Lubrication Systems For Aero Gas Turbines: Ashutosh Panda
Lubrication Systems For Aero Gas Turbines: Ashutosh Panda
Lubrication Systems For Aero Gas Turbines: Ashutosh Panda
Abstract
The lubrication system is an effective means to serve the power transmitting elements of any engine and is
designed to keep the components like bearings, gears, splines, seals etc. lubricated and cooled in gas turbine engines. In
addition,it serves to remove impurities, support loads, prevent corrosion and acts as a diagnostic medium for condition
monitoring of engine parts. The lubrication system for a gas turbine engine includes a pressure system for supplying oil to
various components, scavenge system to collect the used oil, breathing unit for air evacuation and pressurization unit for
stopping the ingress of oil into gas flow path. With few exceptions, the lubricating system can be of the dry sump design
where bulk of the oil is stored in an engine-mounted separate tank. All gas turbine engine lubrication systems normally use
synthetic oil.Various properties of lubricants affect the system design and behaviour.The proper selection and use of
lubricants, as well as the care and operation of lubricating system is an essential part of any gas turbine maintenance program.
Correct maintenance procedure must be executed to ensure proper amount and type of lubricant getting used, and lubrication
system runs free of contaminants with the aid of protective devices.
Keywords: friction, dry sump design, synthetic oil, properties of lubricants, operation of lubricating system.
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
1.2 Necessity of lubrication for gas turbine engines. measure of internal fluid friction by virtue of which fluid
offers a resistance to shear displacement. Higher the
In a gas tubine engine bearings are used to support the viscosity, greater the protection against various failures.But
turbomachineries and gears, which are subjected to both too much viscosity causes excessive heat generation.
axial load and radial load.Lubrication system is essential to Generally viscosity of oil varies with time as shown in
keep the bearing and gears lubricated and also to remove Fig-3.
the heat away from the system.Prolonged safe and reliable
operation of a gas turbine engine can be possible with a
suitably designed and fully operational lubrication system.
2. Properties of Lubricants: Viscosity tends to keep the lubricant film from being
squeezed by the pressure of the bearing surfaces. Viscosity
The ability of a lubricant to satisfy above requirements, is usually expressed by kinematic viscosity.The ideal lubri-
together with any other requirement, depends on its funda- cant is one whose viscosity is least affected by the variation
mental characteristics, some of which may be inherent of engine operating temperatures.
properties of the lubricants while others originate from the An indication of rate of change of viscosity of oil with
use of suitable additives. temperature is expressed by its Viscosity Index (VI), higher
The important properties of lubricating oil are value of which indicates less variation with temperature.
viscosity, density, volatility, thermal stability, flash point, Synthetic oils have a higher value of Viscosity Index in
pour point, freeze point, fire point, specific gravity, comparison to mineral oils.
chemical stability, oiliness, volatility etc. Some of the
important properties of aero engine lubricants and their 2.2. Pour point
applicability are listed in Table.1.
Oil gets thicker when the temperature falls. At a particular
temperature the oil stops flowing.[1] This temperature
below which the oil stops to flow is called Pour Point. The
lower the pour point, the better the oil performance at
lower temperatures.[2] The pour point depends on, e.g., the
viscosity and chemical structure of the oil. Mineral oil has
a higher pour point than synthetic oil because of presence
of paraffin or wax in the base oil. (Fig-4)
Undoubtedly, the most important property of any Pour point depressants are added to lubrication oil to
gas turbine lubricant is its viscosity and to be more accu- improve their pour point.
