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A paradigm shift in lubricant maintenance

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High Purity Fluids and Lubricants for Turbine, Compressor, and Hydraulic applications

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A paradigm shift in lubricant maintenance

  1. 1. Copyright © EPT 2017, All rights Reserved A Paradigm Shift In the Application of Lubricant Maintenance ©Copyright 2018, EPT STLE, Hamilton Chapter Meeting Jan 16 2018 Peter Dufresne, EPT, When Results Matter
  2. 2. Copyright © EPT 2017, All rights Reserved ©Copyright EPT 2018 Copyright, Peter Dufresne, EPT 2015. This work is the intellectual property of the author. Permission is granted for this material to be shared for non-commercial, educational purposes, provided that this copyright statement appears on the reproduced materials and notice is given that the copying is by permission of the authors. No commercial use is allowed. No Re- publishing in part or in while is allowed without the written permission of the author. The author can be contacted at pdufresne@cleanoil.com 2
  3. 3. Copyright © EPT 2017, All rights Reserved 3 WHEN RESULTS MATTER High Purity Fluids and Lubricants for Turbine, Compressor, and Hydraulic applications • 20+ Years experience • 1000 turbines/ compressors worldwide • Largest fleets in the world • 50 million operating hours • $100 million+ proven cost savings EPT Background
  4. 4. Copyright © EPT 2017, All rights Reserved 4 What is Maintenance? Definition: 1. the process of maintaining or preserving something, or the state of being maintained. synonyms: preservation, conservation, keeping, prolongation, perpetuation, carrying on, continuation, continuance antonyms: breakdown, discontinuation 2. the process of keeping something in good condition. "car maintenance" synonyms: upkeep, service, servicing, repair(s), care antonyms: neglect
  5. 5. Copyright © EPT 2017, All rights Reserved Maintenance is so important it is legally required in some Industries Photo: Air Canada Boeing 787-8 Dreamliner
  6. 6. Copyright © EPT 2017, All rights Reserved Lubricant maintenance issues are frequently observed, with common parallels from site to site. These issues are costing Industry billions annually. In other Industries, Maintenance has a Discretionary Component Is the safe and reliable operation of this equipment less important????
  7. 7. Copyright © EPT 2017, All rights Reserved The Cost of Failure can be Extreme Sherburne County Generating Station Catastrophic failure 2012 in Unit 3 1100MW ST. Failure costs 200 million Source: MPR News, Oct 21, 2013
  8. 8. Copyright © EPT 2017, All rights Reserved “Rare but not uncommon in Industry for failures of this type” – Ron Brevig, Plant Director, Xcel Sherburne County Generating Station – Star Tribune Oct 2, 2012 8
  9. 9. Copyright © EPT 2017, All rights Reserved “Majority of costs will be covered by insurance” – Ron Brevig, Plant Director, Xcel Sherburne County Generating Station – Star Tribune Oct 2, 2012 9
  10. 10. Copyright © EPT 2017, All rights Reserved 10 Insurance companies are now watching!
  11. 11. Copyright © EPT 2017, All rights Reserved Lubricant Maintenance Issues 1. Not following operating fluid specifications.
  12. 12. Consequences of Not Following Specification Laguna Verge Nuclear Power Plant 30 day outage from Hydraulic Failure caused from incorrect fluid maintenance in EHC system. Loss to Company @ $50MW/h > $25Million.
