NEW GENERATION LUBRICATING

OILS FOR INDIAN NAVY

Nitish Mittal
Indian Oil Corporation Ltd.
Maharashtra State Office
 Applications & Change drivers in Lubricant Technology

Engine Oil Hydraulic Oil

Fuel Economy, Emission Control,
Extended Drain Longer oil life, Productivity

Driveline Lubricant Metal Working Fluids

Shift Fee, Efficiency,
Extended Drain Better solvency, Emulsion strength,
Cooling efficiency
Grease
Gear Oils
Low temperature applications,
Aesthetics, Manufacturing cost Micro pitting resistance,
Longer oil life, Energy saving.
Turbine Oils

Higher bearing temperatures , Mill Bearing Oils

Smaller sumps,
Demand for higher oxidation life Dynamic demulsibility

2
HI-PERFORMANCE TURBINE OILS
Trends in operating conditions of steam turbine oils

SUPER
CONVENTIONAL CRITICAL
UNIT SIZE, MW 100-200 600/660/ 800
OIL SUMP CAPACITY,KL 10-20 30-50
OIL TANK TEMPERATURE, DEG C 45-60 55-65
STEAM PRESSURE, MPa 15.5 24.7
STEAM TEMPERATURES, DEG C <537 565/593
GROSS PLANT EFFICIENCY,% < 35 40-41

More thermal stress on turbine oil in the modern super critical

turbines
 OEM’s Requirements for Turbine oils

CUSTOMER’s NEED OIL FEATURES REQUIRED

MAXIMUM EQUIPMENT LIFE GOOD OXIDATION AND

LEAST MACHINE DOWNTIME THERMAL STABILITY
EXTENDED OIL LIFE (10-20 YEARS)

RUST INHIBITION OF THE SYSTEM

GOOD ANTIRUST PROPERTY

NO SYSTEM CORROSION
GOOD METAL COMPATIBILITY

EXCELLENT SURFACE ACTIVITY OF

ADEQUATE WATER / AIR SEPARATION THE OIL TOWARDS ANTIFOAM
OF SYSTEM OIL DEMULSIBILITY & AIR RELEASE PROPERTIES

MINIMAL WEAR IN HEAVILY LOADED GOOD AW/EP PERFORMANCE APPLICATIONS

 Turbine oil specifications

# BS 489 (U.K.) # DIN 51515 (GERMANY)

# ISO 8068 # CEGB 20722 (EUROPE)
# IS 1012 (INDIA) # JIS K-2213 (JAPAN)
# SIEMENS TLV 9013 # SOLAR ES 9-224
# GEK 32568A # GEK 107395
# ALSTOM HTGD 9017 # MHI (CL001, CL 002,
CL003 & CL005)
 New Requirements from Turbine Oils
Development of Improved Quality of Turbine oils
To match the high temperature requirements
Built-in anti-wear performance for Gear lubrication
New Requirements demand for higher D 943 oxidation life and
lower sludge in Dry TOST & simultaneous FZG load characteristics

Extended ASTM D943 Life TOST performance using Group II/III

base stocks is a major marketing feature especially for combined
cycle and gas turbine applications

In January 2001 General Electric released a combined cycle

turbine specification, GEK 107395, which required extended
oxidation performance
RPVOT (ASTM D2272) of 1000 minutes
RPVOT (Mod) of >85%
Life TOST (ASTM D943) of 7,000 hrs
 Turbine oil – Market Requirements & Trends
MHI CL 001
MHI CL 002
MHI CL 003
MHI CL 005

Top tier Sludge &

Siemens TLV 9013 04 varnish control
Alstom HTGD 9017
Performance

Premium

DIN 51515-1
Economy BS 489:1999

Benefits & End users

 Servoprime 32 G

• Different Viscosity Grades

• Improved Oxidation Stability - D 943-10,000 hrs for VG 32
• Built-in antiwear performance : FZG – 10th stage
• Excellent rust and corrosion prevention properties
• Better water and Air separation characteristics
• Adequate Lubrication characteristics

In the area of Turbine Lubrication, enhancing Oxidation stability

is a continuous effort world over
 Mechanism of Sludge Formation

Lubricants = In a Machine
Severe Hydrocarbon
Hydrocarbon Environment Molecules
Base Stocks High Temp. Converted into
+ High Load Polymers, acids,
Performance Resins, varnishes etc.
Contaminants
Additives
Metals

