1、Designation: D4378 08D4378 12Standard Practice forIn-Service Monitoring of Mineral Turbine Oils for Steam andGas Steam, Gas, and Combined Cycle Turbines1This standard is issued under the fixed designation D4378; the number immediately following the designation indicates the year oforiginal adoption
2、or, in the 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 pow
3、er-generationindustry as 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 toconfigured as combine cycle turbines.Combined
4、 cycle turbines are of two types; the first type connects a gas turbine with a steam turbine,with separate lubricant circuits, and the second type mounts a steam and a gas turbine on the sameshaft and has a common lubricant circuit. The lubrication requirements are quite similar but there areimporta
5、nt differences in that gas turbine oils are subjected to significantly higher localized “hot spot”temperatures and water contamination is less likely. Steam turbine oils are normally expected to lastfor many years. In some turbines up to 20 years of service life has been obtained. Gas turbine oils,
6、bycomparison, have a shorter service life. Many of the monitoring tests used for steam turbine oils areapplicable to gas turbine oils.life from 2 to 5 years depending on severity of the operating conditions.One of the benefits of the gas turbine is the ability to respond quickly to electrical power
7、generationdispatching requirements. Consequently, a growing percentage of modern gas turbines are being usedfor peaking or cyclic duty (frequent unit stops and starts) that subjects the lubricant to variableconditions (very high down to ambient temperatures), which put additional stresses on the lub
8、ricant.This practice is designed to assist the user to validate the condition of the lubricant through its lifecycle by carrying out a meaningful program of sampling and testing of oils in use.service. Thispractice is performed in order to collect data and monitor trends which suggest any signs of l
9、ubricantdeteriorating. This can be used as a guide for the direction of system maintenance deterioration andto ensure a safe, reliable, and cost-effective operation of the monitored plant equipment.Also coveredare some important aspects of interpretation of results and suggested action steps so as t
10、o maximizeservice life.1. Scope Scope*1.1 This practice covers the requirements for the effective monitoring of mineral turbine oils in service in steam and gasturbines, as individual or combined cycle turbines, used for power generation. This practice includes sampling and testingschedules to valid
11、ate the condition of the lubricant through its life cycle and by ensuring required improvements to bring thepresent condition of the lubricant within the acceptable targets. This practice is not intended for condition monitoring of lubricantsfor auxiliary equipment; it is recommended that the approp
12、riate practice be consulted (see Practice D6224).1.2 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibilityof the user of this standard to establish appropriate safety and health practices and determine the applicability of reg
13、ulatorylimitations prior to use.1 This practice is under the jurisdiction of ASTM Committee D02 on Petroleum Products and Lubricants and is the direct responsibility of Subcommittee D02.C0.01 onTurbine Oil Monitoring, Problems and Systems.Current edition approved May 1, 2008Nov. 1, 2012. Published M
14、ay 2008March 2013. Originally approved in 1984. Last previous edition approved in 20032008 asD437803.08. DOI: 10.1520/D4378-08.10.1520/D4378-12.This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previ
15、ous version. Becauseit may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current versionof the standard as published by ASTM is to be considered the official document.*A Summary of Chan
16、ges section appears at the end of this standardCopyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States12. Referenced Documents2.1 ASTM Standards:2D92 Test Method for Flash and Fire Points by Cleveland Open Cup TesterD130 Test Method for Corro
17、siveness to Copper from Petroleum Products by Copper Strip TestD445 Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)D664 Test Method for Acid Number of Petroleum Products by Potentiometric TitrationD665 Test Method for Rust-Preventing Chara
18、cteristics of Inhibited Mineral Oil in the Presence of WaterD892 Test Method for Foaming Characteristics of Lubricating OilsD943 Test Method for Oxidation Characteristics of Inhibited Mineral OilsD974 Test Method for Acid and Base Number by Color-Indicator TitrationD1401 Test Method for Water Separa