rate, its viscosity/pressure/temperature relationship. It is the
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
2.4. Fire-Point
The wetting effect of oil which reduces friction is called a. Hydrodynamic lubrication or thick film lubrication
oiliness of oil. It is the power of oil to maintain a continu- b. Hydrostatic lubrication
ous film under pressure while it is used as lubricants. A c. Boundary lubrication or thin film lubrication
lubricant which does not squeeze out from the sliding d. Extreme pressure lubrication
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
3.1 Hydrodynamic lubrication or thick film lubrication 3.3 Boundary lubrication or thin film lubrication
Hydrodynamic lubrication is said to exist when the moving Boundary lubrication may happen when two surfaces slide
surfaces are separated by the pressure of a continuous or rotate against one another under heavy load, and in such
unbroken film or layer of lubrication. In this type of lubri- conditions there may be contact between the moving sur-
cation, the load is taken completely by the oil film. [6] faces and film breaks down, an oil is used which interact
The basis of hydrodynamic lubrication is the formation with the solid surface of the metal.(Fig-9)This can be pos-
of an oil wedge. When the journal rotates, it creates an oil sible by adsorption of lubricant molecules on the surfaces
taper or wedge between the two surfaces, and the pressure or by chemical reaction of the lubrication substances with
build up with the oil film supports the load. [6](Fig-7) metal surfaces.[5]
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
5.1 Dry sump lubrication system The return oil from the bearing supports and gear box
passes through oil cooler and flows back into the oil tank.
In dry sump lubrication system oil is stored in a separate (Fig-10)
tank outside the engine. There are at least two oil pumps in
a dry sump -one pulls oil from the sump and sends it to the 5.2.2 Hot tank lubrication system
tank, and the other one sucks oil from the tank and sends it
to lubricate the engine parts..[7] In this lubrication system the oil cooler is usually placed in
Dry sump systems gives certain advantages over wet pressure lines. Hot scavenged oil returns directly from the
sumps:[7] engine supports into the oil tank without cooling.(Fig-11)
a. Engine’s centre of gravity can be lowered which im-
proves aerodynamics. The oil capacity of a dry sump is
much more than that of wet sump system.
b. Less chances of oil leakage in to the engine.
c. Less oil consumption.[7]
Venting system.
De-aerator to separate entrained air from the oil.
Oil level transmitter or dipstick.
Rigid or flexible oil pickup.
Coarse mesh screens.
Various oil and air inlets and outlets.
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
The oil tank is usually placed close to the engine and high
enough above the oil pump inlet to ensure gravity feed.
Oil tank capacity and size varies with the different
types of engine and aircraft, but generally it is sufficient to
ensure an adequate supply of oil to for the rotating compo-
nents. Oil tank vent line is provided to ensure proper tank
ventilation with variation of flight altitude. [9]
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
The high pressure filters are generally accompanied Oil pressure at the outlet from delivery pump is adjusted by
by a bypass valve which by passes the unfiltered oil to the pressure relief valve.
engine when the filter blocks, thereby saving the engine
components from any damage during flight. 6.5 Scavenge pumps
Thread-type filters (fig.15) are often fitted as a last chance- Scavenge pumps are also of gear type positive displace-
filter immediately upstream of the oil jets. ment pumps .Separate scavenge pumps are used to collect
return oil from each support bearings and gear boxes. Some
of the scavenge pumps are fitted in a common housing
known as scavenge pump block and gets drive from the
engine gear box. (fig-17)
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
COMPONENTS
Fig-19 A typical static air separator. Fig-21 A typical metal chip detector.
(Source: Internet) (Source: Author)
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
As soon as the metal particles enter the clearances between ized oil, the same is supplied to different rotating compo-
the current conducting washers, the resistance of the sensi- nents like gears, bearings and seals through supply pipe-
tive element is sharply decreased and a signal is fed. They lines and flow nozzles.
are generally fitted in the scavenge line of the oil system . The used oil gets collected by separate scavenge pumps
fitted with different bearing supports and gear boxes. The
6.9 Oil space pressurization unit scavenge pumps collect return oil through scavenge filters
and pressurize it and delivers the same to oil cooler through
This unit is meant for protection of air gas path of engine air separator and chip detectors. The cooled oil form the
against the falling of oil from rotor supports. The oil in the cooler gets back to the oil tank, thus completing one cycle.