Contaminants
(Rust and wear)
Harmful to the Machine
# Decrease Life of oil & Machine
SLUDGE
# More Wear of machine parts

# Corrosive wear may also occur

 Servoprime 32 XL

High performance turbine oil developed for MHI Gas & Steam
Turbines
Formulated with Group II base oils with special additive
package.
Approved by MHI for CL001 specifications
Meets the requirement of MHI’s CL002 & CL005 as well.
Available in ISO VG 32 & 46
Special characteristics
 higher TOST & RPVOT
 low Sludge generation
 passes most stringent special dry-TOST & mixture
stability test designed by MHI in its specifications.
NEW GENERATION HYDRAULIC OILS
 Trends in Hydraulic Systems- Delphi study 2010

• Speed of hydraulic pumps and motors increased by 15%

• Dimension of pumps, motors and valves reduced by 20%

• For some applications, operating pressures increased by

20-30%

• Speed of circulation also enhanced.

Trends in Performance Attributes of Hydraulic Oils
 SHORTER CYCLE TIME
◦ LESS TIME FOR :- Greater focus on the
 WATER SEPERATION quality of the base oil
 AIR RELEASE being used to
 FOAM DISSIPATION formulate the fluid
 COOLING
 HIGH PRESSURE SYSTEMS
◦ REQUIRE CLEANER OILS :- Greater focus on the
 WITH GOOD FILTERABILITY & cleanliness and filterability
 LOW SLUDGE FORMING TENDENCY of the fluid being supplied
◦ REQUIRE MORE ANTI WEAR PROTECTION

 INCREASED OPERATING TEMPERATURES

◦ REQUIRE MORE OXIDATIVE & Greater focus on the
additive package being
◦ THERMAL STABILITY PROPERTY
used to formulate the fluid
Choosing your Hydraulic Oil

DESIRE A HYDRAULIC FLUID which prevent :-

Wear …. , valve sticking,
metal transfer…. , filterability issues…
 BUT is compatible with seals”
 SERVOSYSTEM HLP SERIES

in modern hydraulic systems working in

extreme conditions of load and temperature.
in the presence of air, water and copper.
Turbine Oil Stability Test (TOST) results show outstanding
performance
 Chemical
are incorporated
 Are , an essential requirement in
today’s hydraulic systems.
 Best
 Suitable for a wide range of hydraulic applications .
 SERVOSYSTEM XLP SERIES
:
.
 It has much & thus longer oil life
 It has lower pour point
 It provides as it passes
Vickers vane pump test and Eaton test ;
- FZG gear test pass 12
( + 2)
 It has better demulsibility characteristics

 To help provide extra protection and improved filter performance

for less maintenance, “super cleanliness levels” are stipulated ..
(< NAS 7).
 ENERGY EFFICIENT HYDRAULIC OILS

The energy loss is in two main forms :-

• Mechanical losses – energy lost to fluid friction

• Volumetric losses – energy lost as the result of internal

fluid leakage (slippage) within the pump.

… it is primarily a function of the fluid’s viscosity and lubricity

properties.

“HYDRAULIC EFFICIENCY” DEPENDS ON :-

1. VISCOSITY OF OIL
2. VISCOSITY INDEX OF THE OIL
3. SYSTEM PRESSURE
EFFECT OF VISCOSITY ON PUMP EFFICIENCY
EFFECT OF VI ON EFFICIENCY

LESS THINNING
ME
VE
LESS THICKNING

HIGH VI OIL …
PREFERRED
 SERVOSYSTEM HVLP/ SERVOHYDREX SERIES

SERVOSYSTEM HVLP
 High VI product (i.e. 145-165 against 110 -115 for HLP type)
 Recommended for systems even under severe operating conditions
in stationary and mobile equipment.
 PERFORMANCE STANDARDS - DIN 51524 Part III

SERVOHYDREX TH 46 PLUS ( MOBILE HYDRAULIC SYSTEMS)

• Recommended for increased ODI
• Superior temp. viscosity performance
• Fuel efficient
• Gives productivity benefits
• Better demulsibility & filterability properties
FIRE RESISTANT HYDRAULIC OILS
 Fire resistant Hydraulic Fluids
 Hydraulic fluid performance demands
have increased due to high operating
pressures , safety & reliability needs.

