CASE STUDY

Increased the Lube Oil Change Interval From 1000 Hours to 2000 Hours by Prolonging The oil life (Oil Analysis Report Verified).

Background

India’s largest oil and gas exploration Public Sector Undertaking (PSU) was facing a challenge.Frequent lube oil changes on their offshore jack-up rig engines drained both their finances and the environment. Furthermore, unnoticed engine issues added to their woes, lacking real-time oil health trends for early detection.Their mission was clear: extend engine lube oil life, bolster reliability, and proactively identify faults before they crippled operations.

Equipment

CAT engines

Vessel

Offshore Jack-Up Rig

Solution

Oil Quality Management Solution

Customer

Biggest Oil PSU In India

Challenges Faced By Oil PSU Operators

Cost Savings through Oil Life Extension

Prolong life of oil and therebyRead more

Higher
Machine
Uptime

Frequent oil sampling and its Read more

Better Maintenance Planning

Relying heavily on lab results Read more

A Higher Level Of Customer Satisfaction

The absence of a real-timeRead more

Environmental Impact of Low-Quality Oil

Poor quality lubeoil as well as Read more

Why is it necessary to improve oil health?

  • For smooth engine operation and maintaining optimal performance levels.
  • Oil in good condition helps enhance the life of critical components.

Why is it necessary to improve oil health?

In Diesel engines, an improvement in oil cleanliness level from ISO 21/18 to 17/14 can lead to a "3 TIMES" increase in the Mean Time Between Failure (MTBF).

Evaluation Process

Step 1: Install the OQMS for Engine 4, which











includes a 3-micron filtration system with an oil












condition sensor.

Step 3: Check that oil characteristics are within












permissible limits that determine good oil health.

Step 2: Test the oil sample at every 250-500 hour











interval from a lab and compare it with results from our











system.

Step 1: Install the OQMS for












Engine 4, which condition












sensor.

Step 2: Test the oil sample at













every 250-500 hour interval













from a lab and compare it with












results from our











system.

Step 3: Check that oil











characteristics are within











permissible limits that











determine good oil health.

OQMS Performance vs Lab Report

Results For Engine 4

On comparison it was observed that the key oil parameters such as TBN and TAN are within permissible limit (Refer Chart)

Key Results

The lube oil drain interval has been prolonged by 2x

Potential savings of $233K over 20 engines over a period of 5 years

No dependence only on lab results

Greener environment

Early identification of potential faults in lube oil

Prolonged lifespan of critical components, which lowers spare part expenses

Lube oil health trends also serve as a great insight into engine health trends

Breakdown of Potential Saving as a result of Doubling the Oil Drain interval

Oil Tank Capacity = 650 liters

Estimated yearly running hours /engine = 4000 hours

Current replacement frequency = at 1000 hours (4 times/year)

Cost of lube oil = $1.39/ liter

$ 1807 saved by changing oil interval by only 2 times in a year

Additional savings of $ 537 on Caterpillar filter elements in a year

The potential saving of $ 233561 for the biggest oil PSU in India for 4 oil rigs of 5 engines each for the tenure of 5 years.

Full Lab Report

Below are the oil health parameters at the end of the 2000 hours. Parameters still look good to extend lube oil life further