Innovative Lubricating Solution For Gas Turbines Gas Turbine Users Forum Sydney November 25 2015 Warren Scott- Lubricants Specialist
4/01/2016
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TODAY’S TURBINES HAVE TO WORK HARDER THAN EVER BEFORE Environmental legislation continuously driving towards lower emission levels
Greater demand for less downtime, extended oildrain intervals and efficiency improvements
Turbine sump volumes are shrinking in size while handling the same or increased power
Cyclic operating conditions are placing more stresses on turbines
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Affects the turbine oil
Increased operating temperatures drive requirements for greater component protection
Increased pressure on gearboxes
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OIL STRESS HAS INCREASED BY 400% AND OPERATING TEMPERATURES ARE HIGHER Increasing oil stress and operating temperatures* 12
80 70 60
8
50 40
6
30
4
20 2
Oil temperature, °C
Oil stress index, MW m-3
10
10 0
0 8C
GE fr 5
Oil stress index, MW m-3
GE fr 6A
GE fr 6B
GE fr 9E
Oil temperature, °C *Shell calculation based on publically available data
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Why the lubricant is important – reliability •
Turbine reliability requires – Prevention of metal-to-metal contact in hydrodynamic lubrication regime and control valve sticking both during start up and shut down and across the range of operating temperatures – Cooling to prevent rapid oil degradation and the formation of bearing deposits – Corrosion protection for the main bearings and system components
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Shell Turbo
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WHY THE LUBRICANT IS IMPORTANT – EFFICIENCY Deposit build-up on metal surfaces
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Why the lubricant is important – efficiency • Turbine system efficiency is affected by Deposit build-up on metal surfaces
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Excessive foam in the turbine reservoir
Shell Turbo
The formation of emulsions
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TYPICAL TURBINE OIL COMPOSITION Base Oil 98-99% Antioxidants R&O Additive System < 1-2%
Rust Inhibitor Corrosion Inhibitor Others *
Turbine oil additive system
* Defoamer, demulsifier, AW/EP additives (where required)
Group
Typical Process Route
Sulphur (Wt %)
Saturates (Vol %)
Viscosity Index
I
Solvent refining
> 0.03 &/or
<90
≥ 80 – < 120
II
All-Hydro-processing
≤ 0.03 &
≥ 90
≥ 80 – < 120
III
All-Hydro-processing
≤ 0.03 &
≥ 90
≥ 120
IV
Synthetic
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Poly-Alpha-Olefins (PAO) Other Base Oils Not Group I, II, III or IV 7
GAS-TO-LIQUIDS (GTL) BASE OIL TECHNOLOGY •Catalytic process converting gas to oil products
GTL base oil API group III+ base oil Primarily iso-paraffinic, no impurities, excellent antioxidant response, surface properties, narrow molecular distribution
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INNOVATIVE TURBINE OILS BASED ON GTL TECHNOLOGY •High performance turbine oils to: – Meet the demands of the latest highefficiency turbine systems – Offer outstanding, long-term performance under the most severe operating conditions – Help to minimise deposit formation, even under cyclic peak loading. The use of GTL technology enables performance enhancements in the area of: – High viscosity index – Rapid air release – Foaming resistance – High flash point – Rapid water separation
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DEPOSIT FORMATION TENDENCY – ASTM D7873 DRY TURBINE OIL STABILITY TEST (DRY TOST) •1,008 hour Dry TOST (ASTM D7873)
Oxidation of the fluid is promoted by heat, in the presence of oxygen and metals (copper and steel coils), no water Measure RPVOT and oxidation products (sludge) after 1,008 hours
Test Conditions • Temperature 120ºC (248ºF) • Copper and steel catalyst • Evaluate the sample at 1008 hrs
Assesses the sludge tendency by measuring insoluble oxidation products and RPVOT retention Copyright of Shell Lubricants
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DEPOSIT FORMATION TENDENCY – ASTM D7873 DRY TURBINE OIL STABILITY TEST (DRY TOST)
Dry TOST Evaluation at 1008 hrs (D7873)
1000 5000
Better Performance
Sludge, mg/kg
800 4000
600
400
200
0
Turbo S4 GtL-based Oil
Oil A
Oil B
Oil C
Oil D
Oil E
Testing based on commercially obtained samples
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OXIDATION STABILITY AND DEPOSIT CONTROL MAN-LTAT (LUBRICANT TEMPERATURE AGING TEST) AT 180°C Static Oven = 180ºC (356ºF) Test Time = 48 hours Air Flow = None Metal Catalysts = None
Measurable: – Sludge, mg/kg – Volatility of base oil and formulation This thermal stability test assesses the oil’s short term deposit resistance when exposed to very high temperatures. The test result indicates the oil’s resistance against sludge formation and is key to obtaining MAN Turbo approval. The lower the sludge levels in the oil at the end of test the better the performance. 4/01/2016
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PREVENTING CRITICAL COMPONENT FAILURE & UNPLANNED SHUTDOWNS •
