Oil and Gas Case Studies

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Upstream


Ocean's Edge Services avoids millions in repair costs

Problem:

Ferrous and non-ferrous contamination under 5 microns in size in the water based glycol hydraulic fluid used to operate the sub-sea HPU. Resulting damage can cost millions to resurface the HPU for repairs.

Result with OEI Filtration:

Analysis of the contamination trapped on the magnetic filters identified ferrous and non-ferrous contamination down to below 1 micron, leaving it cleaner than ever recorded prior. If left in the stream those contaminants may have cost up to $3.4 million to repair the pair of PODS.

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Step Energy: Full fleet filtration

Problem:

STEP Energy was looking for solutions to decrease equipment maintenance and increase reliability for their fleet.

Result after OEI Filtration: 

“The amount of contamination found in the Twin Pumpers oil circuit, would have clogged off between 15 and 20 traditional filters and caused component failure,” stated Dale Constantine, Maintenance Manager for STEP Energy.

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Basic Energy: Hydraulic Fuel Filtration on Coil Tuber Saves $96,000+ over 5 months

Problem:

The hydraulic cartridge valves on the bi-directional hydraulic line have very tight tolerances and with only unilateral filtration the contamination present in the system was causing these valves to fail every 6-12 hours. After 5 weeks of failures BASIC Energy went looking for a solution to remove the contamination to below tolerance levels

Result after OEI Filtration: 

Since the installation of the High Pressure Magnetic Y-Strainer the contamination has been removed to submicron levels and there have been no cartridge valve failures. Each valve costs $480 equating to $96,000 of savings over the past 5 months plus downtime costs.

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Canyon Technical Services: Lube Oil Filtration on Quintuplex Reciprocating Pump

Problem:

On cold start up, the traditional filter goes into bypass allowing the inherent contamination to flow through the system causing premature component failure and costly hose and cooler clean up. The most damaging contamination is below 10 microns. Traditional filtration is unable to remove contamination below 25 microns in size due to flow restriction.

Result after OEI Filtration:

The magnetic filter collected all the contamination extending the life of the failing components. Every other eccentric group and the gearbox was protected from the contamination by this magnetic filter.

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Precision Drilling Saves $280K After Installing OEI Filtration

Problem:

Traditional 10 micron filtration couldn’t filter bi-directionally, going from the pump to the motor and the motor to the pump, or remove contamination to submicron levels.

Result after OEI Filtration:

Pumps are now changed out only every 2-3 years instead of anually for a savings of $280,000/year.

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Midstream


Taminco NV: Magnetic Drive Compressor Pump Protection

Problem:

Taminco has a large number of magnetic drive (magdrive) pumps, pumping corrosive & highly toxic liquids. The pumps were failing within 6 months, due to contamination between the wetted end magnetic drive and the protection or containment shell. Besides manpower and operational turn-down, Taminco had to renew bearings with almost every inspection.

Result after OEI Filtration:

All the pumps have operated without failure. To date none of the pumps have failed due to metal particles.

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Energy Transfer: Gas Station Compressor Lube Oil

Problem:

Contamination was causing traditional Baldwin filters to become saturated at 30 PSI differential, every 30 minutes. Changing these was very time consuming and costly.

Result after OEI Filtration:

The PSI did not rise above 10 in the first hour even though a large amount of contamination had been trapped. The next run lasted 10 hours.

“Had the Baldwin filters alone been installed, this amount of contamination would have saturated 30+ filters,” stated Mr. Etchison.

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Solvay Chemical Plant: Mann Turbine Lube Oil Filtration

Problem:

Ferrous metal contamination in the Mann turbine.

Result after OEI Filtration:

The Turbine was overhauled completely, the reservoir flushed and cleaned, and new oil added to properly test the OEI Magnetic Filter. To accurately test the OEI Filters, workers started the oil circulation system to filter any possible remaining contamination. The engineers were so astonished that they ran the circulation system for three more days before they started up the turbine.

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Momentive: Circulation Pump Filtration

Problem:

The company experienced multiple premature failures of the pumps and seals, which was due to excessive ferrous metal contamination. The ferrous contamination is a result of erosion and corrosion of the piping, caused by the dangerous process fluid Trimethoxy(methyl)silane.

