1、Designation: D 4378 03An American National StandardStandard Practice forIn-Service Monitoring of Mineral Turbine Oils for Steam andGas Turbines1This standard is issued under the fixed designation D 4378; the number immediately following the designation indicates the year oforiginal adoption or, in t
2、he case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.INTRODUCTIONThe in-service monitoring of turbine oils has long been recognized by the power-gene
3、ration industryas being necessary to ensure long trouble-free operation of turbines.The two main types of stationary turbines used for power generation are steam and gas turbines; theturbines can be used as individual turbines, or can be coupled to combine cycle turbines. Thelubrication requirements
4、 are quite similar but there are important differences in that gas turbine oilsare subjected to significantly higher localized “hot spot” temperatures and water contamination is lesslikely. Steam turbine oils are normally expected to last for many years. In some turbines up to 20 yearsof service lif
5、e has been obtained. Gas turbine oils by comparison have a shorter service life. Many ofthe monitoring tests used for steam turbine oils are applicable to gas turbine oils.This practice is designed to assist the user to validate the condition of the lubricant through its lifecycle by carrying out a
6、meaningful program of sampling and testing of oils in use. This practice isperformed in order to collect data and monitor trends which suggest any signs of lubricantdeteriorating. This can be used as a guide for the direction of system maintenance to ensure a safe,reliable, and cost-effective operat
7、ion of the monitored plant equipment. Also covered are someimportant aspects of interpretation of results and suggested action steps so as to maximize service life.1. Scope1.1 This practice covers the requirements for the effectivemonitoring of mineral turbine oils in service in steam and gasturbine
8、s, as individual or combined cycle turbines, used forpower generation. This practice includes sampling and testingschedules to validate the condition of the lubricant through itslife cycle and by ensuring required improvements to bring thepresent condition of the lubricant within the acceptable targ
9、ets.1.2 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenc
10、ed Documents2.1 ASTM Standards:D 92 Test Method for Flash and Fire Points by ClevelandOpen Cup2D 130 Test Method for Detection of Copper Corrosion fromPetroleum Products by the Copper Strip Tarnish Test2D 445 Test Method for Kinematic Viscosity of Transparentand Opaque Liquids (and the Calculation o
11、f DynamicViscosity)2D 664 Test Method for Acid Number of Petroleum Productsby Potentiometric Titration2D 665 Test Method for Rust-Preventing Characteristics ofInhibited Mineral Oil in the Presence of Water2D 892 Test Method for Foaming Characteristics of Lubri-cating Oils2D 943 Test Method for Oxida
12、tion Characteristics of Inhib-ited Mineral Oils2D 974 Test Method for Acid and Base Number by Color-Indicator Titration2D 1401 Test Method for Water Separability of PetroleumOils and Synthetic Fluids2D 1500 Test Method for ASTM Color of Petroleum Prod-ucts (ASTM Color Scale)2D 2272 Test Method for O
13、xidation Stability of Steam Tur-bine Oils by Rotating Pressure Vessel Oxidation Test2D 2422 Classification of Industrial Fluid Lubricants byViscosity System21This practice is under the jurisdiction of ASTM Committee D02 on PetroleumProducts and Lubricants and is the direct responsibility of Subcommi
14、ttee D02.C0 onTurbine Oils.Current edition approved May 10, 2003. Published July 2003. Originallyapproved in 1984. Last previous edition approved in 1997 as D 437897.2Annual Book of ASTM Standards, Vol 05.01.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 194
15、28-2959, United States.D 4057 Practice for Manual Sampling of Petroleum andPetroleum Products3D 4241 Practice for Design of Gas Turbine Generator Lu-bricating Oil Systems3D 4248 Practice for Design of Steam Turbine Generator OilSystems3D 6810 Test Method for the Measurement of HinderedPhenolic Antio
16、xidant Concentration in HL Turbine Oils byLinear Sweep Voltammetry4F 311 Practice for Processing Aerospace Liquid Samples forParticulate Contamination Analysis Using Membrane Fil-ters5F 312 Methods for Microscopical Sizing and CountingParticles from Aerospace Fluids on Membrane Filters52.2 ISO Stand
17、ard:ISO 4406:1999 Hydraulic fluid powerFluidsMethodfor coding the level of contamination by solid particles63. Significance and Use3.1 This practice is intended to assist the user, in particularthe power-plant operator, to maintain effective lubrication ofall parts of the turbine and guard against t
18、he onset of problemsassociated with oil degradation and contamination.4. Properties of Turbine Oils4.1 Most turbine oils consist of a highly refined paraffinicmineral oil compounded with oxidation and rust inhibitors.Depending upon the performance level desired, small amountsof other additives such
