1、Designation: D 6224 02An American National StandardStandard Practice forIn-Service Monitoring of Lubricating Oil for Auxiliary PowerPlant Equipment1This standard is issued under the fixed designation D 6224; the number immediately following the designation indicates the year oforiginal adoption or,
2、in the 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.INTRODUCTIONA more systematic approach to monitoring auxiliary power plant equipment can hel
3、p to minimizethe high cost of oil changes and unplanned shutdowns. These avoided costs must be balanced againstthe cost of sampling and laboratory testing.This practice is designed to assist the user in planning and implementing a meaningful,cost-effective program of sampling and testing of oils in
4、use. Also covered are some important aspectsof interpretation of results and suggested action steps so as to maximize service life of the oil andequipment.1. Scope1.1 This practice covers the requirements for the effectivemonitoring of mineral oil and phosphate ester fluid lubricatingoils in service
5、 auxiliary (non-turbine) equipment used forpower generation. Auxiliary equipment covered includes gears,hydraulic systems, diesel engines, pumps, compressors, andelectrohydraulic control (EHC) systems. It includes samplingand testing schedules and recommended action steps, as well asinformation on h
6、ow oils degrade.NOTE 1Other types of synthetic lubricants are sometimes used but arenot addressed in this practice because they represent only a small fractionof the fluids in use. Users of these fluids should consult the manufacturerto determine recommended monitoring practices.1.2 This practice do
7、es not cover the monitoring of lubricat-ing oil for steam and gas turbines. Rather, it is intended tocomplement Practice D 4378.1.3 The values stated in SI units are to be regarded as thestandard.1.4 This standard does not purport to address all of thesafety concerns, if any, associated with use. It
8、 is the responsi-bility of the user of this standard to establish appropriate safetyand health practices and determine the applicability of regu-latory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:D 92 Test Method for Flash and Fire Points by ClevelandOpen Cup2D 95 Test Method
9、for Water in Petroleum Products andBituminous Materials by Distillation2D 96 Test Method for Water and Sediment in Crude Oil byCentrifuge Method Field Procedure2D 257 Test Methods for D-C Resistance or Conductance ofInsulating Materials3D 445 Test Method for Kinematic Viscosity of Transparentand Opa
10、que Liquids (and the Calculation of 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-catin
11、g Oils2D 893 Test Method for Insolubles in Used Lubricating Oils2D 943 Test Method for Oxidation Characteristics of Inhib-ited Mineral Oils2D 974 Test Method for Acid and Base Number by Color-Indicator Titration2D 1169 Test Method for Specific Resistance (Resistivity) ofElectrical Insulating Liquids
12、4D 1298 Practice for Density, Relative Density (SpecificGravity), or API Gravity of Crude Petroleum and LiquidPetroleum Products by Hydrometer Method2D 1401 Test Method for Water Separability of Petroleum1This practice is under the jurisdiction of ASTM Committee D02 on PetroleumProducts and Lubrican
13、ts and is the direct responsibility of Subcommittee D02.C0 onTurbine Oils.Current edition approved Nov. 10, 2002. Published February 2003. Originallyapproved in 1998. Last previous edition approved in 1998 as D 622498.2Annual Book of ASTM Standards, Vol 05.01.3Annual Book of ASTM Standards, Vol 10.0
14、1.4Annual Book of ASTM Standards, Vol 10.03.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.Oils and Synthetic Fluids2D 1500 Test Method for ASTM Color of Petroleum Prod-ucts (ASTM Color Scale)2D 1533 Test Method for Water in Insulat
15、ing Liquids byCoulometric Karl Fischer Titration4D 1744 Test Method for Water in Liquid Petroleum Prod-ucts by Karl Fischer Reagent2D 2272 Test Method for Oxidation Stability of Steam Tur-bine Oils by Rotating Pressure Vessel2D 2273 Test Method for Particulate Contamination in Avia-tion Fuel by Line
16、 Sampling2D 2422 Classification of Industrial Fluid Lubricants byViscosity System2D 2668 Test Method for 2,6-Ditertiary-Butyl Para-Cresoland 2,6 Ditertiary-Butyl Phenol in Electrical Insulating Oilby Infrared Absorption4D 2896 Test Method for Base Number of Petroleum Prod-ucts by Potentiometric Perc
17、hloric Acid Titration2D 2982 Test Method for Detecting Glycol-Base Antifreezein Used Lubricating Oils2D 3427 Test Method for Air Release Properties of Petro-leum Oils5D 3524 Test Method for Diesel Fuel Diluent in Used DieselEngine Oils by Gas Chromatography5D 4052 Test Method for Density and Relativ
18、e Density ofLiquids by Digital Density Meter5D 4057 Practice for Manual Sampling of Petroleum andPetroleum Products5D 4378 Practice for In-Service Monitoring of Mineral Tur-bine Oils for Steam and Gas Turbines5D 4739 Test Method for Base Number Determination byPotentiometric Titration5D 5185 Test Me
