BSA BRIEF - Reduced Packing and Cylinder Lube Rates on Two, Four (4) Throw Hydrogen Process Compressors

Refinery primary compressors typically operate uninterrupted from 3 to 5 years and are only down during a unit turnaround or a non-routine maintenance event. During a turnaround inspection on two, four (4) throw hydrogen compressors at a gulf coast refinery, the refinery’s machine reliability group observed and noted that excess oil was found in compressor valves, downstream bottles, and the process. Additionally, a major concern for the process industry is the carryover of too much oil downstream can affect and contaminate catalyst beds. The machine reliability group assigned to the operating unit contacted Bill Spitzer & Associates for help to analyze circumstances that can affect over lubrication. These discussions led to the following key action steps.

  • Determine current lube rates of OEM equipment

    • Specific to the machine’s cylinder and packing points

    • Based on refinery operating conditions and operating process

  • Evaluate the OEM supplied divider block system

    • Formulate a recommendation if re-sizing the existing packing and cylinder lubrication system would be required


Planning: The refinery communicated with the compressor OEM for input and a recommendation on lube rates. As subject matter experts, Bill Spitzer and Associates’ would evaluate the existing lube system design to ensure they are sized appropriately and in line with the OEM’s lube rate recommendation.

Recommendations: The OEM recommended a lube rate reduction near 25% and Bill Spitzer & Associates advised minor changes to the current OEM distribution block design.

Actions Taken: The refinery decided to implement the lube rate reduction from the OEM’s recommendations immediately.

Project Take-a-way: Monitoring, recording, and documenting compressor lubrication rates makes practical and financial sense for all compressor users: refinery, gas transmission station, or gas processing locations. This proactive service by Bill Spitzer & Associates can have measurable benefits, enhanced ma-chine reliability, reduction in operating costs, and improve the environment.

Results:

  • Lowered lube consumption over 25% on both compressors

  • Saved over 450 gallons per year in lubricant consumption

  • Achieved over $5,500 in annual lubricant savings

  • Reduced the downstream process impact by lubricant being introduced

  • Met OEM lube recommendations

  • Improved machine reliability

  • Decreased lubricant consumption impacts

The final system cycle time goal was about 30 seconds on both machines, effectively reducing the lube rate almost 30%.

BSA BRIEF - BSA Increases Grouting Efficiencies Saving Client Time and Money

Date: July to September 2021

Location: Gulf Coast Texas Petrochemical Facility

Escoweld 7505E/7530 Epoxy Grout: 3-Component and highly flowable epoxy grout.  This epoxy grout can be pumped and has one of the lowest thermal expansion rates of 14.6 x 10-6.  For this project, compressive strengths surpassed 15,000 psi.

On-Site Technical Grouting Guidance:

A Bill Spitzer & Associates (BSA) subject matter expert was on-site to supervise the mixing and placing of Escoweld epoxy grout. Additionally, reviewed the site for compliance with API 686, ACI 351, and facility specifications. Hot temperatures were a concern; however, those were avoided by tenting and cooling the equipment system environment and grout. After one day, BSA realized wasted time in the grout mixing and placing process. A new procedure was introduced and followed to increase the efficiency and show the value of BSA on-site guidance for the contractor.  

 Bill Spitzer & Associates Values Provided

  • Escalated hourly units placed by 30%

  • Saved 98.1 hours of labor

  • Advised new grouting procedure

    • Broadened schedule flexibility

    • Created economical & efficient solutions

    • Reinforced jobsite safety & ergonomics

 BSA On-Site Aspects:

  • Total Project - 609 ft3 or 254 units

  • Manpower - 9 men / bucket pouring

  • Initial Output - 16.8 ft3 per hour

  • BSA Modified Output - 24 ft3 per hour

  • 7.2 ft3 Efficiency Improvement

  • Total Time Saved - 98.1 hours

Packing and Cylinder Lubrication System Advancements on Reciprocating Compressors

Are you experiencing premature wear or failure of compressor parts, i.e., rings, packing or excessive oil consumption, or phantom no-flow shut down issues? If so, these symptoms can be attributed to poor divider block system performance, typically due to the system design, wear, and/or age.  Or,  if you are just looking to “bounce off” a lubrication problem with a subject matter expert at BSA, we invite you to contact us. We can help to review, explore, and analyze your divider block system design and drawing…….and this initial review comes at no cost to you.  We are confident we can recommend improvements to your divider block lubrication system that impact performance, reliability, and production that will save you money.

Bill Spitzer & Associates has over 40 years of experience in lubrication system applications, ranging from design, installation, preventative maintenance service to root cause analysis.  We are also pleased to announce being recently appointed a Patton Divider Block Systems distributor. With our knowledge, experience and field service capability, along with Patton’s innovative and patented product offering, our team now offers the industry an expanded array of cost effective solutions and services, unmatched in the market.   

