LUBRICATION SYSTEMS FOR TURBOMACHINERY

by
Fredrick B. Wilcox
Staff Engineer-Lubrication

Shell Oil Company

Houston, Texas

gases from the compressor if that should be the driven unit.

Fredrick B. Wilcox is a staff engineer­
The oil can become contaminated with oxidation and thermal
lubrication specialist with Shell Oil
degradation products due to exposure to excessive tempera­
Company, Houston, Texas. He currently
tures for long periods of time. Some materials not only con­
provides technical service in applications
taminate the oil but also act as catalysts to promote degrada­
of lubricants and in lubrication problems
tion. Corrosion of system materials can form metal oxides
to the operating divisions of Shell Oil
which contaminate the oil and cause abrasion.
Company, U.S.A., and is concerned with
design and engineering standards for the
It is the intent of this paper to emphasize certain design
lubrication systems of rotating machin­
features and operating techniques which have been found ben­
ery. He joined Shell in 1948 and was
eficial in maintaining the cleanliness in the oil and the system.
engaged in various supervisory positions
in refinery laboratory and plant operations. For the last ten
years, he has been involved in technical service and research
DESIGN
and development of industrial and automotive lubricants. He Reservoir. The reservoir provides a quiescent place in the
holds a B.S. degree in Chemistry from Mississippi College and circulating system where water and vapors that have gotten
took graduate work in Organic Chemistry at the University of into the oil in the bearing housings or other contact areas can
Pittsburg. He was a member of ASTM D-2, Section I, Tech Div separate out. Separation can be effective only if the reservoir is
C, ]oint Committee on Turbine Lubrication Systems, i968 - designed and sized properly. Oil should enter near the top and
1970, and is currently chairman of the Petroleum and Chemical exit near the bottom of opposite ends of the reservoir as shown
Industries' Council of ASLE. in Figure 2.
The normal operating volume of the reservoir should
provide a total residence time of not less than eight minutes
ABSTRACT [2]. The required residence time in industrial applications may
A lubrication system for turbomachinery of significant size vary from as low� 3 minutes for low viscosity oils to as high as
generally consists of a reservoir, pump, filter, cooler, piping 40 or 60 minutes for high viscosity oils [3]. Higher viscosity oils
and controls. Experience through the years has indicated de­ have higher gravities. Water separation becomes more difficult
sign criteria required to minimize equipment failures and op­ as the gravity of the oil approaches that of water. Increasing the
erational problems. Reservoirs must be designed to allow for temperature in the reservoir will increase the gravity differen­
proper separation of water and vapor from the circulated oil. tial between the oil and water, making separation more effec­
Oil flow rates and cooling equipment should be designed to tive.
maintain proper oil and bearing temperatures and also op­ Baffli ng arrangements and dimensions of reservoirs have
timize the water separation efficiency. Filters should be dur­ varied according to individual requirements and space limita­
able for long life and adequately sized to maintain a low level of tions. An ideal design is one in which the linear velocity of the
contamination. oil is one foot per minute maximum. Excellent separation of
Proper operating techniques and controls are required to water can be accomplished at this velocity.
minimize oil contamination and the resultant equipment dam­ Reservoirs should be provided with a manway to permit
age. Special purification considerations may be required to internal cleaning, a vent, an appropriate gauging device and
combat oil deterioration due to contamination from sour gases the bottom should be sloped away from the outlet end at a rate ·

such as H2S. of lh inch per foot. The reservoir should be located off the
ground to permit drainage of water.
INTRODUCTION The return oil should enter the reservoir at or just above
The design and operation of a lubrication system is as the level of oil to minimize splashing, foaming and electrostatic
important as the design and operation of the machine of which charge buildup.
it is a part. The larger and more complex the machine, the The reservoir should be made of stainless steel or coated
more significant this factor becomes. The basis for minimizing with a corrosion and oil resistant paint.
equipment failure is lubricant system cleanliness. A variety of Cooler. Bearing temperature and oil life as well as other
methods and designs have been developed which obtain a de­ factors are related to the oil temperature. Maximum bearing
gree of satisfactory results, but are inconsistent and dependent temperatures allowed will vary depending on how the temper­
upon opinion [1]. ature is measured. When measuring the oil exiting the bearing
A circulating lube oil system, as shown in Figure 1, con­ housing, maximum is about 1 80°F. Higher temperatures re­
sists of a reservoir, pump, cooler, filter, controls, piping, etc. quire corrective action. Once the design engineer has all the
Lubricating oil and the system in which it is used can become necessary data, he should have no difficulty in determining the
contaminated with moisture, solids and gases absorbed from type and size of heat exchanger required to maintain the tem­
the atmosphere, condensed steam from turbine seal leaks and peratures of the bearings and the oil at satisfactory levels. The

189
190 PROCEEDINGS OF THE SEVENTH TURBOMACHINERY SYMPOSIUM

OIL SUPPLY HEADER

SLOPE+-

Figure 1. Circulating Lube Oil System.