19、as metal deactivators, pour depressants,extreme pressure additives, and foam suppressants can also bepresent.4.2 New turbine oils should exhibit good resistance tooxidation, inhibit sludge formation, and provide adequateantirust, water separability, and nonfoaming properties. How-ever, these oils ca
20、nnot be expected to remain unchanged duringtheir use in the lubrication systems of turbines, as lubricatingoils experience thermal and oxidative stresses which degradethe chemical composition of the oils basestock and graduallydeplete the oils additive package. Some deterioration can betolerated wit
21、hout prejudice to the safety or efficiency of thesystem. Reinhibition may improve some properties of the oil.Good monitoring procedures are necessary to determine whenthe oil properties have changed sufficiently to justify schedul-ing corrective actions which can be performed with little or nodetrim
22、ent to production schedules.5. Operational Factors Affecting Service Life5.1 The factors that affect the service life of turbine lubri-cating oils are as follows: (1) type and design of system, (2)condition of system on startup, (3) original oil quality, (4)system operating conditions, (5) contamina
23、tion, (6) oil makeuprate, and (7) handling and storage.5.1.1 Type and Design of SystemMost modern turbinelubricating systems are similar in design, especially for thelarger units. For lubrication, the usual practice is to pressure-feed oil directly from the main oil pump. The rest of the systemconsi
24、sts of a reservoir, oil cooler, strainer, piping and additionalpurification or filtration equipment, or a combination thereof.Miscellaneous control and indicating equipment completes thesystem. If there is an opportunity to participate in systemdesign, it is recommended that appropriate practices be
25、 con-sulted (see Practice D 4241 and Practice D 4248), as well OEMguidelines and oil monitoring specifications.5.1.2 Condition of System on Start-up:5.1.2.1 The individual components of a lubrication systemare usually delivered on-site before the system is installed. Thelength of on-site storage and
26、 means taken to preserve theintegrity of the intended oil wetted surfaces will determine thetotal amount of contamination introduced during this period,the magnitude of the task of cleaning and flushing prior to use,and the detrimental effects of the contaminants. Guidance oncontamination control, f
27、lushing, and purification may be soughtfrom the equipment supplier or other industry experts.5.1.2.2 Turbine oil system contamination prior to startupusually consists of preservatives, paint, rust particles, and thevarious solids encountered during construction, which canrange from dust and dirt to
28、rags, bottles, and cans. Their effecton turbine oil systems is obvious.5.1.3 Original Oil Quality:5.1.3.1 Use of a high-quality oil is the best assurance ofpotentially long service life. Oils meeting recognized standardsare generally available, and one that at least meets therequirements of the turb
29、ine manufacturer shall be used. Carefuloil storage, including labeling and rotation of lubricant con-tainers, is vital to ensure proper use and prevent degradation ofthe physical, chemical, and cleanliness requirements of thelubricant throughout storage and dispensing.5.1.3.2 It is advisable to obta
30、in typical test data from the oilsupplier. Upon receipt of the first oil charge, a sample of oilshould be taken to confirm the typical test data and to use as abaseline. This baseline should act as a starting point for thephysical and chemical properties of the lubricant, and forfuture comparisons w
31、ith used oil information. This is mostimportant! Recommended tests for new oil are given in theschedules of this practice (see Table 1 and Table 2).5.1.3.3 When new turbine oil is to be mixed with a chargeof a different composition prior checks should be made toensure no loss of expected properties
32、due to incompatibility(see lubricant suppliers specifications). These should includefunctional tests and checks for formation of insolubles.5.1.4 System Operating Conditions:5.1.4.1 The most important factors affecting the anticipatedservice life of a given lubricating oil in a given turbine systema
33、re the operating conditions within the system. Air (oxygen),elevated operating temperatures, metals, and water (moisture)are always present to some extent in these oil systems. Theseelements promote oil degradation and must consequently berecorded.3Annual Book of ASTM Standards, Vol 05.02.4Annual Bo
34、ok of ASTM Standards, Vol 05.04.5Annual Book of ASTM Standards, Vol 14.02.6Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036.D43780325.1.4.2 Most turbine oil systems are provided with oilcoolers to control temperature. In many cases, bulk oil t