  13. 13. Copyright © EPT 2017, All rights Reserved Servo Failure Vs ISO Code. $5 million Cost at this Location Figure 3: ISO particle count vs. System Changes time Line 1 10 100 1000 10000 100000 12/10/02 6/28/03 1/14/04 8/01/04 2/17/05 9/05/05 3/24/06 10/10/06 4/28/07 Date (dd/mm/yy) ParticleCount(permL) ISO(4) ISO(6) ISO(14) Servo Failure Filter Change Polishing Filter Conditioning Filter Fluid change
  14. 14. Copyright © EPT 2017, All rights Reserved Concept of “Trouble Free Operating Window” 14
  15. 15. Copyright © EPT 2017, All rights Reserved MOOG Study • Recommend ISO 14/11 cleanliness – This level enables equipment to operate continuously, trouble free for at least 9,000hrs – Achieving ISO 13/10 extends trouble free window to 30,000hrs. – Almost NO plants operate at this guideline • What is the trouble free operating window in this case??? 15
  16. 16. HOW MANY POWER PLANTS OPERATE OUTSIDE OF FLUID SPECIFICATION? 16
  17. 17. Acid Number Results 17 Summary of 484 EHC oil samples analyzed Average Acid Number (AN) 0.31 mgKOH/g with 50% of sites >0.10 and 30% >0.20
  18. 18. Copyright © EPT 2017, All rights Reserved a 18 NOT DISCLOSED
  19. 19. Copyright © EPT 2017, All rights Reserved Understanding Particle count 19 (ISO CODE) 4 (# particles/ml) 6 (# particles/ml) 14 (# particles/ml) 1 (14/11) 120 120 15 2 (13/10) 60 60 7.5 3 (24/22/17) 120,000 30,000 240 2000x or 200,000% 500x or 50,000% 32x or 3,200% *Using midpoint of each ISO category
  20. 20. If safe and reliable equipment operation requires a proper maintenance program that at least keeps lubricants within operating specification, why would companies choose to operate outside of specification? 20
  21. 21. Possible Reasons: • Lack of knowledge • Lack of resources – Lack of staff – Lack of budget – None or incorrect maintenance tools. • Run to failure methodology • Incompetence/Negligence 21
  22. 22. Copyright © EPT 2017, All rights Reserved Lubricant Maintenance Issues 1. Not following operating fluid specifications. 2. Lab Analysis is often not reporting products of oxidation, and conventional lubricant maintenance lacks the capability to remove this material
  23. 23. Copyright © EPT 2017, All rights Reserved Oxidation Material Accumulates 23 AFTER INSTALLING ICB CARTRIDGES 26-SEP-12 04-OCT-12 15-OCT-1219-SEP-1229-AUG-12 BEFORE ICB INSTALL Source: EPT This contamination cannot be viewed with traditional oil analysis
  24. 24. Hexane Reveals Hidden Contamination 24 NEW FYRQUEL Source: EPT Exelon/EPRI Deposition Tendency Test
  25. 25. Copyright © EPT 2017, All rights Reserved Nicks in the land of the spool allows high pressure flow first Spray pattern of high temp fluid Copyright © EPT 2012, All rights ReservedSource: EPT
  26. 26. Copyright © EPT 2017, All rights Reserved Measuring Varnish Potential: MPC ASTM D7843-16 26 • Membrane Patch Colorimetry (MPC): assesses oil’s potential to produce varnish. • Passes oil through 0.45 μm filter patch. • Quantifies color of deposit left on filter patch. • Darker patch suggests higher potential for varnishing. • Consistent sample prep required to obtain reproducible results: • Heating for 24 hours then incubating for 72 hours @ room temperature. • Updated in 2016, to protect sample from UV. Source: ASTM D7843-16
  27. 27. Copyright © EPT 2017, All rights Reserved 27 Measuring Varnish Potential: MPC ASTM D7843-16
  28. 28. Copyright © EPT 2017, All rights Reserved Misinterpretations with MPC (ASTM 7843-16) Unit Test ∆L ∆A ∆B 2AFR Initial 49.5 8.0 13.5 2GFR Initial 70.5 0.9 3.6 28 • MPC measurement: • ∆E = 𝐿2 + 𝑎2 + 𝑏2 • Where: • ∆E = color difference L = white/black a = yellow/violet b = red/green
  29. 29. Copyright © EPT 2017, All rights Reserved 29 Misinterpreting MPC Fine Carbon Can Mask MPC A and B Values Electrostatic Cleaning +30 and 60 days
  30. 30. Copyright © EPT 2017, All rights Reserved Lubricant Maintenance Issues 1. Not following operating fluid specifications. 2. Lab Analysis is often not reporting products of oxidation, and conventional lubricant maintenance lacks the capability to remove this material 3. Oxidation mechanisms are not being managed.
  31. 31. Copyright © EPT 2017, All rights Reserved 31 Oxidation Oxygen Heat Metals Hydrolysis (Esters) Water Metals Heat Thermal Degradation Static Discharge Hot Spots Micro- dieseling Lubricant Breakdown Mechanisms
  32. 32. Copyright © EPT 2017, All rights Reserved 32 Oxidation varies with temperature Svante August Arrhenius 1859 –1927 was a Swedish scientist and one of the founders of the science of physical chemistry. He received the Nobel Prize for Chemistry in 1903. Rate of oxidation doubles for every 10C increase in operating temperature
  33. 33. Copyright © EPT 2017, All rights Reserved 33Source: EPT Low Fluid Levels Promote Air Entrainment
  34. 34. Copyright © EPT 2017, All rights Reserved 34Source: EPT Fluid Return Line Above Fluid Level Increases Air Entrainment
  35. 35. Copyright © EPT 2012, All rights Reserved 35 Accumulated Oxidation Leads to Varnish • The Varnish Cycle: Particulate Removal vs Soluble Varnish Removal Varnish Levels Saturation Point Oxidation Step 1: Soluble Varnish Step 2: Insoluble Varnish Step 3: Varnish Deposit Chemical Change Physical Change Physical Change • 2 Approaches to Varnish removal • Soluble varnish removal (SVR) using Ion exchange resin (ICB) • Insoluble removal using particulate removal technology ICB
  36. 36. Copyright © EPT 2017, All rights Reserved Normal Turbine Lubricant Life Cycle • Common for gas turbine lubricants to last 4-8 years. – Corresponds to anti-oxidant consumption rate of 1/4 – 1/8th per year. – Additive consumption rate year/year determines maximum life • Steam turbine lubricants expected to last 2x as long in general due to lower temperatures. – Scheduling of replacement very important in nuclear industry. • Lubricants currently replaced on: – Combination of high acid number, and low additive or low RPVOT – Elevated MPC – Poor demulsibility • Flushing often required at time of replacement.