need for a spare cooler is considered by some to be an option of volume, has a high solids holding capacity, small pressure drop
the user. change with increase in oil viscosity, and appropriate elements
Every effort should be made to maintain the temperature do not plug from water in the lube oil.
of the oil at all points in the circulating system below 150°F. The lubricating oil in many systems can be satisfactorily
For every 18 °F above 180°F the deterioration rate of the oil cleaned with 10 micron elements. However, nominal5 micron
doubles. Optimum reservoir temperature for circulating sys­ is considered to be required in systems on machinery with oil
tems using ASTM/ISO 3 2 grade oils is 120-130°F. Water sep­ lubricated couplings. A coupling performs like a centrifuge and
aration is less effective below 1 20°F and higher temperatures any foreign material heavier than the oil such as solids and '
than 1300F may result in higher than desirable bearing tem­ water, is separated out of the oil in the coupling. The material 1
peratures. fills the outer area where the gear teeth are located and pre­
Filters. It is rather unfortunate that there are essentially vents their lubrication, resulting in coupling failure. To obtain t
no universal standards for evaluating the effectiveness of car­ satisfactory operation for periods exceeding one year, it may be
tridge filters designed for liquid service [ 4, 5]. Nevertheless necessary to use, in addition to the 5 micron system filter, a 0.5
the use of reputable brands of nominal 5 to 10 micron resin micron separate filter on the stream to the coupling or provide
impregnated pleated paper filters in central lubricating oil sys­ nitrogen blanketing of the reservoir.
tems can provide reliable performance in keeping the oil clean Full flow dual oil filters, as shown in Figure 3 , should be
[ 1]. This type of filter provides a large surface area in a small provided and located downstream of the cooler [ 1]. Continu­
ous flow transfer valves and a differential pressure indicator
with alarm should be provided. By-pass and relief valves
should not be used since they will permit unfiltered oil to reach
the bearings, governors, etc.
Piping. All piping used in the system should be made from
BAFFLE, WHEN REQUIRED
steel. The use of copper and zinc should be held to a minimum,
since both act as catalysts to promote oxidation and degradation
of the oil. Copper and copper alloy tubes are generally used in
heat exchangers to minimize water fouling problems and for
more efficient heat transfer [ 6]. The temperatures, normally
below 1500F, encountered in turbomachinery equipment do
not usually cause copper to have an appreciable catalytic effect
on the oil.
Oil drain piping should be sized to operate no more than
half full to ensure good drainage despite possible foaming [ 2].
Horizontal runs should slope continuously toward the reservoir
and the angle of the slope should be a minimum of lh inch per
TO PUMP foot. Tie- ins to the main drain header should be at a 45 degree
SUCTIONS
STEAM HEATER
angle in the direction of slope as shown in Figure 4. The main
,........___ header should be provided with a suitable vent.
)
2-INCH _ -·-·--
DRAIN AND CLARIFIER
SUCTION CONNECTION
Drain piping is exposed to vapors including air and
moisture. This piping should be made of stainless steel or
Figure 2. Lube Oil Reservoir (API STD 614). coated internally with corrosion and oil resistant paint.
 LUBRICATION SYSTEMS FOR TURBOMACHINERY 191

O I L OUT V E NT

PR ESSU R E
RELIEF

R ES E R VO I R
5- 1 0 R I GHT
M I CR O N
F I LT E R E L E M E NTS FI LTER

R E S E R VO I R
WRONG

Figure 4. Oil Re tu rn Line R outing.

in satisfactory condition. Two methods have been suggested

OIL IN
[1], ASTM F-312 Microscopic Sizing and Counting Particles
Figu re 3. Du al Filte rs wi th Continuous F low Transfe r Valves from Aerospace Fluids on Membrane Filters and ASTM
D-2276 Patriculate Contaminant in Aviation Turbine Fuels.
(API S TD 614).
The particle size method ASTM F-312 is time consuming and
not readily adaptable to routine use. The latter, ASTM D-2276
or alternatively ASTM F-313 for hydraulic fluids is preferred.
CO M M ISSIO N I N G N E W E Q U IPM E NT
If the contamination level of the oil is below 100 ppm by
Establishing a clean lubrication system at commissioning ASTM D-2276 or F-313 using a 5 micron Millipore filter, the
is extremely important. Improper cleaning of the new system system can usually be considered to be in satisfactory condi­
prior to operating will result in continuing problems for years. tion.
Many good procedures for cleaning central lube oil systems
have been published [7, 8 , 9, 10]. O PERATIO N A N D M AINTE NANCE
There are certain factors w hich should be emphasized. The oil in a turbomachinery lubrication system can be
Rust preservatives used by manufacturers, and which are in­ contaminated from many sources. Steam leaks across the
compatible with lube oil, must be removed. Many rust preser­ labyrinths result in water in the oil. Breathing of the reservoir
vatives contain petrolatum (wax) and/or calcium/sodium deter­ will allow moisture, dirt and various other contaminants such
gent type wetting agents. As much as 30-50 ppm of a calcium as acid gases, chemicals, etc. , to contaminate the oil. Products
detergent contaminant will promote emulsions with water. De­ handled by the driven element can contaminate the oil by
tergent contamination must be reduced to below 10 ppm cal­ leakage across the seal system. The rate will vary depending on
cium (or sodium) to prevent emulsion formations and obtain design conditions, types of seals and age of the equipment.
good water separation characteristics with the oil. Precautions should be taken during operation to maintain the
Sandblasting and pickling procedures should be avoided if oil in good condition. Periodicinspections can be of great assis­
at all possible since these add contaminants to the system tance in preventing oil deterioration and subsequent equip­
which are as difficult to remove as rust, preservatives, dirt, etc. ment failure.
Agitation is required during flushing to break loose mate­ The type of oil used should be a high quality rust and
rials adhering to pipe walls, etc. High flow velocities and high oxidation (R&O) inhibited turbine quality mineral oil with good
temperatures (160-170°F) are required. Mechanical vibration water demulsibility. Oils of this type used in a properly de­
of pipes, etc. , and injection of nitrogen downstream of the signed and properly operated system will stay clean and clear.
pump can be beneficial in breaking loose materials that tend to Oils with detergent and/or antiwear additives should not be
cling to internal sufaces. used. Visual inspection of a sample of the oil at a specific
Laboratory tests can be performed on the oil after the interval, such as once per week, is the only routine test re­
flushing and cleaning procedures to determine if the system is quired on the oil. Any change in the oil due to water or dirt
192 PROCEEDINGS OF THE SEVENTH TURBOMACHINERY SYMPOSIUM