19、bility of Petroleum Oils and Synthetic FluidsD1500 Test Method for ASTM Color of Petroleum Products (ASTM Color Scale)D2272 Test Method for Oxidation Stability of Steam Turbine Oils by Rotating Pressure VesselD2273 Test Method for Trace Sediment in Lubricating OilsD2422 Classification of Industrial
20、Fluid Lubricants by Viscosity SystemD2668 Test Method for 2,6-di-tert-Butyl- p-Cresol and 2,6-di-tert-Butyl Phenol in Electrical Insulating Oil by InfraredAbsorptionD3427 Test Method for Air Release Properties of Petroleum OilsD4057 Practice for Manual Sampling of Petroleum and Petroleum ProductsD48
21、98 Test Method for Insoluble Contamination of Hydraulic Fluids by Gravimetric AnalysisD5185 Test Method for Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils andDetermination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spec
22、trometry (ICP-AES)D4241D6224 Practice for Design of Gas Turbine Generator Lubricating Oil SystemsIn-Service Monitoring of Lubricating Oilfor Auxiliary Power Plant Equipment (Withdrawn 2008)D4248D6304 Practice Test Method for Design of Steam Turbine Generator Oil SystemsDetermination of Water in Petr
23、oleumProducts, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration (Withdrawn 2008)D6439 Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication SystemsD6810 Test Method for Measurement of Hindered Phenolic Antioxidant Content in Non-Zinc
24、 Turbine Oils by Linear SweepVoltammetryD6971 Test Method for Measurement of Hindered Phenolic andAromaticAmineAntioxidant Content in Non-zinc Turbine Oilsby Linear Sweep VoltammetryD7155 Practice for Evaluating Compatibility of Mixtures of Turbine Lubricating OilsD7669 Guide for Practical Lubricant
25、 Condition Data Trend AnalysisD7720 Guide for Statistically Evaluating Measurand Alarm Limits when Using Oil Analysis to Monitor Equipment and Oil forFitness and ContaminationF311 Practice for Processing Aerospace Liquid Samples for Particulate Contamination Analysis Using Membrane FiltersF312 Test
26、Methods for Microscopical Sizing and Counting Particles from Aerospace Fluids on Membrane Filters2.2 ISO Standard:International Organization for Standardization Standards:3ISO 4406:19994406 Hydraulic fluid powerFluidsMethod for coding the level of contamination by solid particlesparticles,Second Edi
27、tion, 1999ISO 4407 Hydraulic Fluid Power - Fluid Contamination - Determination of Particulate Contamination by Counting MethodUsing an Optical Microscope, Second Edition, 2002ISO 11500 Hydraulic fluid power - Determination of the particulate contamination level of a liquid sample by automatic partic
28、lecounting using the light extinction, Second Edition, 2008ISO 11171 Hydraulic Fluid Power Calibration of automatic particle counters for liquids3. Significance and Use3.1 This practice is intended to assist the user, in particular the power-plant operator, to maintain effective lubrication of all p
29、artsof the turbine and guard against the onset of problems associated with oil degradation and contamination. The values of the varioustest parameters mentioned in this practice are purely indicative. In fact, for proper interpretation of the results, many factors, suchas type of equipment, operatio
30、n workload, design of the lubricating oil circuit, and top-up level, should be taken into account.4. Properties of Turbine Oils4.1 Most turbine oils consist of a highly refined paraffinic mineral oil compounded with oxidation and rust inhibitors. Dependingupon the performance level desired, small am
31、ounts of other additives such as metal deactivators, pour depressants, extreme2 For referencedASTM standards, visit theASTM website, www.astm.org, or contactASTM Customer Service at serviceastm.org. For Annual Book of ASTM Standardsvolume information, refer to the standards Document Summary page on
32、the ASTM website.3 Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http:/www.ansi.org.D4378 122pressure additives, and foam suppressants can also be present. The turbine oils primary function is to provide lubrication andcooling of bearings
33、 and gears. In some equipment designs, they also can function as a governor hydraulic fluid.4.2 New turbine oils should exhibit good resistance to oxidation, inhibit sludge and varnish deposit formation, and provideadequate antirust, water separability, and nonfoaming properties. However, these oils
34、 cannot be expected to remain unchangedduring their use in the lubrication systems of turbines, as lubricating oils experience thermal and oxidative stresses which degradethe chemical composition of the oils basestock and gradually deplete the oils additive package. Some deterioration can betolerate
