Afton Chemical's Microbotz Turbine Guide Sample Content

INDUSTRIAL

TURBINE

TURBINE

TURBINE

ASIA PACIFIC Afton Chemical Asia Pte. Ltd. 111 Somerset Road #09-05 TripleOne Somerset Singapore 238164 T: +65 6732-0822 F: +65 6737-4123

EMEAI Afton Chemical Limited London Road, Bracknell Berkshire RG12 2UW England T: +44 1344 304-141 F: +44 1344 420-666

LATIN AMERICA Afton Chemical Industria de Aditivos LTDA Avenida Rio de Janeiro 901 (Parte) CEP-20931-675 Brazil T: +55 21 3295-4050 F: +55 21 2580-8647 & 2589-0531

NORTH AMERICA Afton Chemical Corporation 500 Spring Street Richmond VA 23219 USA T: +1 804-788-5800 F: +1 804-788-5184

A comprehensive guide to INDUSTRIAL TURBINE LUBRICANTS

TURBINE

www.aftonmicrobotz.com ©2013. Afton Chemical Corporation is a wholly owned subsidiary of NewMarket Corporation (NYSE:NEU).

AFTON®, HiTEC®, Microbotz™ and Passion for Solutions® are trademarks owned by Afton Chemical Corporation.

08/13

CONTENTS

Introduction

4 Turbine Market ANALYSIS

6

ndustrial Turbine 1 IApplications • • • • •

istory of industrial turbines H 9 Types of turbine 10 What are turbines used for?

11 Turbine manufacturers – at-a-glance 14 How turbines work – the basics:

15 gas, steam, combined cycle operation 18 • How turbines work – the details: turbine components, lubrication and control systems, gears Challenges for turbine operators 22 • • Turbine lubricants: 24 A brief introduction

2 Turbine Lubrication Needs

• What do turbine lubricants do?

• What role do additives play?

• Lubrication system design and components • Turbine lubricants in-service: • Typical in-service lubricant requirements • In-service oil condition monitoring • Solving persistent lubricant problems • Introduction to lubricant classifications

ey Turbine lubricant 5 KTests explained

27 28 30

• Description of key tests 69 • Specification cross reference tables 74

The Afton Industrial 6 Turbine, Circulating and

34 34

Compressor Portfolio

34 36

• Turbine & circulating range • Compressor range • Portfolio overview by market segment • Turbine & circulating product benefits • Compressor product benefits • Market segment overview • Applications, standards and specification overview – at-a-glance

37

Major OEMs and 3 Equipment Builders • • • • • • • • •

verview of key turbine OEMs O Alstom SA Bharat Heavy Electricals Ltd (BHEL) Dongfang Electric Corporation (DEC) General Electric (GE) MAN Diesel & Turbo Mitsubishi Heavy Industries (MHI) Shanghai Electric Group Co. Siemens

• Global

power generation 61 • Global power generation to 61 2035 by geographic region • Global power generation 62 2013 and 2035 by turbine type • Global OEM-reported new turbine 62 orders 2012 by turbine type and geographic region • Market trends in gas and steam 63 turbine equipment • Impact of key trends on 64 turbine lubrication • Drive for efficiency 64 • Base oil choice 64 • Field vs. lab lubricant performance 65 • Lubricant market segmentation 66

41 42 44 46 48 50 52 54 56

7 Appendices • • • •

5

Turbine dictionary Turbine acronyms Base stocks explained Base stock comparisons

79 80 80 82 87 88 88

93 95 96 98

INTRODUCTION Afton Chemical is a leading global supplier of industrial lubricant additive packages.

The Afton Industrial portfolio covers a broad range of industrial lubricant additives, including additive packages developed for Wind Turbine, Industrial Gear, Turbine, Hydraulic, Grease and Slideway applications.

WIND TURBINE

INDUSTRIAL GEAR

TURBINE

HYDRAULIC

GREASE

SLIDEWAY

COLOR CODING FOR APPLICATION GROUPS

This guide focuses on industrial turbine applications. It covers the different types of industrial turbines and how they work, market trends in hardware and lubricants as well as the additives and specifications for turbine oils. It also presents the Afton Industrial Portfolio.

It aims to be a useful reference guide for our customers, our distributors, the OEMs and our internal staff. This guide is the first in a series of guides from Afton Industrial and forms part of a limited edition collectible box set of guides to industrial lubricants.

