For internal Circulation only

COS-ISO-00-OGN/OPS/CHEM/021
Rev. No.: 0 Nov. 2023

Supersedes: OGN/OPS/CHEM/009, Rev 4 Nov21

OGN/OPS/MECH/017, Rev 2 Jul-22

OPERATION GUIDANCE NOTE

The Examination and Maintenance of Lubricating Oils of Turbine &

Boiler Feed Pumps

OPERATION AND MAINTENANCE DOCUMENTATION

SYSTEM
Approved for implementation by Director (Operations)
E Office Ref No ……………………
Date ………………………………….
Prepared by CC-OS (Chemistry & ST)

CORPORATE OPERATION SERVICES

NTPC Ltd
 Table of Contents
1.0 SUMMARY................................................................................................................................ 1
2.0 INTRODUCTION.........................................................................................................................1
3.0 RECORDS OF REVISION............................................................................................................. 2
4.0 NEW OIL.................................................................................................................................... 2
5.0 OIL IN SERVICE.......................................................................................................................... 2
6.0 SAMPLING FOR TESTING OF LUB OIL........................................................................................3
7.0 TREATMENT AND MAINTENANCE.............................................................................................3
8.0 CONDITION MONITORING OF OIL IN SERVICE..........................................................................3
9.0 TURBINE LUBRICATING OIL SPECIFICATIONS:...........................................................................5
SUB-CRITICAL UNITS:........................................................................................................................... 5
SUPERCRITICAL UNITS:........................................................................................................................ 6
10.0 TURBINE LUB OIL FLUSHING PARAMETERS MONITORING (POST ANNUAL OVERHAULING)....9
11.0 INTERPRETATION CHART OF TESTING PARAMETERS................................................................9
12.0 NON-COMPATIBILITY OF TURBO-GENERATOR LUBRICATING OILS SUPPLIED BY DIFFERENT
OIL COMPANIES................................................................................................................................. 10
12.1 CONTROL PROCEDURES:............................................................................................................10
12.2 RECOMMENDATIONS:............................................................................................................... 11
13.0 RECORDS TO BE MAINTAINED:...............................................................................................11
14.0 ASSOCIATED DOCUMENTS:.....................................................................................................12
ANNEXURE-1......................................................................................................................................12
TABLE A: COMPARATIVE TABLE BETWEEN NAS-1638 AND ISO:4406 (BASED ON MAXIMUM
CONTAMINATION LIMITS AND PARTICLES PER 100 ML)..................................................................12
15.0 Checklist for OGN-OPS-CHEM-009, Rev No-05 on “The Examination and Maintenance of
Turbine Lubricating Oils”................................................................................................................... 13
 The Examination and Maintenance of Lubricating Oils of Turbine & Boiler Feed Pumps
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1.0 SUMMARY

OGN-OPS-CHEM-009 Rev No.: 4 Nov 2021

Superseded Document OGN-OPS-MECH-017 Rev No.: 2 July 2022
Steam and Gas Turbines and their associated generators or pumps.
Scope (Note: It is not intended to apply to those gas generators which use
a synthetic lubricant).
Review
COS-Chemistry & COS-ST
Responsibility
Review 2 yearly basis, or as and when required, whichever
Frequency is lower.
Review Head of Operation Services will be the reviewing
Review authority and Director (Operations) will be
Approval approving authority for any revision in this
document.

2.0 INTRODUCTION

Due to high specific loadings of bearings and peripheral speeds of journals, the duty that
turbine lubricating oil is required to perform is arduous. It has to withstand continuous thermal
cycling and a variable degree of contamination by solid particles, sludge, water, hydrogen and
air. It is required to release readily such contaminants and retain its lubricating and other
properties over very long periods.

The purpose of this Guidance Note is to define the oil monitoring that is necessary to ensure
that appropriate lubricants are used and that any degradation in service does not result in
undue threat to the integrity of the plant.

Test methods for various parameters along with limits are mentioned in Table-IIA & IIB.
Interpretation of reason of violation of recommended limits is tabulated on Table-III.

