Maintenance Turbine Lubrication System

REP 0 R T -8 U M MAR Y
SUBJECTS Steam turbines and related auxiliaries I Plant systems and performance
assessment
TOPICS Lubrication Bearings

Maintenance Turbogenerators
AUDIENCE Generation engineers and analysts
Guidelines for Maintaining Steam Turbine

Lubrication Systems
Failures of steam turbine bearings and rotors cost the utility in-
dustry an estimated $150 million a year. A third of these failures
involve contaminated lubricants or malfunctioning lubricant sup-
ply system components. This report, outlining a comprehensive
surveillance program, presents guidelines for maintaining major
elements in the turbine lubrication system.
BACKGROUND The lubrication system of a turbine generator supplies oil to the thrust and
journal bearings under all operating conditions. After many years of trouble-
free operation, these systems can suddenly fail because of degradation of
the lubricant, malfunction of mechanical or electrical components, and de-
terioration of the emergency power source. Although lubrication system
failures are rare, they cause major damage to turbine bearings and rotors.
Since the result can be extended plant outages, regular inspection and
maintenance of system elements are essential.
OBJECTIVES To assist power plant managers in the establishment and implementation of

a lubrication system maintenance program and to provide background infor-
mation on bearing lubrication theory.
APPROACH The project team compiled information on lubrication system surveillance

and operation from 15 utilities, three turbine manufacturers, two insurance
companies, numerous oil and equipment suppliers, and organizations such
as ASTM, ASME, and EEL They then identified and documented industry
practices related to maintaining the lubrication system's major elements:
mechanical and electrical components, lubricant, and emergency power
source.
RESULTS The guidelines presented in this report identify and describe procedures for
inspecting, testing, and maintaining a turbine lubrication system. An in-
troductory section presents background information on lubrication system
components, lubricant characteristics, and service conditions. Subsequent
sections include
Procedures for monitoring each major element in the lubrication system,
along with a discussion of relevant industry standards
EPAI CS-4555s
Detailed steps for establishing a surveillance program
Schedules for performing inspection, testing, and maintenance activi-
ties under normal operating conditions
Quality control measures to ensure coordination, continuity, and com-
pletion of all program activities
Bearing lubrication principles
Rotor dynamics considerations
Also included are appendixes presenting (1) ASTM standards for
designing a lubrication system, specifying a lubricant, and monitoring
overall system condition; (2) organizations that sponsor conferences,
publish literature, or supply lubrication system equipment or services;
(3) a comprehensive bibliography; (4) detailed maintenance procedures;
and (5) theories of hydrostatic and hydrodynamic lubrication.
EPRI A systematic maintenance program is essential to ensure the reliability

PERSPECTIVE of turbine lubrication systems. The guidelines developed in this study
provide utility personnel with the information necessary to establish a
systematic program for lubrication system maintenance. Such programs,
which feature single-point responsibility for coordinating inspection and
testing activities, provide information for detecting lubricant deterioration
and ensuring that key system components function properly.
PROJECT RP1648-7
EPRI Project Managers: Thomas H. McCloskey; Stanley E. Pace
Coal Combustion Systems Division
Contractor: Southwest Research Institute
For further information on EPRI research programs, call

EPRI Technical Information Specialists (415) 855-2411.
Guidelines for Maintaining Steam Turbine Lubrication
Systems
CS-4555
Research Project 1648-7
Final Report, July 1986
Prepared by
SOUTHWEST RESEARCH INSTITUTE

6220 Culebra Road
San Antonio, Texas 78284
Principal Investigators
G. A. Lamping
J. P Cuellar, Jr.
H. S. Silvus
H. F. Barsun
Subcontractor
FRANKLIN RESEARCH CENTER

Twentieth and Race Streets
Philadelphia, Pennsylvania 19103
Principal Investigators
H. C. Rippel
R. Colsher
Prepared for
Electric Power Research Institute

3412 Hillview Avenue
Palo Alto, California 94304
EPRI Project Managers

T H. McCloskey
S. E. Pace
Availability and Life Extension Program
Coal Combustion Systems Division
ORDERING INFORMATION
Requests for copies of this report should be directed to the EPRI Distribution Center,
207 Coggins Drive, P.O. Box 23205, Pleasant Hill, CA 94523, (510) 934-4212.
Electric Power Research Institute and EPRI are registered seNice marks of Electric Power Research Institute, Inc.
Copyright 1986 Electric Power Research Institute, Inc. All rights reserved.
DISCLAIMER OF WARRANTIES AND

LIMITATION OF LIABILITIES
THIS REPORT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK
SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI,
ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON
BEHALF OF ANY OFTHEM:
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO
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APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS REPORT.
ORGANIZATION(S) THAT PREPARED THIS REPORT:

Southwest Research Institute
San Antonio, Texas
ABSTRACT
The Guidelines on Maintenance Practices for Steam Turbine Lubrication Systems are
for use by electric utility power plant personnel to establish a comprehensive sur-
veillance program on lubrication system components of a main steam turbine generator
unit. It is intended to aid plant managers and personnel in the conduct of tests,
inspections, and maintenance activities to ensure that system components are capable
of performing their required function. Information is provided on current industry
practices to monitor the condition of the lubricant, mechanical and electrical com-
ponents, and emergency power sources.
The Guidelines contain information about industry standards for testing lubricant
properties, testing electrical equipment, flushing and hydrocleaning system piping,
monitoring stationary batteries, and specifying disposable filter cartridges.
Industry practices are detailed for maintenance of pumps, reservoirs, heat exchang-
ers, oil conditioners, motors, starters, cables, wiring, emergency power supplies,
and pressure, temperature, and liquid level switches. The resources and quality
control requirements for a professional surveillance program are given. Basic prin-
ciples of hydrodynamic and hydrostatic full film lubrication are explained and
illustrated. The Guidelines provide an outline of maintenance practices that are
conducted under normal operating conditions. Equipment manufacturers' instructions,
plant operation conditions, and individual experiences may dictate more extensive
maintenance activities for a specific surveillance program.
iii
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ACKNOWLEDGMENTS
The authors want to acknowledge the contribution from Harry Rippel and Richard
Colsher of Franklin Research Center on bearing lubrication principles. Their thor-
ough presentation of the subject will be beneficial to many utility engineers and
plant personnel. The authors gratefully acknowledge the information provided by
R. E. Dundas of Factory Mutual Research, F. D. Mansfield of Hartford Steam Boiler
Inspection and Insurance Company, D. D. Dorman of Conoco, Inc., H. C. Atchison of
Dowell Division of Dow Chemical, B. Daly of Semler Industries, G. W. Lewis of Halli-
burton Industrial Services, Inc., T. Meyers of Facet Enterprises, B. W. Dinius of
Velcon Filters, F. H. Hilts of Alfa-Laval, Inc., J. W. Munger of Special Fluid Prod-
ucts, G. F. Krivejko of Pall Industrial Hydraulic Corporation, Wm. W. Nugent & Co.,
and Keene Corporation Fluid Handling Division. A debt of gratitude is owed to the
engineers at the electric utility companies that provided information about their
lubrication system maintenance practices, especially W. Gunst of San Antonio City
Public Service, H. R. Westerson of Los Angeles Department of Water and Power,
H. Franz of Southern California Edison Company, H. J. Shire of Commonwealth Edison
Company, R. F. Angeli of Detroit Edison Company, Chuck Kochanowski of Ohio Edison
Company, S. Molick of American Electric Service Corporation, J. G. Converse of
Carolina Power & Light, S. Mangan of South Carolina Electric and Gas Company, A. M.
Foote of Boston Edison Company, W. H. Broos of Georgia Power Company, R. McCloud of
Texas Electric Service Company, S. Matthey of Arkansas Power & Light Company,
R. K. Herdon of Alabama Power Company, and K. J. Brown of Ontario Hydro. The
authors wish to thank the turbine manufacturers for providing figures and equipment
details for this Guidebook, especially Dale C. Delano and Michael K. Russell of
General Electric Company, Paul W. Viscovich of Westinghouse Electric Corporation,
and Guenther Gartner of Utility Power Corporation.
v
CONTENTS
Section
SUMMARY S-1
1 INTRODUCTION 1-1
1.1 Lubrication System Reliability 1-1

1.2 Lubrication System Description and Functional Requirements 1-5
Lubrication System Components 1-6

Oil Pumps 1-6
Oil Reservoirs 1-11
Oil Piping 1-14
Heat Exchangers 1-16
Oil Conditioners 1-18
1.3 Lubricant Characteristics and Service Conditions 1-23
Viscosity 1-27
Oil Service Life 1-28
Heat Transfer Capability 1-28
Oxidation Resistance 1-29
Thermal/Oxidation Degradation 1-30
Foaming Resistance 1-31
Contamination 1-31
Particle Contamination 1-31

Water Contamination 1-32
Turbine Severity Level 1-35

Oil Suppliers 1-36
REFERENCES - Section 1 1-39
2 IDENTIFICATION OF TESTING AND MAINTENANCE REQUIREMENTS 2-1
2.1 Steam Turbine Oils 2-1
Specifications 2-1
Additives 2-1
Contamination 2-2
Analyses 2-2
Anti-Rust Protection 2-2

Remaining Oil Life 2-3
Viscosity 2-3
Total Acid Number (TAN) 2-6
Cleanliness 2-9
Foaming 2-12
Color/Appearance 2-14
vii
Section
Water Content 2-16

Flash Point 2-16
2.2 Mechanical Components 2-19
Reservoirs and Piping 2-19

Pumps and Vapor Extractors 2-20
Valves 2-24
2.3 Motors and Control Components 2-26
System Description 2-26

Scope 2-28
Rationale 2-28
Applicability 2-29
Dc Motors 2-30
Ac Motors 2-31
Motor Starters 2-32
Pressure Switches 2-33
Alarm Sensors 2-33
Liquid Level Switches 2-33
Temperature Switches 2-34
Cables and Wiring 2-35
2.4 Emergency Power Sources 2-36
Ac Power Supplies 2-36

Dc Power Supplies 2-37
Overload Protection Devices 2-39
3 TEST, INSPECTION, AND MAINTENANCE PRACTICES 3-1
3.1 Oil Condition Monitoring 3-1
Sampling Procedures 3-1

Sampling Schedules 3-2
Used Oil Property Limits 3-3
3.2 Mechanical Components 3-4
Reservoirs and Piping 3-4

Supplemental Flushing Equipment 3-6
High Pressure Water Jet Cleaning 3-22
Pumps and Vapor Extractors 3-23
Valves 3-34
3.3 Motors and Control Components 3-37
Scope 3-37
System Design Recommendations 3-37
viii
Section
Procedure Design Recommendations 3-40
Dc Motors - Weekly 3-42

Dc Motors - Monthly 3-42
Dc Motors - Quarterly 3-43
Dc Motors - Annual 3-43
Ac Motors - Weekly 3-44
Ac Motors - Monthly 3-45
Ac Motors - Annual 3-45
Motor Starters - Monthly 3-46
Pressure Switches - Monthly 3-47
Pressure Switches - Annual 3-47
Liquid Level Switches - Monthly 3-48
Liquid Level Switches - Annual 3-48
Temperature Switches - Annual 3-48
Cables and Wiring - Monthly 3-48
Cables and Wiring - Annual 3-49
3.4 Emergency Power Sources 3-50
Ac Power Supplies 3-50

Dc Power Supplies 3-51
4 TEST, INSPECTION, AND MAINTENANCE SCHEDULES 4-1
5 RESOURCES AND QUALITY CONTROL 5-1
One-Person Responsibility 5-1

Quality Control Program 5-2
Available Resources 5-3
REFERENCES - Sectidn 5 5-5
6 BEARING LUBRICATION PRINCIPLES 6-1
6.1 Frictional Response Characteristics 6-3

6.2 Operational (Lubrication) Regimes 6-6
6.3 Operational Modes of Full Film Lubricated Bearings 6-12
7 ROTOR DYNAMICS CONSIDERATIONS 7-1
7.1 Rotor Dynamics System 7-1

7.2 Rotor Dynamics-Related Failure Modes of Bearing Systems 7-3
7.3 Rotor Dynamics Analyses 7-6
APPENDIX A Industry Technical Organizations A-1
APPENDIX B Industry Business Organizations B-1
APPENDIX C ASTM Standards C-1
ix
Section
APPENDIX D Example of a Turbine Bearing Lubrication System

Flush Procedure D-l
APPENDIX E Hydrodynamic Full Film Lubrication E-l
APPENDIX F Hydrostatic (Oil Lift) Full Film Lubrication F-l
APPENDIX G Bibliography G-l
x
ILLUSTRATIONS
Figure
l-l(a) Subsystems of the Turbine Bearing System with Their

Interrelationships 1-2
l-l(b) Subsystems of the Turbine Bearing System with Inputs of Events

and Maintenance 1-3
1-2(a) Steam Turbine Generator Lubrication Supply, Return, and Reservoir

Subsystem 1-7
1-2(b) Schematic of Steam Turbine Generator Lubrication Supply, Return,

and Reservoir Subsystem 1-8
1-3(a) Arrangement of Oil System Pumps When an Oil Turbine Driven

Booster Pump Is Used 1-9
1-3(b) Arrangement of Oil System Pumps When Oil Ejectors Are Used 1-9
1-4 Oil Reservoir Levels and Capacities 1-12
1-5 Arrangement of Oil Reservoir Screens and Sediment Drain 1-13
1-6 Cross Section of Guard, Return, and Supply Piping Configuration 1-15
1-7 Telltale and Seals of an Oil Cooler 1-17
1-8 Sizing of Oil Conditioner Subsystem 1-19
1-9 Combination Vented Sight Overflow Device to Prevent Siphoning

and to Indicate Oil Reservoir Levels 1-19
1-10 Piping Arrangement for Bypass Oil Conditioner 1-20
1-11 Lubrication System Full Flow, In-Line Filters 1-22
1-12 Shaft Damage Caused by Carbon Deposits 1-33
1-13 Example of Equilibrium Water Concentration in a Turbine Oil

as a Function of Temperature 1-34
1-14 Example of Equilibrium Water Concentration in a Turbine Oil

as a Function of Relative Humidity 1-34
1-15 Effect of Makeup Rate on Oil Degradation 1-37
1-16 Effect of Turbine Severity (B) and Makeup Rate (M) on Oil Degradation 1-38
xi
Figure
2-1 Apparatus for Conducting the ASTM D 665 Test Method for Rust-
Preventing Characteristics 2-4
2-2 Apparatus for Conducting the ASTM D 2272 Test Method for Continuity
of Steam Turbine Oil Oxidation Stability by a Rotating Bomb 2-5
2-3 Apparatus for Conducting the ASTM D 445 Test Method for Kinematic
Viscosity 2-7
2-4 Apparatus for Conducting the ASTM D 664 Test Method for Neutraliza-
tion Number by Potentiometric Titration 2-8
2-5 Apparatus for Processing Liquid Samples for Particulate Contamina-

tion Analysis Using Membrane Filters (ASTM F 311) 2-10
2-6 Chart for Plotting Particle Count Results 2-13
2-7 Apparatus for Conducting the ASTM D 892 Test Method for Foaming
Characteristics of Lubricating Oils 2-15
2-8 Apparatus for Conducting the ASTM D 95 Test Method for Water in
Petroleum Products b~ Distillation 2-17
2-9 Apparatus for Conducting the ASTM D 92 Test Method for Flash and
Fire Points by a Cleveland Open Cup 2-18
2-10 Specification Sheet for Disposable Filter Cartridges 2-25
3-1 Settling Velocity for Particles in Turbine Lubricating Oil 3-7
3-2 Motor Driven Supplemental Flushing Pump 3-10
3-3 Full Flow Strainer 3-12
3-4 Cleanup Rate for Full Flow Filtration Vessels 3-13
3-5 Full Flow Cartridge Vessels 3-14
3-6 Auxiliary Oil Heat Exchangers 3-15
3-7 Flow Regulation Station 3-16
3-8 Piping Arrangement for Supplemental Flushing Equipment 3-18
3-9 Piping Arrangement for Bypassing Bearings During a Flush 3-19
3-10 Automatic Particle Counter 3-21
3-11 Motor Driven Auxiliary Oil Pump 3-24
3-12 Oil Conditioning Using Gravity Precipitation 3-28
3-13 Oil Conditioning Using Centrifugal Separation 3-29
3-14 Oil Conditioning Using Coalescer/Separator Filters 3-31
xii
Figure
3-15 Oil Conditioning Using Heated Oil/Vacuum Dehydration 3-32
3-16 Oil Conditioning Using Heated Air/Vacuum Dehydration 3-33
3-17 Oil Transfer Valve 3-35
3-18 Oil Throttle Valve 3-36
3-19 Piping Arrangements for Pressure Switches That Initiate Operation

of Motor Driven Oil Pumps 3-38
3-20 Pump Motor Starter Coil Lamp 3-41
3-21 Stationary Battery Report 3-53
6-1 Development of Hydrodynamic Oil Film 6-2
6-2. Frictional Response Characteristics of Sliding Surface Bearings 6-4
6-3 Variation of Coefficient of Friction of Sliding Surface Bearings 6-7
6-4 Schematic of Variations of Speed, Temperature, and Bearing Wear

as Functions of Time After Shutdown from Full Speed in a Bearing
Experiencing Metal-to-Metal Contact During Shutdown 6-9
6-5 Field Observations of Bearing Metal Temperature During

Coastdown with a Scored Journal 6-10
6-6 Lubrication Regimes Whereby Sliding Surface Bearings Provide

Load Support 6-11
6-7 Modes by Which Sliding Surface Bearings Achieve Full Film

Lubrication 6-13
6-8 Ideal Application of All Modes of Fluid Film Lubrication 6-15
7-1 Rotor Dynamics Model of a Large Steam Turbine (Generator not shown) 7-9
E-1 Formation of Converging Wedge in a Hydrodynamic Journal

Bearing and Resulting Pressure Distribution E-2
E-2 Thrust Bearing Surfaces E-3
E-3 Common Types of Purposefully Altered Surfaces for Promoting

Hydrodynamic Fluid Film Pressurization E-5
E-4 Performance Parameters of a Hydrodynamic Journal Bearing

(Laminar Flow) E-8
E-5 Oil Film Stiffness Parameters of a Hydrodynamic Journal

Bearing (Laminar Flow) E-9
E-6 Oil Film Damping Parameters of a Hydrodynamic Journal Bearing

(Laminar Flow) E-10
xiii
Figure
E-7 Comparison of Performance Parameters of a Hydrodynamic Journal

Bearing for Turbulent Operation (R N=8050) and for Laminar
Operation (RN=O) E-25
E-8 Comparison of Principal Direction Stiffness Parameters of

Hydrodynamic Journal Bearing for Turbulent Operation (R N=8050)
and for Laminar Operation (RN=O) E-26
E-9 Comparison of Cross-Coupled Stiffness Parameters of Hydrodynamic

Journal Bearing for Turbulent Operation (R N=8050) and for
Laminar Operation (RN=O) E-27
E-IO Comparison of Principal Direction Damping Parameters of

Hydrodynamic Journal Bearing for Turbulent Operation (RN=8050)
and for Laminar Operation (RN=O) E-28
E-ll Comparison of Cross-Coupled Damping Parameters of Hydrodynamic

Journal Bearing for Turbulent Operation (RN=8050) and for
Laminar Operation (RN=O) E-29
E-12 Schematic Views of Uncoupled Shafting When All Bearing

Centerpoints Are on the Same (Z) Axis E-32
E-13 Schematic Views of Coupled Shafting Showing Purposefully

Displaced Elevations (Yn) and Inclinations (an) of Journal
Bearing CL Axes E-34
E-14 Schematic Geometry of Aligned and Misaligned Journal Bearings

and Axial Distributions of Their Oil Film Pressure E-38
E-15 Minimum Film Thickness and Friction Power Parameters of a

Hydrodynamic Journal Bearing for Various Pitch-Direction
Misalignments E-42
E-16 Side-Leakage and Critical Deadweight Parameters of a Hydro-

dynamic Journal Bearing for Various Pitch-Direction Misalignments E-43
E-17 Pitch and Yaw Direction Moment Parameters of a Hydrodynamic

Journal Bearing for Various Pitch-Direction Misalignments E-44
E-18 Simplified Typical Heat Balance Model for Flowing Oil (Only One
Bearing Illustrated) E-51
E-19 Trends of Various Oil Temperatures as Functions of Supply Oil

Temperature for Sample Problem Bearing Supplied With an Oil
Flow Rate Equal to the Bearing Side-Leakage Flow Rate E-58
E-20 Trends of Bearing Performance as Functions of Supply Oil

Temperature E-59
F-l Cross Section of Hydrostatic (Oil-Lift) Journal Bearing at

Zero Speed Showing "Floated" Journal and Oil-Film Pressure
Distribution F-2
F-2 Typical Hydrostatic Bearing System F-4
xiv
Figure
F-3 Dimensionless Performance Characteristics of an Example Oil

Lift Journal Bearing Centrally Loaded and Perfectly Aligned F-8
F-4 Oil Lift Film Thickness and Recess Oil Pressure as Functions
of High Pressure Supply Oil Flow Rate for Example Oil Lift
Journal Bearing F-12
xv
TABLES
Table
1-1 Screen Mesh Sizes 1-13
1-2 ASTM Standards for Turbine Oils 1-24
1-3 ASTM Recommended Minimum Requirements for Mineral-Based Turbine Oil 1-26
2-1 Viscosity Conversion Factors 2-6
2-2 Comparison of SAE and NAS Cleanliness Classification Systems 2-11
2-3 Comparison of ISO Solid Contaminant Code to SAE, NAS, and ACFTD
Contamination Levels 2-14
2-4 IEEE Standards for Motors and Controls 2-27
3-1 Recommended Used Turbine Oil Property Limits 3-3
3-2 List of Resources Necessary for Performing High Velocity Flush 3-8
3-3 External Supplementary Flushing Pump Selection Data 3-9
4-1 Daily Test, Inspection, or Maintenance Activity Summary 4-4
4-2 Weekly Test, Inspection, or Maintenance Activity Summary 4-6
4-3 Monthly Test, Inspection, or Maintenance Activity Summary 4-8
4-4 Quarterly Test, Inspection, or Maintenance Activity Summary 4-10
4-5 Yearly Test, Inspection, or Maintenance Activity Summary 4-12
5-1 Quality Control Program Work Elements for All Lubrication System
Activities 5-3
5-2 Resources for Test, Inspection, and Maintenance Activities 5-4
A-I Technical Organizations for Lubricant and Lubrication System

Technology A-2
A-2 Publications on Lubrication A-4
A-3 Annual Conferences on Lubrication A-5
A-4 Technical Organizations for Motors and Controls Technology A-6
B-1 Business Organizations for Lubricant and Lubrication System

Technology B-2
xvii
Table
E-I Temperature-Dependent Physical Properties of a Typical

ISO-Second Lubricant for LST-G Units E-14
E-2 Predicted Performance Characteristics of Example Bearing E-18
E-3 Comparison of Predicted Performance of Example Bearing for Turbu-

lent Flow with Those for Assumed Laminar Flow (Perfectly Aligned) E-30
E-4 Effects of Pitch Misalignments on Performance Quantities of

Example Bearing Evaluation E-47
F-I Values of Pad Coefficients af and qf for a Hydrostatic

Oil Lift Journal Bearing at Zero (N=O) Rotational Speed
When Centrally Loaded and Perfectly Aligned F-7
F-2 Calculated Values of Oil Lift Film Thickness, Recess Pressure,

and High Pressure Supply Oil Flow Rate for Example (Oil Lift)
Journal Bearing F-Il
xviii
SUMMARY
INTRODUCTION
Satisfactory performance of a steam turbine generator unit depends on a thin inter-

face of oil separating the rotating journals from the stationary bearings. Any dis-
ruption in the quantity or quality of oil supplied through a continuous lubrication
system can have disastrous effects on the components of a turbine generator unit.
Normally, a lubrication system operates with very little attention, due to its sim-
plicity and automatic control. However, when an element of a system malfunctions,
prompt and proper attention must be given to restore that element to a functional
condition. Delayed or deficient corrective action can result in disabling a turbine
generator unit for several weeks to repair damaged journals, bearings, and seals.
It behooves an operating plant to perform test, inspection, and maintenance activi-
ties to determine the condition of the main lubrication system elements in order to
prevent malfunctions during unit operation.
The four main lubrication system elements are:
(1 ) Lubricant
(2) Mechanical components
(3) Electrical components
(4) Emergency power source
These elements must function reliably both during operation for long periods of
continuous service and immediately upon demand after long periods of standby duty.
Each element must function as intended for the lubrication system to be successful
in its mission.
The lubricant consists of a high quality mineral based oil compounded with rust and
oxidation inhibitors and can have selected additives to control foam, wear, demu1-
sibi1ity, or other factors. Mechanical components include pumps, reservoirs, pipes,
heat exchangers, oil conditioners, and valves, which control circulation of the
S-l
lubricant through the system. Electrical components include motors, starters, pres-
sure and level controls, alarms, monitors, and cables, which provide regulation and
automatic features. Emergency power sources consist of batteries, auxiliary steam
turbine drives, on-site and off-site ac power supplies, diesel generators, and over-
load protection devices, which supply energy to emergency pumps when normal and
auxiliary pumps fail to operate.
Each main element performs vital functions that are taken for granted, since deteri-
oration of components is usually a slow process occurring over several months or
years. The consequences of a component malfunction are so severe, however, that
they justify continuous and arduous surveillance of each component to assure that
it can perform its required function." Periodic test, inspection, and maintenance
activities must be practiced to assure that all vital functions can be performed
without compromise. The practice of these activities involves:
(1) Dedication of resources including time, manpower, equipment, and

money.
(2) Management involvement including control, direction, and incentive.
(3) Technical knowledge of tribology, mechanical engineering, and elec-

trical energy.
Misjudgments of priorities and lapses in surveillance can suddenly result in a tur-

bine catastrophe. The likelihood that any vital activity will be overlooked can be
diminished when plant personnel have knowledge of system elements, characteristics,
and deterioration modes. This knowledge, coupled with a conviction to practice sur-
veillance activities in a systematic manner, can significantly decrease the prob-
ability that component deterioration will go unnoticed and unrepaired.
PURPOSE AND SCOPE
The purpose of this Guidebook is to provide a single reference source for use by
power plant personnel for establishment and practice of a lubrication system sur-
veillance program. These gui.delines are intended to aid plant personnel who are
responsible for operating, testing, and maintaining a turbine lubrication system.
Background information on lubricants, mechanical and electrical components, bearing
design, and lubrication principles is provided. Detailed information on lubrica-
tion system surveillance practices has been acquired from utility plant staffs,
turbine manufacturers, insurance companies, oil and auxiliary equipment suppliers,
technical societies, and the open literature. This information includes details on
5-2
component deterioration modes and on guidelines for surveillance activities. Addi-
tional details are provided for establishing one-person responsibility, quality con-
trol, and a network for professional assistance. Information is also provided on
bearing lubrication principles and on rotor dynamic aspects of bearings.
These guidelines are for use in establishing and conducting test, inspection, and
maintenance practices for each turbine generator unit operated at a power station.
Specific equipment, piping, components, and power supply schemes for each unit must
be incorporated with these guidelines into a comprehensive program that is exclu-
sive to the unit. Reference to manufacturers' instruction manuals is required when
developing maintenance practices from these guidelines. The guidelines encourage
written procedures, schedules, and reports with quality control measures explaining
the proper conduct of a practice and documenting its performance and findings.
OUTLINE
The Guidebook is divided into seven major sections with seven appendixes. Section 1
contains background information on lubrication system components, lubricant charac-
teristics, and service conditions. Sections 2 through 5 contain specific informa-
tion about testing, inspection, and maintenance activities, schedules, resources,
and quality control. Section 6 contains information on lubrication principles for
turbine bearingse Section 7 contains information on rotor dynamics. The appendixes
contain lists of technical and business organizations that can provide technical
information, services, equipment, or other resources of value to those responsible
for lubrication system surveillance. Current ASTM Standards pertaining to system
design and lubricant specification and monitoring are provided. An example of a
lubrication system flushing procedure is included. Technical details about hydro-
dynamic and hydrostatic modes of lubrication are given and a bibliography of tech-
nical literature is provided.
Section 1 - Introduction
Section 1 introduces the subject of lubrication system operation. Typical system

components are described with their functional requirements explained. Important
lubricant characteristics and typical service conditions are identified.
Section 2 - Identification of Testing and Maintenance Requirements
Section 2 identifies the testing and maintenance activities required to monitor the
condition of a lubrication system. Components from each of the four main system
elements are covered.
S-3
Section 3 - Test, Inspection, and Maintenance Practices
Section 3 provides details for establishing a complete surveillance program to

perform the testing and maintenance activities identified in Section 2. Specific
activities are included for each major lubrication system component.
Section 4 - Test, Inspection, and Maintenance Schedules
Section 4 contains master lists of test, inspection, and maintenance activities

according to performance frequency. Schedules are provided for daily, weekly,
monthly, quarterly, and yearly performance.
Section 5 - Resources and Quality Control
Section 5 contains suggestions for establishment of a surveillance program. Infor-

mation is presented for assignment of one-person responsibility to assure coordina-
tion, continuity, and completion of all program activities. Quality control measures
and additional resources are identified that are necessary to achieve a complete
professional program.
Section 6 - Bearing Lubrication Principles
Section 6 explains the principles involved in bearing lubrication during various

operational modes. Frictional response characteristics are discussed in relation-
ship to the bearing parameter.
Section 7 - Rotor Dynamics Considerations
Section 7 contains a discussion of important factors for rotor stability with regard
to failure modes of bearing systems. Bearing analyses for stability and response
are discussed.
Appendix A - Industry Technical Organizations
Appendix A contains lists of the significant technical organizations that sponsor

conferences, publish literature, and support activities related to the four main
lubrication system elements.
Appendix B - Industry Business Organizations
Appendix B contains lists of the significant business organizations that provide

professional expertise, services, or equipment in support of an in-plant lubrica-
tion system surveillance program.
5-4
Appendix C - ASTM Standards
Appendix C contains three ASTM Standards for designing a lubrication system, spec-
ifying a turbine lubricant, and monitoring the condition of a lubricant during
service. The three ASTM Standards are:
D 4248-83: Standard Practice for Design of Steam Turbine Generator

Oil Systems
D 4304-84: Standard Specification for Mineral Lubricating Oil Used

in Steam or Gas Turbines
D 4378-84: Standard Practice for In-Service Monitoring of Mineral

Turbine Oils for Steam and Gas Turbines
Appendix D - Example of a Utility Bearing Oil System Flush Procedure
Appendix D contains a procedure that was developed by one utility for use after
major inspections of a particular turbine generator unit. Examples of instructions
and checklists are provided to illustrate the necessary steps prior to, during, and
after the flushing process.
Appendix E - Hydrodynamic Mode of Full Film Lubrication
Appendix E explains the theory of hydrodynamic lubrication. Factors affecting the

load-carrying and other performance parameters are discussed. Analytical methods
to predict bearing performance characteristics and capabilities are presented and
examples are given.
Appendix F - Hydrostatic Mode of Full Film Lubrication
Appendix F explains the need for and use of hydrostatic or oil lift bearings to pro-
vide a full film in the absence of hydrodynamic action. Relationships between load,
film thickness, flow rate, viscosity, and pressure are presented. An example evalu-
ation is given.
Appendix G - Bibliography
Appendix G lists numerous technical papers for journal bearings, lubrication sys-
tems, maintenance, diagnostics, and miscellaneous problem areas.
8-5
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Section 1
INTRODUCTION
1.1 LUBRICATION SYSTEM RELIABILITY
The lubrication system of a steam turbine generator unit performs the vital function
of supplying lubricating oil to the thrust and journal type bearings at all times
under all operating conditions. Without proper design, installation, operation, and
maintenance of the lubrication system, reliable performance of the turbine generator
unit cannot be achieved. Failure of the lubrication syste~ to perform its function
can cause significant damage to the turbine generator. While lubrication system
failures are not common occurrences, they can result in extended unit outages to
repair or replace damaged turbine generator components such as blades, casings,
rotor windings, and entire shafts.
The term "lubrication system," as used in this Guidebook, refers to three of the
eight interdependent subsystems identified in an earlier EPRI project ["Failure-
Cause Analysis: Turbine Bearing Systems" (RP1265-3)] as necessary for successful
operation of a turbine generator "bearing system" (.!..). Each subsystem joins with
the others to form. a "bearing system" which allows a turbine generator rotor to
rotate at high revolutions per minute but at a low vibration level. Figures 1-1(a)
and 1-1(b) from Reference 1 present the overall "bearing system" and the eight sub-
systems. In Figure 1-1(a) the connecting lines illustrate the functions and inter-
relationships of the various subsystems. In Figure 1-1(b) the long-dash lines
represent inputs of events that are "communicated" to the operator and/or the con-
trol subsystem. The short-dash lines connecting the human interfaces to the other
seven subsystems imply input primarily by maintenance and repair personnel. This
report details the maintenance practices needed for a lubrication system that
includes all parts of the subsystems identified in Figure 1-1 as "LUBRICATION
SUPPLY/RETURN/RESERVOIR" and "LUBRICANT/PURIFICATION" and some parts of the subsys-
tems identified as "INSTRUMENTATION/ALARM" and "CONTROLS." Subsection 1.2 of this
report describes the lubrication system components and functional requirements.
This report also contains information on lubrication principles for "OIL FILM
BEARINGS."
1-1
LOCATES AND SPATIAL LOCATIONS AND
--
""""'I11III
ORIENTS ROTOR
.... OIL FILM BEARINGS
-
~
ORIENTATIONS OF BEARINGS
HOUSINGS/PEDESTALS/
~ FOUNDATIONS
'LOADINGS ON BEARINGS LOADINGS ON BEARING
HYDRAULIC
I
SUFFICIENT,
SUPPORT STRUCTURE
ROTOR/STATOR RESISTANCE CLEAN, COOL,

PRESSURIZED
STANDBY/EMERGENCY *
SUPPLY-OIL
PUMPS -. LUBRICATION SUPPLY / I... MANUAL CONTROL

~
RETURN/RESERVOIR

i
THROTTLE DEGRADED SPECIFIED

OIL OIL
AUTOMATIC *
t--'
N
I
l
CONTROL
- LUBRICANT/
PURIFICATION
~
........-
MANUAL CONTROL
SYSTEM
INSTRUMENTATION/ STATUS
ALARM HUMAN INTERFACES
SYSTEM
~ STATUS
~
--
- CONTROLS
~ OPERATOR ACTIONS *
Figure l-l(a). Subsystems of the turbine bearing system with their interrelationships. A turbine
bearing system consists of eight subsystems. The subsystems Oil Film Bearings, Lubrication Supp1y/
Return/Reservoir, Lubricant/Purification, Instrumentation/Alarm, and Controls are the subjects of
concern in this Guidebook.
r1 OIL FILM BEARINGS r---1
1 h II
I
r-: ROTOR/STATOR
BEARING TEMPERATURE &
VIBRATION INFORMATION
:
:
I
I HOUSINGS/PEDESTALS/
FOUNDATIONS
A
VIBRATION, II OIL
SAMPLING
I
1
~~R
SPEED,
RADIAL &
AXIAL II LUBRICATION SUPPLY/
RETURN/RESERVOIR 1. M/R I M/R
I II
I
DISPLACEMENT SUPPLY OIL PRESSURE AND

II
INFORMATION
I TEMPERATURE; DRAIN AND
RESERVOIR OIL TEMPERATURE I
MAINTENANCE/
REPAIR (M/R)
I II II LUBRICANT/
PURIFICATION
LEVEL AND FLOW OIL
-
I I
I I
A :
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I INFORMATION SAMPLING I I
La ' I
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. M/R I I
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M/R
I CONTROLS I
_ _ _ M/R
::l
I
..J
I
~ J
- - - - - - MAINTENANCE/REPAIR
-- -- - DATA/EVENTS
Figure l-l(b). Subsystems of the turbine bearing system with inputs of events and maintenance.
This Guidebook contains maintenance guidelines for the subsystems Lubrication Supp1y/Return/
Reservoir, Lubricant/Purification, Instrumentation/Alarm, and Controls. The Guidebook also
contains operating principles of Oil Film Bearings.
An EPRI-sponsored survey of the electric power industry was conducted as part of a
failure cause analysis of turbine generator bearing systems (!). The survey estab-
lished that two of the three major failure areas of turbine generator bearing sys-
tems involved the lubrication supply/return/reservoir, lubricant/purification, and
instrum~ntation/alarm subsystems. Backup oil supply failures and lubricant purity
failures were identified as major failure areas because they usually result in a
forced outage of extended duration and a large power generation loss. Outages
caused by these two failure types during the two-year study period from January
1979 through December 1980 resulted in a 0.9 percent loss in power generation and
an estimated annual cost to the industry of over 600 million dollars. The results
of the study indicated that improvements in testing and maintenance practices for
backup supply systems and lubricant quality could help in prevention of such fail-
ures. During the study, wide variation was found from plant to plant and from util-
ity to utility in the amount of concern for the lubrication system as measured by
the following parameters:
(1) Frequency of testing and maintenance
(2) Types of tests and maintenance
(3) Documentation of procedures and results
(4) Equipment available at plant or within utility
(5) Technical expertise within utility
(6) Plant staff dedicated to lubrication
In one plant it was revealed that a test was regularly performed on one unit (but
not on the other only because one manufacturer's instruction book recommended the
test while the other manufacturer's manual. did not mention it. The test involved
simulated automatic startup of the backup supply system, which is applicable to
both types of units.
This Guidebook was prepared to satisfy the need of electric generating plant person-
nel for a comprehensive manual that identifies and describes pertinent testing and
maintenance practices applicable to the lubricant and lubrication system for reli-
ability. The Guidebook also provides technical discussions on basic operating prin-
ciples for oil film bearings. The previously mentioned EPRI survey revealed a lack
of understanding by plant personnel of how turbine bearings operate and of the
important principles for achieving satisfactory turbine operation. The technical
discussions provide information about the effects of the various bearing and lubri-
cant characteristics on bearing performance and rotor stability.
1-4
1.2 LUBRICATION SYSTEM DESCRIPTION AND FUNCTIONAL REQUIREMENTS
The lubrication system provides a clean, cool, and copious supply of refined petro-
leum oil for lubrication of the multiple journal bearings and the thrust bearing of
a steam turbine generator unit. The lubrication system also provides for retention
of the generator hydrogen cooling gas, and may provide for emergency closure of the
turbine steam regulation valves. The lubricant must also provide for corrosion pro-
tection of the lubrication system internal seal and contact surfaces.
Operation of a lubrication system is relatively simple when the turbine generator

unit is at full operating speed. A main shaft oil pump (MSOP) connected to the tur-
bine shaft provides high pressure oil to the system. The complexity of the lubrica-
tion system is increased when the turbine generator unit is below full operating
speed because the MSOP is not capable of providing high pressure oil when the shaft
speed is below approximately 90 percent of full operating speed. Auxiliary motor
driven oil pumps (AOP) and subsystems are necessary to replace the MSOP during tur-
bine generator startups and shutdowns. Emergency oil pumps (EOP) and subsystems
are provided as backup to the MSOP and AOP subsystems to allow safe shutdown of the
turbine generator unit. The EOP may be driven by either a dc electric motor or a
st,eam turbine. Elaborate instrumentation and power supply schemes are involved to
start up the AOP and/or EOP when the bearing oil pressure decays below a specific
set point.
Design of the lubrication system is usually provided by the original equipment manu-
facturer (OEM) as part of the scope of supply for the main steam turbine generator
unit. The utility as owner and operator must provide specifications for the system
and the numerous interfaces for power supplies, oil supply, and instrumentation and
control. To aid in obtaining satisfactory performance of the lubrication system,
the American Society for Testing and Materials (ASTM) has issued a standard practice
titled "Design of Steam Turbine Generator Oil Systems (D 4248-83)" <.~). This Stan-
dard provides recommended practices for design of the turbine generator lubrication
system including the high pressure supply, bearing oil, control oil, generator seal
oil, and drain oil return subsystems. The 1983 Edition of this Standard is included
in Appendix C.
The lubrication system may also include the oil supply and return lines for a
boiler feed pump, hydraulic coupling, or pump driver. The above ASTM standard pro-
vides recommendations for lubrication system materials and components including
pumps, reservoirs, piping, heat exchangers, filters, and instruments. This ASTM
standard replaces the earlier ASME Standard Practice No. 116 titled "Recommended
1-5
Practices for the Design of Steam Turbine Generator Oil System" published in 1968
by the Joint ASTM-ASME-NEMA Committee on Hydroelectric Turbine Lubrication Sys-
tems (i). Another widely used standard is American Petroleum Institute (API) Stan-
dard 614 titled "Lubrication, Shaft-Sealing, and Control Oil Systems for Special-
Purpose Applications" (~).
Lubrication System Components
The primary purpose of the lubrication system is to provide a continuous flow of oil
to all bearings and seals of the turbine generator. To accomplish this, several
subsystems must function on demand if the primary pumping system malfunctions.
These subsystems are composed of electrical and mechanical components which must be
designed and maintained for high reliability. Electrical components include motors,
motor starters, pressure and level switches, batteries, cables, and circuit breakers.
Mechanical components include pumps, reservoirs, vapor extractors, piping, heat
exchangers, and oil conditioners. A typical arrangement of mechanical components
is illustrated in Figure 1-2(a), and a schematic of the arrangement is shown in
Figure 1-2(b).
Oil Pumps
Pumps are required to circulate oil from the main storage reservoir to the bearings,
seals, and controls. The pumps must provide sufficient oil flow to each bearing
during startup, shutdown, turning gear, and full speed operation. Figures 1-3(a)
and 1-3(b) are schematics showing the piping arrangements for various pumps used
for primary and backup functions.
The primary pumping system supplies oil during full speed operation through the main
shaft oil pump. The MSOP is connected to and driven by the main turbine generator
rotor shaft. The MSOP is usually a centrifugal pump that is not self-priming, and
since it is located above the oil reservoir it must be supplied with oil from the
reservoir by another means. Oil to the MSOP suction is supplied by either a motor
driven suction pump (MSP), an oil turbine driven booster pump, or oil ejectors. The
MSP supplies suction oil when the turbine generator shaft is rotating below approxi-
mately 90 percent of its normal speed. When the turbine generator shaft is rotating
above 90 percent of its normal speed, oil from the MSOP discharge can be used to
supply either an oil turbine driven booster pump or oil ejectors. The oil turbine
driven booster pump or oil ejectors are located in the main oil reservoir along with
associated flow regulation valves.
1-6
EXCITER
ELECTRIC GENERATOR AND

H2 ENCLOSURE
"B" LOW PRESSURE TURBINE
"A"LOW PRESSURE TURBINE

OIL VAPOR
EXTRACTOR
HIGH PRESSURE AND
REHEAT TURBINE
AIR DETRAINING
SECTION MAIN SHAFT OIL PUMP
(MSOP)
TO HYDROGEN
SEAL UNIT
GRAVITY
1--1
I DRAIN AND
'-J
GUARD PIPE
PRESSURIZED
OIL PIPES
OIL VAPOR EXTRACTOR
OIL RETURN
AUXILIARY
SCREENS
A.C. (AOP) OIL PUMP
\1\;". > OIL

D. C. EMERGENCY
COOLERS
(EOP) OIL PUMP
OIL RESERVOIR AND

OIL EJECTORS
Figure 1-2(a). Steam turbine generator lubrication supply, return, and reservoir subsystem.
A typical arrangement of the mechanical components of a lubrication system except for the oil
conditioners and make-up supply connections. Arrangement varies with the turbine manufacturer.
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t AIR DETRAINING SECTION
GRAVITY DRAIN AND GUARD PIPE
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I LOOP SEAL
I OIL VAPOR EXTRACTOR
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I.-
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Ii r r~E~; BOUNDARY OF SYSTEM THAT IS EVACUATED
! L--~-=-_=__=__=__=__=_!_==_~ik I
- - - - - BY OIL VAPOR EXTRACTORS
- - - - - - PRESSURIZED OIL PIPING
I I.--------------------~ I
OIL RESERVOIR
Figure 1-2(b). Schematic of steam turbine generator lubrication supply, return, and reservoir subsystem.
Lubricant is continuously pumped to the bearings, couplings, and seals where it drains into the return
piping and flows back to the reservoir for recirculation.
200-300 PSIG
MAIN TURBINE
SHAFT TO BEARING
SUPPLY HEADER
MOTOR DRIVEN TURBINE DRIVEN MOTOR DRIVEN MOTOR DRIVEN

SUCTION PUMP BOOSTER PUMP AUXILIARY PUMP EMERGENCY PUMP
PRIMARY PUMPING SYSTEM BACK-UP PUMPING SYSTEM
Figure 1-3(a). Arrangement of Oil System Pumps When an Oil Turbine

Driven Booster Pump Is Used
320-380 PSIG
MAIN TURBINE
SHAFT TO BEARING
25-30 PSIG
SUPPLY HEADER
SUCTION BEARING
OIL OIL MOTOR DRIVEN MOTOR DRIVEN
INJECTOR INJECTOR AUXILIARY PUMP EMERGENCY PUMP
PRIMARY PUMPING SYSTEM BACK-UP PUMPING SYSTEM
Figure l-3(b). Arrangement of Oil System Pumps When Oil Ejectors Are Used
1-9
When an oil turbine driven booster pump is used as shown in Figure 1-3(a), two
baffler valves and a relief valve are provided for adjustment of the oil pressure
and flow. The booster nozzle baffler valve controls the oil supply from the dis-
charge of the MSOP to the oil turbine. The bypass baffler valve allows oil from
the discharge of the MSOP to flow around the oil turbine. These two valves are
adjusted to provide the following conditions:
(1) The booster nozzle baffler valve must pass sufficient oil to
supply power to the oil turbine for pumping oil to the suction of
the MSOP. MSOP suction pressure should be approximately 15 psig
(103.4 kPa). The valve plug is drilled to allow a minimum of
60 percent of the bearing oil flow requirement to pass should the
valve be unintentionally closed.
(2) The flow through the oil turbine plus the bypass baffler valve
must be sufficient to supply all of the turbine bearings plus
maintain some flow through the relief valve. The relief valve is
commonly adjusted to hold bearing header pressure at 25 psig
(172.4 kPa) at the turbine centerline.
When oil ejectors are used as shown in Figure 1-3(b), the nozzle inlet of each ejec-
tor is supplied with motive oil from the discharge of the MSOP. Each ejector con-
sists of a nozzle, pickup chamber, throat, and diffuser. As oil passes through the
ejector, it creates a low pressure zone in the pickup chamber which draws oil from
the reservoir. The quantity of oil picked up from the reservoir is approximately
equal to the quantity provided to the nozzle inlet by the MSOP. One ejector pro-
vides oil for the suction of the MSOP while the other ejector discharges oil into
the bearing oil supply header after passing through the oil coolers.
The backup pumping system consists of one or more ac motor driven auxiliary pumps
and a dc motor driven or steam turbine. driven emergency pump. The auxiliary and
emergency pump drivers are sized to provide adequate capacity even when operating
with a high oil viscosity such as can be obtained during cold startups of the unit.
The auxiliary oil pump has enough capacity to permit continued turbine generator
operation if the MSOP fails; however, unit shutdown should commence upon MSOP fail-
ure. The emergency pump should be sized to supply oil during unit coastdown upon
failure of the main and auxiliary oil pumps.
All pumps except the MSOP are located within the main oil reservoir to provide for
positive suction. The pumps are submerged with their suction inlet located at least
6 inches (150 mm) below the minimum operating level and 6 inches (150 rom) above the
bottom of the reservoir. They are arranged to avoid air pockets in the suction
piping and entrainment of air. Emergency oil pump suction is lower than that of
1-10
other pumps to provide shutdown oil even with loss of oil to other pumps in the
reservoir. The suction systems of all pumps are provided with coarse mesh strainers
for protection from large pieces of debris.
Oil Reservoirs
Oil reservoirs or oil tanks are required to provide an oil reserve during turbine
generator operation and for oil storage when the unit is shut down. One main oil
reservoir is usually provided for each turbine generator unit with sufficient capac-
ity to store a full charge of oil. A full charge is the amount of oil being circu-
lated in the lubrication system piping and bearings plus the volume of oil in the
reservoir required for oil pump submergence. Other oil storage tanks are required
in the plant for storage of makeup oil and cleanup of the oil charge during turbine
generator overhaul periods. The bearing pedestals or housings also serve as small
reservoirs to collect oil used for lubrication and cooling and to direct the oil
into the return piping.
The main oil reservoir is located below the turbine generator operating floor so
that oil returns to the reservoir from the bearings by the force of gravity. Fig-
ure 1-4 illustrates the various reservoir oil levels as defined in API Standard 614.
To allow for separation of entrained air and settling by gravity of water and solid
contaminants, retention time of oil in the reservoir should be 8 minutes. Division
panels or baffles may be employed to provide a longer flow path through the reser-
voir. Reservoirs with a capacity of 15,000 gallons are common since the working
capacity between Levels C and D should be at least five times the normal oil flow
to the bearings and seals.
Air in the oil can result in excessive oil foaming, air entrainment, and oxidation.
Design of the reservoir should minimize turbulence at the oil return line discharge
and maximize oil deaeration. The reservoir should provide surface area and reten-
tion time to enhance air separation from the oil. API Standard 614 specifies a min-
imum of 0.25 square foot (0.023 m2 ) of free oil surface for each gallon (3.7 liters)
per minute of normal oil flow.
The bottom of the reservoir should slope toward a low point drain at a rate of
1/2 inch/foot (40 mm/m) or greater. To prevent accidental draining of the tank, the
bottom drain connection should have a locked valve. All open lines should be blanked
or capped to prevent a leaking valve from spilling oil. Connections for the oil
purification system are provided so that the supply oil is taken from as close as
possible to the reservoir bottom. The oil purification system connections should
be arranged so that siphoning of the reservoir below a safe level is not possible.
1-11
A- -RUNDOWN-LEVEL-~- - - - - - - -
B - __M~~I~U_MJ>!:E!!~~Cl.LEV.EI:...~
- --
SUCTION LOSS LEVEL ---....

0-----------------------
PUMP SUCTION LEVEL ---....
E----------------------
Charge capacity is the total volume below Level A.

Low level alarm is set at Level C.
Normal operating range is any level between Levels Band C.
Retention capacity is the total volume below Level C.
Rundown capacity is the volume between Levels A and B.
Suction loss level, Level D, is above Level E as required by pump
suction vortex and net pump suction head requirements.
Working capacity is the volume between Levels C and D.
Figure 1-4. Oil Reservoir Levels and Capacities

Source: API Standard 614 (Reference 5).
Oil returning to the reservoir passes through strainers or screens to trap any
debris that may be transported by the oil. ASTM D 4248 recommends that the strainer
openings be smaller than 0.025 inch (0.6 mm) or approximately 30 standard sieve num-
ber mesh. Higher mesh numbers up to 150 mesh are used by some turbine manufacturers
for normal operation and especially during lubrication system flushing. Table 1-1
lists the units of measurement equivalents for various meshes commonly used for
strainer material (~). A small opening size will retain smaller sized debris, and
the possibility of screen blockage is increased. More frequent monitoring of oil
level before the screens and cleaning of the screens are necessary when screens with
high mesh numbers are used. A means for removal, inspection, and cleaning of the
screens while the turbine generator unit is in operation should be provided. Fig-
ure 1-5 shows a typical arrangement for two screens in series, which allows one
screen to be cleaned while the other screen remains in place. Another common
arrangement which is not shown employs a basket. type strainer. Spare screens should
be considered to minimize the time period that either screen is out of the oil stream.
1-12
Table 1-1
SCREEN MESH SIZES
Mesh Opening Designation

Number, USA ISO
Medium Opening Industrial Metric
C Grade (inch) Standard (inch) Standard (lJm)
10 0.0680 0.0661 1700

30 0.0198 0.0197 500
50 0.0115 0.0117 300
60 0.0097 0.0098 250
100 0.0060 0.0059 150
140 0.0041 0.0041 106
200 0.0029 0.0029 75
400 0.0015 0.0015 38
Source: "Standard Specification for Industrial Wire Cloth and Screens, E437-80."
1984 Annual Book of ASTM Standards: Steel-Plate, Sheet, Strip, Wire. Vol.01.03.
Philadelphia: ASTM, 1984.
ACCESS OPENING
TO REMOVE SCREENS
BACK TO BACK
FINE MESH REMOVABLE SCREENS
TANK TOP
TOP OF SCREENS -----R-----_ TOP OF COMPARTMENT

SIDEWALL
COMPARTMENT
CAP/
VALVE
J SEDIMENT
DRAIN
FLOOR
(NORMALLY TANK BOTTOM

CLOSED)
Figure 1-5. Arrangement of oil reservoir screens and sediment drain.

Spare screens and screen removal cleaning devices are important con-
siderations often not provided in the original plant design but nec-
essary for screen maintenance.
Source: General Electric Company.
1-13
Oil reservoir access covers or top doors can provide for relief of pressure in the
reservoir should a hydrogen gas or oil vapor explosion occur (l). These covers
should not be locked down unless an alternative explosion relief device is provided
which is capable of maintaining the reservoir internal pressure at a safe level.
Covers, doors, and other reservoir openings should be kept closed and sealed to min-
imize ingress of dust and other contaminants.
A vapor extractor is connected to the highest point of the reservoir to remove any
accumulation of gases and oil vapors that form in the reservoir, return oil piping,
and bearing housings. The vapor extractor produces a slight vacuum in these compo-
nents. Vacuum level should be optimized and monitored to prevent oil vapors from
leaking out of the bearing housing seals and to limit the amount of air and airborne
contaminants that enter the lubrication system. A vacuum level of 1/2 inch (1.27 cm)
of water is recommended (~), but the actual level depends on condition of the oil
deflector seals and reservoir access door seals. Periodic inspection and replace-
ment of these seals will be necessary to control the amount of air and contaminants
drawn into the lubrication system.
A demister or oil mist eliminator is often needed and is mounted on the vapor
extractor piping to remove entrained liquid from the vapors. Vapor extractor dis-
charge is routed to a remote open-air location, since the oil vapor and gases are
flammable and may even be explosive. The liquid is collected for reclamation or
disposal.
Oil Piping
The lubrication system is composed of several hundred feet of piping that may be
30 inches (76.2 cm) or more in diameter. Piping is often designed to American
National Standards Institute (ANSI) Standard B31, "Code for Pressure Piping, Sec-
tion 1, Power Piping," since it must be rugged and reliable. Design of the oil
piping minimizes potential for fire since all pressurized piping is enclosed in
guards or troughs. Welded construction is also utilized to prevent leakage at
joints. Piping design also minimizes the potential for contamination and the pos-
sibility of localized oil heating from external sources. Piping must withstand
vibration and thermal expansion and must provide for inspection, cleaning, and
flushing. Usually oil piping is constructed of carbon steel material because stain-
less steel piping is three to four times more expensive and is not justifiable except
in some limited sections of the system (~).
1-14
Thick walled, small diameter piping supplies oil to the bearing at a pressure of
15-25 psig (103-172 kPa). Oil flows from the bearings by gravity through large
diameter return lines. These lines often serve as the guard or enclosure for pres-
surized feed piping. Figure 1-6 illustrates this arrangement. Return lines are
designed to be no more than one-half full during normal operation so that the vapor
extractor on the oil reservoir can pull a vacuum in the bearing housings and the oil
can return with minimum flow restriction.
DISCHARGE AND SUCTION

LINES FOR MAIN SHAFT
OIL PUMP
SUPPLY LINES
TO TURBINE
AND GENERATOR
BEARINGS
~GRAVITY DRAIN
OIL RETURN LINE
AND GUARD PIPE
FOR PRESSURIZED
OIL SUPPLY LINES
BACK-UP SUPPLY
LINE TO HYDROGEN
SEAL SYSTEM
Figure 1-6. Cross section of guard, return, and supply piping configuration.
The oil return line acts as a guard pipe for the pressurized oil supply lines
to prevent leakage of oil onto hot steam pipes that could result in a fire
hazard. Inspection and cleanout ports are important for return lines to
locate leaks and remove contamination.
The inside surface of the return piping and the external surface of the supply pip-
ing are coated with an oil-soluble or permanent type rust preventive as part of the
manufacturing process.
1-15
Flow through the piping to the bearings is regulated by orifices or flow control
valves at each bearing. The amount of oil supplied is set to limit the oil tempera-
ture rise to a maximum of 50F (27.7C) with the inlet oil at a temperature of 110F
(43.3C). Actual flow to the bearing depends on oil viscosity, so oil temperature
should be maintained close to the design value.
Oil exposed to hydrogen gas in the generator is separated from the turbine drain
system to prevent entry of hydrogen into the main oil reservoir. Isolation is
accomplished by placing a hydrogen detraining section and a loop seal in the return
line between the generator bearings and the main oil reservoir. The hydrogen
detraining section is a large diameter pipe with internal dams, screens, and baf-
fles, which reduce oil velocity, maintain oil level, and hold back and break up
foam and allow hydrogen gas to escape. Oil level is maintained in the detraining
section by a dam around the loop seal drain. A vapor extractor is sometimes pro-
vided to remove detrained hydrogen and air and to produce a slight vacuum in the
generator bearing housings.
Heat Exchangers
Heat exchangers or oil coolers are provided to remove heat acquired by the oil as
it circulates through the lubrication system. Usually two coolers are installed in
parallel so that one is used as a spare in case the operating cooler develops a leak
or becomes fouled. Since cooling water flows through the inside of the tubes, the
inside is likely to become plugged or dirty and require frequent cleaning. Coolers
are located at the discharge of the oil pumps so that the oil is cooled before it
is distributed to the bearings.
The oil circuit side may also require periodic cleaning to remove sludge or other
system debris that can accumulate within the shell. Since solubility of some oil
oxidation products decreases with decreasing temperature, these products will pre-
cipitate and deposit in the oil cooler. Frequency of oil side cleaning depends on
the amount of oxidation experienced by the lubrication oil.
To facilitate transfer from one cooler to the other, interlocking three-way inlet
and outlet valves are used. These valves are designed so that oil flow is not
interrupted when performing the transfer. In some parts of the country where sea-
sonal water temperature is unusually high, it is sometimes necessary to operate both
oil coolers simultaneously and with special operating precautions.
1-16
Oil coolers are continuously vented through a small line that connects the cooler
from just below the top tubesheet to the main reservoir. A sight flow is installed
in each vent line to allow visual observation of oil flow. The continuous vent pre-
vents accumulation of air and gases in the coolers and keeps the spare cooler full
of oil and ready for immediate operation.
Telltales are provided to indicate leakage across packing seals that may be used to
separate the oil side from the water side of the cooler. Figure 1-7 illustrates
such a seal between the floating tubesheet end and the water box.
TELLTALE
1. LANTERN RING
2. WATERSIDE PACKING SEAL
3. OILSIDE PACKING SEAL
4. FLOATING WATER BOX
5. COVER GASKET
6. FLOATING WATER BOX COVER
Figure 1-7. Telltale and seals of an oil cooler. Seals and gaskets
deteriorate over time and require visual observation of their seal-
ing capability.
1-17
Oil coolers are pressure vessels and are designed in accordance with the ASME Boiler
and Pressure Code, Section VIII, "Rules for Construction of Pressure Vessels."
Coolers have a design pressure rating which may limit the pumping capacity available
for use during lubrication system flushing.
When copper alloy tubes are used, water velocity through the tube should be no more
than 5 to 8 feet per second (1.5 to 2.4 m/sec) to prevent erosion and subsequent
tube leaks. The water velocity may be higher for stainless steel tubes. API Stan-
dard 614 calls for the oil side pressure to be greater than the water side; however,
at least one turbine manufacturer prefers the opposite pressure differential to
eliminate one potential path for accidentally draining all oil from the lubrication
system. A minimum cooling water flow should also be considered to prevent pitting
corrosion and bacterial interactions.
Oil Conditioners
Oil conditioners are provided to remove water and solid particle contamination that
enters or is produced in the lubrication system. Usually these components are used
in a bypass or supplementary mode in which oil flows from the reservoir, through the
conditioner, and directly back into the reservoir. Various types of conditioners
are employed includ-ing particulate filters, oil centrifuges, precipitation chambers,
vacuum dehydration tanks, and coalescence cartridges. Adsorption purification that
utilizes an active medium such as fuller's earth is not recommended since some of
the additives in inhibited oil may be removed by this material (lQ). Water washing
of oils containing rust and oxidation inhibitors is also not recommended since expe-
rience indicates that this method may cause some reduction in inhibitor content (!l).
In the bypass method, a percentage of the oil volume in the system is pumped through
the oil conditioner each hour. Several utilities recommend 20 percent as the mini-
mum based upon their experience. They have updated older units to this standard in
order to maintain desired contamination limits. Figure 1-8 presents capacity
requirements for different sized reservoirs (~). The higher percentage of bypass
flow allows for more rapid removal of contamination and lower equilibrium level of
contaminants. Bypass circulation should be continuous to reduce the possibility
that contaminants will accumulate and exceed an acceptable purity level.
Connections in the reservoir to and from the oil conditioner should be designed to
prevent loss of oil by siphoning or pipe rupture. Figure 1-9 shows a combination
vented sight overflow device which prevents siphoning and indicates oil reservoir
level (~). Figure 1-10 illustrates a piping arrangement used to prevent oil loss
1-18
3500
3000
::I:
Cl.
~.. 2500
>-
t-
U
~2000

u
~
z 1500
>=
LL
a:
~ 1000
500
4 5 6 7 8 9 10 1112 13 14 1516 17 18 1920

THOUSANDS OF GALLONS OF OIL IN SYSTEM
RESERVOIR AND FLOW BACK
Figure 1-8. Sizing of oil conditioner subsystem. The capacity

of purification equipment actually falls somewhere between 10%
and 20% as a manufacturer's standard unit is usually purchased.
Reprinted by permission from the American Society of Lubrication
Engineers. All rights reserved.
___-------I.. VENT TO
RESERVOIR
OUTSIDE
VENT
OPERATING lEVEL
~--~ - - - - --+-I+-- - - - - - -
INLET
.. FROM RESERVOIR
12'
TOOll
II
PURIFICATION
EQUIPMENT
Figure 1-9. Combination vented sight overflow device to prevent siphoning

and to indicate oil reservoir levels. the top connection from the vented
sight overflow to the reservoir is to equalize the pressure within the
sight glass. A reservoir vacuum is usually maintained at 1/2 inch of water.
A loop seal prevents loss of reservoir vacuum in the event of an open line
to the purification equipment. the outside vent eliminates siphoning in the
event of line break. Since the oil purifier must be capable of operating
when the turbine is shut down, the top of the vent must be above the flow-
back level in the reservoir.
Reprinted by permission from the American Society of Lubrication Engineers.
All rights reserved.
1-19
OVERFLOW
SIGHT
VENT
ISOLATION
VALVE
r-~=====:a....a:==U::::=:=~~~...L.IIh-.)
'-FLOW
__ ~MAL OIL LEYE_L_ _

,,--
~-
I I
SUCTION LINE -I I
(OPENED AT ::
BOTH ENDS) :I LOCKED VALVE
I I
I I
I I I~--BLANK & SPACER
-~~==============~~-_-_~---rr-
MAIN TURBINE OIL RESERVOIR
I
FLOW
I
FLOW +FLOW
+ + I
TO DIRTY OIL
STORAGE
ISOLATION I'I::=-----+-~
VALVES
FLOW BACK
SAMPLE
VALVE
LINES _ TO CLEAN OIL
OIL CONDITIONER
~Ut:::,,;::;...u."""---C:.;c:::J--I-F-L~O--W~ ....
~I----f-I-t-1' :J I
STORAGE
FROM CLEAN OIL
STORAGE
~LOW
WATER & PARTICULATE REMOVAL

EQUIPMENT
Figure 1-10. Piping Arrangement for Bypass Oil Conditioner

1-20
below a safe level in the reservoir (~). The supply suction point in the reservoir
is near the bottom of the tank while the return discharge point is above the maximum
oil level. Piping connections to or from the station oil storage tanks are provided
so that oil passes through the oil conditioner before entering or leaving the main
oil reservoir. A strainer is also installed in the piping just before the reservoir
to trap any particles that may be produced from the oil transfer piping between the
main reservoir and the storage tanks. An emergency bypass capability is included
to allow the conditioner to be bypassed during extraordinary situations. Sample
cocks are provided in the piping into and out of the oil conditioning unit.
The oil conditioning equipment or system should remove both water and particulate
contaminants, since both can produce degradation of the oil and damage to other com-
ponents. The oil conditioner should be capable of maintaining particulate matter
and free water contamination below the limits established for the system by the
equipment manufacturer (~).
If it is necessary to heat the oil in the oil conditioner, a temperature limit of