Products

  • Replacement parts in stock, including box lubricators for the most common frames

  • Patton ALB-1 Gearbox adapts to: Ariel 1 & 2, Worthington Cub, Super Cub, White Superior, Chicago Pneumatic, Dresser Rand, and Gemini

  • Off machine or standalone lubrication system packages, specifically designed to pre-lubricate cylinder and packing components prior to machine start up

  • Form, fit, and functional replacements for other brands, CPI©, Graco-Trabon©, & DropsA©

  • All products are in stock and ready for immediate delivery

 Services

  • Experienced service technicians, who can quickly and effectively analyze, troubleshoot existing systems

  • Onsite audits available designed to improve and validate system reliability and to eliminate costs due to over lubrication

  • Complete turnkey system installation and preventative maintenance services

  • Onsite or virtual training available

 BSA’s Divider Block System “Tips of the Day”

  • Always be sure to purge all air from the system after any maintenance performed

  • Contamination is the leading cause of lubricator pump failure, it is highly recommended to incorporate both low and high pressure filtration

  • We recommend using SS filter elements rather than the traditional bronze elements in certain gas service, the bronze will corrode and will eventually cause system clogging and eventual system failure

  • If you’re using a typical pump to point lubricator pump with a sight glass, we recommend periodic pressure testing of the pumps to ensure the drops in the sight glass are equal to the volume is being delivered to the application point

CASE STUDY - Additional 6,000 HP Compressor Packages Grouted By Pumping

Client:

One of the largest diversified corporations in the world, with businesses in insurance, energy, hospitality, and packaging industries. Additionally, they are traded on the NYSE over 35 years. The customer has 15 offshore drilling rigs, over 13,000 miles of gas pipelines, over 400 miles of NGL pipelines, and underground gas storage capacity of over 200 billion ft3.

Overview:

From a previous successful project, Bill Spitzer & Associates (BSA) was asked to administer choices for the contractor to be successful in pumping epoxy. Two 6,000 hp compressor packages were required to utilize the engineered pumpable epoxy grout to ease constructability, empower schedule flexibility, maximize effective bearing area, and produce advantageous efficiency. Chockfast® Red HF decreased the total grouting project time (about 50%) and lowered expenses associated with labor and materials (1 mortar mixer versus 4).

Location: Petal, MS
Date: March 2020
Product: Chockfast® Red HF
Size: 100 units or 251 ft³
Skid Dimension: 186” x 378”
Crew Size: 10 installers
Install Time 6 Hours
Low Ambient: 57°F
High Ambient: 79°F
Max Wind Speed: 67 mph
Avg Dew Point: 59°F

Challenges:

  • Managing project scheduling targets and goals

  • Enhancing constructability

  • Evaluating project parameters and difficulties

  • Prohibiting overrun costs

  • Acclimating to the specific site variables and conditions

  • Consulting in the field 

Action Steps:

  • Analyzed blueprints

  • Investigated formwork

  • Reviewed facility constraints

  • Recalculated grout supply

  • Organized pre-grout meeting

  • Supervised grout pumping

  • Adapted to cooler climates

  • Taught finishing techniques

  • Oversaw proper sampling procedures

Cold Weather Grouting:

Although Bill Spitzer & Associates (BSA) operates in warmer climates, BSA has extensive field knowledge to adapt to many circumstances.  For this colder field environment, BSA pre-conditioned the materials 48 hours, pre-conditioned the working environment 12 hours, and post-conditioned the compressor packages 48 hours.  This aided a high effective bearing area (EBA) of 99%, maintained flow rates to meet schedules, and provided predictable installing attributes.  Moreover, the expansion joint spacing was reduce to eliminate the concerns of thermal shocking or cracking. Temperatures should be 65°F - 95°F.  Since it was difficult to have hot water for grout clean up, IXT-59 was the preferred solution to adequately clean tools and equipment.      

Solutions:

Bill Spitzer & Associates (BSA) sold the compressor packager Chockfast® Black previously and later Chockfast® Red HF at the jobsite to provide a monolithic structure between the mechanical and civil engineering practices.  Moreover, Chockfast® Black is an example of how BSA is involved at many supply chain stages to advise clients of reliability applications with grout.  The uniquely specialized concepts of epoxy grouting can be simplified with BSA differentiated expertise.  Also, BSA fosters engineers, owners, and contractors to become more profitable, timely, and productive. BSA operates a client first mindset.

6,000 hp Compressor - Petal, MS (1).png

CASE STUDY - Increase Frac Pump Packing Life & Uptime Performance for Top Well Service Provider

Client:

Founded over 100 years ago, this customer has about 50,000 employees in over 80 countries.  For this case, we worked with their Mega-Camp in the Eagle Ford Shale operating 10 Frac Fleets.  

