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Bambang Wahyudi
VP Technical
PT Shell Indonesia
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Bharata Satria
GM HSSE for
East Asia
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Shell Safety Day 2020
Note that this is archive imagery. Please follow social
distancing rules at all times.
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A Bit of History
2007 – Goal Zero 2020 – Safety Refresh
- Follow the Rules - Human Performance
- Intervene - Learner Mindset
- Respect
2009 -- 12 Life Saving Rules
1 2 3 4 5 6
7 8 9 10 11 12
Human Performance is the way People, Culture,
Equipment, Work Systems and Processes interact as a
system
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Safety Refresh
Human Error is an abused Majority of errors How leaders respond to Our people are the masters
term associated with incidents failure matters; we need to of their job and the key to
stem from latent conditions learn from mistakes solutions
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Shofwatuzzaki Arif Setiawan
B2B Lubricants Technical Manager Direct Lubricants Technical Manager
Shell Indonesia
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Shell Indonesia
Tackling Varnish Formation in Turbo
Machinery to Maximize Turbine
Availability
Shofwatuzzaki
Copyright of Shell International Petroleum Company Limited June 10, 2020 9
Varnish - What are the deposits?
◼ Is a thin, orange - brown or black film deposit
occurring on the interior of lubricant systems.
◼ Is a contaminant composed typically of high
molecular weight, oil degradation by-products
which have limited solubility in the oil
◼ Is difficult to remove by wiping.
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Turbine oil varnish formation theory
Oxidation by-products can impact equipment operation in a number of ways
As a turbine oil ages (thermal degradation and
oxidation) by-products form which are polar
The polar by-products will tend to attract each other
and form “soft contaminants”
The oil will hold these higher soft contaminants in
solution
Eventually, the by-products are too heavy, they drop-
out as sludge (still “wet”) in the cooler spots, low
clearance areas and low flow areas in the lube system
The continued action of heat dries sludge out to form
varnish or lacquer
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Potential consequences of varnish deposits
◼ Reduced running clearances in
bearings leading to higher
temperatures and vibration
◼ Promote wear to reduce bearing
life
◼ Acts to speed up the rate at
which the oil degrades (reduces
oil service life)
◼ Control valve response can be
compromised
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Evolution in turbine hardware
Turbine Oil Spesification Addressing These Challenge
TLV 901305
Turbine oils with higher thermal
stability
TLV 901304
DIN 51515-2
Turbine oils for Higher
Temperature Service
DIN 51515-1
GEK 32568K
Increased RPVOT & TOST
requirements
GEK 32568F
Increased RPVOT & TOST
GEK 28143A requirements for higher bearing
ambients
MS-04-MA-CL005
Increased RPVOT & TOST
requirements for higher bearing
MS-04-MA-CL002 ambients
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Dry 2020 Test
Dry TOST: MHPS in-house method to predict varnish tendency of fresh turbine oil
Dry TOST Life @ 25% RPVOT
1400
GTL-based Conventional Turbine Oils
1200 Turbine Oil
1000
800
hr
600
400
200
0
GTL Based… Group III Based… Group II Based… Group I Based… ASTM D7873 Dry TOST
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Shell Lubricants from driving collaboration to delivering value
Challenge Solution ◼www.youtube.com/watch?v=4nbhllcGSxU
An issue with the Change oil to
compressors´ bearings was
Shell Turbo S4 X
causing unplanned outages ▪ Extended oil life*
▪ Enhanced efficiency*
Varnish identified from
degradation of the oil
VALUE
Improved equipment performance of the Shell Scotford Upgrader after oil change to Shell Turbo S4 X.
Collaboration has led to total savings of $20000 per month.1
1The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site and from time to time, depending on, for example, the application, the operating conditions, the current products being used, the condition
of the equipment and the maintenance practices.
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How to predict the varnish tendency of turbine oil in service
Shell
Test Alstom GE MAN Siemens
LubeAnalyst
Colour X – – – X
ICP X – – – X
Total acid
X X X X X
number
Viscosity X X X X X
Water X – X X X
Millipore – X – – X
MPC X X X X X
Cleanliness X – X X X
FTIR/ruler X X X X X
RPVOT X X – – X
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Varnish mitigation techniques
Filtration In-Direct effect Cleaning process
Electrostatic Remove of dissolved polar contaminants (no Partly removes deposits, and clean up the
precipitator water allowed!) oil
By-pass (depth) filter Remove dissolved contaminants and can adsorb Limited effect on existing deposits
units water
Less effect on remaining oil live, auxiliary Need for spare filter elements
equipment risks
Refresh the oil Direct effect No thorough cleaning
(before oil drain add Uncomplicated process: Drain old oil, refill with Remaining dirt will work as catalyst
Shell solubilising agent new oil oxidation new oil
to clean up the system)
New oil can dissolve old deposits Fast re-loading of new oil with
contaminating
Possibility to upgrade oil High stress/long live oil
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Conclusion
❑ Varnish is a by product of oil oxidation and thermal degradation Shell Comprehensive
❑ It’s a growing problem and will be costly if not properly
Solution:
addressed
❑ Using oil with high oxidation stability and thermal stability is the
key to prevent varnish
❑ It is challenging to detect varnish, it can occur to the oil that
appears normal. Advanced oil analysis needed to predict the
varnish potential of oil in service
❑ Varnish potential and soft contaminants can be eliminated
through advanced filtration, however oil flushing (replacement) is
needed when the oil is heavily degraded
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Filtration for Lubricant
Arif Setiawan
Lubricant Technical Advisor
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Filtration technique for varnish mitigation
Electrostatic Precipitator
Electrostatic
Precipitator
Balanced Charge Agglomeration
Electrophysical Separation Technology *Image Courtesy
CLARCOR Industrial
Air
Depth Filtration
Balanced
Others Charged
Agglomeration
*Image Courtesy
Isopur Fluid
Technologies Inc
Copyright of Shell International Petroleum Company Limited 10 June 2020 20
What is good Filtration
Filtration definition
The process in which solid particles in a liquid or gaseous fluid are
removed by the use of a filter medium that permits the fluid to pass
through but retains the solid particles.*
Why we need filtration
It is widely accepted that approximately 60% of all hydraulic system
Source: Pall Filters
failures are the result of lubricant contamination.