This Operation Guidance Note guideline should be considered in conjunction with the
Operation Information Note: COS/ISO/00/OIN/OPS/CHEM/015 - Manual on Sampling & Testing
procedures for oil.

Individual oil companies use different base oils and additives to produce lubricants conforming
to NTPC standards. Oils conforming to the same standard but from different manufacturers
must not be mixed. Such mixing may result in unpredictable chemical reactions between
additives and consequent degradation of the lubricant performance. An experience of the
Castrol company was the formation of a gel within the oil as a result of such mixing. Should

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 The Examination and Maintenance of Lubricating Oils of Turbine & Boiler Feed Pumps
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such a reaction occur within a turbine generator lubrication, control and sealing system, the
results could be catastrophic or at least very difficult and expensive to rectify. Additionally, if
oils from different suppliers are mixed it is unlikely that any single supplier will accept
responsibility for the consequences of any degradation that may occur. Manufacturers are,
however, careful to ensure that different batches of their own oils of any particular type can be
mixed safely.

3.0 Major changes in base document

Section 8.0: Monitoring frequency of BFP oils have been incorporated.

Section 9.0: Turbine Lub Oil Specifications.

Section 10.0: Lub Oil Flushing Clearance parameters (post AOH)- separate section incorporated.

Following two TC Documents have been merged together:

i. OGN/OPS/CHEM/009 Rev 03, Dec-2021: The Examination and Maintenance of Turbine

Lubricating oil.
ii. OGN/OPS/MECH/017 Rev 02, Jul-2022: Non-compatibility of Turbo Generator Lubricating/ Oils
Supplied by Different Oil Companies.

Section 15.0: Check-list is incorporated.

4.0 NEW OIL

All new turbine lubricating oil should comply to the following:
i. All supplies should be delivered with a BIS marking along with the procurement
specification.
ii. If a BIS certificate is not available, samples, may be taken and examined for appearance
and viscosity.
iii. All samples should be within the permitted viscosity range and should appear clear and
bright and visually free from solid and liquid contaminants.

5.0 OIL IN SERVICE

Turbine oils will gradually deteriorate in service due to oxidation and the presence of water,
corrosion and wear products. Purifying equipment (i.e. Centrifuge etc.) should be pressed into
service to maintain the quality of the oil supplied to the bearings.

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Sampling and monitoring should be carried out on a regular basis to ascertain the rate of
deterioration and to enable necessary corrective measures to be taken.

6.0 SAMPLING FOR TESTING OF LUB OIL

During normal Unit operation: Representative samples of the oil being delivered to the
machine should be obtained from any convenient point preferably from turbulent flow areas
such as turbine bearing return lines, when the oil is in circulation, and tested as specified in
Table-II.

When the unit is coming after overhauling, during the turbine lub oil flushing activity, oil
samples should be taken from Oil tank inlet and outlet line for monitoring the parameters and
clearance is to be accorded as per the limits mentioned in Table-III (Sec 10.0).

It may be desirable to obtain samples at different positions in order to trace sources of

contamination as per the requirement. For detail sampling procedure, the Operation
Information Note titled “Manual on Sampling and Testing Procedure for Oil:
COS-ISO-00-OIN/OPS/CHEM/015”, should be referred to.

7.0 TREATMENT AND MAINTENANCE

i. Water, dirt, hydrogen and air should be removed from the oil as efficiently and as
quickly as the system design allows using the installed purification equipment. It is
desirable to use condensate or de-mineralized water for sealing centrifuges and
operation of these at a temperature of at least 65 deg. C is normally required to break
oil / water emulsions. Wet and / or dirty oil returned to the turbine will eventually
manifest itself in corrosion, wear malfunctioning of the equipment and biological
growth.
ii. Water and water / oil emulsion should be drained from the main oil tank drain at
intervals to ensure that a low level of water is maintained in the tank. The necessary
frequency of draining shall be determined by local experience.

