Fundamentals of Lubrication Relating to Operation and Maintenance of Turbomachinery

8/9/2019 Fundamentals of Lubrication Relating to Operation and Maintenance of Turbomachinery

1/8

FUND MENT LS OF LUBRICATION R LATI G TO OPER TIONM INT NC OF T R BOM CH N RY

MDepa tme upe so - ub a on

The Dow Ch mka oF eepo Texas

M Clapp a s p s b ic t n. techn ca s ru cesJ a /Ch mica ! is a me b r fAS E.

Clapp s a h r d s :ralpap rs n ar a oflubricat on

A ST ACTpr per desi nedin a dp rate and m in

tained ubricati n st m is n c < r r ia e mac ine per rman e. is a e e ri ci ! in t per ti n and aint c a s < p a ied T e primar c mp ts o s des r bed in udin t e u ri ti - f S p in andt > in tec niques d t eiri ifi"anc a d cu

ith p cial ref ren tu u i e ricanan e O ini nar e pr ssed re ar inc nt inan

and t eir con r ifi r e ti nf u in;: an eanin te ni ues and ou inu ric ti n

.

INTROD CT ONT e r per d si n d, insta d kand ai

tained ubri ati n stem is a r ia eperf rman e fturl ; mac in T is ap r i deamain wit the rincip ratin amaintain n

lubri ation s st m i ur s lt i s thatill e di uss din t ispap r an e c mme ts

e pressedwi e pini n based nm x ri nc ith

1, Basic Oil System

2 Oil Sel tion

3 . mpling and T sting

Oil Contamination and Control

5 Filter Selection

6 Cleaning and Flushing

7 Coupling ubrication

F

6

u ric i ns te s orturb ma i x ed t peatin n iti n r a i tur an ich i cate

n t e u f C ast Te a . A u m ur mainea licati ns adi rfr m

'urit im ief

t ata luersf tur ma i \ i a\es n!ial ! bai c n rn s ia osr ated t eu ricati ns t ms f u a equ sti nsr i udisa r

it m) pinion l as mak n t en and dui int e qu si and anser p ri d i! a te pt t ariand urt er discuss urqu ti n.BAS C OIL SYSTEM

spe ial A l tak or e hasbeen 1 orking on a lu w

an sea i standard f r 1 r r ars t is In\unders andin th at the propos d and w ill be relea se ;late in l1 J7 2 T itandard 1 i l t d si; a t d API 61an 1i lc ver the minim um r qu irem:' t f r urica i nS\ ste s il typ a t aing Sj ste ; and c n r oil supp s st msf r sp cia pu e p i ati ns c mpress r ,gears u sand dri rs T is i;

muc needed d c nt t at pe i bee eas i lanned

I i l not attempt o ive a detai ed r i f thispropod standard but 1i make 5o m n oncernin th ajor c om onents of a typica oil system.Fi;mr 2 ists so e o s co ponents. Most of th curre nt turbo 1i ryis


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68 PROCEEDINGS OF THE FI ST T BOMACHIN RY SY OSIU

A _S r

. W y

I ' Dnl&G rE H4 v1 t TI P

: ,.rl;: )

{E L _-

Fig r R s rv ir

WD c '"}

X

nes s u d enter t e reser ir a ay fr m t e pump suct n t a id d stur an e f t e pum su ti nT e rk n capac ty s u be at east fi e minutesbased n n rma f w Reser ir retenti n time sh u de 8 m nutes based n n rma f and t ta umebe m n mum eratin e e eatin t e s u da s e pr dedt erm stat a c ntr ed e e tri

a emers n ea ing s pr ded t e ma i um atdens ty sh u d be atts per square nc en steamheat n s used the ea in e ement s u d e e ternat t e reser r