Result after OEI Filtration:

In over 32 months, there have been no pump failures and maintenance intervals have been extended. In addition, there has been reduced contact with dangerous Trimethoxy(methyl)silane when workers are replacing failed pumps.

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Pioneer: Pioneer Natural Resources Protects Turbo Coolant System Through Magnetic Filtration

Problem:

Two problems exist in this case: oil, even new, contains ferrous contamination down to submicron levels. And secondly, rotating equipment coolant systems are traditionally not filtered. These harmful ferrous particles cause premature wear and failures in equipment seals and pumps. The contamination also degrades the quality of the oil, by reducing its ability to cool and lubricate the turbo charger.

Result after OEI Filtration:

Photo A shows the amount of contamination removed after just 11 hours in operation. Analysis of the trapped contamination (see graph below) shows a high level of oxygen (27%) indicating moisture, as well as ferrous (59%), and non-ferrous material (32%) mainly silica particles. These particles range in size from 40 microns to submicron.

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Alliance Pipeline: Cyclopentane Cogen Heat Exchange

Problem:

Black Powder contamination resulting from the corrosion and erosion of the piping system. This results in the premature wear of the seals and other essential system components.

Result after OEI Filtration:

BPS efficiently removed Black Powder from the pentane thereby reducing wear on the pump seals and system components by this abrasive contamination if left in the system.

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Petromax: LPG Mechanical Pump Seal

Problem:

The crude oil entering the Petromax Refining Company Refinery is contaminated with Black Powder in the LPG stream damaging the mechanical seal face on the process pump. Over time, the entire inboard seal system will be compromised as it will coat the inside of the exchanger coil, causing a loss of efficiency in temperature exchange. It seizes the seal gap components and compromises faces.

Result after OEI Filtration:

After 10 days of operation, the Magnetic Separator Rod removed an excessive amount of Black Powder identifying the volume of contamination in the flow.

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Washington: Silicon Processing Plant

Problem:

Production downtime from pump failure due to black powder contamination (sub-micron to 100+ microns in size primarily made up of ferrous metals) originating from corrosion and erosion of the transmission lines. The fine ferrous black powder is magnetically trapped in the impeller drive causing premature wear of the journal bearings, internal shaft, impeller and magnet carrier.

Result after OEI Filtration:

Install OEI Magnetic Separator Basket Strainers prior to the pump to remove the corrosion and erosion contamination with minimal flow restriction resulting in reduced component wear, improved product purity , and identification of warranty issues related to premature pump component failure. One Eye Industries Magnetic Separators are designed with over-sized housings to allow maximum exposure of our patented magnetic technology. This design ensures the most efficient contamination removal from high flow and viscous fluids associated with chemicals, oils, and gas products basket strainers with minimal flow restriction.

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Downstream


Eni S.P.A: Glycol Filtration

Problem:

Traditional filtration, was unable to remove high levels of contamination inherent in the new glycol fluid, and corrosion present in the 32km feed pipeline and storage reservoir. The contaminated glycol was damaging valves, pump seals, degrading the quality of the glycol, and reducing its efficiency as a coolant and as a dehydrator.

 

Result after OEI Filtration:

Results far exceed the holding capacity of similarly sized traditional filters (170 grams holding capacity). Analysis of the contamination identified: 74% was non-ferrous and 26% ferrous.

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Alliance Pipeline: Heat Recovery System Filtration

Problem:

Alliance Pipelines Ltd. was experiencing high levels of contamination in their pentane waste heat recovery systems. This contamination mainly consisted of the mineral magnetite and other ferrous metals. Without extraction of these contaminants, there was risk of causing premature wear of the pumps, seals and piping components of the pipeline.

Result after OEI Filtration:

With the harmful contaminants out of the system, it will result in cleaner pentane. Additionally, it could be assumed that without these contaminants, there is now reduced wear on the whole waste heat recovery system. Eugene Kuhn is very pleased with the results, and is looking at employing OEI magnetic rods at other locations where ferrous and non-ferrous contamination is a problem.

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Poor Buffer Gas Fluid Main Cause of Gas Compressor Seal Failure

Most failures of refurbished compressor gas seals result from lack of clean and dry buffer gas supplied to the compressor, according to a recent analysis conducted by a leading supplier of engineered sealing systems and associated products. These seals are used on most pipeline compressors that supply gas to gas turbines at power plants and in compression systems needed to boost gas pressure in power plant gas turbines.

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