lubricant
Maintenance
Peter Dufresne EPT, Oct 2017
When Results Matter

©Copyright EPT 2017
Copyright, Peter Dufresne, EPT 2017. This work is the
intellectual property of the author. No Re-publishing in
part or in while is allowed without the written permission
of the author. The author can be contacted at
pdufresne@cleanoil.com
2

Copyright © EPT 2017, All rights Reserved 3
EPT: Experts in the field of high purity
turbine lubricants and control fluids
using Ion Exchange resin based lubricant
treatment called ICB™
• 20 years experience.
• 1,000 installations on largest turbine
fleets in world.
• 50 million operating hours.
• Proven cost savings of $100 million.
Introduction

Introduction
Taichung Fossil Plant, Taiwan
Largest Fossil Power Plant in the World
JFK International Airport, New York City, USA
One of the Busiest Airports in the World
TransCanada
1 of the Largest Fleets of Gas Turbines

We Combine Expert Service

Best in Class Technology
6

World Class Research Lab
7

To Delivery Exceptional Results
8
AntiOxidants: Amine 75%, Phenol 76%. Consumption rate <4% per year, Projected life >20 Years
1-Perfect lube oil quality, 0 issues, and lowest risk level and cost operating profile achieved.

• Pier Reviewed
Publications, April 2014
• Economic case study of
on fleet of 100 turbines
• Cost savings of $90
million
• Ongoing ROI, 680% per
year
And Best in Class Cost Savings
9

• ASTM Definition (D7843-16):
• “A thin, hard, lustrous, oil-insoluble deposit, composed
primarily of organic residue, and most readily definable
by color intensity’ .

What Causes Varnish?
• Varnish occurs when the lubricant break-down
products (created from Oxidation) accumulate
past the point of saturation.
• These oxidation by-products (waste products)
are dissolved in the oil until the oil becomes
saturated.
• When the oil is saturated, these waste
products convert to a solid form.
11

Varnish Cycle
• The Varnish Cycle:
Varnish
Levels
Saturation Point
Step 1:
Soluble
Varnish
Step 2:
Insoluble
Varnish
Step 3:
Varnish
Deposit
Chemical
Change
Physical
Change
Physical
Change
Oxidation

Varnish Formation
• Left: “as received.” Right: soluble varnish removed
>50°C:
Soluble
Varnish
<20°C:
Insoluble
Varnish
Insoluble Varnish Formation as and Oil Cools
Turbine oil sample split in 2:

Measuring Varnish Potential: MPC
ASTM D7843-16

Measuring Varnish Potential: MPC
ASTM D7843-16
15
• Membrane Patch Colorimetry (MPC): assesses oil’s potential to produce varnish.
• Passes oil through 0.45 μm filter patch.
• Quantifies color of deposit left on filter patch.
• Darker patch suggests higher potential for varnishing.
• Consistent sample prep required to obtain reproducible results:
• Heating for 24 hours then incubating for 72 hours @ room temperature.
• Updated in 2016, to protect sample from UV.
Source: ASTM D7843-16

Varnish Removal
• The Varnish Cycle: Particulate Removal vs Soluble Varnish Removal
Varnish
Levels
Saturation Point
Step 1:
Soluble
Varnish
Step 2:
Insoluble
Varnish
Step 3:
Varnish
Deposit
Chemical
Change
Physical
Change
Physical
Change
• 2 Approaches to Varnish removal
• Soluble varnish removal (SVR)
using Ion exchange resin (ICB)
• Insoluble removal using
particulate removal technology
SVR
ICB

• Resin based system (ICB) that deals
with the issue during normal turbine
operating condition so that no
varnish is formed during cool down
periods.
• Eliminates existing varnish deposits
and the feedstock from which
varnish is created.
• Low cost of ownership over 10 years,
High Return on Investment
18
SVR™, Lube Oil Conditioner

Filter Matrix inside SVR/ ICB™ Benefits
• Removes oxidation products
transforming lubricant
maintenance from Reactive to
Proactive.
• Improves lubricant performance by
maximizing effectiveness of anti
oxidants
• Improves effectiveness of lubricant
top ups
• Removes particulates reducing the
load on main lube oil filters
19
ICB is a trademark of EPT
Source: EPT
ICB™ more than Varnish Removal

Reversing Varnish
• Because varnish formation is a physical change of
contamination from one form to another (dissolved
to solid), the process can be reversed.
• Equilibrium chemistry dictates that if you return the
oil to an unsaturated condition by removing the
dissolved contamination you will force varnish
deposits back into solution
• STRATEGY
– If you can prevent the oil from getting saturated you can
prevent varnish under all operating conditions.
20

• Why Varnish Removal Fails
relates to the Soluble/
Insoluble varnish
equilibrium
• Clearly demonstrates the
limitation with particulate
removal devices that have
to wait for varnish to form
before they can be of any
value.
PUBLICATIONS, OilDoc 2017, Germany
21

Cleanup Phase Vs Stability Phase

Demulsibility Improvement
23
Sample
Demulsibility
(mL Oil/
mL Water/
mL Emulsion)
Separation Time
(Minutes)
MPC
ΔE
AN
(mg KOH/g)
FTIR
Oxidation
(%)
Additives
Amine (%) Phenol (%)
Target 40/40/0 < 10 < 15.0 < 0.10 < 15 100 100
ATA 7 40/33/7 > 30 1.4 0.02 26 100 100
Post “VH” 40/40/0 10 1.4 0.02 0 100 100
Change Improved Improved - 0% - 0% - 100% - 0% - 0%

Case History- Gas Turbine, GE Frame 5
Oil life 25 years using SVR Oil Conditioning since 2016
Anti Oxidants: Amine 56%, Phenol 23%. Consumption rate <1% per year, Projected life – Indefinite. SVR
returned oil to spec allowing for top up with same oil used to boost additives which avoided replacement
1-Perfect lube oil quality for an oil at 25 years age is unprecedented in industry and offers a look into the
future of lube oil maintenance where oils are no longer replaced on acid number, MPC, RPVOT, or low
additive. Improved oil conditioning offers extended run times, avoids cost of replacement downtime and
flushing when quality oils are used in conjunction with top up.

