ANALYSIS & TESTING OF FUEL OIL LUB OIL INSULATING OIL & HYDRAULIC FLUIDS

DIFFERENT TYPES OF OILS USED IN POWER PLANT

FUEL OIL LUBRICATING OIL FIRE RESISTANT FLUID INSULATING OIL or TRANSFORMER OIL

FUEL OIL
FUEL OILS BEING USED AT POWER STATIONS - LDO - HSD - FO (FURNACE OIL)

- LSHS (LOW SULPHUR HEAVY STOCK)

LDO & HSD

LOW VISCOSITY LOW FLASH POINT COSTLY NO NEED OF HEATING NO STEAM REQUIRED CV ~10720 KCAL/KG IDEAL FOR STARTING OF BOILER FROM COLD

FURNACE OIL
MUCH HIGHER VISCOSITY THAN LDO OR HSD REQUIRES HEATING AT THE TIME OF UNLOADING & PUMPING PREHEATING UPTO 110 DEGC FOR USE BETTER ATOMISED WITH STEAM COMPARATIVELY CHEAPER THAN LDO & HSD CV ~ 10270 KCAL/KG **LSHS- HIGHLY VISCOUS, CHEAPER THAN FO

Parameters Monitored of Fuel oil

Standard: IS 1593/1971, Grades: LV-MV-HV API gravity: 12 sp. 0.986 at 15 degc Viscosity- 80-120-370 cst at 50 degc Flash point- 66 degC (min) Pour point

FO Monitoring
GCV: 10270 kcal/kg Total Sulphur : 3.5-4.0-4.5% by weight

Water Content
Ash content Sediments

FUNCTIONS OF FO
Coal fired units contains oil burners having capacity of 15-20% Ignition energy to light off coal burners Stabilization of coal flame at low loads Safe and reliable heat input source during light up of boiler

PROPERTIES OF LUB OIL TO BE CHECKED

KINEMATIC VISCOSITY: The Redwood viscometer determines the time usually expressed in sec required for a standard volume of oil to flow through a standard orifice at specified pr. & temp. Kinematic viscosity= const. x time

 Moisture content: By Crackle test or

by Karl Fischer titration method

Mechanical Impurities: A fixed

volume of oil is dissolved in a solvent like Toluene or Pet. Ether and passed through pre weighed 45 micron filter paper. MI is determined from difference in weight

PROPERTIES OF LUBRICATING OIL TO BE CHECKED

Foaming Characteristics Copper strip corrosion Emulsion Characteristics Cloud and pour point Acidity Oxidation Characteristics Flash point

LIMIT OF DIFFERENT LUBE OIL

S.No Equipment Stage Name of oil SERVO PRIME-32

Moisture (ppm)
150

MI (ppm)
50

Viscosity (cst)
27.6-36.3

MOT/BFP/ ID/FD

PA FAN

SP-68

150

50

60.8-79.2

CT FAN/ASPH

SERVO 200 SYSTEM-121

500

118-124

MILL GEAR HOUSING

SERVO MESH SP320

1000

0.1%

320-350

LIMIT OF DIFFERENT LUBE OIL

S.N o Equipment Stage Name of oil

Moisture (ppm)
100

MI (ppm)
50

Viscosity (cst)
41.4-50.6

TURBINE

II

DAPHANE SUPER TURBINE-46

SERVO CYCLE-660 SERVO PM68 SERVO PM46 T

2 3 4

PA FAN/SAPH FD/ID TDBFP BRG & COUPLING

II II II

100 100 300

50 50 50

615-680 64-72 43-48

MDBFP

II

SERVO SYSTEMHLP32

300

50

29-39

MAIN MILL LUBE UNIT

II

SERVO 500 SYSTEM-460

500

440-500

FIRE RESISTANT FLUID

FIRE RESISTANT FLUID

FRF is known as phosphate ester hydraulic fluids. They are used in 500 MW turbine control system They are fire resistant, exhibit good resistance to oxidation hydrolysis, adequate air release and low foaming properties when compared to petroleum oil.