180F (82.2C) is required. Any heating device should have skin temperature below
250F (121.1C), and flow rate over the surface should be on the order of 2 to
3 feet per second (0.6 to 0.9 m/s).
Some manufacturers install filters in pump discharge or supply lines to lubrication

system components. In the past, full flow, in-line filters were normally provided
to filter oil going to generator hydrogen seals, thrust bearings, and hydraulic con-
trol devices. Recently, full flow filters are being installed in the oil supply
lines to turbine generator shaft bearings (~). These filters are designed for
high flow rates and low pressure drop conditions with manual bypass and automatic
pressure relief capability, as .shown in Figure 1-11. Instrumentation is provided
for indication of differential pressure (~P) and alarm of a high ~p condition (1l).
1-21
IN
FROM
LUBE OIL
PUMP
II
1'1
(U --~-~I "I
ANIFOlD Iii
BLOCK-+;i
',?
~
. . ~ IN
( I
II
I:
I'
FILTER
VESSEL !
WITH
CARTRIDGES
III
!il
IIF
I
I
I
~ III
i
I
N
N
il
~I iNLET I
~
IVAlVE
SHUTOFF
[]-~
~
,:
fJ
~; I
I
BEARING
FEED
VALVES
ORIFICEI ) I
. STRAINER
: TO
I BEARING(S) , ) ) !I I
CLEAN SIDE ~ ,
-\ DRAIN
'SCREEN
I
I
II DRAIN VALVE
--"--- ----
f t ~ flOOP - STATUS PANEL
~lU8EO~ FILTER ENCLOSURE DRAINS
SYSTEM DRAIN t USEAl
LOOP OUT OUT
SEAL TO BEARINGS
Figure 1-11. Lubrication system full flow, in-line filters. Full flow, in-line filters have been
successfully installed on oil supply lines to the main turbine generator bearings. Carbon steel
piping is provided up to the filter and stainless steel piping is used between the filter and the
bearing. Manual and automatic bypasses allow for filter blockage and cleaning.
Source: General Electric Company (References 16 and 17).
1.3 LUBRICANT CHARACTERISTICS AND SERVICE CONDITIONS
Seven essential characteristics or properties of a turbine oil enable it to perform

its critical functions so that a turbine generator unit will operate reliably for
long periods. These inherent characteristics are the capabilities of the oil to:
(1) Maintain viscosity over a range of operating temperatures and with

some degree of contamination
(2) Minimize friction and protect against wear during periods when only
very thin oil films are present between the journals and bearings
(3) Transfer heat from the journals, bearings, and other sources to a
heat exchanger
(4) Resist oxidation and degradation due to exposure to air (oxygen),

water, and hydrogen at high temperature
(5) Resist foaming and air entrainment
(6) Protect other components from corrosion
(7) Separate rapidly from water that may enter the lubrication system
These characteristics, as well as others that are important in specification and

selection of lubricating oil, can be determined by test methods approved by the
American Society for Testing and Materials (ASTM). ASTM publishes an annual book
of standards which contains the procedures to be followed when measuring a certain
property or capability. Table 1-2 lists the appropriate turbine oil standards
found in the 1985 Annual Book of ASTM Standards. These standards will be cited and
further explained in subsequent sections of this Guidebook.
Oil requirements are established by the turbine generator manufacturer since bear-
ing and lubrication system designs are dependent on oil properties. As a guide to
defining the properties of mineral oil based turbine lubricating oil, ASTM has
approved the standard specific~tion titled "Mineral Lubricating Oil Used in Steam or
Gas Turbines (D 4304-84)" (~). The 1984 Edition of this specification is included
in Appendix C. Table 1-3 lists the minimum requirements from this Standard for a
Type I turbine oil for steam turbine lubrication systems where the machinery does
not require lubricants with enhanced load carrying capacity. Exceptions to specific
items in this Standard may be required and agreed upon between the user and supplier.
This Standard is intended to define only new lubricating oil before it is installed
in the machinery. ASTM D 4298-83 defines the requirements for phosphate ester based
fire resistant fluid when used as turbine generator lubricant (~).
1-23
Table 1-2
ASTM STANDARDS FOR TURBINE OILS
Standard
Number Standard Title
(Test Method for:)
D 1500-82 ASTM Color of Petroleum Products (ASTM Color Scale)
D 4177-82 Automatic Sampling of Petroleum and Petroleum Products
D 130-83 Detection of Copper Corrosion from Petroleum Products by the Copper

Strip Tarnish Test
D 1298-80 Density, Specific Gravity, or API Gravity of Crude Petroleum and

Liquid Petroleum Products by Hydrometer Method
D 1401-84 Emulsion Characteristics of Petroleum Oils and Synthetic Fluids
D 92-78 Flash and Fire Points by Cleveland Open Cup
D 892-74 Foaming Characteristics of Lubricating Oils
D 3427-75 Gas Bubble Separation Time of Petroleum Oils
F 313-78 Insoluble Contamination of Hydraulic Fluids by Gravimetric Analysis
F 312-69 Microscopical Sizing and Counting Particles from Aerospace Fluids

on Membrane Filters
D 974-80 Neutralization Number by Color-Indicator Titration
D 664-81 Neutralization Number by Potentiometric Titration
D 943-81 Oxidation Characteristics of Inhibited Steam-Turbine Oils
D 2272-84 Oxidation Stability of Steam-Turbine Oil by Rotating Bomb
D 97-66 Pour Point of Petroleum Oils
D 665-83 Rust-Preventing Characteristics of Steam-Turbine Oil in the Presence

of Water
D 3603-82 Rust-Preventing Characteristics of Steam Turbine Oil in the Presence

of Water (Horizontal Disk Method)
D 270-65 Sampling Petroleum and Petroleum Products (Discontinued 1984 -

Replaced by Practice D 4057 and Method D 4177)
D 4310-83 Sludging Tendencies of Inhibited Mineral Oils
D 2273-81 Trace Sediment in Lubricating Oils
1-24
Table 1-2 (Cont'd)
ASTM STANDARDS FOR TURBINE OILS
Standard
(Test Method for:)
D 3339-80 Total Acid Number by Semi-Micro Color Indicator Titration
D 2161-82 Viscosity, Conversion of Kinematic to Saybolt Universal Viscosity or

to Saybolt Furol Viscosity
D 2270-79 Viscosity Index from Kinematic Viscosity, Calculating
D 445-83 Viscosity, Kinematic, of Transparent and Opaque Liquids (and the

Calculation of Dynamic Viscosity)
D 1744-83 Water in Liquid Petroleum Products by Karl Fischer Reagent
D 95-83 Water in Petroleum Products and Bituminous Materials by

Distillation
(Practice for:)
D 4248-83 Design of Steam Turbine Generator Oil Systems
D 4057-81 Manual Sampling of Petroleum and Petroleum Products
D 2422-75 Viscosity System for Industrial Fluid Lubricants
D 4378-84 In-Service Monitoring of Mineral Turbine Oils for Steam and Gas
Turbines
LOS-1M-1980* Cleaning, Flushing, and Purification of Steam and Gas Turbine

(ASME) Lubrication Systems
(Specification for:)
D 4304-84 Mineral Lubricating Oil Used in Steam or Gas Turbines
D 4293-83 Phosphate Ester Based Fluids for Turbine Lubrication
Source: 1985 Annual Book of ASTM Standards

Volume 05.01, Petroleum Products and Lubricants (I)
Volume 05.02, Petroleum Products and Lubricants (II)
Volume 05.03, Petroleum Products and Lubricants (III)
Volume 15.03, Space Simulation; Aerospace Materials; High Modulus Fibers
and Composites
*Panel 1 of the Joint ASTM-ASME-NEMA Committee on Turbine Lubrication

Systems. American Society of Mechanical Engineers
1-25
Table 1-3
ASTM RECOMMENDED MINIMUM REQUIREMENTS FOR MINERAL-BASED TURBINE OIL
ASTM Test
Property Method Values
Physical:
ISO--viscosity grade D 2422 32 46
Flash point, c, min D 92 180 180
~our point, c, max D 97(a) -5 -5
Viscosity, cSt, (mm2 /s), 40C D 445 28.8-35.2 41.4-50.6
Visual examination at 20C clear and bright
Chemical:
Total Acid Number, mg KOH/g, max D 974(b) report report
Performance:
Emulsion characteristics: D 1401
at 54C minutes to 3 mL emulsion, max 30 30
at 89C minutes to 3 mL emulsion, max
Foaming characteristics: D 892
Sequence I, tendency/stability, mL, max 400/0 400/0
Rust preventing characteristics D 665A pass/fail pass/fail
Copper corrosion, 3 h at 100C, max D 130 1 1
Oxidation stability(C)
Hours to neut. No. 2.0, min D 943 2000 2000
Minutes to 175 kPa drop, min D 2272 200 200
Cleanliness(d):
Gravimetric, mg/100 mL, max 0.8 F 313 3.0 3.0
micrometer filter porosity
Source: Standard Specification for Mineral Lubricating Oil Used in Steam or Gas
Turbines, D 4304-84, 1984 Annual Book of ASTM Standards: Petroleum Products and
Lubricants (III), Vol. 05.03. Philadelphia: ASTM, 1984.
(a)Lower pour point may be required for some applications.
(b)Test Method D 3339 may be used as an alternative method.
(c)Test Method D 943 is the accepted test method for oxidation stability of new
steam turbine oils in the USA and Canada. It is recognized that Test Method D 943
is a lengthy procedure. Thus, D 2272 is a suggested shorter test for quality
control.
(d)Cleanliness of the oil may also be described by either the microscopic particle
count or the electronic particle count method, by agreement between the purchaser
and the seller.
1-26
Viscosity
Of the seven characteristics of oil, the most important for turbine generator opera-
tion is viscosity. Viscosity is a measure of flow resistance and is important for
establishment of an oil film between the journal and bearing and for determination
of bearing performance or stability characteristics.
Viscosity determines the capability of oil to flow in a lubrication system and to

support bearing loads and transfer heat. The preferred method for measuring viscos-
ity is ASTM "Standard Test Method for Kinematic Viscosity of Transparent and Opaque
Liquids (D 445-83)" (20). The unit of measurement is millimeters squared per second
(mm 2 /s), which is called a centistoke (cSt). Prior to 1976, ASTM Test Method D 88
was used to measure the viscosity in Saybolt Universal Seconds (SUS), and many pre-
vious documents and references still use the SUS units. Conversion from cSt to SUS
units can be accomplished by using the tables in ASTM D 2161-82, "Conversion of Kine-
matic Viscosity to Saybolt Universal Viscosity or to Saybolt Furol Viscosity" (~).
The International Organization for Standardization (ISO) has established a viscosity

classification system for industrial fluid lubricants. ISO classifies lubricants
by their viscosity grade (VG) based on the lubricant viscosity in centistokes (cSt)
at 40C. ASTM Standard Practice D 2422-75, "Viscosity System for Industrial Fluid
Lubricants," explains the viscosity classification system (~). Choice of viscos-
ity grade for a particular turbine generator should comply with the manufacturer's
recommendations. ISO VG of either 32 or 46 is typical for electric utility units.
Since the viscosity of these oils varies significantly with temperature, the allow-
able variation within the normal operating temperature range is specified by the
turbine manufacturer. The maximum oil viscosity and/or minimum oil temperature
before attempting to start the lubrication system oil pumps is recommended by the
turbine manufacturer. Sometimes the viscosity at 100C or the viscosity index is
also specified to establish a value for this oil property at higher than normal
operating temperatures. The viscosity index is an arbitrary number used to charac-
terize the variation of kinematic viscosity with temperature and is determined by
calculation in accordance with ASTM D 2270-79, "Calculating Viscosity Index from
Kinematic Viscosity" (32).
Oil used for turbine generator units is considered a "light" oil because it has a
relatively low viscosity rating. This reduces frictional drag in the bearing and
lowers power loss from the turbine generator bearings. Although a light oil does
provide a relatively full film between the rotating shaft journal and the bearing
1-27
at operating speed, some metal-to-metal contact occurs between these members during
starting, stopping, and turning gear operation periods. Bearing loads must be kept
low, and the oil must have adequate film strength to minimize friction and to pro-
tect against wear when journal speed is low. A properly refined petroleum-based
lubricating oil will have a high film strength value. Section 6 on bearing lubrica-
tion principles will further discuss lubrication of bearings during periods of dif-
ferent shaft rotational speed.
Oil Service Life
A turbine generator oil is expected to have long service life, on the order of 15 to
20 years. Certain environmental conditions, however, can result in or accelerate oil
degradation and reduce service life. Primary environmental conditions that influence
oil life are:
(1) Exposure to high temperature in the presence of oxygen
(2) Contamination by particulate materials and water
The degree of exposure to these environmental conditions and capability of the oil
(oil quality) to resist them are factors that determine the exact period of service
life obtained from the oil. Other important factors affecting the oil service life
are:
(1) Type and design of the lubrication system
(2) Condition of the system after construction
(3) Oil make-up rate
Combinations of these factors vary from unit to unit so that service life of the
oil is difficult to predict solely on original oil properties. A useful approach
for monitoring service life is to determine a turbine severity level, which will be
explained in the subsection titled "Turbine Severity Level" (page 1-35).
Heat Transfer Capability
As oil is circulated in the lubrication system, its temperature will be raised by

heat produced from several sources. Heat is generated by friction at the bearings
and in oil pumps and is also conducted along the shaft to the bearings from the
higher temperature regions of the steam turbine rotor. Heat can be transferred to
the oil piping from adjacent high temperature steam piping or induced in the piping
from electromagnetic forces in adjacent electrical circuits. Heat is also produced
by friction when turning gear teeth and the coupling bolt nuts are rotated in air
1-28
(windage). An important oil function is to transport heat from all these sources
to a heat exchanger to transfer the heat to the cooling media. This heat transfer
requirement is one factor that determines the amount of oil required for circula-
tion in the lubrication system.
Oxidation Resistance
During circulation, air is picked up by the oil. Air is also entrained into the oil
through turbulence and oil streams at the bearings, couplings, and drains. Oil can
combine with oxygen in the air to form soluble and insoluble products. A slight
oxidation of the oil is normally harmless because the initial products are soluble
and are carried by the oil without effect. More harmful insoluble products can
form as oxidation continues. Excessive oxidation results in the formation of gum,
varnish, or sludge in the bearing passages, coolers, strainers, oil reservoir, and
rotor couplings. Their accumulation can interfere with the supply of oil to a bear-
ing or form an insulating layer that restricts flow of heat from a bearing compo-
nent. Some soluble oxidation products become insoluble at lower temperatures and
accumulate at cooler locations in the lubrication system and especially at the oil
coolers.
Oxidation of oil can increase oil viscosity which, in turn, affects bearing perfor-
mance. Oxidation also results in formation of complex organic acids which can be
corrosive to bearing and other lubrication system materials. Corrosion inhibitors
may be used to protect sensitive metal components from the effect of oil oxidation
products. Test methods used to indicate the progress of oxidation and potential
for acidic corrosion are the Total Acid Number or Neutralization Number methods
D 3339-80, D 664-81, or D 974-80 (24-26). Rust inhibitors used in lubricating oils
are acidic, so that an increase in acid number above the value for a new oil indi-
cates the presence of acidic products from oxidation.
The rate of oil oxidation depends on capability of the oil to resist oxidation, oil
temperature, and presence of contaminants such as metal particles that act as oxida-
tion promoters or catalysts. Low quality oils have poor oxidation resistance and
under severe conditions form deposits and increase in viscosity within a short time.
In a high quality turbine generator oil, the base is selected for its natural abil-
ity to resist oxidation. To enhance this inherent capability of the oil, additives
are used to retard the oxidation process. One type of additive reacts with the ini-
tial oxidation products (hydroperoxides) and stabilizes them to prevent further oxi-
dation. Another type prevents catalytic action of the metals (iron or copper)
present in the system. These additives are called metal passivators or catalyst
1-29
poisoners. An effective additive package combined with the natural characteristic
of the oil can provide high resistance to oxidation over a wide temperature range.
The ASTM approved test method for determining oxidation stability of a new oil is
titled "Oxidation Characteristics of Inhibited Steam-Turbine Oils (D 943-81)" (J:L).
This method reports the time in hours for the acidity to reach 2.0 mg of potassium
hydroxide per gram of sample in a sample of oil containing water, steel, and copper
wire coiled together and maintained at a temperature of 95C (203F) with oxygen
passing through the sample. ASTM specification D 4304-84 recommends a 2000 hour
period, but alternative criteria for evaluation of oils using this test method may
be used.
Capability of the oil to resist oxidation decreases with time in service since the
additives are depleted by performance of their function, by gradual removal by water,
or by volatilization. Normally additives are replenished with make-up oil that is
added to replace losses; however, sometimes new oil charges or additive packages are
necessary to provide continued oxidation protection. The ASTM test method for moni-
toring oxidation stability reserve of inservice oil is titled "Test Method for Oxi-
dation Stability of Steam-Turbine Oil by Rotating Bomb (D 2272-84)" (28). The
Rotating Bomb Oxidation Test (RBOT) is shorter than D 943 and measures the time for
the test oil to react with a given volume of oxygen. RBOT time which is less than
one half of its original value before 20,000 running hours indicates above normal
degradation and warrants an investigation into the cause.
Thermal/Oxidation Degradation
The effect of temperature on oxidation rate is substantial. An increase of 18F

(10C) will double the oxidation rate (~). This doubling effect can become criti-
cal if oil supply temperature is increased above its normal operating value of
between 110 and 120F (43 to 49C). Oil flow through a bearing can be regulated to
assure a maximum oil temperature rise of 50F (28C) when measured at the discharge
from the bearing. The temperature that an oil reaches in performing its heat trans-
fer function is referred to as its thermal loading. The effect of temperature is
one major reason why similar turbine generator units will have different service
lives for their respective lubricating oils. Local "hot spots" in the lubrication
system can enhance the oxidation process or produce thermal/oxidative degradation.
At higher temperatures, thermal cracking of the hydrocarbons can form unstable com-
pounds which polymerize to form viscous resins and sludge deposits. At temperatures
over 285F (140C), oil varnish becomes carbonized; and cake-like deposits can accu-
mulate, which can cause significant rotor damage (30). Carbon can build up on the
1-30
oil seal rings at the bearing housing and cause substantial wear of the turbine gen-
erator shaft if it touches the deposit. Figure 1-12 is a photograph of a high pres-
sure turbine shaft with a 3 inch (8 cm) deep groove produced by carbon deposits on
the oil seal ring. A deposit can also build up on the bearing babbitt immediately
following the point of minimum oil film thickness. This deposit can alter stability
characteristics of the bearing and shift the centerline of the shaft. Care must be
taken during design and operation of the lubrication system to provide sufficient
space between the hot labyrinth shaft sealing section of the turbine casing, espe-
cially when converting from water seals to steam seals. Turbine rotor shafts have
been damaged after the conversion when coke deposits formed on the No. 1 bearing
housing seal ring. Oil piping in the vicinity of high temperature steam piping may
have to be rerouted or thermally insulated to control thermal loading of the oil.
Foaming Resistance
Foaming of the oil may result when air is picked up by the oil and is thoroughly
mixed by agitation and churning. Normally only a thin layer of foam will be present
on the oil surface due to turbulence in oil return lines, especially as they dis-
charge into the reservoir. High quality oil should have good resistance to exces-
sive foaming, and the air bubbles formed on the surface should break up quickly.
Foaming increases the rate of oil oxidation, since more oil is exposed to the
entrapped air than would be in nonfoaming situations. Oxidation products, in turn,
promote the formation and stabilization of the foam. Contaminants in the oil also
reduce the capability of the oil to resist excessive foaming. Excessive foam accu-
mulation can result in loss of oil by overflow or seepage. In some instances, foam
weeping from generator bearings has been drawn into the electrical windings or onto
the collector rings to cause insulation damage, short circuits, and sparking. The
foaming properties of an oil can be determined by ASTM Test Method D 892-74, "Foam-
ing Characteristics of Lubricating Oils" (1l).
Contamination
The remaining factor that influences the rate of oil oxidation is the amount of con-
tamination present in the oil. Metal particles and water contaminants promote oil
oxidation and contribute to formation of foam, deposits, and sludge.
Particle Contamination. Pulverized coal, fly ash, airborne dirt, and sand can enter
the lubrication system through openings at the bearing housings and at the oil reser-
voir covers and doors. Pipe scale, rust, and other metal particles may enter the
1-31
system during construction and remain there even after the post-construction lubri-
cation system flush. Fine metal particles act as a catalyst to the oil oxidation
process. All hard contaminants have the potential to cause excessive wear or scor-
ing of the bearings and journals, and damage to other lubrication system components.
Rusting of oil system piping and other carbon steel components can occur in service
on both submerged and exposed locations. Rust can be produced in both the hematite
(red color) form and the magnetite (black color, magnetic) form. Rust particles can
be swept up by the flow of oil and transported throughout the lubrication system,
particularly after the piping has been vibrated from external sudden forces. Rust
inhibitors are added to the oil to protect against rusting of oil-wetted metal sur- _
faces. Volatile vapor phase inhibitors (VPI) may also be added to protect the non-
oil-wetted locations. ASTM Test Methods D 665-82 and D 3603-82, "Rust-Preventing
Characteristics of Steam-Turbine Oil in the Presence of Water," are used to evaluate
the corrosion protection of the oil (32-33). However, the most effective method of
preventing rust is to keep the lubrication system and the oil free from water.
Water Contamination. The most common contaminant in a lubrication system is water.

Water may enter the system from leaks in water cooled heat exchangers, from conden-
sation of humid air, and from leakage of the steam turbine shaft seals. Water in
the oil results in promotion of rust, formation of emulsions, and accumulation of
sludges. Consequently, the water separating ability of the oil is an important
characteristic and water must separate quickly from the oil so that it can be col-
lected in and removed from the bottom of the oil reservoir. Large amounts of water
form persistent emulsions that join with insoluble oxidation products to form
sludges. Accumulation of sludges in oil piping passages and coolers impairs cir-
culation of the oil and causes higher bearing and oil temperatures. As stated
earlier, higher temperatures, in turn, increase the oil oxidation rate. Sludges
also can cause sluggishness or sticking of oil pressure relays and governor pilot
valves if the oil is used as the hydraulic control fluid.
Water exists in the dissolved state in oil and will precipitate as free water when
it exceeds the saturation point. The saturation point of an oil varies with its
additive package and its temperature. Generally, more additives in oil increase
its solubility limit. Figure 1-13 is an example of water absorption capability of
turbine oil as a function of temperature at 40 percent relative humidity (l). Fig-
ure 1-14 is an example of water absorption characteristics of turbine oil as a func-
tion of relative humidity at 100F (38C) (l). At conditions above the line, water
will tend to be absorbed from the air into the oil, while at conditions below the
1-32
~
I
LV
LV
Figure 1-12. Shaft damage caused by carbon deposits. A high pressure turbine shaft was damaged
when carbon deposits on the oil seal ring caused a 3 inch (8 cm) deep groove to form.
200 100
180 90
160 ~ 80
140 ....>- 70
u:: 0
~ ~
w 120 :::>
ex: ::I: 60
:::> w
~ >
ex:
w
a.
100 ~
..J
50
W
~ ex:
W
.... 80 ....Z 40
..J
w
0 U
t--A a::
I
60 w
l.V a. 30
~
40 t-. 20
TOF-32
TOC =
1.8
2:[ I I
10
0
100 200 100 200
WATER CONCENTRATION (PPM) WATER CONCENTRATION (PPM)
Figure 1-13. Example of equilibrium water concentra- Figure 1-14. Example of equilibrium water concentra-
tion in a turbine oil as a function of temperature. At tion in a turbine oil as a function of relative humid-
40% relative humidity, typical turbine oil can absorb ity. At 100F (38C), typical turbine oil can absorb
water approximately as shown. Free water will not water as shown.
exist until the water content exceeds the line at any Source: Reference 34.
given temperature.
Source: Reference 34.
Reprinted by permission from the American Society of Lubrication Engineers. All rights reserved.
line, water will evaporate from the oil. Light-colored turbine oil will usually
remain clear with up to 75 ppm water at room temperature and will show a haze when
water exceeds its solubility limit. ASTM Standard Practice D 4378-84, "In-Service
Monitoring of Mineral Turbine Oils for Steam and Gas Turbines," states that new oil
should contain no free water and that used oil should not contain more than 200 ppm
(0.02%) water. The water content in an oil is determined by either ASTM D 95-83,
"Test Method for Water in Petroleum Products and Bituminous Materials by Distilla-
tion" (~) or ASTM D 1744-83, "Test Method for Water in Liquid Petroleum Products
by Karl Fischer Reagent" (~).
Hot oil dissolves more water than cold oil so that a drop in oil temperature can
result in conversion of part of the dissolved water to free water to collect in low
spots or low-flow branches of the lubrication system. Even periodic excursions in
the water content can cause corrosive attack of lubrication system components,
resulting in rust spots, corrosion pits, or rapid corrosive removal of bearing
surfaces.
The water separability properties of used turbine oil can be measured using ASTM
Test Method D 1401-84, "Emulsion Characteristics of Petroleum Oils and Synthetic
Fluids" (l,Z). This method supersedes the Steam Emulsion Number procedure, which is
not recommended although it is still used in some power plants.
Turbine Severity Level
Each turbine generator lubrication system is unique due to exclusive conditions that
occur during construction and operation of the system. These conditions set the
rate at which a new charge of fresh oil will lose its oxidation resistance. A prop-
erty called turbine severity (B) level has been established which can be used to
take these conditions into consideration when monitoring the remaining oxidation
resistance of the oil during its service life (38). "B" is defined as the percent-
age of fresh oil oxidation resistance lost per year due to oil reactions in the tur-
bine generator lubrication system. "B" takes into consideration the following three
factors:
(1) Amount of make-up oil added to the system to replenish the oil
oxidation resistance
(2) Time that the oil has been in use
(3) Oxidation resistance that remains as determined by a Rotating Bomb

Oxidation Test (RBOT), ASTM D 2272-84
1-35
An equation that determines turbine severity has been developed:
B M (I-X/I00)/(I-e-Mt/l00)
where
B Turbine severity
M Amount of oil added as makeup into the system per year, expressed
as a percentage of the total ~mount of oil originally placed in
the system (percent per year)
X Amount of oxidation resistance that remains in the oil, expressed

as a percentage of the original oxidation resistance of the oil
(percentage of fresh oil)
t Amount of time the original oil has been in service in years
Figure 1-15 shows the effect of makeup rate, M, on oil degradation for a turbine
with a severity level of 25 perce~t per year.
The severity level for a particular lubrication system should be determined over a
period of time beginning with initial operation or installation of a fresh oil
charge. Accurate record keeping of the amount of oil makeup is essential, and RBOT
should be conducted at three- to six-month intervals for one to two years. By know-
ing the oil makeup and degradation of the oil with time, the turbine severity for
the oil can be found from Figure 1-16.
A lubrication system with a high severity level requires frequent makeup or com-
pletely new charges, whereas one with a low severity level may have no problems with
routine makeup. Turbine generator units of recent design have higher "B" levels
than units installed before 1965. Increases in lubrication system temperatures are
suspected as reasons for the higher "B" levels obtained in new turbines. Larger
shafts, turning gears, and couplings, and smaller oil reservoir volumes have
increased the amount of heat each gallon of oil must transfer per hour to the oil
cooler. Oil contamination by coal dust and fly ash from pressurized furnaces has
also been a factor.
Oil Suppliers
Selection of the turbine oil used by a utility involves many factors based on the
turbine manufacturer's specification, the oil supplier's recommendation, and the
1-36
100
90
80
70
60
x 50
c!i
z 40
Z

~
w
a: 30
w
u.
~
...J
0
...J
< 20
~ M = 30%
S2
a:
0
u.
0
.-z
w
u
a: 10
w
Cl.
5L.-...J.....-.L._.........-4--...........- - - I _...........--L.-..&._...L----L..---&._..L...-....L_--&-----J~...L____'__L........I
o 2 4 6 8 10 12 14 16 18 20
YEARS OF USE
Figure 1-15. Effect of Makeup Rate on Oil Degradation.

(Turbine severity, B = 25 percent per year).
Reprinted by permission from the American Society of
Lubrication Engineers. All rights reserved.
utility's experience. Given a normal service environment, the oil charge should
last for many years, and in some cases up to 20 years of service life have been
obtained. A documented sampling and testing schedule can be followed as discussed
in Section 3 to monitor ingress of contaminants and buildup of oxidation products.
Communications with the oil supplier can also be established to discuss test results
and to pursue any corrective actions necessary to restore important oil properties.
The major oil companies have supplied oil to utilities over the years under a vari-
ety of trade or product names. The more commonly used turbine oils according to
manufacturer and product names are Amoco, Nonpareil Medium Industrial Oil 32; Exxon,
Teresstic 32; Gulf, Gulfcrest 32; Mobil, D.T.E. 797; Shell, Turbo 32; Texaco, Regal
Oil R8032; and Conoco. Other manufacturers and products have also been satisfacto-
rily used for steam turbine generator applications.
1-37
100
80
./
150 ./
./
2.0 eft.
./
60
/
m"
100 /
/
>.. ./
50
t:: 70 ./
./
a: ./
w ./
> 50 / 40
w /
en 40 /
w / ~
z 30 /
CD
a:
=>
t-
25
20./
/ 30
25
-z..
8
, O
~
/
/
c
20
0.6 /
~

a:
./ 10 17
/ ~
X 0.5 / w
c
~
./
/ 7 15 -J
./
...... 0
m 0.4 5 t-
12 zw
4 u
M = 30% 10 a:
w
9 c...
25%
8
20% 7
0.2
6
15%
5
0.1
0 2 4 6 8 10 12 14 16 18 20 3
TIME
Figure 1-16. Effect of Turbine Severity (B) and Makeup Rate (M) on
Oil Degradation. The dotted lines show the process for obtaining a
value for turbine severity, B. In the example, the turbine oil has
been in service for 5 years, and the annual makeup rate is 15% per
year. The oil has degraded from a rotary bomb test life of 1700
minutes initially to only 350 minutes, a loss of 79.5 percent.
Starting at 5 years on the time axis, a point on the 15% makeup
curve is determined, and a line is projected left to B/(100-X) axis.
A straight line between this point on the B/(100-X) axis and a point
at 79.5 percent on the percent oil degradation axis intersects the
turbine severity scale at 22% per year.
Reprinted by permission from the American Society of Lubrication
Engineers. All rights reserved.
1-38
REFERENCES Section 1
1. H. C. Rippel and R. Colsher. "Failure-Cause Analysis: Turbine Bearing Sys-

tems." In Proceedings of Turbine Bearings and Rotor Dynamics Workshop,
CS-4024. Palo Alto, California: Electric Power Research Institute (EPRI),
June 1985, Section 2, page 23.
2. Franklin Research Center. "Failure-Cause Analysis: Turbine Bearing Systems."

Research Project 1265-3. Palo Alto, California: EPRI, March 1984
(unpublished).
3. American Society for Testing and Materials (ASTM). "Standard Practice for
Design of Steam-Turbine Generator Oil Systems, D 4248-83." 1984 Annual Book
of ASTM Standards: Petroleum Products and Lubricants (III). Vol. 05.03.
4. American Society of Mechanical Engineers (ASME). "Recommended Practices for

the Design of Steam Turbine Generator Oil System No. 116." New York: ASME-
ASTM-NEMA Committee on Hydroelectric Turbine Lubrication Systems, 1968.
5. American Petroleum Institute (API). "Lubrication, Shaft-Sealing, and Control

Oil Systems for Special-Purpose Applications, Standard 614." Washington, D.C.:
API, September 1973.
6. ASTM. "Specification for Industrial Wire Cloth and Screens, Standard E437-80."
1983 Annual Book of ASTM Standards, Steel Plate, Sheet, Strip, and Wire.
Vol. 01.03. Philadelphia: ASTM, 1983.
7. General Electric Company (GE). "Lubricating Oil System: Safety and Fire Pro-
tection, GEK-63439." Schenectady, New York: GE, April 1980.
8. GE. "Turbine Lube Oil (Recommended Properties and Maintenance Practices),

GEK-46506B." Schenectady, New York: GE, November 1979, p. 9.
9. A. Missana. "Design and Experience with Steam Turbine-Generator Bearings and

Lube Oil System." In Proceedings of Large Steam Turbine, 1980 Seminar.
Schenectady, New York: GE, October 1980, p. 11.
10. ASME. "Recommended Practices for the Cleaning, Flushing, and Purification of
Steam and Gas Turbine Lubrication Systems, LOS-1M-1980." New York: ASME,
1980, p. 15.
11. GE. "Turbine Lube Oil," p. 4.
12. J. R. Conklin. "Design Philosophy-Turbine Generator Lubricating Oil Systems."

Park Ridge, Illinois: American Society of Lubrication Engineers, ASLE Preprint
Number 69AM6B-3, 1969, p. 17.
13. Ibid., p. 16.
14. A. Missana and J. H. Steenburgh. "Lube Oil Cleanliness for Large Steam Tur-
bines." Proceedings of Turbine Bearings and Rotor Dynamics Workshop, CS-4024.
Palo Alto, California: EPRI, June 1985, Section 3, pp. 94-108.
15. ASME. "Recommended Practices," p. 5.
16. D. C. Delano. "Development Test of a Full-Flow Oil Filter for Turbine-Generator

Main Bearings." In Proceedings of Turbine Bearings and Rotor Dynamics Work-
shop, CS-4204. Palo Alto, California: EPRI, June 1985, Section 3, pp. 44-57.
1-39
17 A. Missana. "Design and Experience-," p. 12.
18. ASTM. "Standard Specification for Mineral Lubricating Oil Used in Steam or Gas
Turbines, D4304-83." 1984 Annual Book of ASTM Standards: Petroleum Products
and Lubricants (III). Vol. 05.03. Philadelphia: ASTM, 1984.
19. ASTM. "Standard Specification for Phosphate Ester Based Fluids for Turbine
Lubrication, D4293-83." 1984 Annual Book of ASTM Standards: Petroleum Prod-
ucts and Lubricants (III). Vol. 05.03. Philadelphia: ASTM, 1984.
20. ASTM. "Standard Test Method for Kinematic Viscosity of Transparent and Opaque
Liquids, D 445-83." 1984 Annual Book of ASTM Standards: Petroleum Products
and Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
21. ASTM. "Standard Test Method for Conversion of Kinematic Viscosity of Saybolt
Universal Viscosity or to Saybolt Furol Viscosity, D 2161-82." 1984 Annual
Book of ASTM Standards: Petroleum Products and Lubricants (II). Vol. 05.02.
22. ASTM. "Standard Practice for Viscosity System for Industrial Fluid Lubricants,
D2422-75." 1984 Annual Book of ASTM Standards: Petroleum Products and Lubri-
cants (II). Vol. 05.02. Philadelphia: ASTM, 1984.
23. ASTM. "Standard Test Method for Calculating Viscosity Index from Kinematic
Viscosity, D 2270-79." 1984 Annual Book of ASTM Standards: Petroleum Products
and Lubricants (II). Vol. 05.02. Philadelphia: ASTM, 1984.
24. ASTM. "Standard Test Method for Total Acid Numbers by Semi-Micro Color Indi-
cator Titration, D 3339-80." 1984 Annual Book of ASTM Standards: Petroleum
Products and Lubricants (III). Vol. 05.03. Philadelphia: ASTM, 1984.
25. ASTM. "Standard Test Method for Neutralization Number by Potentiometric Titra-
tion, D 664-81." 1984 Annual Book of ASTM Standards: Petroleum Products and
Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
26. ASTM. "Standard Test Method for Neutralization Number by Color Indicator
Titration, D 974-80." 1984 Annual Book of ASTM Standards: Petroleum Products
and Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
27. ASTM. "Standard Test Method for Oxidation Characteristics of Inhibited Mineral
Oils, D 943-81." 1984 Annual Book of ASTM Standards: Petroleum Products and
Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
28. ASTM. "Standard Test Method for Oxidation Stability of Steam-Turbine Oil by
Rotating Bomb, D 2272-84." 1985 Annual Book of ASTM Standards: Petroleum
Products and Lubricants (II). Vol. 05.02. Philadelphia: ASTM, 1985.
29. Socony Mobil Oil Company, Inc. "Steam Turbines and Their Lubrication." New
York: Socony Mobile Oil Company, 1965, p. 32.
30. W. E. Enz and A. Hausermann. "Particular Problems of Steam Turbine Lubrica-

tion." In Proceedings of the Seventh Turbomachinery Symposium. College Sta-
tion, Texas: Texas A&M University, December 1978, p. 130.
31. ASTM. "Standard Test Method for Foaming Characteristics of Lubricating Oils,
D 892-74." 1984 Annual Book of ASTM Standards: Petroleum Products and Lubri-
cants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
1-40
32. ASTM. "Standard Test Method for Rust-Preventing Characteristics of Steam-
Turbine Oil in the Presence of Water, D 665-82." 1984 Annual Book of ASTM
Standards: Petroleum Products and Lubricants (I). Vol. 05.01. Philadelphia:
ASTM, 1984.
33. ASTM. "Standard Test Method for Rust-Preventing Characteristics of Steam-

Turbine Oil in the Presence of Water, D 3603-82." 1984 Annual Book of ASTM
Standards: Petroleum Products and Lubricants (III). Vol. 05.03. Philadelphia:
ASTM, 1984.
34. H. P. Block. "Criteria for Water Removal from Mechanical Drive Steam Turbine
Lube Oils." Lubrication Engineering. Vol. 36, No. 12. Park Ridge, Illinois:
American Society of Lubrication Engineers, December 1980, p. 703.
35. ASTM. "Standard Test Method for \vater in Petroleum Products and Bituminous
Materials by Distillation, D 95-83." 1984 Annual Book of ASTM Standards:
Petroleum'Products and Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1984.
36. ASTM. "Standard Test Method for Water in Liquid Petroleum Products by Karl
Fischer Reagent, D 1744-83." 1984 Annual Book of ASTM Standards: Petroleum
Products and Lubricants (III). Vol. 05.03. Philadelphia: ASTM, 1984.
37. ASTM. "Standard Test Method for Emulsion Characteristics of Petroleum Oils and
Synthetic Fluids, D1401-84." 1985 Annual Book of ASTM Standards: Petroleum
Products and Lubricants (I). Vol. 05.01. Philadelphia: ASTM, 1985.
38. M. J. DenHerder and P. C. Vienna. "Control of Turbine Oil Degradation During

Use." Lubrication Engineering. Vol. 37, No.2. Park Ridge, Illinois: Ameri-
can Society of Lubrication Engineers, February 1981, pp. 67-71.
1-41
I'\)
3: 0
~~
Z--4
~:!!
Z~
~=!
00
mz
:00
m"
0--4
em
-en
~=!
~~
z>
--4z
en o
Section 2
IDENTIFICATION OF TESTING AND MAINTENANCE REQUIREMENTS
2.1 STEAM TURBINE OILS
Present-day turbine oils are formulated with a highly refined mineral oil base and
a varying number of additives which enhance or impart a specific oil property. The
finished oil is required to resist thermal or oxidative breakdown, inhibit rusting
or corrosion, provide satisfactory lubrication and cooling of load-carrying compo-
nents, resist foaming, and possess good water separation properties. Through use,
certain of these properties may deteriorate over extended periods of time. As a
consequence, it is important to establish a sampling and analysis schedule which
permits the turbine operator to monitor the oil condition. Information obtained
from oil sample analysis not only provides a basis for judgment as to oil suitabil-
ity, but also may identify system problems not otherwise detectable, such as cool-
ant leaks, excessive wear, overheating, etc.
Specifications
Specifications for new lubricating oil are formulated by equipment manufacturers,

oil suppliers, and certain technical societies active in the field of turbine lubri-
cation. A minimum specification guide has been issued by the American Society for
Testing and Materials (ASTM) and titled "Standard Specification for Mineral Lubri-
cating Oil Used in Steam and Gas Turbines (D 4304)." The 1984 edition of this Stan-
dard is included in Appendix C.
Additives
As a minimum, steam turbine oils contain an antioxidant to retard oxidative attack

and a rust inhibitor to protect iron-base metals. In addition, an antifoam agent
and a metal deactivator may be present. Depending on the properties of the mineral
oil base, other functional additives may be used to achieve the required performance
characteristics.
Over extended periods of time, some additives may be consumed through adsorption
onto system materials or contaminants, deterioration by chemical reaction, thermal
2-1
degradation, etc. This consumption may be wholly or partially offset by the routine
addition of makeup oil. It is not unusual for turbine oils to remain in service for
periods between 15 and 20 years. In turbine lubrication systems requiring relatively
low makeup, oil properties should be monitored closely to make certain that any per-
formance loss is identified. While it is possible to reinhibit an oil by mixing in
an additive, this approach should be carefully considered and should only be taken
after close consultation with the turbine oil supplier.
Contamination
Contaminants within the turbine oil system may be generated internally or drawn into
the system from the surrounding environment through entry at seals or vents. Exter-
nal contamination may include airborne dust, sand, coal particulates, moisture, etc.
Internally generated contaminants may consist of wear-metal particulates, which are
constantly being produced in some degree; leaked coolant; oil degradation products
such as sludge; and rust particles.
Excessive or uncontrolled buildup of contaminants should alert the turbine operator

to identify the source, take corrective action, and determine whether oil purifica-
tion equipment or system filters are properly functioning.
Analyses
Inservice monitoring of the condition of a turbine oil should focus on the following
properties:
Anti-rust protection
Remaining oil life (oxidation stability)
Viscosity
Total acid number
Cleanliness
Foaming tendency
Color/appearance
Water content
Flash point
In the following paragraphs the significance of the above properties is discussed,

along with recommended test procedures that have been developed, approved, and pub-
lished by ASTM (see Tables 1-2 and 1-3).
Anti-Rust Protection. Within the turbine oil system, numerous ferrous metals
require rusting protection. This protection is afforded in large part by the anti-
rust additive present in the oil. New and used oils suitable for continued service
2-2
must pass ASTM Method D 665-83 Procedure A, or D 3603-82. This is a dynamic test
designed to evaluate the ability of steam turbine oils to prevent the rusting of
ferrous components should water become mixed with the oil in service.
In this method, a cylindrical steel specimen is immersed in a glass beaker contain-

ing 300 mL of the test oil and 30 mL of distilled water at a temperature of 140F
(60C). The mixture is stirred throughout the test, which normally lasts 24 hours.
Figure 2-1 illustrates the test apparatus and components used with D 665-83. Rust-
ing of the steel specimen is determined by visual examination after test.
Remaining Oil Life. Remaining oil life is a measure of the remaining capability of
oil to resist severe thermal/oxidative breakdown. Remaining useful oil life is
strongly related to the remaining concentration of the antioxidant in the oil. The
oxidation stability of new oils is generally measured by ASTM Method D 943-81. How-
ever, this procedure can take a relatively long time (greater than 6 weeks) and, as
a consequence, is not employed for monitoring the condition of oils in service.
For this purpose, ASTM Method D 2272-84, the rotary bomb oxidation test (RBOT), is
preferred.
The apparatus for D 2272-84 is shown in Figure 2-2. A 50-g sample of the test oil
and 5 mL of water are placed in a small glass container containing a copper catalyst
coil. The container is put into a metal oxidation bomb which is pressurized with
oxygen to 90 psi (620 kPa), and then placed in a constant temperature bath at 302F
(150C). The bomb is rotated at 100 rpm at an angle within the bath of 30 from
horizontal. Oxygen pressure is monitored continuously during a run, and the test
is terminated when the pressure drops more than 25 psi (172 kPa) below the maximum
pressure. This event generally reflects accelerated oxidation of the test oil, and
the test time elapsed before accelerated oxidation is a measure of the remaining
oxidation life of the oil in service when compared with the RBOT data for the new
oil.
Viscosity. Oil viscosity is a measure of resistance to flow. In practice it is

unusual to find that viscosity has changed due to thermal breakdown or oxidation.
This property is, however, useful as an indication of the presence of viscosity
modifying contaminants such as water or solvents, and for verification that the
correct grade of oil is being used. ASTM Method D 445-83 is the common procedure
for measurement of kinematic viscosity. With this technique, the time required for
a volume of oil to flow under force of gravity through a calibrated glass capillary
is measured. For accurate results, the glass viscometer tube must be in a precisely
2-3
N
I
~
Figure 2-1. Apparatus for conducting the ASTM D 665 test method for rust-preventing characteristics.
A steel specimen is immersed in oil mixed with water for a 24-hour period. A visual examination of
the specimen reveals if rusting has occurred.
N
I
In
Figure 2-2. Apparatus for conducting the ASTM D 2272 test method for continuity of steam turbine oil
oxidation stability by a rotating bomb. Oxygen pressure inside a metal oxidation bomb containing a
sample of oil and water and a copper catalyst coil is monitored to reveal when accelerated oxidation
occurs. The test time is an indication of the oxidation stability reserve of the oil.
controlled constant temperature bath during the measurement. Figure 2-3 shows a
typical apparatus. Kinematic viscosity, v, is the ratio of absolute viscosity, ~,
to density, p. Table 2-1 lists conversion factors for commonly used viscosity
units (l).
Total Acid Number (TAN). When a petroleum oil chemically oxidizes, small amounts of
acidic products are formed. An increase in the TAN over that for the new oil is an
indication of the extent of oxidation of the used oil. The TAN is determined by
ASTM Method D 664-81, D 974-80, or D 3339-80. To conduct the test, a weighed sample
of the oil is dissolved in a solvent, and the solution is titrated with potassium
hydroxide (KOH) solution to a predetermined endpoint. In D 664, the endpoint is
indicated by electrodes in the solution which give a meter readout of the solution
pH. A typical titration apparatus and pH meter setup is shown in Figure 2-4. In
D 974-80, a color indicator is added to the test solution and the titration endpoint
is visually observed by the solution color change. In both cases, the TAN is calcu-
lated from the amount of KOH required to reach the defined endpoint. D 3339-80 is
an alternative method f~r determining TAN by a semi-micro color indicator titration
process, which uses a substantially smaller sample size than the other two methods.
Table 2-1
VISCOSITY CONVERSION FACTORS
To convert from To Multiply by
Absolute viscosity
Centipoise (0.01 g/cmsec) Pasec 10-3
reyn (lb Fsec/in 2 ) Pasec 6.895 X 10 3
lb/in.sec Pasec 1.786 X 10
Centipoise reyn 1.45 X 10 7
Kinematic viscosity
Centistoke (m2 /sec) 10- 6
in 2 /sec 6.452 X 10- 4
Centistoke 1.550 X 10- 3
Source: CRC Handbook of Lubrication, p. 414.
Note: To convert Saybolt Universal Seconds (SUS) to centistokes (cSt), use

(cSt) = 0.22 SUS - 108/SUS.
2-6
N
I
""-.I
Figure 2-3. Apparatus for conducting the ASTM D 445 test method for kinematic viscosity. A specific
volume of oil is allowed to flow by force of gravity through a calibrated glass capillary. The time
required to pass the oil at a constant temperature is measured to determine the oil viscosity.
Figure 2-4. Apparatus for Conducting the ASTM D 664 Test Method for Neutraliza-
tion Number by Potentiometric Titration. A solution containing oil is titrated
with potassium hydroxide (KOH) to achieve a specific pH level. The Total Acid
Number (TAN) is determined from the amount of KOH used to reach the desired pH.
2-8
Cleanliness. Solid particulates can be generated internally or drawn into the
lubrication system and are of concern because they can accelerate wear of system
mechanical components and can catalyze oxidation of the lubricant. Cleanliness is
expressed in terms of the amount of particles for a given volume of .oil. The three
types of contamination analysis techniques are:
(1) Microscopic particle counting

(2) Automatic particle counting
(3) Gravimetric analysis
Microscopic and automatic particle counting techniques express cleanliness in terms

of the number of particles within a specified size range for a given volume of oil
(particle/ml). Gravimetric analysis expresses cleanliness in terms of the weight
of particles per given volume of oil (mg/L). Industrial standard procedures are
available for use when performing contamination analysis.
For microscopic particle counting, the oil sample is processed according to ASTM
F 311-78 (~). A fixed volume of sample is filtered through a membrane filter with
an imprinted grid. Figure 2-5 shows the typical filtration apparatus used. The
particles retained on the filter are counted under a microscope with a measuring
eyepiece. The procedure described in ASTM F 312-69 may be followed (2). An alter-
native procedure is described in Aerospace Recommended Practice (ARP) 598A-1969,
published by the Society of Automotive Engineers (SAE) ().
When using automatic particle counting, the particle counter should be calibrated to
a known standard. The American National Standards Institute (ANSI) has published an
approved method which uses particles known aS,air cleaner fine test dust (ACFTD) (l).
ASTM F 660-83 provides a procedure for comparing sizes of nonspherical particles
determined with different types of automatic particle counters such as image ana-
lyzers, optical counters, and electrical resistance counters (~).
Several different classification systems have been used in the past to express
contamination in number of particles per size range. These systems were developed
to rate hydraulic systems, but were applied to turbine lubrication systems by the
turbine manufacturers. SAE published in 1963 a tentative classification system in
which particles were sized in micrometer ranges of 5 to 10, 10 to 25, 25 to 50, 50
to 100', and 100 or greater (~). This system has been disavowed by SAE and is no
longer in use. Another system developed in 1964 by the Aerospace Industries Associ-
ation of America is titled National Aerospace Standard (NAS) 1638 (~). Table 2-2
presents the two classification systems.
2-9
N
I
\-1
o
Figure 2-5. Apparatus for processing liquid samples for particulate contamination analysis using
membrane filters (ASTM F 311). A known volume of oil is filtered through a membrane filter, and
particulate contamination is deposited on the surface of the membrane filter with a pore size of
less than 1.0 micrometer. Residual contamination is sized and counted by microscopic analysis as
described in ASTM F 312.
Table 2-2
COMPARISON OF SAE AND NAS CLEANLINESS CLASSIFICATION SYSTEMS
SAE, ASTM, AND AlA Tentative Standard, SAE 749D, September 1963 (Disavowed)
Contamination Class
Size Range
1 2 3 4 5
(\lm)*
6
5-10 2,700 4,600 9,700 24,000 32,000 87,000 128,000
10-25 670 1,340 2,680 5,360 10,700 21,400 42,000
25-50 93 210 380 780 1,510 3,130 6,500
50-100 16 28 56 110 225 430 1,000
over 100 1 3 5 11 21 41 92
N
I
J-1 Source: Reference 7.
J-1
Aerospace Industries Association of America, Inc. (NAS 1638, January 1984)

Classes*
Size Range
(11 m) 00 1 2 3 4 5 6 7 8 9 10 11 12

5-15 125 250 500 1,000 2,000 4,000 8,000 16,000 32,000 64,000 128,000 256,000 512,000 1,024,000
15-25 22 44 89 178 356 712 1,425 2,850 5,700 11,400 22,800 45,600 91,200 182,400
25-50 4 8 16 32 63 126 253 506 1,012 2,02~ 4,050 8,100 16,200 32,400
50-100 1 2 3 6 11 22 45 90 180 360 720 1,440 2,880 5,760
Over 100 1 1 2 4 8 16 32 64 128 256 512 1,024

Source: Reference 8
*Particles per 100 mL.

While NAS 1638 is still in use, an improved classification system is being consid-
ered by the International Organization for Standardization (ISO) and is known as the
ISO Solid Contaminant Code (~). This classification system is endorsed by SAE (lQ)
and ANSI (ll). The ISO Solid Contaminant Code is based on the fact that a step
ratio of two for particle concentration is adequate both to differentiate between
two significantly different systems and to allow for reasonable differences in
measurement.
The ISO Solid Contaminant Code is assigned on the basis of the number of particles
per unit volume greater than 5 ~m and greater than 15 ~m (~). Results from a par-
ticle count measurement are plotted on an ISO chart as shown in Figure 2-6. The
range of numbers at 5 ~m and 15levels are cited when expressing the contamina-
~m
tion level. For example, a fluid rated as 18/16 has 1.3 x 10 3 particles per milli-
liter greater than 5 ~m in size and 3.2 x 10 2 particles per mil~iliter greater than
15 ~m in size. A fluid rated as 27/23 has 6.4 x 105 particles per milliliter
greater than 5 ~m and 4.0 x 10 4 particles per milliliter greater than 15 ~m in size.
Since the ISO Solid Contaminant Code is relatively new, Table 2-3 shows the relation-
ship between the old coding systems and the improved ISO system.
Table 2-3 also lists an equivalent gravimetric level in terms of the weight of par-
ticles per liter of sample. ASTM F 313-78 describes a procedure for determining
contamination by weight (11). SAE ARP 785-1963 is an alternative procedure (~).
In addition to these gravimetric analysis methods, ASTM D 2273-81 is sometimes used

to measure trace sediment in oil by volume (~).
Foaming. Problems associated with excessive oil foaming may include oil pump inlet
starvation and loss of capability to transfer heat away from mechanical components.
Foaming tendency is frequently a consequence of soluble contamination or loss of the
antifoam additive. Loss of the antifoam agent may be corrected by additive makeup,
but only on the advice of the oil supplier. An excess of the additive may actually
aggravate foam problems.
Laboratory evaluation of foaming tendency is made using ASTM Method D 892-74. The
equipment required for the test is shown in Figure 2-7. A sample of the test oil is
placed in a graduated cylinder. Air is blown at a constant rate through the sample
held at a controlled temperature. After an airflow period of 5 minutes, the volume
of foam generated is noted. A second foam reading is taken after a 10-minute set-
tling period.
2-12
c10~ ~IOS
30 r----
~- DATE:
5.0 1---5
~ 2....
29 I S C f---4-
f---3
SAMPLE IDENTIFICATION:
1---2-
1--1.3
28 SOLID ~
t:10~ 27 r=:10~
~6.4
CONTAMINANT ::::==:=
~
-5-
26
~3.2
CODE --4-
1---3-
25 ~2-
~1.6
'---
10-====
24 10~ Nw SUBMITTED BY:
8.0
w
23
--'~
en
~ 5-
(/) 4.0 1---4- Q
i W
22 3-
Q to-
W i <
to-
<
2.0
I
2-
U PARTICLE COUNT METHOD:
u 21 0
0
~
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4
==== ~1.0
i i
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AUTOMATIC
20
Z 5.0
~--t I .~~.~ Z
<
x:
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: 1--+- -4-
to-
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a:
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to-
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I
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loh
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w
to-
<
w
MICROSCOPIC
<
w H0 ====
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17
i
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PARTICLE COUNT SUMMARY:
a:
-r--=E-=t=~
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w
---6.4
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, ,----t-i--r-
I ~H~_ 5 lIJ
0:: PARTICLES NUMBER
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15 ~ ;--r -i--r-
1 i
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t:
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> SIZE PER
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to- II ...J
a: I ! I 2 11m
< 10 - 1.0 10~ to-
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t --+--'-+---
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urn
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a: I 9 ! i I 0
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REMARKS:
8.0
3 5-
4.0 4
I
3-
2 I
2.0 2-
I i I
i I j
5 10 15 20 25 30 40 50 60 70 80 90 100
PARTICLE SIZE, micrometres
Figure 2-6. Chart for plotting particle count results. The ISO Solid
Contaminant Code classifies the contamination level of a fluid accord-
ing to the number of particles greater than 5 and 15 ~m in size. Par-
ticle count results are plotted on the chart to obtain the range num-
bers at 5 and 15 ~m, which are used to express the cleanliness of the
lubrication system.
Source: Extracted from the American National Standard Hydraulic Fluid
Power-Contamination Analysis Data: Reporting Method, ANSI/B93.30M-1980.
2-13
Table 2-3
COMPARISON OF ISO SOLID CONTAMINANT CODE TO SAE, NAS, AND ACFTD

CONTAMINATION LEVELS
Disavowed ACFTD a
SAE Gravimetric
ISO NAS 1638 Level Level
Code (1964) (1963) (mg/L)
26/23 1000
25/23
23/20 100
21/18 12
20/18
20/17 11
20/16 10
19/16 10
18/15 9 6
17/14 8 5
16/13 7 4 1
15/12 6 3
14/12
14/11 5 2
13/10 4 1
12/9 3 0
11/8 2
10/8
10/7 1
10/6 0.01
9/6 0
8/5 00
7/5
6/3 0.001
5/2
2/0.8
aACFTD (Air Cleaner Fine Test Dust): ISO-approved test and calibration contaminant.
Color/Appearance. Visual observation of the color and appearance of the oil pro-
vides a rapid and inexpensive measure of its condition. A hazy appearance may be
indicative of entrained water or particulates. A rapid darkening of the oil could
be a consequence of excessive deterioration. (A slow, gradual darkening over a
period of years is considered normal.) Although laboratory measurement of oil
2-14
Figure 2-7. Apparatus for conducting the ASTM D 892 test method for foaming
characteristics of lubricating oils. Foam is produced by injecting air for
5 minutes into a volume of oil held at a controlled temperature. The amount
of foam after the 5-minute aeration period and after a lO-minute settling
period determines the foaming tendency of the oil.
2-15
color is not normally performed, ASTM Method D 1500-82 is available for the deter-
mination of color on a precise scale. This procedure employs a colorimeter with a
light source and glass color standards. The test sample is placed in a glass jar,
and its color compared against that of the glass standards.
Water Content. The presence of free (undissolved) water in the lubricant can result
in numerous performance problems. Free water will promote sludging and additive
loss, impair the lubricating ability of the oil, accelerate rusting, etc. Excess
water in a turbine oil can frequently be detected by visual observation. A more
quantitative measure is provided by either ASTM Method D 95-83 or D 1744-83. The
apparatus for method D 95-83, shown in Figure 2-8, is composed of a heated still, a
reflux condenser, and a graduated glass trap. The oil sample is refluxed with a
water-immiscible solvent which distills with the water. After condensing, water
settles in the graduated trap, and the solvent overflows back to the still section.
The test is complete when the volume of condensed water remains constant for a
period of 5 minutes.
Flash Point. The usefulness of the flash point determination for a used oil is in
the detection of volatile solvents that may have been inadvertently introduced into
the oil system. Such an occurrence should also be indicated by a reduction in oil
viscosity. A number of test methods for flash point determination are available,
but ASTM Method D 92-78 is the most frequently used. Figure 2-9 shows the Cleveland
open cup apparatus used in this determination. The cup is filled with the test oil
and heated at a specified rate dictated by the sample temperature. At intervals of
temperature, indicated by a thermometer in the sample, a small flame is passed over
the surface of the cup. The sample flash point is defined as that temperature at
which a flash appears on the oil surface.
2-16
Figure 2-8. Apparatus for conducting the ASTM D 95 test method for water
in petroleum products by distillation. The oil sample is heated to evapo-
rate the water and a water-immiscible solvent. Upon condensing, the water
remains in a graduated glass trap while the solvent overflows back into
the heated still.
2-17
'AV:~:;:~::;i~~~,;::;:~:;~:;;;:';::':';~~~::;'~~-:;~~::;~~:;'~M::;:;~::;~'-~;~~
::;::::::.;;;;,:;;;{~;:;;;;;;;.:;;;;;;;:;::;;:;;W:::
};;;~:W:;:;;:rm ;~*~~*:.::.::::**:::~::~:::::::X:X;;.;.;~.;.;.; .
N
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~
00
Figure 2-9. Apparatus for conducting the ASTM D 92 test method for flash and fire points by a
Cleveland open cup. A small flame is passed over a heated oil sample in an open cup. The oil
temperature at which a flash appears on the oil surface is defined as the flash point.
2.2 MECHANICAL COMPONENTS
Mechanical components of the lubrication system require periodic testing and main-
tenance to assure continued reliable service. Oil reservoirs, piping, pumps, heat
exchangers, oil conditioners, and valves require inspection and maintenance to
detect and correct for wear, corrosion, and fatigue-caused degradation. These
inspections normally are performed during a major turbine generator overhaul period
when the lubrication system can be drained and the components can be disassembled.
Reservoirs and Piping
Testing and maintenance requirements for reservoirs and piping involve visual
inspections to reveal the following degradation mechanisms:
(1) Structural deformation, damage, or cracking

(2) Corrosion or oxide scale formation
(3) Sludge and debris accumulation
Normally the reservoirs and piping are constructed from carbon steel material. Wall
thickness is selected with a design safety factor of 8 considering the operating
pressure involved (~). Thermal expansion of the piping is a consideration when it
is placed around the high temperature steam lines or when it is exposed in an out-
door installation. Vibration of the piping can occur from excitation from other
sources. The vibrations are transmitted through the foundation and structural sup-
ports and impose fatigue loads on the piping which can result in cracks and leaks.
The carbon steel material can corrode in the presence of moisture and oxygen.
Internal surfaces of the reservoir and piping may have protective coatings which
can blister or flake off and leave a corrosion site. Corrosion can penetrate the
wall of the pressure boundary, resulting in a leak. Corrosion products can also
flake off the steel to be distributed throughout the lubrication system and damage
other system components.
Sludge and debris accumulate as a result of contamination from impurities such as

dust, dirt, lint, pulverized coal, fly ash, rust, welding beads, scale, water emul-
sions, insoluble oil degradation products, material in the atmosphere surrounding
the plant, rustproofing or pipe thread compounds, gasket or insulation materials,
or incompatible oils (1l).
Visual inspections of the reservoir and piping can pinpoint where further mainte-
nance may be required to remove the accumulated material or to repair the structural
defects. Draining of the oil is performed to expose locations where degradation
2-19
can occur. This process removes only a portion of any debris accumulation and does
not remove any sludge deposits or oxide scales that are adhering to internal
surfaces.
Wiping, scrubbing, and flushing are normal maintenance activities required for
cleaning reservoirs and piping. Other methods of cleaning may be necessary for
built-up varnishes, gums, and other insoluble materials. The exact method of clean-
ing will depend on the amount and nature of the material. Concurrence of the tur-
bine generator manufacturer and the oil supplier should be obtained when considering
a method to remove any insoluble material to ensure compatibility.
Seals and access cover gaskets should be inspected and replaced when deteriorated to
reduce the amount of air being drawn into the system.
Pumps and Vapor Extractors
Oil pumps and oil vapor extractors are rotating machinery that require periodic
testing and maintenance to detect degradation primarily from wear and fatigue.
Long-term service periods for these rotating components produce conditions where
sudden failure can occur if wear or fatigue cracks propagate beyond critical dimen-
sions for dynamic stability and structural integrity.
Bearing temperature, vibration, and discharge oil pressure are operating parameters
which can be monitored on these components for indications of degradation. Records
of maintenance and operating history are useful for guidance in scheduling component
disassembly for a more thorough examination of internal parts.
Complete disassembly of these types of rotating equipment provides more certain

determination of their mechanical condition through actual dimensional measurements
and visual examination.
Clearances between rotating parts and stationary members should be measured and
restored to specified tolerances. Diametrical clearance of a bearing controls
vibrational stability of the pump while impeller clearance controls internal leak-
age back to the pump suction.
Keys and retaining nuts, rings, or washers should be examined for integrity, posi-
tion, and dimension. Looseness or cracks in these parts can result in pump insta-
bilities and metal-to-metal contact.
2-20
Couplings need to be checked for alignment, fit-up, and lubrication to assure that
bending forces are not placed on the rotating shaft. Pump suction screens should
be checked for blockage and integrity.
Some pump bearings are lubricated through small tubing or internal passages connect-
ing to the pump oil discharge nozzle. These lubricant supply lines should be exam-
ined for integrity and blockage.
The shaft, support piping, and pump casings can experience degradation in the form
of deformation, wear, or cracking. Dimensional measurements and visual examinations
are performed to verify condition of these parts.
Written instructions for disassembly, inspection, and assembly for all oil pumps
and vapor extractors are required, since these activities are not regularly and rou-
tinely performed.
Heat Exchangers
Heat exchangers are subject to blockage of the internal and external passageways and
to leakage of tubes and tubesheet seals. Inspections are periodically required to
determine if additional maintenance activity is necessary.
The water side of the oil cooler tubes can experience erosion, corrosion, or fouling
by materials carried with the cooling water. Deposits and blockage on the water
side often affect performance of the cooler so that frequent cleaning is necessary.
If the proper arrangement of valves is installed, water flow through the cooler can
be reversed to remove silt or other foreign material from the tube walls. If flow
reversal is not successful or not possible, air lancing, scrubbing with fiber
bristled brushes, or chemical cleaning may be necessary to remove the accumulated
dirt or debris.
The oil side of the tubes may require cleaning to remove deposits of insoluble oil
oxidation products. Because these deposits normally form gradually, the cleaning
requirement is very infrequent compared to the water side of the tube. An allowance
for tube fouling is included in the cooler design so that the effect of any slow
increase in deposits on the oil side can be offset by repeated partial cleaning of
the water side. Hot water, steam washing, and compatible petroleum solvents are
usually the cleaning agents used for the oil side. Sludge can be removed from the
cooler shells and passages by hot water, but the cooler tube bundle requires clean-
ing by a solvent in a suitable cleaning tank. The bundle should be completely
immersed in the bath and rotated or lifted up and down until the deposit is softened.
2-21
Oil leakage through tubes or tubesheet seals can flow either way depending on the
differential pressure between the two fluids. A telltale on a floating-type tube-
sheet seal can indicate whether the packing is defective.
Hydrostatic testing on the water side can determine if the tube bundle is leaking;
however, to locate a leaking tube, the oil side should be pressurized by the auxili-
ary oil pump. Pressure testing of the tube bundle is performed only when the tur-
bine generator unit is not in operation. Oil pressure should be adjusted to provide
as high a value as possible without exceeding the rated design capability of the
cooler.
Oil coolers are continuously vented to assure that they are full of oil when a
transfer is performed. Small diameter vent lines return oil and air from the top
of the cooler oil side to the main oil reservoir. Verification of flow through the
vent lines is performed to assure that they have not become plugged or restricted.
Oil Conditioners
Numerous types of oil conditioners are used to remove solid and water contaminants
from the oil. These include particulate filters in combination with a gravity pre-
cipitation chamber, centrifuge separator, coalescer/separator, or vacuum dehydration
tanks. Each type of oil conditioner requires special maintenance activities that
are specified in the equipment maintenance manual. However, some consistent prob-
lems are experienced by all types of oil conditioners and include inadequate flow
rates, insufficient cleaning of settlement sumps and solids compartments, and exces-
sive pressure drops across the particulate filters.
Inadequate flow rates are usually caused by an insufficient hydraulic head and
excessive pressure drop in the piping supply to the oil conditioners (~). Gravity
fed piping arrangements with an anti-siphoning suction standpipe and an overflow
sight glass require that the oil reservoir operating level be maintained at a suffi-
cient level to produce the hydraulic head and cause oil flow to the conditioner. A
reduction in the oil reservoir level will reduce flow of oil to the conditioner.
The flow resistance in the piping must be well below the flow-inducing hydraulic
head available. The size and slope of the piping configuration are important fac-
tors in establishing adequate flow to the conditioner. Tests to determine flow
into the oil conditioner should be performed and compared with the desired amount
and the capacity of the oil conditioning unit.
2-22
Oil conditioning units employ particulate filters which remove solid particles by
passing the oil through media in a cartridge. As the particles are removed from
the oil and collected on the media surface, the pressure drop across the cartridge
increases. When the pressure differential becomes excessive, flow through the fil-
ter will be reduced, and the cartridge is in danger of collapsing or breaking up.
Replacement or cleaning of the cartridge at a prescribed differential pressure level
is required to restore flow and to maintain the filter's structural integrity.
Replacement cartridges should be selected in accordance with filter rating specifi-

cations and differential pressure capacity limitations. The American National Stan-
dards Institute (ANSI) Multipass Test Procedure, B 93.31, can be used to evaluate
efficiency and capacity of particulate filters (~).
Figure 2-10 is an example of a disposable cartridge specification sheet covering

every parameter for which an international standard has been issued (20-25). Sec-
tion 1 contains information pertinent to all tests. Section 2 contains information
on the specific test sequence and minimum acceptable performance. Any test not
required for a specific application can be crossed off. Two cartridges or test
samples A and B are used for a given test and test sequence. Section 3 is used only
when the cartridge is intended for pressure-containing duty, such as a spin-on ele-
ment. Section 4 allows for any additional requirements.
The terminal pressure drop, Item 1.5, should be selected by deciding what is the
maximum pressure drop the cartridge will see in service. This value can be set in
relation to a differential pressure switch alarm setting, a bypass valve setting,
or an arbitrarily selected value such as 100 psid (690 kPa) (~).
Fabrication integrity, Item 2.1, varies with the type of filter medium and cannot
be used for comparing filters from two different manufacturers. The actual value
is supplied by the cartridge manufacturer, since it only verifies that the cartridge
has not been mechanically damaged prior to the remaining tests.
Beta (610) values, Item 2.3, indicate the particle separation capability of the car-
tridge and are defined as the ratio of the number of particles larger than 10 ~m in
the influent to the number of particles larger than 10 ~m in the effluent, 610 = NI0
(influent)/N 10 (effluent). The higher the 610 value, the greater the capability of
the cartridge to capture particles larger than the indicated beta size. When removal
of particles smaller than 10 ~m is nec~ssary, the beta value for the desired parti-
cle size rating of the cartridge should be specified.
2-23
The value for the flow fatigue test, Item 2.5, should be greater than the maximum
number of cold starts and flow surges the cartridge will experience in service
before it is changed.
Valves
Flow control, pressure regulation, and three-way flow diverting valves require peri-
odic inspection to detect degradation from vibration and/or corrosion. Manual
valves used for drain and vent lines, sampling points, and instrumentation isolation
should be checked periodically to assure that they are structurally secure and in
their correct operating position with any locks in place.
Flow control and pressure regulation valves are usually placed. on the discharge or
bypass of the suction pump to the main shaft oil pump. These valves require peri-
odic inspection of their structural integrity and control setting. Flow control
devices may also be installed on individual oil supply lines to the bearings and
couplings. These devices should be inspected for blockage and wear.
An important regulation valve is the cooling water flow control valve to the oil
cooler. This valve is examined to detect deterioration due to corrosion, erosion,
and/or vibration.
Some oil heat exchanger diverting valves have interlocking linkages that open and
close several ports simultaneously. Wear and deformation of these linkages can
result in misplacement of the valve plugs and misdirection of oil flow. Visual
examination of the valve seating sequence is performed to assure proper valve
operation.
Check valves are used on the discharges of oil pumps that are connected in parallel
and run independently. Periodic disassembly of these valves is performed to examine
the swing disc, seat, and hinge pins or guide posts. These examinations are usually
conducted when the oil pumps are inspected and overhauled.
2-24
SECTION 1. TEST CONDITIONS AND DESIGNATED INFORMATION
1.1 Test flow rate: gpm = L/min
Maximum flow rate: gpm = L/min
1.2 Test fluid: unless otherwise noted
viscosity @104F (40C):_ sus = cSt; spec. gravity _
1.3 Maximum system oil temperature: F = C
1.4 Normal direction of flow: 0 outside-in 0 inside-out
1.5 Terminal pressure drop: psid = kPad
1.6 Number of samples to be evaluated: 0 2 or 0 other;
1.7 Designation of filter element:
1.8 Reference drawing for dimensions:
1.9 Reference drawing for installation and mounting: _
SECTION 2. TEST SEQUENCE AND MINIMUM ACCEPTABLE PERFORMANCE
Test Test Min. Acceptable