T e system s u d be equ pped t a ma n pump a standby pum and f r r t ca ma ines anemer ency um Eac pum must a e ts n dr erand c e k va es must be nsta ed n ea pump d s-

ar e t pre ent re erse f t r u d e pumps. T epump capa it s u d eS reater t an ma mum

system usa e. T e standby and emer en y pumps s ae equip ed t aut mat c c ntr s t start t e umpsn fa ure f t e ma n pumps. T is c ntr s stem

s u d a e manua reset f steam turbine and e e tr ct rs are t e used f r t e main and standby

pumps t e steam tur ine s u d dr e t e main pumpand t e e e tr m t r s u d dr e t e standby umpThe emer en i pump can be dr en it an A m t r

ut fr m p er s urce t at s different t t e standbypump. D e ectr m t rs an a s be used en Dp er s a a ab e Pr cess as r a r dri\en tur ines

n qu k start steam turb nes are ften used t dr vethe e er en y pu ps.

n c ers F ure4 sh u d be pr ded andpiped n para e us n a s n e u ip rt tr nsf va et d re t t e f f t the c ers. T e ater sh u de n t e tube s de and the i n t e she s de. T e

i s de pressure s u d be reater t an t e ater s epressure T s is n assuran e that ater n t enterthe syste in the e ent f a tube eak ut t d es reducethe r sk

The system F ure) sh u d be equ pped thfu f t n f ters ate d n stream fr m t e

ers. S n e t e f ters are ated d n streamfr m the ers n y ne u t p rt transf va e

ig r l r-Filt A r ng nt

is requ red t d re t t e f t t e cb nat nsDO NOT pipe t e f ters and separate n et and ut et b k a es t

ss f f fr m t e p ssib e umann t e f dur n a f er s t in

T e m n mum arms and tr ps ended f r each maj r dr er and dr en mace pressure a arm a

s me p nt er t an t e a arm p int, a arm reser rh f ter di erenta arm and bear n meta temperature

Ea pressure and temperature sens nsh u d be n separate h us n s. T e s tc

e sin e p e d ub e t r furnis edener zed) t a arm and "c se ener ize

Low Oil Pressure

Low Oil Level

High Oi Filter

H g Thrust Bearing MetalTemperature

High Thrust B aring OilTemperature

g r 5

Alarm Tr

X X

X

X

X

X


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4/8

70 PRO C EEDINGS O HE IRST RBO CHIN RY S OSI

I. Extraneous Matter

A Atmospheric Dirt

B Metal Particles

C ater

I I. Process Gas

F g r O C a

n e use owe r i a in p ion o e o ane s n in con a ina d oi n e a ar

ance an o or s an d e con a naA samp e o e oi o d w drawn r e

s s m an e ra o i ar r a r d in eabora or T e s c nd c o d ermin eond t on o t e us d oi nc de i co 2 H

an ne ra za on n r nd re p a io T e e

are owe er addi ion e a cane o d c d ora more a e \a a on o e d o T o e e sare: I p ro rap ana sis2 a om a ort on 31 n ra d ana s iX ra an 5 n e

a a ns on he esr s s s o dbe re ewe anompare w e s pp er sp ica ons o he ne

o De end ng upon e na re or degre o depa turerom ne o e abora o e e w appro e he oo con nued us or a he ma h ne o ner o any

ac on hat sho be aken n he a o re on it on nor p a ement o e o oo e o s o be kept

o a sam es test d

OIL ONT OThe con am na on o c rc a ng oFi re 0

n tu o a h n r s a con nu n pro em n a mosa nsta at on T e di eren e s de ree o con am nat on n enced o a ar e ex ent e ronm nta

on ons o w ch t e ach ne pose and theme an al ond on o the o s eam and pro es gasseals.

The r atest so ce o on a ina on s rom ext aneou ma er A mo pher c r s a a s a ser outh eat to t e t r omac ne an a n n rance ntot e o s s m t ro en r a r and a Thee e ts o s pe con amina on o io primareq p ent ear Hower h g ng o oi nes an

o ts an ed c ox a on a o e o are o hee ous e ects.

