L U B R I C AT I O N

In the power industry, every kilowatt hour counts. Using high quality products ensures maximum output, minimal all round costs and increased equipment lifespan. As power plant operators strive to extend the time between outages to maximize revenue and reduce maintenance expenses they rely on their suppliers, particularly lubricant manufacturers, to develop high-quality products to keep their machinery running smoothly.

Selecting the Correct Lubricants for

Power Turbines

a case-study at Corby Power Station

orby Power Station is a 350MW, gas-red power station in the North East of Corby and an important contributor to the national grid. The power station has two 119MW General Electric Frame 9(9001 E) gas turbines produced by EGT, each with a Babcock Energy heat recovery steam generator. These are linked to one 114MW steam turbine. Phil Hindley, Manager of Industrial Lubricants at TOTAL UK said; Lubricants are critical for optimum performance in the power generation industry and we have many years of experience in developing the high quality products needed to meet the exacting demands of the power industry. As gas turbine technology continues to improve, the stress on the turbine oil increases and requires improved base oils and additives. All turbines require a high quality lubricant to protect their moving parts the choice of which depends on the range of stresses they experience. The most signicant stress a gas turbine places on its lubricant is the high operational temperature that can increase the rate of oxidation in the oil stock. The lubricant used in the steam turbine is formulated differently to deal with water contamination from exposure to steam. The lubricant is designed to readily split with water, allowing the water to

We take lubricants and lubrication very seriously at Corby, as any unscheduled downtime in the power generating industry can have serious implications for power supply.

be extracted easily and the lubricant to remain uncontaminated for longer. The condition of the oil in the gas turbines is measured by the Rotating Pressure Vessel Oxidation Test (RPVOT). The RPVOT is carried out by extracting oil samples and sending them away for independent testing. Other factors that are measured are particle counts, lubricant viscosity and foam. The RPVOT measures the levels of antioxidant remaining in the oil stock. As a guideline, when the levels of antioxidant drop to twenty ve per cent of the value of new oil it is time to replace the stock. When antioxidant levels drop below twenty ve per cent the Total Acid Number (TAN) begins to rise steeply, which can cause long term sludge and deposit formation, as well as varnishing on the Moog valves that regulate the lubricant. Wear on these valves will cause reduced efciency, resulting in increased wear on the turbine parts. After assessing the lubricant at Corbys gas turbines in 2005, the power station was advised to replace 33,000 litres of Preslia GT32, and the power stations lubricant supplier, TOTAL, subsequently carried out the work. As a rule, it is advisable to use the same type of oil to replace the old stock, since different oils have different consistencies that may affect the effectiveness of their lubricating properties. (The old oil was disposed of according to current waste regulations and environmental agency legislation.) The deployment of Preslia GT 32 offers a long term cost saving for Corby through extended lubricant life and reduced maintenance costs, commented Hindley. At a power station it is particularly important that the turbine can run for as long as possible without the need to shut it down. Preslia GT32 was chosen because, when new, it has a comparatively high starting gure on the RPVOT which translates into longer periods without needing to have to replace the lubricant, and reduces the downtime associated with this process. Tim Coggin, the Projects Engineer at Corby Power Limited, commented; We take lubricants and lubrication very seriously at Corby, as any unscheduled downtime in the power generating industry can have serious implications for power supply. We have a very strong working relationship with our oil supplier, TOTAL, and rely on their knowledge and expertise to make sure that we have the correct lubricants and lubrication management programmes in place. www.total.co.uk

ME | July/Aug 2010 | 13