Title and procedure Remarks
Sequence Sample Performance
Fabrication Integrity
in. water
o Test fluid (, 1.2)
2.1 1 A&8 ANSI/893.22-1972 or
mm water
ISO 12942-1974 o Isopropanol
Material Compatibility o '1.3 + 27F (15C)
2.2 2 A&8 ANSI/893.23-1972 or
ISO 12943-1974 o Max. test temp._
o MIL-H-5606
or
o Multi-pass Test t o Test fluid (, 1.2)
ANSI/893.31-1973 Pl0 ~ *
a grams
150/015 4572
apparent dirt capacity
o On-line counting
2.3 3a A or
or o 80ttle sampling
P2 ~ *
o Modified for silt control
(silt control filters) o Average P
or
o Minimum P
End Load Test lb. o Compression

2.4 3b B ANSI/893.21-1972 or
150/3723-1976 kg o Tension
Flow Fatigue cycles

2.5 4b 8 ANSI/893.24-1972 to term. press. drop
ISO 13724-1976 (, 1.5)
Collapse-8urst
psid
2.6 5b 8 ANSI/893.25-1972
kPad
150/2941-1974
- -
SECTION 3. PRESSURE RATINGS: if any portion of filter element becomes part of the pressure containing envelop
(all spin-on elements and some modular filter elements)
3. 1 Normal system pressure: psig = kPa *Measured at constant flow. Pulsating flow Pmay
3.2 Proof pressure: psig = kPa be lower. Proposed method being validated.
3.3 Min. burst pressure: psig = kPa
3.4 Min. rated fatigue pressure: psig = kPa (2/90) 107 cycles per NFPA/T2.6.1-1974
SECTION 4. OTHER REQUIREMENTS
Figure 2-10. Specification sheet for disposable filter cartridges. Quality

particulate filter cartridges are required for turbine lubrication system
service. International standards have been developed which test the
critical parameters pertaining to cartridge performance. Filter users and
suppliers should use this specification cooperatively to match cartridge
capabilities with service requirements.
2-25
2.3 MOTORS AND CONTROL COMPONENTS
In critical situations where turbine bearing lubricating oil pressure is decreas-

ing, proper and timely actions of motors and control components in the emergency
lubricating system are vital for prevention of serious bearing damage. There are
numerous cases on record where all auxiliary and emergency turbine bearing lubrica-
tion systems have failed simultaneously resulting in, as a minimum, bearing destruc-
tion and, often, expensive turbine damage. Ultimate cause of an extended outage
following lubrication failure frequently is traced to a relatively simple system
component that could have been checked periodically with ease. Typical examples
are a burned-out motor starter coil, an improperly adjusted or defective pressure
switch, worn brushes on a dc motor, or an open circuit in the electrical supply to
an auxiliary or emergency pump motor.
Because motors and control components associated with auxiliary and emergency bear-
ing lubrication generally are not used while the turbine is in normal operation at
synchronous speed, a tendency exists to ignore these important items or to test them
too infrequently or too casually. However, some relatively simple and straight-
forward inspections and performance tests can minimize the probability of failure
at a critical time. This subsection of the Guidebook (1) identifies turbine-bearing
lubrication system electrical components that can and should be checked periodi-
cally, (2) suggests the frequency of such checks, and (3) recommends procedures for
accomplishing these checks. The Institute of Electrical and Electronics Engineers
(IEEE) has published several pertinent standards that provide guidelines, recom-
mended practices, and procedures for testing and maintenance of electrical compo-
nents used in lubrication systems. Table 2-4 lists the appropriate IEEE Standards.
System Description
In virtually all steam turbine generating systems, turbine bearings are lubricated
with pressurized oil supplied by a main shaft oil pump (MSOP). When the machine is
operating at or near synchronous' speed, the MSOP can supply the volume of oil neces-
sary to maintain proper bearing lubrication; however, during startup or coastdown,
when the rotor must turn at substantially less than synchronous speed, capacity of
the MSOP decreases dramatically so that it can no longer supply an adequate volume
of oil. During these operating periods, or in the relatively unlikely event that
the MSOP fails while the system is operating at synchronous speed, an auxiliary
source of lubricating oil must be provided. Most systems include a bearing oil pump
that is driven by an ac motor. This pump is often referred to as the "auxiliary or
2-26
Table 2-4
IEEE STANDARDS FOR MOTORS AND CONTROLS
Standard
62 Guide for Field Testing of Power Apparatus Insulation
432 Guide for Insulation Maintenance for Rotating Electrical Machinery

(5 HP to less than 10,000 HP)
56 Guide for Insulation Maintenance of Large AC Rotating Machinery

(10,000 kVA and Larger)
67 Guide for Operation and Maintenance of Turbine Generators
95 Recommended Practice for Insulation Testing of Large AC Rotating

Machinery with High Direct Voltage
433 Recommended Practice for Insulation Testing of Large AC Rotating

Machinery with High Voltage at Very Low Frequency
43 Recommended Practice for Testing Insulation Resistance of Rotating

Machinery
113 Standard Test Code for DC Machines
112 Standard Test Procedure for Polyphase Induction Motors and

Generators
48 Test Procedures and Requirements for High Voltage AC Cable

Terminations
115 Test Procedures for Synchronous Machines
Source: Th~ Institute of Electrical and Electronics Engineers, 345 East 47th
Street, New York, New York 10017.
backup" oil pump. Additionally, to accommodate emergency situations when ac power

may not be available, most systems are also provided with a bearing oil pump driven
by a dc motor; this pump is usually referred to as the "emergency" pump. Some sys-
tems may have yet another bearing oil pump for use when the turbine is being rotated
by the turning gear.
2-27
In systems equipped with auxiliary (ac) and emergency (dc) bearing oil pumps, there
are at least two pressure switches that monitor oil pressure. One of these, set to
trip at a slightly higher pressure than the other, controls the ac-powered auxiliary
pump by way of a motor starter; and the second (lower setting) pressure switch con-
trols, again by way of a motor starter, the dc emergency pump. Thus, under normal
conditions, if oil pressure decreases, the auxiliary pump is started first. If for
some reason the auxiliary pump cannot deliver oil (e.g., failure to start, loss of
ac power, etc.), then oil pressure continues to decline and eventually the emergency
pump starts. In addition to automatic operation as just described, the auxiliary
and emergency pumps may be started manually; and, indeed, this is usually done dur-
ing turbine startup and coastdown.
This subsection of the Guidebook deals with electrical components; and motor
starters, motors, and pressure switches are the principal items considered. How-
ever, other peripheral electrical controls in the turbine bearing lubricating oil
system also will receive further discussion, including liquid-level switches in the
oil reservoirs and temperature switches located in the oil stream and on bearings.
Controls of this type usually do not start or stop oil pumps, but instead actuate
alarms that alert the unit operator to impending trouble. Additionally, controls
and power wiring inspection and maintenance will be discussed.
Rationale
Even if loss of turbine bearing lubrication results only in bearing damage, costs
for replacing bearings and associated loss of production are substantial (~). In
recognition of this fact, all utilities conduct periodic tests of auxiliary and
emergency turbine bearing lubrication oil pumps as a means of minimizing such
losses. However, practices vary widely from utility to utility, particularly with
respect to the frequency and scope of such tests. For example, test frequency may
range from daily to annual while scope may range from (1) manual actuation of the
motor starter and observation that the motor shaft turns to (2) starting the motor
by bleeding pressure from the control switch followed by measuring motor rotational
speed, motor current, and pump discharge pressure. Clearly, a balance must be
achieved between the cost (frequency and scope) of testing on one hand and the risk
of failure on the other.
Because an individual utility must make this balance decision based on its own oper-
ating experience and philosophy, a guidebook such as this cannot be regarded as a
2-28
mandate, but should be thought of as a useful source of information indicative of
the norm of industrial practice and a stimulus to periodically reassess the cost-
risk balance as operating conditions change, equipment ages, and long periods of
time elapse without a lubrication failure. Accordingly, this subsection of the
Guidebook attempts (1) to show what many electric utility companies are doing to
ensure operational readiness of turbine bearing lubricating oil systems and (2) to
suggest typical test procedures and frequencies that appear to have supported the
best operating records.
Applicability
Although turbine bearing lubrication systems include certain fundamental components,

equipment of different manufacturers varies, and substantial differences in details
are encountered from utility to utility, from plant to plant within a utility, and
from unit to unit within a plant. Certainly, no single Guidebook procedure can
cover all of the possible variations found in practice; consequently, the proce-
dural suggestions in this Guidebook are rather general in nature and, therefore,
may include components that do not exist in a specific system or, in some cases,
may omit items found in a few isolated systems. Anyone using this Guidebook must
be prepared to adapt and modify the suggested procedures to fit specific details of
the systems to be tested.
Because each test of a turbine bearing lubrication system component should be per-
formed in a consistent manner, it is highly desirable that procedures be written,
and, as a matter of fact, ~ost utilities have written procedures in forms ranging
from a simple checklist to a very formal, detailed, step-by-step test and inspection
process. Suggestions presented in Sections 3 and 5 of this Guidebook can serve as
outlines for preparation of operational procedures. It may be necessary to delete
items that do not apply to the system being considered and, perhaps, to add a few
remarks that accommodate specific features of the system to be tested. Further, it
may be necessary to change the names of various components to agree with local
vocabulary and practice and, perhaps, to insert tag or inventory numbers that spe-
cifically identify the item to be operated or checked. In this way, suggestions
presented in this Guidebook may be used as foundations for specific test and inspec-
tion procedures applicable to a particular unit (or group of units) in a single
plant operated by an individual utility.
Except in extreme cases (e.g., fire or explosion), turbine bearing lubrication

system components should not be removed from service or availability for service
without prior approval of the persons ultimately responsible for plant operation
2-29
and safety. Thus, when periodic tests and inspections reveal a marginal or inoper-
ative turbine bearing lubrication system component, key plant personnel should be
notified immediately so that the risk of operating without normal backup capability
can be assessed and repair can be initiated or planned. Each utility should have a
standard procedure that requires notification of the unit operator before a criti-
cal piece of equipment is removed from service for maintenance. If such a policy
does not exist, one should be implemented to minimize the possibility of removing
equipment from service without proper notification. Each written maintenance pro-
cedure should include an instruction to notify the unit operator before initiating
the activity. Further, each maintenance procedure should include a post-activity
test that demonstrates equipment operability and availability.
Dc Motors
Emergency bearing oil pumps are almost universally driven by dc motors operating
from storage batteries. This provides an ultimate source of lubrication independent
of all other sources of power available to the plant. In most industrial applica-
tions, dc motors have proven to be reasonably reliable; but they do require periodic
inspection, test, and maintenance to ensure that they are in running condition and
to detect conditions indicative of deterioration or impending failure.
Circuit closure to a dc motor is accompanied by short-duration voltage transients,

high inrush current, sudden acceleration, and mechanical stresses that could be dam-
aging to the motor. Further, when the circuit is interrupted, there are inductive
high-voltage transients that could be damaging to winding insulation. Thus, even
though the motor may not be operated under load for extensive periods of time, its
life may be shortened by starting and stopping. As a result, tests beyond the usual
visual inspection and periodic starting are desirable ways of detecting deteriora-
tion that may be indicative of impending failure. IEEE Standard 43 suggests a pro-
cedure for measurement of leakage resistance between windings and ground. Other
tests include measurement of operating current and determination that the motor can
indeed drive its load. Although these tests may be performed infrequently (e.g.,
on a yearly basis or at turbine overhaul), it is highly desirable that they be
conducted.
The commutator and brush assembly of a dc motor is a critical area that should be
inspected frequently. Looking for pitting or scoring of the commutator bars, unu-
sual brush wear, adequate brush length, proper alignment and freedom of movement of
2-30
the brush mechanism, and abnormal sparking while running can provide important clues
to impending trouble. Often, if a problem can be detected as it is developing,
relatively minor repairs can be performed to prevent a catastrophic occurrence.
Motor bearings equipped with grease fittings should be lubricated periodically, and
permanently lubricated bearings should be cleaned and repacked at turbine overhaul.
Further, motors must be kept clean, particularly around the cooling-air intakes and
exhausts and around the commutator and brush assembly. Finally, wiring and connec-
tions should be inspected to ensure that these critical items are not deteriorating.
Current dc motor inspection and test practice varies widely within the electric
power utility industry. Frequency of testing ranges from daily to annual. Scope
of inspection may be as minimal as manual actuation of the motor starter followed
by visual determination that the motor is running or as complete as starting the
motor by simulating loss of oil pressure (i.e., opening the pressure-switch bleed
valve) followed by measurement of motor rotational speed, motor current, and pump
discharge pressure. Although the first case verifies that p~wer is available, the
starter works, and the motor rotates, it does not ensure that the pressure switch
is working or that the motor comes up to full operating speed. In the second case,
however, all of these factors are tested and verified. There have been cases in
the utility industry where a dc emergency pump motor passed the minimal type of
inspection, but failed during a trip-out situation because the motor could not come
up to operating speed and, hence, could not deliver the required oil pressure and
volume. In view of this experience, it seems reasonable to perform the more exten-
sive checks at least part of the time.
Ac Motors
Three-phase ac induction motors are most commonly used to drive auxiliary bearing
oil pumps. These motors have fewer components than dc motors and so have fewer
failure modes. Because ac motors are usually started by direct application of full
line voltage, transients of voltage, current, acceleration, and stress occur during
startup; and inductive high-voltage transients during shutdown (i.e., circuit
interruption). Usually, the rotor structure in an induction motor is less suscep-
tible to sudden acceleration damage than the armature in a dc motor, but stator
windings are equally subject to damage by high-voltage transients. Therefore, occa-
sional tests of insulation resistance (IEEE Standard 43) and of motor load-handling
capability are desirable to ensure maximum reliability and availability for service.
2-31
Additionally, bearings on ac induction motors require periodic service. Often,
motors are equipped with fittings for injecting grease into the bearings; and if a
motor is so equipped, its bearings should be lubricated periodically. Even so-
called "permanently lubricated" bearings require occasional service in which they
are cleaned and repacked; performing this operation coincident with turbine overhaul
is usually adequate. Additionally, it is necessary to keep all motors clean, par-
ticularly around the cooling air intake and exhaust areas, to prevent overheating
and consequent accelerated insulation deterioration.
Current electric utility practice in inspection and test of ac pump motors is simi-
lar to that employed for dc motors; that is, tests and inspections may be performed
at intervals ranging from daily to annually, and scope of the tests may range from
manual starting to simulation of pressure loss with determination of motor speed,
motor current, and pump discharge pressure. However, testing the ac auxiliary pump
motor is probably of less importance than testing the dc emergency pump motor
because (1) there may be more than one ac-operated auxiliary pump which provides
redundancy and (2) in a real emergency, ac power may not be available. In this con-
text the dc emergency pump is the ultimate backup; consequently, it is the one that
must be most carefully monitored and maintained in operational readiness.
Motor Starters
Starters (contactors) used in both ac and dc motor control circuits are reasonably
reliable devices. Most electric utilities perform no direct tests or periodic main-
tenance on this equipment; in fact, the manufacturers do not recommend preventive
maintenance. Of course, whenever the pump motor is started, the motor starter is
also actuated, so it is tested implicitly along with other parts of the system.
Even though motor starters are usually enclosed, insects (particularly ants),
spiders, and rodents may get inside the enclosure and build nests in the vicinity
of critical operating components. Further, atmospheric dust, particularly in coal-
fired plants, may enter the enclosure' and build up on critical surfaces, leading to
malfunction. In view of these possibilities, it is desirable that the interiors of
motor starter enclosures be visually inspected periodically, and if dust or evidence
of animal invasion is present, appropriate cleaning should be initiated.
Also, during visual inspection, general condition of the contacts and the coil
should be observed. If burned, pitted, or corroded contacts are observed or if the
coil is discolored, charred, or burned, immediate repairs should be made.
2-32
Pressure Switches
Pressure switches are used to perform the important action of initiating startup of
auxiliary and emergency turbine bearing lubrication pumps in the event of decreasing
oil pressure. These switches usually do not require scheduled or preventive mainte-
nance, but do require periodic test and calibration. If, during regularly scheduled
tests of the auxiliary and emergency bearing oil systems, pump startup is initiated
by bleeding pressure from the oil pressure switch, then action of this important
component is automatically included in the test. Further, if a pressure gauge is
located at the pressure switch, then it is possible to determine rather accurately
the pressure at which the switch trips; that is, as pressure decreases, gauge read-
ing is noted when the corresponding pump motor starts. If this simple technique is
used, a shift in pressure switch trip point can be detected and corrected. How-
ever, even if the pressure gauge technique is used for monitoring trip points, it
remains desirable to calibrate each pressure switch, usually at annual intervals,
using a standard dead-weight tester; in fact, most electric utilities do perform
dead-weight calibration of pressure switches at annual intervals.
Alarm Sensors
In a typical turbine bearing lubrication system, additional sensors are used that
do not start and stop pumps, but instead actuate alarms intended to alert the unit
operator to potentially dangerous conditions. Such sensors include liquid-level
switches that monitor fluid level in a tank or reservoir and temperature sensors
and switches that may be used to monitor oil temperature or bearing temperature.
While such sensor elements are relatively passive devices, they do require periodic
inspection and test.
Liquid Level Switches
A liquid level switch usually comprises a float that either swings on a pivoted arm
or slides up and down a vertical guide past a preselected trip point. Motion of
the float may be transmitted to an electrical switch by a mechanical linkage or by
magnetic coupling. The float follows the liquid surface; and, as liquid level car-
ries the float past a preselected trip point, an electrical contact changes state.
Liquid level switches may have more than one set point; that is, one contact may
actuate when the liquid level reaches a low point, and a separate contact may actu-
ate when the level reaches a high point.
Liquid level controls are usually very stable and do not require frequent calibra-
tion; however, it is necessary on a periodic basis to ensure that the float has not
developed a leak, the arm or guide is not deformed, the float moves freely, and the
2-33
contact for each trip point closes or opens as it should. Some electric utilities
currently ignore liquid level switches, but others perform simple periodic checks,
typically at monthly intervals.
Temperature Switches
Temperature switches are used to indicate abnormal oil temperature or bearing temper-
ature. Switches of this type may employ basically mechanical operating principles,
including (1) differential expansion between two dissimilar metals and (2) expansion
of a fixed quantity of liquid or gas. In devices employing these principles, the
sensing element directly actuates a snap-action switch. More sophisticated devices
employ thermocouples, resistance thermometers, thermistors, or related devices to
generate an electrical signal that is proportional to temperature; such sensors
require soms form of signal conditioning that is usually performed by an electronic
module having a contact closure as its output function.
Calibration of all temperature sensors drifts with time, so periodic recalibration

is required. Because a minimum of two stable, known temperatures must be available
to facilitate calibration, it is usually necessary to carry out this procedure in a
well equipped instrument laboratory. For this reason, temperature switches are fre-
quently ignored in the routine test and inspection p~ogram; and maintenance is per-
formed only when an instrument failure is obvious. However, temperature switches
perform important functions, and they should not be ignored.
One approach to maintaining properly functioning, accurately calibrated temperature

switches in the plant is to use the rotation principle; that is, a spare temperature
switch is calibrated in the laboratory according to the manufacturer's instructions.
Then the recently calibrated temperature switch is used to replace a similar unit
in the plant, and the instrument removed from service is returned to the laboratory
for calibration. Typically, this rotation procedure is performed at 12-month inter-
vals. However, in applying this process, records should be kept of the calibration
status of each temperature switch and the day it was received in the laboratory for
service; in this way, actual experience can be used to establish a more realistic
rotation schedule based on drift rate and calibration tolerance for each class of
temperature switch employed by the utility. Further, if the rotation principle is
used, there is real value in standardizing on a particular make and model so that
temperature switches are interchangeable; this minimizes the required inventory of
spares and greatly simplifies calibration.
2-34
Cables and Wiring
During the annual boiler inspection outage, power wiring for the bearing oil pump
motors and wiring for the associated control circuits should be inspected for accu-
mulations of dirt (this is particularly important in dusty locations or in coal-
fired plants), insulation deterioration (including cracks, melted areas, rodent dam-
age, etc.), and integrity of connections and terminations. Dirt should be cleaned
from cable troughs and equipment enclosures; and if worn or damaged insulation is
observed, repair or replacement should be accomplished. Also, loose connections
should be cleaned and tightened, and connections showing signs of heating damage
should be repaired. On a more frequent basis (e.g., monthly), wiring in open-top
cable troughs should be cleaned to remove any buildup of dirt or coal dust.
2-35
2.4 EMERGENCY POWER SOURCES
Various emergency electric power sources discussed in this subsection are essential
to assure adequate lubrication to the bearings of turbine generator units. As pre-
viously discussed, a lubrication system has at least two motor driven pumps to pro-
vide oil to the bearings whenever the main shaft driven oil pump is inoperative;
these two pumps are the ac motor driven auxiliary oil pump and the dc motor driven
emergency oil pump. Since these oil pumps are electrically operated, the lubrica-
tion system is critically dependent on continuous availability of ac and dc power.
Neither the controls nor the pumps can be expected to operate properly without
continued adequate electrical power. It is thus imperative that power for the ac
motor driven pumps be supplied by the most reliable source available, with alter-
nate or emergency ac power sources automated to be transferred to the back-up criti-
cal (vital) bus on loss of normal power.
Ac Power Supplies
Historically, the various emergency ac power sources have operated faithfully, espe-
cially since continued technical development has eliminated many problems (~).
However, a potential source for problems is the large variation of ac power supply
schemes that are designed for a specific utility and location. Any deficiencies in
the power circuits to pumps and controls must be corrected immediately, since any
delays invariably result in damage to the turbine generator bearings if the emer-
gency system does not respond when required. Individuals responsible for unit oper-
ation and maintenance should be totally familiar with the scheme used at the unit
location because the power supply arrangement could be different from operators'
previous experience.
A large number of utilities have instituted operating instructions and training to

familiarize the operators with procedures, acquaint them with the equipment, and
direct their actions to standardized prearranged patterns of performance. Preven-
tion of equipment damage encourages definitive operating procedures and intensive
training at each unit location.
Emergency ac electric power sources available to the utilities include an array of

resources such as engine alternator sets, diesel alternator sets, gas turbine units,
and peaking units of various designs. Also, tie lines, networks, loop feeds, back-
feeds, and hydros are used by various utilities. A number of plants are capable of
a "black start" that makes them completely independent of any other electrical
system. Power transfer within a station is a viable source of emergency power
2-36
if designed to automatically transfer electrical loads to a critical or vital bus
when normal unit power ceases to be available.
Dc Power Supplies
Since the dc motor driven pumps are the final safeguard in the back-up lubrication
system, it is recommended that batteries supplying power to these units be capable
of a minimum of eight hours operation without the battery charger(s) connected to
them. Batteries should be kept on constant charge and tested periodically by a com-
plete coastdown with the battery charger disconnected to verify battery capacity.
The capability of each battery set should be verified by periodic load tests between
the coastdown tests.
Utilities normally do not perform the deep discharge test as recommended by IEEE
Standard 450-1980 (~), since it is feared that the outcome of the test can be com-
pletely dead batteries which have to be replaced. However, one utility has just
recently reported on their usage of deep discharge testing (30). Their report states
that the utility had discharge tested 13 battery systems and needed to replace four
of them based upon a 10% or greater loss of battery voltage during the test period.
Testing was performed by an outside service organization that supplied a substitute
battery set to replace the battery under test during the testing period.
The utilities often perform light load partial discharge tests on the batteries on a
weekly basis. This test generally consists of running the dc motor driven oil pump
for 15, 30, or 60 minutes, depending on the utility's preference. In conducting
this test, some utilities remove the battery chargers from the batteries; but others
leave the chargers on the batteries for the duration of the test. All utilities
observe current and voltage during this discharge test as well as recovery of the
batteries while being recharged. A continuing record of these tests provides infor-
mation for determining relative capability of the batteries.
It is important to make visual checks of the batteries that involve the following
actions:
(1) Observe their general appearance

(2) Clean off the tops
(3) Clean connections of corrosion
(4) Check liquid levels
(5) Observe condition of the liquid (clear or cloudy)
(6) Look for sediment or deposits or for gas evolution
(7) Examine physical alignment and straightness of the plates
2-37
More detailed checks should be made on batteries periodically to de'termine specific
gravity of the electrolyte and voltage across each cell, or voltage across each
cell including one connection to find any high resistance connections (~). Resis-
tance of each connection between cells is individually checked and can be improved,
if necessary, by application of "no-oxide" to the connection to reduce corrosion or
by tightening the bolt with a torque wrench to optimize conductivity of the connec-
tion. Cells are found to be deteriorating by the following:
(1) Lower voltage than standard

(2) Excessive water usage
(3) Excessive gas evolution
(4) Low electrolyte specific gravity
Degraded cells are replaced with new cells to maintain integrity of the battery
system.
Care must be taken when using solvents or solvent-containing substances near battery
cases or covers. Tests have shown that some commonly used solvents will induce
almost instantaneous cracking of battery cases. In one situation, a hydrocarbon-
based grease was used to lubricate battery storage racks to permit cells to slide
more easily over the racks. The hydrocarbon oil in the grease attacked the styrene-
acrylonitrile (SAN) case material, and all cells had to be replaced. In another
case, trichloroethylene, used to clean battery posts of anti-corrosion grease,
caused casing cracks. Procedures for maintenance of batteries should ensure that
solvents used in the vicinity of batteries are carefully monitored and that those
applied are used in accordance with recommendations of the battery manufacturer (~).
Lead-acid commercial batteries are still popular, although several utilities are
changing to commercial lead-calcium and lead-antimony batteries. Battery life
expectancy varies considerably, ranging from 15 to 23 years. One utility experienc-
ing many problems with commercial batteries found that it was economical and advan-
tageous to produce their own station batteries as well as the company's transporta-
tion fleet batteries. This utility limits battery usage to eight years and reclaims
the lead to make new batteries. The batteries have been reliable, and the company
has saved approximately 1/3 of the cost for commercial batteries.
Low voltage alarms and ground detector lights are standard instrumentation to assure
availability of the dc power supply. ~ equalizing charge is applied periodically
to the batteries to ensure that each cell is fully charged, and at times, the equal-
izing charge is applied to individual cells to bring them up to standard with other
2-38
cells in the battery set. Batteries are also overcharged periodically, and the float
voltage set at a higher value to maintain a higher dc supply voltage.
Overload Protection Devices
Suppliers and insurance underwriters suggest that overload protection devices should
be molded case, magnetic type air circuit breakers rather than fuses because fuses
tend to deteriorate and change their interruption characteristics. The overload
protection devices should not trip the supply circuit, but should sound an alarm
indicating a problem. The operator can choose the best action to take to eliminate
the problem.
Overload devices should be set no lower than 150 percent of the maximum motor inrush
current. The overload protection device should be set specifically for the motor on
which it is to be applied because each motor has its own characteristics that cause
the inrush current to vary from the standard design value. The overload protection
device should not be set to protect the pump motor, since a damaged motor is a small
loss compared to the damage that can be caused to a turbine generator unit if its
lubricant supply is stopped. However, an overload protection device should protect
the circuit supplying power to the pump motor to prevent overload of the circuit
conductors and a circuit conductor fire. The intent is to permit the pump motor to
run as long as possible so that the turbine generator can coast down completely or
to allow sufficient time to transfer to an alternate oil supply without causing more
damage than a pump motor burnout.
2-39
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of Lubrication. Volume II. E. R. Booser, editor. Boca Raton, Florida: CRC
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11. ANSI. "Hydraulic Fluid Power - Contamination Analysis Data - Reporting Method,
B93.30M-1980." New York: ANSI, June 1980.
12. K. McBroom. "Upgrading Hydraulic System Filtration." Plant Engineering.

Vol. 38, No. 15. Barrington, Illinois: Technical Publishing, June 28, 1984,
pp. 58-61.
13. ASTM. "Test Method'for Insoluble Contamination of Hydraulic Fluids by Gravi-

metric Analysis, F313-78." 1984 Annual Book of ASTM Standards: Space Simula-
tion; Aerospace Materials; High Modulus Fibers and Their Composites.
14. SAE. "Determination of Particulate Contamination of Hydraulic Fluids by the

Control Filter Gravimetric Practice, ARP 785." Warrendale, Pennsylvania: SAE,
1963.
2-40
15. ASTM. "Test Method for Trace Sediment in Lubricating Oils, D2273-81." 1984
Annual Book of ASTM Standards: Petroleum Products and Lubricants (II).
16. E. R. Booser and D. A. Smeaton. "Circulating-Oil-System Design." Standard

Handbook of Lubrication Engineering. J. J. O'Connor, editor. New York:
McGraw-Hill Book Company, 1968, Chapter 25, p. 30.
17. W. H. Fowler, Jr. "Handling and Storage." Standard Handbook of Lubrication

Engineering. J. J. O'Connor, editor. New York: McGraw-Hill Book Company,
1968, Chapter 29, p. 8.
18. GE. "Turbine Lube Oil, Recommended Properties & Maintenance Practices,
GEK-46506B." Schenectady, New York: GE, 1979, p. 17.
19. ANSI. "Multipass Method for Evaluating the Filtration Performance of a Fine
Hydraulic Fluid Power Filter Element." B93.31-1973. New York: ANSI, 1973.
Also National Fluid Power Association Standard T3.10.8.8-1973.
20. ANSI. "American National Standard End Load Test Method for a Hydraulic Fluid
Power Filter Element, B93.21-1972." New York: ANSI, 1972. Also National
Fluid Power Association Standard T3.10.8.2-1972.
21. ANSI. "American National Standard Method for Determining the Fabrication
Integrity of a Hydraulic Fluid Power Filter Element, B93.22-1972." New York:
ANSI, 1972. Also National Fluid Power Association Standard T3.10.8.4-1972.
22. ANSI. "American National Standard Method for Verifying the Material Compati-
bility of a Hydraulic Fluid Power Filter Element, B93.23-1972." New York:
23. ANSI. "American National Standard Method for Verifying the Flow Fatigue Char-
acteristics of a Hydraulic Fluid Power Filter Element, B93.24-1972." New York:
24. ANSI. "American National Standard Method for Verifying the Collapse/Burst
Resistance of a Hydraulic Fluid Power Filter Element, B93.25-1972." New York:
25. E. C. Fitch. "Develop Your Own Hydraulic Filter Element Specification."

Hydraulics and Pneumatics. Vol. 31, No.3. Cleveland, Ohio: PENTO/IPC, Inc.,
March 1978, p. HP-29.
26. J. A. Farris. "Fluid Power Testing and Standards," Hydraulics & Pneumatics.'
Vol. 30, No. 11. Cleveland, Ohio: PENTO/IPC, Inc., November 1977, pp. 10-13.
Also available in Pall Field Service Report-55b. East Hills, New York: Pall
Industrial Hydraulic Corporation, June 1981.
27. H. C. Rippel and R. Colsher. "Failure Cause Analysis: Turbine Bearing Sys-
tems." In Proceedings of Turbine Bearings and Rotor Dynamics Workshop,
CS-4024. Palo Alto, California: Electric Power Research Institute (EPRI),
June 1985, Section 2, pp. 45-50.
28. The Institute of Electrical and Electronics Engineers (IEEE). "Recommended

Practice for Emergency and Standby Power for Industrial and Commercial Appli-
cation, Std. 446-1980." IEEE Orange Book. New York: IEEE, 1980.
2-41
29. IEEE. "Recommended Practice for Maintenance, Testing, and Replacement of Large
Lead Storage Batteries for Generating Stations and Substations, Std. 450-1980."
New York: IEEE Power Engineering Society, 1980.
30. A. R. Overstrom and P. J. DeMar. "Testing Batteries to Ensure Reliability."

Transmission and Distribution. Vol. 36, No.4. Cos Cob, Connecticut: Clewort
Publishing Co., Inc., April 1984, pp. 35-36.
31. R. Fletcher. "Battery Care." Workshop on Vital DC Power, NSAC-48. Palo Alto,
California: Nuclear Safety Analysis Center, EPRI, May 1982, p. K-8.
32. Nuclear Regulatory Commission (NRC). "Various Battery Problems: IE Informa-

tion Notice 84-83." Washington, D.C.: Office of Inspection and Enforcement,
NRC, November 1984.
2-42
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Section 3
TEST, INSPECTION, AND MAINTENANCE PRACTICES
3.1 OIL CONDITION MONITORING
Subsection 2.1 identified the important lubricant properties essential to assuring

continued oil service. A detailed guide for monitoring the condition of turbine
oils in service has been developed by ASTM. This document, titled "Standard Prac-
tice for In-Service Monitoring of Mineral Turbine Oils for Steam and Gas Turbines
(D 4378-84)," is comprehensive and authoritative and is recommended for turbine
operators who desire to establish a detailed oil analysis progra~. The 1984 Edi-
tion of this Standard Practice is included in Appendix C. Also, the International
Electrotechnical Commission (IEC) is preparing a draft standard titled "Maintenance
and Use Guide for Petroleum Lubricating Oils for Steam Turbines" (!). This draft
standard discusses factors that affect oil service life, deterioration modes, recom-
mended tests, sampling techniques, sampling frequency, test results interpretation,
and corrective actions. This subsection of the Guidebook describes an oil monitor-
ing program intended to be somewhat less detailed than the ASTM Standard and the
draft IEC standard.
Sampling Procedures
Sample containers should be clean and free of particulates. If possible, it is rec-

ommended that the container be rinsed at least once with the oil being sampled. The
container should be able to hold a volume of oil necessary for the planned analyses.
Many container cap liners are incompatible with petroleum products; and, therefore,
the container opening should be covered with a small piece of clean plastic film
before sealing. If a portion of the sample is to be used to obtain a particle count,
the container and film cover should be thoroughly rinsed with petroleum ether
(CAUTION - highly flammable) using a solvent filtering dispenser equipped with a
2 ~m or less absolute membrane filter. Metal containers should be avoided since
additives such as rust inhibitors can be affected by the metal surface and alter the
test results.
Oil samples may be taken at two recommended locations--dipped from the main oil
reservoir or tapped from a flowing oil line. If sampled at the main reservoir, the
3-1
oil system pumps should have been in operation for a sufficient period of time to
assure that a representative sample is taken. If sampled from a flowing oil line,
the sampling line should be flushed with the service oil into a waste container. If
possible, the sampling line valve should not be closed between the flushing and sam-
pling operations. This avoids dislodging any adhering particles on the valve. The
American National Standards Institute (ANSI) has adopted National Fluid Power Asso-
ciation standards for sampling fluid from a reservoir or a pressurized line (l,2).
Sampling Schedules
A representative sample of a new oil delivery should be analyzed upon receipt to

make certain before use that the oil conforms to the specifications given by the
supplier and those required by the turbine operator. Following acceptance and
installation of a new oil supply, a one gallon (four liter) sample should be taken
after the unit has been in operation for 24-48 hours. Analysis of this sample pro-
vides baseline data against which subsequent samples may be compared. The unused
portion of this sample should be retained for possible future reference. Where pos-
sible, the sample should be stored at a temperature of 40F (4.4C) or below to min-
imize deterioration.
The following key properties should be determined for the new oil and the turbine
sample taken after 24-48 hours of operation:
Viscosity
Total acid number
Appearance/color
Water content
Rust test
Rotary Bomb Oxidation Test (RBOT)
Cleanliness
Emulsion characteristics
For both samples, the cleanliness of the oil should equal or exceed that specified
by the turbine manufacturer for particle size and number.
Under normal conditions of operation, the sampling and test schedule shown in
Table 3-1 for used oil is recommended.
At the discretion of the operator, sampling may be performed more frequently for a
new turbine installation in order to obtain additional trend data. Similarly, in
instances where analyses indicate the oil is nearing the end of its useful life,
more frequent samples for total acid number and the RBOT test should be taken (see
Turbine Severity Level in Subsection 1.3).
3-2
Used Oil Property Limits
Table 3-1 presents recommended used oil property limits along with probable indica-
tions associated with limits exceeded.
Table 3-1
RECOMMENDED USED TURBINE OIL PROPERTY LIMITS
Sampling
Test Frequency Test Limit* Indication
Appearance Daily Hazy Excess water/solids
Color Weekly Rapid darkening Oil deterioration
Viscosity 3 Months 20% change from new Oil contamination or

oil deterioration
Total Acid Number 3 Months 0.3 mg KOH/g increase Oil deterioration,

from new oil antioxidant depletion
Water Content 3 Months 0.1 wt % Excessive water

contamination
Cleanliness 3 Months Mfgr's recommendation** Excessive particulate

contamination
Rust Test 12 Months Pass/fail Excessive water, rust

inhibitor depletion
RBOT 12 Months Less than 25% of new Oil deterioration,

oil life antioxidant depletion
*Test limits listed are guidelines and actual operating conditions may require more
stringent values.
**The turbine manufacturer's recommendation is generally given as cleanliness level

from the Society of Automotive Engineers (SAE) Aerospace Recommended Practice 749D.
Note that SAE ARP 749D has been disavowed and has been replaced by an ISO Standard.
See Cleanliness in Subsection 2.1 for details and correlations.
3-3
3.2 MECHANICAL COMPONENTS
Subsection 2.2 identified testing and maintenance requirements for mechanical compo-
nents used for turbine lubrication systems. This subsection details specific tests,
practices, and procedures conducted to fulfill the identified requirements. Mainte-
nance tests, practices, and procedures for reservoirs and piping, supplemental
flushing equipment, pumps and vapor extractors, heat exchangers, oil conditioners,
and valves will be discussed.
Reservoirs and Piping
Visual examinations and cleaning are the major testing and maintenance requirements
for oil reservoirs and piping. These activities may reveal that additional mainte-
nance is necessary such as painting, replacing seals and gaskets, repairing broken
structural members, adjusting controls, and flushing.
Visual examinations are important to detect structural degradation, defects, and

accumulations of deposits and debris. Cleaning by wiping, scrubbing, and flushing
is performed to remove particulate matter that has entered or has been formed in
the lubrication system.
A visual examination of the reservoir is done after the oil charge has been trans-
ferred to another storage tank. The purpose of the examination is to:
(1) Reveal accumulation of debris, sludge, or other contaminants

(before cleaning).
(2) Detect structural damage such as deformation, cracking, corrosion,

and loose parts (after cleaning).
The before cleaning examination provides information on the type of contaminants

present in the lubrication system. Samples of the sludges and debris are acquired
and submitted for analysis by a chemical testing laboratory. Identification of the
sample constituents can be beneficial in identifying the source of a contaminant so
that corrective actions can be taken to eliminate or control the source. Serious
oil degradation incidents can be avoided when reservoir contaminants are identified,
and corrective actions are taken before tolerable contamination levels are exceeded.
Cleaning of the reservoir involves precautions to prevent introduction of new con-
taminants and damage to the coating on the internal surface.
The after cleaning examination provides information on the integrity of the reser-
voir members. It also assures the cleanliness of the reservoir prior to refilling
3-4
it with a clean oil charge. Internal surfaces that come in contact with the oil are
coated with an oil-resistant aluminum paint such as Rust Ban P.H. 6297 (i,1). If
this examination reveals that repairs are necessary or if modifications are to be
made, an additional post-structural work final visual examination is necessary to
assure that all work activities have been completed, the protective coating is
restored, all debris has been removed, and the reservoir is ready to be refilled.
Besides examining the reservoir for debris accumulation and structural damage, the
conditions of the following items need to be checked:
(1) Suction strainers for oil pumps
(2) Suction and return lines for. bypass oil conditioning equipment
(3) Level indication devices
(4) Suction to oil vapor extractor
(5) Access door seals and gaskets
(6) Protective coating
A checkoff list with instructions, figures, results, and signoff upon completion is
necessary for use by the examiner. The checkoff list is submitted to the respon-
sible plant engineer as described in Section 5.
A visual examination of the piping is performed on both the internal and external
surfaces where possible. The integrity of the pressurized piping is checked to
detect leaks or to locate malfunctions of piping supports. Internal surfaces are
examined at the following locations: (1) where inspection and c1eanout flanges have
been provided, (2) where piping can be disconnected, and (3) where oil flow orifices
are installed. The scope of examination can be increased by use of fiberoptic bore-
scopes or miniature television cameras designed specifically for piping inspection.
The purpose of piping visual examination is to detect the following:
(1) Formation of scale or rust on internal surfaces
(2) Buildup or deposits at flow control orifices
(3) Accumulation of debris in bends and return oil lines
Cleaning of the oil reservoir and piping is performed to remove the contaminants
that have accumulated within the system. These contaminants, if not removed, could
suddenly be entrained into the circulating oil and be transported to the bearings
where they could damage the load-carrying surfaces and cause bearing failure.
3-5
Cleaning by wiping or scrubbing can be performed where the debris is accessible, but
most piping sections can only be cleaned by flushing. Flushing involves the trans-
port of debris through the system to a location where it can be collected and
removed. Various types of flushing procedures are followed, depending on the amount
and nature of the lubrication pumping system. The most important aspect of the
flushing process is to have sufficient oil velocity to entrain the contaminant par-
ticle and to transport it to the removal location before it can settle out. Turbu-
lent flow is essential to all flushing procedures, since a stationary layer of oil
exists at the surface of the oil piping under laminar flow conditions. The amount
of energy available to pick up and transport a particle is negligible with laminar
flow unless mechanical energy is input through vibration or flexing. The existence
of turbulent flow can be determined by calculating the Reynolds Number. Turbulent
flow conditions exist When the Reynolds Number exceeds 4000 (i). The Reynolds Num-
ber can be determined by the following equation:
35,873 VD 14,646 Q
or (3-1)
v vD
where Nr Reynolds Number (dimensionless)
V Fluid velocity (feet per second)
D Pipe inside diameter (inches)
v Viscosity (Saybolt Universal Seconds)
Q Flow rate (U.S. gallons per minute)
The Reynolds Number can be increased by increasing oil velocity and density or by
decreasing oil viscosity. Low flow flushing at room temperature is not effective
in removing particles that could be transported during actual operating conditions.
Figure 3-1 shows the terminal gravitational settling velocities of different parti-
cle sizes in a turbine oil at 77F (25C) and at 131F (55C) (I). At a higher oil
temperature, larger particles settle out faster, which must be considered during the
flushing process.
Supplemental Flushing Equipment
When sufficient oil pump capacity has not been provided with the installed lubrica-
tion system to obtain turbulent flow conditions, supplemental flushing equipment
must be obtained. Industrial cleaning companies can provide this equipment and ser-
vice on a contract basis; however, several utilities have justified the purchase of
3-6
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Figure 3-1. Settling velocity for particles in turbine lubricating oil. High oil
flow velocity, low oil temperature, and high mesh screen rating are necessary to
remove particles greater than 50 microns in size from turbine lubricating oil.
Source: American Electric Power Service Corporation.
this equipment based on savings in rental charges and flushing time (~,~,10).
Table 3-2 lists the resources necessary to perform a successful high velocity
flush. Resources include supplemental flushing equipment, supplies, devices, and
manpower.
In addition to these resources, an oil flush procedure should be prepared to

describe the preparation requirements, the sequence of the flush, the checklists for
quality control, and other precautions to be observed during the flushing process.
Turbine manufacturers have developed procedures for flushing their own lubrication
systems (~,~,!l). These procedures should be reviewed, and pertinent sections
should be incorporated into the turbine flush procedure. Appendix D contains a
3-7
Table 3-2
LIST OF RESOURCES NECESSARY FOR PERFORMING HIGH VELOCITY FLUSH
Supplemental Flushing Equipment
1. High capacity pump

2. Full flow filtration vessels
3. Auxiliary oil heat exchanger
.4. Flow control valves, pump suction valve, flow meter
5. Pressure relief device
6. Temporary piping
7. Sample strainers
8. Particle counter
Supplemental Flushing Supplies and Devices
1. 60, 100, and 200 mesh stainless steel screening

2. Sponges, lint-free rags, and oil absorbing compound
3. Mechanical pipe vibrators
4. Log books, equipment records, checkoff sheets
5. Oil sample bottles
6. Oil drums for temporary storage
7. Oil reserve for makeup
8. . First aid type gauze for sample wipes
9. Plywood for bearing pedestal enclosures
10. Plastic sheeting
11. Replacement 5-micron particulate cartridges
12. Air inflatable pipe plugs
13. Air injection connections, hoses, and check valves
14. Air operated, portable oil transfer pump
15. Flexible pipe borescope or miniature closed-circuit TV
16. Replacement pump seals and spare parts
17. Turbine floor-mounted pump motor shutoff switch
18. Personnel two-way radios for communications
Supplemental Flushing Manpower
1. Flushing coordinator
2. Equipment operator
3. Maintenance mechanics
4. Technical support engineer and laboratory support
5. Station cleaning support
6. Turbine manufacturer representative
3-8
procedure developed by a utility for flushing a system when in-place pumps are used
instead of a supplemental flushing pump. A major service company has patented a
procedure for cleaning lubrication systems with supplemental flushing equipment and
thermal cycling (~). Plant personnel must develop their own flushing procedure
based upon the contamination level in the lubrication system. The following subsec-
tion describes the necessary supplemental flushing equipment.
Supplemental flushing equipment includes high capacity pumps, full flow filtration
vessels, auxiliary oil heat exchangers, flow control valves, pressure relief devices,
flow meters, and temporary piping.
The high capacity pump must be able to deliver up to 5000 gallons/min at a pressure
below the maximum allowable for the turbine oil heat exchanger [approximately 75 psi
(517 kPa)]. Table 3-3 shows the minimum supplementary flushing pump data recommended
by General Electric (~). The flushing pump can be either motor driven or diesel
engine driven. In addition to the pump and driver, auxiliary devices such as motor
starters, fuel tanks, and connection components are needed. Figure 3-2 shows a skid-
mounted motor driven pump with starter with a flow capacity of 5000 GPM. In some
cases, two smaller pumps connected in parallel have been used in place of one large
capacity pump, but parallel operation has proven to be difficult to control (~).
Spare seals and critical parts should be on hand or available for the pumping unit.
Table 3-3
EXTERNAL SUPPLEMENTARY FLUSHING PUMP SELECTION DATA
Main Bear- Minimum Required Pump Suc- Pump Dis- Maximum Suc-
ing Feed Required Pump Outlet tion Pipe charge Pipe tion Piping
Header Pump Flow Pressure Diameter Diameter Loop Height
Diameter (GPM) (PSIG) (Inches) (Inches) Above Oil
(Inches) Level hI
(Feet)
6 2000 70-75 10 8 25
8 3500 70-75 12 10 25
10 5000 70-75 14 12 25
1 GPM 1 psi 6.9 kPa 1 in 25.4 rmn 1 ft 0.3 m
3-9
Figure 3-2. Motor driven supplemental flushing pump. The skid-mounted motor driven
pump provides up to a 5000 GPM flow rate necessary to achieve turbulent flow in
large diameter lubrication system supply headers. Skid-mounted equipment allows for
transport between power stations and easy installation.
Source: Semler Industries, Inc.
3-10
If motor driven pumps are employed, an emergency shutoff switch mounted on the tur-
bine floor may be helpful to stop an oil spill if a leak develops during the flush-
ing period.
Full flow filtration vessels must be able to remove particulate matter from oil and
prevent it from reentering the lubrication system. Strainers and cartridges are pro-
vided in a series arrangement for efficient particle removal. Strainers with screen
mesh size of 100 (USA Industrial Standard) provide for removal of particles down to
0.060 inch. Figure 3-3 shows a full flow strainer with pressure gauges for differ-
ential pressure measurement. Two strainers in parallel are usually provided to
allow for continuing the flush while cleaning one strainer.
Particulate cartridges provide for removal of particles down to the 5-micron (abso-
lute) size. The cartridges should have a high beta ratio to reduce the total time
requirement for flushing. Figure 3-4 illustrates the difference between a cartridge
with a 85 ratio of 100 and one with a 85 ratio of 10; the number of passes of system
volume to achieve removal of 5-micron particles is cut in half. Figure 2-10 in Sec-
tion 2 contains further details on the specifications for particulate cartridges.
Figure 3-5 shows a set of four full flow cartridge vessels with inlet and outlet con-
nections, valves, and scaffolding for replacing used cartridges. Multiple vessels
are arranged in parallel so that dirty cartridges can be replaced in one vessel with-
out interruption of the flushing process.
Sufficient screening material and spare particulate cartridges should be on hand

before the flush begins, since these items are likely to need several replacements
during the course of the flush.
Auxiliary oil heat exchangers must be able to provide for rapid heating and cooling
of the oil, which aids in pipe surface cleaning. Approximately 120,000 BTU per hour
per 1000 gallons (3785 liters) of oil is needed (!I). This heat input is calculated
to raise the oil temperature 100F (54C) above ambient within three hours at the
maximum pumping capacity. Care should be taken to prevent overheating of the oil.
Hot oil flushing loosens particles from the pipe surface; however, these particles
are not always removed from the system due to a higher settling rate in the less
viscous oil. Cold oil flushing should always follow a hot oil flush to assure that
these particles are removed. Field experience shows that the maximum visible con-
tamination collects on temporary screens during the early phase of a cold flush imme-
diately following a hot flush (!I). Figure 3-6 shows a skid-mounted auxiliary heat
exchanger used to supplement the normal oil heat exchangers. When multiple heat
3-11
Figure 3-3. Full flow strainer. A skid-mounted full flow strainer provides removal
of particles greater than 0.060 inch (1.524 mm) in diameter. The strainer is placed
before the pump to protect it from damage due to large debris or after the pump if
some other type of pump protection is provided.
3-12
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NUMBER OF PASSES OF SYSTEM VOLUME THROUGH CARTRIDGE
Figure 3-4. Cleanup rate for full flow filtration vessels. The clean rate
during flushing depends upon the capability of the cartridge to remove 5 ~m
particles. This capability is defined as its filtration ratio or its beta
ratio. A higher beta ratio reduces the number of times the fluid must pass
through the cartridge to remove all particles from the system.
exchangers are available, a "thermal shock" treatment is effective. After obtaining

a maximum oil temperature of 180F (83C), flow is transferred to a heat exchanger
containing cool oil at approximately 100F (38C) for about 1-1/2 minutes. Flow is
transferred back to the hotter heat exchanger to bring the oil system back up to
180F (83C). This process can loosen particles that are not easily freed by a con-
tinuous flow of hot or cool oil. Caution must be taken to limit the exposure of the
oil to heating elements that have temperatures above 200F (90C).
Flow control valves and pressure relief devices are necessary to allow for varia-
tions in system pressure and to control oil flow to the bearings during different
phases of the flush. Flushing is carried out in a sequential manner so that pipe
3-13
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Figure 3-5. Full flow cartridge vessels. Skid-mounted full flow cartridge vessels provide
5-micron particle size removal capability. Multiple vessels allow replacemen~ of dirty car-
tridges without shutdown of the flushing process. Scaffolding and vessel head lifting rigs
allow cartridge removal.
Figure 3-6. Auxiliary oil heat exchangers. Skid-mounted auxiliary oil heat
exchangers allow for hot oil flushing, which loosens particles from the pipe
surface. Cold oil flushing immediately after the hot oil flush transports the
freed particles out of the lubrication system.
Source: Halliburton Industrial Services, Inc.
sections flushed with their highest attainable velocity are not used in the circuit
again when flushing other pipe sections. Sectionalizing of piping is also performed
to cause the highest possible oil velocity to occur within a particular pipe section.
Pressure relief devices protect system components with limited pressur~ ratings from
exceeding their capability. Figure 3-7 shows a flow regulation station that diverts
oil back to the oil reservoir when it is not required for the flush. This station
allows the pumping unit to stay in operation and minimizes the number of startups of
the pump driver. In some arrangements, check valves or nonreturn valves are neces-
sary to prevent reverse flow when the system is shut down. A pump suction valve may
be necessary to aid in starting and priming the pump.
Valves are installed at the bearing to allow sectionalizing of the lubrication sys-
tem. These valves should be the same size as the oil supply piping and should be a
3-15
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Figure 3-7. Flow regulation station. Flow control valves and pressure relief devices allow
the pumping unit to remain in operation while changing lubrication system pipe arrangements.
This station protects pressure-limited components and minimizes the number of startups of the
pump driver.
low flow restriction type such as a gate, ball, plug, or butterfly valve (~). Sec-
tionalizing allows each section of the lubrication system to reach a maximum oil
velocity. Valves should be full open or closed completely when diverting oil to
another section. Valves should not be throttled because this practice reduces oil
velocity through the supply line and results in an incomplete flush.
Temporary piping is used to make supplemental flushing equipment connections with

the oil reservoir and lubrication system piping. Temporary piping also is used to
bypass journal bearings, hydrogen seals, and other permanent components that can act
as flow restrictors. Caution must be observed to assure that clean piping is used
to prevent additional contamination from entering the lubrication system. Piping
containing rust, grease, paint, sand, or any other type of foreign matter should not
be used. Pickled piping is often provided.
Figure 3-8 illustrates a piping arrangement for supplemental flushing equipment.

Pump suction connection to the oil reservoir may have to be added since it normally
was not provided by the turbine manufacturer prior to 1973. This connection should
be completely welded and should provide for a welded blank flange at the completion
of the flush. A bolted blind flange is not permissible to reduce the possibility of
a leak during turbine operation. The weld joint requires cleaning and painting on
the inside after the blank flange is installed.
Supplemental flushing equipment connection to the lubrication s~stem should provide

for manual bypass and automatic pressure relief into the oil reservoir. Piping
should be arranged to allow access even during hot flushing when oil vapor and hot
oil may be present. Temporary covers over the oil reservoir are necessary during
the flush to accommodate this piping and to prevent entry of contaminants into the
system.
Figure 3-9 is a schematic of a piping arrangement for bypass of a journal bearing.

Generally, temporary piping should be as large as or larger than the permanent pip-
ing to which it is being connected. A 3 inch (8 cm) diameter is suggested as the
minimum pipe size. Screwed connections and flexible hose can be used. Oil leaks
are a common problem during a flush, so careful attention is necessary concerning
pressure ratings, pipe joints, and drain locations. Temporary wood enclosures and
plastic sheet covers are provided to contain oil splashing and leaks during the
flush. Sample strainers with 100 mesh screens are installe~ to collect large parti-
cles and prevent them from entering the oil return lines. Strainers also are used
to monitor progress of the flush through each oil supply line.
3-17
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100 MESH
STRAINER
HIGH CAPACITY
PUMP
FLOW METERl
BLOCK VALVE ~
. CHECK VALVE -----~ ~
. - t--.L-----~-----L.-----L__I
(a) Schematic Arrangement
(b) Physical Arrangement at a Power Station
Figure 3-8. Piping Arrangement for Supplemental Flushing Equipment

Source: Halliburton Industrial Services, Inc.
3-18
TEMPORARY
/PIPING
"B"
t~
TEMPORARY
PIPING
NOTE: PIPES LABELED "A" & liB"

