TACKLING VARNISH

FORMATION IN
TURBOMACHINERY
MAXIMISE TURBINE AND COMPRESSOR AVAILABILITY
WHITE PAPER
Dr Felix Guerzoni, Shell Lubricants

SHELL LUBRICANTS
TOGETHER ANYTHING IS POSSIBLE

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TECHNICAL BROCHURE JUNE 2018

Turbomachinery operators in the power generation, oil, gas and petrochemical industries
are seeking ways to reduce their total cost of ownership and maintenance costs by
maximising asset availability and reliability.

In addition, driven by the goals of reducing To achieve higher operating efficiencies,

emissions and improving efficiency in equipment designs are changing. For
the power generation sector, many older example, turbines operate at higher
coal-fired power plants are being retired temperatures and have a smaller footprint
and replaced with higher-efficiency, and lower-volume lubricant oil reservoirs.
lower-emission, combined-cycle and gas Meanwhile, operators are seeking longer
turbine power plants. Such generating oil and asset life with less downtime.
capacity is more commonly being used in However, these operating and equipment
peaking or cycling duty rather than base- design changes place additional oxidative
load generation, which is because the and thermal stress on turbine oil that
increased thermal cycling of the oil and can result in premature ageing and
the reduced oil flows and low-temperature degradation. The formation of oil-soluble
conditions in key components such as inlet and oil-insoluble degradation products,
guide vanes lead to a higher incidence of also referred to as varnish or deposits,
varnish formation. can lead to operational problems and
associated unplanned downtime.

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 TECHNICAL BROCHURE JUNE 2018

UNDERSTANDING AND CONTROLLING THE RATE AT WHICH TURBINE OILS

DEGRADE AND DEALING WITH THE BY-PRODUCTS FORMED ARE VITAL FOR
MAXIMISING TURBOMACHINERY AVAILABILITY.

WHAT IS VARNISH? As turbine oils degrade in response to Temperature plays a significant role. As
the effects of high, and in many cases the operating temperature increases, it
All turbine oils, whether mineral or
variable, temperatures and/or loads, raises the rate of oxidation and thermal
synthetic based, are composed of
and external and internally generated degradation of the turbine oil, which
hydrocarbons that degrade over time.
contaminants and wear debris, a diverse means that sludge and varnish form more
Understanding and controlling the rate
range of organic hydrocarbon species rapidly at higher temperatures. As a
at which these oils degrade and dealing
may form. These hydrocarbon species general rule of thumb, the Arrhenius rate
with the by-products formed are vital for
originate from degraded base oil or law states that for every 10°C increase in
maximising turbomachinery availability.
additives such as antioxidants and will temperature, the oxidation rate doubles.
Shell scientists have this in mind when
initially be soluble in the oil, for example,
formulating turbine oils to provide Further, the solubility of the oxidation
they may contribute to an increase in
increased resistance to the formation and varnish precursors in the oil is
total acid number (TAN). Over time,
of varnish in service. Shell field-based also temperature dependent. Some oil
however, they develop into insoluble,
technical staff also understand these oil degradation species may be soluble in
polar compounds that then precipitate
degradation pathways when they work the oil at above 55°C, yet insoluble at
out on surfaces such as journal and thrust
with operators on product selection, lower temperatures and fall out of solution.
bearings, servo valves, filters and auxiliary
application and ongoing monitoring. Consider the analogy of dissolving sugar
gear sets, or in the lubricant oil reservoir as
in a hot cup of coffee: while the coffee
varnish or deposits (Figure 1). The resultant
is hot, you can dissolve more and more
varnish can disrupt heat transfer and thus
sugar until it reaches a certain point
lead to increased bearing temperatures,
(becomes saturated) and the temperature
less-responsive servo valves, for example,
falls, then the sugar drops to the bottom of
inlet guide vane valves, and plugged
the cup.
filters, which can cause unplanned
downtime and lower productivity.

Figure 1: Progressive oxidative degradation.

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TECHNICAL BROCHURE JUNE 2018

THE INDUSTRY CONTINUES TO DEVELOP TEST PROCEDURES THAT SIMULATE

BETTER THE PROPENSITY OF AN OIL TO FORM VARNISH IN SERVICE.

