warren scott - viva energy australia - trials and results for a new gas turbine oil

14/01/2016 Shell trademarks used under licence

Innovative Lubricating

Solution For Gas Turbines

Gas Turbine Users Forum

Sydney

November 25 2015

Warren Scott- Lubricants Specialist

24/01/2016Copyright of Shell Lubricants

TODAY’S TURBINES HAVE TO WORK HARDER

THAN EVER BEFORE

Affects the turbine oil

Increased operating temperatures drive

requirements for greater component protection

Turbine sump volumes are shrinking in size while handling the same or

increased power

Greater demand for less downtime, extended oil-

drain intervals and efficiency improvements

Environmental legislation continuously driving towards lower

emission levels

Increased pressure on gearboxes

Cyclic operating conditions are placing

more stresses on turbines

2


OIL STRESS HAS INCREASED BY 400% AND

OPERATING TEMPERATURES ARE HIGHER

3

Increasing oil stress and operating temperatures*

8C GE fr 5 GE fr 6A GE fr 6B GE fr 9E

80

70

60

50

40

30

20

10

0

12

0

10

8

6

4

2

Oil stress index, MW m-3 Oil temperature, °C

Oil

stre

ss in

dex

, MW

m-3

Oil

tem

per

atu

re, °

C

*Shell calculation based on publically available data

44/01/2016

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

..Shell Turbo


WHY THE LUBRICANT IS IMPORTANT –

EFFICIENCY

Deposit build-up on metal surfaces

64/01/2016

Why the lubricant is important – efficiency

• Turbine system efficiency is affected by

..Shell Turbo

The formation of

emulsions

Excessive foam in the

turbine reservoir

Deposit build-up on

metal surfaces

74/01/2016

TYPICAL TURBINE OIL COMPOSITION

R&O

Additive

System

< 1-2%

Base Oil

98-99%

Antioxidants

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 – < 120II All-Hydro-processing ≤ 0.03 & ≥ 90 ≥ 80 – < 120III All-Hydro-processing ≤ 0.03 & ≥ 90 ≥ 120IV Synthetic Poly-Alpha-Olefins (PAO)

V Other Base Oils Not Group I, II, III or IV


GAS-TO-LIQUIDS (GTL) BASE OIL

TECHNOLOGY

•Catalytic process converting gas to oil products

8

API group III+ base oil

Primarily iso-paraffinic, no impurities, excellent antioxidant response, surface properties, narrow molecular distribution

GTL base oil


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

9


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

10

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


DEPOSIT FORMATION TENDENCY – ASTM D7873

DRY TURBINE OIL STABILITY TEST (DRY TOST)

11

Testing based on commercially obtained samples

0

200

400

600

800

1000

Turbo S4 Oil A Oil B Oil C Oil D Oil E

Slu

dg

e, m

g/k

g

Dry TOST Evaluation at 1008 hrs (D7873)

4000

5000

Bet

ter

Pe

rfo

rman

ce

GtL-based Oil


Static Oven = 180ºC (356ºF)Test Time = 48 hoursAir Flow = NoneMetal Catalysts = None

Measurable:

– Sludge, mg/kg

– Volatility of base oil and formulation

OXIDATION STABILITY AND DEPOSIT CONTROL

MAN-LTAT (LUBRICANT TEMPERATURE AGING TEST) AT 180°C

12

This thermal stability test assesses the oil’s short term deposit resistance whenexposed to very high temperatures.

The test result indicates the oil’s resistance against sludge formation and is key toobtaining MAN Turbo approval.

The lower the sludge levels in the oil at the end of test the better the performance.


PREVENTING CRITICAL COMPONENT FAILURE &

UNPLANNED SHUTDOWNS

13Shell Turbo

• 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.

GtL-based oil performs much better than other oils

tested in the MAN-LTAT oxidation test (beaker test)

0

500

1,000

1,500

2,000

Shell TurboS4

Oil A Oil B Oil C Oil D Oil E

Slu

dge

, mg

MAN-LTAT oxidation test (beaker test) at 180°C*

*Source: Shell test data

GtL-based Oil

Bet

ter

Pe

rfo

rman

ce

144/01/2016

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


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


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

18


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

1904 January 2016Shell Turbo

204/01/2016

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

. .

214/01/2016

SHELL TURBO S4 SERIES: FIELD EXPERIENCE TO

DATE

224/01/2016

Current Usage of Turbo S4 X 32 & S4 X46 Shell Turbo S4 X 32 Location Equipment Start Notes

Shell Technology Centre Houston USA Solar Taurus C 60 GT Since 2012

Drain and fill

Dominion Energy USA GE Frame 7 FA GT Since 2013 Replace Texaco GT 32 – drain and fill

Shell Canada Scotford Canada Elliott PAP Compressors x 5 Since 2014

Replace Turbo SG 32 – drain and fill

Shell Canada Scotford Canada Sundyne Compressor x2 Since 2014

Replace Turbo SG 32 – drain and fill

Spectra Energy USA Solar Centaur GT Since 2015 New start-up

Empire District Energy USA

Siemens-Westinghouse 1426RT2 Steam Turbine Since 2015

Conversion from Mobil DTE 732

234/01/2016

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

Drain and fill

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

Samsung (EPC)Saudi-Arabia MAN Turbo-

CompressorSince 2015

Initial fill new project

244/01/2016

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

254/01/2016

warren scott - viva energy australia - trials and results for a new gas turbine oil

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