Metal a t l from ea an r t ar e ome e vo an o p ng corros on an l ad to prematu eeq ment a re and o e ora on mpo tant

o o e s table ter n equ ment fo the e o alo these a t c es rom the s stem

ate ontamina on s a on tant h eat hesou es o ate a e an atmosp e con en at on

tea leak o ooler an e e o eaks R t ngo ma h ne a t and he e e o t part cles n heo l syste the ajo p o t o ate n o l In a

on t orm an m on an omm ur c a w r m a and

a a a promo n o o da onontam na i n r m pro e s as can e

pro l m par c a d rin ar p e or m st e er d pr n h

on an pro m od o d c on

J o rocar on ase are or oo an not o and ;a ow r sc t r e T e ro m o r t ar a

d r n ar p d e o o i co oi can e uippin e r so r oi eaters o

o o e norma opera in t mp rat re e a ne

u p n n and or ne serpro e ed a n t he po r o ese ao O o e r n o d

a ai r sowe r a ondar pro emac ne co d be u i a d w h an aa ka ine add s wo d e a\a ab e o rea

ow on n ra ons o e ac d ases add on o hese a s to t e o molecul

F r er pro e on can be pro ded an a ka ine o m st p r e on e ear ng

e rese o rs T e a ka ine can e a m ea e o 25 F on eac bear n an F

rese o r i h e apor spa es ed h o t an n ress o an ac d as wobefo e on a t w h t e a n o l

ON A NA T R OVALe remova o con am nants ( F gureI ust b

done on n o sl wi eq ipment su ableon am nan n he o Keep n t e mpor nt n on o approa ng ro

on e s o d re ore se e t the veran e ui ment req red o ma n a n c ean

Insoluble Particl

1 Depth Filters

2 Sur e Filters

3 Eleme t Selection

Water

1 Pr e tion Best Cure

2 Rem al Methods

A Centri u s

B Coalescer Separators

ig r C n a in tRemoval.


5/8

FUND ENTALS OF L BRIC TION RELAT NG TO O E T ONAND INT N NC OF lRBO C IN RY

I solu le a t les a e su ssfull mo e f omhe ulat o l th full flo lte s T o e e aly es a usually sele te o the emo al of th s t peo tam a t. The a e su fa e s an d pth f lte s

Both of hese t pe f lte s a e ef e t ve fo t e emovalof a t ulate mat e .

The e th t e f lte l me ts a e e ally use

e the o l s f ee f om ater an he part le s zest e emove a e the 5 m o a la e a ee e all , the epth ty e lem t s ate sens t ve ahe o l s o tam at th m stu e, t s t pe ele

me t ll a so the at a p o u e a ap ease ffe e t al essu e a oss he f lte . h ffe

e a essu es e also ev lope he th f l er eleme t e s t s g eat e ou h to emove pa t les smalle

ha 5 m o s. The s e ma mum ffe t al p essu e a oss a f l e th l an eleme ts s 2 ps , at the

o mal o e at tempe a u e o eve , ma y f lte se e es fo 5 ps 0 m o elem ts These

f te s he equ e th 5 m o t pe eleme ts mayy el ffe t al essu es as h as 8 0 ps

u f e f lte s f manufa tu e f om t e o e tmate al, ll ot be affe e b at t e o l Wate

es sta t pleate pape elem nts ave mu h la e sufa e a eas tha the e th p e eme t a y el a mu hlo e ffe e t al p essu e he us as pla emeeleme ts f lte s o nally equ ppe th pth ypeeleme ts Pleate pape elements a e ava la le that ll

emove a t le s zes o to om al1 m o .

ELE NT ELEC IOThe f lte eleme ts s oul be 5 m o a mus

e ate es stant, have h flo ate apab l ty tho essu e o possess t ete t on apa t

e upture es sta t The lea p essure op s oulno e 5 s at 00 Fe p efe to s ze t e f lte sla e e ou o el t 2 ps ffe t al pressu e a00 The eleme s must have a m mum olla se

ffe e t al of 0 s Ple pape e eme ts a e efe e ov e they meet t ese equ ements sually

he leate pape eleme t l y el the 2 ps lea ophe use a f lte t at as s ze to use epth type

eleme ts. Th s s ue to the la e su fa e a a of thepleate eleme , ove t e the a ea of a onve t o alsta e s y e o othe pth type el ts e a esu essfully e la 5 m o pleate pape eleme ts

t o 80 pm o soles th % m o leate pa eeleme s he t al f e t al essu th he 5m o ele e ts as 2 s a he m o eleme ts