bearing cavities is subjected to differential air pressure Oil tank, gear boxes and all the bearing supports are
across the sealing rings in the bearing housing. For doing connected to atmosphere through separate vent lines for
this compressed air is used which is tapped from fan or LP breathing.Pressure controlled in all the three cavities of the
compressor end during initial periods and then from the pressurization unit ensures constant pressure drop in all the
higher stage HP compressor stages during higher modes and flight of the aircraft (from the pressurization
modes.(Fig-22) cavity to the oil cavity), on the oil contact seals, thus
excluding the possibility of entering of oil and vapors in
the air-gas path of the engine.The filtration capacity of the
oil filter should not be coarser than 40 to 60 microns.
Each rotating engine component needs lubrication and
has its own specific amount of oil requirement for proper
lubrication and cooling. The oil flow to the lubricated areas
as per the need is provided by the cross section of the
supply lines and the oil nozzles.
Oil Quantity
Oil Pressure
Oil Temperature
Low or high Oil Pressure Warning
Fig-22 Bearing cavity pressurization unit. High oil temperature warning.
(Source: Author) Oil Filter Clogging.
The sensors are located at predefined locations within the
7. Functioning of a typical aero-engine lubrication lubrication system. The data provide by the different sen-
system . sors are used to monitor the system functioning. In addition
to this, different types chip detectors are used for wear
A schematic description of an aero engine lubrication debris monitoring and are usually placed in the oil scav-
system is shown below enge lines.
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38th Engine Systems Symposium – March 2013 ESS-38-70
Ashutosh Panda / Lubrication Systems for Aero Gas Turbines
The oil pressure sensor is connected to one of the oil pipe 9.1 Oil consumption
lines in the supply system.[8]They are usually fitted in
pressure line just before delivery to the supply nozzle and Oil consumption check is carried out to collect information
pipelines. (Fig-25) about the sealing efficiency of the bearing compartment
seals and for the early detection of leaks.[8]
Low/High pressure warning switches are provided in addi- [1] http://www.nesteoil.com .(Accessed 19th January 2013)
tion to a pressure gauge to indicate that a minimum pres- [2] http://www.ehow.com. ( Accessed 19th January 2013)
sure is available for continued safe operation of the aero [3] http://www.engineersedge.com/lubrication
engine. These switches are generally connected to a warn- (Accessed 19th January 2013)
ing lamp in the flight compartment and the lamp illumi- [4] http://www.engineersedge.com/lubrication
(Accessed 23rd January 2013)
nates if the pressure falls below an acceptable minimum.
[5] http://www.vidyabhartitrust.org
(Accessed 27th January 2013)
8.4 Oil filter clogging indicator. [6] http://www.brighthubengineering.com
(Accessed 27th January 2013)
It is used for early detection of filter blocking .Whenever [7] http://auto.howstuffworks.com
filter elements are clogged, resistance of the elements (Accessed 29th January 2013)
increased and at a pressure difference of 0.4 to 0.6 kg/cm² [8] http://www.springer.com
across the filter, the pressure sensor gives to the indication (Accessed 29th January 2013)
[9] http://www.greatwarreplicaaircraft.com
in the cockpit. With this early warning pilot can take neces-
(Accessed 30th January 2013)
sary action avoiding damage to bearings. [10] Jet engine © Rolls-Royce plc 1986, ISBN 0902121 235
Fifth edition. Reprinted 1996 with revision.
8.5 High oil temperature sensor [11] http://www.aircraftextras.com
(Accessed 30th January 2013)
In some gas turbine engines a special type of thermo chip [12] http://www.pumpfundamentals.com
detectors are used for generating high oil temperature (Accessed 30th January 2013)
signal. Generally signal is provided by melting of a fusible
insert in an electric circuit. The signal is generated as the
oil temperature reaches nears about 90% of its fire point.
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