Steam Turbine Turbine Oil Care

Maintenance Maintenance Instructions

Introduction The Turbine Oil Specification [1] contains

Function of the turbine oil is to lubricate and standards and selection criteria for turbine
cool the bearings of the turbine generator oil as well as the requirements in terms of
and to actuate governing system physical and chemical properties.
components. Turbine oil is subjected to high The following oil properties are particularly
physical loads, should have a long service important for turbine oil care:
life and must not have any adverse effect on
the proper functioning of the bearings and
Total-acid number
other turbine oil consumers
Water contents and water separability
The physical and chemical properties of new efficiency
turbine oil must comply with the
Solid contaminant quantities, purity
requirements of the Turbine Oil Specification
[1]. The aim of turbine oil care is to maintain
Air release properties
the properties and the useful service life of
Foaming characteristics
the turbine oil for as long as possible.
Turbine oil properties and the values which
This general maintenance instruction can change those properties are discussed
discusses the necessity for, and the briefly below.
procedures involved in turbine oil care.
Further information can be found in the
The program for the care of turbine oil standards cited in the Turbine Oil
includes regular inspection and analysis of Specification [1] as well as technical
turbine oil samples. In this way changes in literature, including those issued by turbine
turbine oil properties can be determined and oil manufacturers.
the necessary actions can be taken to
remedy the situation. Actions to be taken to rectify typical changes
in turbine oil properties are listed in Table-1.
The filters and strainers in the operating oil
systems retain solid contaminants which can
cause damage and/or impair functioning if Total-acid number of the turbine oil
they ingress into turbine oil consumers. The total-acid number is an easily
By centrifuge (i.e. oil conditioning station) determined reference value for turbine oil
which is independent of the oil operating aging.
systems, contaminants and aging and Catalysts and thermal loading of the turbine
corrosion products which are not soluble in oil can trigger an oxidation process in which
oil are removed from the turbine oil. oleic acids are formed, raising the total-acid
Thorough cleaning of the oil system during number of the turbine oil. The oil ages.
initial startup and after inspections and The oleic acids attack oil system component
overhauls is one of the prerequisites for materials and corrosion products are formed
successful turbine oil care. In addition, the which can, in turn, catalytically accelerate
ingress of contaminants into the oil system the oxidation process.
must be prevented.
Under certain circumstances, contaminants
which ingress into the oil system from
Turbine oil properties outside can promote the oxidation process.
As a rule, turbine oils are paraffin-based
New turbine oil contains additives which,
mineral oils which contain additives to
provided that oil is properly cared for, give
improve their resistance to corrosion and
sufficient protection against aging.
their oxidation stability.