VARNISH FORMATION n Siemens: Proactive turbine oil condition Test procedures such as the turbine oil
DRIVING MORE-DEMANDING monitoring and varnish prevention oxidation stability test (TOST) life test
SPECIFICATIONS (E50001-D510-A209-X-7600, 2011) (ASTM D943) and rotating pressure vessel
n MAN Diesel & Turbo: Turbine oxidation test (RPVOT, ASTM D 2272)
The topic of varnish and deposit formation
oils: Tendencies to form deposits provide an indication of a turbine oil’s
in turbine oils, and indeed other lubricants,
and varnishing as well as resulting oxidation resistance. However, they do
is not new and, as the design and ways
recommendations and measures (TMC not address the oil’s propensity to form
of operating turbomachinery change,
15-4338). varnish. As a result, more demanding tests
these oils face increasing levels of stress
such as the dry TOST test (ASTM D7873),
that can lead to the earlier-than-expected GE Power stated in TIL 1528-3 that as many the MAN Turbo & Diesel lubricant
onset of varnish formation. In response, as 33% of the (then installed) F-class turbine temperature ageing test and the Engie
equipment manufacturers have developed fleet show some signs of oil varnishing. (Laborelec) cyclic turbine oil oxidation
more-stringent lubricant specifications and
Table 1 provides a summary of test are now being used to validate and
monitoring practices.
some recent advances in turbine oil approve lubricants, and to differentiate
The industry continues to develop test specifications from industry bodies and turbine oil performance.
procedures that simulate better the leading equipment manufacturers in
propensity of an oil to form varnish in response to issues with varnish formation
service. Several service bulletins on this and reduced oil service life.
topic have been released, including
n GE Power: Lube oil varnishing (Technical
Information Letter TIL 1528-3, November
2005)

OEM SPECIFICATION HIGHER PERFORMANCE SPECIFICATION

Siemens TLV 901304 – Turbine oils with normal TLV 901305 – Turbine oils with higher thermal stability
thermal stability RPVOT added

GE Power GEK 28143A – Recommendations for gas GEK 32568K – Gas turbines with high bearing ambient
turbines Increased RPVOT; TOST life increased

Mitsubishi Hitachi MS04-MA-CL002 – Lubricating oil MS04-MA-CL005 – Lubricating oil recommendations for high temperature
Power Systems recommendations for high temperature turbine application with bearing ambients above 250°C (long life type)
turbine application with bearing ambients Increased RPVOT and TOST life; stricter dry TOST requirements
above 250°C

MAN Turbo & Diesel TED 10000494596 – Quality TED 10000494596 – Quality requirements for lubricants
requirements for lubricants Increased RPVOT and TOST life; MAN LTAT stability test

DIN DIN 51515-1 – Lubricants and governor DIN 51515-2 – Lubricants and governor fluids for turbines – Part 2: L-TG for
fluids for turbines – Part 1: L-TD for normal higher temperature service
service Increased TOST Life; RPVOT

Table 1: Recent advances in turbine oil specifications from industry bodies and leading equipment manufacturers.

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 TECHNICAL BROCHURE JUNE 2018

CONTINUOUS INNOVATION IN Further improvements in performance Consequently, Shell Turbo S4 X 32

LUBRICANT TECHNOLOGY TO have been achieved with the introduction and Shell Turbo S4 GX 32 oils have
ADDRESS TURBINE OIL VARNISH of the advanced Shell Turbo S4 X and been classified as low varnishing type
Shell Turbo S4 GX turbine oil technology. turbine oils by GE Oil & Gas in its latest
Shell’s scientists have worked with leading
These grades use Shell gas-to-liquids specifications that cover turbine oils for
turbine manufacturers and end-users over
Group III base oils in combination with turbomachinery, including gas and steam
many years to understand the contributing
a specially developed additive system turbines, electric motors, generators and
factors to turbine oil varnish formation.
designed to extend oil life, reduce varnish axial and centrifugal compressors. Oils
The Shell Turbo oil family has been
and protect components. Tests in the classified as low varnishing type oils
developed using this understanding to
laboratory and in the field have shown demonstrate the lowest tendency to form
create a range of products that provide
that these products have a high resistance varnish and the highest performance in
protection and performance that match
to oxidation and thermal breakdown terms of oxidation and thermal stability.
customers’ requirements. Shell Turbo T
to minimise the formation of sludge Shell Turbo S4 X and Shell Turbo S4 GX
and Shell Turbo J oils demonstrate reliable
and varnish on critical turbine surfaces. have also been approved by MAN Turbo
performance in the areas of oxidation and
Figure 2 shows that Shell Turbo S4 X & Diesel, and Shell Turbo S4 X 32 has
thermal stability with their long TOST lives,
and Shell Turbo S4 GX oils, while also been approved by Mitsubishi Hitachi
high RPVOT values and low varnish forming
possessing excellent RPVOT and TOST life Power Systems as a long-life oil.
potential. As a result, these products offer
values, have significantly lower varnish
a level of performance and protection that Selecting an oil with lower varnish forming
formation potential than other commercially
gives customers peace of mind. tendency such as Shell Turbo S4 X and
available turbine oils of similar equipment
Shell Turbo S4 GX at the outset of a
manufacturers’ specification levels.
project can help to reduce the
possibility of varnish-related
trips and outages and production
deferment costs.