e e st lle e ffe e t l su e o ly se o s

ome of ou ea ly es g e o l s s ems eequ p e th y ass l ef valv s se o o e at app omately 20 s ff e t al, safe ua a a st o l floloss ue to el me ts T e b ass valves a e ot

e omme e a have bee remove et p ote -o a a s t e los of o l flo s a ffe e t al p ssu e

s t h set to ala m h t e pr ssu e op ea hes a e-ete m o t I a t o to t e fe e t al p es

su e s t h a t o a , h e po valve th a p essu ea e s e a al el th e ffe e t al p essu e

sw h o a u at at o of le af lter ssure a s le t a sflo valve w th a ool r t nstallat o , the ffe e tsw t h a p essu e ga e assembly shoul s a

ool f lte s stemWate o tam nat on the o s stem a

s ous et ment to th tu boma ne a esonable ffo t s oul b made to f rs , p e ent

a e to t s stem a s o d p o e smoval equ pm nt at r an ot f e t lI am a st o b l ev t at"pre e n s the est ure

p e e ates the es n rs a he op ato s a e mo e eff t n p

he s s em. e the ma sou es a f om ato e sat o , st am leaks a faul o l oole

o v ous t a preve t ve measu es shoul be ta e a eas

Co e sat o ll o u the atmos hero l system he eve t e temp atu the vapoa eas o s belo t e e o t. Th s a be

etu o l p p n as ell as t e ese vo stalle u p ote te lo at o s a e mo e v

to l ma han es tha those nstalle ns e bThe ou s e lo at ons ll be a v sely affe tepe atu e y les et e a t me a ght opea so, y sho e s a s e tem atu e opsothe eather ang s, esp all the fall as asons We ave bee ve y su ess ul "o l sys ems y mak a fe s mple alte at of s s ep hat shoul be t ke s to he t e

e The ve shou e lo a e he ve yese vo It shoul e f ee of baff s that ou

a e u o e sate to the ese vo thshoul e k pt as sho t as poss ble to p ov de msu fa e a eas o h h o ensate oul fo m

e ssa to u t e ve t u a a ay f om theo , a ate t ap shoul be ov as los

se vo as poss ble to emove a y o e sate the ve sta k. The e t step s to ov e ata a e t as o y a u e o the eset o o f ve CF s qu e . The ese vo te o subs tute fo the el m at o of otsou es

te m a o e sat leaks a the most sou es of ate to eve t ho eve , t a be eve y effo shoul e ma e to el m ate t ose Obv ously he f s mea s of p ve t o s t

he steam a fe t o t o E psho hat ev tuall the steam p k s l lsteam o e sate ll e te the s st m th ou h th

se ls e h ve so be su ssful "h s t e e o l s stem The p o e u e e o u e he ea laby ths th e t a O e metho s to ll a hole th ough th bea

ap a te se the la th. 7 ops o e te to the hole the bea a ao ome e T e laby th s t e pu e t

y a o e asothe metho as to stall a e te al la y

h u e ov s o s o the ea ho sma h e that ha he e essa s a e o a o

he e te al seal


6/8

7 PRO GS OF TH FIRST T RBO CHI RY S POSI"

oth of th s m t od a1 work d 1 w ane are t r or nco ra i o r rboma n r oto s to mak t ro1i io s a\ai a for us f or

th st a packing b in to akTh m tho s o r m in fr at r fro oi s s

t ms s u ua don 1 i i h r n ri u s or coa rs parators ' ar uc f u ing oth of th sm thods n o r 1ario s o ra in un s. A though ar usin both m t od I pr f r t oa r s aratoEx r nc has shown n rif g is t o t om ho both from ca i a o t a and o ra ng ost.The nt f s w ar he co io al di t pe

ith man al c anin T di cs mustbe c an d at a ton e ach w k 1i on o r r ir p c n nT e coa s r s ara ors u a ire mu h l ss at

n on Som s para ors n r uir l m nt chan son a 1 ar h o h r a1 ir c an s at 6 monthsor 3 m hs an in o i an on a month. Thefrequ nc ap ars o r a d to amount o wate

n th oi s st m T coa r nt chan havn r in man in an s b e of a pr fi t

n the s st m Th pr i r m t w ar usin has nomina m cron r n on ra in T is m nt rov s th par ic at u a r s t at wo d restr tth 2 m cron coa s r nt T tim r tohange bot th r i t r m nt an oa sc s pa ato

e m nts is ss th n on h ur.