 As operating pressures increase, risk of fire

from ruptured lines increases

 A leaking spray from high pressure hydraulic

system can cause serious fire & result in
property damage, personal injury, etc.

 Used extensively in high temperature

applications

Mineral oils can cause fire

Fire resistant hydraulic fluids recommended
 Fire resistant properties-IS 7895

 The fluid must resist ignition - Auto ignition

temperature

 Ability to snuff the flame and prevent it from

spreading when the source of ignition is present
- Spray Ignition characteristics

 Fluid must be self-extinguishing when the source

of flame is removed - Flame propagation test

“ FRFs have higher resistance to ignition than

other fluids & even if ignited, fluids have
properties that arrest the flame ”
Flammability of FRHF (WG type) on propane flame;
No ignition … only deviation observed
Flammability of FRHF (WG type) on same surface
 Fire Resistant Hydraulic Fluids :
Classification (ISO 6743 Part 4)
S.N Type Composition Applications

1. HFA Emulsions or solutions containing -Iron/steel production

more than 80% water -Mining operation

2. HFB Water in oil (invert) emulsion -Iron/steel production

Water content >45% -Mining operation

3. HFC Polymer in water -Underground mining

( water glycols) - Die casting

4. HFDR Water free synthetic fluids – -Mining industry

Phosphate esters -U/G hydraulic systems

5. HFDU Synthetic fluids containing no water -Steel mills

and of other compositions eg. polyol -Automotive industry
esters -Aircraft hydraulic
systems
 Fire resistant Hydraulic Oils from SERVO

Type IOC Product Composition Applications

HFA Servoaquol 250 Emulsions or solutions -Iron/steel production

containing more than 80% -Mining operation
water
HFB Servosystem HFB 68 Water in oil (invert) emulsion -Iron/steel production
Water content >45% -Mining operation

HFC Servofyress WG 46/68 Polymer in water -Underground mining

( water glycols) - Die casting

HFDR Servofyress HFDR 46/ 68 Water free synthetic fluids – -Mining industry
Phosphate esters -U/G hydraulic systems

HFDU Servofyress HFDU 46 / Synthetic fluids containing no -Steel mills

68 ES water and of other -Automotive industry
compositions eg. polyol esters -Aircraft hydraulic systems
 Servofyress HFDU 68ES
S.N Properties Method ASTM/IS:1448 Limits

1 Kinematic viscosity @ 40C,cSt D-445 /P:25 61.0-74.0

2. TAN, mgKOH/gm D-974 2.0 max

3. Density @ 15 C D-1298 / P:16 Report
4. Rust Test D-665A / P:96 Pass
5. Copper Corrosion D-130 / P:15 Pass
6. Pour Point, C D-97 / P:10 -15 max
7. Flash Point, C D-92 / P:69 290 min
8. Fire Point, C D-92 / P:69 >325
9. Auto ignition Temp, C E- 659 315 min
10. ARV @ 50 C, minutes D-3427 / P:102 25 max
11. Demulsibility D-1401/ P:91 40-40-0 (30 min)
12. Foaming, ml D-892 / P:67
Seq. I @ 24 C 300/10
Seq. II @ 93.5 C 300/10
Seq. III @ 24 C 300/10
13. FZG, Failure load stage IP-334 12
14. Fire Resistance Property IS: 7895 – 1975 Tests B, C Pass

15. Biodegradability CECL-33- A-94 Pass

NEW GENERATION GEAR OILS
Industrial Gear Box Trends

HIGHER LOAD ON GEAR TOOTH

“LOADING ON GEAR OIL”

 Type of Gear Failures

Micropitting- Major cause of Gear Failures

 Trends in Gear Oil Technology

Global / OEM Industry trend Lubricant requirements

Smaller sump sizes Improved foam & Air Release
Value
Higher operating temperatures Improved thermal-oxidation
stability
Improved micro-pitting Lower friction & less corrosive
performance wear
Reduced Energy consumption Lower coeff. of friction
Inertness towards seals / Compatibility with new seals &
materials materials
Extended drain intervals Improved overall performance
(GOOT)
 Trends in Gear Oil Technology