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8.0 CONDITION MONITORING OF OIL IN SERVICE

Oil analysis is commonly used as a diagnostic tool in most power generating utilities. Periodic
monitoring of the condition of the lubricating oil of Turbine and BFP in each operational unit
should be carried out in accordance with Table-I & Table-II. If parameters are outside the
recommended range, then the reasons for this should be sought and remedial action taken, as
deemed fit.

The consequences of continued operation with oil outside the specified condition is detrimental
to the health of the equipment and it may be necessary to consult the oil supplier to discuss the
need for an oil change or refurbishment of the oil by the use of an additive package.

The frequency of testing/ monitoring of various parameters on routine basis shall be as follows:

Turbine Lub Oil

Table-IA: Turbine Lubricating Oil

Sl.No. Parameters UOM Testing Frequency
1 Moisture ppm Once/Week
2 Kinematic Viscosity cst Once/Week
3 Total Acid number mg KOH/g of oil Fortnightly
4 Mechanical Impurity ppm Once/Week
5 Particle count and size as per NAS ---- Once/month
1638 and/or ISO 4406

BFP Oils

Table-IB: MDBFP Lub Oil

Sl.No. Parameters UOM Testing Frequency
1 Moisture ppm Once/Week
2 Kinematic Viscosity cst Once/Week
3 Total Acid number mg KOH/g of oil Fortnightly
4 Mechanical Impurity ppm Once/Week
5 Particle count and size as per NAS ---- Once/month
1638 and/or ISO 4406

Table-IC: TDBFP Lub Oil

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Sl.No. Parameters UOM Testing Frequency

1 Moisture ppm Once/Week
2 Kinematic Viscosity cst Once/Week
3 Total Acid number mg KOH/g of oil Fortnightly
4 Mechanical Impurity ppm Once/Week
5 Particle count and size as per NAS ---- Once/month
1638 and/or ISO 4406

Lub oil samples should be sent separately to CC-NETRA (six-monthly) and OEM/Supplier for
detailed analysis and recommendation at least once in a year. But for taking any decision,
OEM/oil supplier’s recommendations have to be considered.

Responsibility:

i. Chemistry: Routine quality checks of lub oil.

ii. Chemistry: Samples to be sent to CC-NETRA once in six months.
iii. TMD: Samples to be sent to OEM/Supplier for testing once/year.

9.0 TURBINE LUBRICATING OIL SPECIFICATIONS:

Sub-Critical Units:
Table-IIA: Turbine Lubricating Oil Specification for ≤500 MW Units (as per OEM
specification and IS 1012:2002, Reaffirmed-2018- Turbine Lubricating Oil Specifications)
Sl Characteristics/ Limits Limits (VG Testing Test method
no Parameter (VG 32) 46) Frequency
1. Moisture Content <100 <100 Weekly ASTM D6304
mg/l (Note ii) (Note ii) (Note ii)
2. Kinematic Viscosity 28.8 – 35.2 41.4 – 50.6 Weekly IS:1448, P:25
at 40 deg C, ASTM D445
centistokes (cSt or
mm2/s)
3. Viscosity index, min 100 98 Six IS:1448, P:56
Monthly# ASTM D2270
4. Density at 15 deg C Max 900 Max 900 Six ASTM D1298
(kg/M3) Monthly#
5. Flash point 190 200 Six IS:1448, P:69
(Cleveland open Monthly# ASTM D92
cup.) 0 C min
6. Copper strip Not worse than Not worse Six IS:1448, P:15
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Table-IIA: Turbine Lubricating Oil Specification for ≤500 MW Units (as per OEM
specification and IS 1012:2002, Reaffirmed-2018- Turbine Lubricating Oil Specifications)
Sl Characteristics/ Limits Limits (VG Testing Test method
no Parameter (VG 32) 46) Frequency
corrosion at 100 No. 1 than No. 1 Monthly# ASTM D130
deg. C for three
hours
7 Rust preventive Shall pass the Shall pass Six IS:1448, P:96
characteristics, 24 test the test Monthly# ASTM D665
hr test
8. Emulsion 40-40-0 40-40-0 Six IS:1448, P:91
characteristics, (20) (20) Monthly# ASTM D1401
Max
9. Total Acid Number ≤0.2 ≤0.2 Fortnightly IS:1448, P:188
(TAN), mg KOH/g ASTM D974
oil
10. Foaming at 25 deg Six IS:1448, P:67
C Monthly# ASTM D892
Tendency (cm3) Max 400 Max 400

