1、Designation: D 4378 08An 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 () indicates an editorial change since the last revision or reapproval.INTRODUCTIONThe in-service monitoring of turbine oils has long been recognized by the power-gener
3、ation 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 life
5、 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 m
6、eaningful 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 operati
7、on 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 gasturbines
8、, 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 targe
9、ts.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. Reference
10、d Documents2.1 ASTM Standards:2D92 Test Method for Flash and Fire Points by ClevelandOpen Cup TesterD 130 Test Method for Corrosiveness to Copper fromPetroleum Products by Copper Strip TestD 445 Test Method for Kinematic Viscosity of Transparentand Opaque Liquids (and Calculation of Dynamic Viscos-i
11、ty)D 664 Test Method forAcid Number of Petroleum Productsby Potentiometric TitrationD 665 Test Method for Rust-Preventing Characteristics ofInhibited Mineral Oil in the Presence of WaterD 892 Test Method for Foaming Characteristics of Lubri-cating OilsD 943 Test Method for Oxidation Characteristics
12、of Inhib-ited Mineral OilsD 974 Test Method for Acid and Base Number by Color-Indicator TitrationD 1401 Test Method for Water Separability of PetroleumOils and Synthetic FluidsD 1500 Test Method for ASTM Color of Petroleum Prod-ucts (ASTM Color Scale)D 2272 Test Method for Oxidation Stability of Ste
13、am Tur-bine Oils by Rotating Pressure VesselD 2422 Classification of Industrial Fluid Lubricants byViscosity System1This practice is under the jurisdiction of ASTM Committee D02 on PetroleumProducts and Lubricants and is the direct responsibility of Subcommittee D02.C0.01on Turbine Oil Monitoring, P
14、roblems and Systems.Current edition approved May 1, 2008. Published May 2008. Originallyapproved in 1984. Last previous edition approved in 2003 as D 437803.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of AS
15、TMStandards volume information, refer to the standards Document Summary page onthe ASTM website.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.D 4057 Practice for Manual Sampling of Petroleum andPetroleum ProductsD 4241 Practice for
16、 Design of Gas Turbine Generator Lu-bricating Oil SystemsD 4248 Practice for Design of Steam Turbine Generator OilSystemsD 6810 Test Method for Measurement of Hindered Phe-nolic Antioxidant Content in Non-Zinc Turbine Oils byLinear Sweep VoltammetryF311 Practice for ProcessingAerospace Liquid Sample
17、s forParticulate Contamination Analysis Using Membrane Fil-tersF 312 Test Methods for Microscopical Sizing and CountingParticles from Aerospace Fluids on Membrane Filters2.2 ISO Standard:3ISO 4406:1999 Hydraulic fluid powerFluidsMethodfor coding the level of contamination by solid particles3. Signif
18、icance 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 the onset of problemsassociated with oil degradation and contamination.4. Properties of Turbine Oils4.1 Most turbine o
19、ils consist of a highly refined paraffinicmineral oil compounded with oxidation and rust inhibitors.Depending upon the performance level desired, small amountsof other additives such as metal deactivators, pour depressants,extreme pressure additives, and foam suppressants can also bepresent.4.2 New
20、turbine oils should exhibit good resistance tooxidation, inhibit sludge formation, and provide adequateantirust, water separability, and nonfoaming properties. How-ever, these oils cannot be expected to remain unchanged duringtheir use in the lubrication systems of turbines, as lubricatingoils exper
21、ience thermal and oxidative stresses which degradethe chemical composition of the oils basestock and graduallydeplete the oils additive package. Some deterioration can betolerated without prejudice to the safety or efficiency of thesystem. Reinhibition may improve some properties of the oil.Good mon
22、itoring procedures are necessary to determine whenthe oil properties have changed sufficiently to justify schedul-ing corrective actions which can be performed with little or nodetriment to production schedules.5. Operational Factors Affecting Service Life5.1 The factors that affect the service life
23、 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) contamination, (6) oil makeuprate, and (7) handling and storage.5.1.1 Type and Design of SystemMost modern turbinelubricating
24、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 systemconsists of a reservoir, oil cooler, strainer, piping and additionalpurification or filtration equipment, or a combination
25、 thereof.Miscellaneous control and indicating equipment completes thesystem. If there is an opportunity to participate in systemdesign, it is recommended that appropriate practices be con-sulted (see Practice D 4241 and Practice D 4248), as well OEMguidelines and oil monitoring specifications.5.1.2
26、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 means taken to preserve theintegrity of the intended oil wetted surfaces will determine thetotal amount of contamina
27、tion 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, flushing, and purification may be soughtfrom the equipment supplier or other industry experts.5.1.2.2 Turbine oil syst
28、em contamination prior to startupusually consists of preservatives, paint, rust particles, and thevarious solids encountered during construction, which canrange from dust and dirt to rags, bottles, and cans. Their effecton turbine oil systems is obvious.5.1.3 Original Oil Quality:5.1.3.1 Use of a hi
29、gh-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 turbine manufacturer shall be used. Carefuloil storage, including labeling and rotation of lubricant con-tainers, is vita
30、l 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 obtain typical test data from the oilsupplier. Upon receipt of the first oil charge, a sample of oilshould be taken to co
31、nfirm 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 with used oil information. This is mostimportant! Recommended tests for new oil are given in theschedules of this prac
32、tice (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 due to incompatibility(see lubricant suppliers specifications). These should includefunctional tests and checks for f
33、ormation 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 systemare the operating conditions within the system. Air (oxygen),elevated operating temperatures, metals, and water (moist
34、ure)are always present to some extent in these oil systems. Theseelements promote oil degradation and must consequently berecorded.5.1.4.2 Most turbine oil systems are provided with oilcoolers to control temperature. In many cases, bulk oil tem-peratures are maintained so low, below 60C (140F), that
35、moisture condensation can occur. Even with low bulk oiltemperatures, however, there can be localized hot spots such as3Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036, http:/www.ansi.org.D4378082in bearings, at gas seals, and in throttle cont
36、rol mechanismsthat can cause oil degradation and eventually cause system oilto 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 vi
37、scous resins and deposits particularly at the pointof initiation.5.1.5 Contamination: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 ma
38、intenance isessential. Once attained, the danger of external contaminationis 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, o
39、r both, should beconsulted before additions are made.5.1.5.2 External contamination 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, contaminatio
40、nmust be dealt with by monitoring oil condition and the use ofpurification devices such as filters and centrifuges on a regularbasis. These can be removed by purification devices such asfilters, centrifuges, coalescers, and vacuum dehydrators.5.1.6 Oil Makeup RateThe amount and frequency ofmakeup oi
41、l added to the system plays a very significant part indetermining the life of a system oil charge. Makeup varies fromTABLE 1 Steam TurbinesSampling and Testing Schedules Mineral OilsSchedule 1 New OilSamples:(a) From transport or drums(b) From storage tankTests:ViscosityAAcid No.BAppearance clear an
42、d 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 thereof.CShould pass D 665A for land-based turbines.
43、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 Installation of a New Oil ChargeASample:After 24-h circu
44、lation. 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 it is an initial fill or an oil replacement.BShoul
45、d 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 isstrongly recommended.DImportant as a baseline to determ
46、ine 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 13monthsEvery 23 monthsSchedule 3B Normal Operati
47、onNote 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 Content Color Rust Test CleanlinessRPVOT/Voltammetry
48、/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 effect of contaminantspresent. An outside laborator
49、y 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.D4378083below 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
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