Presentation

Varnish Control in Combustion Turbines

Pall Power Generation

Filtration. Separation. Solution. SM © Pall Corporation 2009

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 Presentation

This presentation is the confidential work

product of Pall Corporation and no portion of
this presentation may be copied, published,
performed, or redistributed without the express
written authority of a Pall Corporate Officer.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Content Presentation

• Overview: varnish issues in combustion turbines

– Varnish and its consequences
– Formation: precursors and varnish
– Measurement
• Pall Total Varnish Control approach
– Prevention with stress resistant filter technology
– Varnish removal from contaminated systems
• Principles of operation
• Skid details and sizing guidelines
• Examples
• Conclusions

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation

Varnish Issues in Combustion Turbines

Filtration. Separation. Solution. SM © Pall Corporation 2009

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 What is Varnish ? Presentation

• Thin, insoluble film deposit that forms on surfaces inside the turbine lube system
(pipes, tank, bearings heat exchanger, servo-valves, etc)

• Comprised of a wide range of oil additive and thermo-oxidative breakdown, high

molecular weight compounds. Varnish precursors are the result of breakdown
from mainly:
– Oxidation: water, air and metallic contamination from wear
– Thermal stress from extreme temperatures in cases of:
• static discharge
• Micro dieseling: adiabatic compression of air bubbles

• The chemical compositions of varnish precursor vary depending on the turbine

type, operating conditions and the oil type. Varnish precursors are >75% soft
particles, <1 micron

• Varnish precursors are polar, and their solvency is temperature dependent

– Over time migrate from the oil to machine surfaces - depending on system and oil
conditions.
+
Varnish Precursors -
+
- - +

Varnish

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish at 100X Magnification Presentation

50ml oil + 50ml hexane filtered on 0.45 µm 47mm dia membrane

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Turbine Lube Oil System – Common Reservoir Presentation

Compressor/Turbine Shaft

Main bearings ( roller or journal)

Cooler
Seal oil
Main filter Solenoid valve Lift oil
Main
pump
3500 psi Control oil filter

To Hydraulic control circuit

Lube Oil Reservoir little/no flow at turning
Control oil circuit

Hydraulic circuit:
High VPR impact
Lube circuit Low
VPR impact Inlet Vane Control Fail open valve Gas valve

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish: Consequences on GTs Presentation

• Contamination of critical GT control hydraulic components

– Fuel control valves
– Safety fail open valves
– Vane control valves

• Inability to control operation, high maintenance cost for

– Replacement of contaminated valves
– Cost of chemical clean and flush

• Fail to start condition: Loss of flexibility

• Trip during operation: Loss of production

• Downtime and lost production represent a large share of the costs

associated with poor varnish control in GT installations

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish: Cause and Effect Presentation

Increased Output / Production

flexibility
Thermal stresses of larger
amplitudes: Hotter temperatures
Duty Cycle increase formation, cooler More Varnish
Peaking/Cycling temperatures increase varnish
deposits
Higher system
temperatures High temperatures increase oil
oxidation More Varnish

Higher
Higherlube
lube
flow Cooling on main
New oil formulation
flowrates
rates pump outlet

Less tolerant of Cooling of the oil

insolubles/not favors varnish More Varnish
optimized varnish deposit

More air entrainment: greater

Less dwell time More Varnish
oxidation and microdieseling

Tighter filtration Higher risk of static discharge More Varnish

Major Varnish Issue

Filtration. Separation. Solution. SM © 2009, Pall Corporation
 Varnish Formation Presentation

• All turbine oils create varnish precursors under normal operating conditions.

• The rate of generation is higher under severe / unusual operating conditions.