Stability (s) Max 450 Max 450

11. Air release value, at 5 6 Six IS:1448, P:102
50 deg. C. Max in Monthly# ASTM D3427
minutes.
12. Mechanical <0.01 <0.01 Weekly ASTM D4055
impurities % (solid
particles by weight)
13. Particle ≤19/17/14 (ISO ≤19/17/14 Monthly ISO 4406
Distribution 4406) (ISO 4406)
NAS Class 8 NAS Class 8
(max as per NAS (max as per NAS 1638
1638) NAS 1638)
(Note iii) (Note iii)

14. Accelerated ageing 200 (or OEM 200 (or OEM Six ASTM D 2272
test (RPVOT), recommended) recommende Monthly#
Minutes (Min) d)
15. Colour (max) ≤2.0 ≤2.0 Six IS:1448, P:12
Monthly# ASTM D1500

Supercritical Units:
Table-IIB: Turbine Lubricating Oil Specification for Supercritical Units (as per OEM
specification and IS 1012:2002, Reaffirmed-2018- Turbine Lubricating Oil Specifications)
Sl Characteristics/ Limits Limits (VG Testing Test method
no Parameter (VG 32) 46) Frequency
1 Moisture Content <100 <100 Weekly ASTM D6304
mg/kg (Note ii) (Note ii) (Note ii)
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Table-IIB: Turbine Lubricating Oil Specification for Supercritical Units (as per OEM
specification and IS 1012:2002, Reaffirmed-2018- Turbine Lubricating Oil Specifications)
Sl Characteristics/ Limits Limits (VG Testing Test method
no Parameter (VG 32) 46) Frequency
2 Kinematic Viscosity 28.8 – 35.2 41.4 – 50.6 Weekly IS:1448, P:25
at 40 deg C (cSt or ASTM D445
mm2/s)
3 Mechanical <0.01 <0.01 Weekly ASTM D4055
impurities % (solid
particles by weight)
4 Density at 15 deg C Max 900 Max 900 Six ASTM D1298
(kg/M3) Monthly#

5 Flash point 0 C >185 >185 Six IS:1448, P:69

Monthly# ASTM D92
6 Pour Point 0 C Max -6 Max -6 Six ASTM D97
Monthly#
7 Copper strip Max 2 Max 2 Six IS:1448, P:15
corrosion at 100 deg. Monthly# ASTM D130
C for three hours
8 Total Acid Number ≤0.2 ≤0.2 Fortnightly IS:1448, P:188
(TAN), mg KOH/g oil ASTM D974
9 Foaming at 25 deg C Six IS:1448, P:67
Monthly# ASTM D892
Tendency (cm3) Max 400 Max 400

Stability (s) Max 450 Max 450

10 Air release value, at Max 4 Max 4 Six IS:1448, P:102
50 deg. C, in Monthly# ASTM D3427
minutes.
11 Mechanical <0.01 <0.01 Weekly ASTM D4055
impurities % (solid
particles by weight)
12 Water Separability Max 300 Max 300 Six IS:1448, P:91
(s) Monthly# ASTM D1401
13 Demulsibility (min) Max 20 Max 20 Six ASTM D1401
Monthly#
14 Cleanliness Level ≤19/17/14 ≤19/17/14 Monthly ISO 4406
(ISO 4406) (ISO 4406)
NAS Class 8 NAS Class 8
(max as per (max as per NAS 1638
NAS 1638) NAS 1638)
(Note iii) (Note iii)

15 Colour (max) ≤2.0 ≤2.0 Six IS:1448, P:12

Monthly# ASTM D1500

# External testing to be done from CC-NETRA/external Govt/NABL accredited labs.

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For the test methods as mentioned in the Table, latest version of the relevant Standards
(IS/ASTM) should be considered. The limits for the above are based on the OEM specifications/
IS 1012 (latest version). In case of any mismatch in lub oil parameter limits between OEM
recommendation and IS 1012 standard, OEM recommended limit has to be taken into
consideration.