Key Outcomes:

  • Delivered smaller and more precise shots of lubrication more frequently

  • Increased packing life

  • Expanded reservoir capacity

  • Minimized refill intervals, human touches, and time in the Red Zone

  • Evolved the hydraulic fracturing client to continuous production pumping practice by enlarging the capacity 650%

  • Maintained desired performance and reliability with zero component failures over the course of a year


Location: Eagle Ford Shale
Date: Jan. to Dec. 2019
Product: Spitzer FlowMaster Packing Lube System
Reservoir Capacity: 60 lb.
System Driver: 24 VDC Electric Motor
System Type: Centro-Matic 
Application: Reciprocating Plunger Seal Packing on a Trailer Mounted Frac Pump

Overview:

Hydraulic fracturing has evolved into a continuous production situation with rigorous demands on the equipment used and the personnel involved. Our client was experiencing field performance issues throughout their Frac Fleet with their packing lubrication system. Specifically, the previous system was designed to discontinue flow of lubricant to the fluid end upon failure of one packing point. As the fracing industry evolved and the hours of operation increased, the maintenance time of the systems also increased proportionately. Furthermore, the customer struggled with frequent refilling of the small reservoir. This limitation created risk of introducing contamination into the reservoirs and concern of safety hazards with operators in the Red Zone. The goal was to improve system reliability and design that would enhance packing life and uptime performance, while reducing the number of human touches.

Recommendations and Implementations:

  • Advocated a large (60 lb. capacity) single line parallel system

  • Exceptional performance in harsh and severe environments

  • Developed a filtration system on the reservoir lubricant fill port to combat contamination when refilling

  • 90% of lube system failures could be attributed to contamination or impurities

  • Engineered lubrication rates for increased efficiency

  • Delivered smaller, precise shots of lubricant, more frequently

  • Installed and commissioned custom systems in three (3) hours per frac pump

  • Four (4) frac pumps were equipped with the Spitzer FlowMaster Packing Lube System

  • Commenced a 365-day field test of the Spitzer FlowMaster Packing Lube System

  • Pumped from the “dirty” side of the frac manifold

  • Served in numerous Zipper Fac’s in the Eagle Ford

  • Performed frequent system validation checks to monitor success

  • Partnership with the client enabled the packing life to be tracked over the course of a year

Results:

  • Increased average packing life from 50 to 130 stages on pumps working dirty side of the manifold

  • Delivered lubricant more frequently in smaller dosages

  • Created independent operating metering valves for continuous lubrication to all points in the system, should blockages occur

  • Expanded the reservoir capacity eight (8) times than previous reservoir

  • Decreased the frequency in refill from once every shift to every five (5) days

  • Mitigated contamination through filtration resulting in zero component failures to date

  • Constructed a rugged solution that has lasted over a year in some of the harshest environments

  • Achieved the return on investment in less than one year, based solely on packing life

Frac post 1.jpg

Automatic Lubrication Systems for Intrinsically Safe Environments

Situation

A large refinery customer recently reached out to Bill Spitzer & Associates “BSA” looking for assistance in the design and development of a lubrication system that can lubricate new vertical pumps that they are installing at their refinery.  The oil refiner required that the lubrication system be designed for an intrinsically safe environment. BSA representatives conducted a site visit in order to better under the lubrication requirements of the equipment.  Together we collaborated with the customer to design an intrinsically safe automatic lubrication system specific to their needs.  

As the company seeks efficiencies, they were looking for increased equipment reliability, a reduction of labor resources for routine maintenance and repairs due to bearing failures.   While there is a variety of lubrication systems on the market, the customer was most comfortable partnering with BSA to develop a robust system built for longevity and efficiency.

Solution

Together we designed an automatic lubrication system with electrical components suitable for Class 1, Div 2, Groups BCD. The system was assembled by BSA Technicians on a fabricated aluminum panel and included the following components:

  • On/Off Switch

  • Lubrication System Controller mounted in an Adalet explosion proof enclosure: The controller has various settings, allowing the end user the ability to set the system for the specific lubrication needs of the equipment. In addition, the front of the enclosure includes a green manual lubrication button, green power light, and a red fault light. Mounted on the top of the enclosure is an additional red fault light that if lit signals that the lubrication system requires attention.

  • (1) Solenoid: The solenoid valve opens when it receives a signal from the controller, allowing plant air to activate the grease pump.

  • (1) Lincoln Lubrication Air Filter / Air Filter Regulator / Air Pressure Gauge: This system filters and regulates the supplied plant air going to the pneumatic grease pump.

  • (1) Lincoln Model 926 400 lb. Drum Pump: This is equipped with bare pump assembly, a 400 lb drum cover, an air coupler, an air nipple, a 3’ air connecting hose, a 5’ high-pressure grease connecting hose, and volume elbow union.