O L SYST CL A PS r o s m chanica amag to turboma hin y

s lt f om o ra in 1 i dirt oil s st mst i ure 2lI is ss n ia tha the o s s m e thoro hly l aneup prior to the in tia s art p of a n machine a fte

ach ov rha of x sting ma h n sPr minar st p for in tia star up and aft

the ov rha are simi a x p or h r rvoir an o lir m n s on th ma in a r an o1 r au Fo the

ov rhaul d ma ne h oi wo b rain n testfor on t onR ain oi un ss th ab sts in aoth rw s It m ross! co aminat d th m ta at r proc ss roduct or ot r i gra d anunfit fo f t r u f this is th cas th oil shoul

e isc rd d oth rwis the oo oil ou d s o e su table au iar ho in tank

In p t th r oir n ior fo rust an o hos ts. mo1 an r t 1 i h scrap rs and ir brush

and ash down th int rior with a r nt o utionan sh th l an at r r the nt rior lo inthe s r a s w h dr air an us a a m an r fo

u to mo tr app at

1 Initial Strtup

2 Ov rha l d Machin ry

3 Pr liminary Pr parations

lushing Proc dur

g Oi Syst C an

Inst l n w micro p at d ap r lfi t s Conn ct st am pip n to t aoi ool rs or t o d rin tor f e an nsta jump rs at t rin

ontro s o1rnor an o h itica arts a e from d br s d r n the h a

for 0 m h t ta e s ns at ach j mha scr n i pr f rr d b t a f at scr nf the on a s r n is not a ai ab Aal es n th f o n posi ion o ow n f ow Th i1 n ss of h f ar e e t t n hi h f ow 1c i s thro h t

to r y th d bris n o oir and fi rs. Ibe n ssa to s t ona ize

u eloc ti s b t rnate o ki offu h f sh

F the r s rvoir i h n w or n the f h thout te ta s r n b r nor p mps to ro i t h s o i the oi to 60 F wi h t am on th oi coot p ratur b twe n F an 0F to e r ise th ip Tap t pipin to di

sp i alon the horizonta tions. one complete t m ratu l t n snst ll th t tal scre ns and f h o30 inut s mo s s and h ck or atype br s. p t th r din proc ds r ns are an aft r two on c ti1 ins tionsse ve the pr ss re drop acro s h fil rs f ush n op ation Do not al ow th pr se 0 psi the s st m s cone pty he oi res vo n c a ou a l d

th d t rg nt sol tion fo ow d nse Dr in r or y b o in ith r ai

e t . R pla f te m nts n r p a e orif s Retu con ro s o

s tt gs i h o l r s r oir with thn the fl sh ab t sts ind cat t is satis

se efi th ne o l.h s pro r i al o t fa t

of th o l s t m main e to high o t n uring the f u h T obj ti1 is to carr

s nto h reso r and i t rs an h tuf o the high f o s alon th th th r al an

al s n of th iping re mainsa fo fast an ff cti s st c n

GEAR TYP L R C T CO P GThe fl ib o p intFi r 1 i on o th

rit l om on nts n th urbomachin asp al ons rat on from t and oint

stal ation op at on an l ri a on.nless h prop rly s gn o n

the h ne si ner man op ratin pe p e som of h h ma be m

t o pro l m Su essful o rat on ahe the prop r y es n oup n has b

sta l th the most s tab e tho oappl Fo th en f t of th s s uss o

hat prope ly gn ar t pe oupl n ll e or e t y nsta e o h


7/8

F ND EN ALS OF L BRIC IO R LA N O O R IOND IN ENANCE OF RBO H N

73

Coupling ypes

1 G a Pack

2 Oil Filled

3 Continuous Oil Flow

Grease Packed and Oil Filled

1 Advantag s and Disadvanta s

2 Lubricant Selection

Continuous Oil Flow

1 R uisites for Good Performance

2 Adv ntages and Disadvantages

3 Oil FiltrationFig G a T p L r a d p ings

Th ost o o l a li d m hods of ubri a ig a cou li s ar as a k d (21 oil fil dor (31 o ti uous oi f o Ea h of th s thr hods hav rtai adva ta s a d disadva ta s that akth i h a ptabl o u a tabl for a y ia i a io It is obviously i orta t that th m hod