Notes To Be used with the Table-IIA & IIB:

i. The recommended frequency of the above-mentioned tests may be increased if there is

persistent aberration in the testing parameters to ascertain the cause of deviation from
normal parameter range. Oil coolers surface and other associated equipments may also
be inspected to bring and maintain the parameters within the recommended limits.

ii. The moisture content of turbine lubricating oil varies widely with plant design and
operational practices, although, it is desirable to keep the moisture content as low as
practicable and always below 100 mg/l. If this is not achievable with some plant, reasons
for such excursions should be sought and remedial action taken. More frequent
monitoring may be necessary under these conditions to bring down the value to less
than 100 mg/l.

iii. Site is recommended to have a separate mobile filtration unit (As per recommendations
of Turbine Meet-2019) for taking care of any particulate contamination to maintain the
quality of oil as per NAS 1638 or ISO 4406.

10.0 TURBINE LUB OIL FLUSHING PARAMETERS MONITORING

(POST ANNUAL OVERHAULING)

Table-III
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Sl.No. Parameters UOM Limits Remarks

1 Moisture ppm 100 In-line filtration is in clean condition and no choking of
filter has happened during 04 hours of oil flushing
activity.
2 Mechanical ppm 100
Impurity

11.0 INTERPRETATION CHART OF TESTING PARAMETERS

Table-IV
Sl.N Testing Limits Interpretation Action
o Parameter
2 Moisture As per Table 1. More susceptible to oxidation and Investigate/ check functioning
-IIA & IIB degradation of centrifuge equipment.
2. Enhance corrosion
3. Deplete additives
4. Risk of bacterial/fungal growth
5. Increase moisture in Hydrogen
used for generator coolant
3 Viscosity -do- 1. Oil contaminated Consider for oil change.
2. Oil severely degraded.
4 Acidity -do- 1. Oil degraded. Increase frequency of testing
2. Oil contaminated & investigate cause.
3. High acidity will increase corrosion
potential. Consider oil change.
4. Catalyze further degradation
reactions.
5 Flash point -do- 1. Oil contaminated Increase frequency of testing
& investigate cause.
2. Oil severely degraded
Consider oil change
6 Rust -do- 1. The system is very severe on oil, i.e. it Investigate cause immediately
Preventive is very wet and/or dirty. and rectify.
characteristi 2. The system is incorrectly maintained, Recheck oil and consult oil
cs i.e. water drainage neglected and/ or company regarding re-
centrifuge not operating satisfactorily. inhibition if test result is
3. Normal inhibitor depletion in wet unchanged
system.
7 Emulsion -do- 1. Oil degraded. 1. Investigate functioning of
Characteristi 2. Oil contaminated oil purification equipment
cs 3. Oil coolers leakage / centrifuge
2. Check oxidation stability.
3. Check rusting
characteristics

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Table-IV
Sl.N Testing Limits Interpretation Action
o Parameter
8. Mechanical -do- 1. Purification equipment not Centrifuge bowl cleaning
impurities functioning properly.
2. Severe oil degradation is
occurring.
3. Oil contamination is occurring.
4. Additive Precipitation is occurring.
5. Indication of presence of
Corrosion and/or debris.

9. Rotating -do- 1. Determines oxidation stability of oils. Estimate of fluid health and
pressure 2. Measures actual resistance to oxidation provide estimate of remaining
Vessel of oils. life.
Oxidation 3. Performance of added anti-oxidants in
test oil.

12.0 NON-COMPATIBILITY OF TURBO-GENERATOR

LUBRICATING OILS SUPPLIED BY DIFFERENT OIL
COMPANIES
12.1 CONTROL PROCEDURES:
This information is intended for lubricating control and sealing systems containing large
volumes of oil where for reasons of cost, stations may consider topping up systems with oil of
the same specification but from a different manufacturer. Only oil of recommended grade by
equipment manufacturer must be used. However, if, for any reason, the original grade of oil is
not available for topping-up, then the full charge of oil must be replaced with a direct
alternative of the same grade.

