Steam Turbine Turbine Oil Care
Maintenance Maintenance Instructions
Introduction
Function of the turbine oil is to lubricate and
cool the bearings of the turbine generator
and to actuate governing system
components. Turbine oil is subjected to high
physical loads, should have a long service
life and must not have any adverse effect on
the proper functioning of the bearings and
other turbine oil consumers
The physical and chemical properties of new
turbine oil must comply with the
requirements of the Turbine Oil Specification
[1]. The aim of turbine oil care is to maintain
the properties and the useful service life of
the turbine oil for as long as possible.
This general maintenance instruction
discusses the necessity for, and the
procedures involved in turbine oil care.
The program for the care of turbine oil
includes regular inspection and analysis of
turbine oil samples. In this way changes in
turbine oil properties can be determined and
the necessary actions can be taken to
remedy the situation.
The filters and strainers in the operating oil
systems retain solid contaminants which can
cause damage and/or impair functioning if
they ingress into turbine oil consumers.
By centrifuge (i.e. oil conditioning station)
which is independent of the oil operating
systems, contaminants and aging and
corrosion products which are not soluble in
oil are removed from the turbine oil.
Thorough cleaning of the oil system during
initial startup and after inspections and
overhauls is one of the prerequisites for
successful turbine oil care. In addition, the
ingress of contaminants into the oil system
must be prevented.
Turbine oil properties
As a rule, turbine oils are paraffin-based
mineral oils which contain additives to
improve their resistance to corrosion and
their oxidation stability.
BHEL Haridwar
The Turbine Oil Specification [1] contains
standards and selection criteria for turbine
oil as well as the requirements in terms of
physical and chemical properties.
The following oil properties are particularly
important for turbine oil care:

Total-acid number

Water contents and water separability
efficiency

Solid contaminant quantities, purity

Air release properties

Foaming characteristics
Turbine oil properties and the values which
can change those properties are discussed
briefly below.
Further information can be found in the
standards cited in the Turbine Oil
Specification [1] as well as technical
literature, including those issued by turbine
oil manufacturers.
Actions to be taken to rectify typical changes
in turbine oil properties are listed in Table-1.
Total-acid number of the turbine oil
The total-acid number is an easily
determined reference value for turbine oil
aging.
Catalysts and thermal loading of the turbine
oil can trigger an oxidation process in which
oleic acids are formed, raising the total-acid
number of the turbine oil. The oil ages.
The oleic acids attack oil system component
materials and corrosion products are formed
which can, in turn, catalytically accelerate
the oxidation process.
Under certain circumstances, contaminants
which ingress into the oil system from
outside can promote the oxidation process.
New turbine oil contains additives which,
provided that oil is properly cared for, give
sufficient protection against aging.
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The additives become depleted over time.
Under unfavorable conditions, e.g. where
there is improper or negligent oil care, this
depletion process can result in premature
aging of the turbine oil.
In this case, the turbine manufacturer and
the turbine oil supplier should be consulted
in order that measures for restoring the
turbine oil can be implemented.
The turbine oil cannot be used if the function
of sensitive turbine generator components is
impaired through corrosion and/or aging
products and if the aging process, i.e., the
change in the total-acid number, cannot be
reversed by treating the turbine oil.
From this highly simplified description of the
turbine oil aging process, it can be seen that
aging is affected not only by physical loading
of the turbine oil but also by catalysts and
aging products, e.g., oleic acids. Treatment
of the turbine oil in the oil conditioning
station removes products of aging and
corrosion which are not soluble in oil,
thereby slowing down the aging process.
Water content and water separability of
the turbine oil
The value for water content stipulated in the
Turbine oil Specification (1) should not be
exceeded.
Water which ingresses into the oil system
from an oil cooler, in the form of shaft seal
steam or leakage water, results in the
corrosion in ferrous materials and can
adversely affect the aging process and
foaming characteristics of the turbine oil.
Corrosion causes changes in the surfaces
and shape of the sensitive turbine generator
components. The corrosion products behave
in the same as solid contaminants, and lead
to impaired component functioning.
The cause of any increase in turbine-oil
water contents must be determined and
remedied.
High water contents of the turbine oil can
also be the result of low water separability of
the turbine oil. In this case, it is particularly
important that the ingress of water in to the
oil system be prevented.
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Solid-contaminant quantities and purity
of turbine oil
Whereas the material property value for
solid-contaminant quantity defines the
overall content by weight of solid-
contaminant quantities in a turbine oil
sample, when defining turbine oil purity only
the proportion of solid-contaminants of a
specified size is determined. Turbine oil
purity is the more reliable criterion.
Solid-contaminants can ingress into the
turbine oil from outside, or as a result of the
aging process or corrosion. They contribute,
along with other factors, to the turbine-oil
aging process and impair the condition and
function of the turbine components.
Among the principal areas which can be
affected are turbine and generator bearings.
Their load capacity can be reduced due to
scoring caused by solid-contaminants in the
turbine oil. In addition, changes of state and
impaired functioning in control and
protection equipment can be expected.
The oil system is thoroughly cleaned during
initial startup of the turbine generator set.
Flushing of the entire system is included in
the cleaning process.
The filters and strainers of the operating oil
systems are used to retain contaminants
with a particle size larger than the filter mesh
size, before the turbine oil reaches the oil
consumers. The dwell time of the oil in the
filters and strainers will depend on the purity
of the turbine oil.
Purity in accordance with the Turbine Oil
Specification [1] is achieved through
continuous filtration or separation of turbine
oil in the oil centrifuge.
During inspections and overhauls the turbine
must be drained and the main oil tank, the
oil coolers and the bearing pedestals must
be thoroughly cleaned. It is recommended
that the turbine oil be either filtered or
treated in a separator during drainage an
refilling.
The ingress of solid contaminants into the
turbine oil must be prevented.
Air release properties of the turbine oil
The air release property represents the time
taken for a specific volume of air to be
released from the turbine oil sample under
the boundary conditions stipulated in the
testing standard of the Turbine Oil
Specification [1].
The turbine oil circulates inside the oil
system and becomes aerated. This air is
-1
released during the dwell time tv = 60n (in
min) of the turbine oil in the main oil tank, n
corresponds to the number of passes per
hour made by the turbine oil.
If the time required for air release by the
turbine oil is longer than the dwell time in the
main oil tank, an oil-and-air mixture will
develop, which will not have as favourable a
density and compressibility as non aerated
turbine oil. This can lead to faults in the
operating oil pumps, fluctuations in oil
pressure and impaired functioning of any
control and protection equipment which is
supplied with turbine oil.
Only in rare cases it is possible to improve
the Air release properties of turbine oil with
economically viable treatment methods. For
this reason, any factors which might lead to
deterioration of the air release properties of
the turbine oil, must be avoided.
It has been proven that the air release
properties of turbine oil are adversely
affected by materials containing silicone,
e.g., seal materials or foam inhibiting
additives.
Foaming characteristics of the turbine oil
The material property values for foaming
tendency and foam stability of turbine oil
should comply with Turbine Oil Specification
[1].
A certain amount of foaming on the surface
of the oil in the main oil tank can be
expected as a result of air release. If the
turbine oil shows an increased foaming
tendency and high foam stability, the space
above the oil level in the main oil tank
becomes partially or completely filled with
foam which can, under certain
circumstances, result in foam being released
from the oil system. Turbine oil is entrained
with the foam, resulting in a drop in the oil
level in the main oil tank. This change in the
level can cause activation of the level
monitoring equipment for the main oil tank.
Increased turbine oil foaming tendency
occasionally occurs due to high water
content or increased dust contamination of
the turbine oil.
Silicone-based foam inhibiting additives
have an adverse effect on air release
properties. There is no generally binding
evidence regarding any further correlation
between foaming tendency and air release
properties, although such a correlation may
exist in individual cases and should be
investigated.
Turbine oil care program
Owing to correlation between the turbine oil
properties and the factors influencing turbine
oil during operation, the following care
program for turbine oil must be implemented
during and after initial startup of the turbine
generator set:

Regular inspection of turbine oil samples

Continuous treatment of the turbine oil

Protection of the turbine oil system from
the effects of contaminants

Drainage of the turbine oil and cleaning
of the oil system and the turbine oil
during inspections and overhauls.
Inspection of turbine oil samples
By regularly sampling and inspecting turbine
oil and by evaluating the results, it is
possible to adapt oil care measures
optimally to the particular properties of the
turbine oil being used.
Turbine oil samples are taken
simultaneously upstream and downstream
of the oil centrifuge and the inspection
results thus permit an evaluation of the
efficiency of the relevant oil care measures.
The scope and the intervals for turbine oil
inspections are listed in the turbine oil
maintenance instruction.
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If the turbine oil inspections reveal that
alarm levels for certain properties have been
reached or exceeded, it is advisable to
request inspection and evaluation of the
turbine oil by the turbine oil supplier. All data
relevant to turbine oil inspection should be
sent in together with the turbine oil sample
When taking turbine oil samples, care must
be taken to ensure that sampling bottles are
clean.
In case of deviation in properties, actions to
be taken as per table 1.
Treatment of the turbine oil in the oil
filters or strainers of the operating oil
systems

Switchable oil filters
The switchable oil filters of the operating
oil systems are used to protect
downstream consumers. Contaminants
which, because of their size or
consistency, can cause damage and/or
impair functioning are retained in the oil
filters. Because of their relatively large
mesh size, the operating oil filters are
not suitable for complete removal of
contaminants from the turbine oil. The
differential pressure across the oil filters
is monitored.
If the differential pressure across an oil
filter increases, this filter should be
isolated from the system and cleaned.

Oil Strainers of the main oil tank
The oil strainers of the main oil tank
have a relatively large mesh size and
are used to retain contaminants in the
returning turbine oil and to protect the oil
pumps from contaminant damage.
If the strainer mesh becomes clogged
during the course of operation, this can
lead to a drop in the level in the suction
space of the main oil tank as a result of
an increase in the level in the riser
space.
For this reason, the oil strainers of the
main oil tank must be regularly cleaned,
if possible while the oil pumps are shut
down. Metal particles in the oil strainers
can be an indication of bearing damage
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or wear to parts such as oil pump seal
ring, etc.
Treatment of the turbine oil in the oil
centrifuge
The oil centrifuge can be continuously
operated independent of the operating oil
systems. A small volume of turbine oil is fed
through oil centrifuge with a high separation
efficiency. This achieves a high degree of
purity for the treated turbine oil.
As regards the treatment of turbine oil in the
centrifuge, oil filter, dynamic or static
separators, and multipurpose oil purification
units can be used either independently or in
combination. In addition, many power plants
have centralised oil purification equipment,
either permanently installed or mobile.
The function of the most commonly used oil
purification equipment is described below:

Fine-mesh filter
The turbine oil can be conditioned in an
oil filter with filter elements made of fine-
pored cloth or filter paper. Since the fine-
mesh filter has a high separation
efficiency, a high degree of turbine oil
purity can be achieved. Contaminants
insoluble in oil which ingress into the oil
system from outside, as well as products
of system-internal aging and corrosion
mechanisms are almost completely
removed from turbine oil.
Fine-mesh filters with cloth or paper
elements can also retain small amounts
of water. If the turbine oil has a high
water content, a dynamic or static
separator must be used to reduce the
water content in the turbine oil to the
value stipulated in the Turbine Oil
Specification [1].

Dynamic separator
The dynamic separator uses centrifugal
force to remove either solid or liquid
contaminants as required from the
turbine oil. The dynamic separator must
be set to operate in either solid
contaminant or water separation mode
in accordance with the manufacturer’s
instructions.

Static separator
A static separator is used to remove
water from the turbine oil. Since the
efficiency of the filter elements
deteriorates due to deposits of solid
contaminants, and in view of the
expense of filter elements, it is
recommended that the static separator
be used in conjunction with an upstream
fine mesh filter.