  • (1) Grease Filter: The grease filter screens contaminants out of the grease before it reaches the Divider Block assembly to prevent damage to the Divider Block and the bearings being lubricated.

  • (1) Lincoln MC3 Divider Block with cycle indicator (24S, 24S, 24S). MC3 metering devices are modular type metering devices consisting of a baseplate part containing all inlet and outlet connections and a metering sections part containing alternate outlet ports for installation of performance indicators. The baseplate part has one inlet, three intermediate sections, and one end section held via three tie rods. The metering sections part consists of three metering sections which are fixed on the baseplate.

  • (1) Cycle Switch: The cycle switch is the mechanism that is utilized to monitor the operation of the divider block. In the event the divider block does not cycle, the cycle switch will trigger the fault light indicating the system requires attention.

Layout.JPG

In the end the customer was supplied a turn-key lubrication system which required very little resources to install and commission. Partnering with Bill Spitzer & Associates means that we can turn-key custom design, fabricate and install lubrication system specific to unique and individual lubrication needs.

Switching From Grease to Oil: Packing Lube Change in the Frac World

Situation

A pressure pumping company running 6 fleets of Frac Pumps in the Permian Basin has successfully transitioned from grease to oil as a Packing Lube.

Over-greasing had led to an unacceptable housekeeping mess throughout their entire fleet and was creating multiple problems for all involved. They were constantly shoveling grease out of their catch pans and most of the time their pump mechanics were covered in grease from head to toe. At one point, The Department of Transportation had an entire fleet shut down, unable to move to the next pad until the grease was cleaned off. Not to mention the huge environmental issue they had on their hands. With packing failures escalating and the mess building, their Maintenance Manager decided it was time to make a change.

Bill Spitzer & Associates was asked to assist in the transition from using grease to oil. This presented a challenge since this particular client is running both Lincoln and Graco 24 VDC Injector Systems, as well as the BEKA Box Greasers.

Step 1: Specifying the Right Lubricant

Since none of these systems are designed for a continuous feed of oil, we knew we had to specify a product engineered specifically for the application. Conventional rock drill oil was not going to be able to get this done.

We had worked with a lubricant provider in the past and consulted their Well Service Team on what their recommendation would be. They had a product that was being used by other pressure pumping companies in air-over-oil systems and from the success that they had with those companies we chose to move forward with their product.

Step 2: Trial Run on One Unit

We started with a Lincoln System on a Quintuplex Pump. We maxed out the injector output settings and set our cycle time to every 15 Seconds.

The first sign of success was after the very first stage. We took temperatures on the packing nuts and the system running oil was 81 degrees F, while the pump next to it running grease was 97 degrees F. This was very promising.

Our goal for this trial was 50 stages or 100 pumping hours. This seemed to be about the average packing life with the grease systems.

We checked on the unit daily and after a month of pumping we reached 242 stages and 415 pumping hours before the packing was replaced due to concern of hours, NOT failure!

Step 3: Cut Back on Lubricant Consumption

We trialed another unit on the same pad with the injectors set at half-output and the same cycle time, cutting our lube consumption in half.

We reached 146 stages and 238 pumping hours when their Maintenance Manager decided this test was a success and it was time to move forward!

Step 4: Implementation

With all 6 fleets pumping 18-hour days, the implementation proved itself to be very challenging. Each system had to be adjusted and setup to work with oil.  We did not change any parts on these systems or even clean out the reservoirs. Bill Spitzer & Associates assisted in adjusting the injectors and setting the controls as well as applying a sticker to each unit that had been transitioned. Repairs were made during this time and after a couple of weeks all 6 fleets were running oil.

Step 5: Cutting Back on Lubricant Consumption (AGAIN!)

In an attempt to improve upon the already huge success of this project we worked with the Maintenance Manager at the packager to run a unit on test line with our pause time set at 80 Strokes instead of 15 Seconds. Packing Temps stayed below 105 degrees F so we decided to take this setting to the field.

They ran one fleet at this set point for a few weeks with no issues. They made the change across all six fleets and are now running their systems based off of stroke count instead of time.

Value Proposition

When we started this project the main goal was to get rid of the mess. In doing so, we also increased the average packing life, as well as saved on lubricant consumption.

The client was originally using one (1) tote of grease every fifteen (15) days per fleet.

They are now using one (1) tote of oil every twenty-one (21) days per fleet.

Conclusion

The success of this project is hard to overstate. The transition addressed all of the environmental issues they were dealing with and improved upon up-time, efficiency, and performance.  It cut costs on lubricant spending, as well as made it easier for the mechanics on pump maintenance. The client is ecstatic with their decision to switch from grease to oil and Bill Spitzer & Associates is now a huge believer in the use of oil in our packing lube systems!

Contact Steven Logan @ (832) 858-1616 to discuss making the transition and getting rid of the mess!

SYSTEM.jpg