Nevertheless

a) manufacturer or,
b) any Standard Research Laboratory such as
1) CSIR Lab
2) National Test Houses.
3) M/s IOCL, Faridabad etc
should be approached for declaring compatibility of new oil with the existing oil,
available as main bulk, filled inside the system. If it is found compatible, then only replacement
can be planned.

Responsibility: Chemistry- for quality checks of oil for replacement purpose.

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12.2 RECOMMENDATIONS:
i. The lubricating oil Control oil/Seal oil must only be topped-up with oil of the same
type, grade and manufacturer as the original oil.
ii. If oil of the original type is not available for toping-up then the full charge must be
replaced, taking care that all the original oil is removed.
Responsibility: Operation for oil top-up/replacement, as per prevailing practices at station.

13.0 RECORDS TO BE MAINTAINED:

Sl Record Description Maintained by Frequency Remarks
No.
A. For routine lub oil analysis:
1 Test results of routine analysis of Chemistry As per
lub oil samples table-IA, IB,
IC
2 External test reports of CC-NETRA Chemistry Six-Monthly
(external test or earlier if
report copies to required
be available with
site TMD)
3 External test reports of Turbine Yearly or
OEM/Supplier Maintenance earlier if
(external test required
report copies to
be available with
site Chemistry)
B. For Oil replacement/Top-up:
1 Records must be kept for all As per
inspections and should contain the requirement
following data:
Details of oil top-up Operation/ TMD
as applicable
Details of oil replacement & reasons - do-

Quality checks of oil for Chemistry

replacement

14.0 ASSOCIATED DOCUMENTS:

Annexure-1

Table A: Comparative table between NAS-1638 AND ISO:4406 (based on maximum contamination
limits and particles per 100 ml)
Approximate ISO NAS 1638
5-15 µm 15-25 µm 25-50 µm 50-100 µm over 100 µm
4406 Equivalent Code

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- 0 125 22 4 1 0

- 0 250 44 8 2 0

12/10/7 1 500 89 16 3 1

13/11/8 2 1000 178 32 6 1

14/12/9 3 2000 356 63 11 2

15/13/10 4 4000 712 126 22 4

16/14/11 5 8000 1425 253 45 8

17/15/12 6 16000 2850 506 90 16

18/16/13 7 32000 5700 1012 190 32

19/17/14 8 64000 11400 2025 360 64

20/18/15 9 128000 22800 4050 720 128

21/19/16 10 256000 45600 8100 1440 256

22/20/17 11 512000 91200 16200 2880 512

23/21/18 12 1024000 182400 32400 5760 1020

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15.0 Checklist for OGN-OPS-CHEM-009, Rev No-05 on “The

Examination and Maintenance of Lubricating Oils of Turbine & Boiler Fill
Pumps”

Sl Item description Reference Responsibility Compliance

No clause/section in (Yes/No)
OGN/OPS/CHEM/009
1. Compliance check for Section 4.0 TMD Yes/No
new oil specifications
2. Lub oil sample Section 6.0 Chemistry in Yes/No
collection presence of
Operation/TMD
3. Treatment and Section 7.0 TMD Yes/No
maintenance of oil
4. Condition monitoring Section 8.0, 9.0 Chemistry (in- Yes/No
of oil in service house) & CC-
NETRA (external)
TMD (for
external testing
from OEM/
Supplier)
5. Oil flushing parameters Section 10.0 Chemistry Yes/No
monitoring &
clearance
6. Oil Top-up and Section 12.0 Operation (for Yes/No
replacement as per top-up)
compatibility
COS-ISO-00-OGN/OPS/CHEM/021 Rev. No.: 0 Nov. 2023 Chemistry (for Page 13 of 12
testing)
7 Compatibility checks of Section 12.0 Operation Yes/No
new oil
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[Signature of site Chemistry/TMD/Operation executive]

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