– Oxidation
– Additive depletion
– Filter related electrostatic discharge
– Micro-dieseling, adiabatic compression

• Recent increase in varnish related problems is attributed to:

– Higher operating temperatures
– Smaller reservoirs
– More peaking and cyclic service
– Highly refined base-stocks (Group II - lower solvency for varnish)
– Finer filtration resulting in electrostatic discharge

• The solvency of varnish in oil is temperature dependent

– Transition point 54 - 57 °C
– Temperature falls below 54 - 57 °C in the hydraulic section

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 More on varnish Presentation

• Oil has limited solvency for varnish

– Majority of the varnish in a turbine lube system is in the form of deposits
– Small portion of the total is suspended in the oil
– As the oil is cleaned up, it dissolves more varnish
– Lube system is clean when all removable varnish deposit is gone
• Varnish deposits cause
– Restriction and sticking of servo valves
– The cost of valve replacement due to varnish is ~$30,000 + turbine down
time costs

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish Deposits Presentation

Inside filter housing

Contaminated trip relay piston

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish Deposits Presentation

Pencil Filter, contaminated with varnish deposits

Servo valve spool: heavily contaminated

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Measuring Varnish Presentation

• Oil test for visc., TAN, RPVOT, metals, foam, etc will not indicate varnish
potential
• Varnish forming potential of oil can be measured by:
– FTIR - nitration procedure
– Gravimetric analysis (Toluene soluble)
– Ultracentrifuge (~17,500 RPM for 30 minutes)
– 0.2 – 2.0 um Particle Count (Modified ASTM D312) OR
• Color patch - Quantitative Spectrophotometer Analysis (QSATM) –
Analysts Inc)
– Most commonly used – Draft stage ASTM procedure
– Measures discoloration / stain on patch
– Proprietary calculations determines varnish potential rating (VPR)
– Significant variation in VPR values between labs
– VPR of <35 normal - no action
– VPR of 38-58 - active monitoring
– VPR 60-79 - abnormal
– VPR >79 - critical - immediate action

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation
Example of measurement report: QSATM Test Report

Initial Tank Sample

VPRTM <35 – Normal

VPR 36-58 – Monitor
VPR 59-79 – Abnormal
VPR >79 – Critical

QSA & VPR are Registered Trade

Marks of Analysts Inc.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Measuring Varnish: Setting removal targets Presentation

• Measurement of varnish potential does not indicate the actual amount of

varnish deposited on the surfaces of components
• It measures varnish precursors in the oil

• A system can be considered “varnish free” when varnish deposits have

disappeared, not necessarily when varnish potential is down.
• Removal of varnish precursors from the oil displaces the solvency
equilibrium in the oil, forcing deposit to “redissolve” in the fluid, then
removed by varnish removal units. To be free of varnish, varnish
precursor measurements must be consistently low for an extended
period.

• Actual clean up time depends on

– Efficiency of varnish precursor removal
– Amount of deposits already present in the system
– Solvency behavior of varnish in the system (site dependent – machine
dependent – oil dependent…)

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation

Typical Varnish Removal Technology

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 Varnish Removal Technologies Presentation

The electrostatic method (EST)

• Kidney-loop mode, off the main tank
• Oil is subjected to electrical field causing varnish particles to:
– charge / agglomerate to larger particles
– captured by filter mat or
– attach to charged, disposable surface
– As the oil is cleaned up, it lifts varnish deposits into the oil phase,
cleaning the surfaces
• Permanent or long term installations recommended.
• Limitations: moisture < 500 ppm & low metal particle count.
• Mixed results on performance from dependence to many external
factors

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Field Trial with Electrostatic Presentation

Filtration. Separation. Solution. SM Ref: ExxonMobil Presentation STLE 2005 4 Kleentek units on©GE 7FA
2009, Pall Corporation
 Varnish Removal Technologies Presentation

• Chemical cleaning/flushing

– Lube system flushing with chemicals / solvents

– Softens and removes insoluble materials and the flushing action
suspends and helps remove the material by fine filters
– Several hours to several days
– System is flushed with appropriate flush fluid to remove residual
chemicals
– Intensive & costly process.
– Allows quicker removal of deposits.
– Continuous monitoring and turbine shut down
– Cost of flushing: $50,000 to $60,000.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Varnish Removal Technologies Presentation

• The adsorption method:

– Utilizes large surface area, high void volume
– Low fluxes allow proper residence time for adsorption
– Electro-chemical affinity of the filter media for varnish particles is a KPI
Particles captured by adsorption, eg
varnish precursors