ARE TO BE ALL THE SAME
SIZE OR PIPE LABELED liB"
TO BE A MINIMUM OF 3" DIA.
'-OIL SUPPLY
LINE
1..-- GUARD LINE

I THROUGH
FOUNDATION
Figure 3-9. Piping arrangement for bypassing bearings during a flush. Temporary
piping is provided to bypass the bearings and assure maximum oil velocity through
the oil supply line. Sample strainers collect large particles to monitor progress
of the oil cleanup.
Source: General Electric Co.
It is important to record the removal of any flow control orifices and the installa-
tion of fine mesh screens. Failure to return an orifice to its correct location or
to remove a fine mesh screen will cause low oil flow during turbine operation and
could result in a bearing failure.
Cleanout and inspection ports are provided at several locations on large diameter
oil return lines. These ports allow limited access to the inside of pipe. Addi-
tional ports have been installed for greater access. The ports are 8 inch (20 cm)
3-19
diameter and are placed at a 45 degree angle from the vertical in the bottom half of
the pipe.
Particle counting equipment is used to monitor progress of the flush and to judge
when to terminate it. Criteria for determining an acceptable contamination level
are provided by the turbine manufacturer. Several methods are used to perform par-
ticle counting. Automatic particle counting equipment can be used which allows
rapid determination of the number of particles within certain size ranges. Fig-
ure 3-10 shows an automatic particle counter set up in a laboratory. Other recom-
mended methods include the Society of Automotive Engineers (SAE) Standard ARP 598A,
"Determination of Particulate Contamination in Liquids by the Particle Count Method,"
and the ASTM Standard F312-69, "Microscopical Sizing and Counting Particles from
Aerospace Fluids on Membrane Filters." See Cleanliness in Subsection 2.1 for addi-
tional information on particle counting methods and classifications.
When particle counting equipment is not available, a Millipore sample kit may be
used. One hundred milliliters of oil is drawn through a fine paper filter. The
total number of particles can be judged by comparing the discoloration of the filter
paper with calibrated samples (.!2.).
Supplemental flushing supplies and devices are often just as important for a success-
ful flush as the supplemental flushing equipment. An adequate supply of oil, oil
drums, oil absorbing compound, oil. cleaning sponges and rags, oil sample bottles,
and oil sample wipes (first aid gauze) should be on hand because even a small leak
can spill a substantial quantity of oil in a short time. Special devices such as
air inflatable pipe plugs, an air operated portable oil transfer pump, flexible pipe
borescopes, mechanical pipe vibrators, and air injection connections often prove to
be beneficial during the flush. As mentioned .previously, supplies of fine mesh
stainless steel screening, plywood, plastic sheeting, particulate cartridges, and
pump spare parts are necessary to prevent prolonged time periods when circulation
is not possible because these items are not available. Two-way portable radios with
shoulder microphones should be employed to allow communications, especially during
pump startups and shutdowns.
Since a flush can last several days, quality control records are necessary to
assure that instructions and information are passed along to relief crews. Log
books, equipment operating records, and checkoff sheets are necessary to prevent
human errors.
3-20
Figure 3-10. Automatic particle counter. Particle counting is
performed to monitor progress of a flush and to determine contam-
ination level at termination. Automatic particle counters allow
rapid classification of particles in selected size ranges.
Supplemental flushing manpower is required to manage the flush and to perform oper-
ating, maintenance, testing, and cleaning activities. Under direction from one
flushing coordinator, the necessary activities are performed by these supplemental
workers so that time is not lost waiting for someone to be reassigned from another
job. A turbine manufacturer representative may be present to assist the coordinator
in making piping arrangements and evaluating flushing progress.
3-21
High Pressure Water Jet Cleaning
In 1981, a program was initiated to develop a process for cleaning lubrication sys-
tem piping with high pressure water jets (~). During a three-year period, a hydro-
blasting technique was perfected which greatly enhances system cleaning capability
of the supplemental flushing process. High pressure water jets ranging from 4,000
to 10,000 psi (27.6 to 69.0 kPa) are used to strip loose scale, deposits, weld slag,
trapped debris, or other adherent contamination from internal pipe surfaces. Water
jets at lower pressure are subsequently used to move most of the loosened contamina-
tion to removal locations. Final cleanup of remaining contamination is achieved
during the supplemental high velocity oil flush of the system.
The hydroblasting technique has been used in conjunction with the oil flush to clean
approximately forty lubrication systems ranging from 20 megawatt industrial units to
1100 megawatt nuclear steam turbines. One utility reported saving over $175,000 by
performing hydroblasting during lubrication system cleanup after construction (~).
Savings are also anticipated when hydroblasting is used to help clean up a system
that has become contaminated during service or maintenance overhauls.
Special small diameter, flexible hoses are employed which can be inserted into pipe
with diameters as small as 1.5 inches (38.1 rom) and with as many as six elbows.
Pipe lengths up to 500 feet (152.4 m) have been cleaned from end to end depending
on the complexity of the pipe run. Jet nozzle tips direct the high pressure water
against the internal surface and the jet reaction forces help to move the hose along
the pipe circuit. When the hose can no longer be inserted, it is withdrawn and
rotated to ensure that the internal pipe surface is entirely touched by water jets.
Openings such as strainer bodies, gate valve bodies, and flanged connections are
used as entry locations. In some situations, the pipe may need to be cut or drilled
to provide access. The hydroblasting process begins at the highest point in the
system and progresses toward the oil reservoir. Low point drain valves or temporary
openings are used to drain the cleaning water. Any temporary openings must be suit-
ably closed or sealed after cleaning to prevent oil loss during operation.
Since water lying on unprotected carbon steel surfaces for extended periods can
cause significant rusting, additional measures are taken to control flash rusting
after hydroblasting. Rust inhibitors are used which are compatible with the clean-
ing equipment, the lubrication system components, the lubricant, and other turbine
components. Sodium nitrite (N a N0 2 ) mixed with demineralized water is used as the
cleaning solution. The sodium nitrite/water mixture has been shown to be able to
3-22
inhibit corrosion of pipe surfaces exposed to only humid air and condensation drop-
lets. In addition, a low pressure spray of turbine oil is injected in a manner sim-
ilar to the hydroblasting process but using separate pumping equipment. The oil
spray displaces any residual water from pipe surfaces and creates a protective oil
film. Restoration of the lubrication system should be performed and oil circulation
should be started as soon as possible after hydroblasting to assure continuous pipe
protection.
The hydroblasting technique involves use of high pressure water and disassembly of
lubrication system components. Both activities should be properly controlled
through planning, following written procedures, training, and documenting actions
as described in Section 5.
Disassembly and dimensional measurements are major maintenance requirements for oil
pumps and oil vapor extractors. Vibration and wear can affect structural integrity
of parts of these components and can only be detected by internal examinations.
Complete disassembly and nondestructive examination of parts are performed to detect
cracks, deformations, looseness, wear, or corrosion. Clearance measurements between
rotating impellers and stationary casings are compared with manufacturer's recommen-
dations and are restored to recommended clearances when actual clearances are outside
of specifications. Internal passageways are sometime~ used to provide lubricant to
pump bearings. The passageways are checked for pluggage to assure sufficient lubri-
cant flow. Other items of interest are as follows:
(1) Alignment of coupling
(2) Integrity of casings and supports
(3) Fitup of keys and retaining nuts
(4) Condition of bearings
Figure 3-11 illustrates a typical motor driven pump configuration.
The oil vapor extractor runs continuously and is subjected to vibrational forces
from unbalances caused by wear or deposits. In some cases, spare vapor extractors
are provided to allow maintenance activities while the turbine generator unit is in
service. Oil vapor extractors may have an oil mist eliminator or demister located
in the discharge piping. This device needs periodic cleaning to remove accumula-
tions of dirt and to restore its air flow characteristics. The amount of flow
through the oil vapor extractor is determined by the amount of air in leakage into
3-23
ITEM DESCRIPTION
1. CASING
2. IMPELLER
3. RETAINING NUT
4. SUCTION STRAINER
5. IMPELLER KEY
6. LOWER BEARING
7. PUMP BEARING OIL
SUPPLY LINE
8. INTERMEDIATE
BEARING
9. SHAFT
10. OUTER COLUMN
11. THRUST BEARING
12. BEARING LOCKNUT
13. COUPLING KEY
14. COUPLING
15. MOTOR SUPPORT
Figure 3-11. Motor driven auxiliary oil pump. Impeller clearances, coupling
coupling alignment, structural integrity, bearing condition, and tightness of
keys and retaining nuts are checked during pump overhauls. Oil supply lines
to the pump shaft bearing also are checked for pluggage or leakage.
3-24
the lubrication system. A flow regulation valve is provided to maintain a vacuum in
the lubrication system by changing the valve setting. While this valve allows con-
trol of system vacuum level, control of the amount of air flow is achieved by peri-
odic maintenance and restoration of system seals and gaskets. Periodic checks for
hydrogen gas at the oil vapor extractor discharge are conducted to assure that
hydrogen gas is not escaping from the generator enclosure and detraining section.
Heat Exchangers
Cleaning and leak testing are major maintenance and testing requirements for oil
heat exchangers. Erosion, corrosion, and fouling are frequently experienced on the
water side of tubes while sludge and dirt cause pluggage on the tube oil side. Tube
leaks and tubesheet seal leaks are also experienced and cause significant contamina-
tion if they go unnoticed.
Water side fouling results from the following reasons (~):
Precipitation of hardness salts such as sulfates or carbonates
Deposition of suspended solids such as silt or sand
Growth of marine organisms
Development of corrosion product films
Because the difficulty of cleaning increases rapidly as the scale or deposit thick-
ness increases, tube cleaning should be performed when heat transfer capability of
the cooler is only slightly less than design. Deposits also are associated with
pitting of tube material, especially under no-flow or stagnant water conditions.
Cleaning on the water side can be performed with the turbine in service if dual heat
exchangers and isolation valves are provided. Cleaning equipment includes nonmetal-
lic bristled brushes and extension rods. Cleaning should not be performed by blow-
ing steam through individual tubes, since this process heats the tube and results in
tube expansion. Overheating of a tube can occur and cause severe expansion strain,
which could damage the tube (23). Heat may also harden any sludge or debris pres-
ent on the oil side of the tubes. Air lancing may be performed where necessary to
loosen fine silt and suspend it in water to be flushed away. When using lances, care
should be taken to avoid actions that might scratch the inner tube surfaces (24).
Chemical cleaning may be necessary if scale or deposit cannot be removed by mechan-
ical methods.
Water flow should be continuous so that stagnant conditions do not exist even When
the cooler is not in service. Stagnant water conditions promote bacterial growth
3-25
and potential corrosive conditions. When a minimum water flow cannot be maintained,
the water side should be drained and dried out thoroughly (~).
Oil side pluggage results from the accumulation of sludge and debris. Closely
spaced tubes act as a trap for foreign material which settles out due to the low oil
flow velocity inside the heat exchanger shell. Sludge also tends to form on cool
surfaces in a heat exchanger. Cleaning of oil side passages and shell surfaces
requires removal of the tube bundle. Caution must be observed during bundle removal
to prevent damage to tubes and sealing surfaces. Tube bundles should not be handled
with hooks or other devices which might cause punctures or other damage. Bundles
need support on cradles or skids to prevent placing weight loads directly on tubes.
Gasket and packing contact surfaces require protection from accidental marring and
corrosion. Special immersion tanks may be necessary to control the cleaning fluid.
Hot water washing usually removes dirt and sludge from tube bundles; however, in
some cases, a cleaning solvent may be necessary. All traces of the cleaning fluid
must be thoroughly flushed out after cleaning to prevent subsequent contamination of-
the lubricating system. Selection of a cleaning solvent should involve the turbine
manufacturer and the oil supplier because certain solvents remove oxide from tube
surfaces. Oxide removal can have a catalytic effect on turbine oil oxidation and
promote the formation of oil-water emulsions (~). After cleaning, repeated han-
dling, or discovering water in the oil, the tube bundle should be pressure tested.
Pressure testing involves holding a test pressure for approximately one hour on the
water side with the heat exchanger fully assembled. The test pressure should be in
accordance with the test pressure stamped on the heat exchanger nameplate. If a
leak is discovered, an additional hydrostatic test from the oil side is necessary
to identify the leaking tube or tubes. Tube sheet seals and gaskets should also be
inspected for signs of oil leaks. Repair of a leak involves either plugging the
water side of the tube if a through-wall leak exists or rerolling the tube-to-tube
sheet joint if a leak is across the tube sheet. When design operation conditions
can no longer be obtained due to an excess of plugged tubes, replacement of the tube
bundle should be considered.
Oil Conditioners
Differential pressure testing, water draining, chamber cleaning, and replacing dirty
cartridges or filter bags are the major testing and maintenance requirements for oil
conditioners. Other maintenance activities depend on the specific type of condition-
ers and especially on the number of rotating parts such as vacuum pumps, high-speed
3-26
gears, vapor extractors, and auxiliary oil pumps. Since differential pressure indi-
cates when performance of the oil conditioner is less than optimum, periodic cali-
bration of this instrumentation is necessary. Other instrumentation, such as fluid
level controls and alarms, should be regularly checked for proper performance of
their function. Level and flow sight glasses provide visual means to monitor condi-
tioner performance and require cleaning to remove dirt accumulation.
Particulate cartridge units require replacement when the amount of debris trapped
within filter media impedes the flow of oil. Replacement cartridges should be pur-
chased in accordance with cartridge specifications as described in Section 2.2. The
micrometer removal rating of the cartridge is the most important criterion. Care
must be taken during cartridge installation to assure proper alignment and seal of
the cartridge with the filter enclosure. Multiple-element vessels need special con-
sideration when joining one cartridge to another to prevent leakage of contaminated
oil at the joint. Vessel gaskets and fittings require careful inspection and
replacement if damage is revealed. Like-for-like replacements are used to prevent
troublesome oil spillage upon restoration of oil flow.
Gravity precipitation oil conditioning units remove free water and particulate mat-
ter as oil moves through separate chambers and filters, as shown in Figure 3-12.
Contaminated oil enters a precipitation chamber where gross free water separates
from the oil (~). Smaller water droplets coalesce on hydrophobic fine mesh screens.
Water collects at the bottom of the chamber and is drained away. Oil overflows into
the filtration chamber where it passes through cloth-covered filter bags. Particles
sized down to approximately 35 microns are removed, and coarse water emulsions are
broken up (~). Oil leaving the filtration chamber flows into a storage chamber
where it is pumped through a particulate final filter. The final filter particle
removal capability should be in the 3- to 5-micron size range.
Periodic cleaning of precipitation and filtration chambers is necessary to remove

accumulated debris, water, and sludge. Cleaning frequency depends on the amount of
contamination in the oil. The filtration chamber should be checked to see if water
is being carried over from the precipitation chamber. The cloth filter elements
used in the filtration chamber should be removed when dirty and replaced with a new
set or washed with warm soapy water. The filter elements in the particulate final
filter should also be replaced when the pressure differential across the element
exceeds its design capability.
3-27
GRAVITY PRECIPITATION UNIT
HYDROPHOBIC SCREENS CLOTH FILTER ELEMENTS PARTICULATE FINAL FILTER
n ~ CLEAN, DRY
rr----~-r-- ~ OIL OUTLET
CONTAMINATED
OIL INLET
~
LV
I~ -Joo!
N
I
r-
~
00
~
~II~ ~,I ~
WATE~RAIN J
L PRECIPITATION CHAMBER ~
t
FILTRATION CHAMBER
t
~ STORAGE CHAMBER - - -
Figure 3-12. Oil conditioning using gravity precipitation. Hydrophobic screens (16 mesh) coalesce small
water droplets that were not removed by detention time in the precipitation chamber. Oil overflows into
the filtration chamber and passes through cloth-covered filter elements. Oil overflows into the storage
chamber and is pumped through a final particulate filter.
Centrifugal separation oil conditioning units remove free water and particulate mat-
ter as oil moves through a number of closely spaced conical disks which rotate at 7
to 8 thousand revolutions per minute, as shown in Figure 3-13 (~). Contaminated
oil enters the top of the centrifuge and flows into the rotating bowl. Solid par-
ticles and water are thrown outward by centrifugal force which is several thousand
times that of gravity. The centrifuge is effective in removing free water and
larger, heavier solid particles. Extremely fine solid particles can also be removed
at a slower rate of throughput. Solid particles are deposited on the bowl wall
while water is discharged near the top of the bowl. Oil leaves through the top of
CENTRIFUGAL SEPARATOR UNIT
CONTAMINATED ~
OIL INLET ~
WATER
DRAIN
CENTRIFUGE PARTICULATE
FINAL FILTER
DISCHARGE
PUMP
~
CLEAN DRY
OIL OUTLET
Figure 3-13. Oil conditioning using centrifugal separation. Contaminated oil

flows outward at the bottom of the centrifuge bowl, then upward and inward among
a number of closely spaced conical disks which rotate at high speed. Solid par-
ticles and water are thrown outward by centrifugal force. Particles remain on
the bowl wall and are removed during periodic cleaning. Water discharges near
the top of the bowl and is continuously drained. Dry oil leaves the bowl at the
top and is pumped through a fine particulate final filter.
3-29
the bowl and is pumped through a particulate final filter for removal of particles
down to the 3- to 5-micron size range. Periodic cleaning of the bowl is necessary
to remove the accumulated solid particles. At some plants, cleaning may be neces-
sary on a weekly basis, but usually monthly cleaning of the bowl and bowl disks is
performed. Personnel totally familiar with centrifugal conditioners should be
assigned the cleaning task.
A centrifuge has internal worm gears and shafts which require lubrication. The
lubricating oil in the worm gear housing should be replaced every 1000 operating
hours. An annual inspection and overhaul of the centrifuge should be performed to
check for erosion, corrosion, or damage to internal parts. The filter elements in
the particulate final filter should be replaced when the pressure differential
across the element exceeds its design capability.
Water coalescer separation oil conditioning units remove free water and particulate
matter as oil moves through three stages of cartridges, as shown in Figure 3-14
(30,1l). Contaminated oil enters particulate cartridges to remove solid particles
down to a size range of 3 to 5 microns. This prefilter allows for longer service
life for the coalescer and separator cartridges. From the prefilter, oil passes
through coalescer cartridges where free and entrained water is coalesced into drop-
lets Which settle out by gravity. Oil flows through separator cartridges which pro-
vide a hydrophobic membrane preventing passage of any water not removed in the coa-
lescer stage. Water that collects at the bottom of the chamber is drained away.
Periodic replacements of the particulate, coalescer, and separator cartridges are
necessary when the pressure differential across the elements exceeds their design
capability of 15 psig.
Vacuum dehydration oil conditioning units remove dissolved water, free water, gases,
and particulate matter as oil moves through filters and a vacuum chamber, as shown
in Figures 3-15 and 3-16 (~,1l). Contaminated oil enters a particulate prefilter
with a 10-micron nominal rating to remove solid particles prior to entering a vacuum
vessel. Upon entering the vacuum vessel, oil is dispersed into fine layers to allow
maximum surface exposure. Water readily vaporizes within the vessel due to its tem-
perature and low pressure condition. Water vapor and dissolved gases separate from
the oil and are removed at the top of the vessel. Two different types of units are
available. Figure 3-15 shows a unit in which the oil is heated up to 180F (84.4C)
and forced through filter/disperser cartridges. Figure 3-16 shows a unit in which
air is heated to produce a low relative humidity and mixed with the oil to transfer
water as a vapor. The ultimate dryness level obtainable is such that the percent
3-30
WATER COALESCER/SEPARATOR UNIT
WATER COALESCER/SEPARATOR
PARTICULATE PREFILTER
CONTAMINATED
OIL INLET
~
SEPARATOR
G CARTRIDGES
COALESCER
CARTRIDGES
PARTICULATE
CARTRIDGES
LIQUID LEVEL
GAUGE
CONNECTIONS
PUMP DRAIN
CONNECTION
~--&r---_--_-.J..I CLEAN,
DRY OIL
OUTLET
~ CONTAMINATED OIL ~ COALESCED LIQUID
~ PARTICLE FREE OIL :==J CLEAN, DRY OIL
Figure 3-14. Oil conditioning using coalescer/separator filters. The prefilter

removes particulate matter and assures maximum efficiency for the coalescer and
separator stages. Coalescer cartridges unite water to form droplets which settle
out by gravity. Separator cartridges remove particulate matter and provide a
hydrophobic membrane, which repels water droplets.
saturation of the oil equals the relative humidity of the contacting air. Vacuum
dehydration units are the only oil conditioning units that can remove dissolved
water; that is, water content below the saturation level. Dry oil collects at the
bottom of the vessel where it is pumped through a particulate final filter to remove
particles down to the 3- to 5-micron size range.
Periodic replacement of the particulate filter/disperser cartridges is necessary

when the pressure differential across the elements exceeds their design capability.
3-31
HEATED OIL/VACUUM DEHYDRATION UNIT
FILTER/DISPENSER CARTRIDGES: VACUUM VESSEL

INNER ZONE REMOVES SOLIDS
CONDENSER
OUTER ZONE ENHANCES EFFERVESCENT ~ .3 ~ ~::::J ... ~ "'W"
O~ 11m;rn11 ill~lllfl"
REMOVAL OF WATER VAPOR
OJ
l+
CONTAMINATED
OIL INLET
~
I (r:"l.: IIIIIIIIII n 1II1111111 tII ~::~~
1---.
o 11111IIIIIt"'II~11111
IIIIIIIIII n IIII ~1110 EDUCTOR
r'1 ~
'.: 0 6/ ~ 6
6
06
o b
t 6'
6 ,
CHECK WATER OUTLET
W VALVE
I
W
N
PUMP
PARTICULATE CHECK VALVE

PREFILTER OIL HEATERS:
BOOST INLET FLOAT-CONTROLLED ~--
TEMPERATURE FEED VALVE , ~~
CLEAN, DRY
OIL OUTLET
~~_ .... __ RE~~~UlATION LINE .... __ ~)
Figure 3-15. Oil conditioning using heated oil/vacuum dehydration. The prefilter removes particulate
matter to extend the life of the filter/disperser cartridges. Oil heaters increase oil temperature to
1800F (82C). Filter/disperser cartridges remove particles of 2 microns and disperse oil into the
vacuum chamber. Water content is vaporized and drawn off to be condensed. A vacuum is created by the
water eductor.
HEATED AIR/VACUUM DEHYDRATION UNIT
00000000 VACUUM SEPARATOR

PACKED TOWER
{rr::::::::::::::::: 0
IIIIII OIL
MIST
REMOVAL
FILTER
PARTICULATE
AND AIR
PREFILTER
EXHAUST
CONTAMINATED
AIR HEAT
OIL INLET
EXCHANGER
PARTICULATE
~LFILTER
cr=~ OIL PIPING
( }rt:::::::::::::::::::::~ AIR PIP ING
DISCHARGE
PUMP
CLEAN, DRY
OIL OUTLET
Figure 3-16. Oil conditioning using heated air/vacuum dehydration. A prefilter

removes particulate matter from the oil, which is pumped into the vacuum separator
packed tower. In the packed tower, oil is spread and allowed to fall by gravity
over the tower packing until it collects at the tower bottom. While flowing down
the tower, the oil forms a very thin film with a large surface area. The oil is
constantly changing in contour and is exposed to an upward flow of heated air at
a low relative humidity. A vacuum is obtained by using a vacuum pump. Discharge
air and water vapor from the vacuum tower are used to heat the incoming air.
Clean, dry oil is discharged by the pump through a final filter.
3-33
Auxiliary items such as vacuum pumps or eductors, heaters or heat exchangers, float-
controlled feed valves and relief valves, and instrumentation on controls require
additional maintenance for cleaning and to assure proper functioning.
Valves
The main lubrication system valve is the heat exchanger transfer valve that allows
for sWitching oil flow between the two main oil coolers. The valve does not experi-
ence throttling service which could produce damage to valve components; however, mis-
handling during the process of switching coolers can result in broken pins, keys, or
shafts. One type of valve has two handwheels that can cause confusion with inexpe-
rienced operators and can lead to valve damage if operating instructions are not
followed. A valve operation verification test allows determination of the proper
valve sequence. Figure 3-17 is a cross section of a submerged type transfer valve
manufactured by the Schutte and Koerting Company (~). The verification test should
be conducted on an annual basis.
Flow control devices installed on oil supply lines to individual bearings and cou-
plings tend to accumulate dirt. These devices are also known as orifices, or oil
throttles, and are sometimes replaced with fine mesh strainers during system flush-
ing. Valve adjustment is performed during turbine operation to provide sufficient
oil flow to maintain proper bearing temperature. Figure 3-18 shows a cross section
of an oil throttle valve (21).
Oil system pressure regulati~n valves require periodic adjustment of their control
setting. These valves are usually located within the oil reservoir and are adjusted
to maintain the proper oil supply header pressure.
Manual drain and oil transfer valves on piping connected to the oil reservoir should
be locked in one position during. normal operation. Valve line-up checks are per-
formed to verify the correct valve position and the placement of the locks.
3-34
VALVE TURNING
11
HANDWHEEL
~
HAMMERBLOW
HANDWHEEL
FOR LIFTING
PLUG
7
TOP OF TANK
VALVE INLET PORT
Item Description
1 Body
2 Plug
3 Special pin
TO 4 Washer
COOLER NO.1 5 Cotter pin
6 Lifting spindle
7 Tank flange
8 Set screw
9 Collar with lug
10 Lifting bushing
11 Handwheel
I ~ 12 Handwheel
FROMF~
13 Key
14 Stop pin
FROM
COOLER NO.1 COOLER NO.2
Figure 3-17. Oil transfer valve. A multiple port valve diverts flow between
between the two heat exchangers. Unfamiliarity with valve operation causes
mishandling and damaged components.
3-35
~---0
J.er~--------4----4S
1. Cap nut
2. Seal ring
3. Screw plug
(normal operation)
4. Headless screw
5. Adjustable throttle
6. Screw plug
(flushing process)
7. Oil strainer
8. Body
Figure 3-18. Oil Throttle Valve. Flow to individual bearings

bearings and couplings is controlled by throttling valves or
orifices. Dirt can accumulate during normal operation and must
be removed to prevent damage to bearings.
Source: Utility Power Corporation
3-36
3.3 MOTORS AND CONTROL COMPONENTS
Subsection 2.3 identified testing and maintenance requirements for motor and control
components used for turbine lubrication systems. This subsection presents guide-
lines for designing inspection and test procedures to fulfill the identified require-
ments. Maintenance tests, practices, and procedures for dc motors, ac motors, motor
starters, pressure switches, liquid level switches, temperature switches, cables,
and wiring will be discussed. These guidelines have been developed from reviewing
published literature from equipment manufacturers, professional societies, utilities,
and electrical reference handbooks (~.
In addition, several system design recommendations are presented which are intended
to achieve greater reliability of the bearing lubrication system for emergency
situations.
System Design Recommendations
System design recommendations have been compiled from discussions with and litera-
ture published by equipment manufacturers, utilities, professional societies, and
national standards organizations (see Appendix A, Table A-4). Generally, these
recommendations are applicable to almost all turbine bearing lubrication systems
regardless of manufacturer. However, if there is any question about the advisabil-
ity of incorporating one of these suggestions into an existing system, concurrence
of the turbine manufacturer should be obtained. Further, if any recommendation
violates local laws or codes, that recommendation should not be followed. System
design recommendations are given for:
(1) Pressure switches

(2) Power supplies
(3) Motor starters
(4) Control devices
(5) Alarms
Pressure switches should have the following features:
Each pressure switch that starts a pump needs a piping arrangement

that permits testing during turbine operation. A three-way manual
or solenoid valve or a manually actuated needle valve preceded by an
orifice or restriction should be provided, as shown in Figure 3-19.
A pressure gauge should be at the pressure switch to allow determina-

tion of trip point pressure during testing, as shown in Figure 3-19.
3-37
PRESSURIZED
Oil LINE
' - - PRESSURE TAP
PRESSURE
GAUGE
3-WAY PRESSURE
VALVE SWITCH
RESTRICTION )
OR ORIFICE
TOOll
RETURN
HEADER
(a) A three-way manual or solenoid valve allows a pressure

switch to be isolated from the pressurized oil line.
PRESSURIZED
Oil LINE ,
' - - PRESSURE TAP
) ( RESTRICTION OR
ORIFICE
PRESSURE
GAUGE
PRESSURE
SWITCH
NEEDLE
VALVE
TOOll
RETURN
HEADER
(b) A flow limiter and a needle valve allow oil pressure to

be lower at the pressure switch than in the pressurized oil
line.
Figure 3-19. Piping arrangements for pressure switches that initiate

operation of motor driven oil pumps. For either arrangement, a gauge
allows measurement of the oil pressure which trips the switch.
3-38
Duplicate pressure switches with electrical contacts connected in
parallel should be used in all turbine bearing lubrication pump
starting applications, but especially in the dc emergency pump start-
ing circuit; such redundancy greatly increases reliability.
Where multiple pressure switches are used in a pump starting circuit,

independent means of testing (i.e., a pressure bleed valve) should be
prOVided for each switch.
Each pressure switch test valve should be equipped with a limit

switch that closes an alarm circuit when the valve is moved from its
normal operation position.
Redundant control devices are desirable throughout the turbine bear-

ing lubricating oil system so that a single failure does not cause
loss of lubrication.
A pressure switch that actuates a control board light should be pro-

vided for each auxiliary and emergency bearing oil pump to show when
the pump is running; the pressure tap for this switch should be
located between the pump discharge and the pump outlet check valve.
Power supplies should have the following features:
Sources of power for turbine bearing lubrication pump motors and

control systems should be carefully selected so that a seemingly
unrelated failure elsewhere in the plant does not cause loss of
lubrication.
The most reliable source of ac power should be positively available

to the ac auxiliary bearing oil pump; it is desirable that connec-
tions to this source be as direct as possible to avoid excess switch-
ing apparatus that reduces reliability.
If multiple ac power sources are necessary, switching among sources

should be automatic, and the switching system should make it impos-
sible to select a dead bus. Further, when automatic switching occurs,
the ac pump should remain locked to the selected source until that
source fails or normal operating conditions are restored.
Loss of ac power should directly start the dc emergency bearing oil

pump.
Short circuit protection in auxiliary and emergency bearing oil pump

motor circuits should be provided by magnetic circuit breakers of the
instantaneous trip type; the breaker setting should be at least
150 percent of the starting peak inrush current of the motor being
protected.
Fuses in the ac auxiliary and dc emergency oil pump motor circuits

should he avoided.
Motor starters should have the following features:
Starters for ac auxiliary and dc emergency bearing oil pump motors

should seal in when automatic starting occurs; shutdown should be by
manual actuation of a control board switch.
3-39
Overload or overheat sensors in the dc emergency oil pump motor
starter should actuate alarms only and should not stop the motor; it
is far easier and less expensive to repair or replace the dc motor
than to repair turbine damage caused by loss of lubricating oil.
A control board signal lamp wired in series with the coil of each ac
and dc oil pump motor starter should be used to indicate continuity
in the coil circuit and availability of power to operate the coil;
current drawn by the lamp selected for this purpose should be less
than the dropout current rating of the respective motor starter (see
Figure 3-20).
Control devices should have the following features:
Control board switches for ac auxiliary and dc emergency bearing oil

pump motors should spring return from the OFF position to the AUTO
position; to lock these switches in the OFF position should require
a special action such as pulling on the switch handle as it is moved
to the OFF position.
Control and pilot relays in the ac auxiliary and dc emergency bearing

oil pump motor starter coil circuits should have reverse-acting con-
tacts that close when the coil is deenergized; using such an arrange-
ment in motor starting logic will start the respective electric motor
driven pump if the relay coil fails or if power for coil energization
is interrupted.
Control Board Alarms (e.g., a steady or flashing light) should be provided to indi-
cate the following situations:
That the dc emergency oil pump control switch is locked in the OFF
position.
That power to the dc emergency oil pump is not available (e.g., open
switch, open circuit breaker, etc.).
That the dc pump motor is overheated or overloaded.
That a battery is low in voltage.
That the battery charger is off or otherwise not operating.
That one or more of the test valves for the pressure switches which
initiate dc emergency oil pump and ac auxiliary oil pump operation
have been left in the TEST position.
Procedure Design Recommendations
No general procedure can cover all possible situations. Obviously, there are numer-
ous manufacturers of turbine generator equipment, each with its own design and oper-
ating philosophy, and there are many unit configuration options available so that
two units of basically the same manufacturing type may differ significantly in
3-40
SUPPLY BUS
LOW-CURRENT
LAMP
PILOT
CONTACT
MOTOR-STARTER
COIL
RETURN BUS
Figure 3-20. Pump motor starter coil lamp. A low current

signal lamp should be present on the equipment control board
to indicate continuity in the coil circuit and availability
of power to operate the coil.
details. With these points in mind, some general comments on content of inspection
and test procedures, rather than specific step-by-step instructions, are offered in
this subsection. For maximum beneficial use of this Guidebook, utility personnel
charged with writing inspection and test procedures should become thoroughly famil-
iar with recommendations and requirements set forth by the equipment manufacturer
and with suggestions presented in this subsection. Such personnel should then be
able to prepare, with relative ease, step-by-step procedures specifically tailored
to the unit being considered.
In material subsequently presented in this section, suggestions for points to be

considered in preparation of inspection and test procedures are organized by type of
system component. A brief discussion of points to be weighed in preparing a proce-
dure and of the usual frequency of performing the test are given for each equipment
item. Further, in some cases, more extensive tests for use at less frequent inter-
vals are discussed.
The first step in any inspection or test procedure should be notification of the
plant operator that a routine test is going to be performed. This forewarning will
3-41
prevent conducting tests at an inopportune time and will avoid unnecessary response
to control board alarms that may be triggered by the test. At the conclusion of
each test, the procedure should also include instructions to:
(1) Immediately report any system malfunction and initiate necessary

corrective action.
(2) Return all valves, switches, etc. that were disturbed during the
test to their normal operating positions (a good test procedure will
include a checklist that names all valves and switches that are used
during the test and gives the normal position for each).
(3) Reset all alarms that may have been triggered during the test (a
checklist of such alarms is a good feature to include in the
procedure).
(4) Notify the operator that the test is complete.
Comments presented in the following subsections are based on the assumption that the
unit under consideration is properly equipped to perform the necessary tests. For
example, it is assumed that pressure switches used to initiate starting of auxiliary
and emergency bearing oil pumps are equipped with manual or solenoid operated bleed
valves and with pressure gauges so that maximum benefit may be obtained from the
test with minimum effort.
Dc Motors - Weekly. On a weekly basis, the dc bearing oil pump motor should be
started by bleeding pressure from the pressure switch with the appropriate test
valve (see next subsection for additional information on this topic). The person
perfo~ing the test should make sure that the motor does indeed start and continue
to run. Further, the pump discharge pressure gauge should be read, and this reading
should be recorded for future reference.
Dc Motors - Monthly. On a monthly basis coincident with a weekly test, the dc motor
should be visually inspected for accumulation of dirt, insects, spiders, rodents,
etc. Cooling air inlets and outlets should be free of obstructions. If the brushes
and commutator assembly are visible, condition of these components should be deter-
mined. Also, if visible, condition of the coupling between the motor shaft and the
pump shaft should be observed. Of course, if any problems are noted in these areas,
immediate corrective action should be taken.
The best way to test the dc motor is to bleed pressure from the pressure switch
using an appropriate test valve arrangement. Thus, the person performing the test
should actuate the test valve while watching the pressure gauge at the pressure
switch. It is desirable to note and record the actual pressure at which the dc
3-42
motor starts; comparing this observed pressure with previous results will indicate
existence of an adverse trend.
After the dc motor has started, the person performing the test should determine
visually that the motor is actually running and should touch the motor housing to
detect excessive vibration. Further, if the brush-and-commutator assembly is visi-
ble, it should be inspected for excessive sparking. Also, after the motor has been
running for a minute or so, pump discharge pressure should be read and recorded; the
observed value should be compared with previous results to ensure that the pump sys-
tem is performing satisfactorily.
Because some problems do not appear until the equipment is warm, it is desirable for
the pump to run between 5 and 15 minutes to give the motor and the pump an opportu-
nity to warm up. At the conclusion of the test, the dc motor must be stopped (usu-
ally this is accomplished from the control board), and all valves and switches must
be restored to their normal operating positions.
Dc Motors - Quarterly. At approximately three-month intervals, starting of the dc

emergency bearing oil pump should be accomplished by simulating a turbine trip with
loss of ac power. In performing this test, battery chargers should be shut off so
that the dc pump motor actually starts from batteries alone. During this test, all
other loads that normally operate from station batteries during a loss-of-ac inci-
dent should be connected and operating. This test not only ensures that the control
system can function without ac power, but also provides assurance that battery capac-
ity is adequate to start the dc motor.
It is desirable to perform this test at a time When the unit will be out of service
for at least a few hours so that the batteries can recover full charge before the
unit is restarted. Of course, at the conclusion of a dc-only test, it is necessary
that the battery chargers be reconnected and turned on and that any switches used to
simulate loss of ac be restored to their normal operating positions.
Dc Motors - Annual. Prior to performing inspection, cleaning, or maintenance opera-

tions requiring access to the interior of the motor, it is necessary, for safety
purposes, to disconnect the motor from the power supply to prevent accidental start-
ing of the motor, electric shock, or short circuit. When the necessary maintenance
operations are complete, it is imperative that the safety switch or circuit breaker
be reclosed and that the motor be started to ensure that it is functional and avail-
able for service.
3-43
At the annual unit inspection outage, dc motors should be visually inspected for
dirt, insects, spiders, rodents, etc., and any necessary cleaning accomplished.
Further, integrity of the motor-shaft-to-pump-shaft coupling should be determined,
and any deficiency at this point should be corrected. The commutator-and-brush
assembly should be exposed and inspected visually for cleanliness, adequate brush
length, proper brush seating and alignment, freedom of movement of the brush linkage,
pitting or scoring of the commutator surface, proper undercutting of the interbar
insulators, and, with the motor running, for excessive sparking. Additionally, gen-
eral appearance of the exposed winding ends should be noted, and accumulations of
dust should be cleaned. If the motor is equipped with grease fittings, the bearings
should be lubricated with an appropriate grease. It is important in the process of
lubricating the bearings to remove the lubricant drain plugs prior to introducing
new grease so that the bearings are not overpacked and so that hardened and dirt-
laden grease can be expelled. After new lubricant is forced into the bearings, it
is vital that the drain plugs be reinstalled.
When annual inspection and maintenance have been completed, certain characteristics
of the" dc emergency bearing oil pump motor should be determined. First, leakage
resistance from each motor winding to ground should be measured using a standard
instrument designed for this purpose (IEEE Standard 43); observed values should be
recorded and compared with previous results.
Additionally, the motor should be instrumented with a tachometer, a dc voltmeter

connected across motor terminals, a shunt in series with the motor supply, and a
suitable ammeter connected across the shunt; use of a multichannel recorder may be
necessary so that rapidly occurring transient quantities can be determined accu-
rately. When the motor is started by bleeding pressure from the pressure switch,
final.operating speed, voltage at the motor terminals, and steady state motor cur-
rent should be recorded for future reference. Further, from the chart record of
tachometer output, response time (i.e., time required for the motor to accelerate
to its final speed) should also be determined. It is good practice to provide
spaces on the inspection and test procedure form for entry of measured values and
to compare recently obtained data with previous results. Finally, the motor should
be tested after the instrumentation has been removed.
Ac Motors - Weekly. On a weekly basis, the ac bearing oil pump motor should be
started by bleeding pressure from the pressure switch with the appropriate test
valve (see next subsection for further discussion of this point). The person per-
forming the test should make sure that the motor does indeed start and continue to
3-44
run. Further, the pump discharge pressure gauge should be read, and this reading
should be recorded for future reference.
Ac Motors - Monthly. On a monthly basis in conjunction with a regular weekly test,

the ac motor should be visually inspected for accumulation of dirt, insects, spiders,
rodents, etc. Cooling air inlets and outlets should be free of obstructions. Also,
if visible, condition of the coupling between the motor shaft and the pump shaft
should be observed. Immediate corrective action should be taken if any problems are
noted in these areas.
The best way to test the ac motor is to bleed pressure from the pressure switch using
an appropriate test valve arrangement. Thus, the person performing the test should
actuate the test valve while watching the pressure gauge at the pressure switch. It
is desirable to note and record the actual pressure at which the ac motor starts;
comparing the observed value with previous results will indicate whether or not an
adverse trend exists.
After the ac motor has started, the person performing the test should determine
visually that the motor is actually running and should touch the motor housing to
detect excessive vibration. Further, after the motor has been running for a minute
or so, pump discharge pressure should be read and recorded; the observed value
should be compared with previous results to ensure that the pump system is perform-
ing satisfactorily.
Because some problems do not appear until the equipment is warm, it is desirable for
the pump to run between 5 and 15 minutes to give the motor and the pump an opportu-
nity to warm up. At the conclusion of the test, the ac motor must be stopped (usu-
ally this is accomplished from the control board), and all valves and switches must
be restored to their normal operating positions.
Ac Motors - Annual. Prior to performing inspection, cleaning, or maintenance opera-

tions that require access to the interior of the motor, it is necessary, for safety
purposes, to disconnect the motor from the power supply to prevent accidental start-
ing of the motor, electric shock, or short circuit. When the necessary maintenance
operations are complete, it is imperative that the safety switch or circuit breaker
be reclosed and that the motor be started to ensure that it is functional and avail-
able for service.
3-45
At the annual unit inspection outage, ac motors should be visually inspected for
dirt, insects, spiders, rodents, etc., and any necessary cleaning accomplished.
Further, integrity of the motor-shaft-to-pump-shaft coupling should be determined,
and any deficiency at this point should be corrected. Lubrication requirements for
this coupling should be determined and performed. Additionally, general appearance
of the winding ends should be noted, and accumulations of dust should be cleaned.
If the motor is equipped with grease fittings, the bearings should be lubricated
with an appropriate grease. It is important in the process of lubricating the bear-
ings to remove the lubricant drain plugs prior to introducing new grease so that the
bearings are not overpacked and so that hardened and dirt-laden grease can be
expelled. After new lubricant is forced into the bearings, it is vital that the
drain plugs be reinstalled.
When annual inspection and maintenance have been completed, certain characteristics
of the ac auxiliary bearing oil pump motor should be determined.' First, leakage
resistance from each motor winding to ground should be measured using a standard
instrument designed for this purpose( IEEE Standard 43); observed values should be
recorded and compared with previous results.
Additionally, the motor should be instrumented with a tachometer, ac voltmeters

(with potential transformers, if necessary) connected across motor terminals, cur-
rent transformers around the motor-supply conductors, and suitable ammeters con-
nected to the current transformers; it may be necessary to use a multichannel
recorder so that rapidly occurring transient quantities can be determined accurately.
When the motor is started by bleeding pressure from the pressure switch, final oper-
ating speed, voltage at the motor terminals, and steady-state motor current should
be recorded for future reference. Further, from the chart record of tachometer out-
put, response time (i.e., time required for the motor to accelerate to its final
speed) should also be determined. It is good practice to provide spaces on the
inspection and test procedure form for entering measured values and to compare the
newly obtained data with previous observations. Further, it is desirable to test
start the motor after the instrumentation has been removed.
Motor Starters - Monthly. On a monthly basis, it is desirable to open the cover of

each motor starter (ac or dc) and visually inspect for evidence of burned contacts,
burned coils, and presence of insects, spiders, rodents, or dirt. If any abnormal
conditions are observed, appropriate corrective action should be taken immediately.
If the starter appears to be in satisfactory condition, then no further maintenance
is required; and the cover should be closed and secured.
3-46
When regularly scheduled tests of ac auxiliary and dc emergency bearing oil pumps are
conducted, the corresponding motor starters are also tested. Thus, if the respective
pump starts properly, comes up to operating speed, and delivers correct oil pressure,
it can be assumed that the motor starter is also functioning as it should.
Pressure Switches - Monthly. If the system is equipped with pressure-bleed valves

that can be used to initiate starting of the ac auxiliary and dc emergency bearing
oil pumps, then the pressure switches are also tested whenever the respective pumps
are tested; this, of course, is one of the principal reasons for having test valves.
If a particular system has multiple pressure switches for starting the auxiliary and
emergency bearing oil pumps, then the pumps should be started by bleeding pressure
from each of these pressure switches in sequence; this ensures that all pressure
switches are operating correctly and that they do initiate motor starting.
It is highly desirable that each pressure switch and bleed valve combination be
equipped with a pressure gauge so that the trip point of the pressure switch may be
determined. Thus, when the test valve is actuated, the person performing the test
watches the pressure gauge reading fall and notes the value at which the respective
motor starts. This value is then recorded on a data sheet (usually part of the test
procedure form) and compared with earlier values. Any adverse trends (i.e., increas-
ing or decreasing trip point pressure) should be corrected immediately.
Pressure switch settings are adjusted to account for changes in oil pressure between
the switch location and the turbine centerline due to elevation differences and
hydraulic losses. The value of the pressure gauge reading at the switch should be
corrected to correspond with the actual pressure achieved at the turbine centerline.
After the pump starting test is complete, the test valve must be returned to its
normal operating position.
Pressure Switches - Annual. Coincident with the annual unit inspection outage, each
pressure switch and its associated pressure gauge should be calibrated with a stan-
dard deadweight tester. The trip point of the pressure switch should be set so that
it occurs at the correct value as determined by the deadweight tester, and pressure
gauge readings should be checked with a deadweight tester at the trip point and at
normal operating pressure. Security of electrical connections at the pressure switch
should also be checked, and any loose connections or worn wiring should be corrected.
The value of the trip point may have to be adjusted to achieve the proper oil pres-
sure at the turbine centerline.
3-47
After all maintenance and calibration operations have been performed, the pump-
starting system should be tested by the usual method of bleeding pressure from the
pressure switch to ensure operability and availability.
Liquid Level Switches - Monthly. On a monthly basis, liquid level switches should
be checked to ensure that they are working. Normally, the liquid level switch float
must be lifted or depressed manually to perform this test; usually a cover or plug
in the top of the oil reservoir provides access to the float for this purpose. To
check the upper set point of the liquid level switch, the float must be lifted, usu-
ally employing a hook on the end of a rod or stick, until the high level alarm
appears on the control board. To test the low set point, the float must be pushed
down until the low level alarm appears on the control board. If, in either case,
the float is moved to the limit of its travel and no alar~ occurs, then corrective
action is necessary. In performing this test, caution is required to avoid punctur-
ing the float or bending or otherwise damaging the liquid level switch mechanism.
Liquid Level Switches - Annual. During the annual unit inspection outage, or at any
other time when the lubricating oil reservoir is drained for cleaning or maintenance,
the actual low level set point can be determined by measuring depth of oil remaining
in the reservoir or distance between the oil surface and the top of the tank when
the switch trips. Upon refilling the reservoir, the actual set point for both the
lower and upper limits can be determined by making similar measurements as the reser-
voir is filled to the shutdown or rundown level, as shown in Figure 1-4. The shut-
down level is higher than the normal operating high level set point since the reser-
voir is holding additional oil needed to fill the piping system during operation.
Temperature Switches - Annual. Temperature switches and the associated temperature

sensors should be calibrated annually unless actual operating experience indicates
otherwise.
In general, temperature switches should be calibrated in accordance with the manufac-

turer's instructions. ~ecause accurately controlled temperature baths are required,
temperature switch calibration is usually performed in an instrument laboratory. A
rotation scheme, as described in Subsection 2.3, greatly simplifies calibration of
temperature switches and minimizes the time that a particular switch is unavailable
to the system.
Cables and Wiring - Monthly. Monthly tours of cable troughs and wiring passageways
should be conducted to determine if accumulations of dirt, coal dust, wood, general
3-48
trash, or liquid spills have occurred. Good housekeeping practices should be fol-
lowed to prevent fires from being ignited close to these vital power circuits.
Cables and Wiring - Annual. A more thorough inspection of power circuits is

required on an annual basis to determine if insulation, connections, or terminations
have deteriorated. Cables in troughs that are exposed to steam piping or other ele-
vated temperature sources should be checked for heating damage to insulation and
connections. Accumulations of dirt from the plant environment, rodents, or human
carelessness should be cleaned from all cableways and equipment enclosures. Cable
terminations should be cleaned and tightened because vibration or corrosion can pro-
duce degradation in one year's time.
3-49
3.4 EMERGENCY POWER SOURCES
Subsection 2.4 identified testing and maintenance requirements for emergency power
sources used for turbine lubrication systems. This subsection presents guidelines
for designing test, inspection, and maintenance procedures.
Ac Power Supplies
Since ac power can be supplied from a variety of sources, it is difficult to describe

the procedures specifically for each source. An alternator, driven by a gas or die-
sel engine or a gas turbine, generally is provided. This equipment should be
inspected daily to verify that essential components, connections, and fluid levels
are ready for operation. Operational tests are required weekly to demonstrate the
capability to start on demand and to carry load. Since fluids and materials deteri-
orate with time and use, a monthly preventive maintenance program should be estab-
lished and followed. The equipment manufacturer's recommendations for preventive
maintenance give the information for preparing detailed procedures and check lists.
Supply items such as filters, hoses, gaskets, and fluids should be stocked to ensure
they are available when needed. Quarterly operational tests lasting several hours
should be performed, for the equipment must be able to operate for an extended per-
iod when an emergency occurs. This capability should be demonstrated by an actual
operational test.
Yearly retraining of plant personnel is necessary because backup power supply sys-
tems are not part of routine operating practices. Plant personnel must have a full
understanding of the arrangement provided with each turbine bearing lubrication sys-
tem. Retraining can assure that all new personnel are familiar with the operating
procedures and that each operating team can satisfactorily respond to an abnormal
situation.
Besides backup alternator systems, automatic transfer schemes are established to

switch electrical circuits when power is not available from the normal supply. Daily
observation of the availability of backup power supplies is necessary to ensure that
another group has not disabled this supply without contacting responsible plant oper-
ators. A weekly test should be performed to verify the capability of the automatic
transfer devices to function properly. A quarterly test should be conducted to
demonstrate the capability of the automatic transfer scheme to function under simu-
lated power loss conditions. This test should include electrical relays and devices
that monitor power circuits and initiate the transfer process.
3-50
Dc Power Supplies
The dc power supply is normally a station battery set that also supplies power for
electrical control devices, emergency lighting, and other dc motor driven equipment.
The dc power supply must have sufficient voltage and power to start the dc motor
driven emergency oil'pump and to operate that pump for several hours. The start-up
time must be short to prevent loss of oil flow and damage to bearings, while the
operating time must allow for turbine coastdown and cooling on the turning gear.
Daily visual observation of battery cells is necessary to detect:
(1) Accumulation of dirt or deposits on the cell tops

(2) Corrosion of cell connectors
(3) Evolution of excessive amounts of hydrogen gas
(4) Leakage of cell fluids
(5) Breakage of cell casings and supports
Also, daily inspection of dc power supply system instrumentation is necessary to

detect grounds and low voltages. A weekly inspection of cell fluid should be con-
ducted to observe discoloration or sediment accumulation, which indicates degrada-
tion of the cell.
Weekly operational tests of ground detection circuits, low voltage alarms, and bat-
teries should be conducted to verify their capabilities to function when required.
Monthly maintenance activities should be conducted to determine the charge level of

the battery. Normally a typical cell of the battery is selected for testing of its
voltage and specific gravity. Another monthly activity is to equalize the charge of
the battery cells.
More detailed operational and maintenance tests should be performed every three
months to determine battery condition. The operational test should demonstrate the
capability to start the dc motor driven pump and to carry loads by simulation of
loss of ac power. Maintenance tests should record the voltage, specific gravity,
temperature, and fluid condition of each cell in the set. Figure 3-21 is an example
of a stationary battery test report that is beneficial to use when performing the
quarterly tests (1I). Another quarterly battery maintenance activity should be to
overcharge the battery.
A yearly operational test of the battery set to determine its capacity should be
considered. The test is given in IEEE Standard 450-1980, "Recommended Practice for
Maintenance, Testing, and Replacement of Large Lead Storage Batteries for Generating
Stations and Substations" (~). This standard recommends a performance test every
3-51
five years until the battery shows signs of degradation; then, annual performance tests
of the battery should be conducted. Degradation is indicated when battery capacity
falls below 90% of the manufacturer's rating or drops more than 10% of rated capac-
ity determined on previous performance tests.
Safety during battery tests is essential, and protective equipment should be avail-
able to personnel who perform battery maintenance activities. Protective equipment
includes:
(1) Goggles
(2) Acid-resistant gloves
(3) Protective aprons
(4) Water facilities for rinsing eyes' and skin in case of acid spills
(5) Bicarbonate of soda or other suitable neutralizing agents recommended

by the manufacturer for acid spillage
Personnel assigned to maintenance of batteries must have working knowledge of the

procedures involving safety precautions. Work should be performed only with proper,
safe tools and protective equipment. Methods used should preclude circuit interrup-
tion or arcing in the vicinity of the battery. The following precautions are recom-
mended by the IEEE Standard (~):
(1) Insulate the handles of tools used for tightening connector bolts.
(2) Prohibit arcing, smoking, and open flame in the immediate vicinity
of the battery.
(3) Ensure that the test leads are connected with sufficient length of
cable to prevent accidental arcing in the vicinity of the battery.
(4) Ensure that all connections to load test equipment include short
circuit protection.
(5) Ensure that battery area ventilation is operating.
(6) Ensure unobstructed egress from the battery area.
3-52
STATIONARY BATTERY REPORT
Operating Company Date

Address No. of Cells Type
Battery Location Attended 0, or Unattended 0 Office Serial No.
Kind of Service Date New
Type of Charging Equipment KS List
Charging Method Used - Floating Periodic Frequency of Equalizing Charges
Are Cell Covers Dry? Clean?
Condition of Sealing Compound Terminals Connectors
How Often is Water Needed? Date: Last Water Addition
ElectroIyte Height relative to H . Level B eowI Top 0 f PI ates
What is the Position of 2 Up 3 Uo Rate of Charae or Discharae at Time of Following Readings:
Charae indicators in 1 Up-1 Down 1 Down Gen. or Rect. Outout Amo. Time A.M.-P.M.
Batteries so Equipped 2 Down 2 Down Charae Rate Amp. Time A.M.-P.M.
3 Down Discharae Rate Amp. Time A.M.-P.M.
Rack Lavout Information Load Amo. Time A.M.-P.M.
Cells No. Top Tier Total Battery Voltage Panel Meter
Cells No. MiddleTier Date: Last Eq. Chg. I Spr. Gr. Pilot Cell
Cells No. Bottom Tier Amo. Hr. Meter A.H. Out Overcharge
Person Seen Mail Report To
IND IV IDUAL CE LL READINGS A"Ir liemperature
Cell Cell Cell Cell
No. Volts Sp Gr. of No. Volts Sp Gr. of No. Volts Sp Gr. of No. Volts Sp Gr. OF
1 31 61 91
2 32 62 92
3 33 63 93
4 34 64 94
5 35 65 95
6 36 66 96
7 37 67 97
8 38 68 98
9 39 69 99
10 40 70 100
11 41 71 101
12 42 72 102
13 43 73 103
14 44 74 104
15 45 75 105
16 46 76 106
17 47 n 107
18 48 78 108
19 49 79 109
20 50 80 110
21 51 81 111
22 52 82 112
23 53 83 113
24 54 84 114
25 55 85 115
26 56 86 116
27 57 87 117
28 58 88 118
29 59 89 119
30 60 90 120
INTERNAL INSPECTION OF CELL NO.
Positive Plates Negative Plates
Retainers Separators
Sediment Covers
Remarks and Recommendations
Signed
Figure 3-21. Stationary Battery Report

Source: Nuclear Safety Analysis Center
(NSAC)-48, Electric Power Research Insti-
tute, May 1982.
3-53
1. International Electrotechnical Commission (IEC). "Maintenance and Use Guide

for Petroleum Lubricating Oils for Steam Turbines, 10 (Secretariat) 236."
Geneva, Switzerland: IEC Technical Committee 10, Working Group 2, June 1985.
2. American National Standards Institute (ANSI). "Sampling Fluid From Pressurized

Lines, B93.19-1972." New York: ANSI, 1972.
3. ANSI. "American National Standard Method for Extracting Fluid Samples from a
Reservoir of an Operating Hydraulic Fluid Power System, B93.44-1978." New York:
ANSI, July 1978. Also available from the National Fluid Power Association,
Standard T2.9.9-1976.
4. Westinghouse Electric Corporation (Westinghouse). Westinghouse Turbine-

Generator Preservation Manual. Section 11, Preservation Specifications.
Orlando, Florida: Westinghouse, November 1976, p. 11.06.
5. R. L. Ergman, W. J. McLane, and A. E. Roberts. "Protection of Turbine and Gen-

erator Components." General Electric Company (GE) publication GEZ5691, Part 1.
Schenectady, New York: GE, 1973, p. 4.
6. Pall Industrial Hydraulic Corporation. "Please Flush Before Using." Filtra-

tion News. East Hills, New York: Pall Industrial Hydraulic Corporation,
Spring 1973, p. 2.
7. L. R. Roberts. "Turbine-Generator Bearing Damage Causes and Control." Colum-

bus, Ohio: American Electric Power Service Corporation, October 1973.
8. "Turbine Oil Flush System Pays for Itself After One Use." Electric Light and
Power, September 1977.
9. E. P. Payson and G. F. Weinert. "Fast-Flush System Speeds Turbine Lube-Oil

Cleaning." Power. Vol. 129, No.1. New York: McGraw-Hill, Inc., January
1985, pp. 65-67.
10. C. D. Fowler. "Effective Flushing of T-G Lube Oil Systems." Power Engineering.
Vol. 87, No.9. Barrington, Illinois: Technical Publishing, September 1983,
pp. 58-60.
11. GE. "Flushing Procedure for Turbine Lubrication System Piping (EHC)." GE pub-
lication GEK-25560, Rev. D. Schenectady, New York: GE, February 1981.
12. Westinghouse. "Oil Flush Specification and Procedures." Engineering Reference

828A943. Orlando, Florida: Westinghouse, September 1975.
13. Allis-Chalmers Power Systems. "Turbine-Generator Oil Flushing." Product

Service Division Engineer's Handbook. Section HI3.101. Bradenton, Florida:
Utility Power Corporation, December 1976.
14. George W. Lewis. "Cleaning Liquid Systems Including Controlled Heating and
Cooling of the Liquid." U.S. Patent 3,948,679. Duncan, Oklahoma: Halliburton
Industrial Services, Inc., April 6, 1976.
15. GE. "Flushing Procedure," p. 8.
16. Private communication.
17. GE. "Flushing Procedure," p. A2-1.
3-54
18. Ibid., p. A6-1.
19. P. A. Geary, Jr. "Evaluation of In-Service Industrial Lubricants Through Oil

Analysis Kit Methods." Lubrication Engineering. Vol. 40, No.6. Park Ridge,
Illinois: American Society of Lubrication Engineers, June 1984, pp. 352-355.
20. M. K. Russell. "High-Pressure Water-Jet Cleaning as Applied to Turbine-

Generator Lube Oil Systems." Lubrication Engineering. Vol. 41, No.6. Park
Ridge, Illinois: American Society of Lubrication Engineers, September 1985,
pp. 531-533.
21. S. Matthey. "Hydro-Blasting of Turbine Generator Lube Oil System Cuts Duration
of Flush by One-Quarter." Power Engineering. Vol. 88, No. 12. December 1984,
pp. 36-38.
22. D. H. Lister. "Corrosion Products in Power Generating Systems." Fouling of

-H~at Transfer Equipment. E. F. C. Somerscales and J. G. Knudsen, editors.
New York: Hemisphere Publishing Corporation, 1981, p. 183.
23. Tubular Exchange Manufacturers Association (TEMA). Standards of Tubular

Exchanger Manufacturers Association. New York: TEMA, 1968, p. 18.
24. GE. "Lube Oil Cooler 'u' Type." GE publication GEK-63263. Schenectady, New
York: GE, December 1975, p. 3.
25. Westinghouse. "Twin Oil Coolers." 1.L.1310-1723. Orlando, Florida: Westing-

house, p. 2.
26. GE. "Lube Oil Cooler 'u' Type." OF cit.

27. Wm. W. Nugent & Co. "Nugent Series 916 Turbine Lube Oil Conditions." Bulle-
tin 7. Skokie, Illinois: Wm. W. Nugent & Co.
28. Keene Corporation. "Keene Turbine Oil Conditioner, Mode1832P." Form 7.1.000.
Greenville, Tennessee: Keene Corporation, April 1977.
29. Alfa-Laval, Inc. "Alfa-Laval Mineral Oil Seprators, MAB Series." Book No. MR
S93308E 3/8204. Ft. Lee, New Jersey: Alfa-Laval, Inc., 1982.
30. Special Fluid Products, Inc. "Coalescer Filter Separators for Turbine Lube Oil
Reconditioner Model SFP 78238." Farmington Hills, Michigan: Special Fluid
Products, Inc., August, 1983.
31. Facet Enterprises, Inc. "Technical Manual for Main Turbine Lube Oil Condition-
ing Unit." Tulsa, Oklahoma: Industrial Division, Facet Enterprises, Inc.,
August 1983.
32. Pall Industrial Hydraulics Corporation. "The Pall Oil Purification System
Guide." Bulletin 1HD-oP3a. East Hills, New York: Pall Industrial Hydraulics
Corporation, October 1977.
33. Velcon Filters, Inc. "Petroclar Oil Reclamation Systems." Forms 1510, 1569,
and 1580. San Jose, California: Velcon Filters, Inc., August 1983.
34. Schutte and Koerting Company. "Oil-Cooler Transfer Valve." Cornwells Heights,
Pennsylvania: Schutte and Koerting Company.
35. Utility Power Corporation. "Oil Throttle Valve." Steam Turbine HMN-Series.
Bradenton, Florida: Utility Power Corporation, July 1983.
3-55
36. A. S. Gill. Electrical Equipment Testing and Maintenance. Reston, Virginia:
Reston Publishing Company, 1982.
37. R. Fletcher. "Battery Care." Workshop on Vital DC Power, NSAC-48. Palo Alto,
California: Nuclear Safety Analysis Center, Electric Power Research Institute,
May 1982, p. K-8.
38. Institute of Electrical and Electronics Engineers, Inc. (IEEE). "Recommended

Practice for Maintenance, Testing, and Replacement of Large Lead Storage Bat-
teries for Generating Stations and Substations, Std. 450-1980." New York:
IEEE, 1980.
39. Ibid., p. 8.
3-56
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Section 4
TEST, INSPECTION, AND MAINTENANCE SCHEDULES
Previous sections of this report detailed specific test, inspection, and maintenance
activities periodically conducted to assure reliability of a turbine bearing lubri-
cation system. The frequency of these activities depends on plant operating condi-
tions and the type of component deterioration experienced. Some activities should
be performed on a daily schedule while others may be scheduled for weekly, monthly,
quarterly, and yearly performance. For instance, a daily test of oil appearance is
recommended to check for the presence 6f water Which can suddenly occur and drastic-
ally degrade lubricant and system piping properties. In contrast, a yearly test for
oxidation stability is recommended to test for antioxidant depletion, since such oil
deterioration is gradual after the first year.
This section contains five summary tables of various test, inspection, and mainte-
nance activities. The summary tables are compiled according to activity performance
schedules typifying when these activities are conducted under normal operating con-
ditions. During the first year of plant operation, after discovery of abnormal con-
ditions or prolonged plant outages, or When dictated by experience, performance fre-
quency should be accelerated until operating conditions are established or return to
normal practices is warranted.
Each table is divided into four major divisions for lubricant, mechanical compo-
nents, electrical components, and emergency power sources. The mechanical compo-
nents section is further divided into (1) reservoir and piping, (2) pumps and vapor
extractors, (3) heat exchangers, (4) oil conditioners, and (5) valves. The electri-
cal components section is divided into (1) motors and motor starters, (2) switches,
and (3) cables and wiring. The emergency power sources section is divided into
(1) ac power supply and (2) dc power supply. Specific activities are listed in each
table under these subcategories.
Table 4-1 lists the activities that should be conducted on a daily basis. Most
activities can be "walk through" visual tests or inspections and documented by a
simple checkoff sheet.
4-1
Table 4-2 lists the activities that should be conducted on a weekly basis. These
activities require coordination, approval, records, and follow-up. Specific instruc-
tions, following a company approved procedure, are used to control and document per-
formance of each activity.
Table 4-3 lists the activities that should be conducted on a monthly basis. Several
activities involving visual inspections for trash or debris should initiate addi-
tional activity when accumulations are found. Operational tests of electrical compo-
nents requiring approval, coordination, records, and follow-up should be controlled
and documented using an approved procedure.
Table 4-4 lists the activities that should be conducted every three months. Lubri-
cant tests necessitate laboratory equipment that may not be present at the plant
site. Specific processing and follow-up activities are necessary to assure that the
tests are conducted and the results reported in a timely manner.
Operational tests of mechanical components require in-plant equipment and instrumen-

tation. Periodic calibration of these testing devices is necessary to assure that
operational tests are correctly performed.
Operational tests of the dc emergency oil pump motor and the battery set require
that the turbine be out of service for a few hours. An approved procedure is needed
to control and document the simulation of ac power loss.
Table 4-5 lists the activities normally conducted as an annual event or as part of
an annual unit overhaul outage. These intricate activities usually require detailed
setup of test conditions or disassembly of components. Quality control measures are
necessary because the activities are performed yearly and are not routine in nature.
In some cases, manufacturer's representatives or company technical experts are
needed to conduct or oversee the activity. Approved activity procedures are neces-
sary to control and document these activities, since they are conducted during the
hectic overhaul period when numerous other activities are ongoing and often inter-
fering with each other.
The five tables present the major generic test, inspection, and maintenance activi-
ties for turbine lubrication systems identified during this project by the principal
investigators. Specific plants may have additional activities not listed but
required by the plant specific equipment and design. For instance, some plants have
have a turbine driven emergency oil pump requiring periodic testing and maintenance.
4-2
This mechanical component has not been listed, but should be included in plant spe-
cific summary tables. Each responsible plant engineer is encouraged to prepare
activity summary tables similar to these tables, but with the additional activities
required by the actual system arrangement at the plant.
4-3
Table 4-1
DAILY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
LUBRICANT
Visual Test for Change in Appearance to Indicate Excessive Water or Solid

Contamination
MECHANICAL COMPONENTS
Reservoir and Piping
Visual Test for Oil Level and Negative Pressure Inside Reservoir to
Indicate Excessive Oil Leakage or Air Flow
Visual Inspection of Pressurized System Integrity to Reveal Oil Leaks
or Structural Damage
Visual Inspection of System Pressure and Temperature Gauges to Detect
Changes in Operating Conditions
Visual Inspection of Rotating Equipment to Detect Vibration or Abnormal

Sounds
Heat Exchangers
Visual Inspection of Temperature Indicators to Detect Fouling of Heat

Transfer Surfaces
Visual Inspection of Oil Side Shell Vents to Assure Continuous Removal
of Entrapped Air
Visual Inspection of Tubesheet Leak Telltales to Detect Leakage Across
Seal Gaskets or Rings
Oil Conditioners
Visual Inspection of Oil Flow Through Conditioner to Assure Continuous

Removal of Water and Particle Contamination
Visual Test of Water Drainage Devices to Detect Malfunction
Visual Inspection of Rotating Equipment to Detect Vibration
Valves
Visual Inspection of Position of Flow Control, Drain and Fill, and

Instrumentation Valves to Verify Correct Operating Position and Security
Features
Visual Inspection of Stem/Shaft Packing and Valve Positioner to Verify
Integrity of Components
ELECTRICAL COMPONENTS
Motors and Motor Starters
None Required
4-4
Table 4-1 (Cont'd)
DAILY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
Switches
None Required
Cables and Wiring
None Required
EMERGENCY POWER SOURCES
Ac Power Supply
Visual Inspection of Backup Power Supplies to Verify Operational

Readiness
Visual Inspection of Tie Line Availability as Indicated by Dispatcher's
Control Board
Dc Power Supply
Visual Inspection of Batteries to Detect Deposits, Corrosion, Excessive

Gas Evolution, Loss of Liquid, or Loss of Structural Integrity
Visual Inspection of Ground Detection and Voltage Monitoring

Instrumentation
4-5
Table 4-2
WEEKLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
LUBRICANT
Visual Test of Oil Color to Detect Deterioration (Reference ASTM Test Method
D 1500-82)
Visual Inspection of Return Oil -Screens to Detect Pluggage

Visual Inspection of Covers and Access Doors to Assure Proper Sealing
Visual Inspection of Cleanliness of Reservoir Area to Detect Accumula-
tions of Trash, Coal Dust, Dirt, or Oil Spills
Operational Tests of Auxiliary and Emergency Oil Pumps to Verify Capa-

bility of Pumps to Produce Required Pressure
Visual Inspection of Vapor Extractor Oil Mist Eliminator to Detect
Pluggage
Heat Exchangers
None Required
Oil Conditioners
Visual Inspection of Pressure Drop-Through Particulate Cartridges to

Detect Pluggage of Filter Medium
Visual Inspection of Precipitation Chambers in Gravity Type Units or
Bowls in Centrifugal Type Units to Determine Need for Cleaning
Visual Inspection of Operation of Heaters and/or Other Automatic Devices
to Assure Proper Function
Valves
None Required
Operational Tests of Auxiliary and Emergency Oil Pump Motors to Verify

Automatic Start and Running Condition
Switches
None Required
Cables and Wiring
None Required
4-6
Table 4-2 (Cont'd)
WEEKLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
Ac Power Supply
Operational Tests of Backup Power Supplies to Verify Capability to Start

and Carry Load
Operational Test of Automatic Transfer Devices to Verify Capability to
Switch Power Supplies
Dc Power Supply
Operational Test of Battery Set to Verify Capability to Supply Power

Operational Tests of Ground Detection and Low Voltage Alarm Circuits
Visual Inspection of Battery Cell Fluid to Detect Sediment Accumulation
and Fluid Discoloration
4-7
Table 4-3
MONTHLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
LUBRICANT
None Required
None Required
Visual Inspection of Coupling Between Pump and Driver to Detect Loose-

ness or Misalignment
Heat Exchangers
None Required
Oil Conditioners
None Required
Valves
None Required
Visual Inspection for Accumulation of Dirt, Insects, Spiders, or Rodent

Nests Which Could Obstruct Cooling Air Flow or Electrical Connecting
Mechanisms
Operational Test to Allow Pump Motors to Automatically Start and Achieve
Stable Running Temperature
Switches
Operational Test of Pressure Switches to Determine Actual Oil Pressure

Which Initiates Operation of Auxiliary and Emergency Oil Pumps
Visual Inspection of Liquid Level Switches by Manipulation of Switch
Float to Upper and Lower Set Points to Verify Function of Alarms and
Switch Mechanisms
Cables and Wiring
Visual Inspection of Cable Troughs and Wire Passageways to Locate Accu-

mulations of Dirt, Dust, Wood, Trash, or Liquid Spills
4-8
Table 4-3 (Cont'd)
MONTHLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
Ac Power Supply
Maintenance Activities on Backup Power Supplies as Recommended by Equip-

ment Manufacturer
Dc Power Supply
Maintenance Activity to Equalize Charge on Battery Cells to Assure That

Each Cell Is Fully Charged
4-9
Table 4-4
QUARTERLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
LUBRICANT
Laboratory Test for Viscosity to Indicate Oil Contamination or Deterioration

(Reference ASTM Test D 445-82)
Laboratory Test for Total Acid Number to Indicate Antioxidant Depletion
(Reference ASTM Tests D 974-80, D 664-81, D 3339-80)
Laboratory Test for Water Content to Indicate Water Contamination
(Reference ASTM Tests D 95-70, D 1744-64)
Laboratory Test for Cleanliness to Indicate Particle Contamination
(Reference ASTM Tests F 311-78, F 312-69, F 313-78)
None Required
Operational Test for Hydrogen Gas at Vents to Detect Hydrogen Leakage
Heat Exchangers
Operational Test for Cleanliness of Tubing to Determine Need for Water

Side Tube Cleaning
Oil Conditioners
None Required
Valves
None Required
Operational Test of Dc Emergency Oil Pump Motor by Simulation of Turbine

Trip With Loss of Ac Power
Switches
None Required
Cables and Wiring
None Required
4-10
Table 4-4 (Cont'd)
QUARTERLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
Ac Power Supply
Operational Test of Automatic Transfer of Power Upon Low Voltage Signal

Operational Tests of Backup Power Supplies to Verify Capability to Carry
Load for Several Hours
Dc Power Supply
Operational Test of Battery Set to Verify Capability to Start Dc

Emergency Oil Pump Motor and Carry Loads During Simulation of Loss of
Ac Power
Maintenance Test of Battery Set to Measure Cell Voltage, Specific Grav-
ity, Temperature, and Resistance of Connections
Maintenance Activity to Overcharge Battery Set
4-11
Table 4-5
YEARLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
LUBRICANT
Laboratory Test for Anti-Rust Protection Capability to Show Depletion of

Rust Inhibitor (Reference ASTM Test D 665-82)
Laboratory Test for Oxidation Stability to Reveal Anti-Oxidant Depletion and
Oil Deterioration (Reference ASTM Tests D 943-81 for New Oil and D 2272-67
for Used Oil)
Visual Inspection of Internal Surfaces to Detect Accumulation of Contam-

inants and Structural Damage
Visual Inspection of Clearances Between Rotating and Stationary Parts

Visual Inspection of Pump Bearing Lubrication Supply
Heat Exchangers
Maintenance Cleaning of Oil Side to Remove Debris and Show Accumulation

of Sludge
Oil Conditioners
Laboratory Test of Instrumentation Such as Pressure Gauges and Level

Alarms
Maintenance Cleaning of Flow Sight Glasses, Vents, or Other Auxiliary
Parts
Maintenance Inspection of Critical Components Such as Vacuum Pumps,
Eductors, Feed and Re1ief'Valves, and Centrifuge Internals
Valves
Verification Test of Heat Exchanger Transfer Valve to Verify Correct

Valve Port Sequence
Visual Inspection of Motor Winding Ends and Dc Motor Commutator Brush

Assembly for Detection of Dirt and Deterioration
Maintenance Lubrication of Motor Bearings to Replace Grease
Operational Test of Motor Characteristics to Verify Adequate Performance
Electrical Test of Motor-Winding-to-Ground Leakage Resistance to Detect
Insulation (Reference IEEE Standard No. 43)
4-12
Table 4-5 (Cont'd)
YEARLY TEST, INSPECTION, OR MAINTENANCE ACTIVITY SUMMARY
Switches
Maintenance Tests of Pressure Switches to Verify Calibration and Assure

Security of Electrical Connections
Operational Test of Low Level Set Point of Liquid Level Switches to
Verify Actual Reservoir Level Which Initiates Alarm
Maintenance Test of Temperature Switches to Verify Calibration and
Establish Rotation Scheme Based on Experience
Cables and Wiring
Visual Inspection of Power Circuits to Detect Accumulation of Dirt and

Deterioration of Insulation or Connections
Maintenance, Cleaning, and Tightening of Cable Terminations to Control
Effects From Vibration and Corrosion
Ac Power Supply
Operational Test of Plant Personnel to Verify Understanding o~ Backup

Power Supply System and Operating Procedures for Each Turbine Bearing
Lubrication System
Dc Power Supply
Operational Test of Battery Set to Determine Capacity (Reference IEEE

Standard 450)
4-13
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Section 5
RESOURCES AND QUALITY CONTROL
Test, inspection, and maintenance activities required for a lubrication system are
performed by several groups or departments in the plant. For instance, the operat-
ing department may be responsible for obtaining oil samples, but the technical staff
has the responsibility to submit the samples to a testing laboratory for analysis
and to review and report the testing results. In another example of split responsi-
bility, the operating department may be responsible for certain filters but must
rely on the maintenance department to change other types of filters. Such diversity
can result in performance lapses when one group thinks the other group performs an
activity. For example, many cases have been reported wher~ temporary fine mesh
screens have been left in oil supply lines only to plug up and starve flow to bear-
ings because one group thought another group was responsible for screen removal.
A detailed study of steam turbine generator lubrication system failures caused by

construction debris was performed in 1973 by a task force of the Edison Electric
Institute's (EEl) Power Station Chemistry Subcommittee. The task force report rec-
ommended one-person responsibility and establishment of strict quality control pro-
cedures for every phase of plant activity pertaining to the lubrication system (!).
The study found that lack of responsibility and quality control during construction
contributed significantly to the problem. Since these same deficiencies are
involved with other causes of lubrication system failures (l), recommendations from
the EEl task force concerning responsibility and quality control are applicable to
all situations involving testing, inspection, and maintenance of the system.
Successful testing, inspection, and maintenance of the lubrication system requires

coordinated efforts of technical support groups within the company, with equipment
suppliers, and at specialized test laboratories. One person in the plant should be
assigned overall responsibility for the lubrication system and a quality control
program should be established.
One-Person Responsibility
One management person in the plant should be assigned overall responsibility to

coordinate the various activities for lubrication system operation, integrity,
5-1
cleanliness, and reliability. This manager should have available all resources in
terms of equipment, staff, quality control, training, and services necessary to over-
see all testing, inspection, and maintenance practices required during the life of
the lubrication system. This person should be included in the review/approval proc-
ess for all activities associated with the lubrication system and should be the focal
point in the plant for these activities. All plant departments should be aware that
this person is to be notified of any work to be performed on the system. Testing of
the oil and the system is also scheduled through this manager, and results from the
tests are sent to this person's attention. An alternate responsible person should
be named to act during the absence or unavailability of the primary person and to
oversee the necessary functions when the primary person is absent or unavailable.
Quality Control Program
A quality control program should be established for all lubrication system activi-
ties to assure that the tests, inspections, and maintenance activities are being per-
formed correctly. The quality control work elements that pertain to these activities
are listed in Table 5-1 (1). The quality control program should be applicable to the
following:
Oil sampling and testing
Auxiliary and emergency oil pump testing
Power supply testing
Oil charge transferring
Oil conditioning
System flushing
Placement and removal of temporary screens, piping, or other devices
Operation with abnormal conditions or without backup systems
The primary elements of a quality control program are written procedures and instruc-
tions. People who will be using the procedures should participate in their prepara-
tion and approval before they are placed into practice (~). Checklists should be
incorporated into the written procedures to document performance of the activity on
a certain date and to report any abnormal conditions or nonconforming items.
A trial usage of the procedures and checklists should be performed to assure correct
identification of components and proper sequencing of activities or steps. Proce-
dures should be continually reviewed and revised to incorporate field modifications,
5-2
Table 5-1
QUALITY CONTROL PROGRAM WORK ELEMENTS FOR ALL

LUBRICATION SYSTEM ACTIVITIES
Work Elements
Design a plan for the activity

Identify the location for the activity
Define the activity to be performed
Prepare criteria and supplementary standards
Identify precautions and safety items
Prepare activity procedure
Train activity personnel
Conduct activity in accordance with the plan
Report activity findings
Investigate abnormal or nonconforming items
Follow up on corrective action
Dispose of nonconforming items
Document activity results
Compare activity results with prior results
new experiences, and improvements in testing methods. Periodic field spot checks
are necessary to see that practices are being performed according to the written
record.
Available Resources
The various testing, inspection, and maintenance activities require numerous and
specialized resources such as equipment, staff, technical expertise, facilities,
services, and programs. Table 5-2 lists the required resources for several impor-
tant activities. The person responsible for the lubrication system must have these
resources available or must initiate the process to acquire them.
The responsible manager has available industry technical organizations and businesses
that can provide assistance. Numerous suppliers and manufacturers produce informa-
tional and training programs, especially for system flushing, oil filtering, and oil
conditioning (5-9).
Appendix A contains information on industry technical organizations that publish

journals or magazines, sponsor annual meetings, develop codes and standards, and
support committees of technical experts. Appendix B contains information on indus-
try suppliers, manufacturers, and contract service organizations offering products
for lubrication systems. The information is provided without recommendation or
5-3
endorsement by the authors or by the Electric Power Research Institute. Each util-
ity company should make its own decision on services and suppliers. In some cases,
the utility may have the capability and expertise within the company to provide the
service. The plant engineer is encouraged to develop communication channels within
the company with the purpose of determining if such assistance is available.
Table 5-2
RESOURCES FOR TEST, INSPECTION, AND MAINTENANCE ACTIVITIES
Activity Resource
Oil Sampling Sample Acquisition Locations

Sample Collection Equipment
ASTM Standard Test Methods
In-Plant Testing Equipment
In-Plant Testing Personnel
Contract Testing Agency
Oil Service Life Analysis ASTM Standard Practice

Company Technical Expert
Oil Supplier Technical Consultant
Turbine Manufacturer's Lubrication Group
Oil Conditioning In-Plant Permanent Oil Purification Facilities

In-Plant Portable Oil Purification Facilities
Purchase Specifications for Filter Elements
Based on ANSI Standards
Reservoir and Piping System Component Inspection Procedures

Integrity Testing Inspection and Clean-out Flanges
Piping Arrangement Diagrams with Valve
and Pipe Identification
Access Control and Locked Valve System
Hydrogen Leakage Test Equipment
Oil Pump Testing Component Inspection Procedures

Testing Schedule
Piping System Flushing Full Flow Pumping Equipment

Full Flow Filters and Strainers
Temporary Piping and Valves
Temporary Fine Mesh Screens
Manufacturer's Training Programs
Manufacturer's Instruction and
Technical Bulletins
Instrumentation Testing Calibration Standards

Testing Schedule
Spare Instrumentation
Power Supply Testing Testing Equipment

Company Technical Expert
Supplier Technical Consultant
Testing Schedule
5-4
1. R. G. Knight, H. C. Crutchfield, F. N. Megahan, W. L. Riedel, H. J. Vyhnalek,

and E. C. Wackenhuth. "Recommended Standards for Design, Fabrication, Storage,
Erection and Cleaning by Oil Flush of Steam Turbine Generator Lubricating Sys-
tems: Part C." Power Station Chemistry Subcommittee Report to the Edison
Electric Institute's (EEl) Prime Movers Committee. Washington, D.C.: EEl,
April 30, 1973, p. 1C.
2. A. }lissana. "Design and Experience With Steam Turbine-Generator Bearings and

Lube Oil Systems." In General Electric Large Steam Turbine '80 Seminar.
Schenectady, New York: General Electric Company (GE), October 1980, p. 16-17.
3. J. M. Juran. "Organization: Quality Control Work Elements and Jobs." Sec-

tion 7 of Quality Control Handbook. 3rd ed. New York: McGraw-Hill Book
Company, 1974.
-4. C. L. Pope and R. J. Torrens. "Records and Scheduling." Standard Handbook of

Lubrication Engineering. J. J. O'Connor, editor. New York: McGraw-Hill Book
Company, 1968, Chapter 28.
5. Westinghouse Electric Corporation. "Steam Turbine-Generator Lube and EH Sys-

tems Flushing Course No. 2601." Aston, Pennsylvania: Westinghouse Dutton Mill
Training Center. Course is held several times each year.
6. GE. "Flushing Procedure for Turbine Lubrication System Piping GEK-25560D."