SVR, >400 Installations
25

Siemens SGT800 Before and After
26

Siemens SGT800 Before and After
27

Normal Turbine Lubricant Life Cycle
• Common for gas turbine lubricants to last 6-8 years.
– Corresponds to anti-oxidant consumption rate of 1/6 – 1/8th per year.
– Additive consumption rate year/year determines maximum life
• Steam turbine lubricants expected to last 2x as long
– Scheduling of replacement very important in nuclear industry.
• Lubricants currently replaced on:
– high acid number, low additive, low RPVOT, elevated MPC
– + poor Demulsibility in the case of ST’s.
• Flushing often required at time of replacement.

Case History- Gas Turbine Lube
7 years old with SVR Oil Conditioning system from Day 1
29
AntiOxidants: Amine 75%, Phenol 76%. Consumption rate <4% per year, Projected life >20 Years
1-Perfect lube oil quality, 0 issues, and lowest risk level and cost operating profile achieved.

SVR for Steam Turbine Applications
30

Demulsibility/Water Seperability
• ASTM D1401
• Frequency: As needed.
• Warning limit: 15 mL emulsion after 30
minutes.
• In GTs, heat drives off free water while
in STs, free water can be drained off.
• If the fluid has poor Demulsibility,
water can form stable emulsions.
• Emulsions hinder the lubricating
ability of the fluid and expose both
equipment and fluid to the
damaging effects of water.
How to test for water separation

REF: Lubrizol, GT, JCF
Oil/Water Demulsibility
Oil
3 ML cuff allowed
Water
Emulsion
40/40/0 (15) 25/25/30 (60) 0/0/80 (60)

SVR™ Effect on Demulsibility
• “VH” Media treatment completely eliminates emulsified layer in all trials.
• “VH” Media treatment significantly decreases amount of time for emulsion to disappear.
• Demulsibility improvement linked to ↓ in oil’s acid number and oxidation product levels.
• Polar contaminants promote formation of persistent emulsions when water (polar) and
oil (non polar) are mixed.
Fluid Initial Demulsibility Post “V” Demulsibility
A 39/24/17 (>30) 42/38/0 (10)
B 39/39/2 (15) 42/38/0 (5)
C 41/37/2 (25) 42/38/0 (10)
D 39/39/2 (10) 42/38/0 (5)
E 40/37/3 (25) 43/37/0 (10)

Game Changing Results
34

• 14x larger than conventional
systems
• Designed to process 164,000
Liters per day with expansion
module
• VFD Drive
• High efficiency 1 micron
filtration
• ICB filters can be changed
without shutting off machine
35
SVR™, 7200 – High Volume System

• Expansion module
• Connects in parallel
with ICB vessels with all
discharge going through
1um post filter.
• Flow rate measured and
adjustable for each
vessel
SVR7200- For 100,000 Liter Reservoirs
36

New Lubricant Breakdown Testing
• Tested most major brands at
high temperature to
demonstrate what happens
with and without SVR lube oil
conditioning.
37

Lubricant Breakdown Testing – Brand A
Temperature 150C with Copper Catalyst

Lubricant Breakdown Testing, Brand B
Temperature 150C with Copper Catalyst

• Comparison of two different turbine oil brands:
Days
AN (mg
KOH/g)
RULER
Amine
(%)
RULER
Phenol
(%)
MPC ΔE
Patch
Photo
0 0.04 100 100 1.3
4 0.04 91 8 10.6
7 0.03 85 6 39.5
11 0.04 68 5 43.9
14 0.04 34 7 49.7
Days
AN (mg
KOH/g)
RULER
Amine
(%)
RULER
Phenol
(%)
MPC ΔE
Patch
Photo
0 0.14 100 100 4.8
5 0.30 0 10 64.4
9 3.96 0 0 64.4
A vs B
Lubricant Breakdown Testing

• Degraded 2 identical beakers of turbine oil side-by-side.
• LEFT: with SVR™ treatment.
• RIGHT: without SVR™ treatment.
• Test Duration: 53 days.
3 days0 days 17 days 31 days 53 days
Untreated: :SVR™ treated
Testing Repeated
With and Without SVR Lube Oil Conditioner

• SVR™ Treatment Effect Upon MPC ΔE Varnish Potential:
• With SVR™:
MPC ΔE: -99%
• Without SVR™:
MPC ΔE: +196%
0.0
10.0
20.0
30.0
40.0
50.0
MPC ΔE
Varnish
Potential
Time 
Without SVR
With SVR
0 72 240 408 576 744 1080
0 72 240 408 576 744 1080
0 72 240 408 576 744 1080
0 72 240 408 576 744 1080
Testing Repeated
With and Without SVR Oil Conditioner

Thank you
Banff National Park, AB, Canada
Photo Matt Hobbs
Peter Dufresne, EPT
pdufresne@cleanoil.com
(403) 389-4101

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