Particles captured by direct

interception, eg wear metals

“Good” adsorption depends on media

fiber composition, surface treatment
and binders, as well as void volume

Principle of VRF-PGG

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation

Pall Total Varnish Control

Filtration. Separation. Solution. SM © Pall Corporation 2009

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 Pall Total Varnish Control Philosophy Presentation

• Varnish in turbine lube oil needs to be both prevented and eliminated

when present
• Pall key Total Fluid Management aspect: combination of Pall Ultipor SRT
on main lube line (preventive) and VRF skid offline (solution)
• Pall VRF main advantages:
– Reliability and efficiency
– Lower power consumption
– Ease of use
– Pall VRF is high tech element technology packaged in a rugged reliable
system design
• Typical payback is less than 6 months
• Unit is very mobile and versatile
• Adsorption process is not dependent on water content or contamination
levels.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall Total Varnish Control Presentation

• Ability to prevent and solve varnish problems

• Combination of Ultipor SRT on main lube line and VRF in recirculation
on the main tank.
• Ability to “devarnish” metal surfaces as concentration of precursors in
the oil decreases after removal by VRF

Low precursor
High precursor
concentration in the oil
concentration in the oil
(Low VPR). Elimination of
(High VPR). Formation of
varnish deposits
varnish

+
-
Varnish Precursors +
- - +

Varnish

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Turbine Lube Oil System – Common Reservoir Presentation

Varnish removal

Compressor/Turbine Shaft

Prevention: Antistatic Ultipor SRT

Main bearings ( roller or journal)
Cooler
Seal oil
Main filter Solenoid valve Lift oil
Main
Pall VRF skid pump
3500 psi Control oil filter

To Hydraulic control circuit

Lube Oil Reservoir little/no flow at turning
Control oil circuit

Hydraulic circuit:
High VPR impact
Lube circuit Low
VPR impact Inlet Vane Control Fail open valve Gas valve

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Important parameters for varnish issues Presentation

• Turbine Make / Model

– Peaking / base-load
– Year commissioned
• Oil volume / make
– Hours in service
– Hydraulic system separate?
– Typical oil temperature range in tank
• History of problem
– Current & past varnish test reports
– Other key properties of oil (Viscosity, TAN, RPVOT, Demulsibilty, etc)
– Experience with any other technology ?
– Full flow / hydraulic filters – make, rating, service life
• Ambient conditions
– Temperature range
– Covered area?
– Skid connection points to the tank (opposite / below oil surface)
– Possible to connect downstream of system cooler?
• Ability to sample online
– Sample when turbine is running

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Ultipor ® SRT filters: Preventing varnish formation Presentation

Ultipor® SRT design for combustion turbine lubrication

• Specifically designed for combustion turbine applications

• Combines excellent removal efficiency with antistatic
property in an outside to in configuration

• Addresses two major factors of varnish precursor formation

– Static discharge from standard polymeric fine filters
– Metallic contamination catalytic effect on oxidation rates

• bx(c )>1000 rating ensures the best level of contamination

control, in a stress resistant element configuration.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall VRF Skid Presentation

• 42 LPM recirculation flow rate

• Equipped with 3 VRF-PGG modules
• Equipped with cooler (2 options depending on temperature conditions)
• Equipped with Pall Ultipleat SRT filter assembly on the outlet
• Simple controls
• Temperature control to ensure maximum efficiency
• Basic specs (ref. datasheet)
– 0.75 kw pump/motor assembly
– 0.6 kw cooler standard
– Electrical standard 240/410, 3ph, 50Hz
– Maximum operating temperature: 80°C

• Designed for treatment of tanks up to 30,000 litres

Other options can be made available. Consult your Pall representative

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 VRF Skid configuration: standard Presentation

Cooler is key to ensure optimum temperature for best

varnish precursors removal

SRT and its antistatic media

provide particulate removal. In
conjunction with Ultipor SRT
on the main lube line for best
varnish prevention.