Schenectady, New York: GE, February 1981.
7. Pall Industrial Hydraulics Corporation. "Lubricant Contamination and Bearing

Life Symposium." Glen Cove, New York: Pall Industrial Hydraulics Corporation,
April, 1984.
8. Fluid Power Research Center. "Fluid Contamination Control Seminar." Still-

water, Oklahoma: Oklahoma State University. Seminar is conducted several
times each year.
9. E. R. Booser, editor. Handbook of Lubrication (Theory and Practice of Tribol-

~. Vols. I and II. Sponsored by the American Society of Lubrication Engi-
neers. Boca Raton, Florida: CRC Press, Inc., 1983, 1984.
5-5
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Section 6
BEARING LUBRICATION PRINCIPLES
Steam turbine generator bearings are full film lubricated, sliding surface bearings.
The journal and bearing surfaces are separated by a thin, film of lubricant which pro-
vides the necessary load support function. The function of the lubrication supply
system is to provide a continuous supply of oil into the clearance space between the
bearing and the rotating journal. Once the oil is within the clearance space, actual
separation of the journal surface from the bearing surface is achieved by formation
of the load-supporting oil film via hydrodynamic action. This section explains sev-
eral important bearing lubrication principles which control bearing performance from
an at-rest condition to full journal speed operation. The frictional response char-
acteristics of bearings are illustrated during different lubrication regimes, and
the three operational modes of full film lubricated bearings are discussed.
The load-supporting oil film forms between two converging surfaces when one surface
has a velocity relative to the other. The oil film will become wedge-shaped with
the minimum film thickness at the point of highest film pressure. The oil film
develops because oil adheres to the journal and when the journal is rotated, it
pulls some oil with it. Since the radius of the journal is smaller than the radius
of the bearing, the surfaces are converging and the clearance between them will be
minimum at one circumferential position. When oil is pulled from a position with
greater clearance into the position of minimum clearance, oil pressure. within the
film becomes established. The film pressure increases to overcome the journal loads
and push the journal away from the bearing. Development of the oil film is illus-
trated in Figure 6-1 (!,~) and further explained in Appendices E and F on hydrody-
namic and hydrostatic full film lubrication.
6-1
(a) (b)
MINIMUM FILM
(c) (d) THICKNESS
(a) When the journal is at rest, metal-to-metal contact exists,

and no oil film layer is present.
(b) As the journal begins to rotate, friction is high, and the

journal tends to climb up the bearing and onto a layer of oil.
This reduces friction and allows the journal to slide.
(c) As the journal gains in rotational speed, oil is drawn into

the wedge-shaped clearance space, and fluid pressure is
developed between the journal and bearing.
(d) At full journal speed, the converging wedge exists under the
journal, and a minimum film thickness exists to one side of
the bearing.
Figure 6-1. Development of Hydrodynamic Oil Film
6-2
6.1 FRICTIONAL RESPONSE CHARACTERISTICS
The two main criteria of bearing performance are the coefficient of friction and the
minimum thickness of the oil film. When full film lubrication is achieved, the
rotor glides along without any metal-to-metal contact because the journal is sup-
ported by the oil film. Without full film lubrication, metal-to-metal contact of the
rotating journal with the bearing occurs and results in a marked increase in fric-
tional resistance. While the resulting increase of drive torque required to over-
come the increased frictional resistance is of very little concern, the side effects
of increased bearing temperature and wear of the bearing and/or journal surfaces are
of major concern.
A measure of potential bearing distress is provided by its frictional power per unit
area, which can be expressed as:
Frictional Horsepower] ~ f [~] , (horsepower) (6-1)

[ Bearing Area 6600 sq. inch
where
f bearing coefficient of friction
p [Wi (A)] = unit area load on bearing (lb/in 2 )

W load on bearing (lb)
A projected area of bearing (in 2 )
v = ~DN/60 = sliding velocity (in/sec)

D bearing diameter (in)
N rotational speed of rotor (rpm)
Eq. 6-1 can be written as
(Hf/A) = (fpDN))/(126,051), (hp/in 2 ) (6-2)
The coefficient of friction of a given oil-lubricated bearing can vary over a broad
range depending upon the operating value of the following "bearing parameter":
Bearing parameter = [~v] ,(dimensionless) (6-3)
Figure 6-2 is a schematic depiction of the frictional response characteristics of

oil-lubricated sliding surface bearings as a function of the "bearing parameter."
6-3
Operating Complete Mixed- Full-
Regimes Boundary Film Film
Primary Materials
Materials Design
Considerations Lubricant
Lubricant Lubricant
Design
Trends Light Oil Heavy Oil

Low Speed High Speed
High Load Low Load
Small Area Large Area
Starved Lubrication Surplus Oil
High Temperature Low Temp.
I
I
Actual
General Mixed
I
Friction
Response I Friction ~~
Contact I~ I
~~
Fluid
II Friction ~ -E Friction
c
o Only 18 >C1:S1~
C
0 Only
:g I~o QI
+J
~C
.~
=:::
LL
'0
gI t:-
.- Q)
c _
C/)IO
C1:S
~
Q;
~I~
c C1:S t=1
o
() ~I>
.....11 d F ction on\)' ---
_ _ ~~etic~F~..!' __ ----
O_r::;...::;::::;:;..~ ~ ~
o Bearing Parameter, [Viscosity x speed]

load/area
Figure 6-2. Frictional response characteristics of sliding surface bearings.

Two transitions in the coefficient of friction occur as the value of the bear-
ing parameter decreases. The first transition occurs between the full film
and mixed film regimes at the onset of metal-to-metal contact. The second
transition occurs between the mixed film and complete boundary regimes when
total contact exists.
6-4
The solid curve in Figure 6-2 represents the actual coefficient of friction and the
dashed curve represents the theoretical coefficient of friction when there is no
meta1-to-meta1 contact. At very high values of (~v/p), the actual and theoretical
coefficient of friction (f) is relatively low and decreases in value as the operat-
ing value of (~v/p) decreases. Theoretically, this decreasing trend of (f) with
decreasing (~v/p) continues downward to a value of f = 0 at ~v/p = O. However, a
transition value of (~v/p) exists below which the actual value of (f) increases with
decreasing (~y/p). This transition signifies the onset of meta1-to-metal contact.
As the value of (~v/p) continues to decrease, the value of (f) increases very
rapidly due to more and more of the load being supported by meta1-to-meta1 contact.
This trend of increasing actual value of (f) with decreasing value of (~v/p)
contin-
,
ues until yet another transition value of (~v/p) occurs, below which the actual coef-
ficient of friction remains at a relatively high value. This second transition point
signifies total loss of oil film load-carrying capacity, and all of the load is sup-
ported by meta1-to-metal contact.
6-5
6.2 OPERATIONAL (LUBRICATION) REGIMES
The two transition points of frictional response characteristics are the boundaries
that separate three basic regimes of sliding surface bearing friction and lubrica-
tion. These operating regimes are delineated on Figure 6-2 as:
Full film friction and lubrication (high values of ~v/p)
Mixed film friction and lubrication (intermediate values of ~v/p)
Complete boundary friction and lubrication (very low values of ~v/p)
Primary considerations such as materials, lubricant, or design for each of the three
regimes are indicated at the top of Figure 6-2, as are factors affecting trends of
(~v/p).
Figure 6-3 is a more detailed look at the variation of coefficient of friction as a

function of (~v/p). The vertical scale (f) and the horizontal scale (~v/p) have
been quantified in an approximate fashion. Several different curves appear in Fig-
ure 6-3 to illustrate the general effects of certain considerations such as dirt,
deformations, misalignment, roughness, reduced oil flow rate, wearing-in, and bear-
ing clearance upon the resulting coefficient of friction. The frictional response
characteristics of hydrostatically lubricated (externally pressurized) oil-lift
bearings and of dry (unlubricated) sliding surface bearings are also included. It
is important to note that hydrostatically lubricated bearings exhibit relatively
low actual coefficients of friction that continue to decrease in value with decreas-
ing values of (~v/p) all the way down to f = 0 at (~v/p) = 0 at zero speed. Appen-
dix F contains additional information on hydrostatic bearings.
Figure 6-3 shows that dirt, deformations, misalignments, surface roughness, and
reduced supply oil flow rate all have deleterious effects on the resulting coeffi-
cient of friction. When such considerations exist, the onset of metal-to-metal con-
tact occurs at higher values of (~v/p). Wearing-in as opposed to wearing-out of the
bearing has a beneficial effect since hydrodynamic full film operation is maintained
to lower values of (~v/p). In the full film hydrodynamic regime, increasing clear-
ance has a beneficial effect since bearing oil flow rates increase, which lowers oil
film temperature and increases lubricant viscosity (u).
Figure 6-3 includes examples for a 15 inch (38.1 cm) diameter journal bearing sub-
jected to a unit area loading of p 150 (lb/in 2 ) (1.03 mPa). The vertical dashed
lines at (~v/p) = 0.21 x 10-6 and at (~v/p) = 13.5 x 10-6 are for operation of the
6-6
Dry (Un-Lubricated)
Complete Boundary Friction (0.08 <.fs < 0.14)

.....- -....~-Mixed Friction (0.02 < f m < fB)
Fluid Friction (fF >0.001)
fmax= fs = Coeff. of "boundary" friction
~
---
u-
II Dirt
Deformations
Misalignment
Roughness
Reduced Supply Flow
Turning-Gear
Speed
Operation
Example
t/A;]::: 0.21 x 10-6 5 X 10-6 10 X 10-6 15 X 10-6 20 X 10-6 25 X 10-6
Bearing Parameter, IJv/p = r. /AnON

L60(W/LO)
J
Example: 15-inch diameter bearing, 150 (lblin 2) unit loading
:. r;j = 0.00523 (/AN)
For turning-gear speed of For full speed of

N = 10 (rpm) N = 3600 (rpm)
IJ =:: 4.0 x 10-6 (1b-sec/in 2) IJ =:: 0.715 x 10-6 (lb-seclin 2 )
@T=100F @T=200F
:. rpj::: 0.21 X 10-6 :. r;j::: 13.5 x 10-6
Figure 6-3. Variation of coefficient of friction of sliding surface bearings.

In addition to load, speed, and viscosity, the coefficient of friction also
varies with changes in clearance, oil supply flow, surface roughness, alignment,
and oil contamination.
6-7
bearing at turning gear speed (N = 10 rpm) and at full speed (N = 3600 rpm), respec-
tively. Figure 6-3 shows that at full speed operation, the bearing operates in the
"full film friction and lubrication" regime with relatively low coefficient of fric-
tion. When running at the much lower turning gear speed, the bearing operates in
the "complete boundary friction and lubrication" regime with very high coefficient
of friction.
Using these coefficient of friction characteristics, a schematic curve can be con-

structed of bearing temperature as a function of time during coastdown. From
Figure 6-3 with onset of contact starting at (~v/p) 5x 10-6 , the temperature
curve is schematically depicted in Figure 6-4. The solid line curve is temperature
for contact and the dashed line is temperature for zero contact. The form of this
curve is quite similar to field observations in a bearing that has been scored, as
shown in Figure 6-5. Solid particle contaminants in the lubricant and/or deforma-
tions and misalignments of the bearing members would also result in similar contact-
induced transient temperature rise of the bearing during coastdown.
Figure 6-6 presents summary descriptions of the three lubrication regimes by which
sliding surface bearings provide their load-support function.
6-8
I
-0
1
~iTUrning Gear~
'1
e Speed
~I
I
o t= Time
Figure 6-4. Schematic of Variations of Speed, Temperature, and

Bearing Wear as Functions of Time After Shutdown from Full Speed
in a Bearing Experiencing Metal-to-Metal Contact During Shutdown
6-9
Turbine
Trip
_ Scored Journal
- - - Normal Journal
"'0
Q)
~~---~ Coastdown
en
"'0
Q)
i
a:
Metal
Temp (OF) Typically 1-10 Min.
Time --+--
Figure 6-5. Field observations of bearing metal temperature

during coastdown with a scored journal. When a journal becomes
scored, the transition from full film lubrication to mixed film
lubrication occurs at high journal speed. Wiping of the bear-
ing may occur and be evidenced by a spike in the bearing metal
temperature.
Source: G. E. Publication No. GEK-46506B.
6-10
a. "Full-Film Lubrication" Regime
This mechanism (achieved in various "modes") results in complete separation of the
bearing members with all of the load supported by a film of pressurized lubricant.
S Film pressure distribution

/---"""~
/ w
W = WF = Film load
Film'~h
Thickness
, ___" Interposed film separating
bearing members
b. "Mixed-Film Lubrication" Regime

In this mechanism there is some degree of contact of the bearing members in localized
spots. Interposed, very thin layers of lubricant in the remaining areas, if pressurized,also
contribute to load support. Hence, the mixed-film lubrication mechanism provides load-
support by the combination of localized contact reaction and localized thin-film pres-
surized lubricant.
w
/ Contact load
Runner W=Ws + WF
'" Film load
c. "Complete Boundary Lubrication" Regime

In this mechanism, the lubricant does not provide any load support. Hence, load-support
is due entirely to bearing member contact reaction.
" w
w = Ws = Contact load
Figure 6-6. Lubrication Regimes Whereby Sliding Surface Bearings Provide

Load Support
6-11
6.3 OPERATIONAL MODES OF FULL FILM LUBRICATED BEARINGS
The three basic operational modes by which full film lubrication of sliding surface
bearings can be realized are:
(a) Hydrodynamic: Fluid film load-carrying capacity is achieved by

motion of the bearing members in the plane of the mating surfaces.
(b) Hydrostatic: Fluid film load-carrying capacity is achieved by the

introduction of externally pressurized flow to and through the bear-
ing oil film.
(c) Squeeze-Film: Fluid film load-carrying capacity is achieved by

motion of the bearing members normal to the plane of the mating
surfaces.
These three modes of full film lubrication are illustrated in Figure 6-7(a), (b),
and (c). A possible fourth mode, termed hybrid operation, is illustrated in Fig-
ure 6-7(d) and derives its fluid film load-carrying capacity by a combination of two
or more of the three basic modes of operation. General requirements or necessary
conditions for achieving the basic modes of full film lubrication are also indicated
in Figure 6-7.
The bearing surfaces depicted in Figure 6-7 are flat; however, the operational prin-
ciples and requirements are also valid for non-flat surfaces such as cylindrical
journal bearing surfaces.
The sliding surface bearings in steam turbine applications are of two basic surface
geometries:
flat surface thrust bearings and
cylindrical surface journal bearings
Both bearing types achieve full film lubrication during operation by means of hydro-
dynamic action.
In some cases, hydrostatic lubrication is incorporated within the journal bearings

and is activated under the following situations:
Prior to rotor rotation and deactived at some rotational speed less

than rated speed during startup.
At some rotational speed less than rated following shutdown

initiation.
During the subsequent coastdown of the rotor to zero speed and during
turning gear operation.
6-12
SELF- GENERATED LEXTERNALLY SUPPLIED
/,.-~HYDRODYNAMIC HYDROSTATIC FLUID PRESSURE
/ \ FLUID PRESSURE DISTRI BUTION
// \ DISTRIBUTION
/ W \
/1 \ /r--w---1\
l .l
f~~~~~,~~~~:~~:
4:
:\:: ~
I
~ ~
E:::i: :1~::t:\~3
II
I .
1\
1\
(7 7/ ~7~FLUID
FLUID
EXPELLED r ////alr'" a EXPELLED
Q
r
.1. PRESSURIZED FLOW FROM
EXTERNAL SOURCE
(0) Hydrodynamic (b) Hydrostatic

Requires lubricant at leading edge, Requires continuous flow (Q) of pres-
sliding velocity (U) in plane of br'g surface surized lubricant from an external source
and converging film shape.
w
SELF- GENERATED
SQUEEZE FILM
FLUID PRESSURE
DISTRIBUTION
/
I,
,,--
, t
-,....,
,\
HYBRID GENERATED
'~ESSURE DISTRIBUTION
~II, ,
....--/ ' FLUID
~ -~ FLOW RECESS EXPELLED
FLUID k>177 7 ) 7 7 / 7 7j FLUID DRAWN IN
EXPELLED ~ ~EXPELLED OR
EXPELLED
(e) Squeeze Film (d) Hybrid

Requires lubricant between members Combination of two or more of the three
when runner approaches (+ V) bearing. basic modes.
Requires velocities (V) normal to bear-
ing surfaces. Requires replenishment of
lubricant during regression of br'g
members (-V).
Figure 6-7. Modes by Which Sliding Surface Bearings Achieve Full Film
Lubrication
6-13
When hydrostatic lubrication is active, load support is achieved by the hybrid mode
through the combination of hydrodynamic and hydrostatic modes. Hydrostatic bearings
are discussed in Appendix F.
It is significant to note that all operating oil film bearings always exhibit some
degree of squeeze film mode of full-film lubrication load support since
they are always subject to time-varying (dynamic) loads which result

in relative motions normal to the plane of the mating surfaces, and
the moving surfaces are not perfectly flat nor perfectly cylindrical,
which results in time-varying changes in oil film thickness.
The mode of operation of full film lubricated steam turbine bearings is normally
hybrid to some degree by combination of hydrodynamic and squeeze film modes. When
certain unfavorable events occur such as abnormally high transient or dynamic loads
being imposed upon the rotor from blade loss, steam whirl, water induction, etc.,
the squeeze film mode provides the necessary supplemental load support to maintain
complete separation of the bearing mating surfaces.
A steam turbine journal bearing having properly designed and implemented hydrostatic
lubrication represents an ideal bearing in that it has the potential for both gener-
ating and maintaining complete separation of the journal and bearing surfaces. This
is conceptually illustrated in Figure 6-8 showing the following three different
operating conditions:
(a) The journal at rest or at less than rated speed with the hydrostatic
lubrication activated and with steady-state loading
Pure hydrostatic mode at zero speed
Hybrid (hydrostatic plus hydrodynamic) mode when the journal is

rotating
(b) The journal rotating at rated speed with the hydrostatic lubrication
deactivated and with steady-state loading
Hydrodynamic mode of operation
(c) The journal rotating at rated speed with the hydrostatic lubrication
deactivated and with dynamic loading
Hybrid (hydrodynamic and squeeze film) mode of operation
6-14
PRESSURE
DI STRI BUT 10 N
(a) STARTING AND STOPPING

Pure Hydrostatic at Zero Speed
H y d r 0 stat i c - H y d rod y nami cup to
or down from Speed N.
"""-"""'---CHECK VALVE
RESTRICTOR
~--- PRESSURIZED FLOW
(b) AT OPERATING SPEED WITH

DEAD WEIGHT LOAD ONLY.
Pure Hydrodynamic
PRESSURE
DISTRIBUTION
(c) AT OPERATING SPEED WITH DEAD

WEIGHT LOAD AND SHOCK LOAD
Hydrodynamic - Squeeze Fil m
Figure 6-8. Ideal application of all modes of fluid film lubrication.

(a) Starting and stopping: pure hydrostatic at zero speed; hydrostatic
and hydrodynamic up to or down from operating speed, N.
(b) At operating speed with deadweight load only: pure hydrodynamic.
(c) At operating speed with deadweight load and shock load; hydrodynamic
and squeeze film.
6-15
1. Mobil Oil Corporation. Lubrication Fundamentals. New York: Mobil Oil Corpo-
ration, 1971, pp. 53-67.
2. D. D. Kramer. "How to Select the Proper Lubricant for Bearings." Plant Engi-
neering. Barrington, Illinois: Technical Publishing, Inc., November 1984,
pp. 68-70.
~
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0 0
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me
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03:
zC5en
Section 7
ROTOR DYNAMICS CONSIDERATIONS
7.1 ROTOR DYNAMICS SYSTEM
During both "steady-state" and "transient" operation, the rotating rotor is continu-
ously subjected to time-varying disturbances. Determining the stability and response
of the rotor to the magnitudes, frequencies, directions, and natures of these dynamic
disturbances is a complex function which involves use of a rotor dynamics system.
A rotor dynamics system is represented by masses, stiffnesses, and damping of the
rotor, the supporting structures, and foundations which are coupled with the dynamic
stiffness and damping characteristics of the interposed bearing oil films.
As presented and discussed in Appendix E, the dimensionless stiffness and damping

characteristics of any given oil film bearing are highly variable, nonlinear quanti-
ties that are functions of the dimensionless bearing parameter involving:
bearing design (L, D, C)
rotational speed (N)
oil film viscosity (~F)
load magnitude (W) and direction
Since speed, viscosity, and bearing load are all operation-dependent variable quan-
tities, the dimensional values of the given bearing's:
four cross-coupled stiffness coefficients
~' ~Y' ~x and ~ (lb/in)
and the
four cross-coupled damping coefficients
D ' Dxy ' DyX and Dyy (lb-sec/in)

XX
7-1
will vary over broad ranges depending upon operational values of speed, bearing oil
film viscosity, and bearing load. Accordingly, the stability and response of the
rotor to time-varying disturbances can and will change when operating conditions
change.
7-2
7.2 ROTOR DYMANICS-RELATED FAILURE MODES OF BEARING SYSTEMS
There are three general categories of rotor dynamics-related failure modes of bear-
ing systems:
resonance
bearing whirl or oil whip
subsynchronous resonant whirl
A resonant condition exists when the turbine is operating at one of its natural fre-
quencies causing high vibration levels of the turbine and its bearings. Depending on
the amount of damping in the system, excessively high vibration levels could cause a
bearing failure such as a bearing wipe. Usually the most potentially destructive
natural frequencies are those associated with the first bending modes of each rotor
section (HP, IP, LP, generator). The first bending frequency is typically well
below the operating speed of 3600 rpm and is normally 600-1000 cpm for the generator,
1000-1500 cpm for the LP rotor, and 1600-2000 cpm for the HP, IP rotors. The only
time a turbine will be operating at or near its first bending natural frequency is
during startup and shutdown. There are other natural frequencies which are strongly
related to the compliance of the bearing oil films and of the bearing support struc-
tures and which could also cause bearing failure. In any event, vibratory transla-
tions and pitch and yaw rotations of the rotor at frequencies near that of the
natural frequency of the bearing housing or pedestal could cause a resonance-induced
failure of the bearing.
Bearing whirl, sometimes referred to as oil whip, is a bearing-induced, self-excited

vibration problem. It can result in large vibrations with an associated vibratory
frequency that is below the operating speed (subsynchronous). If the rotor is oper-
ating above twice that of its first bending mode frequency, then the whirl frequency,
in general, is equal to the first bending frequency. On the other hand, if the
rotor is not operating above twice the first bending mode frequency, then the whirl
frequency is near half the operating speed. In general, bearing whirl is a function
of the bearing stiffness and damping coefficients, the compliance (flexibility) of
the rotor, the compliance of the bearing support system (housing, pedestal, founda-
tion), and the mass that the bearing must support. It is primarily caused by the
magnitudes and directions of the cross-coupling effects that occur in the fluid film
bearing stiffness and damping. In the example given in Appendix E and Subsections 2
and 3, it was determined that the example bearing could have a whirl problem. The
calculations assumed that the housing and rotor are rigid. For most steam turbine
applications, the rotor cannot be considered rigid. By including its flexibility
7-3
in the stability calculation, the rotor system will become less stable. In any
given hydrodynamic journal bearing with a given value of L/D, the onset of bearing
whirl will occur when the value of the bearing parameter
reduces to some particular "critical" value Wo*. At values of W* > Wo *' the bearing
will be stable. When W* Wo *' the bearing will begin to whirl at small magnitudes
(i.e., become unstable). As W* becomes progressively less than Wo * (i.e., by further
increases in rotational speed, reduction of load, or reduction of supply oil tempera-
ture**), the amplitude of bearing whirl will progressively i~crease. Thus, if a
normally stable bearing exhibits bearing whirl, it is an indication that the load (W)
on that bearing has decreased and/or supply oil temperature has decreased. In any
event, bearing whirl is an indicator of pending bearing distress and steps should be
taken to alleviate the situation, including the following:
(a) If the bearing load is too low, check its load-sharing alignment.
Increasing the bearing elevation will increase the bearing load.
(b) Check to see that supply oil temperature is not too cold.
(c) If alignment and supply oil temperature are as they should be, then
modifications to the bearing design should be considered, including:
Decrease the axial length (L) of the bearing bore.
Increase the bearing clearance (C).
Modify the bearing bore geometry (i.e., elliptical shape) to

modify (enhance) its stiffness and damping characteristics and
to induce self-preloading of the journal.
Retrofit a tilting pad journal bearing which has extremely good

resistance to self-generated bearing whirl.
The subsynchronous resonant whirl phenomenon is very similar to bearing whirl,

except that it is not initiated by the bearing and needs some dynamic disturbance
such as seal forces to excite it. It results in large sub synchronous vibrations at
a frequency of the first bending natural frequency of the rotor. In general, for
this type of failure mode to be destructive, the operating speed of the rotor has
to be above the first bending natural frequency of the machine and usually above
twice the first bending frequency, which is normally the case for large steam
**Reduction of supply oil temperature results in lower oil film temperature, with
attendant greater value of oil film viscosity, UF
7-4
turbines. The excitation usually comes from steam flow conditions or rubs. Steam
flow can cause a phenomenon called steam whirl. This can be controlled somewhat
during the design stage of the turbine. Rubs can occur due to (1) large abnormal
mechanical unbalance; (2) water induction, which can cause severe bows in the inner
cylinder; (3) steam inlet conditions, which can cause abnormally high radial load-
ing; (4) shock, which can be caused by external disturbances such as earthquakes;
and (5) abnormal thermal conditions especially during startup or shutdown. If sub-
synchronous resonant conditions exist in an operating unit, one possible corrective
measure would be to add damping to the first bending natural frequency of the rotor.
This could be accomplished by modifying the bearings or the bearing support struc-
ture or by adding a fluid film damper to the rotor.
The most frequently occurring generic problem area of turbine bearing systems is the
matter of rotor dynamics-related "vibration." A previous EPRI research project on
failure causes of bearing systems reported the following findings (!):
Vibration was the number one generic problem which occurred in 62%
of all bearing system failure incidents reported and accounted for
42% of the total 1.45% loss of theoretical generation.
Virtually all such vibration incidents occurred on 3600 rpm shafts

as opposed to 1800 rpm shafts.
Of the cited causes of vibration, rotor unbalances were the most

commonly cited, lower level causal event of vibration.
One of the hidden causes of rotor dynamics-related problems is the matter of mis-
alignment, both load-sharing misalignment and bearing-to-rotor misalignment. Load-
sharing misalignment, depending on the severity, can and does cause significant
changes in the loadings of various bearings. This can cause variation in the bear-
ing oil film stiffness and damping Which can alter the rigid body frequencies suffi-
ciently to cause a resonant condition. Changes in bearing loading would not have a
significant effect in the bending natural frequencies of the rotor; however, they
could significantly affect the damping characteristics. Also, unloading a bearing
could cause bearing whirl to occur and, if the misalignment is large, there could be
rubs in one or more of the heavier-loaded bearings which could cause subsynchronous
resonant whirl. Appendix E contains further information on misalignment.
7-5
7.3 ROTOR DYNAMICS ANALYSES
In order to assess the dynamic characteristics of an operating unit, one must per-
form what is termed a "nonsynchronous, flexible rotor dynamics analysis" of the spe-
cific rotor, its oil film bearings and supporting structures and foundations, and
their interactions when subjected to the inherent and abnormal (steady-state and
transient) disturbances associated with its operation. While complex, such computer-
implemented analyses can be and are being employed during the design phase and/or
during vibration-related failure investigations. The purpose of a rotor dynamics
analysis is to evaluate the following primary considerations:
Stability of the rotor-bearing system
Natural frequencies and mode shapes
Response of the rotor-bearing system
The stability study indicates whether there are any self-excited vibration problems
in the system such as bearing whirl. Also, if steam whirl or rubs are present and
if these forces can be suitably approximated, then their influence on rotor stability
can be determined. Another value of the stability analysis is that it determines the
amount of damping associated with the first bending mode. If this damping is low,
then it will be easy to excite the particular mode of vibration.
The natural frequency analysis determines for a given set of operating conditions
all of the natural frequencies of the system and their modes of vibration, including
the bearing support natural frequencies. If any natural frequency is close to the
operating speed, then a resonant condition will occur. Depending on the amount of
damping associated with this mode, the resonant frequency vibration levels mayor
may not be serious. Also, the mode shapes provide an indication of where the peak
vibrations are occurring for measurement purposes and where and what corrective mea-
sures would be of most help.
The response analysis determines predicted vibration levels at various locations

along the steam turbine rotor for a given operating condition. The vibration levels
could be caused by a number of disturbing forces such as unbalance, steam force,
rubs, shock, etc. The most common disturbing force is rotor unbalance. Parametric
studies can be conducted to determine the rotor response due to various unbalance
conditions along with other disturbing forces acting on the rotor.
7-6
To conduct a rotor dynamic analysis, the turbine assembly is subdivided into compo-
nents (rotor, bearings, bearing supports, coupling, external loadings), which are
then represented in mathematical terms.
The rotor is mathematically represented by a series of flexible beams which denote

the shaft and disks which denote the turbine blading and shrouding. Figure 7-1
illustrates a typical rotor dynamics model of a large steam turbine (generator not
shown). At each mass station, two orthogonal translational degrees of freedom are
permitted. In order to include the important effects of gyroscopic action, two
degrees of rotational freedom should be allowed at the stations which include blad-
ing and couplings.
Bearings are treated as springs and viscous dampers. They are represented in the
analysis by cross-coupled spring and damping coefficients. These coefficients are
nonlinear with respect to the rotor position (eccentricity magnitude and direction)
in the bearing. Because of this, it is first necessary to compute the equilibrium,
steady-state operating position of the rotor in the bearing, then calculate dynamic
coefficients by taking small perturbations about that point. To determine these
coefficients, the following steps are performed:
Compute the steady-state load on each bearing.
Mathematically model the bearings taking into account the actual

grooving, pad length and angle, clearance, etc.
Perform a heat balance for each bearing to determine average film

temperature, which is used to establish the oil film viscosity.
Recorded field-measured temperatures will assist in this evaluation.
Compute the eccentricity ratio (rotor eccentricity in each bearing

divided by the machined-in radial clearance) for the computed load.
Calculate the spring and damping coefficients at the eccentricity

ratio computed above.
Bearing spring and damping coefficients for fixed type bearings are represented in
the following matrix form:
Bearing Stiffness Bearing Damping
DXX
K.1.J
[ Dyx
where the subscripts i,j mean a response in the ith direction due to a perturbation
in the jth direction. For example, Kxy is the spring stiffness in the X direction
7-7
due to a displacement in the Y direction and Dyx is the damping coefficient in the
Y direction due to a velocity in the X direction. For the example problem given in
Appendix E, these coefficients are contained in Table E-3 (turbulent flow).
Spring and damping coefficients for tilting pad bearings take into account the pitch
direction degree of freedom of each pad. Therefore, for a 6-pad bearing, the coeffi-
cients would be represented in matrix form as:
o o o o o
o K~2~2 o o o o
o o o o o
o o o K~4~4 o o
o o o o o
o o o o o
K~ x of the above matrix means the pitching spring rate of pad 1 due to an X dis-
1
placement of the rotor. Note that there are no cross-coupled effects between pads.
For example, K~ ~ = o.
1 2
The bearing support systems are modeled similar to the bearings. Their flexibili-
ties are treated as spring and damping coefficients. Depending on the degree of
complexity desired, the bearing support system can be broken down into a number of
masses (housing, pedestal, foundation) supported by springs and dampers. For the
example of the rotor model of Figure 7-1, the bearing support structure is divided
into the bearing housing and the pedestal. These dynamic coefficients of the sup-
porting housing and pedestal can be computed using finite element computer programs
or evaluated experimentally.
The couplings for large steam turbines are rigid as opposed to flexible such as those
in gear or diaphragm couplings. Therefore, they are modeled as shaft elements.
7-8
~--rr-----",------_.-\-------""'\
ft ~
U!lJ , I I. ;
TO
-----.
GENERATOR
JB JBSCJB JBSCJB ~
BL JBSCJB BL JBSCJB BL JS SC
rr--"Il ~~
'-J
I
\.0
Brg. Film Brg. Housing Brg. Housing Pedestal Pedestal

Stiff. & Damp. Mass Stiff. & Damp. Mass Stiff. & Damp.
JB = Journal Brg.
BL = Blading
SC = Solid Coupling
Figure 7-1. Rotor dynamics model of a large steam turbine (generator not shown). Mathematical terms are
used to represent the various turbine components. The analysis is used to evaluate the stability and
response of the rotor bearing system considering its natural frequencies and shapes.
Disturbing forces can be modeled in the response analysis. Unbalance location, mag-
nitude, and phase relationships can be applied at various stations along the rotor
model. In general, disturbing forces are modeled as a force with a magnitude, fre-
quency and phase relationship. They can be applied at any station along the rotor
model and to the bearing support structure which would be the case for shock loading
occurring during a seismic disturbance. In cases where large vibrations occur from
loss of blades or shroud, the nonlinear effects in the bearings can be examined by
treating the bearings as a disturbing force.
Properly utilized and implemented, a rotor dynamics analysis can provide valuable
technical insights into the stability, natural frequency(s), and response character-
istics before and/or after turbine installation. During the design phase, a rotor
dynamics analysis can provide a measure of reasonable assurance that the dynamic
performance of the unit will be acceptable. During the operational phase, a rotor
dynamics analysis can provide a tool for
(1) identifying the more likely cause(s) of a vibration problem,
(2) defining suitable corrective actions for alleviating the problem,

and
(3) evaluating the benefits through elimination of costly tria1-and-

error practices with different correction action proposals.
Additional information on rotor dynamics analysis is available through EPRI Research

Project 1648-2. The authors recommend to those who are interested in performing a
rotor dynamics analysis that they investigate the application of the FEATURE computer
code that was developed for utility rotor dynamics evaluations (1).
7-10
1. H. C. Rippel and R. J. Colsher. "Failure-Cause Analysis: Turbine Bearing Sys-

tems." Draft Final Report No. F-CS25S(D2). Prepared by the Franklin Research
Center under the Electric Power Research Institute (EPRI) Research Project
1265-3. Philadelphia, Pennsylvania: March 1984 (unpublished).
2. Mechanical Technology, Inc. (MTI). "Finite-Element Analysis Tool for Utility

Rotordynamics Evaluations (FEATURE), RP 1648-2." CS 3999-CCM, Vols. 1-2.
Palo Alto, California: EPRI Coal Combustion Division, 1984.
7-11
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Appendix A
INDUSTRY TECHNICAL ORGANIZATIONS
Several national and international technical organizations have been involved with
development of lubricants and lubrication system design for over 60 years <l).
These technical organizations have acted as an open forum for exchange of technical
information and promotion of industry standards for design, specifications, test
methods, practices, and requirements. Utility personnel at a power plant site are
not normally associated with these organizations; however, technical specialists
within the utilities' central engineering staff are likely to be involved. Also,
utility consultants or technical experts emploed by oil suppliers or equipment man-
ufacturers participate in technical organizational committees and publish technical
papers on their activities.
It behooves the plant person responsibl~ for the lubrication system to communicate
with someone in the utility or with a supplier or consultant who is active in these
technical groups. The plant person needs to contact those who can keep him abreast
of advances made in lubricant and lubrication technology such as new test methods,
new purification equipment, or recent experiences with component operation or
malfunction.
Table A-l lists the names and addresses of technical organizations that can provide
information about various aspe~ts of a lubrication system. Table A-2 lists some of
the publications available from these groups that could be of interest and benefit
to a utility person. Table A-3 lists annual conferences sponsored by the organiza-
tions at which significant technical papers or reports are presented and during
which industry committees meet. A review of the conference program and committee
meeting schedule can provide information on conference activities and availability
of conference papers. Table A-4 lists the names and addresses of technical organi-
zations that publish information on motors and controls.
A-I
Table A-1
TECHNICAL ORGANIZATIONS FOR LUBRICANT AND

LUBRICATION SYSTEM TECHNOLOGY
American Society for Testing and Materials (ASTM)

1916 Race Street
ASTM Committee D-2 on Petroleum Products and Lubricants

Technical Committee C on Turbine Oils
American Society of Mechanical Engineers (ASME)

Tribo10gy Division & Power Division
United Engineering Center
345 East 47th Street
New York, New York 10017
ASME Research Committee on Lubrication
Edison Electric Institute

Power Station Chemistry Committee
1111 19th Street, N.W.
Washington, D.C. 20036
Institute of Electrical and Electronic Engineers (IEEE)

Power Engineering Society
United Engineering Center
American Society of Lubrication Engineers (ASLE)

833 Busse Highway
Park Ridge, Illinois 60068
ASLE Power Generation Council
American Petroleum Institute (API)

2101 L Street Northwest
National Electrical Manufacturers Association (NEMA)

2101 L Street Northwest
Used Oil Task Force
National Fluid Power Association (NFPA)

3333 N. Mayfair Road
Milwaukee, Wisconsin 53222
International Organization for Standardization (ISO)

Technical Committee 28
Geneva, Switzerland
A-2
Table A-I (Cont'd)
TECHNICAL ORGANIZATIONS FOR LUBRICANT AND

American National Standards Institute (ANSI)

1430 Broadway
Society of Automotive Engineers, Inc. (SAE)

485 Lexington Avenue
Aerospace Industries Association of America, Inc.

National Aerospace Standards (NAS)
1725 De Sales Street Northwest
The Institute of Petroleum (IP)

61 New Cavendish Street
London, Great Britain W1M 8AR
International Electrotechnical Commission

3, Rue de Varembe
Geneva, Switzerland
Technical Committee 10, Working Group 2,

Steam Turbine Lubricants and Control Fluids
A-3
Table A-2
PUBLICATIONS ON LUBRICATION
American Society of Lubrication Engineers (ASLE)
Lubrication Engineering
ASLE Transactions
Handbook of Lubrication: Volumes I and II
Turbine Lubrication
American Society of Mechanical Engineers
Wear Control Handbook
Journal of Tribology (formerly: Journal of

Lubrication Technology)
Journal of Engineering for Gas Turbines and Power

(formerly: Journal of Engineering for Power)
Butterworth & Co. (Publishers) Ltd, England
Tribology International
The Institute of Electrical and Electronics

Engineers (IEEE)
IEEE Transactions on Power Apparatus and Systems
Annual Book of ASTM Standards
Journal of Testing and Evaluation
ASTM Standardization News
Several Special Technical Publications (STP)
Institute of Petroleum
IP Standards for Petroleum and Its Products:

Part 1, Methods for Analysis and Testing
A-4
Table A-3
ANNUAL CONFERENCES ON LUBRICATION
ASME!ASLE Lubrication Conference (October)
ASLE Annual Meeting (May)
Texas A&M University Annual Turbomachinery Symposium
International Tribology Conference
A-5
Table A-4
TECHNICAL ORGA1~IZATIONS FOR MOTORS AND

CONTROLS TECHNOLOGY
American National Standards Institute (ANSI)

1430 Broadway

1916 Race Street
Factory Mutual System

1151 Boston-Providence Turnpike
Norwood, Massachusetts 02062
Institute of Electrical and Electronics Engineers (IEEE)

Instrument Society of America (ISA)

400 Stanwix Street
Pittsburgh, Pennsylvania 15222
Insulated Power Cable Engineers Association

192 Washington Street
Belmont, Massachusetts 02178
National Electrical Manufacturers Association (NEMA)

National Fire Protection Association

60 Batterymarch Street
Boston, Massachusetts 02110
A-6
REFERENCES Appendix"A
1. A. N. Smith. "The Role of Technical Societies with Turbine Lubrication." In

Proceedings of Turbine Bearings and Rotor Dynamics Seminar and Workshop. Palo
Alto, California: Electric Power Research Institute, September 1982.
A-7
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Appendix B
INDUSTRY BUSINESS ORGANIZATIONS
Several national and international business organizations provide equipment, sup-

plies, services, and technical information pertaining to lubricants and lubrication
system components. Table B-1 lists the names and addresses of organizations that
have provided information for use in preparing this Guidebook. The authors and the
Electric Power Research Institute (EPRI) do not endorse or recommend these companies
over other companies offering similar products or services, but list them here simply
to give utilities the names of companies who have provided these products or services
in the past.
B-1
Table B-1
BUSINESS ORGANIZATIONS FOR LUBRICANT AND

Alfa-Laval Incorporated
2115 Linwood Avenue
Fort Lee, New Jersey 07024
201-592-7800
Allis-Chalmers Corporation
Steam Turbine Division
1126 South 70th Street
West Allis, Wisconsin 53214
Automatic Switch Company

50-56 Hanover Road
Florham Park, New York 07932
Brown Boveri Electric, Inc.

Switchgear System Division
Spring House, Pennsylvania 19477
Dowell, Division of Dow Chemical

P. O. Box 2710
Tulsa, Oklahoma 74102
918-250-4200
Facet Enterprises, Inc.

Industrial Division
P. O. Box 50096
Tulsa, Oklahoma 74150
FLC Instruments, Inc.

2055 Comprehensive Drive
Aurora, Illinois 60505
312-851-7665
General Electric Company

Steam Turbine-Generator Engineering
and Manufacturing Department
1 River Road
Schenectady, New York 12345
Halliburton Industrial Services, Inc.

P. O. Box 297
Duncan, Oklahoma 73536
1-800-932-5326
Keene Corporation
Fluid Handling Division
P. O. Box 250
Greenville, Tennessee 37743
Lake Shore Electric Corporation

205 Willis Street
Bedford, Ohio 44146
B-2
Table B-1 (Cont'd)
BUSINESS ORGANIZATIONS FOR LUBRICANT AND

Pall Industrial Hydraulics Corporation

30 Sea Cliff Avenue
Glen Cove, New York 11542
516-671-4000
Semler Industries, Inc.

3800 North Carnation Street
Franklin Park, Illinois 60131
312-671-4970
Special Fluid Products

30903 Ten Mile Road
Farmington Hills, Michigan 48024
Square-D Company
P. O. Box 472
Milwaukee, Wisconsin 53201
Testing Machines, Inc.

400 Bayview Avenue
Amityville, New York 11701
512-842-5400
Utility Power Corporation

Post Office Box 180
Bradenton, Florida 33506
Velcon Filters, Inc.

1750 Rogers Avenue
P. O. Box 6828
San Jose, California 95150
Westinghouse Electric Corporation

The Quadrangle
University Boulevard at Alafaza Trail
Orlando, Florida 32817
Wm. M. Nugent & Company

3440 Cleveland Street
Skokie, Illinois 60076
National Standard Manufacturing, Inc.

P. O. Box 9874
Mobile, Alabama 36609
B-3
Appendix C
ASTM STANDARDS
ASTM has published numerous Standards for test methods, practices, and specifica-
tions (see Table 1-2 in Section 1) through its D-2 Committee on Petroleum Products
and Lubricants.' Most of these Standards pertain to specific methods to determine a
property or characteristic of oil and have been highlighted in Subsection 2.1. Of
particular interest are three other Standards that pertain to designing a lubrica-
tion system, specifying a lubricant, and monitoring a lubricant during use. Since
these Standards are of more general interest, permission was requested and received
by ASTM to include them in their entirety in this Appendix. The following ASTM
Standards are reproduced:
D 4248-83, Standard Practice for Design of Steam Turbine

Generator Oil Systems
D 4304-84, Standard Specification for Mineral Oil Used in

Steam and Gas Turbines
D 4378-84, Standard Practice for In-Service Monitoring of

Mineral Turbine Oils for Steam and Gas Turbines
C-l
Reprinted, with permission from the Annual
Book of ASTM Standards. Copyright ASTM,
1916 Race Street, Philadelphia, PA 19103.
~ t Designation: D 4248 - 83
AMERICAN SOCIETY FOR TESTING AND MATERIALS
An American National Standard
1916 Race St., Philadelphia, Pa. 19103

Reprinted from the Annual Book of ASTM Standards, Copyright ASTM
If not listed in the current combined index, will appear in the next edition.
Standard Practice for

DESIGN OF STEAM TURBINE GENERATOR OIL SYSTEMS 1
This standard is issued under the fixed designation D 4248: the number immediately following the designation indicates the year of
original adoption or. in the case of revision. the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (d indicates an editorial change since the last revision or reapproval.
INTRODUCTION
The ever-increasing size and complexity of steam turbine generators makes the oil system
more important than ever. The system is required to provide not only lubrication but
surface protection. cooling. sealing. and control as well. Failure in anyone of these functions
could result in damage to expensive equipment with loss of system capability and increased
generation costs due to the use of less efficient equipment or the purchase of power through
interconnections.
This practice has resulted from a culmination of the experiences of the turbine builders,
the erectors. the oil suppliers and the operators. Of necessity it is a generalized and minimal
standard. Previous issues of this standard have been used in specifications to aid in obtaining
satisfactory performance of the lubricating oil system.
I. Scope mutually acceptable to the parties concerned.

1.1 This practice is applicable to steam tur- 3.1.2 Installation, cleaning, and flushing will
bine-generator units and provides recommended be facilitated.
practices for the design of the oil system. 3.1.3 Satisfactory system cleanliness can be
1.1.1 The oil system is defined as that assem- maintained.
hly which uses and circulates the turbine-gener- 3.1.4 Safe practices are observed.
ator lubricating oil. The oil system generally in- 4. System Components
cludes high pressure. bearing. control. generator
seal. and drain systems. The system may also 4.1 lv/aleria!s:
include the supply and return lines for a boiler 4.1.1 Steel piping. tubing, valves. fittings, and
feed pump and hydraulic coupling. fabrication piates are acceptable and recom-
mended. The use of catalytic and corrodible ma-
2. Applicable Document terials such as copper, zinc. and lead should be
2.1 ASAIE Standard: minimized and if used they should be properly
LOS-I M Recom mended Practice for the I This practice is under the jurisdiction of ASTM Committee
Cleaning. Flushing. and Purification of D-2 on Petroleum Products and Lubricants and is the direct
Steam and Gas Turbine Lubrication responsibility of Subcommittee D02.DC on Turbine Oils.
All previous recommended practices have been published by
Systems:! ASME as joint ASTM-ASME-NEMA standards. With the issu-
ance of this document all standards under the auspices of
3. Significance and lise Suhcommittee C ofASTM Committee D-2 will be published by
ASTM as ASTM standards. This standard replaces ASME
3.1 The purpose of this guide for turbine gen- Standard Practice No. 116.
erator oil systems is to ensure that: Current edition approved April 29. 1983. Published August
1983.
3.1.1 Lubrication. control. and sealing will be :! Available from ASME. 345 E. 47th St.. ;\lew York. N. Y.
performed satisfactorily by the oil in a manner 10017.
C-2
04248
alloyed. Bearing linings should be made of tin 4.2.5.2 The pump motor overloads shall not
base babbitt. trip the motor breaker. The overload shall only
4.1.2 All materials used in system construc- provide a warning.
tion including gaskets. seals. diaphragms. interior 4.2.6 Several application requirements must
permanent type surface coatings, and hoses be considered for proper pump functioning.
should be resistant to turbine oils and maintain 4.2.6.1 The main shaft driven pump must
adequate physical and chemical properties at the have adequate suction conditions to provide un-
maximum expected operating temperatures and interrupted supply of oil. Pumps shall be pro-
service life. vided with a positive suction.
4.2 Pumps: 4.2.6.2 Pump suctions shall be below the min-
4.2.1 Pumps must circulate lubricating oil imum reservoir operating level. The exact sub-
from the reservoir to the bearings. controls, and mergence will be determined by the pump suc-
other points of use. The pressure level must be tion requirements including the consideration of
high enough to ensure proper distribution and air entrainment in the pump suction. In many
satisfy control functions. cases the pump suction is at least 150 mm (6 in.)
4.2.1.1 Satisfactory circulation and pressure below the minimum operating level.
levels must be provided for start-up, operation, 4.2.6.3 The auxiliary and emergency pumps
and shut down. shall be submerged with their suction below the
4.2.2 Several commonly used pumps are de:- minimum reservoir operating level.
fined as follows: 4.2.6.4 The emergency pump suction shall be
4.2.2.1 The main pump normally supplies the lower than other pumps so that with the loss of
oil circulation and pressure for the steam turbine oil in the reservoir. shut down oil would still be
generator operation. available.
4.2.2.2 The auxiliary pump is sized to permit 4.2.6.5 Coarse strainers should be provided in
continued operation if the main pump fails. the suction system of all pumps.
4.2.2.3 The emergency pump is of reduced 4.2.7 Pump suctions should be at least 150
capacity. Its function is to pFovide last resort mm (6 in.) from the bottom of the reservoir.
lubrication for coastdown, should the other 4.2.8 The pump suction is defined as starting
pumping fail. at the solid fluid conveyance to the pump inlet.
4.2.2.4 Many combinations of pumps can be Normally this begins at attachment ofthe suction
satisfactory. As a minimurn these should be two strainer to the pump inlet or to the pump suction
pumps driven from two independent and differ- pipe.
ent power sources. Thus, no single incident or 4.3 Reservoirs:
p;quipment failure can cause loss of pumping. 4.3.1 The capacity of the reservoir should be
(a) An exception may be made to the two sufficient to hold the sum of the operating oil
pump recommendation if the turbine generator volume contained within the normal operating
can survive shut-downs without oil circulation. range plus the volume that will drain from the
4.2.3 Examples of these pump drive combi- remainder of the system when the turbine gen-
nations are listed as follows: erator unit is shutdown.
Main Auxiliary Emergency 4.3.2 To allow for the separation of entrained
shaft a-C motor d-C motor air and the settling by gravity of water and solid
shaft none a-C Id-C motor contaminants the normal operating oil volume
shaft a-C motor turbine should not be less than five times the tlow per
a-C motor none d-C motor
minute to the bearings.
4.2.4 The auxiliary and emergency pump 4.3.3 A drain connection should be provided
drivers shall be sized for adequate capacity when at the lowest point on the reservoir. A shut off
operating with the oil viscosity corresponding to valve should be located in the drain near the
the minimum temperature for start-up. reservoir. To avoid accidental draining of the oil,
4.2.5 Control of the auxiliary and emergency the valve should be locked closed or have a blank
pump drivers can significantly affect reliability. in the drain line immediately downstream.
4.2.5.1 The auxiliary and emergency pump 4.3.4 The bottom of the reservoir should slope
drive controls shall provide for automatic starting towards the drain connection. On rectangular
and in-service testing. reservoirs the slope should be 40 mm/m (~ in./
C-3
04248
ft) or greater. 4.3.16 Strainers for the main-bearing oil re-

4.3.5 Connections for the oil purification sys- turn to the reservoir can be provided for the
tem should be provided. The supply should be removal of solids. Strainer openings should not
so located that oil is taken from as close as exceed 0.6 mm (0.025 in.). Means for removal.
possible to the reservoir bottom. Both the supply inspection, and cleaning of the strainers while
and return connections should be arranged and the turbine is in operation should be provided.
located so that siphoning of the reservoir below These may not be necessary especially when full
a safe level is not possible. flow filtration is provided.
4.3.6 Oil reservoir connections for major 4.4 Piping:
drain lines from bearings should be as far from 4.4.1 The soil system piping should be de-
the pump suction as practical or baffled to pre- signed so that the requirements in ASME Stand-
vent return oil from flowing directly to pump ard LOS-l M can be followed.
suction, thereby providing a maximum oil rest 4.4.2 Welded or flanged and bolted joint con-
period. Drains should be arranged to provide for struction should be used for all oil piping. When
maximum deaeration and minimum oil agita- screwed or threaded fittings are used they should
tion. be guarded within a housing or pipe or seal
4.3.7 A method for oil level determination welded.
should be provided. 4.4.3 Pipe joints. field welds and bends should
4.3.8 The discharge of relief valves should be be minimized commensurate with shipping, erec-
at least 150 mm (6 in.) below the operating oil tion and cleaning requirements.
level. 4.4.4 When butt welds are made with backing
4.3.9 A vapor extractor connected to the high- rings. the rings should be carefully fitted to min-
est point of the reservoir should be provided for imize the gap between the ring and pipe. If butt
the removal of gases and vapors. Internal baffles welds are made without backing rings, care must
should have openings above the oil level to equal- be taken to minimize the weld splatter on the
ize the vacuum within the reservoir. The vacuum inside of the pipe. If necessary to assure a clean
produced in the bearing housings should not weld. the inside of the pipe should be ground or
average more than approximately 0.5 KPa (2 in. back welded when accessible.
water) to minimize the entrance of atmospheric 4.4.5 The inside surface of all pressure and
contaminants into the oil system. drain piping should be cleaned and coated with
4.3.10 The interior surfaces wherever possible an oil soluble rust preventive. The outside surface
should be protected by a permanent type, oil of the pressure piping contained within an oil
resistant surface coating unless a corrosion resist- transmitting guard pipe and the inside surface of
ant metal is used. oil transmitting guiard pipes should be cleaned
4.3.11 The entire inside of the reservoir and coated with a permanent type rust preventive
should be accessible. or an oil soluble rust preventive.
4.3.12 For hydrogen cooled generator appli- 4.4.6 The drain and ventilation system should
cation. the reservoir should contain an explosion be designed to assure atmospheric pressure or
door capable of maintaining the reservoir inter- less in all bearing housings. When drain lines are
nal pressure at a safe le~el at all times. This used for systeln ventilation, they should be sized
explosion door may serve as an access door. and pitched to maintain adequate air space above
4.3.13 All connections and openings should the normal steady state oil level at all points. If
be sealed to minimize air leakage and the en- low loops cannot be avoided in the piping drain
trance of atmospheric contaminants into the res- system. supplementary vents and means for
ervoir. drainage during shutdown should be provided.
4.3.14 The reservoir should be located such 4.4.7 For hydrogen cooled generator applica-
that the entire oil system external to the reservoir tion. the generator drain piping system should be
can drain. by gravity. into the reservoir. separated from the turbine drain system and
4.3.15 Pumps and ejectors located inside the main oil reservoir by a loop seal to minimize the
reservoir should be so located that the inlet is system volume subject to possible hydrogen con-
completely submerged at all times but no less tamination. A vent to atmosphere should be
than 150 mm (6 in.) from the reservoir bottom. provided on the generator side of the loop seal
C-4
04248
with a vapor extractor if necessary to maintain a with the lube oil system requirements including
vacuum in the generator bearing housings. the operating pressure and temperature.
4.4.8 Vents to atmosphere and discharge lines 4.6.2.1 A nominal element rating of 25 Jlm or
from vapor extractors should be routed to a safe finer is suggested.
location for the possible discharge of hydrogen 4.6.2.2 The element pressure drop shall not
and oil vapors. significantly increase with as much as 10 % water
4.4.9 The piping system should be designed in the oil.
to: NOTE-Do not interpret this as condoning unit op-
4.4.9.1 Minimize local heating from external eration with this much water in the oil.
sources such as turbine shells or casings, steam 4.6.2.3 Filter pressure drop with the start-up
pipes, and induced heating from buss ducts. viscosity shall be within the system capabilities.
4.4.9.2 Withstand vibration by adequate brac- 4.6.2.4 Filter case drains should be provided.
ing and contain adequate flexibility to account
4.6.2.5 Provisions should be made for remov-
for the thermal expansion of the unit. ing air that may be trapped in the filter.
4.4.9.3 Avoid contamination of the conden-
4.7 Instruments:
sate system. 4.7.1 Provision should be made for determin-
4.4.9.4 Minimize potential fire hazards by ing oil temperatures 3.t each bearing discharge
providing guards or barnes to prevent oil from
and at the oil cooler inlet and outlet. Welded or
contacting high-temperature surfaces. threaded and seal welded thermometer and ther-
4.5 Coolers: mocouple wells should be used if located in pres-
4.5.1 The oil coolers should be located so that sure lines or below the oil level in drain lines.
the tube bundle removal will be possible. 4.7.2 Provision should be made for determin-
4.5.2 If the location of the cooler does not ing the significant operating pressure of the oil
permit gravity drain to the reservoir, means for
system.
draining the oil side of the cooler during shut- 4.7.3 All unguarded gage lines should be pro-
down should be provided. vided with shutoff valves and orifices near the
4.5.3 Vent connections should be provided on
source connection.
the coolers to permit continual air removal.
4.5.4 When dual coolers are used, the three- S. General
way change over valve should be designed so that 5.1 All valves capable of draining the oil sys-
oil flow will not be interrupted when transferring tem should be locked or blanked downstream
from one cooler to the other. when not in use.
4.5.5 Separate gaSkets or seals with provision 5.2 All flange joint bolting should be secured
for an intermediate tell-tale to indicate leakage with an appropriate locking means.
should be provided fer the water and oil side of 5.3 All bearing oil drains are to be provided
the coolers. with an accessible oil flow observation point.
4.6 Filters: 5.4 Storage facilities should be provided for
4.6.1 Full-flow or by-pass filtration is recom- the oil when drained from the system.
mended to reduce the contamination level of the 5.5 Consideration should be given to the pro-
lubricating oil system. tection of electrical devices and wiring that may
4.6.2 The filter shall be designed compatible be exposed to oil vapors.
TIle ,4.merican Socierr/or Testing and ,\faterials takes no {'osition respecting rhe validity l?lany patent ri~hts asserted in connection
1\ illt anr item mt!ntiont!d in thiS standard. esers of this standard are expresslv advised lhat determination of the validitv o(am: such
pa/em ;ighIS. I.md the n.~k l?(tntringement I)(sllch nghts. are t!nllrt!ly therr o~:n responsibility. . .'.
This standard is suhjt!ctto re\'ision at anr time h.1' the resJ'onsihle technical committt!e and must he reviewed el'er.l'Jive years and
It" not re\ised. either reapprO\'ed or I\'ithdral\'n, Your commt?nts art! invited t!ither for rerision of this standard or far additional
.\wndtlrds and should he addressed to .4.ST.\/ Headquarters, Your comments \\'11/ recei..'e care.fiti ~'onsideration at a meeting of fhe
responsihle lechmcal committee, ~'hich you may attend. ~f'.Wli feel lhat . . our comments ha.. .e iwt received a fair hearing you should
make ,l'Ollr l'leu's known to rht! .,:ST.H Commillt!l.' on Standards. 19/6 Race St.. Philadt!lphia. Pa, 19103.
c-s
~ mt1 Designation: D 4304 - 84
Standard Specification for

MINERAL LUBRICATING OIL USED IN STEAM OR GAS
TURBINES 1
T~i~ standard .is issue~ under the ~xed. designation 04304: the .n.umber immedi~tely following the designation indicates the year of
ongmal ad?puon. or. In t~e ~ase ot revls~on: the year o~ last revISIon. A number In parentheses indicates the year of last reapproval
A superscnpt epsIlon (E) indIcates an edltonal change SInce the last revision or reapproval. .
1. Scope acteristics of Steam Turbine Oil in the Pres-

1.1 This specification covers mineral oils used ellce of Water
in steam and gas turbine lubrication systems D 892 Test Method for Foaming Characteris-
where the performance requirements demand a tics of Lubricating Oils1
highly refined mineral base oil compounded with D 941 Test Method Density and Specific Grav-
rust and oxidation inhibitors plus selected addi- ity of Liquids by Lipkin Bicapillarv
tives as needed to control foam. wear. demulsi- Pycnometer .
bility. etc. D943 Test Method for Oxidation Character-
1.2 This specification is intended to define the istics of Inhibited Steam-Turbine Oils2
properties of mineral oil based turbine lubricat- D974 Test Method for Neutralization Num-
ing oils that are functionally interchangeable with ber by Color Indicator Titration 2
existing oils of this type. and are compatible with D 1401 Test Method for Emulsion Character-
most existing machinery components and. with istics of Petroleum Oils and Synthetic
Fluids1 .
appropriate field maintenance. will maintain
their functional characteristics. D 1947 Test Method for Load Carrying Ca-
1.3 This specification is intended to define pacity of Fluid Gear Lubricants3
only new lubricating oil before it is installed in D 2272 Test Method for Oxidation Stability of
the machinery. Steam Turbine Oil by Rotating Bomb 3
1.4 This specification is intended to be used D 2422 Practice for Viscosity System for In-
as a guide. It is possible that oils that do not meet dustrial Fluid Lubricants3
this specification may perform satisfactorily in D 3339 Test Method for Total Acid Number
some turbines. There may be exceptions to spe- of Petroleum Products by Semi-Micro Color
cific items which may be required and agreed Indicator Titration 4
upon between the user and supplier. D 4057 Practice for Manual Sampling of Pe-
troleum and Petroleum Products4
2. Applicable Documents F 3 1I Method for Processing Aerospace Liq-
2.1 AST.\4 Standards: uid Samples for Particulate Contamination
D92 Test Method for Flash and Fire Points Analysis Using Membrane Filters S
by Cleveland Open CUp1 F 3 12 Methods for Microscopical Sizing and
D 97 Test Method for Pour Point of Petroleum Counting Particles from Aerospace Fluids
Oils2 1 This specification is under the jurisdiction of ASTM Com-
D 130 Test Method for Detection of Copper mittee 0-2 on Petroleum Products and Lubncants and is the
direct responsibility of Subcommittee D02.C on Turbine Oils.
Corrosion from Petroleum Products bv the Current edition approved Jan. 3. 1984. Published Februarv
Copper Strip Tarnish Test 2 1984. .
D 445 Test Method for Kinematic Viscosity of 2 Annual Book ofASTJf Standards. Vol 05.01.
J .i.nnual Book o(AST.H Standards. Vol 05.02.
Transparent and Opaque Liquids2
4 .~nnual Bvok v(ASTJI Standards. Vol 05.03.
D665 Test Method for Rust Preventing Char- S Annual Book vIA.ST.W Standards. Vol 15.03.
C-6
04304
on Membrane Filterss 3.3 Functional Properties-Those properties

F 313 Test Method for Insoluble Contamina- of the mineral lubricating oil which are required
tion of Hydraulic Fluids by Gravimetric for the design. manufacture. and operation of the
AnalysisS machinery. The equipment manufacturers and
users may have some special requirements. These
3. Definitions properties are listed in Section 5.
3.1 Type I .\lineral Oils-Oils for steam and
gas turbine lubricating systems where the ma- 4. Sampling and Testing
chine~' does no! require lubricants with en- 4.1 Salnpling-Generally. take all oil samples
hanced load carrying capacity. Such oils nor- in accordance with Practice D 4057.
mally contain rust and oxidation inhibitors plus 4.2 Salnpling-Contractual arrangements
other additives as needed to meet the specified will define the point of sampling.
performance characteristics. Type I oils usually 4.3 Use the ASTM and other test methods
are available in ISO-VG 32. 46. 68. and 100 (see described in Section 5.
Practice D 2422).
3.2 Type 11 .\1ineral Oils-Oils for steam and 5. Functional Property Requirements
gas turbine lubricating systems where the ma- 5.1 Mineral lubricating oils conforming to the
chinery requires enhanced load carrying capac- specification shall meet the functional property
ity. These oils are similar to Type I and are limits specified in the following sections and
typically used in marine turbines. Such oils con- tables. The significance of these properties is
tain rust and oxidation inhibitors. plus mild ex- discussed in Appendix XI.
treme pressure (EP) additives and other additives 5.2 Requirements for Type I oils are shown
as needed to meet the specified performance in Table 1.
characteristics. Type II oils usually are available 5.3 Requirements for Type II oils are shown
in ISO-VG 68. 100. and 150. in Table 2.
C-7
~mtt 04304
TABLE 1 Requirements for Type I Turbine Oils
NOTE-The nature of some tests are such that they are not necessarily run on each batch. The values are representative.
ASTM Test
Property Limits
Method
Physical:
ISO-viscosity grade 02422 32 46 68 100
Rash point. Co min 092 180 180 180 180
Pour point. C. max 097 A -5 -5 -5 -5
Viscosity. cSt (mm 2 /s) 4OC 0445 28.8-35.2 41.4-50.6 61.2-74.8 90-110
Visual examination at :WC clear and bright
Chemical:
Total Acid Number. MgKOH/g. max 09748 report report report report
Performance:
Emulsion characteristics: 01401
at 54-C minutes to 3 mL emulsion. max 30 30 30
at 8Z-C minutes to 3 mL emulsion. max 30
Foaming characteristics: 0892
Sequence I. tendency/stability, mL, max 400/0 400/0 400/0 400/0
Rust preventing characteristics 0665A Pass Pass Pass Pass
Copper corrosion. 3 hat 100tC. max 0130 1 1 1 1
Oxidation stabilityC
Hours to neut. No. 2.0. min 0943 2000 2000 1500 1000
Minutes to 175 kPa drop. min 02272 200 200 175 ISO
OeanlinessD:
Gravimetric. mg/l00 mL max 0.8 micrometer F313 3.0 3.0 3.0 5.0
filter porosity
A Lower pour point may be required for some applications.
BTest Method 03339 may be used as an alternative method.
cTest MethcJ 0943 is the accepted test method for oxidation stability of new steam turbine oils in the USA and Canada. It is
- recognized that Test Method 0943 is a lengthy procedure. Thus. 02272 is a suggested shorter test for quality control. See Appendix
X3.1.5 for significance of Test Method 02272.
DCleanliness of the oil may also be described by either the microscopic particle count. or the electronic particle count methods
by mutual agreement between the purchaser and the seller. Point and time of sampling for any of the methods are subject to
negotiation between purchaser and seller. The agreed upon cleanliness is intended to apply at the time of delivery. The cleanliness
limits are meant to be only representative of good workmanship in manufacture and as general practice the oil must be filtered
prior to its installation in the equipment according to the equipment manufacturer's recommendations.
C-8
~t 04304
TABLE 2 Requirements for Type II Turbine Oils
NOTE-The nature of some tests are such that they are not necessarily run on each batch.
Property ASTM Test Method Limits
Physical:
ISO-viscosity grade 02422 68 100 150
Flash point. 0c, min 092 180 180 210
Pour point. 0c, max DenA -5 -5 -5
Viscosity. cSt. 40C (mm 2/s) 0445 61.2-74,8 90-110 135-165
Visual examination at 20C clear and bright
Chemical:
Total Acid Number. mg KOH/g. max 09748 report report report
Performance:
Emulsion characteristics: 01401
at 54C. minutes to 3 mL emulsion. max 30
at 82C. minutes to 3 mL emulsion. max 30 60
Foaming characteristics: 0892
Sequence I. tendency/stability. mL. max 400/0 400/0 400/0
Rust preventing characteristics 0665B pass pass pass
Copper corrosion. 3 hat 10<tC. max 0130 1 1 1
Oxidation stabilityC
Hours to neut. No. 2.0. min 0943 1500 1000 1000
Minutes to 175 kPa drop, min 02272 175 150 150
Load carrying ability
kN/m of face. min 01947 385 385 385
CleanlinessD :
Gravimetric. mg/IOO mL. max 0.8 J.1m filter poros- F313 3.0 5.0 5.0
it~
A Lower pour point may be' required for some applications.