PARAMETERS OF FRF MONITORED

Water Content-Potential for Hydrolysis Fluid Cleanliness/ Particle Count Total Acid No-Hydrolysis that has occurred Mineral oil content Air release Viscosity Resistivity

FRF POLISHING UNIT

Mechanical filter and strainers removes mechanical impurities Fuller earth and activated alumina treatment to remove acidic ions. They acts as ion exchangers. Air drier or desiccant breather to remove moisture-moisture filter.

LIMIT OF DIFFERENT PARAMETERS S.N Parameter

1
2 3

Test Method
ASTM D-445
ASTM D-974 ASTM D-1744

Permissible Limit
30-50 cst
0.2 mg KOH/gm 1500 ppm

Viscosity
Acid Number Water Content

4
5

Sediments
Particle Count

AFNORE-48652
ASTMF-662/322

5 mg/100 ml
Class 16/13

INSULATING OIL

USE OF INSULATING OIL

Insulating oils are derived from mineral oil. Insulating oils are used in transformers, reactors switchgear and cables. It quenches arcs when switching. Prevents glow discharge. Act as a cooling agent.

AGEING OF OIL DURING OPERATION Increased temperature. Absorption of gases mainly oxygen. Absorption of water from atmosphere. Ageing through contacts with metal plates like copper and iron High temperature decomposition.

PARAMETERS OF INSULATING OIL MONITORED

Dielectric breakdown test. Dielectric dissipation factor or tan-d. Specific resistances.

Water content test.

Acidity Test.

RECONDITIONING OF INSULATING OIL

Reconditioning of oil means removal of water and solid particles from oil. This is done by using several available type of filters, centrifuge and vacuum dehydrators. Filter removes mechanical impurities. The centrifuge is used when there is large amount of water or other contamination present. Vacuum dehydrator removes water and dissolved gases.

Condition Monitoring of HV Transformers and Reactors by DGA technique

Degradation of insulating oil

Electrical discharges or thermal stresses in the oil or solid insulator of an oil filled transformer produces gases. The most significant gases produced are hydrogen, methane, ethane, ethylene and actylene. The relative quantity of various gases depends on the energy available.

GASES GENERATED UNDER DIFFERENT CONDITION

S.N
1 2 3 4 5

Phenomenon
Partial discharge Little heating Low temp. hotspot Moderately high temp hotspot Very high temp hotspot

Gases Generated
H2 gas (mainly) CH4,H2 CH4 C2H4,C2H6 C2H2 in significant amount.

Steps involved in D G Analysis

Sampling of oil - Stainless steel oil sampling containers of capacity up to 1000 ml with needle valves and tube adaptors at both ends can be used for sampling. Gas Extraction from oil Dissolved gases are extracted by degassing flask attached with a vacuum pump assembly. The extracted gas is then compressed to atmospheric pressure and volume of the gas is measured.

Steps involved in D G Analysis

Analysis of gas extracted- The gas extracted can be analyzed by a Gas Chromatograph fitted with a thermal conductivity cell detector. The carrier gas is helium. The column used is poropak N and Molecular sieve 5A.The gases determined are Hydrogen, oxygen, nitrogen, methane, ethane, ethylene, acetylene, propane, propylene, CO, CO2 etc.

HYDRAULIC FLUIDS

MINERAL OIL HYD FLUIDS

SOLUBLE IN WATER, FORMING EMULSIONS USED WHERE NOT MANY MOVING PARTS ARE INVOLVED CHEAP IF LEAK OCCURS, PRESENT A DEFINITE FIRE HAZARD AT ELEVATED TEMP

WATER/GLYCOL HYD FLUID

BETTER OILLINESS THAN MINERAL OIL HF

ARE REASONABLY FIRE RESISTANT

FLUID BECOMES THICKER & STICKY AT HIGH TEMP

WATER CAN BE ADDED TO RESTORE ITS ORIGINAL CONSISTENCY

MORE EXPENSIVE THAN THE SOLUBLE MINERAL OIL HF

SYNTHETIC HYDRAULIC FLUID

MAN-MADE PRODUCT

CHEMICAL NAMES SUCH AS CHLORINATED HC & PHOSPHATE ESTERS

HIGH RESISTANCE TO FIRE

USED IN BOILER DAMPERS & OTHER SYSTEMS WHERE HIGH TEMP ARE ENCOUNTERED COSTS ABOUT 8 TIMES AS MUCH AS MOHF

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