BHEL Haridwar 4-1210-01/1

The additives become depleted over time. Solid-contaminant quantities and purity
Under unfavorable conditions, e.g. where of turbine oil
there is improper or negligent oil care, this Whereas the material property value for
depletion process can result in premature solid-contaminant quantity defines the
aging of the turbine oil. overall content by weight of solid-
contaminant quantities in a turbine oil
In this case, the turbine manufacturer and
sample, when defining turbine oil purity only
the turbine oil supplier should be consulted
the proportion of solid-contaminants of a
in order that measures for restoring the
specified size is determined. Turbine oil
turbine oil can be implemented.
purity is the more reliable criterion.
The turbine oil cannot be used if the function
Solid-contaminants can ingress into the
of sensitive turbine generator components is
turbine oil from outside, or as a result of the
impaired through corrosion and/or aging
aging process or corrosion. They contribute,
products and if the aging process, i.e., the
along with other factors, to the turbine-oil
change in the total-acid number, cannot be
aging process and impair the condition and
reversed by treating the turbine oil.
function of the turbine components.
From this highly simplified description of the
Among the principal areas which can be
turbine oil aging process, it can be seen that
affected are turbine and generator bearings.
aging is affected not only by physical loading
Their load capacity can be reduced due to
of the turbine oil but also by catalysts and
scoring caused by solid-contaminants in the
aging products, e.g., oleic acids. Treatment
turbine oil. In addition, changes of state and
of the turbine oil in the oil conditioning
impaired functioning in control and
station removes products of aging and
protection equipment can be expected.
corrosion which are not soluble in oil,
thereby slowing down the aging process. The oil system is thoroughly cleaned during
initial startup of the turbine generator set.
Flushing of the entire system is included in
Water content and water separability of
the cleaning process.
the turbine oil
The value for water content stipulated in the The filters and strainers of the operating oil
Turbine oil Specification (1) should not be systems are used to retain contaminants
exceeded. with a particle size larger than the filter mesh
size, before the turbine oil reaches the oil
Water which ingresses into the oil system consumers. The dwell time of the oil in the
from an oil cooler, in the form of shaft seal filters and strainers will depend on the purity
steam or leakage water, results in the of the turbine oil.
corrosion in ferrous materials and can
adversely affect the aging process and Purity in accordance with the Turbine Oil
foaming characteristics of the turbine oil. Specification [1] is achieved through
continuous filtration or separation of turbine
Corrosion causes changes in the surfaces oil in the oil centrifuge.
and shape of the sensitive turbine generator
components. The corrosion products behave During inspections and overhauls the turbine
in the same as solid contaminants, and lead must be drained and the main oil tank, the
to impaired component functioning. oil coolers and the bearing pedestals must
be thoroughly cleaned. It is recommended
The cause of any increase in turbine-oil that the turbine oil be either filtered or
water contents must be determined and treated in a separator during drainage an
remedied. refilling.
High water contents of the turbine oil can The ingress of solid contaminants into the
also be the result of low water separability of turbine oil must be prevented.
the turbine oil. In this case, it is particularly
important that the ingress of water in to the
oil system be prevented.

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Air release properties of the turbine oil with the foam, resulting in a drop in the oil
level in the main oil tank. This change in the
The air release property represents the time
level can cause activation of the level
taken for a specific volume of air to be
monitoring equipment for the main oil tank.
released from the turbine oil sample under
the boundary conditions stipulated in the Increased turbine oil foaming tendency
testing standard of the Turbine Oil occasionally occurs due to high water
Specification [1]. content or increased dust contamination of
the turbine oil.
The turbine oil circulates inside the oil
system and becomes aerated. This air is Silicone-based foam inhibiting additives
-1
released during the dwell time tv = 60n (in have an adverse effect on air release
min) of the turbine oil in the main oil tank, n properties. There is no generally binding
corresponds to the number of passes per evidence regarding any further correlation
hour made by the turbine oil. between foaming tendency and air release
properties, although such a correlation may
If the time required for air release by the exist in individual cases and should be
turbine oil is longer than the dwell time in the investigated.
main oil tank, an oil-and-air mixture will
develop, which will not have as favourable a
density and compressibility as non aerated
Turbine oil care program
turbine oil. This can lead to faults in the
operating oil pumps, fluctuations in oil Owing to correlation between the turbine oil
pressure and impaired functioning of any properties and the factors influencing turbine
control and protection equipment which is oil during operation, the following care
supplied with turbine oil. program for turbine oil must be implemented
during and after initial startup of the turbine
Only in rare cases it is possible to improve
generator set:
the Air release properties of turbine oil with
economically viable treatment methods. For
Regular inspection of turbine oil samples
this reason, any factors which might lead to

Continuous treatment of the turbine oil
deterioration of the air release properties of
the turbine oil, must be avoided.
Protection of the turbine oil system from
the effects of contaminants
It has been proven that the air release
properties of turbine oil are adversely
Drainage of the turbine oil and cleaning
affected by materials containing silicone, of the oil system and the turbine oil
e.g., seal materials or foam inhibiting during inspections and overhauls.
additives.