BTest Method 03339 rna\' be used as alternative method.
CTest Method 0943 is th~ accepted test method for oxidation stability of new steam turbine oils in the USA and Canada. It is
recogmzed that Test Method 0943 is a lengthy procedure. Thus, Test Method 02272 is a suggested shorter test for quality control.
See Appendix X3.1.5 for significance of Test Method 02272.
DCleanliness of the oil may also be described by either the microscopic particle count. or the electronic particle count method~
by mutual agreement between the purchaser and the seller. Point and time of sampling for any of the methods subject to negotiation
between purchaser and seller, The agreed upon deanliness is intended to apply at the time of delivery. The cleanliness limits are
meant to be only representative of good workmanship in manufacture and as general practice the oil must be filtered prior to its
installation in the equipment according to the equipment manufacturer's recommendations.
By agreement between the supplier and the user, load carrymg ability of the oil may also be described by the FZG ::::: OJ]\; in
51354 procedure (A/8.3/90C) for which a minimum failure stage of eight for all viscosity grades is recommended.
APPENDIX
(Nonmandatory Information)
XI. SIGNIFICANCE OF FUNCTIONAL PROPERTIES OF TURBINE OILS
X1.1 Physical Properties and the flammability of these volatiles. This is mainly
of value as a quality'control test. .
X 1.1.1 ISO- Viscositv Grade Test MeThod D 2422- X 1.1.3 Pou.r Paint Test Method D 97-The pour
The International Standards Organization has estab- point is an indication of the lowest temperature at
lished a viscosity classification system for industrial which the oil will flow from a container. In application
fluid lubricants. Such lubricants are classified by grades to a lubrication system. limiting low temperature levels
designated as ISO-VG based on their viscosities in are established corresponding to maximum viscosity
centistokes at 40C. The choice of viscosity grade for for proper circulation.
use in a particular turbine should comply with the X 1.1.4 l'isCOSll1; Test Method D 445-The viscositv
turbine manufacturer's recommendations. Deviations of a turbine oil determines its ability to flow in a
must be agreed upon between the manufacturer and lubrication system and. to support bearing loads. trans-
the purchaser. fer heat. and operate hydraulic controls.
X 1.1.2 Flash Poim Test A1ethod D 92-Flash point XI. i.5 Visual Examination-In the manufacture.
is the temperature at which the fluid contained in a test distribution. and use of turbine oils. fresh oils should
cup and heated at a constant rate will flash but not be examined for appearance and clarity compared to a
continue to burn when a flame is passed over the cup. standard reference sample or as agreed upon by both
It is indirectly a measure of both the volatility of the oil parties.
C-9
04304
X2.1 Chemical Properties this method. other signs ofdeterioration. such as slUdge
X2.l.l Total Acid Number Test Method D974- formation or catalyst coil corrosion. may appear which
The total acid number is the milligrams of potassium are not reflected in the calculated oxidation lifetime.
hydroxide (KOH) required to neut~~~ the ~cidic con- The committee responsible for this method is investi_
stituents in a gram of sample. The InItial aCId number gating the application ofalternate criteria for evaluation
is influenced by functional additives which are usually of lubricants using this test method....
mildly acidic.
In Test Method 02272, the test oil. water, and copper
X3.1 Performance Properties catalyst coil. contained in a covered glass container, are
placed in a bomb equipped with a pressure gage. The
X3.l.l Emulsion Characteristics Test .Method bomb is charged with oxygen to a pressure of 90 psi
D 140 I-This test is used to measure the ability of an (620 kPa), placed in a constant-temperature oil bath set
oil to separate gross amounts of water (50%). at 150C. and rotated axially at 100 rpm at an angle of
X3.1.2 Foaming Characteristics Test Jfetho~ 30 from the horizontal. The time for the test oil to
D 892-In oil systems having high circulation rates. It react with a given volume of oxygen is measured.
is important that the oil release air readily from the completion of the time being indicated by a specific
body of the fluid and that such air not collect as ~ubbles drop in pressure. This test method includes the follow.
on the surface of the fluid as this lowers the 011 level ing statements:
and impedes circulation. Foam is not a good lubricant. "'This method covers a rapid means for estimating the
X3.1.3 Rust Preventive Characteristics Test Jfethod oxidation stability of new turbine oils having the same
D 665-This test or its alternative measures the ability composition (base stock and additives). This stability
of an oil to prevent rusting of a polished steel surface estimation is useful in controlling the continuity of this
when the surface is wet with oil and the oil has been property from shipment to shipment. The method is
agitated with a given quantity of either distilled (Test also used to assess the remaining oxidation test life of
Method 0665 Procedure A) or synthetic sea water such oils from service....
(Test Method 0665 Procedure B). It is an indication
of rust protection of the oil wetted surfaces. . ""It is not intended that this method be used to estimate
X3.1.4 Copper Corrosion Test Method D 130-ThIS the service life of new oils, especially those of varying
test indicates the relative tendency of turbine oils to compositions. Furthermore. it is not intended that this
corrode copper and copper alloys which may be present method be a substitution or a replacement for Test
in the lubrication system. (The use ofcopper and copper Method 0943. Test for Oxidation Characteristics of
allovs in contact with mineral oil base lubricants is to Inhibited Steam-Turbine Oils. or a rapid means of
be discouraged.) estimating the results to be obtained from Test Method
X3.1.5 Oxidation Stability-Several laboratory 0943....
tests are used to indicate oxidation stability of mineral
oils. and there is a continuing search to correlate these The correlation of oxidation laboratory test results with
test results with field experience. The tests referenced field service is a difficult one. The tests used and the
in this document are Test Methods 0943 and 02272. values given in this specification are a representation of
Test Method 0943 reports the time in hours for the the present state of the art.
acidity to reach 2.0 mg of po~ium hy~~oxide per X3.1.6 Cleanliness Test ,Method F 313-There are
gram of sample in a sample of 011 contaImn~ w~ter. several recommended standards for lubrication system
steel. and copper wire coiled together and maIntal~ed cleanliness published by technical societies and equip-
at a temperature of 95C (203F) with oxyge~ passIng ment manufacturers.
through. This test method includes the followl~g s~te X3.1.6.l As is stated in the table notes. several meth-
ments: "This method is widely used for specIficatIon ods of measurement are available: and the choice is
purposes and is considere~ of value in. estimating the between the seller and the purchaser to agree upon.
oxidation stability of lubncants. especIally those that Beyond the gravimetric method is the microscopic par-
are prone to water contamination. ~ ticle count and the electronic particle count.
""It should be recognized. however. that correlation X3.1.7 Load Carrying Ability Test .Method
between results of this method and the oxidation sta- D 1947-The test method measures the load carrying
bility of a lubricant in field service may vaIY: markedl~ abilitv of a turbine oil in a four square-type gear rig. It
with field service conditions and with vanous lubn- emplovs step-type loading until a predetennined level
cants.... of wea~ or gear scuffing appears. FZG A/83/90C is an
alternative test procedure agreed upon between the
"'Furthermore, in the course of testing a lubricant by supplier and the user.
The A.merican Society for Testing and Jfaterials takes no position respecting the ~'aiidit..... ofany p~ten~ rights assert~~ in conn~ction
.....ith anv item mentioned in this standard. C./sers ofthis standard are express!.",' adVised ~h':l~ determmatlOn ofthe validity ofan.'" such
patent ;ights. and the risk ofinfringement of such Tights. are entirely their own responslbliuy.
This standard is subject to revision at any time by the responsible technical commi!tee and must be .reviewed every five yea~s. and
if ot revised either reapproved or withdra.....n. Your comments are mvued either jor revision of thiS standard or for addmo.nal
~ta:dards and should be addressed to AST.W Headquarte:s. Your comments will receive careful con~ideraJio~ aJ a r.nee~ing oj the
responSible technical committee. which you may attend. lj you feel that your comm.ents ha~e not received a fair hearmg you should
make your \'iews known to the AST.V Committee on Slandards. /9/6 Race SI.. Philadelphia. Pa. 19J03.
C-IO
~~ Designation: 04378 - 84 An AnwtcIn NdanIf ~
AMERICAN SOCIETY FOR TESTING ANO MATERIALS

191E Race St., Philadelphia, Pa. 19103
Reprinted from the Annual Book of ASTM Standards, Copyright ASTM
If not listed in the current combined index, will appear in the next edition.
Standard Practice for

IN-SERVICE MONITORING OF MINERAL TURBINE OILS
FOR STEAM AND GAS TURBINES 1
This standard is issued under the fixed designation 04378; the number immediately following the designation iDdiClteS the year of
original adoption or, in the case of revisi~ the year of last revision. A Dumber in parentheses indicates the year of last aupprovaL
A supencript epsilon (f) iDdicates aD editoria1 cbanse since the last revision reapproval.
INTRODUcnON
The in-service monitoring of turbine oils has long been recognized by the power-
generation industry as being necessary to ensure long trouble-free operation of turbines.
The two main types of stationary turbines u;Sed for power generation are steam and gas
turbines. The lubrication requirements are quite similar but there are important differences
in that gas turbine oils are subjected to significantly higher localized "hot spot" temperatures
and water contamination is less likely. Steam turbine oils are normally expected to last for
many years. In some turbines up to 20 years of service life has been obtained. Gas turbine
oils by comparison have a shorter service life. Many of the monitoring tests used for steam
turbine oils are applicable to gas turbine oils.
This practice is designed to assist the user to understand how oils deteriorate and to carry
out a meaningful program of sampling and testing of oils in use. Also covered are some
important aspects of interpretation of results and suggested action steps so as to maximize
service life.
1. Scope D 130 Test Method for Detection of Copper

1.1 This practice covers the requirements for Corrosion from Petroleum Products by the
the effective monitoring of mineral turbine oils Copper Strip Tarnish Tesr
in service in steam and gas turbines used for D445 Test Method for Kinematic Viscosity of
power generation. It includes sampling and test- Transparent and Opaque Liquids (and the
ing schedules and recommended action steps, as Calculation of Dynamic Viscosityf
well as information on how oils degrade. D664 Test Method for Neutralization Num-
1.2 This standard may involve hazardous ma- ber by Potentiometric Titration2
terials, operations, and equipment. This standard D665 Test Method for Rust-Preventing Char-
does not purport to address all ofthe safety prob- acteristics of Inhibited Mineral Oil in the
lems associated with its use. It is the responsibil- Presence ofWater2
ity of whoever uses this standard to consult and D892 Test Method for Foaming Characteris-
establish appropriate safety and health practices tics of Lubricating 0ils2
and determine the applicability ofregulatory limi- D943 Test Method for Oxidation Character-
tations prior to use.
I This practice is under the jurisdiction ofASTM Committee
2. Applicable Documents
0-2 on PeuoIeum Products and Lubricants and is the direct
2.1 ASTM Standards: respoasibility of Subcommittee D02.C OD Turbine Oils.
Current editiOD approved June 29, 1984. Published August
D 92 Test Method for Rash and Fire Points 1984.
by Oeveland Open CUlT 2 AMutU Book of ASTM Standards.. Vol OS.O 1.
C-ll
04378
istics of Inhibited Mineral Oils2 properties cannot be expected to remain un-

0974 Test Method for Neutralization Num- changed during the life of the oil. Some deterio-
ber by Color-Indicator Titration2 ration can be tolerated without prejudice to the
o 1298 Test Method for Density, Relative safety or efficiency of the system. Frequently
Density (Specific Gravity), or API Gravity reinhibition will improve some property of the
of Crude Petroleum and Liquid Petroleum oil. Good monitoring procedures are necessary
Products by Hydrometer Method2 to determine when the properties have changed
01401 Test Method for Emulsion Character- sufficiently to warrant corrective action.
istics of Petroleum Oils and Synthetic 5. Operational Factors Affecting Service Life
Aui<fs2
01500 Test Method for ASTM Color of Pe- 5.1 The factors that affect the service life of
troleum Products (ASTM Color Scalef turbine lubricating oils are as follows: (1) type
D 2272 Test Method for Continuity of Steam- and design of syst~ (2) condition of system on
Turbine Oil Oxidation Stability by Rotating startup, (3) original oil quality, (4) system oper-
Bomb3 ating conditions, (5) contamination, and (6)
D4057 Practice for Manual Sampling of Pe- oil make-up rate.
troleum and Petroleum Products" 5.1.1 Type and Design ofSystem-Most mod-
04241 Practice for Design of Gas Turbine ern turbine lubricating systems are similar in
Generator Lubricating Oil Systems4 desi~ especially for the larger units. For lubri-
04248 Practice for Design of Steam Turbine cation, the usual practice is to pressure-feed oil
Generator Oil Systems4 directly from the main oil pump. The rest of the
F 311 Practice for Processing Aerospace Liq- system consists of a reservoir, oil cooler, strainer,
uid Samples for Particulate Contamination piping and additional purification or filtration
Analysis Using Membrane Fl1tersS equipment, or a combination thereof. Miscella-
F 312 Methods for Microscopical Sizing and neous control and indicating equipment com-
Counting Particles from Aerospace fluids pletes the system. If there is an opportunity to
on Membrane Futers' participate in system design, it is recommended
2.2 ASME Standard: that appropriate practices be consulted (see Prac-
LOS-IM- Recommended Practice for Qean- tices 04241 and Practice D 4248).
ing, Flushing, and Purification ofSteam and 5.1.2 Condition ofSystem on Stanup:
Gas Turbine Lubrication Systems6 5.1.2.1 The individual components of a lubri-
2.3 National Aerospace Standard 16387 cation system are usually delivered on-site before
the system is installed. The length of on-site
3. Significmce aDd Use storage and means taken to preserve the integrity
ofthe intended oil wetted surfaces will determine
3.1 This practice is intended to assist the user,
the total amount of contamination introduced
in particular the power-plant operator, to main-
during this period, the magnitude of the task of
tain effective lubrication ofall parts ofthe turbine
cleaning and flushing prior to use, and the det-
and guard against the onset of problems associ-
rimental effects of the contaminants. Similarly,
ated with oil degradation and contamination.
during installation, the more attention paid to
maintaining system integrity, the less contami-
4. Properties of Turbine Oils
nation. ASME Standard LOS-l M provides guid-
4.1 Most turbine oils consist of a highly re- ance on this.
fined paraffinic mineral oil compounded with 5.1.2.2 Turbine oil system contamination
oxidation and rust inhibitors. Depending upon prior to startup usually consists of preservatives,
the performance level desired, small amounts of paint, rust particles, and the various solids en-
other additives such as metal deactivators, pour countered during construction which can range
depressants, and foam suppressants may also be
present. 3 Annual Book ofASTM Slllndtuds~ Vol 05.02.
4 Annwzl BooIc ofASTM Sltzndtu~ Vol 05.03.
4.2 New turbine oils should exhibit good re- S Annual Book ofASTM SlJzndtu4 Vol 15.03.
sistance to oxidation, low tendency to sludge A vail3ble from ASME;. 345 East 47th S~ New York. NY
10017.
formation and adequate antirust, demulsibility, 7 Av3ilable from Aerospace IDdusbies Association of Amer-
and nonfoaming properties. However, these Inc.~ 1725 De Sales St.~ N.W.~ Washingtou. DC.
ica,.
C-12
04378
from dust and dirt to rags, bottles, and cans. Practice. Once attained, the danger of external
Their effect on turbine oil systems is obvious. contamination is less but should be guarded
5.1.3 Original Oil Quality: against. The oil may be contaminated by the
5.1.3.1 Use of a high-quality oil is the best introduction of different type oils which are of
assurance of potentially long service life. Oils the wrong type or are incompatible with the
meeting recognized standards are generally avail- system oil. The oil supplier or the turbine man-
able, and one that at least meets the requirementsufacturer, or both, should be consulted before
of the turbine manufacturer shall be used. additions are made.
5.1.3.2 It is advisable to obtain typical test 5.1.5.2 External contamination may enter the
data from the oil supplier. Upon receipt of the system through bearing seals and vents. Internal
first oil charge, a sample of oil should be takencontaminants are always being generated. From
to confirm the typical test data and to use as a whatever source, contamination must be dealt
base line for future comparisons with used oil with by monitoring oil condition and the use of
information. This is most important! Recom- purification devices such as filters and centrifuges
mended tests for new oil are given in the sched- on a regular basis. Such contaminants include
ules of this practice (see Tables 1 and 2). water, metal wear particles, and oil degradation
5.1.3.3 When new turbine oil is to be mIxed products. All of these can be effectively removed
with a charge of a different composition prior by properly desi,gned filters or centrifuges, or
checks should be made to ensure no loss of both.
expected properties due to incompatibility. These 5.1.6 Oil Make-up Rate-The amount and
should include functional tests and checks for frequency of make-up oil added to the system
formation of insolubles. sometimes plays a very significant part in deter-
5.1.4 System Operating Conditions: mining the life of a system oil charge. Make-up
5.1.4.1 The most important factors affecting varies from below 5 % per year to as much as
30 % in extreme cases. In turbines where make-
the anticipated service life of a given lubricating
oil in a given turbine system are the operating up is relatively high compared to the oil degra-
conditions within the system. Air (oxygen), ele- dation rate, the degree of degradation is compen-
vated temperatures, metals and water are always sated for and long oil life can be expected. In
present to some extent in these oil systems. Theseturbines where the make-up is very low (below
elments promote oil degradation. 5 %), a truer picture of oil degradation is ob-
5.1.4.2 Most turbine oil systems are provided tained. However, such a system should be care-
with oil coolers to control temperature. In many fully watched since the oil life is dependent al-
cases, bulk oil temperatures are maintained so most exclusively on its original quality. In the
low [below 60C (140F)] that moisture conden- United States, the average make-up is probably
sation can occur. Even with low bulk oil temper- around 7.to 10 % per year.
atures, however, there can be localized hot spots 5.2 The combination of all of th~ above op-
such as in bearings, at gas seals, and in throttleerational factors for a given turbine determine its
control mechanisms that can cause oil degrada- severity level. Each unit is different and the equi-
tion and eventually cause system oil to show librium operating conditions for each system
signs of deterioration. must be determined in order to fix its severity
5.1.4.3 Under the higher temperature condi- level. The more severe a turbine system, the
tions which may be present in gas and steam shorter the service life for a given oil. A useful
turbines, oxidation of the oil may be accelerated approach to detennine the severity of a turbine
by thennal-oxidative cracking leading to the pro- is given in Appendix XI.
duction of viscous resins and deposits particu-
larly at the point of initiation. 6. Sampling
5.1.5 Contamination: 6.1 General-When taking lubricant samples
5.1.5.1 Contamination of turbine oils occurs from storage tanks or equipment in service, it is
both from outside the system and from within important that proper sampling techniques are
due to oil degradation and moisture condensa- followed. The following are some suggested
tion or leaks. Development ofa clean turbine oil guidelines for proper sampling technique and
system on start-up or following maintenance is sampling handling techniques (see Practice
discussed in ASME LOS 1M-Recommended D4057).
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6.2 Representative Sampling- To be repre- resistance, if time permits, allow the sample to
sentative.. a sample must be obtained either from stand in the container and observe its effects.
an agitated tank or a free flowing line. Aluminum foil makes a good, resistant cap liner.
6.2.1 The preferred sampling method is: 6.3.3 Appropriate for Whatever Handling Is
6.2.1.1 Dipping from the Tank-Lubricant Required-Containers with leaking tops and
fluid sample should be taken by dipping from glass containers improperly protected are not
the tank. Lubricant should be thoroughly circu- suitable for shipment. Note that stringent pack-
lated (with one or ~ore lubricant oil pumps) aging requirements must be foHowed ifshipment
before the sample is taken. is to be made by air.
6.2.2 The secondary sampling methods are: 6.3.4 Appropriate/or the Analyses Required-
6.2.2.1 Sampling from a Line-The line An extensive chemical analysis.. if that is why a
should contain lubricating fluid which is free sample is required, cannot be done on the con-
flowing and not deadheaded. For instance, the tents of a container which is too small.
lines in a bearing header, an active filter and NOTE-Some lubricant suppliers provide sample
active heat exchanger are free flowing; the lines containers which meet all these requirements. These
to a gage cabinet are deadheaded. In equipment should be used whenever possible. If frequent samples
with dual filters or heat exchangers, the inactive are taken, aD adequate supply of containers should be
kept.
filters or heat exchangers do not have flowing
fluid and are not suitable sampling points. When 6.4 Sample Markings-A sample should be
using a sampling line, it is necessary that the line properly marked. Markings should include at
has been thoroughly flushed before taking a sam- least the following information:
ple. Adequate amount offlushing will depend OD 6.4.1 Customer name (if appropriate),
sampling line dimensions, length and diameter. 6.4.2 Site,
6.2.2.2 Tapping from a Reservoir-As de- 6.4.3 Location,
scribed above, the lubricant fluid must be thor- 6.4.4 Turbine serial number,
oughly agitated in the reservoir and the tap line 6.4.5 Turbine service hours,
flushed before a sample can be taken. 6.4.6 fluid service hours,
6.2.3 A fluid sample is probably not repre- 6.4.7 Date sample taken,
sentative if: (1) the system fluid is hot while the 6.4.8 Type of fluid sampled,
sample is cold, (2) the fluid in the system is one 6.4.9 Sampling point,
color or clarity in a sight glass while the sample 6.4.10 Type of purification system (filters/
is a different color or clarity, and (3) the fluid centrifuge, etc.), and
viscosity of the reservoir fluid is different from 6.4.11 Make-up (gallons) since last sample
that of the sample when both are at the same was taken.
temperature. 6.5 Sampling of New Oil Deliveries:
6.2.4 It should be noted that on occasion a 6.5.1 Samples taken should be representative
sample may be requested which will not be rep- of the fluid being examined but obtained from
resentative. At that time, sampling instructions, the point(s) most indicative of gross contamina-
as specified by the requestor, must be followed. tion by debris and water, that is, just above the
For example, a sample might be taken off the top bottom of the drum or tanker compartment bot-
or the bottom of a tank to check for contamina- tom.
tion. In all cases the sample point should be 6.5.2 When consignments of oil are in drums,
marked on the sample container. sample them in accordance with Practice D 4057.
6.3 Sample Container-5amples should be 6.5.3 For bulk consignments, sample each
taken in a suitable container. To be suitable the tanker compartment. If these are clear of debris
container should be: and water then the samples can be combined for
6.3.1 Clean-If in doubt about its cleanlin~ subsequent laboratory analysis of the consign-
use another container; ifthis is not possible, flush ment.
it out with the fluid to be sampled. 6.5.4 In cases where the product is suspected
6.3.2 Resistant to the Material Being Sam- of being nonuniform, sample a larger number of
pled-For example, fire-resistant phosphate ester drums. Where contamination is suspected there
fluids will dissolve certain plastics. This includes is no alternative to sampling every drum.
the liner in bottle caps. To verify the container's 6.5.5 From tanker deliveries, in addition to
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sampling individual tanker compartments~ fur- acceptance of nonspecification product, that is,
ther sample(s) should be taken preferably from can the charge be readily recovered and corrected
the outlet of the flexible pipework or at least from before passing into service if the subsequent tests
the tanker bottom valve manifold. This further indicate this to be necessary.
sampling is necessary because the tanker contents
can become contaminated by residual material 8. Deterioration of Turbine Oils in Service
left in the bottom valve manifold. This can occur 8.1 How Turbine Oils Degrade-Irrespective
particularly when different products are being of initial quality, turbine oils will deteriorate in
carried in separate compartments or previous service. In the case of oils in some large steam
deliveries of a different product have been made turbines, this may be a slow process so that for
to other locations without subsequent adequate many years the oil may look like new. Deterio-
cleaning and flushing. ration occurs by one or more of the following
6.5.6 Bottom samples must be collected by processes:
either a tube or thiefsampler (for example, Bacon 8.1.1 Oxidative Degradation-This occurs as
bomb). These samplers permit collection of set- the result of chemical changes brought about by
tlings on the bottom of the container without oxygen in the atmosphere. Initially, hydroper-
introducing false contamination by scraping the oxides are formed and the process proceeds by a
container lining or wall. chain reaction.
6.5.7 Take the sample(s) from the outlet of 8.1.2 Thermal/Oxidative Degradation-This
the flexible pipework or the tanker bottom valve may occur at hot spots in turbines. At elevated
manifold while maintaining a good flow after tenlperatures, hydrocarbons are subject to ther-
flushing the line. mal cracking to fonn unstable compounds.
These unstable compounds are easily oxidized
7. Examinatio~ of New Oil on Delivery and also tend to polymerize to form resins and
7.1 Experience has shown the need for stan- sludge.
dardizing procedures to be undertaken for the 8.1.3 Water Accumulation in the System-
sampling, examination~ and acceptance of in- Accumulated water promotes oil degradation as
coming supplies of turbine oil. It is essential that well as interfering with lubrication.
personnel responsible for sampling and testing 8.1.4 Loss 0/ Additives-This can result in
shall have the necessary experience and skills, more rapid oxidation and premature rusting.
and that scrupulous attention to detail be applied 8.1.5 Infiux 0/ Contaminants-Contaminants
at all times to avoid erroneous results. arising within the system (corrosion and wear
7.2 .It is equally essential that all incoming products) or from without (fly ash~ dirt, fluids)
supplies of oil be adequately monitored to guard cause lubrication and wear problems.
against incorrect or contaminated material being 8.2 Properties 0/ Oils Which A/ust be Re-
delivered. Contamination of lubricating oils with tained-In determining the condition of the sys-
particulates has been noted especially when sup- tem oil for continued service, the most important
pliers have made deliveries in hired tanker vehi- properties of the used oil are: (a) viscosity, (b)
cles. oxidation stability reserve, (c) freedom from
7.3 Sampling of incoming supplies should be sludge, (d) freedom from abrasive contaminants,
in accordance with proper sampling procedures (e) anticorrosion protection, and (j) water sepa-
(see Section 6). rability.
7.4 All samples should be immediately ex- 8.2.1 Viscosity-Most commercial turbine
amined for appearance. oils are sold under ISO (International Standards
7.5 A testing schedule for new oil is included Organization) viscosity classification system. Oils
in this practice (see Tables 1 and 2). With drums, fall into IS0-VG-32, VG-46, VG-68 and VG-
tests should be completed on the bulked sample 100 viscosity grades corresponding to 32, 46, 68
before the oil is used in service. Individual sam- and 100 cSt at 40C and to approximately 165,
ples should be retai~ed until the bulk sample is 240. 350 and 515 SUS at 100F. The main pur-
passed as satisfactory. pose for checking the viscosity of used turbine
7.6 With tanker deliveries the additional tests oil isto determine if the correct oil is being used
to be completed before the tanker is discharged and to detect contamination. Used turbine oils
can only be judged from the risk involved by the rarely show significant viscosity changes due to
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04378
degradation. Occasionally, viscosity may increase carefully monitored. Only a relatively small de-
due to an emulsion with water contamination. gree of oxidation can be pennitted, otherwise
The method normally used for viscosity deter- there is considerable risk of sludge deposition in
minations is Test Method D 445. bearing housings, seals, g~ and pistons.
8.2.2 Oxidation Stability Reserve: 8.2.3.2 Measurement of "the amounts of
8.2.2.1 One of the most important properties sludge in turbine oils (for example, by porous
of new turbine oil is its oxidation stability. Tra- membrane filtration) is possible. Sludge already
ditionally this has been measured by the Test laid down within the system would not be in-
Method D943 procedure with Test Method cluded in such a determination. Other tests, how-
D 2272 being used as an ancillary (rapid) method ever, can signal deteriorating quality in the oil
for following changes of oil condition in service. even before any significant formation of sludge
Oxidation stability will gradually decrease in ser- occurs.
vice, deterioration being promoted by the cata- 8.2.3.3 Filtration and centrifugation assist in
lytic effects of metals in the system (iron and removing sludge from the oil as it is formed but
copper) as wen as by the depletion of the antiox- cannot protect the system if the oil is allowed to
idant. The latter occurs as a result of the normal deteriorate too far before an oil change.
function of the additive (chemically it acts as a 8.2.4 Freedom from Abrasive Contaminants:
chain-stopper in controlling oxidation), or by 8.2.4.1 The most deleterious solid contami-
volatilization. As the oxidation stability reserve nants found in turbine oil systems are those left
decreases, acidic compounds are produced which behind when the system is constructed and in-
in tum undergo further reactions to form more stalled or when it is opened for maintenance and
complex compounds. The end product of these repair. The need for proper cleaning and flushing
processes is an insoluble sludge. Although only a of new or repaired turbine oil systems according
minute fraction of the oil is converted in this to the latest ASTM-ASME-NEMA Recom-
way, sufficient sludge may be fonned to settle in mended Practices (ASME Standard LOS-IM-
critical areas of the system and interfere with 1980) is emphasized. Beyond these types of con-
proper lubrication and cooling of bearings and taminan~ there are few opportcnities for solids
moving parts. to enter the lube oil system, although in very
8.2.2.2 The test most used to indicate the dusty areas where units may be out-of-doors,
progress of oxidation (and indirectly the oxida- some solids may enter through improperly in-
tion stability reserve) is the total acid number stalled or operating vents.
(Test Methods 0664 and 0974). Most rust in- 8.2.4.2 During operation, the equipment may
hibitors used in turbine oils are acidic and con- begin to accumulate significant particulates.
tribute to the acid number of the new oil. An Some may enter the system through the make-
increase in acid number above the value for new up oil when it is added. fly ash may be drawn in
oil indicates the presence of acidic oxidation with the air at bearing shaft seals. Other contam-
products or, less likely, contamination with inants may be abrasive degradation and corro-
acidic substances. An accurate determination of sion products developed in the system. Whatever
the total acid number is very important. How- the source, the presence of abrasive solids in the
ever, this test does not strictly measure oxidation oil cannot be tolerated since they will promote
stability reserve which is better determined by scoring and damage to bearings and journals as
the Rotating Bomb Oxidation Test (Test Method well as causing malfunction and sticking of con-
D 2272). This latter test is included in the rec- trol mechanisms. These must be removed by the
ommended testing schedules (see Tables 1 and use of filters or centrifuge, or both. When the
2). make-up is low and the various filters and puri-
8.2.3 Freedomfrom Sludge: fiers are operating satisfactorily, abrasive solids
8.2.3.1 The term "sludge'" is usually applied are generally removed before any damage is
to the sediment deposited as the end result of the done. In a properly maintained system the par-
oxidation process. Due to the nature ofthe highly ticulate level presents no problem. Oeanliness of
refined lubricant base stocks used in the manu- the system oil can be detennined by gravimetric
facture ofturbine oils, they are very poor solvents means (Practice F 311 or Methods F 312) or by
for sludge. This is the main reason why the particle counting, the latter normally by means
oxidation stability reserve of the oil must be of electronic particle counters. Desired cleanli-
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04378
ness levels are sometimes designated by the has developed poor water separability properties
equipment manufacturer or user. A ma\imum (poor demulsibility) significant amounts of water
rating of eight on the National Aerospace Stand- will stay in the system and create problems. In
ard 1638 scale is usually considered satisfactory. addition to chemical effects on the oil and addi-
8.2.5 Anlico"osion Protection: tives, the lubricating properties of the oil may be
8.2.5.1 Antirust protection provided by the adversely affected; acf~quate lubrication cannot
lubricant is of significant importance for turbine be maintained by an oil which contains a signifi-
systems. Protection is required in areas of fluid cant quantity of water. Therefore, lubricant flow
flow, for surfaces covered by static drops of water to bearings should not contain significant
and for areas which are only occasionally amounts of free or dispersed water. There are
splashed by the lubricant. New oil usually con- considerable differences of opinion as to what
tains an antirust inhibitor additive and must level of water is harmful but 0.5 % is generally
meet test requirements such as Test Method considered significant.
D665 procedure. In service this additive may 8.2.6.2 The water separability characteristics
become depleted by (1) perfonning its proper of an oil are adequately measured using the Test
function, (2) by removal with water, (3) byad- Method D 140 1 procedure. The Steam Emulsion
sorption on wear particles and other solid debris, Number, a method now removed from ASTM
or (4) by chemical reaction with contaminants. Standar~ is not recommended although still in
In exceptional circumstances where alkaline or use in a few plants.
polluted water enters the system, additive re- 8.3 Other Properties of Used Oils-There are
moval will be much more rapid. The D 665 Pro- various other properties of used turbine oil which
cedure A (distilled water rust test) is adequate for can be measured but are considered of less sig-
determining a satisfactory level of antirust inhib- nificance. These are discussed as follows:
itor for land-based turbines. For marine usage, 8.3.1 Color-New turbine oils are normally
D665 Procedure B (seawater rust test) is recom- light in color. Some turbine oils darken on ex-
mended. posure to sunlight or VIV light. This is not
8.2.5.2 Although rusting is the most impor- abnormal. Darkening will occur in service but
tant corrosive tendency to guard aga.in~ the the change is usually slow over years of service.
possibility exists of other types of corrosion Frequent checks for color are therefore useful as
brought about by active sulfur or strong acids. a quick on-the-spot test. ~ignificant color
Generally these factors are of little significance change would be indicative that something has
for turbines since new oils must meet very strict changed. A more detailed examination would be
requirements in this regard and used oils are necessary to find the cause. Test Method D 1500
normally discarded before any corrosive break- is the standard method for defining the color of
down products are formed. Contamination is the lubricants. Color darkening alone is not itself a
most likely factor ifthe used oil does not continue cause for alarm (unless supported by additional
to meet new oil standards for copper strip cor- tests).
rosion (see Test Method D 130). 8.3.2 Interfacial Tension-Although still
8.2.6 Water Separability: used, this test is a carryover from early turbine
8.2.6. 1 Water can get into turbine systems due oil fonnulations which contained highly refined
to oil cooler leaks, normal breathing and gland base stocks with no additives. Base stocks alone
seal steam. Water adversely affects turbine oils gave high 1FT readings. Modern turbine fluids,
by acting with metals to catalyze oxidation. It however. contain valuable additives which are
also depletes water sensitive oil additives such as surface active so that 1FT is no longer a criterion
some types of turbine oil rust inhibito~ and may of turbine oil quality. IFf results on used oils,
cause rusting and corrosion. In gas turbines, mi- therefore, can only give misleading information
nor amounts of water are driven off during nor- unrelated to the condition of the oil. This test
mal operations. In steam turbines, normally if should not be used as a criterion of oil condition
the oil is in good condition, water will settle to or useful service life.
the bottom of the storage tank, where it should 8.3.3 Gravity-This test has only significance
be drained otT as a routine operating procedure. ,vith respect to contamination. It is of little value
Purification systems will also assist in removing to determine the degree of degradation. The
the water. Unfortunately if the steam turbine oil method usually used is Test Method D 1298 (hy-
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04378
drometer). substance and needs its own method. In addition

8.3.4 Steam Emu/sian Number- This test to DBPC new developments have brought many
was used extensively at one time to detennine other excellent antioxidants into use so that no
the ability of water to separate from oil which one method can be applied to accurately monitor
had been emulsified with steam. It was particu- antioxidant level. For assessing remaining service
larly useful for measuring the degree of refining life.. an oxidation test (for example RBOT) is far
of the turbine oils made without additives. The more useful.
test has now been superseded by the Test Method 8.3.9 Wear and Contaminant Metals-Quan-
D 1401 demulsibility test which has proved to be titative spectrographic analysis of used oil sam-
entirely adequate for the purpose. ples may be used to detect trace metals (and
8.3.5 Flash Point-Turbine oils, like most lu- silica) and identify metal containing contami-
bricants, must have flash points well above the nants. System metals such as iron and copper
minimum applicable safety requirements. How- can be accurately determined if the sample is
ever, flash point is of little significance for deter- representative and the metals are solubilized or
mining the degree of degradation of used oils, are very finely divided. The presence ofelements
since normal degradation has little effect on the such as calcium could be indicative of motor oil
flash point. It is useful for detecting contamina- contamination. High-silicon level would gener-
tion with low-boiling solvents. The method in ally indicate dirt contamination.
common use is Test Method 092 (Oeveland
Open Cup). 9. Monitoring Program
8.3.6 Foaming Characteristics-Foaming 9.1 A sound monitoring program is based on
characteristics are measured by Test Method three factors: (1) sampling and testing of oil
0892 which indicates both the tendency of the samples at suitable intervals, (2) logging and
oil to foam and the stability of the foam after it interpretation of test data.. and (3) action steps.
is generated. Foaming problems have three pos- 9.1.1 Sampling and Testing 0/ Oil Samples-
sible origins: Schedules should be tailored to the individual
8.3.6.1 Mechanical-Usually the most diffi- power plant depending on conditions and sever-
cult to overcome if due to design feature. ity ofthe turbines. The schedules included in this
8.3.6.2 Anti/oam Depletion, (possible drop out manual are typical and should only be used as a
of dispersed defoamant). guide. The importance of proper sampling can-
8.3.6.3 Contamination-In some instances not be overstressed (see Section 6). Easily run
this may be corrected with defoamant. Determi- tests can be run fairly frequently at the plant. A
nation of the cause is necessary to effect a solu- central or base laboratory can run more complex
tion to a problem. testing with assistance from the oil supplier or
8.3.7 ,",Pater Content-If an oil is clear and outside laboratory. Examination and identifica-
brigh~ the amount of dissolved water present is tion of any depo.sits found in the oil or removed
oflittle significance. Most turbine oils will remain from the system must also be taken into account.
clear with up to 75 ppm water at room temper- Tables 1 and 2 contain recommended sampling
ature. and testing schedules.
8.3.8 Inhibitor Content-In view of the fact 9.1.2 Logging and Interpretation 0/ Test
that the stability of modem turbine lubricants is DaLa-It is important to keep accurate records
based on the combination of high-quality base of test results and make-up. Graphical represen-
stocks with highly effective additives, attempts tations are highly recommended for key param-
have been made to follow the reduction in oxi- eters such as Total Acid Number and Rotary
dation inhibitor concentration during use. Since Bomb Oxidation Test. In this way unusual trends
dibutyl-paracresol (DBPC) is a common antiox- become apparent and better estimates made of
idant in use, most methods are based on an remaining service life. Interpretation of test data
infrared technique using DBPC as a standard. should take into account such factors as oil ad-
However.. the method lacks accuracy at low levels dition (make-up), possible intermixing of oils,
and there is some evidence to suggest that many etc. A guide to the proper interpretation of test
oils retain good oxidation resistance when anal- results is part of this practice.
ysis indicates zero inhibitor. The main problem 9.1.3 Action Steps-The main purpose of a
is that each antioxidant is a specific chemical monitoring program is to ensure long trouble-
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04378
free operation of the turbine. This can only be 11. Test Schedules
achieved by prompt and proper action steps 11.1 Steam and Gas Turbines-}JineralOils:
when necessary. Such action steps must be based
11.1.1 The following test schedules are based
on a correct interpretation of test results (see mainly on tests that can be run by most power
Table 3), us~aJly gathered over a period of time. station laboratories. An important exception is
Action should never be taken on the basis of one probably the RBOT (Rotary Bomb Oxidation
test result that might be incorrect either due to
Test) to determine remaining service life where
poor sampling or faulty testing. Resampling and the assistance of an outside laboratory or the oil
retesting is necessary before proceeding. See the
supplier may be necessary.
appropriate section of this practice for recom-
11.1.2 New oil should be sampled and tested
mended action steps.
for agreement with quality requirements as it is
received. Upon the installation of a new oil
10. Sludge and Deposits charge, either as an initial fill or as replacement
charge, an approximately 4-L (I-gal) sample
10.1 The accumulation of sludge or deposits should be taken after 24-h circulation. This is a
in any part of a turbine system is cause for most important sample since it is used as the
concern. During outages, inspection should be baseline for comparison with later test data. The
made of all accessible parts of the system, in sample should be retained for at least 12 months.
particular the reservoir, turning gear, etc. Var- Significant differences in quality between the new
nishing is usually an indication that the oil has oil (as received) and the 24-h sample should be
been in service too long. Samples of the deposits investigated. A check sample is sometimes nec-
should be taken for analysis. During operation, essary. Contaminants in the system and residues
any unusual amount of solids removed during from degraded oil can adversely affect the poten-
centrifugation or filtration should be noted. An tial service life of the new oil charge. The purpose
initial examination of any deposit can be made of the initial schedules, 12 months for steam
very simply. For this, a small amount of the turbines and 6 months for gas turbines, is to
deposit may be washed free of oil with a petro- determine the severity of service. For this, fairly
leum solvent from a squeeze bottle. After drying, frequent sampling and testing is required. The
a small magnet can be used to separate iron- amount of degradation occurring during this in-
derived matter. Examination with a simple 10- itial period serves as a guide to establish future
power pocket magnifying glass will often help to sampling frequency.
decide the nature and source of the debris. If 11.1.3 The normal test schedules are for sys-
necessary, the deposit may be sent to a well- tems which normally expect a long service life.
equipped laboratory for full identification. If sig- The history of the present charge or the results
nificant amounts of sludge, arising from oil oxi- of the first 6 to 12 months testing of a replace-
dation, are found in the system, action should be ment charge is usually sufficient to determine if
taken to clean out the system and replace the oil the nonna! schedule will apply. Eventually, as
charge. If the deposit consists essentially of con- test results indicate that the oil is becoming de-
taminant material such as fly ash or other deb~ graded and may be approaching the end of its
appropriate action is necessary to reD;ledy the service life, the sampling frequency should be
cause. increased.
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4t 04378
Schedule 1 New Oil

Samples:
(a) ,From transpon or drums
(b) From storage tank
Tests:
Viscosity
Total acid No.
Appearance clear and bright
Water content no free water
.4
Color
Rust test
Qean1iness
RBOT
Should agree with usen purchase specification.
.4
Should pass D66SA for laDd-based turbines. Should pass D66SB for marine turbines.
C Definition of suitable cleanliness levels depends on turbine builder and user tequimnents. Futration or centrifuptiOD of oil,
or both, into turbine and during service is strongly recommended.
Schedule 2 InstalJation ofa New Oil ~
Sample:
After 24-h circulation. Retain 4 L (approximately) (I gal).
Tests:
Viscosity
Total acid No.
Appearance clear and bright
Water content no free water
Color
c
Oeanliness
D
RBOT
A Follow recommended flushing procedures prior to installing a new oil charge whether it is an initial fill or an oil replacement.
Should agree with new oil test results.
C Definition of suitable cleanliness levels depends on turbine builder and user requirements. Filtration or centrifuptiOD of oil, or
both. into turbine and during service is strongly recommended
D Imponant as a baseline to determine turbine system severity.
Scbedule3A (First 12 Months Operation (New Turbine

Total Acid A Wa~ Con-
T~ Viscosity No. ppearance tent Color Rust Test Ceanliness RBOT
Frequen~ Every 1-3 Monthly Daily' Monthly Weekly Every 6 Every 1-3 Every 2-3
months months months months
Schedule 3B NonnaJ Operation

NOTE I-This schedule should be used as a guide. Increased frequency is required for a severe turbine or for oils approaching
the end of their service life. Most turbines should be covered by this schedule.
Total Acid Appear- WaterCon-
Test'" Viscosity
No. ance tent
Color Rust Test RBOT
Frequency' Every 3-6 Every 1-3 Every 1-3 Weekly 1 Year Every 1-3 Every 6-12
months months mon~ months months
Frequency is based on continuous operation or total accumulated service time.
.4
If product hazy or contains water in suspension.. check water content.
C If contamination is s~ additionaJ tests such as Rash Point. Foam" Water Separability, may be useful to determine
degree and effect of contaminants present. An outside laboratory or oil supplier can also assist in a more in~tb analysis.
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D4378
TABLE 2 Gas T.'Les Se 2 c'" TesbIw SdIaWes fMi-nJ 0iIsI

ScbeduJe 4 New Oil
Samples:
From transport or drums
From storage tank
Tests:
V1SCQ5ity
Total acid No.
AppcaraDCe
Color
0eanIincss
RBOT
A Should agree with users purcb2se sprific:atiowL
Should agree with turbi.De builder ~ user ~ 01' bodL
Sample:
After 24 bours (h) circuIidioa. Rd:aiD 4 L (applCwmllldy) (1 pi).
Tests:
V"zscosity
Total acid No.
AppcaraDCe
Color
C'Iean1iDcsa
RBOT
A Follow recoD1D1CDdcd flushing procaiun:s prior to iDsI3JJiDI a DeW oil c::harzc wbc:1ber it is aD iDitial 6D or an oil replacemenL
Shoukl agree with new oil test rc:su1a
C Should agree with turbiDe baiJdc:r aDd lSI' u:quiJWiCiItL FiJIatioa of oil into tuIbiDe aDd during service is strongly
recommended.
D Important as a baseline to deu:rmi.De tuJbiDe system sevrrily.
Toca.I Acid
Test viscosity RBOT
No.
SOOb SOOb IOOb 2mb SOOb ~IOOOb
ScbeduIe 68 ID-Scnice Normal ()pcRrioas

NOTE I-This scbedule should be used as a guide. FrcqucDcy sboaid be vaDcd depeDding on the tuJbiDe SC'Verity aDd oil condition.
Test Viscosity Tocal Acid No. ~ Col 0cm1iDeS' ROOT
Frequ~ SOO b 500-1000 b tOO b 200 h 1(XX) h 1500-2000 h
A Frequency is based on hours of ac:naI savicc.
C-21
TABLE 1 Continued
Steam (S)
orGas Oil Life Interpretation
Test Warning limit Turbine (Running Hours) Action Steps
(G)
Rust test light fail S up to 20 000 h (a)The system is wet or dirty. or both. Investigate cause and make necessary main-
D 665, Procedure (b)The system is not maintained properly tenance and operatina changes. Check
A (for example. water drainage nesJected. Rust Test. Consult oil supplier regardina
centrifuge not operating.) reinhibition if tcst result unchanged.
Rust test light fail S,G after 20 000 h during life Normal additive depletion in wet system. Consult oil supplier regardins reinhibition.
D 665, Procedure of oil charge
A
(J
~
I Appearance hazy S,G at any time Oil contains water or solids. or both. Investigate cause and remedy. Filter or cen-
N trifuge oil. or both. CJ
N
t.......
Color unusual and rapid S.G at any time This is indicative of: (a) contamination or Determine cause and rectify. CD
darkenins (b) excessive degradation.
Viscosity :t 20 % from ongi nal oil S,G at any time (a)Oil is contaminated, or (b) oil is severely Determine cause. If viscosity is low deter-
viscosity degraded. mine nash point. Chanse oil, if necessary.
Aash point drop 30F or morc com- S.G at any time Probably contamination. Determine causc. Check other quality pa-
pared to new oil. rameters. Consider oil change.
Foam tcst 0 892 excews following limits. S,G at any time Possibly contamination or antifoam deple- Rectify cause. Check with oil supplier re-
tiona In new turbines residual rost pre- prding reinhibition. Note-Plant prob-
Sequence I tendency-4S0 ventives absorbed by oil may cause problems often mechanical in origin.
stability-IO lem.
TABtE 3 Interpretation of Ttlt Data and Recommended Action
Steam (5)
orGas Oil Life
Test Warning limit Interpretation Action Steps
Turbine (Running Hours)
(G)
Total acid No. 0.1-0.2 mg KOH/g S up to 20 ()()() h This represents above normal deterioration. Investigate cause. Increase frequency of test-
Possible causes are: (a) system very se- ing--compare with ROOT data. Consult
Innease ovcr new G up to 3 000 h vere, (b) antioxidant depleted. (c) wrong with oil supplier for lpossible reinhibition.
oil oil used, (d) oil contaminated.
Total acid No. 0.3-0.4 mg KOH/g 5,G at any time during life of Oil at or approaching end of service life, (c) Look for signs of increased sediment on fil-
oil charge or (d) above may apply. ters and centrifuge. Check ROOT. If
Increase over new ROOT less than 2S % of original, review
oil status with oil supplier and consider oil
change. Increase t:st frequency if left in
system. ..a..
CJ ~
I ROOT less than half value on 5 up to 20 000 h Above nonnal degradation. Investigate cause. Increase frequency of test-
N
LV
original oil iog. e
ROOT less than half value on G up to 3 000 h Above nonnal degradation. Investigate cause. Increase frequency of test-
t
~
Qt
original oil ing.
ROOT less than 25 % of original 5,G at any time Together with high TAN indicates oil at or Resample and retest. If same, consider oil
approaching end of service life. change.
Water content exceeds 0.2 % 5 at any time Oil contaminated. Potential water leak. Investigate and remedy cause. Qean system
by centrifugation. If still unsatisfactory
consider oil change or consult oil sup-
plier.
Cleanliness exceeds accepted limitsA S,G at any time Source of particulates may be: (a) make-up Locate and eliminate source of particulates.
oil, (b) dust or ash enterina system, (c) Clean system oil by filtration or centrifug-
wear condition in system. ing. or both.
.4Limits will depend on method used. (Consult equipment builder or oil supplier.)
Satisfactory for land-based turbines.
e 04378
APPENDIX
(Noamancbtory Information)
Xl. SEVERIlY FAcroR CALCULATIONS
X 1.1 In a previous section of this practice., mention X 1.2 To be able to use this equation to obtain the
was made of the severity of a turbiile and lube oil severity factor for a particular system, it is apparent
system together with the faeto~ that determine the that both the oil make-up rate and results of the rotary
severity. In a paper on turbine oil degradationS the bomb test must be known over a significant period of
turbine severity has been defined as the w,percent of turbine operation. The latter requires periodic testing
fresh oil oxidation resistance lost per year due to oil at 3to 6-month intervals for I to 2 years, while the
reactions in the turbine oil system~'" An equation was former is obtained through accurate record-keeping. In
developed for turbine severity, B, as follows: some ~ multiple unit installations having common
piping and oil storage facilities, special efforts are
B = M (l - X/I OOf1- e-'1<> 4';7 needed to keep track of oil make-up rates for each uniL
where: e -fWl~oo X 1.3 For greater detail on the significance ofturbine
oil system severity and its use in controlling oil degra-
B = turbine severity,
M = fresh oil make-up expressed as the percent of total dation it is recommended that the original paper be
charge per year, consuJted.
I = years of oil use, and
X = used oil oxidation resistance in the Test Method i Den Herder. M. J., and Vienna. P. C~ 06Control of Turbine
02722 rotary bomb test expressed as % of fresh Oil Degradation During Use," Uibriauion Engineering, Vol
oiL 37(2), 1981, pp. 67-71.
T1rL Ammcan Soci~yfor T~ing aNi ,\{a.teriab taJu:s no positior: respecting 1M validity ofany palen! rights asserted in connection
with any iJem mmtioned in tJzis staNiard. Usen ofthis standard ar~ apresslyadvised thal determinatiOll ofthe validity ofany such
palmt rights. aNi w ri.sJc of infringemmt of sud! rigfus. are enJireiy their own responsibilily.
This SUJNiard is subject to r~isiOff at any t~ b.v 1M respon.sibl~ technical committee and must be r~iewed every five years and
if not revised. eilMr r~~ or witJuirawn. YOUT ~ ar~ invited either for r~ision of this staNiard or for addilional
staNiards and should ~ ~ to ASTJY H~ers. YOUT commenJ.S will reaiY~ CIlTefuJ considerazion at a meeting of the
r~ible ler::hnicaJ commit1~. whidf you may atteNi. If you fm tJuzt yow comments h/lv~ not received a fair Maring you should
rruzke}'OUT vi~.bIown to l~ ASTM CommiJteeon Sumdards. 1916 Re Sl. PhiladelphiD.. Pa. 19103.
C-24
Appendix D
EXAMPLE OF A TURBINE BEARING LUBRICATION SYSTEM FLUSH PROCEDURE
Flushing a turbine bearing lubrication (oil) system is usually an involved process

that is accomplished over several days. Usually temporary piping, sample points,
fine mesh screens, and contamination analysis equipment are required. In some cases,
supplemental oil pumps, valves, heat exchangers, and filters are employed. The com-
plexity of a system flush requires the use of a procedure with checklists. Turbine
manufacturers and service companies have developed procedures for flushing a system
when supplemental flushing equipment is used to obtain a "high velocity" oil flow.
A utility may decide not to perform a "high velocity" oil flush and instead use the
auxiliary and emergency oil pumps to achieve a higher than normal oil velocity.
For either situation, a flushing procedure specific to the turbine lubrication sys-
tem is followed which describes the detailed steps to be accomplished prior to, dur-
ing, and after the flushing process. A procedure developed by one utility for use
after major inspections of one of its turbine generator units is provided as an exam-
ple of the type of instructions and checklists that have been successfully employed
to accomplish an oil system flush. Figures of equipment and piping arrangements have
been removed from this example but they should be included in any procedure developed
for use by a utility for a specific unit.
D-l
TURBINE BEARING LUBRICATION (OIL) SYSTEM FLUSH PROCEDURE
PROCEDURE NO.
REVISION
DATE ---------
PAGE -----------
I. INTRODUCTION
After major inspections of the turbine generator, the bearing lubrication

(oil) system should be flushed and cleaned. The following procedure is used to
flush and clean an oil system using the auxiliary and emergency oil pumps.
NOTES:
A. The oil system is a large and complex system with large diameter p1p1ng
and high oil flows. A small particle can be harmful and can damage a
journal bearing, resulting in a costly unit shutdown to correct the
damage.
B. The primary function of the oil flushing operation is to remove any harm-
ful particle contaminants which can damage or cause any related turbine
generator component to malfunction.
c. The turbine generator will be completely assembled before the start of

oil flush.
D. Lubricating oil is recommended for flushing.
E. The oil flush should be carried out in steps.
F. After the oil flush, be sure everything is returned to normal operating

condition, especially the orifices and strainers.
II. PRE-FLUSH PREPARATION
A. Lube Oil Reservoir
1. Inspect and clean the inside of the oil reservoir thoroughly.
2. Place 100 mesh or smaller wire cloth guillotine screens in the oil
reservoir.
Contamination larger than 150 micrometers contained in the oil

returning to the reservoir after being flushed from the piping and
bearing standards will be caught by the 100 mesh screens and not
recirculated back into the system.
Caution: These screens have to be checked quite often during the

flush procedure and cleaned as necessary to prevent oil
overflow. (Use a sheet of Plexiglas to cover the guillo-
tine screen opening on top of the reservoir.)
3. The reservoir should be sealed with all access openings taped or

locked closed.
D-2
4. Fill the oil reservoir to 12 inches above normal operating level.
Normal level is 36 inches below the top (approximately 6400 gallons).
Caution: Make sure oil used as makeup during the flush meets the
acceptable particle count range. (Checklist 2C)
B. Oil Coolers
1. If possible, oil cooler tube bundles should be pulled and cleaned.

The cooler shells should likewise be cleaned.
2. During the flush, both oil cooler shells have to be in operation to

achieve maximum flushing velocity.
Caution: Do not, under any circumstances, pressurize the coolers

above 75 psi.
3. Drain and close the circulating water supply line.
Min. oil temp = 100F. Max. oil temp = 190F.

C. Nugent (Oil Conditioner)
1. Perform a complete oil conditioner drain and clean operation. If

necessary, replace all filter elements, clean all screens and filter
bags, and calibrate polishing filter gauges.
2. Nugent must be in operation prior to the start of flushing and

throughout the flushing period.
3. Have the Instrument Maintenance Department install a pressure gauge

and a sampling tap at the discharge line of the Nugent oil transfer
pump.
D. Turning Gear Bearing Oil Pump and Emergency Bearing Oil Pump
1. Make sure the following oil pumps are in good operating condition:
a. Turning Gear Bearing Oil Pump (TGBOP) - Ac Pump

Pressure ~ 15 PSIG
Nameplate (Full Load) amps = 49.5 amps
b. Emergency Bearing Oil Pump (EBOP) - Dc Pump

Pressure ~ 12 PSIG
Nameplate (Full Load) amps 3.06 amps
It is essential that the oil flow during the flushing operation

be greater than it is during the normal operation. Therefore,
both ac and dc oil pumps (TGBOP and EBOP) will be running simul-
taneously throughout the entire flushing operation.
2. Have the Electrical Maintenance Department install an ammeter for

each pump (TGBOP and EBOP) in the 480V MCC Electric Equipment Room.
Check motor current for both pumps. If the motor current exceeds
100% of nameplate, turn off that particular pump fast! (Safety
Related!)
D-3
E. Turbine Generator (Checklist 1)
1. Remove all feed orifices and wrap 150 mesh screens at each strainer
housing.
2. Jumper the bearing oil supply and drain lines at bearings #9 and
#10.
3. Remove pedestal covers by bearings #2 and #3 to gain access to the

150 mesh strainers.
F. Oil Samples and Particle Samples (Checklists 2A & 2B)
1. Extra material (Checklist 2B)
a. 7 turkey basters
b. 14 oil sample jars
2. Oil samples will be taken either at the drain lines or at the supply
lines according to Checklist 2A.
3. Particle samples will be taken at each journal bearing and each

side of the thrust bearing, and also at the guillotine screens
(lube oil reservoir). (Checklist 2A)
III. FLUSHING PROCEDURE
A. Steps to Accomplish Oil Flush
1. Prior to flushing, complete Checklists 1 and 3.
2. Start the turning gear bearing oil pump and the emergency bearing
oil pump simultaneously.
3. a. Monitor the pump motor currents (ammeters are provided in the

480V MCC Electrical Equipment Room).
b. Whenever the TGBOP motor current is approximately 49.5 AMPS,

stop the pump and let the motor cool before starting it again.
c. Whenever the EBOP motor current is approximately 3.06 AMPS,

stop the pump and let the motor cool before starting it again.
Caution: The motor current must not exceed 100% of its

nameplate.
4. a. At the start of the oil flush, record the lube oil header
pressure.
b. Continuously monitor the lube oil header pressure. (Gauges

are located in the control room and on the front stand of the
turbine.)
Monitor computer trends and pressure gauges.
c. When the lube oil header pressure rises by 3-4 psig, stop the
oil pumps and clean the 150 mesh strainers. (Checklist 1)
D-4
d. Take particle samples from the strainers. (Checklists 2A
and 2C) Analyze the contaminants through the microscope.
Keep track of size and amount of contamination.
5. a. Monitor the lube oil reservoir level.
b. If the oil level rises in the oil return trough, check the
guillotine screens for pluggage.
Clean the guillotine screens if necessary to prevent overflow.

