March 14 – 17, 2010

San Diego, CA – San Diego Convention Center

• What is varnish
• Formation of varnish
• Measurement of varnish
• Varnish Removal
• Experience with Pall VRF (Varnish Removal Filter)
• Filter induced Electrostatic Charging
• Pall Electrostatic Dissipative (ESD) Filter
• Conclusions
• Thin film deposit that forms on surfaces inside the turbine lube
system
– pipes, tank, bearings, heat exchanger, servo-valves
• Varnish precursors - the semi-soft, resinous material in the oil
that form varnish deposits on surfaces:
– Forms as result of thermo-oxidative breakdown of the oil
– High molecular weight compounds
– Sub-micron size when formed – tend to agglomerate
• Chemical composition may vary depending on oil breakdown
pathway, oil type, turbine type, temperature, duty cycle
– Polar – have oppositely charged ends
– Over time deposit on machine surfaces
– Deposits cause operation problems
• Most notably – valve stiction, bearing deposits
 On filter patch at 100X magnification

Inside the main filter housing

 On filter patch at 100X magnification

SEM photo at 1000X magnification

• All turbine fluids generate varnish precursors under normal
operating conditions
– Oxidation
– Additive depletion
• The rate of generation is higher under severe / unusual
operating conditions
– Micro-dieseling, adiabatic compression
– Filter related electrostatic discharge
– Hot spots
• Recent increase in varnish related problems is attributed to:
– Higher turbine operating temperatures
– Smaller reservoirs
– More peaking / cyclic service
– Highly refined fluids that have lower solvency for varnish
– Finer filtration resulting in electrostatic discharge
• Gas turbines in peaking service are known to have formed
varnish deposits within 2.5 years of commissioning
 !

• Oil has limited solvency for varnish

– Majority of the varnish in a contaminated turbine lube system is in
the form of deposits
– Smaller portion is suspended in oil, in a 'quasi-equilibrium' with the
varnish deposits on surfaces
– As the oil is cleaned up, it dissolves more varnish deposits from
the component surfaces
– Lube system is clean when the soluble varnish deposits are
removed – a slow process
• The solvency of varnish is temperature dependent
– Transition point 130-135 °F
– Temperature falls below 130-135F in the hydraulic section –
releasing varnish
• Varnish deposits cause
– Restriction and sticking of servo valves
– Bearing deposits; reduced film thickness
– Varnish captures & retains abrasive particles; increased wear
 Measurement of Varnish

• FTIR - nitration procedure (absorbance in 1,600 to 1,640 cm-1)

• Gravimetric analysis (Toluene soluble)
• Ultracentrifuge (~17,500 RPM for 30 minutes)
• 0.2 – 2.0 um Particle Count (Modified ASTM F312)
• Membrane Patch Colorimetric (MPC) Analysis
– Most commonly used – ASTM procedure (draft stage)
– Measures discoloration / stain on patch
– Significant variation in results / interpretation between labs
– Agglomerated varnish poses problems
Measurement of Varnish – MPC Method
 Varnish Removal Methods

• The electrostatic method - Oil is subjected to

electrical field causing varnish particles to:
– charge / agglomerate to larger particles
– captured by filter mat or
– attach to charged, disposable surface
• Kidney-loop mode, off the main tank
• Permanent or long term installation
• Mixed results on performance reported
• Limitations: moisture < 500 ppm & low metallic
debris
 Varnish Removal Methods

• Chemical flush
– Vanish deposits are softened and lifted by circulating
flushing fluid through the system. The fluid is
drained, system is flushed with lube oil before refilling
– Time intensive, expensive process
• The adsorption method:
– Utilizes large surface area, high void volume
– Low flow rate (density)
– Affinity of the adsorbent media for varnish particles
 " # $" %

• Pall has developed VRF for the removal of varnish

precursors from fluids
– Large surface area, high void volume
– Low flow rate per unit area (low flow density)
• VRF is based on physical adsorption - Physisorption
– The fundamental mechanism is the relatively weak interaction
forces such as van der Waals
– The electronic structure of the atom or molecule does not change
– Most effective in environment of low temperature
• Varnish molecules are attracted to VRF media through
weak molecular forces such as van der Waals and weak
hydrogen bonding
 " !

• Engineered, composite filter media made with

cellulose & other proprietary materials
• Pronounced affinity for the polar varnish precursors
• High void volume (70 – 80%)
• High fluid permeability
• Water absorbing – will not deteriorate
• Fully compatible with mineral turbine oils
• No adverse impact on the fluid and the additives
 Laboratory Testing of VRF Media

Details Varnish Rating Varnish Rating

Turbine Fluid - Initial - Filtered
GE Frame 7Ba Shell Turbo 59 0
TX32
GE Frame 7FAa Texaco GT32 47 0
GE Frame 7FAa Texaco GT32 47 22b
GE Frame 7FA Conoco Diamond 62 15c
Alstom GT8C Caltex Regal 34 11
EP46
Alstom GT24B Chevron GST46 85 15c
MHI 501 (G) Mobil DTE 797 58 15c

!
" #$ %"
& '' (& ) *(
Laboratory Testing of VRF Media
" &
'
" ())' $
*)+
, %
! - . (/00 1 $ )00 %
. 2 " ' ()34 '5 )0 '
! - ' (),06 $7)6 %
(*80 9: 9,0 ;< =
> 8+
0
; (. 5 )+
0?2 9 ' 5
0+
7/?2 2 '( 5 -