The long-term resistance to formation of sludge and varnish deposits of GtLbased turbine oil helps reduce the risk of bearing temperature issues and control valve positioning problems, which can upset running stability and cause turbine trips. MAN-LTAT oxidation test (beaker test) at 180°C*
Better Performance
2,000
Sludge, mg
1,500
1,000
500
GtL-based oil performs much better than other oils tested in the MAN-LTAT oxidation test (beaker test)
0 GtL-based Oil Shell Turbo S4
Oil A
Oil B
Oil C
Oil D
Oil E *Source: Shell test data
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Shell Turbo
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EFFICIENCY BENEFITS OF API GRP iii BASED TURBINE OILS •
•
Turbine oil formulated with GTL base oil provide a higher inherent viscosity index and lower friction coefficient relative to turbine oils formulated with API Grp I or Grp II base oils Provides a thicker lubricating film at higher operating temperatures versus conventional GP I/II (lower VI) based oils of the same ISO grade
--- GTL Based Turbine Oil --- Converntional API Grp II Turbine Oil
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EFFICIENCY BENEFITS OF GTL BASED TURBINE OILS AIR RELEASE AND FOAMING •Turbine oil reservoirs are circulating oil system and entrainment of air and foaming is possible •Important to consider residence time of oil in tank to help settle contaminants (including air, water) •Turbine oils formulated with GTL base oils can significantly improve air release times and reduce foaming potential
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EFFICIENCY BENEFITS OF GTL BASED TURBINE OILS AIR RELEASE AND FOAMING – Poor air separation properties leads to:
Adiabatic compression within the oil (micro-dieseling), acidic contaminants, rapid decrease of the antioxidant system and an increase in oil insoluble material
– Operational difficulties due to poor air separation include:
Cavitation, loss of oil pressure, reduced oil flow, poor response in high pressure servos, filter blocking
– Use of turbine oils formulated with GtL base oils show an outstanding air separation properties leading to:
Reduced maintenance cost, increased turbine reliability, extended oil life, higher return on investment, peace of mind
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PROACTIVE TURBINE OIL MONITORING – Turbine oil condition monitoring is critical – Important to use an oil analysis testing programme that includes targets, warning limits and frequency, with diagnosis and recommended actions
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Shell Turbo
04 January 2016
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Summary – Turbine oils play a critical role in the availability and reliability of turbines used in the power generation, oil & gas and heavy industry sectors – In response to field issues, OEMs and industry bodies are developing increasingly differentiated turbine oil requirements with a focus on longer life and reduced deposit forming tendencies
Innovation in turbine oil technology such as the use of Gtl technology based oils in Shells new Turbo S4 X/GX range allows operator needs to be met
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SHELL TURBO S4 SERIES: FIELD EXPERIENCE TO DATE
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Current Usage of Turbo S4 X 32 & S4 X46 Shell Turbo S4 X 32
Location
Equipment
Start
Shell Technology Centre Houston
USA
Solar Taurus C 60 GT
Since 2012
Dominion Energy
USA
GE Frame 7 FA GT
Since 2013
Shell Canada Scotford Shell Canada Scotford Spectra Energy Empire District Energy
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Notes Drain and fill Replace Texaco GT 32 – drain and fill
Since 2014
Replace Turbo SG 32 – drain and fill
Sundyne Compressor x2
Since 2014
Replace Turbo SG 32 – drain and fill
USA
Solar Centaur GT
Since 2015
New start-up
USA
Siemens-Westinghouse 1426RT2 Steam Turbine
Since 2015
Conversion from Mobil DTE 732
Canada Canada
Elliott PAP Compressors x 5
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Current Usage of Turbo S4 GX 32/46 Shell Turbo S4 GX
Location
Equipment
Start
Notes
Stadtwerke Rostock
Germany
ABB V32A Steam Turbine
Since 2015
Stadtwerke Rostock
Germany
Siemens SGT 600 GT
Since 2015
Drain and fill
Vattenfall
Germany
Siemens GT
Since 2015
Top off – Shell Turbo CC 46
Drain and fill
EDF
France
GE Frame 9FHA
Since 2015
Initial fill new combined cycle
EDF
France
GE D14 Steam Turbine
Since 2015
Initial fill new combined cycle
Samsung (EPC)
SaudiArabia
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MAN TurboCompressor
Since 2015
Initial fill new project
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Dominion Energy First field trial candidate selected in US
Heavy duty gas turbine GE frame 7 FA Power Generation service Product: Shell TURBO S4 X 32 Field trial started mid April 2013 In service > 2 year with Shell Turbo S4 X 32 • Peaking Power Plant - low operational hours (~2,628) • Peaking and cylic duty is more severe on lubricant performance than base load - Starts= 279
– Overall oil condition very good • No filterability or servo valve varnish issues •
Good foaming & water separation characteristics
•
Air release < 2 minutes
•
MPC < 10; RPVOT retention >95% (1426 minutes)
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