This can be done without interrupting the oil flushing
procedure.
Caution: Be extra careful not to let any contaminants get

into the tank while cleaning the screens.
6. a. Take oil samples and analyze them. (Checklists ZA and 2C)
b. Take oil samples every 8 hours until the oil is reasonably

clean. Duration of oil sampling is determined by the oil par-
ticle count results.
Increase rate of sampling as the oil becomes cleaner.
7. Repeat Steps 2 through 6 until the oil sample from the turbine bear-
ing oil supply line reaches acceptable range. (Checklist 2C)
B. Steps to End Oil Flush
1. Stop the oil pumps (TGBOP and EBOP).
2. Remove all the 150 mesh strainers. (Checklist 4)
3. Install all the feed orifices back onto their original position.
(Checklist 4)
Caution: It is very important that the orifices be returned into

their original places. (Reliability Related!)
4. Place the original 30 mesh wire cloth guillotine screens back into
the lube oil reservoir.
5. On #9 and #10 bearings, remove the temporarily jumpered oil lines

and return the original piping to normal position.
6. Replace or clean all the filter elements at the Nugent oil

conditioner.
7. Open the circulating water supply line at the lube oil coolers and
let the cooling water flow through the coolers.
8. Remove ammeters from pumps.
9. Operators must go through their normal "after the major overhaul"

checklist before starting the unit.
D-5
Checklist 1: Removal of Feed Orifices and Installation of
150 Mesh Strainers Prior to Initiation of Oil Flush
Location Orifice Size Orifice Removed 150 Mesh Installed
PMG 3/16"
Low Speed Switch 15/16"
Oil Trip and Reset 15/16"
Bearing 1 3/4"
Bearing 2 13/16"
Thrust Bearing 1-13/16"

(Turbine End)

(Generator End)
Bearing 3 1/2"
Bearing 4 23/32"
Bearing 5 27/32"
Bearing 6 27/32"
Bearing 7 I"
Bearing 8 13/16"
Bearing 9 N/A
Bearing 10 N/A
Guillotine Screen N/A

(Lube Oil Reservoir)
SIGNED
DATE
FORWARD TO:
D-6
Checklist 2A: Locations for Oil and Particle Samples
Oil Samples Particle Samples

Location Position Check Strainer Check
Bearing 1 Supply at
Bearing
Bearing 2 Supply at
Bearing
Thrust Bearing
(Turbine End)
Thrust Bearing
(Generator End)
Bearing 3 Supply at
Bearing
Bearing 4 Drain
Bearing 5 Drain
Bearing 6 Drain
Bearing 7 Drain
Bearing 8 Drain
Bearing 9 Supply at
Sampling Valve
Bearing 10 Supply at
Sampling Valve
Guillotine Screen Lube Oil

Reservoir
Nugent Oil Conditioner Discharge N/A N/A
Nugent Oil Conditioner Inlet N/A N/A
Oil Sampling Method:
At Supply Positions: Place a sampling jar into the oil flow at the bearing.
At Drain Positions: Remove cap; use a turkey baster to sample the oil.
SIGNED DATE TIME
FORWARD TO:
D-7
Checklist 2B: Contamination Analysis Equipment
A. The following equipment is required for contamination analysis of the particle

samples from the strainers.
1. Order from Millipore Corp., Bedford, MA 01730 (Telephone 800-225-1380):
a. Pyrex filter holder with stainless screen, Catalog No. XX1004730.
b. Filtering flask, 1 liter capacity, Catalog No. XXI004705.
c. Vacuum hose, 4 ft. gum rubber, Catalog No. XX7100004.
d. Filter pads, NF-Millipore, 0.45 micron pore size, Catalog

No. HAWG04700.
2. Order from Fisher Scientific Co., 191 S. Gulph Rd., King of Prussia, PA
19406 (Telephone 215-265-0300):
a. One vacuum pump, Model 1-092-10.
3. 200* mesh wire cut at site to fit item I-a. Wire should be purchased
locally.
4. Order from Edmund Scientific Co., 617 Edscopr Bldg., Barrington, NJ 08007
(Telephone 609-547-3488):
a. One lOX (Min.) scaled magnified, Catalog No. 761, 70, 266, or equal.
b. Or a microscope.
B. The following equipment is required for contamination analysis of the oil

samples from the supply and drain positions:
Automatic particle counter from equipment supplier or central laboratory.
*150, 160, or 170 mesh can be used depending on local supplier availability. This
is also applicable to 150 mesh required in all strainers throughout the procedure.
The same mesh should be used throughout the system.
D-8
Checklist 2C: Oil Contamination Levels for Operation
Particle Max. Allowable

Size Range Particles Per
(Microns, lJ) 100 ml of Oil
5-10lJ 32,000
10-25lJ 10,700
25-50lJ 1,510
50-100lJ 225
100-250lJ 21
250ll None
III 0.001 nun

llJ 0.0004 rom
When the bearing oil reaches this level, stop the lube oil flush procedure.
OIL SAMPLE ANALYSIS
1. Process each oil sample through an automatic particle counter.
2. Record the number of particles in the ranges listed on the data sheet.
This will be an indication of the progress of the oil flush.
3. The oil flush will continue until it has been determined that the number of
particles ineach range is acceptable.
PARTICLE SAMPLE ANALYSIS
1. Rinse the strainers with solvent.
2. Collect the solvent and particles in a beaker.
3. Filter the fluid through filter paper.
4. Look at the filter paper under the microscope.
5. The amount of visible particles will be decreasing as the flushing continues.
6. Save and label the filter papers as to which strainer the sample is from and
the time and date the strainer was removed.
D-9
Checklist 3: Items Necessary Prior to Start of Oil Flush Procedure
1. Lube oil reservoir level is 12 inches above normal operating level
2. Both lube oil coolers are in service
3. Nugent is in service
4. Low pressure circulating water has been drained and

taken out of service
5. Ammeters for lube oil pumps (TGBOP and EBOP) have been installed
6. Computer is trending the bearing oil header pressure
7. Seven turkey basters and 14 oil sampling jars are "available
8. Valves at bearings #9 and #10 are closed
SIGNED
D~E
D-IO
Checklist 4: Installation of Feed Orifices and Removal of
150 Mesh Strainers After Completion of Oil Flush
Location Orifice Size Orifice Installed 150 Mesh Removed
PMG 3/16"
Low Speed Switch 15/16"
Oil Trip and Reset 15/16"
Bearing 1 3/4"
Bearing 2 13/16"

(Turbine End)

(Generator End)
Bearing 3 1/2"
Bearing 4 23/32"
Bearing 5 27/32"
Bearing 6 27/32"
Bearing 7 1"
Bearing 8 13/16"
Bearing 9 N/A
Bearing 10 N/A
Guillotine Screen N/A
SIGNED
DATE
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Appendix E
HYDRODYNAMIC FULL FILM LUBRICATION
E.1 PRINCIPLES AND THEORY OF HYDRODYNAMIC OPERATION
The generation and maintenance of full film lubrication by hydrodynamic action

requires:
a working fluid (oil),
motion of the bearing members to drag fluid between their surfaces,

and
a converging, wedge-shaped fluid film in the direction of motion.
The combination of these three factors results in pressurization of the interposed

fluid, thereby providing the necessary load support without metal-to-metal contact.
In the journal bearing, a converging wedge is automatically formed by virtue of the

eccentricity of the cylindrical bearing, as S?own in Figure E-1. This is not the
case for thrust bearings, as shown in Figure E-2(a). Plain, flat bearing surfaces,
such as exist in a thrust washer or wear plate applications, do not provide a con-
verging wedge. To promote fluid film lubrication, one of the surfaces must be
altered to provide a hydrodynamic shape such as shown in Figure E-2(b).
Another means of providing a converging wedge in flat surface hydrodynamic lubrica-

tion is by use of a pivoted pad. This allows the bearing pad to automatically
incline itself in the direction of motion, as illustrated in Figure E-2(c), to the
degree required to support the load. Tilting pad thrust bearings are frequently
used in steam turbines to provide hydrodynamic lubrication.
A closer look at the operating geometry and fluid film pressure distribution of the
journal bearing (Figure E-1) shows that the journal center, 0', is displaced radi-
ally from the bearing center, O. The resulting line of centers is not in line with
the direction of the applied radial load but is at an angle ~ to it. Choosing the
angular location of maximum film thickness as a reference, (6 = 0), the minimum
film thickness will be at 6 180. The solid line pressure distribution is typical
for incompressible fluid film journal bearings. In this case, positive pressures
E-l
w
NEGATIVE PRESSURE
(SUB - AMBIENT)
JOURNAL
~---POSITIVE PRESSURE
Figure E-l. Formation of converging wedge in a hydrodynamic journal

bearing and resulting pressure distribution. Journal rotation pulls
oil into the convergence between the journal and bearing to produce
positive oil pressure. Maximum pressure is obtained just before the
location of minimum film thickness.
E-2
w
RUNNER
....-u
(a) Plain Thrust Surface (no pressure generaled)
w
PRESSURE DISTRIBUTION
RUNNER
---BEARING
(b) Alt~red Thrust Surface To Provide Converging Wedge
w
PRESSURE DISTRIBUTION
RUNNER
u---~-
TILTING PAD
(c) Tilting Pad Automatically Forms Converging Oil-Film Wedge
Figure E-2. Thrust bearing surfaces. (a) Plain thrust surface, no

pressure generated; (b) Altered thrust surface to provide coverging
wedge; (c) Tilting pad automatically forms converging oil film wedge.
E-3
are generated within the converging film thickness zone with peak pressure obtained
just before the location of minimum film thickness. The pressure is reduced to ambi-
ent pressure just after the location of minimum film thickness. Beyond this point
of return to ambient pressure, an incompressible fluid cavitates (unless the ambient
is a pressure environment) because of the rapidly diverging (expanding) film thick-
ness. In the case of a compressible fluid, subambient pressure can exist and is of
the form indicated by the dashed pressure distribution in Figure E-l.
As already discussed, some fluid film bearing geometries allow or provide an inher-
ently favorable relative surface (film) geometry such as in the journal bearing.
When the bearing geometry does not inherently provide a favorable film shape for
hydrodynamic action (i.e., flat surfaces), it must be provided by purposeful altera-
tion of one of the surfaces or by the use of movable bearing members such as the
tilting pad bearing of Figure E-2(c).
Figure E-3 illustrates a number of common types of hydrodynamic film shapes provided
by alteration of the bearing surface. It should be understood that the depth, 8,
of the alteration is of the same order of magnitude as the minimum film thickness,
hI' namely in the range of 0.001 to 0.010 inch (0.025 to 0.25 rom). For steam tur-
bine thrust bearings, the tapered land and pocket type bearings are sometimes used,
both of which are fixed types. The pocket type bearing has the Qdvantage of rela-
tively lower viscous friction torque.
The governing equation (Reynolds' Equation) for the pure hydrodynamic mode of full
film lubrication with an incompressible fluid can be expressed as:
a [b3(~)J
ax x,z x,z
6llFv (ab) (E-l)
ax + az ax x,z
where
x direction of motion of the moving member (in)
z direction normal to the motion of the moving member (in)
h film thickness at (x,z) (in)
p oil-film pressure at (x,z) (lb/in 2 )
wF absolute viscosity of the fluid in the film (lb-sec/in 2 )
v sliding velocity of moving member in the x direction, (in/sec)
E-4
LAND LAND
~u
(0) TAPERED LAND (b) STEPPED LAND
SPIRAL GROOVES
OF DEPTH 8
LAND
L
POCKET A
(DE E p) N
D
LAND
(c) POCKETED (d) SPIRAL GROOVE
Figure E-3. Common types of purposefully altered surfaces for promoting

hydrodynamic fluid film pressurization. (a) Tapered land, (b) Stepped
land, (c) Pocketed, (d) Spiral groove. The depth of the alteration (0)
equals h Z - hI and is the same order of magnitude as the minimum film
thickness.
E-5
Solution of Eq. E-l yields the resulting oil film pressure distribution, p (x,y) in
both the x (circumferential) and z (axial for journal bearing or radial for thrust
bearing) directions. The oil film load capacity (W) is obtained by double integra-
tion (in x and z) of the oil film pressure. The flow of fluid in the direction of
velocity of motion (v) is obtained by integrating:
(E-2)
and the side leakage (at z) in the z direction is obtained by integrating:
(E-3)
The friction force to be overcome in a fluid film lubricated bearing is that caused
by the velocity induced and pressure induced fluid shear stresses, namely:
F (E-4)
x
E-6
E.2 ANALYTICAL PREDICTIONS OF PERFORMANCE CHARACTERISTICS OF HYDRODYNAMIC BEARINGS
(LAMINAR FLOW)
Currently available hydrodynamic lubrication technology includes numerous solution

approaches (computer implemented) to the above governing equation of hydrodynamic
lubrication. Using such solution approaches, one can obtain theoretical predictions
of the performance characteristics and capabilities of hydrodynamic full film lubri-
cated bearings in terms of their
physical design,
rotational speed, and
lubricant properties.
Figures E-4 through E-6 are graphical presentations showing representative theoreti-
cal results of the analysis of a hydrodynamic journal bearing. In particular, the
results shown are the dimensionless performance parameters for a hydrodynamic jour-
nal bearing
having an (LID) ratio of 0.8;
having two opposed, 160-degree included angle pads separated by two

20-degree axial oil grooves (see Figure E-4);
that is radially loaded midway between the grooves (see Figure E-4);
with its journal perfect~ aligned to the bearing bore; and
using an incompressible fluid, the flow of which is laminar.
Note: Journal bearings of this general geometry have been applied in steam
turbines.
In each of these figures, various theoretical dimensionless performance parameters

for the above described centrally loaded, hydrodynamic journal bearing (LID = 0.8)
having laminar flow conditions are plotted as functions of the dimensionless journal
bearing parameter W* defined as:
which for (LID) 0.8 can be written as:
W* (E-5)
E-7
N
RANGE FOR ~
RANGE FOR
~
~ 0 1.0i i i ' i i i i i i
:z ~
",_ 0 U
")( t ~e
11\0 -;
~_s::.ON
""--"1
lA. ~ a::
L:::.-..-.J- 0 UJ
- II '"----J ....
cr o~ CX)
lLJ
~
o E rO <t
- ::I: ex> a:
ro
(\J
"
~
-;
*u. 0.1 t-i- - - - - - <J :J' 110 ~ * lA. 0-
Q)
I'
~ 0 a: Q. "t)
II W II UJ II -
~
*u
~
~
<t
0::
W o
a.
r---"'
N
Z
..
c:s
II
0:: ....
II <{ w Z&&. ~ ILl
t1j ~ a. ~ 00. - ....J
(/) <t -;;e tOo CJ
I
CO ....WW (/) ~ .- 0 - z
W <t ~ - :. <t
~ Z a. a:~ :l UJ
<t ~ u.._ - C
~ u ~ 0.01. I I ,. I 1.0 <.!)L.....-.I ~
<t
a. ....J: ....J
lJ..
-
Z
a::
m-
0
t-
_
I-
(/)
(/)
<t
~
....J
W
C)
<t:
lLJ
=- ...<t
f'-
<{ IX) C\J
~ u.. ~ ....J tq ....J
....J :E
<t
W
Z II <t
Z
<t ~ ....J a::
....~ ~
0::
UJ ~ :::>
z o oJ 0
0::: ~ U; 0.001' , " , i " , i i ' , i i i i i ' i ' ..,
0
0.001 0.01 0.10 1.0 10 100
3 3
JOURNAL BEARING PARAMETER=W*=(IO)(.Q.}3[W(CXI0 )2 ] -6.217 [WCCXI0 )2 ]
.". L (fLF x 10') 0 4 N (fLF x 10~ 04 N
Figure E-4. Performance Parameters of a Hydrodynamic Journal Bearing (Laminar Flow)

N
RANGE FOR RANGE FOR ~
DIMENSIONAL STIFFNESS
K, , _ [CHANGE IN i-DIRECTION REACTION FORCE]
(/)
0:: ',J - CHANGE IN j-DIRECTION DISPLACEMENT
W
.....
W
~ r---:-t Ki,j = (~~i)) (Ib/in)
<t~Z
0:: ~
<{ 0
ttl
0 1.01 I I ' v I "- '"' .1.0
0.. -)(0
-
(/)UO
(J}--
W ." )(
.. LA. +x
Z
LL 'iZ ::t..
l.L.~
txj
I
\D
t=
(f)
N
C\J
C> U>
Z 0
0:: 0
<t
W
al ":'-
II'
'-=
0.101
",
~ 110
",
--J ~ ",
II ",
Z
a::
::)
o
--:J
0.01 0.10 1.0 10 100
JOURNAL BEARING PARAMETER W*= 6.217 [W(C)(IO~2 4 ]

(JLFxIO )0 N
Figure E-5. Oil Film Stiffness Parameters of a Hydrodynamic Journal Bearing (Laminar Flow)
CD
N N
o CD
o RANGE FOR RANGE FOR
FULL-SPEED OPERATION TURNING GEAR OPERATION
DIM:ENSIONAL DAMPING (Ib-'Ic/in)

/
en
a:: D.. [CHANGE IN i-DIRECTION REACTION FORCE] /
~ I.) = j_ DIRECTION VELOCITY OF JOURNAL /
LLJ ,..-,--,
~ rt) ~ /
a:: '0
. . . . . ..-.
0
Di,i = (6 Wi)
-.-
(Ib-sec /In) /
~ X ~ 1.0 j ) I / I ~ /1 11.0
g X
C) .... "-
Z ...: ~
-0-"""-
Q. L.-..!.-J
:E .--.
~
I:%:i
c 0
r C) -.....-
t-A
o z
_ an
rf)
a: 0
<t N
W 6 0.10 I I " I ~ ~ I I 10.10
m ..
-J ....,
<t ~i:5
Z
n: II
:::>
o
~
0.01 0.10 1.0 10 ~o
JOURNAL BEARING PARAMETER W*= 6.217 [W(CXIO:>2 4 ]

(fLFx 10 )0 N
Figure E-6. Oil Film Damping Parameters of a Hydrodynamic Journal Bearing (Laminar Flow)
where
W radial load (lb)
C radial clearance (in)

(R B - RJ ) = (bearing bore radius - journal radius)
1JF absolute viscosity of the fluid in the oil film at (average) temperature
(T F ) (lb-sec/in 2 )
D bearing nominal diameter (in)
N rotational speed of journal (rpm)
The dimensionless performance parameters plotted in Figure E-4 are defined as:
~in/C = Minimum Film Thickness Parameter (E-6 )
Attitude angle of journal radial eccentricity direction with respect to

radial load direction
3
p*
F 0.627(10 9 )
[
(1J
(C x
F
x
10 )PF ]
10 6 )D 4N2 =
Frictional Power Parameter (E-7 )
Q* 3 F
F 183.8(10 ) [ 2 Q 3] Side Leakage Flow Parameter (E-8)
D N(e x 10 )
3
m* [ (C x 10 ) 3NWC ]
C 17.23(10-9 ) Critical Mass Parameter (E-9)
6 4
(1J x 10 )D
F
where
h min minimum oil film thickness (in)
PF fluid film viscous friction power (hp)
QF side leakage flow rate (expelled) by bearing (gpm)
We critical load of "journal" (lb)
E-ll
Figures E-5 and E-6 present the dimensionless oil film stiffness and damping param-
eters, respectively, which are defined as:
3 3
K* K. . (C x 10 )
i,j 0.00622 1,J oil film stiffness parameters (E-10)
4 6
(llF x 10 )D N
change in i direction oil film dimensionless reaction force ]

[ change in j direction dimensionless displacement
3 3
D. . (C x 10 )
D* 1,J
= 0.2035(10-3 )
1,J 6 4 (E-11)
(lJ x 10 )D
F
change in i direction oil film dimensionless reaction force]

[ j direction dimensionless velocity of journal
where
[d:~ ] oil film stiffnesses = change in i direction oil film

reaction force due to a j direction displacement of the
journal (lb/in)
D1,J (dWi) ] = oil film stiffnesses = change in i direction oil film

[ (dj/dt) reaction force due to a j direction velocity of the
journal (lb-sec/in)
The Journal Bearing Parameter (W*) of Eq. E-5 can be reworked to be expressed as:
m2 p
w* 1.2434
[
6 ] (E-12 )
(llF x 10 )N
where
m [2C x 10 3 /D] = clearance ratio (mils/in)
p [W/(LD)] = [W/(0.8D 2 )] = unit area loading (lb/in 2 ) (for L/D 0.8)
Typical values of bearing clearance ratio are in the range of
1.5 ~ m ~ 2.0 (mils/in)
E-12
Nominal design point unit area bearing loadings are typically 150-200 (lb/in 2 ), but
can vary over broader limits during operation (due to changes in load-sharing align-
ment) to be in the range of:
50 $ P $ 250 (lb/in 2 )
Full, rated speed is:
N~x 3600 or 1800 (rpm)
In most steam turbines, turning gear speeds are in the range of:
3 $ Nmin $ 10 (rpm)
As seen in Table E-1, lubricant viscosity (w) varies inversely with lubricant tem-
perature (T). The average temperature within the oil film (T F ) increases with
increasing supply oil temperature (T S ) and increases with increasing speed. At the
much lower turning gear speed, supply oil temperature can vary from TS = 70F (cold
start) to $120F, and oil film temperature rise will be very slight. Thus, for
turning gear operation,
3-10 (rpm)
At rated full speed(s), supply oil temperature is normally controlled to be in the

range of:
1800/3600 (rpm)
and the average oil film temperature will be more elevated, namely:
1800/3600 (rpm)
The following provide summary tabulations for the resulting ranges of W* for slow-
speed turning gear operation and for rated speed operation.
E-13
Table E-I
TEMPERATURE-DEPENDENT PHYSICAL PROPERTIES OF A TYPICAL ISO-SECOND

LUBRICANT FOR LST-G UNITS
SUS at 100 DEG.F - 151.0

SUS at 210 DBG.F a 43.8 COMPUTER PROGPJrn INPUTS
API GRAVITY at 60 DBG.F m 31.50
T 'lJ z v p y Cp
yo .... ko Te
KINEMATIC SAYBOLT SPECIFIC WEIGliT SPECIFIC IIEAT THERMAL

TEMP. ABSOLUTE VISCOSITY VISCOSITY UNIVERSAL lIEAT CONTENT CONDUCTIVITY TEMP.
GRAVITY DENSITY
(Deg.F) (LB-SEC/ (CENTI- (CENTI- VISCOSITY (BTU/ (BTU/ (BTU/ (DEG. C)
(GH/CC) (LB/GAl.)
IN.-lN. ) POISE) STOKE) (SEC. ) LB-DEG.F) GAL-DEG.F) IN-SEC-DEG. F)
30 0.3752E-04 0.2580&+03 0.2933E+03 0.1353E+04 0.8796 7.340 0.4403 3.232 0.1813E-05 -1.11
40 0.2492E-04 0.1713+03 0.1957+03 0.9031E+03 0.8757 7.308 0.4462 3.261 0.1808E-05 4.44
50 0.1715-04 0.1179+03 0.1352E+03 0.6246E+03 0.8719 7.276 0.4520 3.289 0.1802E-05 10.00
60 0.1218-04 0.8372E+02 0.9644B+02 0.4459E+03 0.8681 7.244 0.4579 3.317 0.1797E-05 15.56
70 0.8893E-05 0.6114E+02 0.7074+02 0.3275B+03 0.8643 7.213 0.4638 3.345 0.1792E-05 21.11
80 0.6659E-05 0.4578F.+02 0.5321+02 0.2470E+03 0.8605 7.181 0.4697 3.373 0.1786E-05 26.67
90 0.5100E-05 0.3506E+02 0.4092E+02 0.1908E+03 .0.8567 7.150 0.4756 3.400 0.1781E-05 32.22
100 0.3935&-05 0.2739E+02 0.3212+02 0.1510+03 0.8530 7.118 0.4815 3.427 0.1776-05 37.78
tx:1
110 0.3170&-05 o.2179E+02 0.2566+02 0.1224+03 0.8493 7.087 0.4873 3.454 0.1770B-05 43.33
I 120 0.2563E-05 0.1162E+02 0.2084B+02 0.1016E+03 0.8455 7.056 0.4932 3.480 0.1765B-05 48.89
~
~ 130 0.2103E-05 0.1446+02 0.1717E+02 0.8639+02 0.8418 7.025 0.4991 3.506 0.1760-05 54.44
140 0.1748E-05 0.1202E+02 0.1434E+02 0.7521E+02 0.8381 6.994 0.5050 3.532 0.1754E-05 60.00
150 0.1471E-05 0.1011E+02 0.1212E+02 0.6690&+02 0.8345 6.964 0.5109 3.558 0.1749&-05 65.56
160 0.1250E-05 0.8597E+Ol 0.1035E+02 0.6062E+02 0.8308 6.933 0.3168 3.583 0.1743E-05 71.11
170 0.1074E-05 0.7382E+Ol 0.8925&+01 0.5579E+02 0.8272 6.903 0.5226 3.608 0.1738E-05 76.67
180 0.9303E-06 0.6396+01 0.7766E+Ol 0.5200E+02 0.8235 6.872 0.5285 3.632 0.1733E-05 82.22
190 0.8125E-06 0.5586E+Ol 0.6813E+Ol 0.4896&+02 0.8199 6.842 0.5344 3.657 0.1727E-05 87.78
200 0.7149&-06 0.4915E+Ol 0.6021E+Ol 0.4647E+02 0.8163 6.812 0.5403 3.681 0.1722E-05 93.33
210 0.6333E-06 0.4354E+Ol 0.5357E+Ol 0.4439&+02 0.8127 6.782 0.5462 3.704 0.1717E-05 98.89
220 0.5645-06 0.3881E+Ol 0.4796E+Ol 0.4263E+02 0.8092 6.752 0.5521 3.728 0.1711E-05 104.44
230 0.5060E-06 0.3479E+01 0.4318E+Ol 0.4113&+02 0.8056 6.723 0.5579 3.751 o.1706l~-05 110.00
240 0.4560E-06 0.3135E+01 0.3909E+Ol 0.3982&+02 0.8021 6.693 0.5638 3.774 0.1701E-05 115.56
250 0.4129E-06 0.2839E+Ol 0.3555&+01 0.3868+02 0.7985 6.664 0.5697 3.796 0.1695E-05 121.11
260 0.3756-06 0.2582+01 0.3248E+Ol 0.3767E+02 0.7950 6.634 0.575(, 3.819 0.1690B-05 126.67
270 0.3431E-06 0.2359+01 0.2980E+Ol 0.3678+02 0.1915 6.605 0.5815 3.841 0.1685E-05 132.22
280 0.3146E-06 0.2163+01 0.21458+01 0.3597E+02 0.7880 6.576 0.5874 3.862 0.1619E-05 137.78
290 0.2895-06 0.19908+01 0.25378+01 0.3525E+02 0;7845 6.547 0.5932 3.884 0.1614E-05 143.33
100 0.2673E-06 0.1887E+Ol 0.2353E+Ol 0.3460E+02 0.7810 6.518 0.5991 3.905 0.16688-05 148.89
310 0.24758-06 0.17028+01 0.21898+01 0.3401E+02 0.7776 6.489 0.6')50 3.926 0.1663E-05 154.44
320 0.2299E-06 0.1581E+Ol 0.2042E+Ol 0.3348E+02 0.7741 6.460 0.6109 3.941 0.1658E-05 160.00
330 0.2142E-06 0.1472EtOI 0.1911+01 0.32981H02 0.7707 6.432 0.6168 3.967 0.16528-05 165.56
340 0.20008-06 0.1375E+Ol 0.1792+01 0.3253E+02 0.7613 6.40'3 0.6227 3.981 0.1647E-05 171.11
350 0.1872E-06 0.1287E+Ol 0.1685E+Ol 0.3212E+02 0.7639 6.375 0.6285 4.007 0.1642E-05 176.67
360 0.1751E-06 0.1208E+01 0.1588E+Ol 0.3173+02 0.7605 6.346 0.634/. 4.026 0.1636E-05 182.22
370 0.1652E-06 0.1136E+01 0.1500E+Ol 0.3138E+02 0.7571 6.318 0.6403 4.045 0.1631E-05 187.78
Turning Gear Speed Full Speed
Quantity Minimum Maximum Minimum Maximum
N (rpm) 3 ~ 10 1800 ~ 3600
m (mils/in) 1.5 ~ 2.0 1.5 ~ 2.0
p (lb/in 2 ) 50 ~ 250 50 ~ 250
TS (OF) 70 ~ 120 100 ~ 120
TF (OF) z 70 ~ 120 z150 + 225
(lJF x 10 6 ) (lb-sec/in 2 ) 2.56 ~ 8.9 0.54 + 1.47
W* 1.56 + 162 0.026 + 1.28
It is seen that the value of journal bearing parameter W* varies over broad ranges
for both turning gear and full speed operation (i.e., 100:1 and 50:1, respectively).
These two ranges of W* are plotted at the tops of Figures E-4 through E-6 containing
the curves of dimensionless performance parameters for the example journal bearing.
It is seen that the upper limit of W* for full speed operation is almost equal to
the lower limit of W* for turning gear operation. Thus the overall range of W* is
0.026 ~ W* ~ 162
Examining Figures E-4 through E-6 over this range of W*, we note that the dimension-
less performance parameters exhibit large changes in value. It is seen that as W*
increases:
minimum oil film thickness parameter decreases
friction power parameter increases
side leakage flow parameter
critical mass parameter increases
attitude angle decreases
oil film stiffness parameters increase
oil film damping parameters increase
Considering the full ranges of bearing clearance ratio (m), unit area loading (p),
and fluid viscosity speed [lJF x l06 N] values, it is seen that
'~i~
max ~ 6230
Wi',
mln
E-15
In a given bearing (C = constant) subjected to a given load (p constant), the pos-
sible ratio of W~ax/W~n decreases to a value of
W*
max $ 700
W*.
IDln
which still implies a broad range of bearing operation and performance.
In order to illustrate the effect of changing speed and changing temperature, con-
sider the following sample problem.
A 20-inch diameter x 16-inch long bearing having a radial clearance of

0.020 inch is subjected to a radial load of 64,000 (lb). Evaluate the
dimensional performance characteristics of the bearing for the following
operating conditions.
Case (a) At rated speed of 3600 rpm and (assumed) film temperature of
200F.
Case (b) At turning gear speed of 4 rpm and (assumed) film temperature
of 100F.
The known values are:
D 20.0 (in)} LID 0.8

L 16.0 (in)
C 0.020 (in)
~v 64,000 (lb)
Case (a): N 3600 rpm
TF 200 (OF) (assumed)
. .. lJF 0.7149 x 10-6 (lb-sec/in 2 ) [from Table E-1]
Case (b): N 4 rpm
TF 100 (OF) (assumed)
... lJF 3.985 x 10-6 (lb-sec/in 2 ) [from Table E-1]
E-16
Substituting known (and assumed) values into Eq. E-5 yields values of W* as:
W* = 0.3865 for Case (a) at N = 3600 rpm
and
W* 62.4 for Case (b) at N 4 rpm.
Entering Figures E-4 through E-6 at these values of W*, the interpolated (and esti-
mated) values of the dimensionless parameters obtained are then substituted into
Eqs. E-6 through E-ll. We then obtain the dimensional performance characteristics
listed in Table E-2 for the example bearing for rated speed (3600 rpm) and for turn-
ing gear speed (4 rpm). It should be noted that these performance results are based
upon the assumptions that
bearing members are perfectly aligned,
bearing load is W = 64,000 (lb) directed midway between the oil

grooves,
fluid film oil flow is laminar,
average oil film temperature is TF 200F for Case (a) at rated

speed (3600 rpm), and
average oil-film temperature is TF 100F for Case (b) at turning

gear speed (4 rpm).
Examining the results in Table E-2, we can make the following significant
observations.
1. While the minimum oil film thickness (hmin ) value of about 4 mils
should imply zero contact of the bearing members at rated speed, the
exceedingly small value of only 0.06 mils theoretically predicted for
turning gear operation implies that, from a practical viewpoint,
there will probably be some degree of contact with resulting wear of
the bearing. If the bearing alignment during turning gear operation
is reasonably good and if the oil is clean, the bearing will wear in
and the wearing process will, eventually, cease and a thin film of
oil will separate the bearing members during the very slow speed turn-
ing gear operation. Wearing in of the bearing during turning gear
operation, of course, alters the original (cylindrical) bore surface
geometry, which, in turn, can affect bearing operation (to some
unknown degree) at rated speed operation.
2. In the absence of contact, the viscous frictional shearing power of

the oil film (P F ) is quite high (112.3 horsepower) at rated speed but
negligibly small (0.085 horsepower) at turning gear speed. Equiva-
lent theoretical fluid film coefficients of friction are calculated
as
E-17
Table E-2
PREDICTED PERFORMANCE CHARACTERISTICS OF EXAMPLE BEARING

(D = 20 in); (L = 16 in); (W = 64,000 lb); (centrally
loaded); (laminar flow); (perfectly aligned)
Performance Quantity Symbol Units Case (a) Case (b)

Journal Rotational Speed N (rpm) 3,600 4
Assumed Avg. Oil-Film TF (OF) 200 100
Temperature
Abs. Viscosity of Oil 6 0.715
lJFxlO (lb-sec/ 3.895
at TF in?)
Journal Bearing w* -- 0.3865 62.4
Paramet~r
Minimum Oil-Film h . (in. ) 0.003940 0.000060

Thickness mln
Fluid Oil-Film Friction PF (hp) 112.3 0.0085

Power
Side Leakage Flow Rate QF (gpm) 97.2 o. 111
Critical Dead Weight Wc (1 b) 92,~00 00
Attitude Angle a (deg) 31 .0 3.7

(estimated)
Oil-Film Stiffnesses KXX (lb/in. ) -4.8xl0 6 -28xl0 6
KXY II
+O.79xlO 6 +75xl0 6
KyX II
+12.8xlO 6 +75xl0 6
Kyy II
-19.9xl0 6 -600xlO 6
Oil-Film Damping DXX (lb-sec/ -8.43xl0 3 -2.lxl0 6
Coefficients in. )
3
DXY II
+16.2xlO +15xl0 6
DyX II
+16.2xl0 3 +15xl0 6
Dyy II
-62.5xl0 3 -190xlO 6
Note: These results are for assumed laminar flow conditions of the bearing
fluid film.
E-18
0.0985(P F/N)
0.0031 at rated speed, and
0.00021 at turning gear speed.
If there is some degree of metal-to-metal contact (mixed friction)

during turning gear operation, the resulting coefficient of (mixed)
friction will be much greater than
fM >> (f F = 0.00021)
with its minimum value being
3. The predicted side leakage flow rates are those that would occur if
the oil grooves are filled with oil at zero pressure. As such, these
analytically calculated values represent the minimum flow rate of oil
to be supplied to the bearing. It is seen in Table E-2 that when
operating at rated speed, the example bearing requires a mlnlmum sup-
ply oil flow rate (equal to side leakage flow rate) of 97.2 (gpm) in
order to satisfy its lubrication requirements. On the other hand, at
slow speed turning gear operation, the theoretical lubrication
requirements of the bearing are exceedingly small (0.111 gpm).
4. The attitude angle (a) indicates the location of minimum oil film
thickness (hmin ) with respect to the location of applied radial load.
It is seen that at rated speed, minimum film thickness location is
removed from the load direction by some 31 degrees (i.e., 49 degrees
from trailing edge oil groove). For turning gear operation, ~in is
close to the direction of load (within 4 degrees). Thus, turning
gear wearing in of the bearing bore will occur about midway between
the oil grooves.
s. The critical load (We) prediction provides an approximate measure of

the tendency of the bearing oil film to be unstable. Ideally, the
theoretically calculated value of We should be much greater than the
deadweight load supported by the bearing oil film with its stiffness
and damping properties. It is seen in Table E-2 that We is infinitely
large for turning gear operation which implies that the bearing will
not exhibit any tendency to be unstable at turning gear speed. On
the other hand, at rated speed We is calculated to be 92,200 pounds.
If all of the applied load (64,000 lb) consists of only deadweight,
then the critical load of 92,200 lb is 44% greater than the deadweight
of 64,000 lb. This would imply that the oil film is probably stable
at the rated speed condition. However, if for some reason, the applied
load is decreased (as due, for example, to bearing pedestal settling),
the bearing oil film may become unstable.
6. The dynamic performance characteristics of the bearing oil film are

a complex function of its stiffness and damping characteristics
(K i j and Di j)' all of which are nonlinear and direction sensitive
(cross-coupled). The oil film can be thought of as consisting of
four springs (KXX' KXY ' KyX ' and Kyy ), and
four dashpots (DXX' DXY ' DyX ' and Dyy ).
E-19
The results in Table E-2 indicate that the values of Ki,j and Di,j
during turning gear operation are much greater than the values real-
ized during rated speed operation (which is due, primarily to the
much smaller value of minimum oil film thickness when operating at
the slow speed turning gear conditions.
E-20
E.3 THE EFFECTS OF TURBULENT OIL FILM FLOW CONDITIONS
The previous section was devoted to journal bearing performance predictions based on
assumed laminar flow of the oil in the bearing film. The nature (laminar, transi-
tion, or fully turbulent) of the flow in the bearing oil film will depend upon the
local Reynolds Number calculated as:
Px,y Vx,y hx,y

(E-13)
~x,y
where
(x,y) coordinate location within the oil film (in)
p lubricant mass density (lb-sec 2 /in 4 )
v = fluid velocity (in/sec)
h film thickness (in)
~ lubricant absolute viscosity (lb-sec/in 2 )
In general, the nature of the oil film flow is:
laminar when (RN)x,y < 800
transitional when 800 ~ (RN)x,y ~ 2000
fully turbulent when RN > 2000.
Within a given bearing oil film, 0, v, h, and ~ vary throughout the film depending
upon location. For journal bearings, it is fairly common practice to calculate a
single (generalized) value of Reynolds Number based upon the following expression:
R (E-14)
where
journal bearing Reynolds Number
lubricant mass density at average oil film temperature (T F )

(lb-sec 2 /in 4 )
~F lubricant absolute viscosity at average oil film temperature

(T F ) (lb-sec/in 2 )
C machined-in radial clearance of bearing (in)
E-2l
Eq. E-14 can be expressed as:
2
RN 26.18 x 10-6 D m [::N] (E-15 )
In steam turbine applications,
15 ~ D ~ 24 (in)
1.5 ~ (m = 2C x 10 3 /D) ~ 2.0
For maximum (rated) speed: N 3600 (rpm)
150 ~ TF ~ 225 (OF)
1.471 ~ (llF x 10 6 ) ~ 0.54 (lb-sec/in 2 )
78.02 ~ (PF x 10 6 ) ~ 75.49 (lb-sec 2 /in 4 )
Therefore, for N = 3600 (rpm):
0.191 x 10 6 $ [ ::N] $ 0.503 x 10 6 (sec/in 2-min)
For minimum (turning gear) speed: N 3 (rpm)
70 ~ TF ~ 100 (OF)
8.9 ~ (llF x 10 6 ) ~ 4.0 (lb-sec/in 2 )
80.8 ~ (PF x 10 6 ) ~ 79.7 (lb-sec 2fin 4 )
Therefore, for N = 3 (rpm):
27.2$ [::N] $59.8 (sec/in 2-min)
Using these ranges of the variable quantities, the following ranges of generalized
journal bearing oil film Reynold Numbers are calculated using Eq. E-15.
At rated speed of 3600 rpm:
1688 :S (R N) ~ 30,340
At turning gear speeds of 3-30 rpm:
0.25 ~RN $ 2.5
E-22
These results tell us that, based upon the generalized Reynolds Number,
oil film flow will be, for the most part, fully turbulent at rated
speed operation, and
oil film flow will be laminar at turning gear speed operation.
When the nature of the oil film flow is turbulent, the performance characteristics
will change compared to its laminar flow characteristics. For the previously evalu-
ated example bearing operating at rated speed of 3600 rpm, the generalized Reynolds
Number is calculated as:
which indicates that the oil film flow will be fully turbulent. Figures E-7 through
E-ll are comparison plots of the journal bearing dimensionless performance parameters
for both turbulence conditions (R N = 8050) and for (assumed) laminar conditions (R N
= 0). As seen in these comparison plots, the performance parameters exhibit signif-
icant differences depending upon the nature of the flow. Such differences would
increase or decrease with increasing or decreasing values of the oil film general-
ized Reynolds Number.
In order to assess the effects of turbulence, let us again consider the sample prob-
lem previously ,evaluated for the assumption of laminar flow. For case (a) at
3600 (rpm), the Reynolds Number of the example bearing has been calculated as 8050.
Hence, we can use the solid line curves of Figures E-7 through E-ll to determine
values of the dimensionless performance parameters at the applicable value of
W* = 0.3865. Substituting these parameter values into Eqs. E-6 through E-ll to
evaluate the dimensional performance of the bearing under turbulent flow conditions,
we obtain the values tabulated in Table E-3. For comparison purposes, similar per-
formance values for assumed laminar conditions are also given in Table E-3. Compar-
ing the (actual) turbulent film predictions with the (assumed) laminar film predic-
tions, we note that there are startling differences, some of which are favorable and
others unfavorable. In particular, turbulent flow conditions generate:
(a) A large increase of minimum film thickness from 3.9 mils to 7.4 mils,
which is favorable.
(b) A dramatic increase in oil film friction power from 112 hp to 438 hp,
which is decidedly unfavorable from the standpoint of increased bear-
ing cooling requirements.
(c) A significant increase in bearing side leakage flow rate from 97 gpm
to 113 gpm, which is somewhat unfavorable from the standpoint of
increased bearing supply oil flow rate.
E-23
(d) A marked reduction in critical deadweight from 92,000 lb to
42,500 lb, which is decidedly unfavorable from the standpoint of oil
film stability.
(e) Significant reduction of oil film stiffness (Kyy ) in the direction

of applied load from -19.9 x 10 6 (lb/in) to -7.82 x 10 6 (lb/in),
which is unfavorable.
(f) Significant reduction of oil film damping coefficient (Dyy ) in the

direction of applied load, which is unfavorable.
From these results, it is seen that, except for minimum oil film thickness, turbu-
lent film flow, in general, degrades bearing performance and increases its lubrica-
tion and cooling requirements.
E-24
'uti
-------_1__ _..
~z
~ CD U
-
"'0
-
C:;~=-
0"
-
M
c
...
,-
EO
T
"-
N
U
Z
0
1.0
------------ II
a:
CJ' -
a::::.---t
I
0
II
'E
c
'--'
~
ttl
l.LJ
....
l.LJ ,.......-:--"1
J: ~ :E N
If')
..
a:" *ta. <y/
<t
a::
Z
v
C\I W ,,~ ~, 110 !a
r--: ....UJ 0
II
0,10
... ~~
I
Q. .-.. CD
II
n: ttl 0
:E o.~/
*u
&
<t
a::
lLI
t- /
Z
o- -X
0 -
X
I.L
II
a..
W
~ I t- 0 :t.
a:: en 0
-~
....... -
lLI a:: a:
txj ....
W
(J)
lJJ ~
LLtf)
o
f'
I Z
N ~ <.!)
lJl
a::
~
U
J: 0
3:
0.01 \~~" .O'Lf , 11.0 W~ ~
-

a.. t-
--I
IL.
(Q
Vf .....
m*~
II.
(J)
(J)
~
...J
lLI
(!) -" ~

",
:!
LL ~ ...J
<t
-J :E w Z
::J ...J a::
u
E
~
z L&J
0 " ::>
o
J
0: ~ (f)
0
0.01 0.10 1.0 10 100
JOURNAL BEARING PARAMETER = W*= 6.217 [W(CXIO;)2 J

(JLFxIO )0 4 N
Figure E-7. Comparison of Performance Parameters of a Hydrodynamic Journal Bearing for Turbulent Operation
(R N=80S0) and for Laminar Operation (RN=O)
(J)
0::
W
t-
lJJ
:E
<t ~
a::: It) Z
;;; ~ 1.01 I I ~ . .).., ~I 7
I
I I I 1.0
a.
(J)
(f)
0
-;
U
-
a
to
0
lJJ
Z
- .. )(
tL
l.L ..
lJ... .- =l
-~-
t- ~
(J) (\J
txj C\J
I C>
CD
N ~ 0
0\
0:::
L&J a I JAVI I I
.. 0.10 1 10.1
m
-J '-
*..: ~
<! II
Z
a:
:::>
0-,
0.01 0.10 1.0 10

3
W (CXI0 )2 ]
JOURNAL BEARING PARAMETER= W*= 6.217 [ 6 4
(fLFX 10 )0 N
Figure E-8. Comparison of Principal Direction Stiffness Parameters of Hydrodynamic Journal Bearing
for Turbulent Operation (R N=8050) and for Laminar Operation (RN=O)
(J)
a::
w
t-
lJJ
::E r---:-1
<l tI) Z
a:: - ~
~ ~ 0 10
I I 1'" I~ II'
I Y I I 10
.
(f) )( to
(J) U 0
lIJ--
z .- ~
LL
LL~_
.- :t..
. - \....-:...:.J
t- C\J
(J) C\J
C> W
Z 0
~ OC 0
N <X:
~ ~ ~ ~~ 0.10 :CI I I -I 0.10
..J ~ ~ ---,
<t II "O~ ,
z ,~V
~ ~~
:::> ,+:?
o....,
0.01 0.10 1.0 10

3
W (eX 10 )2 1
JOURNAL BEARING PARAMETER = w*= 6.217 [ (JLF xI0 6 )04NJ
Figure E-9. Comparison of Cross-Coupled Stiffness Parameters of Hydrodynamic Journal Bearing

for Turbulent Operation (R N=8050) and for Laminar Operation (RN=O)
.
(f)
a=:
.-ww I. 0 I I I 1.0
:E
,:;-r-'
0:::;;)
~OC
,
~
~-iD
C) x 0
0-
~~x
Q.. ._ lI.
tx:J ~c::t..
I
N
00
~
Q
It)
0.1 I I 10.10
~ b , ",'"
a:: It) -,,"

w
m
It)
0 ,,"
....J
<t
Z
N
0

--". "
II
a::: *.-:
::J
o a
J
0.01 0.10 1.0 10 100

w(eX 1<)3)2 ]
JOURNAL BEARING PARAMETER = w*= 6.217 [ 6 4N
(fLfxlO )0
Figure E-IO. Comparison of Principal Direction Damping Parameters of Hydrodynamic Journal Bearing
for Turbulent Operation (RN=SOSO) and for Laminar Operation (RN=O)
(J)
0::
W ,.--;--,
t-- rt')
,.... ~ ::.'\
w 0 ~o ,
~
rt')
,.... o~
0 4.D
<t: "qj~
0:: X 0
Q.. g x 1.0 '-~~, 1.0
~
Z
6
- LL.
=l
-..... .x
9"+ ~~,,0- I
,.....
L.-..!....-.l
0: ro ~+~
XV
*+
<:)"
::! '0 "., x
-If
<:)+~
0
L.I") x
t:rj ~ r<)
I Z
N 0
\0 ~ N
t
<I 0
w If
0.10 I I I f I I -I 0.1
(%)
o""'='
...J
*0
II /
z /
et:
::> /
0
~
/
/
I
I
0.01 0.10 1.0 10
3
W (CXI0 )2 ]
JOURNAL BEARING PARAMETER = W*= 6.217 [ 6 4
(fLFXIO }D N
Figure E-ll. Comparison of Cross-Coupled Damping Parameters of Hydrodynamic Journal Bearing

for Turbulent Operation (R N=80S0) and for Laminar Operation (RN=O)
Table E-3
COMPARISON OF PREDICTED PERFORMANCE OF EXAMPLE BEARING

FOR TURBULENT FLOW WITH THOSE FOR ASSUMED LAMINAR FLOW
(Perfectly Aligned)
D = 20.0 (in) C = 0.020 (in) (centrally loaded)
L = 16.0 (in) T F = 200 (OF) (~Fx106) = 0.715 (lb-sec/in 2 )

W = 64,000 (lb) N = 3600 (rpm) W* = 0.3865
RN = 8050
Laminar Flow Turbulent

(Assumed) Flow
Performance Quantity Symbol Units (R N = 0) (R N = 8050)
Minimum Oil-Film hmln

. (i n. ) 0.00394 0.00740
Thickness
Oil-Film Friction PF (hp) 112.3 438.4
Power
Side-Leakage Flow QF (gpm) 97.2 113.2
Rate
Critical Dead Weight Wc (1 b) 92,200 42,550
Oil-Film Stiffnesses KXX (lb/in. ) -4.8xl0 6 -4.8xl0 6
KXY II
+0.79xlO 6 +O.96xl0 6
KyX II
+12.8xl0 6 +9.6xl0 6
6 -7.82xlO 6
Kyy II
-19.9xlO
Oil-Film Damping DXX (lb-sec/ -8.43xl0 3 -13.54x10 3
Coefficients in. )
DXY II
+16.2xlO 3 +17.6xlO 3
DyX II +16.2xlO 3 +17.6xlO 3
Dyy II
-62.5xl0 3 -47.78xlO
3
E-30
E.4 THE EFFECTS OF MISALIGNMENTS
In the application of bearings, one is concerned with the following two distinctly
different and important types of alignment:
1. Load-sharing alignment which deals with proper positioning of the

hypothetical centerpoints of all journal bearings in both the verti-
cal and lateral directions with respect to some theoretical, straight
line reference axis in space. Equal load-sharing alignment is
achieved when the journal bearings are subjected to no more nor less
than their share of loading when the unit is fully assembled and
operating in its warmed-up condition.
2. Bearing alignment which implies the relative alignment of the sur-

face of a given bearing with the mating surface of the rotor (journal,
runner).
Load-Sharing Alignment
Figure E-12 presents plan and elevation view schematic illustrations of the uncou-
pled shafting of a three cylinder turbine and generator unit (total of four shafts)
when the centerpoints of all the unit's eight journal bearings lie on a horizontal
straight line (2 axis). In the plan view it is seen that the centerline axes of all
four shafts appear to lie on the same 2 axis. However, as seen in the elevation of
Figure E-12, the deadweight-induced vertical (Y direction) deflections of the vari-
ous shafting sections introduce misalignments of the shafting coupling flange sur-
faces and centerpoints, namely (pitch) rotational misalignment and (vertical) trans-
latory misalignment. The pitch inclination angle of the roth coupling flange and the
centerpoint elevations of the roth coupling are indicated as (Yc)m and (Yc)m' respec-
tively, on Figure E-12. The individual nth (journal) bearing reaction forces (due
to shafting deadweight only) are indicated as W~. The general slope (pitch align-
ment) of the deflected shafting at the axial station of a journal bearing is indi-
cated as an and it is noted that in order for the bearing to be ,aligned to the
inclined shafting, the centerline axis of the journal bearing bore must be inclined
at the same angle an.
For bearing design purposes, the deadweight loadings that would exist for uncoupled
shafting (W~) are used as the design point journal bearing loadings. If the eleva-
tions of all bearing centerpoints were positioned to lie on the same horizontal (2)
axis as shown in Figure E-12, the resulting magnitudes of the vertical reaction
forces at all the bearings would change as the various shafting coupling flange
faces are coupled and forced into alignment. Such journal bearing loadings will
E-31
-x
Br'g Centerpoints
+Z
~ J 1.)-Il1l-(e) \
~[tJ~ .
-z
+x
(a) Schematic Plan - View of Uncoupled Shafting
tJ:j +y
I
W
N
+ (Y c)m
Br'g Centerpoints
Shaft Centerpoints of
/ ' Flanges ' " Mating Flanges
+an
-z
W2 '
" Dead Weight /

Br'g Reactions (W n ')
-y
(b) Schematic Elevation - View of Uncoupled Shafting
Figure E-12. Schematic views of uncoupled shafting when all bearing centerpoints are on the same (Z) axis.
Deleterious cyclic shaft stresses and bearing loadings result when the coupling flanges are bolted together
and forced into alignment.
change in magnitude because of the necessary imposition of coupling lnterface verti-
cal shear forces and pitch moments on the shafting required to force the coupling
flange faces into alignment. In addition to deleterious changes in bearing loading
magnitudes, such forced alignment practices also introduce deleterious cyclic (once
per revolution) stresses on the coupling flanges and shafting.
In order to preserve journal bearing design point (deadweight) loadings and to mini-
mize cyclic shaft stressing, the vertical elevations (Y n ) of the bearing center-
points are purposefully displaced from the horizontal reference (Z) axis by varying
amounts in accordance with
calculated static (vertical) deflection characteristics of the

shafting due to deadweight, and
calculated thermally induced deflection characteristics of the

bearing support structure.
Figure E-13 shows schematic elevation and plan views of the coupled shafting illus-
trating the general catenary form of the vertical displacements of the journal bear-
ing counterpoints required to preserve design point bearing loadings (deadweight)
and to achieve conditions of zero shear force and zero moment loadings at the cou-
pling flange interfaces when the unit is in its warmed-up condition. For the situ-
ation illustrated [HP and generator coupling flange centerpoints on the horizontal
reference (Z) axis], it is seen that the elevations (Y n ) of the bearing centerpoints
increase as axial (Z) location of the bearing increases. When properly accomplished,
load-sharing alignment obtains the design point (deadweight) loadings on all the
bearings at only design thermal conditions for the bearing support structures and
minimizes any deleterious changes in bearing loading when actual thermal conditions
change from the design values. In order to achieve an acceptable degree of load-
sharing alignment during warmed-up operation,
the vertical elevations of the centerpoints of all the journal

bearings with respect to the horizontal reference centerline (Z)
axis must describe some form of catenary, and
the centerpoints must also lie in the same vertical (Y,Z) plane
which may necessitate lateral offsets of the bearings when cold.
In addition to unavoidable periodic, differential changes in thermally induced bear-

ing elevations, bearing reaction loadings are also adversely affected (increase
and/or decrease) by differential settling of the foundations upon which the bearing
support structures are supported. Any such differential settling of the supporting
foundations can be detected by periodic benchmark elevation measurements of the
E-33
-x
+z
eJ C ~ (e
-z
(a) Schematic Plan - View of Coupled Shafting
HP Coupling Flange
t:rj Centerpoint on Bearing
I
Ref. ~ Axis Centerpoint +a n
W
.f:'
W1/~
It/:) S o~~
~'l>-~
0 0 (\0
'"
+z Ref. ~ Axis-.., -2
Generator Coupling
Dead Weight Flange Centerpoint
Br'g Reactions on Reference Cl Axis
-y
(b) Schematic Elevation - View of Coupled Shafting
Figure E-13. Schematic views of coupled shafting showing purposefully displaced elevations (Yn) and
inclinations (an) of journal bearing Ci axes. "Zero" cyclic shaft stresses and "design point" bear-
ing loadings are achieved when bearings are elevated and inclined to account for shaft deadweight
deflections and bearing support structure thermally induced deflections.
of the foundations, particularly during the early service life of the unit. Other,
more subtle but deleterious changes in load-sharing alignment can also be caused by
the occurrence of
excessive wear of a given bearing,
changes in radial load on adjacent bearings (increase in one and

decrease in the other), and/or
excessively, high temperature of a given bearing.
In summary, then, it is essential that a sufficient degree of load-sharing among

the journal bearings be achieved when the unit is operating in its warmed-up condi-
tion. Unless adequate load-sharing alignment is achieved and maintained, certain
bearings will be subjected to deleterious higher loads (introducing the possibility
of metal-to-metal contact) while some of the rest of the bearings will be subjected
to deleterious lower loads (introducing the possibility of oil film instability
and/or oil film whirl or whip). Basically,
journal bearing load will increase if its centerpoint elevation is

too high due to faulty initial installation, abnormally high thermal
environment around its supporting structure, abnormally high operat-
ing temperature of the bearing support structure, or a decrease of
load on an adjacent bearing, or
journal bearing load will decrease if its centerpoint elevation is

too low due to faulty initial installation, abnormally low thermal
environment around its supporting structure, settling of its support
foundation, bearing wear, or an increase of load on an adjacent
bearing.
The degree of deleterious changes in the magnitudes (increases and decreases) of

bearing loadings on a given turbine generator unit will depend upon
(a) the vertical elevation relationships among all of its bearing

centerpoints, and
(b) the flexibility characteristics of the rotor shafting they support

and of their supporting structures and foundations, all of which
are flexible to some degree.
With regard to load-sharing among all of the journal bearings, flexibility of the
rotor and of the bearing support structures and foundations would be beneficial.
However, increasing the flexibility of these members introduces the distinct possi-
bility of experiencing excessively high dynamic vibration problems, which is decid-
edly unfavorable.
E-35
Since there is only one (bidirectional) thrust bearing to provide the necessary axial
direction (Z) reactions, there is no need, as such, for load-sharing of its two
(opposed) thrust bearing surfaces.
Bearing Alignment
In addition to achieving adequate load-sharing alignment of all of the journal bear-

ings, it is also essential that each journal and thrust bearing surface be aligned
with the surface on the rotor upon which it bears. We shall call such bearing-rotor
surface(s) alignment the bearing alignment.
The members of a journal bearing are considered to be perfectly aligned when the
hypothetical axial centerline of the cylindrical (bore) surface on the bearing is
parallel to the hypothetical axial centerline of the cylindrical (journal) surface
on the rotor against which it bears. In steam turbine applications, the fixed types
of journal bearings normally used have a ball-and-socket bearing mounting arrange-
ment. This arrangement, in theory, allows a bearing to align itself to a journal;
however, in practice, the relatively large size of the aligning surfaces makes it
difficult to align during assembly and to maintain alignment during operation.
Tilting pad journal bearings that use spherical (button) pivots are inherently self-
aligning, while those using cylindrical pivots are not.
The members of a thrust bearing are considered to be perfectly aligned when the
flat, annular-shaped surface of the bearing is parallel to the flat, annular-shaped
surface on the rotor which is perpendicular to the axis of rotation of the rotor.
Typically, a fixed type thrust bearing is incorporated on the outboard end face(s)
of a ball-and-socket mounted journal bearing. When the journal bearing bore is
aligned with its journal surface, the thrust bearing surface is aligned with its
rotor surface. Note that the converse is also true; that is, if the journal bearing
is misaligned, then the thrust bearing is also misaligned. The individual pads of
a tilting pad type thrust bearing having spherical pivots are inherently self-
aligning. However, unless it is of the fully equalized load-sharing type, the gen-
eral surface plane described by all of the pad surfaces may be misaligned so that
some of the pads carry more load than others.
In principle, the oil film bearings used incorporate by design concept some form of
static self-aligning feature. In practice, the ability of a given bearing member
to align itself to the time-varying spatial changes of the pitch (about X axis) and
yaw (about Y axis) inclinations of the rotating (about Z axis) rotor requires the
E-36
overcoming of the contact frictional torque generated at the loaded interface of
the aligning mechanism (i.e., the ball-and-socket joint). Furthermore, the torque
required to overcome the alignment-resisting friction torque must be generated and
applied to the bearing member by the loading on the bearing. In essence, the rotor
journal must force the bearing surface to change its pitch and/or yaw inclination so
that the bearing surface becomes aligned to the rotor journal. Ideally, such
alignment-restoring moment capability is generated by the interposed oil film with-
out any metal-to-metal contact at bearing outboard edges.
Figure E-14 provides schematic cross sections of a ball-and-socket full film lubri-
cated journal bearing for the cases of:
(a) perfect alignment of the bearing with respect to the journal, and
(b) misalignment or che bearing with respect to the journal.
As shown, the oil film load-carrying pressure distribution for perfect alignment is
symmetrical, hence, the radial load (W) acts at the bearing mid-plane (i.e., pure
radial load). When the members are misaligned, a skewed oil film pressure distribu-
tion is inherently generate~. For this case, the oil film loading provides a moment
load (MF = W x 2) in addition to the radial load (W). It is this film moment load
(MF ) which, ideally, overcomes the frictional resisting torque (M S = fSWSR S ) of the
ball-and-socket joint. From the geometry of Figure E-14(b), it can be deduced that
in order for aligning motion to occur, the coefficient of friction of the ball-and-
socket joint must be less than the value prescribed by:
(E-16 )
where
fS coefficient of static friction of ball-and-socket joint
~ axial offset of radial load W (in)
L axial length of bearing bore (in)
DS spherical diameter of ball and socket (in)
D diameter of journal bearing (in)
The following design geometry ranges are applicable for turbine bearings:
0.6 ~ (L/D) ~ 1.0
1.2 ~ (DS/D) ~ 1.8
E-37
_ _~ Symmetrical
Oil-Film Pressure
Distribution for
Aligned Case
Journal
(a) Aligned Br'g Socket of Radius Rs = ~s
WS=WF
WF1= FsRs
Fs = fsWs = fSWF
Skewed
Oil-Film Pressure
Distribution of
Misaligned Case
a = Misalignment
Slope Angle
(b) Misaligned Br'g
Figure E-14. Schematic Geometry of Aligned and Misaligned Journal Bearings and
Axial Distributions of Their Oil Film Pressure
E-38
Therefore,
The quantity [t/(L/2)] is zero for perfect alignment and increases with increasing
misalignment of the bearing members. A reasonable upper limit for the maximum value
of [t/(L/2)]F without contact is
[t/(L/2)]max ~ (1/3) (E-17 )
Thus, the ball-and-socket joint static coefficient of friction (to maintain zero-
contact) must be less than
1
(FS)max .$"9 ~ 0.111 for small L/D ratios
and large DS/D ratios
or
5
(FS)max ~ 18 ~ 0.278 for large L/D ratios
and small DS/D ratios
In any case, to avoid contact, the ball-and-socket joint coefficient of static fric-
tion should be less than
(E-18 )
While ball-and-socket joints are normally precision-made (ground to controlled

tolerances), they are not purposefully or effectively lubricated. When new, the
coefficients of friction of ball-and-socket joints are probably in the range of
0.05 ~ f new .$ 0.08
With long-term usage, the range probably increases to be
0.08 .$fold ~0.15 or higher
Accordingly, it would appear that the pitch/yaw orientation of a loaded journal

bearing can only be forced to align itself if a high degree of bearing-to-journal
misalignment exists.
E-39
There have been problems in the past with self-aligning ball-and-socket mounted
bearings becoming misaligned because they were "free" to move and locking up the
ball member after achieving initial bearing alignment is sometimes practiced.
Bearing misalignment occurs When the opposing surfaces (at a cross section normal
to the direction of motion) become nonparallel. Thus, changes in spatial orienta-
tion of the rotor and/or of the bearing member produce changes in bearing alignment.
Such bearing misalignments can occur
in a continuing dynamic mode (changing rapidly with time, i.e., once,

twice, etc., per revolution),
in a continual quasi-steady-state mode (changing slowly with time),

or
in a steady-state mode (not changing with time).
At any given time all three modes of bearing misalignment of some degree exist
within all of the individual bearings, whenever the unit is being driven at any
speed. For example:
Bearing alignment changes in a dynamic mode due to manufacturing

tolerances and assembly and installation errors of the coupled,
multiple section shafting. The results are relative radial offsets
and nonparallelism of the centerline axes of rotation of the indi-
vidual journal surfaces on the rotor, which cause caming and wobbling
motions of the journals when the rotor is rotated. Dynamic bearing
alignment changes are caused, primarily, by the rotating rotor. The
frequencies of bearing alignment dynamic changes are usually multi-
ples of rotational speed (i.e., once, twice, etc., per revolution).
Bearing alignment changes in a quasi-steady-state mode are usually

associated with transient operating conditions during startup, warm-
up, unit loading changes, coastdown, and cooldown. Bearing alignment
changes also occur during the initial operation of new units when the
various multiple interfaces of the ball-and-socket joints, housings,
pedestals, and foundations settle. The magnitudes of quasi-steady-
state bearing alignment changes are generally greater than the magni-
tudes of dynamic bearing alignment changes but occur at much lower
frequencies (i.e., cycle times measured in tens of thousands of revo-
lutions). Quasi-steady-state bearing alignment changes are associ-
ated with relatively slow changes in the inclination of the bearing
member centerline axis due to gradual pitch and/or yaw movements of
the ball within its socket, of the bearing housing, of the bearing
pedestal, or of the foundation.
Some degree of steady-state bearing misalignment still will exist

even when components settle and unit operation is constant.
E-40
In general, bearing misalignment has two components of rotation of the bearing cen-
terline (2) axis with respect to the rotor centerline axis:
pitch component rotation about the horizontal (X) axis
yaw component rotation about the vertical (Y) axis
The occurrence of one or both of these bearing-to-rotor misalignment components

always results in the generation of both pitch direction and yaw direction reaction
moment components by the hydrodynamic bearing fluid film. For example, if the bear-
ing is misaligned in the pitch direction with respect to the journal [i.e., tilted
about the horizontal (X) axis], an oppositely directed pitch direction restoring
moment component will be automatically generated by the oil film and a yaw direction
moment component about the vertical (Y) axis will also be generated.
The effects of pitch bearing misalignment component on the performance characteris-

tics of a hydrodynamic journal bearing are presented in dimensionless form in Fig-
ures E-15 through E-17. For comparison purposes, the same results for perfectly
aligned members are also plotted (solid lines) on these figures. The dimensionless
misalignment (tilt) angles are defined as:
Dimensionless Pitch Misalignment [(aXL )/(2C)] (E-18)
Dimensionless Yaw Misalignment [(ayL)/(2C)] (E-19)
where
aX pitch inclination of bearing with respect to journal (in/in)
ay yaw inclination of bearing with respect to journal (in/in)
L axial length of bearing bore surface (in)
C radial clearance of bearing (in)
The dimensionless restoring moment component parameters are defined (for the example
bearing having L/D = 0.8) as:
(E-20)
E-41
,..,.
<J
""-
z
2
~
........ - [Lax]
ax= 2C
II
0::
LLI
II
~
Z w
~
::I:
II
, ,
A'o
~ I a- _
y-
[L a y ] -0
--
_
:E

0::
~ 2C a.. r-:c\j'
0:: ,~ + z
W
~
w 0.10 I I I 1l
'fo
~ '\,.
~RG MEMBERS ARE
PERFECTLY ALIGNED 10 a: a."...
LL~
:E LLI
\ q/ WHEN ax =" 0
U)
~ ,1)0
a: \ 0 0-
a.. a. -x
\ P..* FOR ax
- =0 X LL
en
en .......
A-~ --
---- ,,,- .01
Z
0
O:l.
~....,.,
L-..:-.J
, i=
w 'F FOR---" Qx=_'
,. ~ O. 5
"...
z a lC , U en
~ ~ O
U LL ~
~
I :f r--
C\I
I I .
C)
.p..
N
t- 0.01 I I I
I I 'x 11.0 Z <D
:E a: 0
d I
LLI
LL
I m
~
::>
I ..J

z I Z
0::
Z ::>
~ ...,
0
II
0.01 0.10 I. 0 10 100
'*a. LL
JOURNAL BEARING PARAMETER =6.217 [W(CXIO:>2 4

(JLFxIO )0 N
J= w*
Figure E-15. Minimum Film Thickness and Friction Power Parameters of a Hydrodynamic Journal
Bearing for Various Pitch-Direction Misalignments
U
:t vc
~~ .D
~O 0
,.....--,
- X
U X I.L
[ Lax]
lL. Z U :l
......-. ......-.
Q~ FOR a~ ~ ~ O~"--"~
0 N
L-..:.-J
0
..
l.-.-.J
~
---------- ax= 2 C
*u
I~
E
* ~ o.~"
J()
<X) ..
..
*u. 0.10
0 Of f~" ."" ~~"'0
~
",0'\ . , , /
II if =
v
[L a
2C
y ]
=0 0.1
a::
.-
IJJ
LLJ
II BEARING MEMBERS ARE ~
0:: oil:-,
.-LLJ
W
------ -t<C:
01(
PERFECTLY ALIGNED
WHEN ti X =0
a::

