Lubrication and condition monitoring for turbines and compressors

3-days basis-seminar

Lubrication, Friction and Wear

• Lubrication and Formation of lubricating film
• Hydrodynamic and hydrostatic lubrication
• Importance of viscosity and temperature
• Wear mechanisms and their causes

Fundamentals of lubricants

• Mineral oils, partially synthetic and synthetic oils in comparison
• Charactersitics and areas of application of Mineral oils, hydrocrack, PAO, Ester oils and polyglycols
• Miscibility and compatibilty of greases (basic oils, thickener, additives)
• Types, active principle and application of lubricants addtives
• Ecologic environmental relevance of lubricants

Lubrication of turbines

• Tasks, requirements and characteristics of turbine oils
• Spezifications and VGB-guidelines
• Bearing and gear lubrication
• Control operating hydraulic
• Sorts and types of turbines and their specific requirements

Lubrication of compressors

• Tasks, requirements and characteristics of compressor oils
• Types of compressors and their lubrication requirements
• Selection of appropriate lubricating oils
• Influence of compacting gas on lubricant (air, processing gas, biologic gas, cooling agent)

Isolating oils

• Tasks, requirements and characteristics
• Oil monitoring via conventional analysis techniques
• Lifecycle-management for electirc Transformators through condition monitoring via gas-in-oil-analysis (DGA)

Operational alterations of lubricating oils

• Application-specific strain and oil ageing
• Causes for sludge formation and varnish
• Oil oxidation, hydrolysis and cracking
• Reduction of antioxidants and other additives
• Contamination through water, dust and external oils
• Air content and foam formation
• Diesel effect and cavitation
• Visible changes: cloudiness, contamination and phase separation

Oil ageing and sediments in turbine oil systems

• Sorts of sediments and their consequences in lubircating oil systems
• Causes of varnish and other sediments as consequence of altered System requirements and oil chemistry ancillary conditions
• Actions for recognition, avoidance and removal of sediments

Filtration and oil care

• Oil change or oil care
• Oil cleanliness, life span and reliability
• Filtertypes: effectiveness and areas of application
• Removal of soild and liquid sediments
• Oil care concepts, operational and installation filtration

Oil analysis for lubricants in power plants

• Oil analysis
  Why, when, how, how often, how many?
  Methods and devices for sampling
  Required data for sampling datasheet 
  Online portal: lab report, data entry, enquiries
  Data migration into a maintenance program
• Analysis techniques
  Analysis sets, areas of application and explanatory power
  Identification of wear characteristic values: element analysis,
  PQ-Index, optical particle analysis
  Characteristic values for oil condition: viscosity, oxidation etc.
  Reduction of additives: antioxidants, FT-IR and RULER, BN and AN
  Contamination: water and particles, purity level, soot, mud, external oils, intermixture
• Interpretation of lab report results
  Define warning and limit values
  Recognize known oil types on lab report
  Interpretation of real lab reports

Oil analysis to identify damages of failures

• Identification of causes for wear and damages
• Reasons for vibration (noise) or high temperature
• Reduced power transfer
• Increased foam forming
• Cloudiness, darkening
• Contamination, sludge formation
• Filter blockage