35、em-peratures are maintained so low, below 60C (140F), thatmoisture condensation can occur. Even with low bulk oiltemperatures, however, there can be localized hot spots such asin bearings, at gas seals, and in throttle control mechanismsthat can cause oil degradation and eventually cause system oilt
36、o show signs of deterioration.5.1.4.3 Under the higher temperature conditions which arepresent in gas and steam turbines, oxidation of the oil can beaccelerated by thermal-oxidative cracking leading to the pro-duction of viscous resins and deposits particularly at the pointof initiation.5.1.5 Contam
37、ination:5.1.5.1 Contamination of turbine oils occurs both fromoutside the system and from within due to oil degradation andmoisture condensation or leaks. Development of a cleanturbine oil system on start-up or following maintenance isessential. Once attained, the danger of external contaminationis
38、less but should be guarded against. The oil can be contami-nated by the introduction of different type oils, which are of thewrong type or are incompatible with the system oil. The oilsupplier or the turbine manufacturer, or both, should beconsulted before additions are made.5.1.5.2 External contami
39、nation can enter the system throughbearing seals and vents. Internal contaminants are always beinggenerated. These include water, dirt, fly ash, wear particles, andoil degradation products. From whatever source, contaminationmust be dealt with by monitoring oil condition and the use ofpurification d
40、evices such as filters and centrifuges on a regularbasis. These can be removed by purification devices such asfilters, centrifuges, coalescers, and vacuum dehydrators.TABLE 1 Steam TurbinesSampling and Testing Schedules Mineral OilsSchedule 1 New OilSamples:(a) From transport or drums(b) From storag
41、e tankTests:ViscosityAAcid No.BAppearance clear and brightWater content no free waterColorBRust test PassCCleanlinessDRPVOT/Voltammetry/FTIRBAShould meet Classification D 2422.BShould be consistent with user purchase specifications, new oil reference, or manufacturers requirement, or combination the
42、reof.CShould pass D 665A for land-based turbines. Should pass D 665B for marine turbines.DDefinition of suitable cleanliness levels depends on turbine builder and user requirements. Filtration or centrifugation, or both, of oil into turbine and during service isstrongly recommended.Schedule 2 Instal
43、lation of a New Oil ChargeASample:After 24-h circulation. Retain approximately 4 L (1 gal).Tests:ViscosityBAcid No.BAppearance clear and brightWater content no free waterColorBCleanlinessB,CRPVOT/Voltammetry/FTIRB,DAFollow recommended flushing procedures prior to installing a new oil charge whether
44、it is an initial fill or an oil replacement.BShould be consistent with user purchase specifications and new oil reference.CDefinition of suitable cleanliness levels depends on turbine builder and user requirements. Filtration or centrifugation, or both, of oil into turbine and during service isstron
45、gly recommended.DImportant as a baseline to determine turbine system severity.Schedule 3A (First 12 Months OperationNew Turbine)TestAViscosity Acid No. Appearance Water Content Color Rust Test CleanlinessRPVOT/Voltammetry/FTIRFrequencyBEvery 13 months Monthly DailyCMonthlyCWeekly Every 6 monthsEvery
46、 13monthsEvery 23 monthsSchedule 3B Normal OperationNote 1This schedule should be used as a guide. Increased frequency is required for a severe turbine or for oils approaching the end of their service life. Most tur-bines should be covered by this schedule.TestAViscosity Acid No. Appearance Water Co
47、ntent Color Rust Test CleanlinessRPVOT/Voltammetry/FTIRFrequencyBEvery 36 months Every 13 months DailyCEvery 13monthsCWeekly 1 YearEvery 13monthsEvery 612 monthsAIf contamination is suspected, additional tests such as Flash Point, Foam, and Water Separability, may be useful to determine degree and e
48、ffect of contaminantspresent. An outside laboratory or oil supplier can also assist in a more in-depth analysis.BFrequency is based on continuous operation or total accumulated service time.CIf product is hazy or contains water in suspension, check water content.D43780335.1.6 Oil Makeup RateThe amou
49、nt and frequency ofmakeup oil added to the system plays a very significant part indetermining the life of a system oil charge. Makeup varies frombelow 5 % per year to as much as 30 % in extreme cases. Inturbines where makeup is relatively high compared to the oildegradation rate, the degree of degradation is compensated forand long oil life can be expected. In turbines where the makeupis very low (below 5 %), a truer picture of oil degradation isobtained. However, such a system should be carefully watchedsince the oil life is dependent almost exclusively on its or
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