Advanced Gear Oil

Technology
improves bearing
life by up to 22%*
vs. standard gear
oil that doesn’t
offer micropitting
protection

* Based on SKF Bearing Life theory

 SERVO Industrial Gear Oils

Type of Specialty IOCL grade (alternative) – benefits / Credentials

Gear Oil
Mineral oil based -SERVO MESH XP
anti micro pitting - Improved thermal / oxidation stability
gear oil for severely - Better Anti-wear / Extreme Pressure performance
loaded mills. … - Improved demulsibility and foaming properties … good
wet filterability
Improved over - Passes Flender foam test
SERVO MESH PLUS - with 20% higher load bearing capacity than OEM
series specification
- giving more protection in case of shock loads. Higher
weld load and scuffing fail load stage
- being supplied to Jindal (Plate Mill by SMS) .. In use for
more than a year / In use in JSPL Patratu (WRM) and SAIL
RSP (plate mill)
 SERVO Industrial Gear Oils

Type of Specialty IOCL grade (alternative) – benefits / Credentials

Gear Oil
Mineral oil based anti -SERVO MESH GOLD
micropitting gear oil

- Max. protection against conventional wear like

scuffing

-Compatible with common gear box seal materials

- Recommended for lubrication of helical, bevel &

planetary type of Gear units.

- Approved by Siemens for Flender gear units (rev. 13)

NEW GENERATION COMPRESSOR OILS
 Compressor Types & Lubricant role
• Lubricate : rotors, valves, shaft seals,
bearings, gears and couplings
Rotary • Seal between: Rotors, vanes, cylinders
Compressor • Cool : Air, Compression chamber &
moving parts
• Reduce wear

• Seal Piston & piston Rings

Reciprocating • Lubricate outlet valves
• Lubricate bearings & other moving parts
Compressor • Reduce wear

Dynamic • Lubricates & cools bearings & seals

Compressor
38
 Compressor Oil Challenges

Compressed gas • Type of gas

Solubility of Gas • Type of oil

Moisture • Working condition

Hot Discharge • Temperature range

temperature

•Long life without need for change out (high oxidation stability)
•Prevention of acidity, sludge, deposit formation
•Excellent protection against rust and corrosion, even during shutdown
•Good demulsibility to shed water that enters the lubrication system
•Easy filterability without additive depletion
•Good foam control
 Performance Test Criteria
TESTS TEMP.,C DURATION CATALYSTS CRITERIA

POT 200 24 hrs IRON III OXIDE - EVAPORATION LOSS

- CCR (% wt)
- % INCREASE IN K.Vis
IP 48(MOD) 200 48 hrs ------ - EVAPORATION LOSS
- CCR (% wt)
- % INCREASE IN K.Vis
CM A 135 168 hrs Cu & Steel rod - % INCREASE IN K.Vis
- SLUDGE, mg/100 ml
- CHANGE IN TAN
- Cu ROD RATING
- STEEL ROD RATING
PANEL COKER 250 6 hrs ------ - DEPOSITS (% wt.)
TEST - % INCREASE IN K.Vis

RPVOT 150 25 psi Cu wire - RBOT LIFE

 Requirements from Modern Compressor Oils

 ADEQUATE THERMAL / OXIDATION STABILITY

 PERFORMANCE WITH MINIMUM CARBONACEOUS DEPOSITS

 EXCELLENT RUST / CORROSION INHIBITION

 GOOD DEMULSIBILITY RETENTION

 REQUIRED ANTI WEAR PERFORMANCE

 ‘SERVO’ Compressor Oils
Product Description / Application
Servopress oils Recommended for reciprocating and rotary air compressors
can be used up to 220 deg C air discharge temperature
meet the requirement of DIN 51506 VD-L group and ISO DlS-6521

Servopress T good demulsibility property

oils low deposit and sludge forming tendency
recommended for lubrication of ammonia and syn-gas centrifugal and
screw type compressors
Servopress XL rotary screw compressor oils specially developed to provide extended
oils drain intervals against conventional compressor fluids
provide improved thermal and oxidation stability over a wide range of
temperatures, reduced carbon forming tendency & reduced volatility.
Servopress AC energy efficient rotary screw compressor oils specially developed for Atlas
oils Copco Compressors
energy savings of 4% achieved in Atlas Copco compressor at R&D.
can provide extended drain intervals of 4000 hrs. against conventional
compressor fluids
SYNTHETIC OILS
 Synthetic Lubricants