Multipurpose oil purification unit
The multipurpose oil purification unit is
used to remove solid and liquid
contaminants from the turbine oil.
Operation and maintenance instructions of
the oil purification unit manufacturer must be
complied with.
The maintenance interval for oil filters
depends on the differential pressure across
the oil filters. For this reason, the differential
pressure instrumentation must be regularly
checked and corresponding annunciations
noted.
Cleaning of the oil system during
inspections and overhauls
Over the course of time, solid contaminants
settle in areas of the oil system not
subjected to high flow velocities, e.g. the
main oil tank. For this reason, the turbine oil
must be drained via filters during inspections
and overhauls, and the main oil tank, the oil
coolers and the bearing pedestals must be
thoroughly cleaned. The drained turbine oil
must either be refilled into the main oil tank
via fine-mesh filters or treated in a
centralised oil purification unit before
refilling.
Measures to protect the oil system from
contaminant ingress
Just as important as turbine oil care are
measures designed to protect the oil system
from contaminant ingress:

Turbine oil
Problems can arise as a result of the
incompatibility of turbine oils from
different manufacturers and containing
different additive packages. For this
reason, when topping up, turbine oil
which has the same product designation
and which is supplied by the same
manufacturer as was originally filled,
should be used.

Hydraulic oil
Hydraulic oil or control fluid containing
phosphoric esters, if in use, must not be
allowed to ingress into the oil system.

Main oil tank
Openings in the main oil tank must
always be closed and sealed in such a
way that there can be no ingress of
contaminants into the main oil tank. The
cover plates of the main oil tank must be
tightly bolted. There must be no bolts
missing from the plates.

Oil coolers
If the water content of the turbine oil
increases, the leak tightness of the
operating oil cooler must be checked.

Oil return lines
Inspection holes in oil return lines must
be sealed to prevent the ingress of
contaminants into the oil system.

Oil vapor extraction system
The throttle check valves in the oil vapor
extraction system must be set so that
the pressure in the bearing pedestals
and the main oil tank is slightly sub
atmospheric. This ensures that no
leakage steam, or airborne water and/or
dust is drawn into the oil system in the
event of turbine oil or oil vapor being
released to the atmosphere.

Dirty fluid
Fluid from the dirty-fluid tank must not
be refilled into the main oil tank without
thorough inspection and treatment.
Small amounts of turbine oil which
accumulate in the dirty-fluid tank are to
be disposed properly.
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Material
The compatibility of materials with the
turbine oil has been taken into account
by the turbine manufacturer during
materials selection. During inspections
and overhauls, care must be taken to
ensure that no incompatible materials
are used. This applies particularly to
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gaskets and silicone-based seal
materials.

Leakage steam system
The butterfly valves of the leakage
steam system must be set to prevent
leakage steam from escaping via the
turbine shaft seals since this could result
in water ingress into the oil system.
Also refer to the following sections:
[1] 2-0400 : Oil Specification
Table1 : Actions to be taken when actual conditions deviate from reference conditions
Fault

Boundary conditions
The Turbine oil properties
do not comply with the
Turbine Oil Specification

Total-acid number
> mg KOH/g
Cause Actions
Turbine oil aging Inspect turbine oil samples for:
- Solid contaminant content
- Purity
- Water content
- Air release properties
- Foaming
- Other physical and chemical
properties
Send further oil samples to
turbine oil supplier for inspection
and evaluation. Check operating
performance and condition of
components supplied with
turbine oil, in order to determine
the effect of the change in total-
acid number. Check oil
purification system and intensify
turbine oil maintenance in
accordance with the
recommendations of the turbine
oil supplier and the turbine
manufacturer:
- Keep oil centrifuge in
continuous operation
- Adjust operation of oil
centrifuge to contaminant
content of turbine oil (solid
contaminants or water)
- If necessary install additional
oil purification equipment
- Take turbine oil samples
upstream and downstream
of oil centrifuge and check
separation efficiency (solid
contaminants and/or water)
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Fault