ich off rs r at st advanta s should b s dh r as a k d and oil fill d of r si ilar a va

ta s a d disad a ta s Th mai adva ta is simp icit of o ratio Th are also o omical asy tomai tai and h r as ty sists th tr of otam a ts I additio hi h too h l adi a b a

o odat d si lubrica ts ith h av bodi d oil ab us d im orta t r quisit fo t oil fi d tis hat cou i must a a a quat stati oil

a a it to ro\id h r quir d amount of oil o sub-m r h th h h cou in is i o atio Thr at st di ad1anta of cou i s is th ossi

loss of u rica durin o ratio d to d f c if a g ask s oos flan bo s u ricant u s andfla s i h ou lin f a s and s ac rs dditio a lth gr as cou i is sub ct o r as s a a ioat hi h s ds Th r or th r as ou li is ot

o sid r d sui a l for hi h s vi t ha o d hi h s d cou in r as is us d a d tho ly for u to o ar of o inuous op ation

Th impo ta of s l in th b st gr as fo thhi h s d cou lin ca ot b ov r phasiz d Labora-to y scr nin a d fi ld x ri nc has be n ou m hodof l ti h o t ui a r as for ou a licatioT labora or s r i a on it a Shar s hi hsp d la ora or c n ri uT as s r t st byc trif in for2Lhours at50, 00 rpm 60 000Th s t e a s d as hos becaus he s l i

of ou trifug1 as 0 0 G a d s a atio hadua iz d i2 o r

I ord r o fur h r tud h s ara io cis i s of r as s rif i was don at four

0 20 a d ou and r m r r n in foof 2 -tO 9 !00 2 . 0and 000 r s i Shour ru s r mad at ach d af r hic

ight r nt and is osi of h oi s araight p rc nt of t soa has as d rmi d sp d Our findin s rom h s s r r latori i a scr in ha i h r ass ara ion charac ri ics i d a d th2 hour runsat 0 000 rpm w r low a a d a h\ i h hi h s ara io c arac ri ics at50 000 m ra so hi h at al s d T r or a d on t s i s l t d r as f r our hi spack d oup i sx ri i th fi d has a ath laborator fi din

Th co ti uous oi flo m hod is ri aril i ou high s d ro a in a hinThis hod ro

id s th o ntia for ma i um o inuous o ra io at hi h t o ra i ds T flo of oa o ro\id s a coo ad a a carr ih at n ra d wi n cou in no ha a a i a i u r lia i i sinc th ois con ta a o o oi om wi i is not a ro m a t is wi oi or r asco lin Th ma r isit s or his m( ro sio of ad a oil f on h cou in(2 th oi must a o u a a d (it mustool i ord to cara a at

o of th i ad\a a s of th o ti ous flo t cou li ar in r as d o 21r uir ssupp y oil a d r oi i in and(3 th r of

or i solids ith h oi i l aus acc raFo a rial in oi is a ma or prob

thi o p in Sin hi h rifu al d v lop d ithi h oupli a i duc d so

a r i l e trac d from th oil a d r tain dcou li ra i ar is usual caus d b thslud In addition to h fo i abrasiv s th

ill r tai th ar m tal a i co tri ut ou lin ear at

Slud in has n r duc d ithi som ofoupli gs b i ro d tratio of th oil Th l m s th co sol o l filt rs

micro l m s wi hout r at a csur dro Th ini ial di f r tial r ss r ith th

i ro l m s as 5 psi Th s lus d i o ous s vic fo si o ths u l th tr

as shut do for i s tio Th diff r tial a ross th filt s at that tim as ss thalO psi a also usi s arat upl filt s o th oito a f coupli gs ith su ss These f lt

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8/8

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Fundamentals of Lubrication Relating to Operation and Maintenance of Turbomachinery

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