Inspection of turbine oil samples

Foaming characteristics of the turbine oil
By regularly sampling and inspecting turbine
The material property values for foaming
oil and by evaluating the results, it is
tendency and foam stability of turbine oil
possible to adapt oil care measures
should comply with Turbine Oil Specification
optimally to the particular properties of the
[1].
turbine oil being used.
A certain amount of foaming on the surface
Turbine oil samples are taken
of the oil in the main oil tank can be
simultaneously upstream and downstream
expected as a result of air release. If the
of the oil centrifuge and the inspection
turbine oil shows an increased foaming
results thus permit an evaluation of the
tendency and high foam stability, the space
efficiency of the relevant oil care measures.
above the oil level in the main oil tank
becomes partially or completely filled with The scope and the intervals for turbine oil
foam which can, under certain inspections are listed in the turbine oil
circumstances, result in foam being released maintenance instruction.
from the oil system. Turbine oil is entrained

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If the turbine oil inspections reveal that or wear to parts such as oil pump seal
alarm levels for certain properties have been ring, etc.
reached or exceeded, it is advisable to
request inspection and evaluation of the Treatment of the turbine oil in the oil
turbine oil by the turbine oil supplier. All data centrifuge
relevant to turbine oil inspection should be
The oil centrifuge can be continuously
sent in together with the turbine oil sample
operated independent of the operating oil
When taking turbine oil samples, care must systems. A small volume of turbine oil is fed
be taken to ensure that sampling bottles are through oil centrifuge with a high separation
clean. efficiency. This achieves a high degree of
purity for the treated turbine oil.
In case of deviation in properties, actions to
be taken as per table 1. As regards the treatment of turbine oil in the
centrifuge, oil filter, dynamic or static
separators, and multipurpose oil purification
Treatment of the turbine oil in the oil
units can be used either independently or in
filters or strainers of the operating oil
combination. In addition, many power plants
systems
have centralised oil purification equipment,

Switchable oil filters either permanently installed or mobile.
The switchable oil filters of the operating The function of the most commonly used oil
oil systems are used to protect purification equipment is described below:
downstream consumers. Contaminants
which, because of their size or
consistency, can cause damage and/or
Fine-mesh filter
impair functioning are retained in the oil The turbine oil can be conditioned in an
filters. Because of their relatively large oil filter with filter elements made of fine-
mesh size, the operating oil filters are pored cloth or filter paper. Since the fine-
not suitable for complete removal of mesh filter has a high separation
contaminants from the turbine oil. The efficiency, a high degree of turbine oil
differential pressure across the oil filters purity can be achieved. Contaminants
is monitored. insoluble in oil which ingress into the oil
system from outside, as well as products
If the differential pressure across an oil
of system-internal aging and corrosion
filter increases, this filter should be
mechanisms are almost completely
isolated from the system and cleaned.
removed from turbine oil.
Fine-mesh filters with cloth or paper

Oil Strainers of the main oil tank
elements can also retain small amounts
The oil strainers of the main oil tank of water. If the turbine oil has a high
have a relatively large mesh size and water content, a dynamic or static
are used to retain contaminants in the separator must be used to reduce the
returning turbine oil and to protect the oil water content in the turbine oil to the
pumps from contaminant damage. value stipulated in the Turbine Oil
If the strainer mesh becomes clogged Specification [1].
during the course of operation, this can
lead to a drop in the level in the suction
Dynamic separator
space of the main oil tank as a result of
The dynamic separator uses centrifugal
an increase in the level in the riser
force to remove either solid or liquid
space.
contaminants as required from the
For this reason, the oil strainers of the turbine oil. The dynamic separator must
main oil tank must be regularly cleaned, be set to operate in either solid
if possible while the oil pumps are shut contaminant or water separation mode
down. Metal particles in the oil strainers in accordance with the manufacturer’s
can be an indication of bearing damage instructions.

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Static separator different additive packages. For this
reason, when topping up, turbine oil
A static separator is used to remove
which has the same product designation
water from the turbine oil. Since the
and which is supplied by the same
efficiency of the filter elements
manufacturer as was originally filled,
deteriorates due to deposits of solid
should be used.
contaminants, and in view of the
expense of filter elements, it is
recommended that the static separator
Hydraulic oil
be used in conjunction with an upstream Hydraulic oil or control fluid containing
fine mesh filter. phosphoric esters, if in use, must not be
allowed to ingress into the oil system.