Boundary conditions

The solid contaminant
content or the purity of the
turbine oil does not comply
with the Specification
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Cause Actions
- Reduce intervals for turbine
oil inspections and monitor
evaluation of total-acid
number
Investigate the origin of
contaminants and prevent
contaminant ingress into oil
system.
The oil centrifuge is not in Put oil centrifuge into operation.
operation
The contaminant separation Take turbine oil samples
efficiency of the oil centrifuge upstream and downstream of
does not comply with the the oil centrifuge and determine
requirements the separation efficiency.
Implement measures in
accordance with the operating
unit manufacturer, in order to
improve contaminant separation
efficiency.
Check oil filter cartridges or
elements, replace damaged oil
filter cartridges or elements.
If necessary, vent the oil filters.
Solid contaminants ingress Check whether and at what
into the oil system point it is possible for air borne
contaminants to ingress into the
oil system.
Check atmospheric pressure in
the main oil tank, the bearing
pedestals and the oil return lines
and, if necessary, correct using
the check valves in the oil vapor
extraction lines.
If necessary, close or reseal the
maintenance covers of the main
oil tank.
High air borne dust content in Reduce airborne dust content in
area around turbine generator area around turbine generator
set set
Fault

Boundary conditions

The water content of the
turbine oil does not comply
with the specification
Cause
There is no permanently
installed dynamic or static
separator for removing water
from the turbine oil
The permanently installed
dynamic separator of the oil
conditioning system is not in
operation
Water is ingressing into the oil
system
Actions
Install a dynamic or static
separator for removing water
form the turbine oil. Take turbine
oil samples upstream and
downstream of the separator
and check water separation
efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
Put dynamic separator of the
centrifuge into the operation.
Note that the required
separation temperature must be
complied with in accordance
with the operating instructions of
the separator manufacturer, and
that the separator must be
protected from the effects of
solid contaminants.
Take turbine oil samples
upstream and downstream of
the separator and check water
separation efficiency.
If necessary, implement
measures in accordance with
the operating instructions of the
separator manufacturer, in order
to improve water separation
efficiency.
Check whether leakage steam is
ingressing into the oil system.
If necessary, prevent the escape
of leakage steam from the
steam seals by the correcting
the seal steam pressure or by
adjusting the butterfly valves in
the seal steam lines.
Check the leak tightness of the
operating oil cooler.
4-1210-01/9
Fault Cause Actions

Boundary conditions

The air release properties In many cases, there is no Check whether the deterioration
of the oil do not comply specific cause for a in air release properties has an
with the Specification deterioration in air release adverse affect on the operating
properties performance of the systems of
components supplied with
turbine oil.
Involve oil supplier and turbine
manufacturer in inspection
program. If effects are
particularly unfavorable,
consider replacing the turbine
oil.
As a precautionary measure,
care should always be taken to
prevent the ingress into the
turbine oil of materials which
could adversely affect the air
release properties (e.g. silicone-
based materials)

Turbine oil foaming The foam inhibiting additives in Consult oil supplier and top up
characteristics do not the turbine oil have been turbine oil with foam inhibiting
comply with the depleted over time additives.
Specification
As a rule, foam inhibiting
additives have an adverse effect
on the air release properties and
for this reason, the air release
properties must be closely
monitored when topping up with
such additives.

The turbine oil contains Determine the water content of

materials which adversely the turbine oil and, if necessary,
affect the foaming take appropriate measures to
characteristics reduce this. In certain
circumstances it may be
advisable to skim off the foam
from the surface of the turbine
oil.

4-1210-01/10
Fault Cause Actions

Boundary conditions
The oil centrifuge is
defective or the operating
conditions for the oil do not
comply with the
requirements

Oil filters
The differential pressure Isolate duplex oil filter and clean
across one oil filter is high filter cartridge
Take oil centrifuge filters out of
operation and replace filter
elements

One oil filter is not sufficiently Open valve in oil filter venting
vented line and adjust

Unit-specific or additional
dynamic separator
The mode of operation of the
dynamic separator does not
correspond to the content of
solid or liquid contaminants in
the turbine oil
Adapt the mode of operation of
the separator (solid-contaminant
separation or water separation)
according to the content of solid
contaminants or water in the
turbine oil

Unit-specific or additional The efficiency of the static Replace filter elements.

static separator
separator is reduced due to
Implement measures to prevent
clogged filter elements
filter element clogging. e.g.
install an upstream fine-mesh
filter.

Turbine oil temperature If necessary, put heating system

Oil circulating pump (if
installed)
upstream of static separator
too low
The oil circulating pump of the
oil centrifuge is not in
operation
of oil centrifuge into operation
If necessary, put oil circulating
pump into operation

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