SYNTHETIC LUBRICANTS (SYNLUBES) ARE LUBRICANT

PRODUCTS THAT CONSIST OF SYNTHETIC BASE STOCK OR
FLUIDS MADE BY CHEMICAL CONVERSION OF LOW-
MOLECULAR WEIGHT COMPONENTS INTO COMPOUNDS OF
CONTROLLED MOLECULAR STRUCTURE WITH PREDICTABLE
PROPERTIES.

THIS PERMITS THE SELECTION OF THOSE CHEMICAL

COMPOUNDS THAT HAVE BEST PROPERTIES & PROVIDE
SUPERIOR LUBRICANT PERFORMANCE COMPARED WITH
CONVENTIONAL MINERAL OIL BASED LUBRICANTS
 Why Synthetics required !

 Factors governing the lubricant trends:

- fill for life lubricant concept
- stringent emission regulations
- drive for fuel & lube efficiency

 Demand for high performance lubricants

 Requirements of high performance lubricants:

- VERY LOW VOLATILITY
- SUPERIOR LOW TEMPERATURE CHARACTERISTICS
- EXCELLENT OXIDATION RESISTANCE
 What makes Synthetics superior !
 Scientifically designed molecules

 Molecules have identical structure

 Fluid properties very predictable

 Because of tailor made molecules

these provide superior performance
over conventional mineral oil based
lubricants

High purity and molecular size uniformity

 What makes Synthetics superior !
Low operating costs and improved performance
Wider operating temperature band
- High Viscosity Index
- Low Pour Point
Extended drain intervals vs. mineral oils by improving
- Oxidation resistance and thermal stability
- Reduced volatility

Longer equipment life and lower downtime

- Improved film thickness, better inherent lubricity, reduced wear
and pitting
- Lubricate under extreme conditions
- Good solvency and low varnish leading to lower filter clog
 Synthetic Lubricant Types
 Wide formulation choice of base oils - to deliver best possible
performance

- PAOs : Mineral oil like with better low temperature & oxidation
stability, VI > 135

- Polyglycols : Water soluble and water insoluble grades with VI

> 200, very high load carrying ability

- Silicones : Very high VI, High temperature applications

- Esters : Excellent lubricity, low temperature performance and

oxidation stability

- Phosphate Esters : High fire resistance, used for high

temperature applications
 Mineral Oil vs. Synthetic Lubricants
Operating Temperature Comparison

350 - High
325 - Intermittent
300 - Service
275 -
250 -
225 -
200 -
175 -
Normal
150 -
Operation
100 -
75 -
50 -
25 - Low
0 - Intermittent
-25 - Service
-50 -
-75 -
Mineral OIls PAOs Polyol Di-esters DABs
Esters

FLUID TYPE
 Synthetic Compressor Oils
Servosynco E series - Gp. IV based compressor oils for
(VG 32, 46, 68, 100 & reciprocating air & screw compressors.
150) - OEM / user approved formulation technology
- can be used against Roto-Xtend duty fluid,
Elgi Airlube Dura Plus, BP Enersyn RC-S46
- suitable for more than 8000 hrs. drain
interval

Servocress series - Hydrocarbon gas compressor oils for LPG,

( VG 68,100,150 & 220) propane, butane, propylene gas
compressors
- Field proven technology for applications in
LPG import terminal, refineries and
petrochemical industry
- can be used against Royco 880/ Mobil
Glygoyle 30/ CP1507/1515
 Synthetic Compressor Oils

Servosynco DE series - Diester based compressor oils

(VG 32, 68, 100 & 150) - Single & multistage air compressors with built
in detergency properties
- Suitable for discharge temperatures up to 200
deg C
- can be used against Mobil Rarus 827/ Anderol
550
Servosynco PE series - Polyol ester based compressor oils for severe
(VG 22,32, 68, 100 & 220) operating conditions in the compressors
- Reciprocating compressors in urea plants
- Suitable for discharge temperatures higher
than 200 deg C
- Can be used against IR Centac Tectrol Gold III/
Shell Corena AP
 Synthetic Refrigeration Oils