The magic happens here: 3 VRF-PGG modules

remove varnish precursors by adsorption.
Media treatment, binders etc… make for its
excellent affinity to varnish

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall VRF Module VRF-PGG Presentation

• VRF-PGG modules
• Number of modules per VRF skid: 3
• Change-out interval: recommended 90 days

• Composite filter media (K-900) made with

cellulose, perlite & special binder resins

• Pronounced positive zeta potential

• High void volume (70 – 80%)
• Max temperature rating: 185 °F
• Max DP: 36 PSID
• Support hardware: Polypropylene
• Seals: Viton o-rings
• Solids removal rating: 18mm nominal
• Water absorbing – will not deteriorate
• Fully compatible with mineral turbine oils
• Does not remove oil additives

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Benefits of Pall varnish control Presentation

• By removing varnish precursors from the lubrication oil, Pall VRF reduces the
varnish deposits on lube and hydraulics systems internals

• By protecting valves and other critical components from stiction, Pall VRF
increases turbine availability and reliability. Instances of “fail to start” and “trip”
conditions are greatly reduced.

• Based on average valve cost replacement and downtime associated with

repair/replacement, typical payback period is less than 6 months

• VRF is combined with Ultipor SRT lubrication filters on the main lube line,
eliminating filter static discharge while still providing efficient particulate control

• Combination of prevention (Ultipor SRT, Water control) and correction (Pall

VRF) is the best way to keep combustion turbines running free of varnish

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation

Varnish Removal Examples

Filtration. Separation. Solution. SM © Pall Corporation 2009

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 VRF trial: GE Frame 7FA simple cycle Presentation

23,500 litres of ExxonMobil Terrestic ISO 32 fluid

In service for 48,816 hours
GE Frame 7FA - simple cycle, peaking units
Using standard 5mm for main flow (3,400 LPM)
Typical tank temp: 54 - 57°C

Pall VRF Trial at Calpine - Blue Spruce

90 3-Sep-08
Varnish Potential Rating

80 4-Sep-08
70
60
50
40 5-Sep-08
30
20 25-Sep-08
10 10-Sep-08 16-Sep-08 7-Oct-08
0
8/28 9/5 9/13 9/21 9/29 10/7 10/15

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation
QSATM Test Report

Initial Tank Sample = 62

VPRTM <35 – Normal

VPR 36-58 – Monitor
VPR 59-79 – Abnormal
VPR >79 – Critical

QSA & VPR are Registered Trade

Marks of Analysts Inc.

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Particle Counts – ASTM D321 Presentation

Size Range (µm) # of Particles in the Size Range

Untreated Sample Treated Sample

0.2 to 1.0 37,600 2,200

1.0 to 2.0 4,320 822

2.0 to 5.0 1,300 389

5.0 to 10.0 432 130

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall VRF Trial at US cogen plant – Skid details Presentation

• 3-module filter housing

• 12 GPM continuous flow kidney-loop mode
• Forced air oil cooler
– Target maximum temperature: 110 °F
• AN grade discharge filter
• Temperature, pressure, DP, flow gages
• 1 ½ “ Inlet, 1” outlet ports
• Dimensions: 5’ x 4’ x 4’
• Electrical: 460V 3Ph 3amps

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 VRF trial: Alstom GT24B Combined cycle Presentation

• Alstom GT24B turbine (257 MW combined cycle)

• 32,000 litres
• Chevron GST 46 (in service for 7yrs)
– Replaced 25% volume 2 yrs ago
• EST installed - did not work
• Test dates: Nov 14th – Jan 11th (8 weeks)
• Oil temperature: 38 – 42 °F
– Tank temperature: 44 – 56 °C
• Module DP: 2 PSID (did not change)
• Initial VPR: 89 Final VPR: 18

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall VRF Trial at US cogen plant – VPRSM Presentation

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Pall VRF Trial at US cogen plant – after 8 week trial Presentation

Final Tank Sample = 18

VPRTM <35 – Normal

VPR 36-58 – Monitor
VPR 59-79 – Abnormal
VPR >79 – Critical

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Same US cogen plant – 6 months later Presentation

EST has been in use for last

6 months

Varnish Deposits

Varnish control and prevention is a continuous improvement…

Filtration. Separation. Solution. SM © 2009, Pall Corporation

 Presentation

Thank You.

Questions?

Filtration. Separation. Solution. SM © 2009, Pall Corporation