Industrial Reports

Document of * Electric Power Test and Research Institute

Report upon the application result of Liquid Bearing products –

* Electric Power Industry Bureau:

Introduction

Liquid Bearing products, produced by the Formula Lubricants International Corp., Canada, are multi-functional, anti-wear and energy-saving lubricating oil additives, and are used for improving the lubricity of turbine oils and other lubricants. In September 1996, in accordance with the arrangement of Electric Power Industry Bureau, these products were accepted into a period of partial trial usage in some electric power stations in * province.

The Chemical Department, Turbine Department and Steam Boiler Department coordinated with * Power Station and * Power Station during the test period. The operational condition of the test units, and the lube oil characteristics were tested before and after applying the Liquid Bearing into the lube oil system. In order to promote the extension of new technology and new material usage in early 1998, the Production and Technology Department of * Electric Industry Bureau decided that extensive application should begin with the turbo-generator set up to 50MW, and the large sized auxiliary machinery.

At that time, our institute sent technical persons to the power stations to give guidance on the test and methods of application. Decisions were made on which units would be the subjects of testing, and the quantity of Liquid Bearing required for this purpose. The quantity of Liquid Bearing applied so far in power stations in * province has reached 14 tons (14,000 Litres) already.

In March of 1998, our Institute organized seminars on the application and testing of Liquid Bearing specified for turbine lube oil, in which about 40 technical persons from the power stations of * province attended. At the seminar we gave a detailed introduction based on the technical documents provided by the manufacturer upon the application procedure, monitoring and test schemes. We requested that the power stations of * province make its own extensive application technology program in accordance with the manufacturer’s requirements as well.

As a result of that seminar, the participants in the test made arrangements for extensive applications applying Liquid Bearing into the lube oil system of turbo-generator sets with an output capacity up to 50MW, as well as auxiliary machinery. The testing procedures are outlined as follows:

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Application

Liquid Bearing products have now been used in 8 power stations. The equipment used consists of; 6 steam turbo-generator sets, 3 hydraulic generator sets, 8 water pump sets, 12 coal ball mill sets, 2 circulation pump sets, 6 flue gas fans and air-blowers and 2 air compressor sets. The breakdown of usage and applications are as follows:

Power station
Turbine No.
Water Pump No.
Coal Ball Mill No.
Circulation Pump No.
Exhaust Fan No.
Blower No.
J Y
2
2
3
2
2
B M
3
3
1
C D
2
2
H J Z
2
3
2
X Z
2
Y X W
1
H M K
1
1
1
B Z S
2
2

Analysis of Application Results

After Liquid Bearing was applied, the bearing vibration of the turbo-generator set and auxiliary machinery changed, but all readings were in range of the required standard.

The detergency function of Liquid Bearing products show the results of cleaning sludge from the lube oil. 200 hours after Liquid Bearing was blended into the lubrication system of the #1 generator set in J Y Power Station, there were about 70 kgs of sludge found in the oil filter. During operation, temperatures of return oil from the bearings reduced by 2º to 3º C.

It is clear that in accordance with the requirements of the manufacturer, samples must be taken from the oil system at regular intervals during operation for testing and inspection, and the oil filter cleaned frequently. If not followed, sludge accumulated in the filter could have an adverse affect.

According to the test results of B M Power Station, efficiency of the #6 turbo-generator set has been increased by 0.08% after the application of Liquid Bearing. When comparing the relative effects of using Liquid Bearing, it is recommended that the operating parameters before and after applying Liquid Bearing into the oil system be maintained the same, but this is difficult to do in practice.

Amperage readings decreased significantly following the application of Liquid Bearing on the electric motors of auxiliary machinery. This indicates that a degree of energy-savings resulted due to the improvement in lubrication.

In B Z S Power Station, oil service life was prolonged significantly after Liquid Bearing was added into the lubrication system of air compressors. Before Liquid Bearing was applied, the running oil had to be changed weekly. After adding Liquid Bearing, the service life of oil treated with Liquid Bearing increased to more than two months.

No corrosion has been found on the test pieces of copper and carbon steel material placed in the oil tank. After applying Liquid Bearing into the lube oil system, open cup flash point value decreased and the acid value increased, but the changes are still in the range of specification.

After applying Liquid Bearing into lube oil system of the auxiliary machinery, the viscosity of the blended oil decreased by a maximum of 16%. According to national standards, there are no viscosity limitations for high grade lube oil used for auxiliary machinery. However, although there are no specified limitations, attention should be paid if the viscosity is reduced excessively.

According to the national specifications for viscosity limitations on turbine lube oil, viscosity deviations of < +/-20% are considered acceptable.

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Conclusion

Based on the results of applying Liquid Bearing products on the turbo-generator sets with an output capacity of up to 50MW, and medium and large sized auxiliary machinery, the improvements have significant advantages as follows: detergency effect helping to separate sludge from lube oil, improving the lubrication condition, reduce electric power consumption of coal ball mills, increasing lube oil service life etc. So far, no abnormal effects regarding the safe operation of the equipment was noticed.

In order to improve equipment efficiency and to reduce the electrical consumption used by our own power stations, we recommend the use of Liquid Bearing Formula 8-10 on medium and large sized auxiliary machinery in all power stations. The use of Liquid Bearing TAP-168 should be used on turbo-generator sets with an output capacity up to 100 MW. Equipment experiencing abnormal operation conditions should also use Liquid Bearing so as to reduce the friction factor of bearings, reduce wear on the shaft journals and bearing liners, and to increase mechanical efficiency.

In order to assure efficient and safe operation of the equipment in the application of Liquid Bearing products, technical programs must be established and followed through to operation and monitoring.

With regards to different kind of additives other than Liquid Bearing products, application could be made only after necessary approvals in accordance with the requirements of the Technical Supervisory Instruction of the Electric Power Industry Ministry of the People’s Republic of China.