19、thod for the Determination of AdditiveElements, Wear Metals, and Contaminants in Used Lubri-cating Oils and Determination of Selected Elements inBase Oils by Inductively-Coupled Plasma Atomic Emis-sion Spectrometry (ICP-AES)5E 1064 Test Method for Water in Organic Liquids byCoulometric Karl Fischer
20、Titration63. Significance and Use3.1 This practice is intended to assist users, particularlypower plant operators, in maintaining effective control overtheir lubricating oils and lubrication monitoring program. Thispractice may be used to perform oil changes based on testresults rather than on the b
21、asis of service time or calendar time.It is intended to save operating and maintenance expenses.3.2 This practice is also intended to assist users in monitor-ing lubricating oils and guarding against excessive componentwear, oil degradation, or contamination, thereby minimizingthe potential of catas
22、trophic machine problems that are morelikely to occur in the absence of such a monitoring program.3.3 This practice does not necessarily reference all of thecurrent oil testing technologies and is not meant to preclude theuse of alternative instrumentation or test methods whichprovide meaningful or
23、trendable test data, or both. Some oiltesting devices (typically used for screening oils which will betested according to standard methods) provide trendable indi-cators which correlate to water, particulates, and other con-taminants but do not directly measure these.4. General Properties of Lubrica
24、ting Oils4.1 In general, lubricating oils are designed to reducefriction and wear, provide cooling, control deposits, andcombat the effects of contamination. A base oils lubricatingproperties are enhanced by selected additives. Different ma-chines have different lubricant additive requirements, some
25、 ofwhich are described in this section. A lubricating oil preventscontact between metal surfaces by the formation of a very thinprotective film (that is, elastohydrodynamic lubrication).4.2 Gear (Circulating) OilsThe primary requirement ofgear oils is that they prevent wear and minimize other forms
26、ofdamage such as pitting and scuffing by maintaining a lubricantfilm between the moving surfaces. Although gears are of manytypes including spur, helical, worm, bevel, and hypoid, they allfunction with some combination of rolling and sliding motion.The unit loadings of gear-tooth surfaces are relati
27、vely highcompared with ordinary bearing surfaces. Where the gearloadings are relatively heavy, mineral oils containing extremepressure (EP) or anti-wear additives may be used as thelubricant. For highly loaded spiral bevel, worm, or hypoidgears where sliding contact predominates over rolling contact
28、between gear teeth, lubricating oils with special wear-reducingadditives are used. Sulfur, boron, and phosphorous compoundscan be used for this purpose. Anti-foaming additives are alsoimportant in gear lubricants.4.3 Hydraulic OilsA hydraulic fluid is required to trans-mit hydraulic pressure and ene
29、rgy, minimize friction and wearin pumps, valves and cylinders, and protect metal surfacesagainst corrosion. To obtain optimum efficiency of machineoperation and control, the viscosity of the oil should be lowenough to minimize frictional and pressure losses in piping.However, it also is necessary to
30、 have a sufficiently highviscosity to provide satisfactory wear protection and minimizeleakage of the fluid. High-viscosity index fluids help tomaintain a satisfactory viscosity over a wide temperaturerange. The anti-wear properties of high-quality hydraulic oilsusually are improved by suitable addi
31、tives. Since the clear-ances in pumps and valves tend to be critical, it is important toprovide adequate filtration equipment (full flow or bypass, orboth) to maintain a minimum particle content and thus mini-mize wear. The oil should have good oxidation stability toavoid the formation of insoluble
32、gums or sludges; it shouldhave good water separation properties, and, because air may beentrained in the system, the oil should have good air-releaseproperties and resistance to foaming. Similarly, good rustprotection properties will assist in keeping system metals insatisfactory condition.4.4 Diese
33、l Engine OilsIn addition to the typical role oflubricating oils which is to lubricate, clean, cool and seal,diesel engine oils are formulated to provide protection fromacids and disperse soot particles that are created during thecombustion process. Diesel engine oils are compounded withalkaline addi
34、tives to neutralize the sulfuric acids that are5Annual Book of ASTM Standards, Vol 05.02.6Annual Book of ASTM Standards, Vol 15.05.D6224022produced when the diesel fuel is combusted. They are alsocompounded with dispersant/detergents to keep the engineclean and the by-products of combustion (fuel so