We hope you will find them interesting and informative!

The Afton Industrial Team, August 2013

6

1

INDUSTRIAL TURBINE APPLICATIONS

History of

Industrial

Turbines

From man’s earliest attempts – the waterwheels used to drive grinding mills in Roman times – to today’s sophisticated hydro, steam or gas turbine equipment costing millions, all turbines serve the same function: to extract kinetic energy from a moving fluid (gas or liquid) and convert it into mechanical energy.

The Industrial Revolution’s advances in engineering, hydraulics and precision manufacturing made modern turbines possible.

Sir Charles Parsons is credited with inventing the steam turbine in the late 19th century. His first prototype generated less than 10 kilowatts of electricity but produced it cheaply, which totally revolutionized marine transport and power generation.

In 1897 Turbinia was the first steam turbine powered ship: George Westinghouse licensed Parsons steam turbine patent in the US and quickly scaled it up. Parsons lived long enough to see turbines generating up to 50,000 kilowatts of power being used all over the world.

9

Turbine Lubrication Needs 2

B. Industrial applications Turbines power all kinds of industrial machinery (like pumps and compressors) for a wide range of applications:

OIL RIGS OIL REFINERIES

MARINE PROPULSION

DESALINATION

OIL & GAS PIPELINES

GAS & STEAM TURBINES

WASTE INCINERATION

CHEMICAL PLANT

SUGAR PROCESSING

PULP & PAPER

13

Key Turbine Lubricant Tests Explained

5

Description of

key tests

Rotating Pressurized Vessel Oxidation Test (RPVOT) RPVOT measures the oxidation stability of a turbine lubricant with typical test methods including ASTM D2272 and IP 229.

The oil sample is placed, in the presence of water and a copper catalyst, in a vessel that is pressurized to 90 psi with oxygen. The vessel is then rotated in a heated bath (an oil or dry bath is suitable) to hold its temperature at 150°C. Pressure inside the vessel rises to 180-200 psi. As the lubricant oxidizes, it consumes oxygen and reduces the vessel’s pressure. The time in minutes taken for the pressure to drop by 25 psi (or other agreed amount) is the measure of oxidation stability.

Typical requirements are for a minimum of 300 minutes, with some OEM specifications and standards requiring over 750 minutes. In general, higher results indicate a lower tendency to oxidation and potentially a longer oil service life. Specifications requiring the longest RPVOT performance are usually more demanding higher temperature gas turbine specifications.

Some specifications require a “Modified RPVOT” using a lubricant sample that has been purged with nitrogen, to remove any volatile components including potential antioxidants prior to testing.

A result of 85% or more of the standard result is commonly required, with results in this range showing minimal depletion in antioxidant performance.

69

Rpvot Test Apparatus (Dry Bath)

THE AFTON INDUSTRIAL TURBINE, CIRCULATING AND COMPRESSOR PORTFOLIO

6

Turbine and

circulating range Afton Industrial offers a complete turbine additive package portfolio.

From best-in-class top tier turbine additives to entry tier turbine and circulating oil products with proven field performance, our advanced additive technology: • Extends the life of turbines and turbine oils • Helps minimize lifecycle costs • Improves reliability and operating efficiency for end users.

Focus on deposit control Internationally acknowledged as being at the forefront of understanding sludge and varnish formation, Afton Industrial’s extensive research and testing programs have led to the development of market-leading solutions to control deposit formation, the single most important issue facing turbine end-users today.

Our Top Tier premium ashless turbine product, hiTec® 2505, is the best in class product in the market today for sludge and varnish control.

Afton Industrial’s broad turbine experience promotes a balanced formulation approach, addressing oxidation and deposit control, water separation, and controlling foam and air release.

Our specially developed fluid aging system ensures our additives retain excellent air and water separation capability throughout the fluid lifetime.

Future proofing turbine oils Deep involvement with turbine OEMs, testing and standards organizations allows Afton to stay ahead of the curve; our solutions are designed to

79

meet future challenges, not just the latest trends and specifications.

Working closely with an Independent Power Producer, oil companies and OEMs gives us access to field demonstration sites and enables applications experience with our technology in service. This keeps us abreast of end-user needs and contemporary fluid filtration and condition monitoring techniques.

APPENDICES

7

Turbine

dictionary Actuator (Hydraulic) A device for converting hydraulic fluid pressure into motion.