  37. 37. Copyright © EPT 2017, All rights Reserved A Shift in Lubricant Maintenance Strategy • To demonstrate that MPC increase is inevitable with conventional practices. • Repeat test while preventing oxidation material from accumulating using ion exchange resin technology 37
  38. 38. Copyright © EPT 2017, All rights Reserved 38 Lubricant Breakdown Testing – Brand A Temperature 150C with Copper Catalyst
  39. 39. Copyright © EPT 2017, All rights Reserved 39 Lubricant Breakdown Testing, Brand B Temperature 150C with Copper Catalyst
  40. 40. Copyright © EPT 2017, All rights Reserved 40 • Comparison of two different turbine oil brands: Days AN (mg KOH/g) RULER Amine (%) RULER Phenol (%) MPC ΔE Patch Photo 0 0.04 100 100 1.3 4 0.04 91 8 10.6 7 0.03 85 6 39.5 11 0.04 68 5 43.9 14 0.04 34 7 49.7 Days AN (mg KOH/g) RULER Amine (%) RULER Phenol (%) MPC ΔE Patch Photo 0 0.14 100 100 4.8 5 0.30 0 10 64.4 9 3.96 0 0 64.4 A vs B Lubricant Breakdown Testing
  41. 41. Copyright © EPT 2017, All rights Reserved 41 PAG vs. Mineral Oils: Breakdown Exact same test conditions PAG (New Left; Degraded Right) A Closer Look: Final stages of PAG breakdown. 500 Hours
  42. 42. Copyright © EPT 2017, All rights Reserved ICB Filter Matrix Benefits • Engineered ion exchange resins designed to remove dissolved oxidation material • By removing oxidation material, additive performance is improved as secondary reactions should be prevented. • Improves effectiveness of lubricant top ups • When packaged with a lubricant conditioner you can use to provide consistent quality. 42 ICB is a trademark of EPT Source: EPT Ion Exchange Technology
  43. 43. Copyright © EPT 2017, All rights Reserved 43 • SVR™ Treatment Effect Upon MPC ΔE Varnish Potential: • With SVR™: MPC ΔE: -99% • Without SVR™: MPC ΔE: +196% 0.0 10.0 20.0 30.0 40.0 50.0 MPC ΔE Varnish Potential Time  Without SVR With SVR 0 72 240 408 576 744 1080 0 72 240 408 576 744 1080 0 72 240 408 576 744 1080 0 72 240 408 576 744 1080 Testing Repeated So Oxidation By-products don’t accumulate
  44. 44. Copyright © EPT 2017, All rights Reserved 44 • Degraded 2 identical beakers of turbine oil side-by-side. • LEFT: with SVR™ treatment. • RIGHT: without SVR™ treatment. • Test Duration: 53 days. 3 days0 days 17 days 31 days 53 days Untreated: :SVR™ treated Testing Repeated With and Without Lube Oil Conditioner
  45. 45. Copyright © EPT 2017, All rights Reserved Operating Case History- Gas Turbine Lube 8 years old with conditioning system from Day 1 45 AntiOxidants: Amine 75%, Phenol 76%. Consumption rate 3% per year, Projected life >25 Years 1-Perfect lube oil quality, 0 issues, and lowest risk level and cost operating profile achieved.
  46. 46. Copyright © EPT 2017, All rights Reserved Paradigm Shift in the Capabilities of Lubricant Maintenance Removing oxidation material as generated offers many exciting possibilities: 1. Maintains consistent high quality through out the oils life cycle 2. The consequences of oxidation are managed i.e. no acids, no oxidation material, no deposits 3. Additive consumption levels are minimized 4. Additive levels can be maintained with regular top up of the existing lubricant.
  47. 47. Copyright © EPT 2017, All rights Reserved Additional Resources 47 http://cleanoil.com/training/resources
  48. 48. Copyright © EPT 2017, All rights Reserved 48 Thank you Banff National Park, AB, Canada Photo Matt Hobbs Peter Dufresne, EPT pdufresne@cleanoil.com (403) 389-4101

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