Académique Documents
Professionnel Documents
Culture Documents
Approved for
Implementation by .......................................................
Director (Operation)
Date :..........
Enquiries to : Executive Director, Operation Services.
CONTENTS
Page Nos.
1.0
Introduction
2.0
Superseded Documents
3.0
Scope
4.0
Safety
5.0
New Oil
6.0
Oil in Service
7.0
8.0
Review
Table-I
BIS - 1012-1993
Table-II
Table-III
Page - 1
OGN/OPS/CHEM/009
Issue - 1
INTRODUCTION
Due to high specific loadings of bearings and peripheral speeds of
journals, the duty that turbine lubricating oil is required to perform is
arduous. It has to withstand continuous thermal cycling and a variable
degree of contamination by solid particles, sludge, water, hydrogen and
air. It is required to release readily such contaminants and retain its
lubricating and other properties over very long periods.
The purpose of this Guidance Note is to define the oil monitoring that is
necessary to ensure that appropriate lubricants are used and that any
degradation in service does not result in undue threat to the integrity of the
plant. Interpretation of reason of violation of recommended limits is
tabulated on Table No. II.
2.0
SUPERSEDED DOCUMENTS
Nil
3.0
Scope
The Operation Guidance Note covers the examination and maintenance of
turbine oils used in steam and gas turbines and their associated
generators or pumps. (Note: It is not intended to apply to those gas
generators which use a synthetic lubricant).
In order to provide assurance that the oil is being maintained in a
satisfactory condition, It is necessary to monitor selected properties of that
oil.
4.0
SAFETY
Page -2
OGN/OPS/CHEM/009
Issue - 1
5.0
NEW OIL
5.1
5.2
All supplies should either be delivered with a BIS with the procurement
specification or, if a BIS certificate is not available, samples, may be taken
and examined for appearance and viscosity. All samples should be within
the perimitted viscosity range and should appear clear and bright and
visually free from solid and liquid contaminants.
5.3
6.0
OIL IN SERVICE
6.1
Turbine oils will gradually deteriorate in service due to oxidation and the
presence of water, corrosion and wear products. Purifying equipment is
provided to maintain the quality of the oil supplied to the bearings.
Sampling and monitoring should be carried out on a regular basis to
ascertain the rate of deterioration and to enable necessary corrective
measures to be taken.
6.2
6.3
6.3.1
Water, dirt, hydrogen and air should be removed from the oil as efficiently
and as quickly as the system design allows using the installed purification
Page - 3
OGN/OPS/CHEM/009
Issue - 1
equipment. It is desirable to use condensate or demineralised water for sealing
centrifuges and operation of these at a temperature of at least 80 deg. C is
normally required to break oil/water emulsions. Wet and/or dirty oil returned to the
turbine will eventually manifest itself in corrosion, wear malfunctioning of the
equipment and biological growth.
6.3.2
Water and water/oil emulsion should be drained from the main oil tank drain at
intervals to ensure that a low level of water is maintained in the tank. The
necessary frequency of draining will be determined by local experience.
7.0
8.0
REVIEW
The Executive Director, Operation Service, will be responsible for reviewing this
document on two yearly basis or as necessary.
Page - 4
OGN/OPS/CHEM/009
Issue - 1
TABLE - 1, BIS - 1012-1993
RECOMMENDED RANGE
SL. CHARACTERISTIC
NO.
LIGHT
TURBINE
OIL
MEDIUM
TURBINE
OIL
HEAVY
TURBINE
OIL
EXTRA
HEAVY
TURBINE OIL
TEST
METHOD
NTPC
1.
Appearance
Note (3)
Note (3)
Note (3)
Note (3)
2.
*Moisture Content
mg/l w/w
<500
(Note 4)
<500
(Note 4)
<500
(Note 4)
<500
(Note 4)
No.0114-84 Monthly
(Note 2)
No.0.129-84 Once a week
(Note 2)
3.
Kinematic Vicosity
at 37.8 deg. C.,
centistokes (CST)
31-33
45-49
62-69
86-95
No.0106-84 Monthly
4.
100
98
95
95
**
Monthly
5.
Acidity inorganic
mg KOH/gm.
Nil
Nil
Nil
Nil
**
Monthly
6.
200
200
200
200
**
monthly
7.
Not
worse
than 1
Not
worse
than 1
Not
worse
than 1
Not
worse
than 1
**
Annual
8.
Rust preventive
characteristics
Shall
Pass
with artificial
sea water
Shall
Pass
with artificial
sea water
Shall
Pass
with artificial
sea water
Shall
Pass
with artificial
sea water
**
Annual
9.
Emulsion characteristics
40-40-0
(20 min.)
.........
40.40-0
(20 min.)
........
**
Annual
2.0
(after
2500 hrs.)
2.0
(after
2000 hrs.)
2.0
(after
1500 hrs.)
2.0
(after
1000 hrs.)
**
Optional
RECOMMENDED
FREQUENCY
(NOTE-1)
REMARKS
Nil
Nil
Nil
Nil
**
Annual
Table-I Contd........
Page - 5
OGN/OPS/CHEM/009
Issue - 1
RECOMMENDED RANGE
SL. CHARACTERISTIC
NO.