Additive Any material added to a base stock to change its properties, characteristics or performance.

Additive Package/Concentrate

Liquid composition containing a mixture of additives, added to a base oil to improve performance.

Adiabatic Compression When oil is subjected to very high pressures, for example in a bearing, entrained air bubbles are compressed and result in very high localised temperatures which can degrade the oil.

Air Release (Time) A measure of how quickly entrained gases are released from oil. Smaller values indicate a faster separation.

Antioxidant A molecule that inhibits the oxidation of other molecules, usually through removing or isolating free radical intermediates.

Anti-wear Additive that prevents wear by forming a protective (usually phosphorus) layer on the surface, preventing metal to metal contact and abrasion.

Base Stock The base fluid, usually a refined petroleum fraction or a selected synthetic material, into which additives are blended to produce finished lubricants.

Bleed and Feed The process of oil replenishment with the recommended lubricant that involves draining from a reservoir a portion of older lubricant volume to replace it with fresh lubricant in an effort to extend the overall fluid life without a complete draining and refilling of the reservoir.

BS

British Standard

Combined Cycle A configuration where the heat from a gas turbine exhaust gas is utilized to generate steam for a gas turbine.

Combustion Turbine

See Gas Turbine

Compressor A section on a gas turbine that compresses the inlet air to increase its pressure before combustion.

Corrosion Inhibitor Additive that protects lubricated metal surfaces from chemical attacks by water or contaminants.

Demulsibility

A lubricant’s ability to separate from water.

Deposit A general term referring to various types of precipitates, insolubles, film, or sediment that has settled out of a lubricating oil on machinery surfaces, including varnish and sludge.

Displacement Fluid

S ee Flush Fluid

Electrohydraulic Servo Valve

An electrically operated valve which controls how hydraulic fluid is ported to an actuator.

Electrostatic Arcing

See Electrostatic Spark Discharge

93

INDUSTRIAL

TURBINE

TURBINE

TURBINE

ASIA PACIFIC Afton Chemical Asia Pte. Ltd. 111 Somerset Road #09-05 TripleOne Somerset Singapore 238164 T: +65 6732-0822 F: +65 6737-4123

EMEAI Afton Chemical Limited London Road, Bracknell Berkshire RG12 2UW England T: +44 1344 304-141 F: +44 1344 420-666

LATIN AMERICA Afton Chemical Industria de Aditivos LTDA Avenida Rio de Janeiro 901 (Parte) CEP-20931-675 Brazil T: +55 21 3295-4050 F: +55 21 2580-8647 & 2589-0531

NORTH AMERICA Afton Chemical Corporation 500 Spring Street Richmond VA 23219 USA T: +1 804-788-5800 F: +1 804-788-5184

A comprehensive guide to INDUSTRIAL TURBINE LUBRICANTS

TURBINE

www.aftonmicrobotz.com ©2013. Afton Chemical Corporation is a wholly owned subsidiary of NewMarket Corporation (NYSE:NEU).

AFTON®, HiTEC®, Microbotz™ and Passion for Solutions® are trademarks owned by Afton Chemical Corporation.

08/13

INDUSTRIAL

TURBINE

TURBINE

TURBINE

ASIA PACIFIC Afton Chemical Asia Pte. Ltd. 111 Somerset Road #09-05 TripleOne Somerset Singapore 238164 T: +65 6732-0822 F: +65 6737-4123

EMEAI Afton Chemical Limited London Road, Bracknell Berkshire RG12 2UW England T: +44 1344 304-141 F: +44 1344 420-666

LATIN AMERICA Afton Chemical Industria de Aditivos LTDA Avenida Rio de Janeiro 901 (Parte) CEP-20931-675 Brazil T: +55 21 3295-4050 F: +55 21 2580-8647 & 2589-0531

NORTH AMERICA Afton Chemical Corporation 500 Spring Street Richmond VA 23219 USA T: +1 804-788-5800 F: +1 804-788-5184

A comprehensive guide to INDUSTRIAL TURBINE LUBRICANTS

TURBINE

www.aftonmicrobotz.com ©2013. Afton Chemical Corporation is a wholly owned subsidiary of NewMarket Corporation (NYSE:NEU).

AFTON®, HiTEC®, Microbotz™ and Passion for Solutions® are trademarks owned by Afton Chemical Corporation.

08/13