Innovative Lubricating
Solution For Gas Turbines
Gas Turbine Users Forum
Sydney
November 25 2015
Warren Scott- Lubricants Specialist
4/01/2016 Shell trademarks used under licence
1
TODAYS TURBINES HAVE TO WORK HARDER
THAN EVER BEFORE
Greater demand for less Environmental
downtime, extended oil- legislation continuously
drain intervals and driving towards lower
efficiency improvements emission levels
Turbine sump volumes are Increased operating
shrinking in size while Affects the temperatures drive
handling the same or
increased power
turbine oil requirements for greater
component protection
Cyclic operating
conditions are placing Increased pressure on
more stresses on gearboxes
turbines
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OIL STRESS HAS INCREASED BY 400% AND
OPERATING TEMPERATURES ARE HIGHER
Increasing oil stress and operating temperatures*
12 80
70
10
60
Oil stress index, MW m-3
Oil temperature, C
50
6 40
30
4
20
2
10
0 0
8C GE fr 5 GE fr 6A GE fr 6B GE fr 9E
Oil stress index, MW m-3 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 . .4
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 Excessive foam in the The formation of
metal surfaces turbine reservoir emulsions
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Shell Turbo . .6
TYPICAL TURBINE OIL COMPOSITION
Base Oil
98-99%
Antioxidants
R&O
Additive
System Rust Inhibitor
< 1-2% Corrosion Inhibitor
Others *
Turbine oil additive system
* Defoamer, demulsifier, AW/EP additives (where required)
Group Typical Process Route Sulphur (Wt %) Saturates Viscosity Index
(Vol %)
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 Poly-Alpha-Olefins (PAO)
V Other Base Oils Not Group I, II, III or IV
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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 high-
efficiency 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 120C (248F)
Copper and steel catalyst
Evaluate the sample at 1008 hrs
Assesses the sludge tendency by
measuring
insoluble oxidation products and RPVOT
retention
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DEPOSIT FORMATION TENDENCY ASTM D7873
DRY TURBINE OIL STABILITY TEST (DRY TOST)
1000
5000 Dry TOST Evaluation at 1008 hrs (D7873)
800
4000
Better Performance
Sludge, mg/kg
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 180C
Static Oven = 180C (356F)
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 oils short term deposit resistance when
exposed to very high temperatures.
The test result indicates the oils 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.
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PREVENTING CRITICAL COMPONENT FAILURE &
UNPLANNED SHUTDOWNS
The long-term resistance to formation of sludge and varnish deposits of GtL-
based 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 180C*
2,000
Better Performance
1,500
Sludge, mg
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 Oil A Oil B Oil C Oil D Oil E
S4
*Source: Shell test data
Copyright of Shell Lubricants Shell Turbo 13
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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
Copyright of Shell Lubricants
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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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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 Notes
Shell Technology Drain and fill
Centre Houston USA Solar Taurus C 60 GT Since 2012
Dominion Energy USA GE Frame 7 FA GT Since 2013 Replace Texaco GT 32
drain and fill
Shell Canada Replace Turbo SG 32
Scotford Canada Elliott PAP Compressors x 5 Since 2014 drain and fill
Shell Canada Replace Turbo SG 32
Scotford Canada Sundyne Compressor x2 Since 2014 drain and fill
Spectra Energy USA Solar Centaur GT Since 2015 New start-up
Empire District Siemens-Westinghouse Conversion from
Energy USA 1426RT2 Steam Turbine Since 2015 Mobil DTE 732
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Current Usage of Turbo S4 GX 32/46
Shell Turbo S4 GX Location Equipment Start Notes
ABB V32A Steam Drain and fill
Stadtwerke Rostock Germany 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
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
Saudi- Initial fill new
Samsung (EPC) Arabia MAN Turbo- Since 2015 project
Compressor
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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)
Shell Global Solutions International B.V,; 2015, All rights reserved
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