LIGHT
TURBINE
OIL
MEDIUM
TURBINE
OIL
HEAVY
TURBINE
OIL
EXTRA
HEAVY
TURBINE OIL
TEST
METHOD
NTPC
RECOMMENDED
FREQUENCY
(NOTE-1)
11
17
**
Monthly
13. *Mechanical
impurities %
<0.005
(Note-7)
<0.005
(Note-7)
<0.005
(Note-7)
<0.005
(Note-7)
**
Weekly
REMARKS
a) at 24 deg. C
b) at 23.5 deg. C
c) at 24 deg. C
after testing
at 93.5 deg. C.
These are the limits for guideline but it is not given in BIS. These are the limits given on the basis of BS &
DIN.
**
As per NTPC test methods mentioned in Manual on Analytical test procedures for oil, No 86, ZWOD- 01003.
Page - 6
OGN/OPS/CHEM/009
Issue -1
NOTES TO BE USED WITH THE TABLE NO. 1
1.
2.
The recommended frequency of these tests may be decided in the light of local
operating experience and conditions on the plant or as per manufacturers
recommendations.
3.
4.
The moisture content of turbine lubricating oil varies widely with plant design
and operational practices, although, it is desirable to keep the moisture content
as low as practicable and below 100mg/l. If this is not achievable with some
plant, excursions above 500 mg/l may be experienced. The reasons for such
excursions should be sought and remedial action taken. More frequent
monitoring may be necessary under these conditions.
5.
These tests may be used for diagnostic purposes, if for example, rapid
darkening or other visual changes occur in the oil.
6.
All test methods are given in manual on analytical procedures for oil no-86
ZWOD 01003.
*7.
Insolubles normal level would be organic insoluble below 20 ppm and inorganic
insoluble below 20 ppm. Thus, attempts should be made in day-to-day practice
to maintain total insolubles below 50 ppm and under extreme conditions, it
should not be allowed to increase above 100 ppm.
Page - 7
OGN/OPS/CHEM/009
Issue -1
TABLE-II, TEST INTERPRETATION CHART
(This table proposes test Limits at which action should be taken, Interpretation of these
limits, and the Action to be taken)
Sl.No. Test
(1)
(2)
1.
2.
3.
4.
5.
Appearance
Moisture
Viscosity
Acidity
Flash point
Limits
(3)
Interpretation
(4)
Action
(5)
As per
Table-1.
1)
More susceptiable to
oxidise and degrade.
2)
Enhance corrosion
Investigate/
check functioning of
centrifuge
equipment.
3)
4)
Deplete additives.
Risk of bacterial/
fungal growth.
5)
Increase moisture in
Hydrogen used for
generator coolant
1)
Oil contaminated
2)
1)
Oil degraded.
Increase frequency of
testing & investigate
cause.
2)
Oil contaminated
3)
4)
Catalyse further
degradation reactions.
1)
Oil contaminated.
-do-
-do-
-do-
Remarks
(6)
Consider for
oil change.
Increase frequency of
testing & investigate
cause.
Consider oil change
Table-II Contd......
PS/CHEM/009
Issue -1
Sl.No. Test
(1)
(2)
Limits
(3)
Interpretation
(4)
Action
(5)
6.
As per
Table-1
1)
Investigate
cause immediately and
rectify.
2)
Recheck oil
and consult
oil company
regarding reinhibition if
test result is
unchanged.
3)
1)
Oil degraded.
2)
Oil contaminated.
3)
7.
Emulsion
Charateristics
As per
Table-1
1) Investigate
functioning
of purification
equipment/
centrifuge.
2) Check oxidation stability.
3) Check rusting characteristics.
8.
Mechanical
impurities
As per
Table-1
1)
Purification equipment
not functioning correctly.
2)
3)
Oil contamination is
occuring.
4)
Additive Precipitation is
occuring.
5)
Due to presence of
Corrosion and/or debris.
Centrifuge
bowl cleaning.
Remarks
(6)
Page - 9
OGN/OPS/CHEM/009
Issue -1
ON REFRERRING, M/S. INDIAN OIL CORPORATION HAS GIVEN LIMITS
OF USED UP AND FRESH TURBINE OIL. REFER TABLE NO. III
Table-III
TURBINE OIL LIMITS FOR FRESH OIL, I.O.C.
CHARACTERISTIC
SERVOPRIME
57
68
32
46
ISD VG
32
46
68
29-33
43-48
55-60
64-72
74-80
100
98
95
95
95
200
200
210
210
220
(-)6
(-)6
(-)6
(-)6
(-)6
0.2
0.2
0.2
0.2
0.2
Pass
Pass
Pass
Pass
Pass
20
20
20
20
20
76
II.
Power Stations
1.
General Manager
SSTPS
2.
General Manager
KSTPS
3.
General Manager
RSTPS
4.
General Manager
FSTPP
5.
General Manager
RhSTPP
6.
General Manager
VSTPP
7.
General Manager
NCTPP
8.
General Manager
BTPS
9.
General Manager
KhSTPP
10.
General Manager
TSTPP
11.
FCUTPP
12.
BCPP
13.
An. GPP
14.
Au. GPP
15.
D.a GPP
16.
Kw. GPP
17.
JG. GPP
18.
TTPS
Allahabad
20.
Hyderabad
III
21.
Nagpur
22.
Patna
23.
New Delhi
New Delhi
25.
Director (Technical)
-do-
26.
Director (Operations)
-do-
27.
Director (Projects)
-do-
28.
-do-
29.
-do-
30.
-do-
31.
-do-
i)
HOD Group-II
ii)
HOD Group-III
iii)
HOD Group-IV
iv)
HOD Group-V
V)
HOD Group-VI
Electrical
VI)
HOD Group-VII
VII)
HOD Group-VII
VIII)
DGM (OS-ER)