1、Designation: D4378 12D4378 13Standard Practice forIn-Service Monitoring of Mineral Turbine Oils for 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 or, in the cas
2、e 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-generationi
3、ndustry 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 configured as combine cycle turbines. Combinedcycle turbines are of t
4、wo types; the first type connects a gas turbine with a steam turbine, with separatelubricant circuits, and the second type mounts a steam and a gas turbine on the same shaft and has acommon lubricant circuit. The lubrication requirements are quite similar but there are importantdifferences in that g
5、as 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, bycomparison, have a sho
6、rter service life from 2 to 5 years depending on severity of the operatingconditions. One of the benefits of the gas turbine is the ability to respond quickly to electrical powergeneration dispatching requirements. Consequently, a growing percentage of modern gas turbines arebeing used for peaking o
7、r cyclic duty (frequent unit stops and starts) that subjects the lubricant tovariable conditions (very high down to ambient temperatures), which put additional stresses on thelubricant.This practice is designed to assist the user to validate the condition of the lubricant through its lifecycle by ca
8、rrying out a meaningful program of sampling and testing of oils in service. This practiceis performed in order to collect data and monitor trends which suggest any signs of lubricantdeterioration and to ensure a safe, reliable, and cost-effective operation of the monitored plantequipment.1. Scope*1.
9、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 validate the condition of the lubricant throu
10、gh 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 appropriate practice be consulted (see Practic
11、e 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 regulatorylimitations prior to use.2. Refer
12、enced Documents2.1 ASTM Standards:2D92 Test Method for Flash and Fire Points by Cleveland Open Cup Tester1 This practice is under the jurisdiction of ASTM Committee D02 on Petroleum Products Products, Liquid Fuels, and Lubricants and is the direct responsibility ofSubcommittee D02.C0.01 on Turbine O
13、il Monitoring, Problems and Systems.Current edition approved Nov. 1, 2012Oct. 1, 2013. Published March 2013October 2013. Originally approved in 1984. Last previous edition approved in 20082012 asD4378D4378 12.08. DOI: 10.1520/D4378-12.10.1520/D4378-13.2 For referencedASTM standards, visit theASTM we
14、bsite, 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 the ASTM website.This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indicat
15、ion of what changes have been made to the previous 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 cons
16、idered the official document.*A Summary of Changes section appears at the end of this standardCopyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States1D130 Test Method for Corrosiveness to Copper from Petroleum Products by Copper Strip TestD44
17、5 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 Characteristics of Inhibited Mineral Oil in the Presence of WaterD892 T
18、est 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 Separability of Petroleum Oils and Synthetic FluidsD1500 Test Method for
19、 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 Fluid Lubricants by Viscosity SystemD2668 Test Method for 2,6-di-t
20、ert-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 ProductsD4898 Test Method for Insoluble Contamination of Hydraulic Fluids by
21、Gravimetric AnalysisD5185 Test Method for Multielement Determination of Used and Unused Lubricating Oils and Base Oils by InductivelyCoupled Plasma Atomic Emission Spectrometry (ICP-AES)D6224 Practice for In-Service Monitoring of Lubricating Oil for Auxiliary Power Plant EquipmentD6304 Test Method f
22、or Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric KarlFischer TitrationD6439 Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication SystemsD6810 Test Method for Measurement of Hindered Phenolic Antioxidant Con
23、tent in Non-Zinc 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 OilsD7647 Test Method f
24、or Automatic Particle Counting of Lubricating and Hydraulic Fluids Using Dilution Techniques toEliminate the Contribution of Water and Interfering Soft Particles by Light ExtinctionD7669 Guide for Practical Lubricant Condition Data Trend AnalysisD7720 Guide for Statistically Evaluating Measurand Ala
25、rm 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 Methods for Microscopical Sizing and Counting Particles from Aerospace Fluids on Mem
26、brane Filters2.2 International Organization for Standardization Standards:3ISO 4406 Hydraulic fluid powerFluidsMethod for codingCoding the levelLevel of contaminationContamination by solidparticles,Solid Particles, Second Edition, 1999ISO 4407 Hydraulic Fluid Power - Fluid Contamination - Determinat
27、ion PowerFluid ContaminationDetermination ofParticulate Contamination by Counting Method Using an Optical Microscope, Second Edition, 2002ISO 11500 Hydraulic fluid power - Determination Fluid PowerDetermination of the particulate contamination levelParticulateContamination Level of a liquid sample b