Servofriz S series - Alkylated Benzene based refrigeration oils

(VG 22 to VG 150) recommended for use with all fluorocarbon
refrigerants.
- For use with hydrocarbons and ammonia in
refrigeration and air conditioning applications
Servofriz SHC series - PAO based refrigeration oils designed for use
( VG 68,100, 150) in industrial refrigeration systems using R 12 ,
R 22, ammonia and carbon dioxide as
refrigerants.
- Developed against Mobil Gargoyle Arctic SHC
Servofriz Eco series - Polyol ester based PAG based Synthetic
(VG 32 to VG 320) refrigeration oils for lubrication of refrigeration
compressors and systems using ozone friendly
HFC refrigerants.
- miscible with R 134a refrigerant
- developed against Suniso SL-32S/ Solest
 Comparison of Servosynco E 68 with
Mineral compressor oil
PROPERTIES SYNCO E 68 MINERAL OIL

 NOACK VOLATILITY % 1.4 3.0

 CARBON RESIDUE AFTER

POT TEST,% WT 0.09 0.42

 POUR POINT -51 -12

 LONG DURATION OXIDATION

TEST,120 C, 1000 HOURS
-% VISCOSITY INCREASE 0.8 7.1
- TAN CHANGE 0.48 0.75
 SERVICE LIFE ,HOURS 8000 1000
 Synthetic Gear Box Oils
Servosyngear series - PAO based gear oils for lubrication of spur,
(VG 100 to VG 680) helical, bevel, worm and hypoid gears
- can be offered against Mobil SHC 600 series
Servosyngear Plus/ AMP - PAO based Anti-micro pitting gear oils
series recommended for all type of gears including
( VG 320, 460, 680) plenary for wind mill gear boxes.
- Syngear Plus has Flender approval.
- can be offered against Mobil SHC XMP/
Shell Omala S4 GX oils for Wind application.
Servosyngear HVI series - PAG based Synthetic gear oil for high
(VG 220, 1000) temperature applications, worm gears
- has very high viscosity index
- developed against Klubersynth GH-6. can be
offered wherever Polyglycol based gear oil is
required.
TURBINE GOVERNOR FLUIDS
 Servosynturbo GF 46
Fire resistant synthetic Turbine Governor fluid for use in
Electro hydraulic governing system of Steam Turbines.
Developed against Chemtura’s Fyrquel EHC-N/ Reolube
Turbofluid 46XC.
Approval obtained from BHEL, Hardwar after meeting the
specifications.
Compatible & miscible in all proportions with other Turbine
Governor fluids.
Special characteristics-
Highest fire resistance property with inherent self
extinguishing characteristics
High oxidation and thermal stability
Excellent hydrolytic stability
 Oil/ Grease Nomenclature as per DEFSTAN
OC Compounded Oils are blends of mineral and vegetable oils only.

OEP Extreme Pressure Oils are gear oils containing additives which
enhance their ability to withstand extreme gear tooth pressures.

OF Fatty Oils are straight vegetable oils.

OM Mineral Oils are straight mineral oils or those containing additives

intended to improve their performance.

OMD Heavy-duty Engine Oils are mineral oil and synthesized hydrocarbon
based lubricants containing detergent or dispersant additives primarily
designed for use in internal combustion engines.

OX Fluids are specialised mineral oil and synthetic fluid based lubricants,
hydraulic fluids and damping fluids not covered by other designations and
may contain water/glycol.
 Oil/ Grease Nomenclature as per DEFSTAN

XG Greases are made using thickeners such as those based on

calcium, clay or lithium. They may be based on mineral oils,
vegetable oils or synthetic fluids and can contain additives such
as solid lubricants to improve their performance.

ZX Specialities are lubricants, damping fluids and compounds

designed for specific applications.

PX Corrosion Preventives are used primarily for the prevention of

corrosion to metal equipment and are easily removable.

AL Fluids are used for engine thrust augmentation, anti-freeze

protection, de-icing, cooling, cleaning or similar miscellaneous
applications and are mostly water soluble.
THANK YOU