~ n..
<{
0:: ....
:r:
<{
~
I
a. (!)
~ IJJ
Lv 3= 0.01 ~ If' I I I I 0.01 ~
0
...J ~
LL o.\~ 0 c
W ~ $":-. ~ '"

C> * 0. ~ ". '()....
LLJ
C
~ \C fO~~ o~

w ",' 'v *~ ..J

u
.-J
l.IJ
0
E
a::
en u
0.01 0.10 1.0 10
JOURNAL BEARING PARAMETER =W*= 6.217

3
W(CXI0 )2 J
[ (J.LFxIO 6 )0 4 N
Figure E-16. Side-Leakage and Critical Deadweight Parameters of a Hydrodynamic Journal

Bearing for Various Pitch-Direction Misalignments
~Hanz
~
~
u c
LL.
=l
I
, I
I
I
L ax]
ax= [ -U-
r--:--1
N
Uc
Z
If')
>- LL.
f'. I I
I'-
r--: .,1 .... / _ [La v1
Qy = 2CJ=0
~
~
:t..
. 07 0", r--
"'x ~I
" Yo
"I I
I'-
~
+t &"tt~ ~
a::
w
~
.. 0.01
.-
+M:!P.!i !X':':05_ $/
~/
If. .0/
~~'1
-()
II
_I
/!
BEA~ING
NOTE:- FOR ALIGNED
:fNUMBERS (QX=O) 0.01
II
*>-
:E
0:: T - -.tJ 0/
X
M My=O
II
a::
"if. "., ",. / " ,:I ....w
.-z / ,,~ lLJ
~
\ :E
/ \
~~

a::
t'Xj
I
0.001 / \ g,'
a..
~
~
Z
__ ---"1"
+My.!OR ax:+ 0.1
/ '
"I~
'.':,
1,1
---
, I
I
....
z
1 0.001 w
~~
0 / :E
/ 'I o
/,/ \I I :E
!!: ,," ,. , z
a
is
!:: I I I
~ I I I I 'I
"
III
o
i=
o
w
a::
0.01 0.10 1.0 10 C
Q.. I
~
JOURNAL BEARING PARAMETER = 6.217 [W(CXIO:>2 4 1= w*
>-
(JLFXIO lO NJ
Figure E-17. Pitch and Yaw Direction Moment Parameters of a Hydrodynamic Journal Bearing for Various
Pitch-Direction Misalignments
and
(E-21)
The performance parameter results in Figures E-15 through E-17 are for a hydrodynamic
journal bearing having
L/D 0.8
two 160 0 pads
central loading
operating at a Reynolds Number of RN 8050 (turbulent flow)
As can be seen, pitch misalignment serves to
reduce minimum film thickness appreciably (unfavorable)
reduce friction power somewhat (favorable)
increase side leakage flow at lower values of W* (favorable)
increase the critical deadweight (favorable)
introduce the generation of a pitch alignment restoring moment

reaction (MX) which is favorable, and the generation of yaw moment
reaction (My) which is unfavorable
It is also seen that the effects of pitch misalignment increase with increasing mag-
nitude of pitch misalignment (aX).
Pitch misalignment also affects the four stiffness and four damping parameters
somewhat, but these curves have not been plotted.
Similar effects on bearing performance are also experienced when there is yaw
misalignment.
Table E-4 is a summary tabulation of dimensional performance quantities for two

pitch misalignment conditions of the example bearing problem previously evaluated
in Section E.3. For comparison purposes, the performance quantities for perfect
alignment are also included in Table E-4. Comparing the results for a pitch mis-
alignment magnitude of 0.00125 (in/in) with the results for perfect alignment, we
observe that
E-45
minimum film thickness is reduced by about 90% (decidedly
unfavorable)
bearing viscous friction power is reduced by about 25% (favorable)
side leakage oil flow (lubrication required) is virtually unchanged
critical deadweight is increased by about 40% (favorable)
principal direction (XX and YY) stiffness and damping increase

slightly (favorable)
The exceedingly small value (0.000086 in) of minimum oil film thickness calculated
for the 0.00125 (in/in) pitch misalignment implies that some degree of deleterious
metal-to-metal contact of the bearing members would probably occur.
E-46
Table E-4
EFFECTS OF PITCH MISALIGNMENTS ON PERFORMANCE

QUANTITIES OF EXAMPLE BEARING EVALUATION
D = 20 (in) C = 0.020 (in) (centrally loaded)
L = 16 (in) TF = 200 (OF) (~Fx106) = 0.715 (lb-sec/in 2 )

W = 64,000 (lb) N = 3600 (rpm) W* = 0.3865
RN = 8050
Perfectly Pitch Misaligned

Aligned ~x : 000025 ax = .00125
Performance a =0 y ay =0
aX = 0
Quantity Symbol Units y (in./in. ) (in./in.)
Min. Film Thickness hmin (i n. ) 0.00740 0.00594 0.00086
Friction Power PF (hp) 438.4 403.1 331.5
Side-Leakage QF (gpm) 113.2 113.0 112.5
Critical Dead-Wt. Wc (1 b) 42,550 42,600 60,680
Oil-Film Stiff- KXX (lb/in. ) -4.8xl0 6 -4.8xl0 6 -4.6xl0 6
nesses
KXY II
+.96xlO 6 -1.24xl0 6 -.77xlO 6
KyX II
+9.6xlO 6 +10.5xlO 6 +11.3xl0 6
Kyy II
-7.8xl0 6 -8.6xl0 6 -11.9xl0 6
-13.5xl0 3 3 -13.6xlO 3
Oil-Film Damping DXX (lb-secl -15.2xlO
Coefficients in. )
DXY II
+17.6xlO 3 +14.5xl0 3 +13.5xl0 3
DyX II
+17.6xlO 3 +14.5xl0 3 +13.5xlO 3
3
Dyy II
-47.8xlO 3 -50.4xlO 3 -53.9xlO
E-47
E.5 OIL FLOW HEAT BALANCE
Analytical evaluation of the dimensional performance and requirements of hydrody-

namic bearings involves the use of an assumed value of the effective absolute vis-
cosity (~F) of the oil within the load-carrying oil film(s). The absolute viscosity
of a particular oil is dependent upon and varies inversely with the temperature of
the oil. Therefore, when one assumes a particular value of absolute viscosity (~F)
to use as input, one is assuming a particular temperature (T F ) at which the given

oil has the absolute viscosity value assumed.
In bearing applications, the effective average temperature (T F ) is a dependent vari-

able quantity, whereas, in the analytical evaluation of oil film bearings, one con-
siders it to be an independent variable. What this implies, therefore, is that when
an analytical evaluation is made for a given oil viscosity value (~F)' at a given
temperature (T F ) for a given oil, the dimensional performance results calculated are
only valid for a given set of values of the pressure (PS) and temperature (T S ) of
the oil in the supply oil header at the inlet to the branch line supplying oil to
the given bearing. In turbine applications, both of these quantities are controlled
to be within certain limits and, hence, are independent variable quantities.
The supply oil header pressure (PS), the hydraulic resistance characteristics of the
branch supply oil line, and the pressure (Pg) of the oil within the internal oil dis-
tribution grooving in the bearing surface dictate the flow rate (QS) of the supply
oil entering the bearing. Thus, the rate of flow (QS) of supply oil is a dependent
quantity. The pressure (Pg) of the oil within the relatively deep oil distribution
grooving pattern(s) is also a dependent quantity, the value of which must be less
than that of the supply oil header pressure (PS) in order for the cool oil from the
supply oil header to flow into the bearing oil groove(s). Depending upon the loca-
tion and configuration of the grooving and the side-leakage flow rate exiting from
the oil film, the groove pressure can even be subambient or less than the bearing
cavity ambient pressure, which would tend to increase the flow rate of supply oil to
the bearing. In any case, the important consideration is that the oil grooves be
maintained filled with oil, particularly at the leading edge(s) of the close clear-
ance load-carrying oil film(s), so that the rotating journal can pick up sufficient
oil and drag it into the load-carrying oil film. If the oil grooves are maintained
filled with oil at ambient pressure (Pg = Pa)' then the flow rate of supply oil
entering the bearing (QS) will be identical to the side-leakage flow rate (QF) of
the oil film. This supply oil flow rate condition (QS = QF) is termed a classical
flow condition. If the oil groove is pressurized (Pg > Pa)' the supply oil flow
E-48
rate (QS) will be greater than the side-leakage flow rate (QF). This supply oil
flow rate condition (QS > QF) is termed an excess flow condition. Conversely, if
the oil groove pressure is subambient (Pg < Pa)' the supply oil flow rate (QS) will
be less than the side-leakage flow rate (QF). This supply oil flow rate condition
(QS< QF) is termed a starved flow condition. Normally, the flow rate condition for
all of the bearings in the steam turbine application is an excess flow condition
which implies that each and every bearing is supplied with more than enough flow
rate (QS) of cool oil to satisfy their side-leakage flow rates and to remove addi-
tional heat from the bearing.
Since the hydraulic resistance of the branch supply oil line is ill-defined and
since the hydraulic resistance of the bearing clearance volume is a highly variable,
dependent quantity, it is difficult to include the effect of supply oil header pres-
sure (PS) in the analytical calculations to predict bearing performance. An easier
dependent variable to consider is the supply oil flow rate QS For the most part,
at full speed operation any excess flow rate (QX) due to groove pressurization is
probably relatively small with respect to the side-leakage rate (QF). Hence, a rea-
sonably valid starting point is to assume that the supply oil flow rate entering the
bearing is equal to the side-leakage flow rate.
That is,
Qs = (QX + QF)' (excess flow condition).
For QX QF' then

Qs ~ QF' (classical flow condition).
With this assumption of QS ~ QF (or any other assumed supply value of QS > QF)' the
performance of a heat balance on the flowing oil allows back-calculation of the sup-
ply oil temperature required to make valid the bearing performance results that were
calculated using the assumed value of oil film average viscosity (~F).
Purpose and Approach of the Heat Balance
The principal purpose of the heat balance is to calculate the temperature (T S ) of

the bearing supply oil temperature required to make the average oil film temperature
(T F ) be equal to the assumed value used to evaluate the bearing performance quanti-
ties. To perform the heat balance, a reasonable and realistic model must be estab-
lished which includes the various flow paths of the flowing oil from the supply oil
E-49
header, through the branch supply oil line, into the oil groove, into the oil film,
out of the oil film, into the drain cavities, out of the drain cavities, and into
the oil return line. All of the flows are identified and the flow rates are known
or assumed. To begin, only one temperature is ~ssumed, namely, the average oil film
temperature (T F ).Another important input is the bearing frictional power (P F )
which serves to heat up the oil. If known, other heat sources or heat sinks within
the model are identified and quantified. The next step involves the writing of vol-
ume flow rate and heat flow rate equations that equate the volume and heat flow
rates entering a certain region of interest to those leaving the region. The multi-
ple equations established are then manipulated to allow calculation of the oil tem-
peratures at all the regions of interest.
The Heat Balance Model
Figure E-18 represents a somewhat simplified heat balance model that would be rea-
sonably valid for use in estimating the temperatures of the flowing oil at various
locations within the bearing and throughout the lubrication supply/return/reservoir
subsystem. The symbols used refer to
Tn nth oil temperature, (OF)
Qn nth oil flow rate, (gpm)
Pn nth oil pressure, (psig)
The blocks represent the regions of interest, and the directional lines connecting
them represent the various ~low paths of the oil.
The oil begins its journey from the oil reservoir by first passing through the supply
oil pumping system and heat exchanger before entering the bearing supply oil header.
The model shown indicates details of only one bearing which is supplied with some
flow rate QS at temperature TS The other bearings also receive their supply oil
flows from the same header. Flow rate QS to the bearing passes through the bearing
supply oil branch line and enters the bearing oil groove(s). The carryover (recir-
culating) oil flow Qe also enters the oil grooves. Exit paths for the oil in the
oil grooves are into the leading edge(s) of the oil film(s) [flow Qi at temperature
Tgl and into both drain cavities (flow QX = QXI + QXZ) if QSsupplied is greater
than bearing side-leakage flow (QF = QFI + QFZ) Some of the oil flow Qi entering
the oil film(s) exits from its side edges (QF = QFl + QFZ) and from its trailing
edge(s) (Qe). The trailing edge(s) flow Qe recirculates back into the oil groove(s).
The side leakage flows (QFI and QFZ) enter the two drain cavities. Before entering
E-50
QX .2
Drain Cavity 2
atT,
Recirculating Oil
Oil T Qi
Groove(s) g @ Tg
atTs
atT, Drain Cavity 1
~
"Oil to Other
~4. ---. ---. ~ ----.,
I
- - - - -
Other Bearings
- -
I
~ ~
~~eturnOilfrom
Other Br'gs
---.
<0 / .~OJ~QT@Ts
v~'/' _ I
8
L QT@ToD
Ps
/~ ~
<Q0 Q xs = Excess Supply Header Oil Return Q
--@-=r: --+ --+ --+ --+ --- --+ ---.. --- --+ --+ ~ TR
Return-Oil Header at
Supply-Oil Header at T=TR , p= PR
T= Ts , P = ps
Supply-Oil
Pumping Oil
Sub-System Reservoir
----------~ Pp
Figure E-18. Simplified Typical Heat Balance Model for Flowing Oil (only
one bearing illustrated)
E-51
the bearing return oil branch line, the oil from both drain cavities combines to
form flow rate QD = QF + QX QS After passing through the bearing return oil
branch line, the oil enters the return oil header where it combines with return oil
from the other bearings before, finally, returning to the oil reservoir.
Heat is added to the oil within the oil film(s) by virtue of dissipation of its fric-
tional power (P F). Also, heat can be removed from the oil film (+HF ) or added (-HF )
by virtue of heat transfer. In any case, the total heat power added to the oil in
the oil film(s) of the bearing is (P F - HF ) Similarly, the total heat added to the
oil film oil in the other bearings is [(PF)T - (HF)T] Heat is removed from the oil
by the cooling power (He) of the heat exchanger. Likewise, some cooling power (H R)
is provided by heat transfer from the hot oil in the reservoir to its ambient envi-
ronment. The relationship among the various friction powers and heat transfer
powers is:
(E-22 )
From the performance predictions for a given bearing, the following quantities will
be known:
TF average oil film temperature (OF)
Qi flow rate entering leading edge (gpm)
QF (QFl + QF2) = total side leakage (gpm)
PF frictional power (horsepower)
Since TF (1/2)(T g + Te ), then
(E-23 )
and since Qi QF + Qe' then
(E-24 )
Equating the oil film heat rate inputs to the heat rate outputs from the oil film,
we can write the following heat rate flow equation:
E-52
2(T F - Tg ), we can solve for temperatures Tg and Te as:
42.4(PF - HF)
TF - (YC )F(2Qi - QF) (E-25)
p
42.4(P - H )
F F
TF + (YC )F(2Qi - QF)
(E-26 )
p
Performing a similar heat balance for flows entering and leaving the oil groove, we
can write:
Substituting other known relationships, we can evaluate the required temperature of

the bearing supply oil as
(E-27 )
The return oil temperature (Tn) can be calculated as:
42.4(P - H )
F
F
(E-28 )
(YC p )F(2Qi - QF)
Note: When QS
The quantity (YCp)F is the heat content property of the lubricant (Btu/gal-OF) at
temperature TF which can be obtained (see Table E-l).
Thus, all of the quantities required to calculate the various temperatures of inter-
est are known except for HF (if any) and supply oil flow rate QS For subsequent
discussion purposes, let us assume that there is no heat transfer out of (or into)
the oil within the bearing oil film (i.e., HF ~ 0). With this assumption of zero
E-53
heat transfer, the temperatures of interest can be calculated as follows in the order
indicated:
(1) groove-to-fi1m temperature rise:
(E-29 )
(2) groove oil temperature:
(E-30)
(3) carryover oil temperature:
(E-31 )
(4) bearing return oil temperature (function of QS):
(E-32 )
(5) -required supply oil temperature (function of QS):
(E-33 )
In order to illustrate the use of such heat balance equations, let us consider the
performance results obtained for the bearing evaluated in Section E.3 (Table E-3)
from which known values are:
TF 200(OF) (assumed)
PF 438.4 (hp)
Qi 275.0 (gpm)
QF 113.2 (gpm)
From Table E-1, (YCp)F = 3.681 (Btu/gal-OF) at IF 20QOF. Substituting these values
into the above 5-step equations, we obtain:
E-54
(2) Tg (200 11.558) 188.442 (OF)
(3) Te (200 + 11.558) 211.558 (OF)
(4) Tn 200 - [ 1 - ~
113.2 ] (11.558) ?
(5) TS = 200 - [1 161. 8

+~ ] (11.558) ?
Note: Tn and TS are functions of QS
In order to evaluate the required supply oil temperature and the resulting drain oil
temperature, a value of supply oil flow rate must be assigned. From the earlier dis-
cussion, it was noted that the supply oil flow rate (QS) must be equal to or greater
than the side-leakage flow rate (QF). Assigning various values of QS ~ QF' we obtain
the following results for drain oil temperature and required supply oil temperature.
Qs (gpm)
Classical Flow ~ ~ 1.0 113.2 200.000 171.921

1.2 135.84 198.074 174.674
1.4 158.48 196.698 176.635
1.6 181.48 195.666 178.116
1.8 203.76 194.863 179.263
2.0 226.40 194.221 180.181
2.5 283.0 193.065 181.833
3.0 339.6 192.294 182.934
Infinite Flow ~ ~ 00 00
188.442 Tg 188.442 + Tn Tg TS
Interpreting these sample problem results we can state that: If the bearing is sup-
plied with oil at a flow rate and temperature of, for example,
Qs QF = 113.2 (gpm) , and

TS 171.921 (OF)
then,
(a) the average oil film temperature will be
E-55
(b) the groove oil temperature will be
Tg = 188.442(OF),
(c) the carryover oil temperature will be
Te = 211.558(OF),
(d) and the drain oil temperature will be
Tn = 200.000(OF)
For turbine bearing applications, the supply oil header pressure is usually con-
trolled to be within the range of
For the above example problem, the value of TS required (to yield an average film
temperature of TF = 200F) was 171.9(OF), which is much higher than the control
range of TS What this implies is that if the supply oil header temperature (T S ) is
within its control range of lOO-120(OF), the actual average oil film temperatures
will be less than the assumed value of 200F for the example problem. Thus, in
order to establish the actual value of TS ' one must restart the evaluation process
from the beginning using a new (lower) assumed value for average oil film tempera-
ture. Figure E-19 illustrates the general trends of the resulting actual oil tem-
peratures as functions of supply oil temperature, for the case of QS = QF. The cir-
cled data points are those obtained for the evaluated case of TF = 200F. The trend
of decreasing oil temperatures within the bearing as supply oil temperature decreases
is readily apparent.
Since oil temperature changes with supply oil temperature and since fluid viscosity
changes with temperature, it necessarily follows that all of the bearing performance
characteristics will also change. Figure E-20 illustrates the general trends of
variations of performance with changing supply oil temperature for a given bearing
operating at a given speed and subjected to a given load. The plotted curves repre-
sent the ratios of the values of the performance quantities for any temperature TS
divided by their values at a temperature of TS = T = 172F for our sample problem.
S
It is seen that if the supply oil temperature TS is within the control range, then
compared to the sample problem performance quantity results,
minimum oil film thickness will increase (favorable)
friction power will increase (unfavorable)
E-56
critical deadweight will decrease (unfavorable)
side-leakage flow will decrease (mixed blessing)
carryover (recirculating flow) will increase (unfavorable)
In summary then, a thorough evaluation and prediction of the performance character-

istics of any bearing must include a valid "heat balance" in order to: (1) gain
assurance that its performance capabilities are adequate when the supply oil temper-
ature (T S) is within its control range, (2) gain insights into bearing performance
if the control range of TS is exceeded, (3) establish the minimum supply oil flow
rate required, and (4) evaluate any benefits of increasing the flow rate.
E-57
TRENDS OF VARIOUS OIL TEMPERATURES AS FUNCTIONS OF
SUPPL Y - OIL TE MPERATURE FOR SAMPLE PROBLEM BEAR-
ING SUPPLIED WITH AN OIL FLOW RATE EOUAL TO THE
BEARING SIDE-LEAKAGE FLOW RATE (QS=' QF)
NOTE:- FOR THIS CONDITION,
TD = TF
260
lL.
IL 0
240 0
0
0 N
0
n a
)(
~ C
220
-~ 2
.......
2
......fI)
I-
200
TEM~ \~G
,... CONTROL '\e ~
lL RANGE
!.-180
lIJ
..
r
:::l
~160
a:
LaJ
a.
:E
lJJ 140 ~
~ 1&.1
~
m
..J 0
0
a:
Q.
" 120 .....
.... ..J
a.
~ ~
0 ~ en
100
>-
~
a:
a.. II..
0
a..
80 / :::)
en
80 100 120 140 160 180 200 220

T5 = SUPPL Y - OIL TEMPERATURE, (OF)
Figure E-19. Trends of Various Oil Temperatures as Functions of Supply Oil

Temperature for Sample Problem Bearing Supplied With an Oil Flow Rate Equal
to the Bearing Side-Leakage Flow Rate
E-58
Classical Flow OS= OF
Constant Load, Speed on Given Br'g
.u.. LL.
3.0 0 0
0
,...
0 N
0
,...
III: 1I)t
c:s
'i Ts E
~ Control ~
Range .E 1 E
~ u..1~ .....
~ ~ o .c
II
Nlo
,..... ~ ,~
'0 ,... a.
~~ ~
. .III ~
Q)
:J a. 'b
i '0
> Q) ~I E ~
>. :J ~ II S Q
c: i ~.~ J::',.: ~I(1) ~
<{ > 2.0 ICt"
101} S
E ~
E
>. >.
JO
o
~(9r
I (j
5 5 I /~G
Q)
0
c:
Q)
0
c:
I
S
E
S
E
I
~
~
.E I
Q)
Q)
I
~ I
II
Qi' Inlet Flow.
CJ)
0 1.0
:;
a:
Q)
0
c:
S
E
E
Q)
a.
80 100 120 140 160 180 200
TS = Supply-Oil Temperature, (OF)
Figure E-20. Trends of Bearing Performance as Functions of Supply Oil

Temperature
E-59
E.6 FIXED VS. TILTING PAD BEARINGS
There are basically two types of bearings used in steam turbine generator units.
They are the fixed type and the tilting pad type. Typically, the fixed types con-
sist of the axial groove and elliptical configurations for the journal bearings and
the tapered land configuration for the thrust bearing. The tilting pad configura-
tions are utilized for both journal and thrust bearings.
The reason for going from a fixed geometry to a tilting pad type depends upon the
application. For the journal bearing application, the major reason is dynamics.
The tilting pad journal bearing is inherently stable (free of bearing half-frequency
whirl). For the example given in the previous subsections (Table E-3, Turbulent
Flow), the fixed 2-groove bearing would probably be unstable because the critical
mass (42,500 lb) is less than the deadweight mass supported (64,000 Ib). Therefore,
for this application, a tilt pad configuration or a more stable fixed type (ellipti-
cal) bearing should be considered. In fact, a tilt pad bearing would be stable for
the above example. Another advantage of a tilt pad journal bearing is that it is
superior for start-stop and turning gear operation. The reason for this is that the
pads can pitch and form a good hydrodynamic film shape at all speeds. Therefore,
the shaft lifts off at a lower speed and thus reduces startup and shutdown wear. A
third advantage is that the spherical pivots incorporated in this bearing configura-
tion make it truly self-aligning.
However, there are some disadvantages related to tilt pad bearings. Normally, they
have higher power losses and operate at higher temperatures for a given set of sup-
ply oil flow conditions. Tilt pad bearings operate at a smaller minimum film clear-
ance. Also, the pivots will wear and must be considered during maintenance inspec-
tions. If properly designed, however, these disadvantages can be minimized.
For the thrust 'bearing application, tilt pad bearings are often utilized because of
their superior characteristics relating to alignment and thermal distortion. This
is accomplished because each pad can roll and pitch to adjust to misalignment and
thermal distortions. Also, for fully equalized thrust bearings, the linkage behind
the pads ensures good load-sharing among all of the pads. One manufacturer has had
success using a copper material which helps compensate for deleterious thermal
effects in their fixed thrust bearing configurations.
The disadvantages associated with the tilt pad thrust bearing are the complexity and
wear of the additional moving parts (linkages and pivots). Also, the initial cost of
tilting pad bearings is greater than that of the fixed type bearings. Furthermore,
E-60
because of their relative complexity, a higher level of skill is required for their
maintenance and repair. Therefore, when designing bearings for large steam turbines,
the choice as to which type bearing is most suitable is not clear-cut but depends
on the specific requirements of a particular application. Usually, combinations of
both fixed and tilting pad types of bearings are incorporated in a given turbine
generator unit design.
E-61
Appendix F
HYDROSTATIC (OIL LIFT) FULL FILM LUBRICATION
F.1 THE ROLE OF HYDROSTATIC (OIL LIFT) BEARINGS
At rated operational speeds of either 1800 or 3600 rpm, the self-generated load-
carrying capability of journal bearings is produced by the pressurized oil film
which is self-generated by hydrodynamic action and is sufficiently thick to preclude
contact of the bearing member surfaces. This self-generated, pressurized oil film
does not exist when the turbine is operating at very slow turning gear speed. In
domestically made units, turning gear speeds range from 3-10 or 10-30 rpm depending
upon the manufacturer, while some foreign made units have turning gear speeds in the
range of 100-200 rpm. Typically, the ratio of turning gear speed to rated speed
ranges from 1:1000 to 1:100, which implies a severe reduction in oil film thickness
to the point where some degree of metal-to-metal contact and wear is to be expected.
To combat this problem, journal bearings, especially those for heavy low pressure
rotors and/or generators, are provided with so-called "oil lift" bearings which can
provide the desired full film lubrication at any speed. Figure F-1 illustrates the
introduction of high pressure oil flow into a recess incorporated at bottom dead
center of the bearing bore from an external high pressure oil supply system.
Accordingly, the intent and role of the externally pressurized "oil lift" bearing
is to:
Promote and maintain complete separation of the bearing member sur-

faces (i.e., full film lubrication) when the unit is in the "ready-
reserve" state at turning-gear (minimum) speed.
Maintain application of the high pressure supply oil to the bearing

during the process of increasing the rotor speed from turning gear
(minimum) speed up to some much higher speed (i.e., 1000 rpm) on the
way up to rated (maximum) speed.
Maintain its application during coastdown to turning gear (minimum)

speed and thereafter.
F-l
W=Load
II Floated II
Journal
Br'g Center
. 13 , . ---r--
Jr I Center e
. --- - - - --tJH--- al-~I:- -1J-
Pressure
f
...
ell
:J
en::: cu
..
en 0 0
~ ~a::
Q..-
~8:~
o :J 0
...J(/')G:
..
Q..
..J
o
hL = Oil Lift
C=(RS-RJ) QHP = High Pressure Oil Flow Rote
Figure F-l. Cross Section of Hydrostatic (Oil-Lift) Journal Bearing at Zero

Speed Showing "Floated" Journal and Oil-Film Pressure Distribution
F-2
F.2 PRINCIPLES OF HYDROSTATIC (OIL LIFT) BEARINGS
Design of a Hydrostatic Bearing System
Figure F-2 is a schematic representation of a typical hydrostatic bearing system.

All hydrostatic bearings have two main parts:
the pad (i.e., the bearing liner)
the runner (i.e., the rotor journal)
The "inlet hole" of the hydrostatic pad supplies the high pressure oil into the
recess incorporated within the pad surface, and the pad sills over which the oil
flows as it is forced out of the bearing to the ~ad outer edges.
When operating properly, the runner is separated from the pad by an oil film. In
order to maintain the oil film, the outflow of oil from the hydrostatic bearing must
be continuously replenished with high pressure oil. In Figure F-2, a restrictor
such as a flow control valve, orifice, or capillary tube is shown interposed between
the pad recess and the high pressure oil supply manifold. If the pad contains only
one recess, and if there is only one bearing pad with only one recess to be supplied,
the restrictor and the oil supply manifold can be eliminated since a high pressure
pump can be direct-connected to the pad recess. Depending upon bearing design and
high pressure oil supply system circuit, restrictors mayor may not be required. If
the high pressure oil supply system is to supply more than one bearing or more than
one recess, a restrictor is required in each oil supply line to each recess in each
bearing. Restrictors play an important role with regard to:
allowing all bearings to become "floated" (lift)
maintaining the supply of sufficient flow rate to all bearings and

all of their recesses at all times
Restrictors introduce an additional pressure drop, requiring a higher oil supply

pump discharge pressure compared to that for a direct-connected pump to a single-
recess bearing. While not shown in Figure F-2, check valves should be incorporated
in each recess supply line to preclude reverse flow of oil from the bearing oil film
during normal hydrodynamic operation.
It is essential that cool, clean oil be introduced into the hydrostatic bearing
recesses. Dissipation of the high pressure introduces heat to the oil of about 7F
per 1000 psi (3.8C per 6.9 MPa) of pump discharge pressure; however, because the
rotational speeds are so low, oil film temperature rise (TF-T S ) is moderately low.
F-3
Load
W
Film
Bearing Thickness,h
Runner
"----~t-+-+-f-+-+-I~-----J -L
--,
Pod Sill
~-- Supply Line
Restrictor
(Compensating
Supply Pressure) F: ~-r-------- Element)
To Other To Other
Supply Manifold
Bearing Bearings
Pump Pressure) F:> Oil Inlet

Hole
Flow
Direction
Source of
Pressurized
Lubricant
Figure F-2. Typical Hydrostatic Bearing System

Source: "Cast Bronze Hydrostatic Bearing Design
Manual," Copper Development Association, Inc.,
Greenwich, Connecticut
F-4
Load/Pressure and Load/Film Thickness/Flow/Viscosity Relationships
The relationship between load and recess pressure in any given hydrostatic bearing
can be expressed as:
TN af ApPr' (lb) (F-l)
where W load normal to the pad projected surface (lb)
Ap projected area of the pad (in 2 )
Pr recess pressure (psig)
af pad load coefficient
The relationship among load, film thickness, flow rate, and viscosity can be
expressed as:
(F-2)
where Q supply oil flow rate (in 3 /sec)
h thickness of oil film (in)
~F average viscosity of oil film (lb-sec/in 2 )
qf pad flow coefficient
When the oil film thickness (h) is uniformly thick over the entire pad surface, the
pad coefficients af and qf are constants regardless of the thickness of the oil film
because the relative shape of the oil film is constant. In utility journal bearing
applications, the oil film is not uniformly thick because the journal is eccentric
with respect to the bearing bore, as shown in Figure F-l. As eccentricity ratio
(s = e/C) increases from zero, the form of the pressure distribution changes, result-
ing in decreasing values of load coefficient af. Since the recess pressure required
for a given load is (Pr) = [(W/Ap)/(af)sl, then recess pressure required will
increase as eccentricity increases. Also, the hydraulic resistance of the oil film
changes, resulting in decreasing values of pad flow coefficient (qf) as eccentricity
increases. For the eccentric journal bearing, Eq. F-2 can be written in terms of
the oil lift film thickness (hL ) and radial clearance (C) as follows:
Q (F-3)
F-5
Table F-1 is a tabulation of pad coefficients (af) and (qf)' for various values of
eccentricity ratio () for a centrally loaded, nonrotating, perfectly aligned, oil
lift journal bearing with a single centrally located, rectangular recess of the fol-
lowing geometry relationships:
160 (deg) = included angle of journal pad
0.8 journal bearing LID ratio
0.2 recess arc length ratio
0.4 recess axial length ratio
Note: The LID ratio of the bearing of Table F-1 corresponds to the LID ratio of the
example hydrodynamic bearing (LID = 16/20 = 0.8) evaluated in Appendix E.
Table F-1 shows that the load and flow coefficients both decrease with increasing
eccentricity ratio. While the changes in load coefficient are relatively minor,
particularly at low eccentricity ratios, the changes in flow coefficient are quite
large, particularly at higher eccentricity ratios. While the results of Table F-1
are for a specific geometry of a single, rectangular, centrally located recess, the
actual recess designs of t~e various manufacturers exhibit similar trends in their
individual pad load and flow coefficients.
Figure F-3 is a plot of the data of Table F-1 in the form of dimensionless perfor-
mance characteristics:
HL = (hL/c) = oil lift film thickness ratio, and
recess pressure ratio
as functions of
flow coefficient of the

given oil lift journal bearing
This figure can be used to determine the oil lift film thickness and recess pressure
for a perfectly aligned, centrally loaded bearing of given geometry [D, L=0.8D,
8 p =160 (deg), 8r =0.28 p ' (lr/L) = 0.4L = 0.32D, C] for any given combination of flow
rate Q, oil film viscosity ~F' and radial load W.
F-6
Table F-1
VALUES OF PAD COEFFICIENTS af AND qf

FOR A HYDROSTATIC OIL LIFT JOURNAL BEARING
AT ZERO (N=O) ROTATIONAL SPEED WHEN
CENTRALLY LOADED AND PERFECTLY ALIGNED
[(LID) = 0.8; (Sp) = 160 (deg); (lr/L = 0.4; (Srlsp) = 0.2]
Eccentricity Oil Lift Load Flow

Ratio Ratio Coefficient Coefficient
e: =(e/C) HL=(1- e:)=(hL/C) (af)e: (qf)e:
0.0 1.0 0.410702 1.217267

0.1 0.9 0.403946 0.931967
0.2 0.8 0.396172 0.694393

0.3 0.7 0.387122 0.500267
0.4 0.6 0.376438 0.345321

0.5 0.5 0.363599 0.225301
0.6 0.4 0.347809 0.135956

0.7 0.3 0.327745 0.073052
0.75 0.25 0.315416 0.050194

0.80 0.20 0.300920 0.032363
0.85 0.15 0.283415 0.019034

0.90 0.10 0.261351 0.009678
0.95 0.05 0.231144 0.003768

0.975 0.025 0.209892 0.001938
0.985 0.015 0.199092 0.001394

0.990 0.010 0.192880 0.001161
F-7
0.8 ~0/ -
~0~
0.6 -",,0~
~0~
0.4 ./0/' 40
((..0\\0 ./' .Q
.2 'f.(:<e'i>'i> ~0 "0
"0
a: ~~/G 0 " a:
Q)
en ~~~ :; 20
. ';/\~\.
0.2 .
en
'
(/)
Q,) \ 0 en
c cu
~ 0'\' t-
o.
u
:c \~\.Ic.\-:' 0
7
~
t- Q)
u
E ~'v Q)
0.10 u: o a:II 10
~ 0.08 S
~ r;:::::I
I
00 '- 8
I ~
6
.. !
0.06
8 ..........
-
~..J..... LJ
"ct:
II
6
.c -"tl.
0.04 J
II ('la ) = [P,.I(W/A,.U =Recess Pressure Ratio ~ 4
..J
J: -1::1_ _ 1::1- -1::1-1::1_1::1_ 1::1 1::1-1::1-8_
o.oj d
(qt)= [~~P3~ = Flow Coefficient of Oil-Lift Journal Bearing

2
.004 .006 0.010 .02 .04 .06 0.10 .2 .4 .6 .8
Figure F-3. Dimensionless Performance Characteristics of an Example Oil Lift Journal Bearing Centrally
Loaded and Perfectly Aligned
Example Evaluation of an Oil Lift Journal Bearing
In the example hydrodynamic journal bearing evaluation of Appendix E.Z, it was

established that when a ZO inch diameter, 16 inch long, 160 degree arc journal bear-
ing was operated at a turning gear speed of N = 4 rpm under a radial load of
W = 64,000 lb and an average oil film temperature of TF = 100F (with ~F = 3.895 x
Z
10-6 lb-sec/in ), the resulting minimum oil film thickness was only 0.060 mil (see
Table E-Z). At these conditions, it was found that a low pressure oil supply flow
rate of only 0.111 gpm was required by the bearing.
To assess the increased value of minimum oil film thickness and the pressure and
flow rate requirements of incorporating an oil lift bearing recess for this applica-
tion, the pad coefficient data of Table F-1 areused. The data in Table F-1 are
valid for
(LID) = 0.8 (same as example bearing)
Sp = 160 (deg) (same as example bearing)
and since (SrISp) = 0.2, therefore,
0.2(160) 3Z (deg) recess included angle
and since (Ir/L) 0.4, therefore,
0.4L 6.4 (in) recess axial length
Other known values of interest are:
w 64,000 (lb) radial load
Ap LDsin(Sp/Z) (16)(20)sin(160/Z)
315.14(in Z) projected area of bearing pad
~F 3.895 x 10-6 (lb-sec/in Z) = oil film viscosity at 100F

C 0.020 (in) = radial clearance of bearing
Required recess pressure is evaluated from Eq. F-1 as:
(Pr)s (F-4)
F-9
Required oil supply flow rate is evaluated from Eq. F-3 as:
or
(F-5 )
Finally, the resulting value of oil lift film thickness, for a given eccentricity
ratio, is evaluated as:
C(l-E) 0.020(1- E), (in) (F-6)
Equations F-4 through F-6 were evaluated for each of the 16 different values of
eccentricity ratio in Table F-1, and their associated values of
oil lift (hL)E attained,
recess pressure required (Pr)E' and
high pressure oil supply flow rate required (QE)
for each are tabulated in Table F-2. These results are plotted in Figure F-4 with
the dependent quantities hL and Pr as functions of the independent quantity Q. The
figure shows that as the oil supply flow rate is increased, oil lift film thickness
increases, and recess pressure decreases.
A plot such as Figure F-4 for a specific journal bearing with a specific recess
incorporated within its bore surface and subjected to a set of operating conditions
[load (W), oil film temperature, viscosity (T F , ~F)] can be used to establish
(1) the flow rate required to achieve a given oil lift film thickness and (2) the
resulting oil pressure within the recess after lift. For example, Figure F-4 shows
that at hL x 10 3 = 2 mils, the required flow rate is 1.05 gpm and the recess pres-
sure will be 777 psig after lift-off.
Sizing of Oil Lift Journal Bearing Oil Supply Circuit(s)
Generally, the minimum value of oil lift film thickness should be greater than about
100 microinches per inch of axial length. That is,
O.l(L/D)D, (mils)
F-IO
Table F-2
CALCULATED VALUES OF OIL LIFT FILM THICKNESS,

RECESS PRESSURE, AND HIGH PRESSURE SUPPLY OIL FLOW RATE
FOR EXAMPLE (OIL LIFT) JOURNAL BEARING
Bearing: L = 16 (in), D = 20 (in), 8 p = 160 (deg), (C x 10 3 ) = 20 (mils)
Recess (Centrally Located): lr = 6.4 (in), 8 r = 32 (deg)
Operating Conditions: W = 64,000 (lb), N = 0
(~F x 10 6 ) = 3.895 (lb-sec/in 2 ) at TF = 100 (OF)
Eccentricity Oil Lift Film Thickness Req'd Recess Pressure Req'd Oil Flow Rate
Ratio (h Lx10 3 ) = (20)(1-) (Pr) = 203.085/(af) Q = 108.343(qf)

(mils) (psig) (gpm)
0.0 20.000 494.48 131.882

0.1 18.000 502.75 100.972
0.2 16.000 512.62 75.233

0.3 14.000 524.60 54.200
0.4 12.000 539.49 37.413

0.5 10.000 558.54 24.410
0.6 8.000 583.90 14.7299

0.7 6.000 619.64 7.9147
0.75 5.000 643.86 5.4382

0.80 4.000 674.88 3.5064
0.85 3.000 716.57 2.0622

0.90 2.000 777.06 1.0486
0.950 1.000 878.61 0.4083

0.975 0.500 967.57 0.2100
0.985 0.300 1020.06 0.15112

0.990 0.200 1052.91 0.12581
F-ll
80
Journal Bearing Geometry: - L = 16 (in.), 0 = 20 (in.), 8, =160(deg), (C X 10 3 ) = 20(mils)
6000 60
Recess Geometry:- 8".=32 (deg), lr = 6.4 On.)) Centrally- Located
4000 Q) ~ 40
Operating Conditions: - W= 64,OOO(lb), N=O (rpm)) Centrally Loaded
~
:J
en 6 'E
en (,uFxI0 )= 3.895(1b-sec/in 2 ) 01 100F . "(..(\ee;,fb ....."
Q)
\~\(,
d:
2000
.
.
\,\'<\
~W'(\,..0"d 0 ~
Q)
20
D .. c
,-- , O~' 0 ,..0
~ '\ .,
~
C\ .~
1000 'U; x- x R
(Pr ) - ,0 ' 0'" ~ 10
800
Q.
Pr .=. 777 {psi} -xx _ _ x; ' . eTP::ssure lX'''.... 0 / '
.-----~~~~ x ,~ E 8
~ for 2 (mil) Lift --x--x-0~x ~ 6
600
Q)
u t ".,0/ - x-x-x-x_x-x ~
~ ...J
~
400
"0
t 0/0 ~
o
4
I
~
N
~
:J
t/ (h L xIO ) = 2 (mils)
J
II
200 CT 0---- ---- ~ ~ - . - .....- ---- ~ ~ - +oJ 2
0~IE
Q)
a::
II
,.....
....."
rt)
100
~
;r o I
~
)(
80 <t .-
0-,--
C7 u .8
60 ~
6-1;;;e
t - II
.6
L--I o / Q)
a:: o~N It)
40 ~ / 0 ~ II ~ o .4
.~ )(
a. o .c
..J
20 o
/ Q = High Pressure Supply - Oil Flow Rate, (gpm) .2
.02 .04 .06 0.10 .2 .4 .6 1.0 2 4 6 10 20 40 60 100 200 400 600
Figure F-4. Oil Lift Film Thickness and Recess Oil Pressure as Functions of High Pressure Supply Oil Flow Rate
for Example Oil Lift Journal Bearing
For the example bearing having D=20 (in.), L=16 (in.), and (C x 10 3 ) 20 (mils):
The oil lift (dimensionless) film thickness ratio should, accordingly, be greater
than
(HL)min ~ [(hL x 10 3 )min/(C x 10 3 )] (1.6/20)
(hL)min ~ [0.08]
To satisfy this condition, the flow coefficient shown in Figure F-3 must be greater
than
Since
qf = ~FApQ/(WC3)
and ~ LDsin(e p /2)
C .020 (in),
then the supply oil flow rate required must be greater than
Q ~ .001777 [Wmax/(lJF x 10 6 )min], (1n 3 /sec)
~.000046156[Wmax/(~F x 10 6 )min], (gpm)
where Wmax maximum anticipated radial load (lb)
minimum anticipated viscosity (lb-sec/in 2 )

at maximum anticipated supply oil temperature
In the example, values of Wand lJF were 64,000 lb and 3.895 x 10-6 lb-sec/in 2 at
TF = 100F, respectively. Assuming that
max. load ~ 250 lb 80,000 lb
and
min. viscosity ~ 2.563 x 10-6 lb-sec/in 2 at (TF)max 120F,
F-13
then the supply oil flow rate required should be greater than
Q ~ .000046156 [80,000/2.563]
Q ~ 1.4407 gpm
Thus, on this basis, a "design point" flow rate of
1.5 gpm
would, for example, be selected, yielding a minimum anticipated value of qf as
(~F)min Qmin Ap/(WmaxC3)

2.563 x 10- 6 (5.775)(315.14)/(80,000 x .020 3 )
0.007288
From Figure F-3 at this value of (qf)min'
(HL)min = 0.082
and [(Pr)/(Wmax/Ap)]max 3.9
Therefore, for a flow rate of 1.5 gpm,
(hL x 10 3 )min = (HL)min (C x 10 3 ) = .082(20) 1.64 (mils)
and (Pr)max = (3.9)(Wmax /A p ) = 990.04 (psig)
If the subject single-recess oil lift bearing were the only oil lift bearing, its
high pressure oil supply circuit would be very simple and consist of a single high
pressure pump direct-connected to the bearing's single recess with a reverse flow
check valve interposed in the supply line between the pump discharge port and the
bearing rec.ess.
The flow pressure characteristics of the pump would require it to deliver at least
1.5 gpm at a discharge pressure of
(Pn) (Pr)max + ~p (of check valve) + line losses
F-14
The pump's rated discharge pressure should be about 20% greater than the above value
of Pn in order to provide reserve load capacity for higher than anticipated loadings,
and to allow long duration inservice operational life of the pump.
Thus, rated pressure of the high pressure oil supply pump should be
(Pn)R ~ 1.2[990 + ~p (of check valve and line losses)]
(Pn)R ~ 1300 psig
If more than one oil lift bearing or more than one recess is supplied from a common
header, a restrictor (orifice, capillary, or flow control valve) is required in each
recess oil supply line in addition to the reverse flow check valve. The restrictor
in a given recess supply line is sized in accordance with the following equations.
For orifice type restrictors:
where Ao orifice area (in 2 )
orifice diameter (in)
Cd ~ 0.6 = orifice coefficient of discharge
Q flow rate (in 3 /sec)
P lubricant mass density (lb-sec 2 /in 4 )
Pu pressure upstream of orifice
Pr recess pressure
For capillary tube restrictors:
(d c4 /l c ) = [128 (lJ)Q/(Pu-Pr)]' ( in 3 )
where d c capillary tube inside diameter (in)
lc capillary tube length (in)
lJ absolute viscosity of lubricant (lb-sec/in 2 )
For flow control valve restrictors:
Q flow rate of FCV (in 3 /sec)
F-15
The upstream pressure for the various types of restrictors should be
(pu) ~ 1.2(Pr)max for capillary tubes or orifices
(pu) ~ 1.2(Pr)max + 100 for FCVs
where (Pr)max is max value of Pr in any recess.
Thus, required header pressure is:
Ph Pu + ~p (check valve and line losses)
Effects of Changing Load and/or Oil Film Viscosity
Once the supply circuit is sized for worst case conditions of (Wmax/~min)' any
decreases in load W or increases in viscosity will result in
larger values of oil lift film thickness
lower values of recess pressure
higher flow rates (if orifices or capillary tubes are used)
Effects of Misalignment
When the journal becomes misaligned with respect to the bearing bore, the effective
hydraulic resistance of the bearing decreases. In general, the degree of lift will
decrease and minimum oil film thickness, somewhere in the bearing bore, will be con-
siderably less than when alignment is perfect. If, for one reason or another, mis-
alignment of the bearing members is anticipated, oil supply flow rates should be
increased.
Effects of Rotational Speed
When the journal is operating at turning gear speed, some degree of hydrodynamic
load-carrying capacity will also be generated. As a result, minimum oil film thick-
ness (i.e., oil lift) will increase. However, depending upon the size, shape, loca-
tion, and construction of the recess, normal hydrodynamic operation at full speed
may be penalized since the recess short-circuits the normally high hydrodynamic
pressure zone to other normally low pressure zones. In some designs, this adverse
effect is mitigated by constructing the recess in the form of a closed-grooving
configuration or by using two smaller recesses in low pressure hydrodynamic zones
near each side edge of the bearing bottom dead center. An ideal arrangement of
F-16
oil lift bearing recesses would be to use four relatively small recesses centered
symmetrically about the bottom centerpoint of the bearing bore (i.e., centered at
30 degrees from bottom and 70% axially removed from the center). One very desir-
able advantage of such an arrangement of four recesses is that nonuniformity of
recess pressures provides a method to measure pitch and yaw misalignments of the
journal within the bearing bore. In any event, design of an oil lift bearing is
not complete without a realistic analysis of its unfavorable impact upon its normal
hydrodynamic performance capability at full speed operation.
F-17
F.3 CURRENT PRACTICE, EXPERIENCE, AND BENEFITS OF HYDROSTATIC (OIL LIFT) BEARINGS
A survey of fossil-fired units revealed that less than 10 percent of the units are
equipped with one or more oil lift journal bearings. The two principal domestic
manufacturers use totally different oil lift design concepts. One uses two small
circular recesses at the bottom of the bearing near each side edge, while the other
uses a centrally located single recess constructed with an interconnected growing
pattern in a bow-tie configuration. Limited information on supply system flow rates
and pressures would indicate that very low flow rates of less than 1 gpm and very
high pressures of greater than 1000 psi are utilized.
Operational experience on fossil-fired units with currently supplied oil lift bear-
ings has not been totally favorable for the following reasons:
Wear of the bearing surfaces still occurs.
Failure of the high pressure oil supply system is not uncommon.
Maintenance of the high pressure oil supply system is excessive.
Because of these experiences and in spite of their obvious potential benefits,

numerous users believe they are better off without hydrostatic (oil lift) bearings
than with them.
In order to realize the unique advantages of hydrostatically lubricated oil lift

bearings, currently used bearing designs and their high pressure oil supply systems
should be reevaluated and upgraded from the standpoint of achieving enhanced perfor-
mance characteristics and reliability coupled with reduced maintenance requirements.
The principal role of hydrostatic lubrication is to generate and maintain a full
film of pressurized oil between the loaded bearing member surfaces during very slow
turbine rotational speeds. During turning gear operation, it is not possible to
achieve complete separation of the bearing members by normal hydrodynamic operation.
In addition, hydrostatic (oil lift) bearings can provide the following additional
unrealized benefits:
Provide an effective on-line option for cooling down a hot running

bearing, thereby precluding the need for an immediate shutdown.
Provide a method to measure load on the bearing via recess pressure

measurements.
Provide a check on load-sharing (elevation) alignment of all bearings

prior to startup.
F-18
Provide a check on relative alignment (pitch and yaw) of the bearing
with respect to its journal.
Allow a rotor segment or entire rotor train to be rotated by hand to

conveniently measure the following parameters:
(1) Coupling face nonsquareness and radial offset with respect to

its rotational axis.
(2) Radial offsets and pitch and yaw misalignments of adjacent

(uncoupled) rotor section axes.
(3) Bearing load changes during slow rotation of the coupled rotor
assembly (which would provide a measure of load-sharing align-
ment of the bearing, either purposeful or abnormal).
F-19
Appendix G
BIBLIOGRAPHY
There is a wealth of published technical literature dealing with or related to steam

turbine bearing and lubrication systems. During an Electric Power Research Institute
(EPRI) sponsored project entitled "Failure-Cause Analysis: Turbine Bearing Systems,"
a comprehensive literature search and review were conducted. The more relevant and
useful technical literature identified is categorized and listed in this Appendix.
These entries are taken directly from the bibliography in the EPRI-sponsored project
report.
G.1 JOURNAL BEARINGS
E. R. Booser, A. Missana, and F. D. Ryan, "Performance of Large Steam Turbine

Journal Bearings," ASLE Transactions, Vol. 13, pp. 262-268.
S. Duffin and M. Sanders, "Bearings and Lubrication Practices Currently Used

in British Steam Turbine Generators," Journal of the American Society of Lubri-
cation Engineers, December 1970, pp. 439-448.
S. Duffin and B. T. Johnson, "Some Experimental and Theoretical Studies of

Journal Bearings for Large Turbine-Generator Sets," Froc. lME 181, 89-97 (1966).
A. Hohn, "Journal Bearings for Steam Turbosets," Brown Boveri, Rev. (Switzer-
land), Vol. 62, No.3, March 1975, pp. 72-83.
z. Varger, "900 mm Pivoted-Pad Journal Bearing for Steam Turbosets," Brown

Boveri, Rev. 64, June 1977.
E. R. Booser, F. D. Ryan and C. L. Linkinhober, "Maximum Temperature for Hydro-

dynamic Bearing Under Steady Load," ASLE Lubrication Engineering, July 1970,
pp. 226-235.
Wronski, G., A. Davies and B. D. Burrows, "Behavior of Turbo-Generator Bearings

Under the Influence of Varying Operational Conditions," Steam Plant Operation,
lnst. Mech. Eng., 1973.
Morrison, D., "Rotor Vibration: The Choice of Optimal Journal Bearings," Inst.
Mech. Engrs., 1976, pp. 7-14.
Holmes, A. G., C. M. McEttles and I. W. Mayes, "The Dynamics of Multi-Rotor

Systems Supported on Oil Film Bearings," Journal of Machine Design, ASME Trans-
actions, Vol. 100, January 1978, pp. 156-164.
S. H. Greathead, "Investigations into Load Dependent Vibrations of the High

Pressure Rotor on Large Turbo-Generators," Vibration in Rotating Machines,
lnstr. Mech. Engrs., 1976, paper 9, C220/76.
G-l
Ettles, C., D. E. l~ells, M. Stokes and J. C. Mathews, "Investigation of Bearing
Misalignment Problems in a 500 MW Turbo-Generator Set," Proc. Instr. Mech.
Engrs., Vol. 188, 35/74.
Seery, T. J., Coldiron, W. B., and M. Markowsky, "Analyzing Turbine Alignment

and Bearing Problems by Monitoring Oil-Film Pressure," ASME Paper 72WA/pwr-6.
Azzoni, A., A. Clapis, R. Gariboldi, G. Lapini, G. Possa, and T. Rossini,

"Experimental Studies on the Shaft Dynamics of Large Turbo-Generators for an
Improved Surveillance," Inst. Mech. Engineers, 1976.
Pollman, E., H. Schwerdeftger, H. Termuhlen, "Flow Excited Vibrations in High-

Pressure Turbines (Steam Whirl)," Journal of Engineering for Power, April 1978,
Vol. 100, pp. 219-228.
Pollman, E., and H. Termuhlen, "Turbine Rotor Vibrations Excited by Steam

Forces (Steam Whirl)," an ASME publication, 75WA/Pwr-11, pp. 1-6.
Warner, R. E., and A. I. Soler, "Stability of Rotor-Bearing Systems with Gener-

alized Support Flexibility and Damping and Aerodynamic Cross-Coupling," Journal
of Lubrication Technology, July 1975, Vol. 97, Series F, 1975, pp. 461-471.
Davies, W. G. R., A. W. Lees, I. W. Mayes, J. H. Worsfold and F. J. P. Crampton,

"Vibrational Problems in Modern Power Station Plant," Proc. I Mech E, 1976,
pp. 215-222.
Morrison, D., "Rotor Vibration: The Choice of Optinal Journal Bearings,"

Instr. Mech. Engrs., pp. 7-14, 1976.
Rippel, H. C., "Cast Bronze Hydrostatic Bearing Design Manual," available from
Copper Development Association, Inc., Greenwich, Conn., 2nd Ed., 4th Printing,
August 1975, 75 pp.
G.2 THRUST BEARINGS
Duffin, S., and M. Sanders, "Bearings and Lubrication Practices Used in British
Steam Turbines," Journal of the American Society of Lubrication Engineers,
December 1970, pp. 439-448.
Missana, A., E. R. Booser and F. D. Ryan, "Performance of Tapered Land Thrust

Bearing for Large Steam Turbines," ASLE Transactions, Vol. 14, No.4, October
1971.
Saichuk, I. V., and I. D. Usachev, "Design of Thrust Bearing Pad for Large
Steam-Turbines," Vestnik Mashinostroeniya (Russian Engineering Journal), V54,
No.8, 1974, pp. 3-6.
Bielec, M. K., and A. J. Leopard, "Tilting Pad Thrust Bearings: Factors Affect-
ing Performance and Improvement with Directed Lubrication," Proc. Intrn. Mech.
Engrs., 1969-70, Vol. 184, p3L, pp. 93-102.
G.3 LUBRICATION SYSTEMS
Kure-Jensen, J., "Cleanliness of Large Steam Turbine Lube Oil Systems," Lubri-
cation Engineering (ASLE), Vol. 28, August, 276-281.
G-2
ASTM-ASME-NEMA Recommended Practices for the Purification of Steam Turbine Gen-
erator Oil, ASME Standard 118, the ASME, New York.
ASTM-ASME-NEMA Recommended Practices for the Design of Steam Turbine Generator

Oil Systems, ASME Standard 116, the ASME, New York.
Wolfe, G. F., and A. Whitehead, "Experience with Phosphate Ester Fluids as

Industrial Steam Turbine Generator Lubricants," Journal of American Society of
Lubrication Eng., Vol. 34, 8, August 1978, pp. 413-420.
"How to Trim Steam-Turbine Lube-System," Power, September 1973, pp. 46-47.
Fowler, W. H., Jr., "When to Drain a Lubricant, It. Standard Handbook of Lubrica-
tion Engineering, 1968, pp. 29.4-29.11.
Evans, C. E., J. B. ~..J'agner and W. F. Lopes, "A Unitized Lubrication System for
Turbine-Generators Using Fire-Resistant Fluid," Proc. of the American Power
Conf., 1970, Vol. 32, pp. 363-370.
Duffin, S. and M. Sanders, "Bearings and Lubrication Practices Used in British

Steam Turbines," Journal of the American Society of Lubrication Engineers,
December 1970, pp. 439-448.
G.4 FOUNDATIONS
Nag, P. C., and P. N. V. Iyengar, "Design and Construction of Reinforced Con-

crete Pedestal Type Foundation for Turbo-Generators of Thermal Plants," Indian
Concrete Journal, February 1973, pp. 7-80.
Probst, Paul H., John S. Joyce, "The Development of Helical-Spring Foundations

for Large Steam Turbine-Generators," Proceedings of the American Power Confer-
ence, 1972, 1973, pp. 424-437.
Steam Turbine-Generator Foundations, General Electric (GET-1749C) pp. 1-102.
G.5 DIAGNOSIS OF BEARING-RELATED PROBLEMS
Seery, T. J., W. B. Coldiron, and J. Markowsky, "Analyzing Turbine Alignment

and Bearing Problems by Monitoring Oil-Film Pressure," an ASME publication
72-WA/Pwr-6, pp. 1-7.
Bannister, R. L., ~. L. Osborne and S. J. Jennings, "Diagnostic Technique for

Steam Turbines," pp. 97-116.
Bannister, R. L.) R. L. Osborne and S. J. Jennings, "Modern Diagnostic Tech-

niques Improve Steam-Turbine Reliability," Turbine and Diesels Power, January
1979, pp. 46-50.
Clapis, A., G. Lapini, and T. Rossini, "Diagnosis in Operation of Bearing Mis-

alignments in Turbogenerators," an ASME publication, 77-DET-14, pp. 1-11.
Downham, E., "Vibration in Rotating Machinery: !1alfunction Diagnosis - Art and

Science," I Mech E, 1976, pp. 1-5.
Cook, T. S., H. G. Pennick and C. H. Wells, "Development of an Automated Life

Prediction System for Steam Turbine Rotor," an ASME publication, 78-WA/DE-15 ,
pp. 1-9.
G-3
G.6 MAINTENANCE ASPECTS
Burris, R. E., G. B. Jongeling, and H. I. Shakeshaft, Jr., "Operating and Main-

taining Steam Turbine/Generators - VII - Plan Early for Turbine Maintenance,"
Power, October 1976, pp. 77-78.
Durkin, T. and R. Menning, "How Regular Inspection and Maintenance Boost Reli-
ability," Power, October 1978, pp. 99-50.
Lindsey, J. R., M. R. Bishop and R. L. Ullinge, "Operating and Maintaining

Steam Turbine/Generators - Improving Steam-Turbine Reliability," Power, March
1976, pp. 43-48.
O'Neil, P. L., and G. P. Tupper, "Recent Trends in Steam Turbine Generator

Maintenance," an ASME publication, 75-PEM-14, 5 p.
"How to Trim Steam-Turbine Lube-System," Power, September 1973, pp. 46-47.
Missana, A., S. C. Barton and F. H. Reck, "Operating and Maintaining Steam Tur-
bine/Generator-II, Achieve Higher Availability through Better Lubrication and
Shaft Sealing," Power, April 1976, pp. 49-54.
Ohmstedt, H. 0., J. S. Bishop, C. V. Maughan and W. J. McMillan, "Operating and

Maintaining Steam Turbine/Generator-III, Maintaining Carbon-Brush Collectors,"
Power, June 1976, pp. 71-74.
Carson, R. L., C. A. Bucci, and R. J. Airhart, "Operating and Maintaining Steam

Turbine/Generator-IV, Periodic Operational Tests Help Keep Unit Availability at
High Levels," Power, July 1976, pp. 59-64.
Baily, F. G., H. A. Bardwick and R. E. Fenton, "Operating and Maintaining Steam

Turbine/Generator-V, Operating at Off-Normal Conditions," Power, August 1976,
pp. 61-65.
Cowgill, T. and K. Robbins, "Operating and Maintaining Steam Turbine/Generator-

VI, Understanding the Observed Effects of Erosion and Corrosion in Steam Tur-
bines," Power, September 1976, pp. 66-72.
G.7 RELIABILITY AND AVAILABILITY
Sperry, R. E. and J. R. Hull, "Factors Affecting Turbine-Generator Reliability

and Availability," Toppi, November 1971, Vol. 54, No. 11, pp. 1863-1869.
Bannister, R. L., R. L. Osborne, and S. J. Jennings, "Modern Diagnostic Tech-

niques Improves Steam Turbine Reliability," Power, January 1979, pp. 46-50.
Dukin, T. and R. Menning, "How Regular Bearing Inspections and Maintenance

Boost Reliability," Power, October 1978, pp. 49-50.
Lindsey, J. R., M. R. Bishop and R. L. Ullinge, "Operating and Maintaining

Steam Turbine/Generator-I, Improving Steam-Turbine Reliability," Power, March
1976, pp. 43-48.
Steltz, W. G., D. D. Rosard, P. H. Maedel, and R. L. Bannister, "Large Scale

Testing for Improved Turbine Reliability," Proc. of the American Power Conf.,
1977, Vol. 39, pp. 282-293.
G-4
Johnson, L. H., P. C. Callan and J. Kure-Jensen, "Designing for Reliability:
the Large Steam Turbine Mark II Control System," an ASME Publication, 77-JPGC-
Pwr-4, 7 p.
Ortolano, R. J. and H. L. Franz, "A Power Company's Approach to Improved Steam

Turbine Availability," an ASl1E publication, 78-WA/Pwr-l, 12 p.
Quick, S. L., "Large Scale Test Facilities to Assure Future Turbine-Generator

Reliability," Nuclear Engineering International, pp. 59-60.
G.8 MISCELLANEOUS PROBLEM AREAS
Boyd, J. and H. N. Kaufman, "The Cause and the Control of Electrical Currents
in Bearings," Lubrication Engineering, Jan. 1959, pp. 28-35.
Dubner, R. M., "The Catastrophic Failure of a Three-Bearing Steam Turbine-

Generator Set," an AS"ME publication, 77-Pet-7, 11 p.
Huppmann, H., "Damage of Hydrodynamic Bearings Used in Heavy Machinery," (in

German), Der Maschinenschaden No. 42, n1, 1969, pp. 1-9.
Dickenson, R., "How to Stop Water-Induction Damage," Turbine and Diesel Power,
February 1979, pp. 99-103.
Hanfling, R. I., E. Kovacic, and R. M. Nelson, "Power Plant Productivity and

National Energy Policy," Proc. of the American Power Conf., 1976, Vol. 38,
pp. 63-70.
Downs, J. E., "Forced Outage of Large Steam Turbines - An Analysis of Causes,"

Proc. of the American Power Conf., 1970, pp. 371-375.
G-5

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Maintenance Turbine Lubrication System

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REP 0 R T -8 U M MAR Y

TOPICS Lubrication Bearings

AUDIENCE Generation engineers and analysts

Guidelines for Maintaining Steam Turbine

OBJECTIVES To assist power plant managers in the establishment and implementation of

APPROACH The project team compiled information on lubrication system surveillance

EPRI A systematic maintenance program is essential to ensure the reliability

For further information on EPRI research programs, call

Final Report, July 1986

SOUTHWEST RESEARCH INSTITUTE

FRANKLIN RESEARCH CENTER

Electric Power Research Institute

EPRI Project Managers

DISCLAIMER OF WARRANTIES AND

ORGANIZATION(S) THAT PREPARED THIS REPORT:

1.1 Lubrication System Reliability 1-1

Lubrication System Components 1-6

1.3 Lubricant Characteristics and Service Conditions 1-23

Particle Contamination 1-31

Turbine Severity Level 1-35

REFERENCES - Section 1 1-39

2 IDENTIFICATION OF TESTING AND MAINTENANCE REQUIREMENTS 2-1

2.1 Steam Turbine Oils 2-1

Anti-Rust Protection 2-2

Water Content 2-16

2.2 Mechanical Components 2-19

Reservoirs and Piping 2-19

2.3 Motors and Control Components 2-26

System Description 2-26

2.4 Emergency Power Sources 2-36

Ac Power Supplies 2-36

REFERENCES - Section 2 2-40

3 TEST, INSPECTION, AND MAINTENANCE PRACTICES 3-1

3.1 Oil Condition Monitoring 3-1

Sampling Procedures 3-1

3.2 Mechanical Components 3-4

Reservoirs and Piping 3-4

3.3 Motors and Control Components 3-37

Procedure Design Recommendations 3-40

Dc Motors - Weekly 3-42

3.4 Emergency Power Sources 3-50

Ac Power Supplies 3-50

REFERENCES - Section 3 3-54

4 TEST, INSPECTION, AND MAINTENANCE SCHEDULES 4-1

5 RESOURCES AND QUALITY CONTROL 5-1

One-Person Responsibility 5-1

REFERENCES - Sectidn 5 5-5

6 BEARING LUBRICATION PRINCIPLES 6-1

6.1 Frictional Response Characteristics 6-3

REFERENCES - Section 6 6-16

7 ROTOR DYNAMICS CONSIDERATIONS 7-1

7.1 Rotor Dynamics System 7-1

REFERENCES - Section 7 7-11

APPENDIX A Industry Technical Organizations A-1

APPENDIX B Industry Business Organizations B-1

APPENDIX C ASTM Standards C-1

APPENDIX D Example of a Turbine Bearing Lubrication System

APPENDIX E Hydrodynamic Full Film Lubrication E-l

APPENDIX F Hydrostatic (Oil Lift) Full Film Lubrication F-l

APPENDIX G Bibliography G-l

l-l(a) Subsystems of the Turbine Bearing System with Their

l-l(b) Subsystems of the Turbine Bearing System with Inputs of Events

1-2(a) Steam Turbine Generator Lubrication Supply, Return, and Reservoir

1-2(b) Schematic of Steam Turbine Generator Lubrication Supply, Return,