Multipurpose oil purification unit
The multipurpose oil purification unit is
Main oil tank
used to remove solid and liquid Openings in the main oil tank must
contaminants from the turbine oil. always be closed and sealed in such a
Operation and maintenance instructions of way that there can be no ingress of
the oil purification unit manufacturer must be contaminants into the main oil tank. The
complied with. cover plates of the main oil tank must be
tightly bolted. There must be no bolts
The maintenance interval for oil filters missing from the plates.
depends on the differential pressure across
the oil filters. For this reason, the differential
pressure instrumentation must be regularly
Oil coolers
checked and corresponding annunciations If the water content of the turbine oil
noted. increases, the leak tightness of the
operating oil cooler must be checked.
Cleaning of the oil system during
inspections and overhauls
Oil return lines
Over the course of time, solid contaminants Inspection holes in oil return lines must
settle in areas of the oil system not be sealed to prevent the ingress of
subjected to high flow velocities, e.g. the contaminants into the oil system.
main oil tank. For this reason, the turbine oil
must be drained via filters during inspections

Oil vapor extraction system
and overhauls, and the main oil tank, the oil
coolers and the bearing pedestals must be The throttle check valves in the oil vapor
thoroughly cleaned. The drained turbine oil extraction system must be set so that
must either be refilled into the main oil tank the pressure in the bearing pedestals
via fine-mesh filters or treated in a and the main oil tank is slightly sub
centralised oil purification unit before atmospheric. This ensures that no
refilling. leakage steam, or airborne water and/or
dust is drawn into the oil system in the
event of turbine oil or oil vapor being
Measures to protect the oil system from released to the atmosphere.
contaminant ingress
Just as important as turbine oil care are

Dirty fluid
measures designed to protect the oil system
from contaminant ingress: Fluid from the dirty-fluid tank must not
be refilled into the main oil tank without
thorough inspection and treatment.

Turbine oil Small amounts of turbine oil which
Problems can arise as a result of the accumulate in the dirty-fluid tank are to
incompatibility of turbine oils from be disposed properly.
different manufacturers and containing

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Material gaskets and silicone-based seal
materials.
The compatibility of materials with the
turbine oil has been taken into account
by the turbine manufacturer during
Leakage steam system
materials selection. During inspections The butterfly valves of the leakage
and overhauls, care must be taken to steam system must be set to prevent
ensure that no incompatible materials leakage steam from escaping via the
are used. This applies particularly to turbine shaft seals since this could result
in water ingress into the oil system.

Also refer to the following sections:

[1] 2-0400 : Oil Specification

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Table1 : Actions to be taken when actual conditions deviate from reference conditions

Fault Cause Actions

Boundary conditions
The Turbine oil properties
do not comply with the
Turbine Oil Specification

Total-acid number Turbine oil aging Inspect turbine oil samples for:
> mg KOH/g
- Solid contaminant content
- Purity
- Water content
- Air release properties
- Foaming
- Other physical and chemical
properties
Send further oil samples to
turbine oil supplier for inspection
and evaluation. Check operating
performance and condition of
components supplied with
turbine oil, in order to determine
the effect of the change in total-
acid number. Check oil
purification system and intensify
turbine oil maintenance in
accordance with the
recommendations of the turbine
oil supplier and the turbine
manufacturer:
- Keep oil centrifuge in
continuous operation
- Adjust operation of oil
centrifuge to contaminant
content of turbine oil (solid
contaminants or water)
- If necessary install additional
oil purification equipment
- Take turbine oil samples
upstream and downstream
of oil centrifuge and check
separation efficiency (solid
contaminants and/or water)

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Fault Cause Actions

Boundary conditions
- Reduce intervals for turbine
oil inspections and monitor
evaluation of total-acid
number
Investigate the origin of
contaminants and prevent
contaminant ingress into oil
system.