Important terms in filtration
Cleanliness (kebersihan)
Filterability
Lubricant Filterability
to ensure filtered particle is contaminant, not important active
material for lubricant (fine filter) Picture of a filter after Picture of a filter after
service with oil that additive reaction products
has good filterability have clogged the filter
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Terms in filter selection
Medium type
❑ Metallic or mechanical filters contain closely woven metal or discs of
metal as the filtering elements
❑ Absorbent (inactive) filters contain materials such as cotton waste, felt,
cloth, paper, mineral wool and diatomaceous earth as filtering
elements.
❑ Absorbent (active) cartridge filters remove impurities and contaminants
by chemical attraction as well as by purely mechanical means.
Micron rating and Beta Ratio
Dirt Holding Capacity
❑ Capacity of filter to hold the dirt/particle, units kg/element
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Lubricant Cleanliness measurement method
Methode Units Sampling Benefits Limitations
Optical Particle Number/ml Offline; Laboratory Provides size distribution. Sample preparation time
Counts (Microscope) Cleanliness Code Unaffected by fluid opacity, water
and air in fluid sample
Automatic Particle Number/ml Off-line; “Sip” from Fast and repeatable Sensitive to ‘silts’,
Count (APC) Cleanliness Code containers; On-line water, air and gels
Filter / Mesh Cleanliness code Off-line; “Sip” from Not affected by the presence of air Does not provide the size distribution
Blockage Technique containers; On-line or free water in the fluid sample of the contamination
Patch Test and Fluid Visual comparison/ Off-line; Rapid analysis of system fluid Provides approximate Contamination
Contamination Cleanliness code Point of use cleanliness levels in field. Helps to levels
Comparator identify types of contamination
Ferrography Scaled number of Off-line; Laboratory Provides basic information on Low detection efficiency on non-
large/small Particles ferrous and magnetic particles magnetic
particles e.g. brass, silica
Spectrometry PPM Off-line; Laboratory Identifies and quantifies Limited detection above 5 μm
contaminant material
Gravimetric mg/L Off-line; Laboratory Indicates total mass of contaminant Cannot distinguish particle size. Not
suitable for moderate to clean fluids.
i.e. below ISO 18/16/13
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Measuring Cleanliness by Microscope
100 X
Magnification
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Measuring Cleanliness by Automatic Particle Count (APC)
L
A
S
E
R
> 14 µm
FLOW FLOW
6-14 µm 4-6 µm < 4 µm
15 µm Timer/Counter
Sensor
Three size ranges reported
18 / 16 / 13
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Measuring Cleanliness by Automatic Particle Count (APC)
L
A
S
E
R
> 14
WAX
µm Air
FLOW FLOW
Anti 4-6 µm
6-14 Additives Water
foam < 4 µm
µm
15 µm
Timer/Counter
Non- Solid “Particles”
Sensor
FALSE POSITIVES reported
25 / 20 / 15
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Cleanliness in Lubrication
ISO 4406 Cleanliness Code NAS 1638
Hydraulic Fluid Power – Fluids –Methods for coding The NAS 1638 cleanliness standard was developed for aerospace components in the US
the level of contamination by solid particles and is still widely used for industrial and aerospace fluid power applications.
ISO/NAS Code
Comparison Table
ISO 4406 NAS 1638
16/14/11 5
17/15/12 6
18/16/13 7
19/17/14 8
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Suggested Acceptable Contamination Codes
Criteria to determine
Cleanliness level:
◼ Criticality
◼ Clearance
◼ Operating Pressure
Why Important:
Abrasive wear Fatigue wear Erosive wear
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What are some critical factors delivering turbine oil?
❑ OEMs require initial fill to meet cleanliness specifications
❑ Initial fill should be clean and uncontaminated with other oil products (delivery)
❑ Lubricant handling and delivery must not affect oil quality
❑ Flush and fill procedures
❑ Critical to remove machining debris, preservatives and contaminants
❑ Flush oil should not be reclaimed and used as initial fill oil
❑ Commingled oil can lead to poor performance
Copyright of Shell International Petroleum Company Limited Jun 2020 30
Filter Selection
Weighting method:
1. Operating Pressure and Duty Cycle
2. Component Sensitivity
3. Life Expectancy (hours)
4. Component Replacement Cost
5. Equipment Downtime Cost Courtesy by Pall Filtration
6. Safety Liability
7. Sum of Weighting from point 1 – 6 to determine required
cleanliness by using right above chart (redline)
8. Environment Weightng
9. Determine the filter rating by adding Point 7 + point 8
Tentukan jenis filter dengan total bobot poin 7+ poin 8 Courtesy by Pall
Filtration
dengan kurva di samping
Copyright of Shell International Petroleum Company Limited Jun 2020 31
Contamination Control
◼ To have a good contamination
control we must maintain
excellent Storage and Handling
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For more information: https://solutions.shell.com/id/
Or you can contact us:
– Shofwatuzzaki.Sh@shell.com
– Setiawan.Arif@shell.com
– christian.natala@shell.com
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