35、d without prejudice to harming the safety or efficiency of the system. Reinhibition may improve some properties of the oil.Good monitoring procedures are necessary to determine when the oil properties have changed sufficiently to justify schedulingcorrective actions which can be performed with littl
36、e or no detriment to production schedules.5. Operational Factors Affecting Service Life5.1 The factors that affect the service life of turbine lubricating oils are as follows: (1) type and design of system, (2) conditionof system on startup, (3) original oil quality, (4) system operating conditions,
37、 (5) contamination, (6) oil makeup rate, and (7)handling and storage.5.1.1 Type and Design of SystemMost modern turbine lubricating systems are similar in design, especially for the larger units.For lubrication, the usual practice is to pressure-feed oil directly from the main oil pump. The rest of
38、the system consists of areservoir, oil cooler, strainer, piping and additional purification or filtration equipment, or a combination thereof. Miscellaneouscontrol and indicating equipment completes the system. If there is an opportunity to participate in system design, it isrecommended that appropr
39、iate practices be consulted (see Practice D4241 and Practice D4248), as well OEM guidelines and oilmonitoring specifications.5.1.2 Condition of System on Start-up : Start-up:5.1.2.1 The individual components of a lubrication system are usually delivered on-site before the system is installed. Thelen
40、gth of on-site storage and means taken to preserve the integrity of the intended oil wetted surfaces will determine the totalamount of contamination introduced during this period, the magnitude of the task of cleaning and flushing prior to use, and thedetrimental effects of the contaminants. Guidanc
41、e on contamination control, cleaning, flushing, and purification of steam, gas, andhydroelectric turbine lubrication systems is provided in Guide D6439 or may be sought from the equipmentequipment/lubricantsupplier or other industry experts.5.1.2.2 Turbine oil system contamination prior to startup u
42、sually consists of preservatives, paint, rust particles, and the varioussolids encountered during construction, which can range from dust and dirt to rags, bottles, and cans. Their effect on turbine oilsystems is obvious.5.1.2.3 Ongoing purification may be required to maintain the in-service oils at
43、 an acceptable particle cleanliness level and watercontent level in the case of steam turbines for reliable lubrication and control systems operation. In operational systems, theemphasis is on the removal of contaminants that may be generated due to normal oil degradation or ingressed during operati
44、onand by malfunctions that occur during operation or contaminants that are introduced during overhaul, or both.5.1.3 Original Oil Quality:5.1.3.1 Use of a high-quality oil is the best assurance of potentially long service life. Oils meeting recognized standards aregenerally available, and one that a
45、t least meets the requirements of the turbine manufacturer shall be used. Careful oil storage,including labeling and rotation of lubricant containers, is vital to ensure proper use and prevent degradation of the physical,chemical, and cleanliness requirements of the lubricant throughout storage and
46、dispensing.5.1.3.2 It is advisable to obtain typical test data from the oil supplier. Upon receipt of the first oil charge, a sample of oil shouldbe taken to confirm the typical test data and to use as a baseline. This baseline should act as a starting point for the physical andchemical properties o
47、f the lubricant, and for future comparisons with used oil information. This is most important! Recommendedtests for new oil are given in the schedules of this practice (see Table 1Tables 1 and 2 and Table 2).5.1.3.3 When new turbine oil is to be mixed with a charge of a different composition prior c
48、hecks should be made to ensureno loss of expected properties due to incompatibility (see lubricant suppliers specifications). These should include functional testsand checks for formation of insolubles. Guidance for such compatibility testing can be referenced in Practice D7155 for evaluatingcompati
49、bility of mixtures of turbine lubricating oils.5.1.4 System Operating Conditions : Conditions:5.1.4.1 The most important factors affecting the anticipated service life of a given lubricating oil in a given turbine system arethe operating conditions within the system.Air (oxygen), elevated operating temperatures, metals, and water (moisture) are alwayspresent to some extent in these oil systems. These elements promote oil degradation and must consequently be recorded.5.1.4.2 Most turbine oil systems are provided with oil coolers to control temperature. In many cases, bulk