The solid contaminant The oil centrifuge is not in Put oil centrifuge into operation.
content or the purity of the operation
turbine oil does not comply
The contaminant separation Take turbine oil samples
with the Specification
efficiency of the oil centrifuge upstream and downstream of
does not comply with the the oil centrifuge and determine
requirements the separation efficiency.
Implement measures in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements, replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.

Solid contaminants ingress Check whether and at what

into the oil system point it is possible for air borne
contaminants to ingress into the
oil system.
Check atmospheric pressure in
the main oil tank, the bearing
pedestals and the oil return lines
and, if necessary, correct using
the check valves in the oil vapor
extraction lines.
If necessary, close or reseal the
maintenance covers of the main
oil tank.

High air borne dust content in Reduce airborne dust content in

area around turbine generator area around turbine generator
set set

4-1210-01/8
Fault Cause Actions

Boundary conditions

The water content of the There is no permanently Install a dynamic or static
turbine oil does not comply installed dynamic or static separator for removing water
with the specification separator for removing water form the turbine oil. Take turbine
from the turbine oil oil samples upstream and
downstream of the separator
and check water separation
efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.

The permanently installed Put dynamic separator of the

dynamic separator of the oil centrifuge into the operation.
conditioning system is not in
Note that the required
operation
separation temperature must be
complied with in accordance
with the operating instructions of
the separator manufacturer, and
that the separator must be
protected from the effects of
solid contaminants.
Take turbine oil samples
upstream and downstream of
the separator and check water
separation efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.

Water is ingressing into the oil Check whether leakage steam is

system ingressing into the oil system.
If necessary, prevent the escape
of leakage steam from the
steam seals by the correcting
the seal steam pressure or by
adjusting the butterfly valves in
the seal steam lines.
Check the leak tightness of the
operating oil cooler.

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Fault Cause Actions

Boundary conditions

The air release properties In many cases, there is no Check whether the deterioration
of the oil do not comply specific cause for a in air release properties has an
with the Specification deterioration in air release adverse affect on the operating
properties performance of the systems of
components supplied with
turbine oil.
Involve oil supplier and turbine
manufacturer in inspection
program. If effects are
particularly unfavorable,
consider replacing the turbine
oil.
As a precautionary measure,
care should always be taken to
prevent the ingress into the
turbine oil of materials which
could adversely affect the air
release properties (e.g. silicone-
based materials)

Turbine oil foaming The foam inhibiting additives in Consult oil supplier and top up
characteristics do not the turbine oil have been turbine oil with foam inhibiting
comply with the depleted over time additives.
Specification
As a rule, foam inhibiting
additives have an adverse effect
on the air release properties and
for this reason, the air release
properties must be closely
monitored when topping up with
such additives.

The turbine oil contains Determine the water content of

materials which adversely the turbine oil and, if necessary,
affect the foaming take appropriate measures to
characteristics reduce this. In certain
circumstances it may be
advisable to skim off the foam
from the surface of the turbine
oil.

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Fault Cause Actions

Boundary conditions
The oil centrifuge is
defective or the operating
conditions for the oil do not
comply with the
requirements

Oil filters
The differential pressure Isolate duplex oil filter and clean
across one oil filter is high filter cartridge
Take oil centrifuge filters out of
operation and replace filter
elements

One oil filter is not sufficiently Open valve in oil filter venting
vented line and adjust

Unit-specific or additional The mode of operation of the Adapt the mode of operation of
dynamic separator dynamic separator does not the separator (solid-contaminant
correspond to the content of separation or water separation)
solid or liquid contaminants in according to the content of solid
the turbine oil contaminants or water in the
turbine oil

Unit-specific or additional The efficiency of the static Replace filter elements.

static separator separator is reduced due to
Implement measures to prevent
clogged filter elements
filter element clogging. e.g.
install an upstream fine-mesh
filter.

Turbine oil temperature If necessary, put heating system

upstream of static separator of oil centrifuge into operation
too low

Oil circulating pump (if The oil circulating pump of the If necessary, put oil circulating
installed) oil centrifuge is not in pump into operation
operation

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