contamination or darkening in color will be readily perceptible. 2. API Standard 6 14, " Lubrication, Shaft-Sealing and Con­
Significant changes observed visually may be determined trol Oil Systems for Special Purpose Applications, " Sep­
quantitatively by lab tests. Viscosity, total acid number, insol­ tember 1973.
ubles and water are usually all that are necessary to determine 3. Booser, E. R. and Smeaton, D. A., "Circulating-Oil­
the condition of the oil. Any rapid, significant changes in the System Design, " Standard Handbook of Lubri cation Engi­
oil require remedial action. neering, ASLE, 1968.
The bottom of the reservoir should be checked daily for
water and drained when necessary. Log sheets should be main­ 4. Soules, W. J. " C hemical Engineering Progress, " pg.
tained to record pressures and temperatures about the system. 43-45, December 1974.
If the lube oil in a particular system is being unduly con­ 5. N ickolaus, N. " Filtration Engineering, " pg. 8-9 May/June
taminated with water or gases (particularly H2S or acid gases) 1975.
because of excessive leakage across seals, additional facilities 6. ASME Standard N o. LOS-5D1 "Recommended Practices
should be engaged to maintain the oil in good condition until for the Design of Oil Systems for Lubrication and Control
the equipment can be shut down for repairs. A vacuum de­ of Hydroelectric Equipment," 1972.
hydration/degasification unit can be very effective for remov­
7. Morrow, A. S. " Cleaning Lubrication Systems" ASLE
ing both water and contaminating gases [ 11, 12, 13]. This type
unit can also be used for purification of compressor waste seal New York Section Meeting, May 6, 1952.
oil for recycling to the lube oil system. 8. Peterson, F. S. " Large Industrial Circulating Oil Systems
A centrifuge can be used to remove water and solids from - Cleaning and Maintenance, " Lubrication Engineeri ng
the oil and nitrogen sparging [ 14] in the reservoir can be used Vol. 29, 12, pg. 534-538, December 1973.
to reduce gas contamination. 9. ASM E Sta�dard No. LOS-4C 1 "Recommended Practices
for the Flushing and Cleaning of Gas Turbine Generator
CO NCLUSIONS Lubricating Oil Systems" 1971. (Also ASM E Standards
There are various types of materials which can contami­ 113, 114, LOS-2C 1, LOS-5C 1)
nate a turbomachinery lube oil system resulting in equipment 10. Kure-Jensen, J. "Cleanliness of Large Steam Turbine Oil
failure. Reservoirs should be designed to provide adequate Systems, " Lu brication Engineering, August 1972.
residence time and proper flow to maximize separation of
11. "A Low-Cost Answer to Oil Recycling" Factory Manage­
water and gases. Return oil lines should be sized and routed
ment pg. 32-33, January 1977.
properly to eliminate flow restrictions. Filters s hould be
selected and used to effectively remove solids from the oil. The 12. Baranowski , L. B. " Compressor Seal Oil Recycling, "
system must be made clean during commissioning and must be Baron & Associates, Inc. , Cookeville, Tennessee.
maintained clean during operation. Procedures should be 13. Steele, F. M. " Filtration and Reclamation of Turbine
selected to obtain the best performance practical. Oils , " Lu brication Engineering, Vol. 34, pp. 252-257, May
1978.
RE FERE NCES
14. Bloch, Heinz P. " Reclaim Compressor Seal Oil," pg. 1 15-
1. Smith, A. N. "Clean Oil Systems for Heavy Duty Gas 1 18, Hydrocarbon Processing, October 1974.
Turbines, " ASTM Symposium Boston, Massachusetts,
June 1967.