28、y automatic particle counting using the light extinction,Liquid Sample byAutomaticParticle Counting Using the Light Extinction, Second Edition, 2008ISO 11171 Hydraulic Fluid Power Calibration of automatic particle counters for liquidsPowerCalibration of AutomaticParticle Counters for Liquids3. Signi
29、ficance and Use3.1 This practice is intended to assist the user, in particular the power-plant operator, to maintain effective lubrication of all partsof the turbine and guard against the onset of problems associated with oil degradation and contamination. The values of the varioustest parameters me
30、ntioned in this practice are purely indicative. In fact, for proper interpretation of the results, many factors, suchas type of equipment, operation 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 cons
31、ist of a highly refined paraffinic mineral oil compounded with oxidation and rust inhibitors. Dependingupon the performance level desired, small amounts of other additives such as metal deactivators, pour depressants, extreme3 Available from American National Standards Institute (ANSI), 25 W. 43rd S
32、t., 4th Floor, New York, NY 10036, http:/www.ansi.org.D4378 132pressure additives, and foam suppressants can also be present. The turbine oils primary function is to provide lubrication andcooling of bearings and gears. In some equipment designs, they also can function as a governor hydraulic fluid.
33、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 cannot be expected to remain unchangedduring their use in the lubrication systems of turbin
34、es, 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 betolerated without harming the safety or efficiency of the system. Good monitoring procedures are nec
35、essary to determine when theoil properties have changed sufficiently to justify scheduling corrective actions which can be performed with little or no detrimentto production schedules.5. Operational Factors Affecting Service Life5.1 The factors that affect the service life of turbine lubricating oil
36、s are as follows: (1) type and design of system, (2) conditionof system on startup, (3) original oil quality, (4) system operating conditions, (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 des
37、ign, especially for the larger units.For lubrication, the usual practice is to pressure-feed oil directly from the main oil pump. The rest of the system consists of areservoir, oil cooler, strainer, piping and additional purification or filtration equipment, or a combination thereof. Miscellaneousco
38、ntrol and indicating equipment completes the system.5.1.2 Condition of System on Start-up:5.1.2.1 The individual components of a lubrication system are usually delivered on-site before the system is installed. Thelength of on-site storage and means taken to preserve the integrity of the intended oil
39、 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. Guidance on cleaning, flushing, and purification of steam, gas, and hydroelectric turbinelu
40、brication systems is provided in Guide D6439 or may be sought from the equipment/lubricant supplier or other industry experts.5.1.2.2 Turbine oil system contamination prior to startup usually consists of preservatives, paint, rust particles, and the varioussolids encountered during construction, whi
41、ch 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 an acceptable particle cleanliness level and watercontent level in the case of steam turbines for reliable lubrica
42、tion 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 operationand by malfunctions that occur during operation or contaminants that are introduced during overhaul, or both.5.1.
43、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 at least meets the requirements of the turbine manufacturer shall be used. Careful oil storage,including labeling an
44、d 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 dispensing.5.1.3.2 It is advisable to obtain typical test data from the oil supplier. Upon receipt of the first oil
45、 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 of the lubricant, and for future comparisons with used oil information. This is most important! Recommendedtests for
46、 new oil are given in the schedules of this practice (see Tables 1 and 2).5.1.3.3 When new turbine oil is to be mixed with a charge of a different composition prior checks should be made to ensureno loss of expected properties due to incompatibility (see lubricant suppliers specifications). These sh
47、ould include functional testsand checks for formation of insolubles. Guidance for such compatibility testing can be referenced in Practice D7155 for evaluatingcompatibility of mixtures of turbine lubricating oils.5.1.4 System Operating Conditions:5.1.4.1 The most important factors affecting the anti
48、cipated 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 c
49、onsequently be recorded.5.1.4.2 Most turbine oil systems are provided with oil coolers to control temperature. In many cases, bulk oil temperatures aremaintained so low, below 60C (140F), that moisture condensation can occur. Even with low bulk oil temperatures, however, therecan be localized hot spots such as in bearings, at gas seals, and in throttle control mechanisms that can cause oil degradation andeventually cause system oil to show signs of deterioration.5.1.4.3 Under the higher temperature conditions which are present in gas and steam turbines, oxidation