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

2,000

1,500
Sludge, mg

1,000

500

0
Shell Oil A Oil B Oil C Oil D Oil E
Turbo S4

Figure 2: The varnish formation potential of commercially available turbine oils of similar equipment manufacturers’ specification levels.

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TECHNICAL BROCHURE JUNE 2018

SEVERAL VARNISH REMOVAL TECHNOLOGIES HAVE DEMONSTRATED THEIR ABILITY TO

CONTROL THE RATE OF VARNISH FORMATION, INCLUDING ELECTROPHYSICAL SEPARATION,
ELECTROSTATIC TECHNOLOGY, BALANCED CHARGE AGGLOMERATION AND DEPTH FILTRATION.

IN-SERVICE STRATEGIES TO It is important for operators to understand In systems experiencing electrostatic

MINIMISE THE IMPACT OF what information each of these tests discharge, operators should look to
VARNISH provides and the necessary actions in use antistatic filter elements and ensure
response to any alarms flagged by looking adequate grounding of bearings and shafts.
In addition to selecting a low varnishing
potential oil such as Shell Turbo S4 X or at the entire dataset and trends over
Shell field staff are available to support
Shell Turbo S4 GX, a series of preventive time. Shell LubeAnalyst limits have been
customers in managing their oil changeout
maintenance measures can be employed aligned with the requirements from leading
requirements (refer to the Shell white paper,
to mitigate further against the risks of varnish equipment manufacturers. Shell’s technical
Maintaining your turbine oil to help extend
formation. One of the most effective is a specialists can provide the necessary
oil and component life).
detailed oil condition monitoring programme guidance to operators on how to design
and implement an effective turbine oil
such as the Shell LubeAnalyst CONCLUSION
advanced turbine oil monitoring monitoring programme though the Shell
LubeCoach and Shell LubeAdvisor Turbomachinery operators are seeking
service to determine the condition of the to reduce unplanned downtime and the
oil and the equipment. This service enables value-adding services.
incidence of trips that may be related to
operators to understand the condition of their Several varnish removal techniques varnish formation in service. By using a
oil in terms of have demonstrated field experience in combination of high-performance, low
n acid number formation by TAN controlling the rate of varnish formation, varnish formation potential oils such as
n antioxidant reserves using techniques including electrophysical separation, Shell Turbo S4 X and Shell Turbo
such as RULER or RPVOT electrostatic technology, balanced charge S4 GX and a preventive maintenance
n varnish formation potential by membrane
agglomeration and depth filtration. These strategy involving regular oil condition
patch colorimetry (MPC) can also be used in combination with monitoring, varnish removal techniques and
an effective oil changeout and flushing system flushing and cleaning procedures
n the presence of external contaminants
process to help in removing sludge and during oil changeover, operators can
or wear particles by inductively coupled
in‑service oils having a high varnish reduce their total cost of ownership and
plasma optical emission spectrometry
formation potential before changing to an help to maximise equipment availability.
n cleanliness
oil with lower varnish potential.
n other key properties, including foaming
tendency, air release and water
shedding characteristics.

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BIBLIOGRAPHY (6) GE Power: Lubricating oil (10) Mitsubishi Hitachi Power Systems:
recommendations for gas turbines Lubricating oil recommendations for
(1) GE Power: Lube oil varnishing
with bearing ambients above 500°F high temperature turbine application
(Technical Information Letter TIL 1528-
(260°C) (GEK 32568K) with bearing ambients above
3, November 2005)
250°C (MS04-MA-CL002)
(7) GE Power: Hydrocarbon base
(2) Siemens: Proactive turbine oil
lubricating oil recommendations for (11) ASTM D2272 − 14a Standard
condition monitoring and varnish
gas turbines (GEK28143b) test method for oxidation stability
prevention (E50001-D510-
of steam turbine oils by rotating
A209-X-7600, 2011) (8) MAN Diesel & Turbo: Quality
pressure vessel
requirements for lubricants (TED
(3) MAN Diesel & Turbo: Turbine
10000494596) (12) ASTM D7843 – 12 Standard test
oils: Tendencies to form deposits
method for measurement of lubricant
and varnishing as well as resulting (9) Mitsubishi Hitachi Power Systems:
generated insoluble color bodies
recommendations and measures Lubricating oil recommendations for
in in-service turbine oils using
(TMC 15-4338) high temperature turbine application
membrane patch colorimetry
with bearing ambients above 250°C
(4) Siemens: Turbine oils with normal
(long life type) (MS04-MA-CL005)
thermal stability (TLV 9013 04)
(5) Siemens: Turbine oils with higher
thermal stability (TLV 9013 05)

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