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CASTROL PERFECTO HT 5 DELIVERS ESTIMATED $275K IN SAVINGS FOR FPSO OPERATOR

How expert used oil analysis (UOA) interpretation and technical SmartGains support from Castrol engineers helped maximize efficiency, limit maintenance costs, and reduce downtime.

SMARTGAINS CASE STUDY UOA AND FLUSHING

THE PROBLEM: GAS TURBINES AT RISK OF VARNISHING

A floating production storage and offloading unit (FPSO)customer was planning a flush and change-out of lubricantson three out of five gas turbine generators (GTGs) andapproached Castrol for advice on procedures/routines. One ofour technical experts reviewed historical used oil analysis (UOA)on all five GTGs and discovered that the two not scheduledfor maintenance had UOA failure modes indicating increasedrisk of varnishing – a problem that could lead to GTG failure,unplanned downtime and loss of production revenue.

THE RESULTS: IMPROVED RELIABILITY, AVAILABILITYAND MAINTAINABILITY (RAM) AND REVENUEGENERATION

Identifying the undetected UOA failure mode on the twoadditional turbines has potentially prevented a catastrophiccomponent failure linked to varnishing.

By collaborating with the customer, various OEMs, and third-party gas turbine specialists, Castrol experts were able to developprocedures that optimized the condition of GTG lubricationsystems and improved future maintainability by reducing overallmean time to repair (MTTR). The new detailed flushing and UOAprogramme focuses on reducing potential for oxidation, therebyreducing downtime to conduct repairs.

As a result of Castrol’s intervention and subsequent actionsby the on-site team, the mean time between failures (MTBF)has increased, in turn improving reliability statistics. Improvedreliability allied with improved maintainability leads toimproved availability statistics, and increases the FPSO’s overallperformance. This creates potential for more uptime, production,and associated revenue generation.

THE CASTROL SOLUTION: CASTROL PERFECTO HT 5 ANDSMARTGAINS EXPERTISE

By reviewing UOA data, Castrol identified that a further twoturbines had potential for oxidation by-products and varnishing.It was also discovered that the customer’s changeover proceduresdid not include a highly soluble flushing fluid and electro-staticfiltration to remove soft carbon deposits. Our recommendedflushing fluid, Castrol Perfecto HT 5, replaced the additionalvolume of the in-service lubricant which allowed for flushing at alower unit cost per litre. In addition, Castrol’s expert consultancyservices reduced the customer’s operational expenses andimproved their understanding of the failure modes associatedwith turbine lubrication and UOA.

THE FIGURES: SMARTGAINS ACHIEVED

SMARTGAINS AREA SAVINGS COST TO CUSTOMER TOIMPLEMENT CHANGE  CREATED VALUEPER YEAR 
** Technical review and troubleshooting on turbine oil condition for five turbines based on historical trending of UOAreports. Risk mitigation of potential Gas Turbine Generator (GTG) equipment failure, cost of maintenance and unplanned shutdown avoided. Downtime calculated @ 16,000 barrels per day. USD$63 per barrel average price May/June 2019, Exchange rate 0.70 = AUD$90 per barrel. Downtime Cost per hour $60,000; Minimum downtime avoided 4 hours x$60,000 per hour = $240,000 N/A $240,000
*** Discussions regarding varnishing in GTG, how to remove and next steps. Understanding underlying causes of varnishing and potential solutions. Negates need for 12hr hire external consultant @$150/hr N/A $1,800
*** Varnish removal campaign analysis. Varnish removal campaign was cancelled as the existing lubricant would not have been within specification even after polishing. Campaign costs not incurred. Polishing costcalculated @ $2,000 per unit x 3 = $6,000 N/A $6,000
*** Development of turbine oil changeover procedure and recommendations onflushing requirements. Processes developed including mitigation of potential errors in lubricant changeover and flushing process to minimise downtime. Negates need for 36hr hire external consultant @$150/hr N/A $5,400
*** Assessment and selection of flushing lubricant. Perfecto HT5 chosen for superior flushing ability and lowercost per litre. 24,000L @ $0.25 lower cost   N/A $6,000
*** Joint discussions with Castrol team, customer team, OEM and external third party turbine maintenance specialists to review proposed process and thenreassess after first campaign.  Reviewed procedures based on the first changeover of GTG, particularly on the flushing process, risk reduction, ongoing varnish removal and to improve overall efficiency. Negatesneed for 36hr Hire external Consultant @ $150/hr  N/A $5,400
*** Review of parameters in UOA programme for turbine oils with UOA laboratory on behalf of the customer. Presentation of Castrol recommended UOA parameters and intervals to supplement the existing UOA programme provided by UOA laboratory to extend oil life via polishing and Condition Monitoring utilising a Condition Based Main- tenance Strategy (CBM). Negates need for 66hr hire externalconsultant @ $150/hr  N/A $9,900
SMARTGAINS Total $274,500
*** Estimates verified with the customer
** Credible assumptions based on market knowledge
* Estimated mitigated costs, risk, or created value.

Based on a case study from a single customer. SmartGain results can vary depending upon the type of equipment used, its maintenance, operating conditions, and any prior lubricant used.
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