Can Phosphorous Levels of used Turbine Oil be higher than the new oil ?

I received a used Turbine Oil Analysis recently that had higher levels of Phosphorous in elemental analysis as well it had dropped viscosity.

I doubted two matters when visited the plant noted the same filtration unit was used to top up gear or hydraulic oils and as well as turbine oils without proper flushing the filtration skid while switching the filtration unit using it on a gearbox to the Turbine !

So wrote below for plant manager:

• Anti-Wear Additive Should Deplete Not Increase! The primary source of phosphorus in turbine oil is anti-wear additives. These deplete over time, and their concentration decrease compared to new oil.

The Trouble with Tiny Drops: Gear Oil in Turbine Oil

While a single drop of contaminant in a massive 20,000-liter turbine oil tank might seem trivial, its effects can be surprisingly significant. Let's delve into the specific problems that can arise when gear oil or diesel fuel accidentally mixes with turbine oil, focusing on the chemical reactions and their consequences:

Gear Oil Mischief: EP Additives Wreak Havoc

Gear oil is formulated for heavy-duty applications where extreme pressure (EP) is a major concern. To combat this pressure and minimize wear, gear oil contains special additives. But these very additives can wreak havoc in turbine oil:

• Degradation of Anti-Foam Agents: Turbine oil relies on anti-foam agents to prevent excessive foaming, which can disrupt lubrication and damage components. The EP additives in gear oil can deactivate these anti-foam agents, leading to
• Excessive Foaming: Air bubbles get trapped in the oil, reducing its ability to form a proper lubricating film and potentially causing cavitation (formation and collapse of vapor bubbles) that can damage machinery.
• Increased Viscosity: EP additives often increase the viscosity (thickness) of oil. While this is desirable in gearboxes, it's problematic in turbine oil. A thicker oil film can lead to:
• Increased Power Consumption: The machinery has to work harder to pump thicker oil through the system, wasting energy.
• Reduced Lubrication at Startup: During cold starts, thicker oil may take longer to circulate properly, leading to increased wear and tear on components.

Chemical Breakdown:

• In some cases, the specific chemistry of the EP additives in gear oil might not be compatible with the turbine oil. This incompatibility can lead to:
• Sludge Formation: Incompatible molecules can clump together, forming sludge deposits that clog filters and reduce lubrication efficiency.
• Increased Acidity: Certain chemical reactions can cause the oil to become more acidic, accelerating corrosion of metal components.