35、ot) suspended.The combination of wear regimes found in the diesel enginerequire the lubricants to have high levels of anti-wear additivesto protect the engine from wear during the most severecondition. Multi-grade lubricants (high viscosity index) areoften employed in diesel engine lubricants that a
36、re required tooperate over a wide temperature range.4.5 Turbine-type (Pump) OilsTurbine oils provide satis-factory lubrication and cooling of bearings and gears (forexample, in auxiliary turbines and gearboxes). They also canfunction as a governor hydraulic fluid. The oil must have aviscosity high e
37、nough to maintain a sufficiently thick film of oilon load-bearing surfaces, but low enough to minimize energylosses while providing adequate cooling. These oils are rec-ommended where the degree of loading on bearings and gearsis less than in gear oil applications. Turbine oils have excellentoxidati
38、on resistance and contain rust inhibitors; they are oftenreferred to asR consequently, the interpretation oftest results will be significantly different. The fluid suppliershould be consulted if there is a question about interpretation ofanalytical results.5. Factors Affecting the Service Life of Oi
39、ls5.1 New Oil Quality and Suitability for Intended UseUseof high-quality oils that meet recognized standards (such asmanufacturer or military specifications) is the best assurance ofpotentially long service life.5.1.1 Viscosity is the most important characteristic of an oil.An oils load bearing and
40、lubricating properties are relateddirectly to its viscosity. The use of oil with incorrect viscositycan increase wear rates, heat build-up, and lube degradation. Inextreme cases, the use of oils with incorrect viscosities canresult in rapid catastrophic failures.5.1.2 Oils that meet the equipment ma
41、nufacturers require-ments should be used. For situations where the manufacturersimply offers a generic viscosity classification without specificperformance criteria, the user should consult the equipmentmanufacturer, lubricant suppliers, and experts in the field oflubrication.5.1.3 When fresh, unuse
42、d lubricants are received, a repre-sentative sample of oil may be taken and tested (see Table 1) toensure that general specifications are met. This test data shouldbe compared to a reference baseline from the lubricant supplierand then used for future condition monitoring.5.1.4 Manufacturer shelf li
43、fe recommendations should beobserved. Oils should be stored to preserve their originalquality and prevent contamination. Stored oils may be tested toensure and document their quality, cleanliness, and continuedsuitability for their intended use.5.1.5 Make-up oils should normally be of the same type,
44、quality, and manufacturer. Available formulations may changeover a period of time. Lubricant incompatibility can arise frommixing differing base stocks and additive packages and shouldbe avoided. When oils must be mixed, testing should beperformed in an attempt to determine compatibility. Consider-a
45、tion should be given to consulting the lubricant supplier(s)and equipment manufacturer prior to mixing oils.5.2 Deterioration of Oils in ServiceAir (oxygen), el-evated temperatures, metals, and water are present to someextent in oil systems. These factors promote oil degradation.Deterioration occurs
46、 by one or more of the following pro-cesses:5.2.1 Oxidation DegradationChemical changes arebrought about by oxygen in the atmosphere forming oxidationby-products which degrade the performance of the oil. Thesechanges can adversely affect the oils viscosity and acidity.5.2.2 Thermal/Oxidation Degrada
47、tionAt elevated tem-peratures, hydrocarbons are subject to thermal cracking whichforms unstable compounds. Performance additives in the oilmay also degrade at high temperatures. The unstable com-pounds are easily oxidized and also tend to polymerize to formresins, waxes, and sludge. Thermal oxidatio
48、n can occur at localhot spots within a system and as a result of high bulk oiltemperatures.5.2.3 Loss of AdditivesAdditives are used to protect theoil and enhance its performance abilities. When these additivesare depleted with service, oil oxidation, foaming, excessivewear, or premature rusting may
49、 result.5.2.4 New Oil Make-upAddition of new oil is required innearly every system to make up for losses due to leakage, filterchanges, or other maintenance. The amount and frequency ofadded make-up oil sometimes plays a very significant part indetermining the life of a system oil charge. Make-up can varyfrom less than 5 % per year to greater than 30 % in extremecases. In equipment where the make-up is very low (belowD62240235 %), oil oxidation and additive depletion are the primarydeterminants of service life. In-service oil should be tested atsufficient intervals to dete
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