( *04 $)9
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0 % ' (7,4
$
)9@:0+* % ' (,,4 $
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/70 +$
7)3+
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 " &

• Operates in kidney-loop mode

– Feed from one end of the main reservoir; return to
the opposite side
– 11 GPM gear pump – Continuous operation
– High capacity VRF modules
– Fluid temperature control
– Instrumentation / DP alarms for filter change
– Automatic shutdown & alarm under unusual pressure
and temperature conditions
 Field trial of VRF Skid

GE Frame 7FA - simple cycle, peaking units

90 23,500 Liters of ExxonMobil T errestic ISO 32 fluid
80
Varnish Potential Rating

In service for 48,816 hours

70 Full flow filters: 5um nominal
Initial VPR: 85
60
Final VPR: 18 in one week; dropped to 11 at the end
50
40
30
20
10
0
8/28 9/5 9/13 9/21 9/29 10/7 10/15
Date
 VRF Test Results

Used VRF medium (right), rinsed with hexane

(center) and rinsed with toluene (left).

Unused VRF medium

)000A - )000A
 Field trial of VRF Skid

Alstom GT24B Combined Cycle - Baseload

100
30,000 Liters of Chevron GST 46 fluid
90 In service for 7 years – 25% w as replaced year ago
Varnish Potential Rating (VPR)

Full flow filters: 7 um(c)

80
Initial VPR: 89
70 Final VPR: 18 w ithin 8 w eeks

60
50
40
30
20
10
0
11/4 11/14 11/24 12/4 12/14 12/24 1/3 1/13 1/23
Sample Dates
 = B 3*C5 ,

Electrostatic unit was re-installed &

was in use for 6 months after the oil
clean-up

Varnish Deposits
 ' B

Suspected as a major cause of varnish formation

Frictional contact between fluid and surfaces of various materials in
the fluid system
- Result in charge transfer between the fluid and material resulting in
triboelectric charge generation
The electrical charge accumulates and discharges
- Causing high temperature fluid degradation
- Source of varnish precursors

- - + + + + + + +
+ + - - Isolated
+ + - - electrode
+ + - -
+ + - -
- - + + + + + + +

Pipe wall
Flat sheet filter
material T o meter
 D ' '

• Electrostatic charging increases with:

– Lower Fluid Conductivity
– Higher Flow rate or velocity Higher Flux
– Lower Temperature Higher Viscosity
• Electrostatic charging leads to charge
accumulation
– Discharging to nearest lower potential surface
• Charge accumulation is related to Charge
Relaxation Time
– Longer it takes for charge to relax, the higher is
charge accumulation & discharge
– Shorter relaxation time results in faster charge
dissipation
 2
D ' 'E

• Turbine lube fluids have low conductivity

– Typically < 40 pS/m
• Modern turbine lube filtration systems are:
– Smaller with lower fluid volume
• High fluid turnover - More stress on oil - Less time for charge
dissipation
– Higher Flow rate through filter
• Higher flow density Higher charge generation
– Finer filtration
• Higher surface area Higher charge generation
• All manufacturers’ standard glass-fiber media generate
electrostatic charging
 D !

• Development of Electrostatic Charge Dissipative

(ESD) Filter at Pall
– Designed & investigated several filtration media
materials, configuration with various fluids
– A composite glass-fiber, resin bonded media
exhibited optimum ESD properties
– Thorough testing of filters made with the ESD media
in the laboratory and field in various applications
• Pall ESD filters have been in service across a
wide range of applications for over 5 years
 Measuring Charge From Filter Elements

Charge
Temperature
Collector
Probe
Apparatus

Reservoir

Cleanup
Keithley
Filter
Multimeter
Pressure
Heat Gauge
Exchanger
Test Filter
Housing

Flowmeter Pump 3-Way Valve

 ' ' '

Out-to-In Flow
-90

-80

-70

-60 -61.3
Surface modified
Gas plasma glass
treated fiber
glass fiber
Voltage (V)

-50
New ESD filter material
-40
-39.7
Standard glass fiber material
-30

-19.06
-20 -15.19 -14.48
-13.39 -14.35 -12.7
-11.04 -11.43
-10 -13.17 -13.28 -11.89 -9.02
-10.18 -7.07 -5.69

0
5 10 15 20 25 30 35 40 45 50 55 60 65
Flowrate (gpm)
Field trial of ESD filters – GE Frame 7FA
 D 52
2

Fluid Charge Measurement Frame 7 Turbine

4
2
0
Volts AC

-2
-4
-6
-8
-10
0 10 20 30 40 50 60 70
Time (seconds)
Non-Pall 25um Non-Pall 15um Pall AN (6um)

F 3/ ' ' 2 , D
F 3/ # ' . )@G),G)*
 D- D ,

#+, -./' ' #

#+, '
' '
• Effective varnish mitigation in turbine lubrication
systems requires
– Removal of existing varnish precursors from the fluid and
varnish deposits from the surfaces
– Control of its generation by filter induced ES
• The Pall VRF media, engineered for varnish removal by
adsorption is simple, highly effective and robust
– Removes varnish precursors from the fluid
• Cleaned fluid lifts deposits from surfaces
• Pall ESD filters eliminate electrostatic charge generation
– Allows finer filtration within the existing housing & flow
– Eliminates fluid degradation & varnish formation
0 1