COURSE OVERVIEW:

Varnish formation in turbine lubrication systems is a silent but devastating phenomenon that can lead to catastrophic mechanical failure and unplanned outages. This course provides an advanced exploration of the chemical degradation processes that transform clear lubricant into sticky, insoluble deposits. Participants will examine the roles of oxidation, thermal stress, and micro-dieseling in the creation of varnish, and how these sub-micron particles compromise the operation of sensitive servo valves and bearings.

The scope of this training focuses on the diagnostic tools and mitigation strategies required to maintain oil health in high-demand environments. We will investigate the Membrane Patch Calorimetry (MPC) test as the industry standard for quantifying varnish potential, as well as the limitations of traditional oil analysis in detecting polar degradation products. The curriculum covers the engineering of various varnish removal technologies, including electrostatic oil cleaners, ion-exchange resins, and depth filtration, comparing their effectiveness in both gas and steam turbine applications.

Coverage also includes the operational practices that influence varnish production, such as cooling rates, filtration efficiency, and the selection of base oils. By focusing on the proactive management of lubricant chemistry, the course ensures that the turbine’s control and lubrication systems remain free of deposits. Through this detailed study, attendants will gain the expertise necessary to implement a comprehensive varnish mitigation program, extending the life of the oil and the reliability of the rotating asset.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the chemical and physical mechanisms of varnish formation.
2. Identify the impact of varnish on servo valve response and bearing life.
3. Interpret Membrane Patch Calorimetry (MPC) results to assess varnish risk.
4. Differentiate between soluble and insoluble degradation products.
5. Evaluate the effectiveness of various varnish removal technologies.
6. Diagnose the causes of thermal degradation such as micro-dieseling and sparking.
7. Select high-performance turbine oils with superior oxidation stability.
8. Implement an advanced oil monitoring program beyond standard viscosity tests.
9. Oversee the installation and maintenance of varnish mitigation skids.
10. Analyze the relationship between oil temperature and varnish precipitation.
11. Troubleshoot valve sticking and "sluggish" control system behavior.
12. Conduct root cause analysis on turbine trips related to lubricant varnish.
13. Formulate a long-term oil management strategy to minimize lifecycle costs.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Lubrication Specialists, Turbine Maintenance Managers, Plant Chemists, and Condition Monitoring Technicians.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.