CASE STUDY
Unlocking $233k Potential Savings, Enhancing Reliability, and Advancing Green Initiatives
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 thereby critical component to reduce cost
Higher
Machine
Uptime
Frequent oil sampling and its logistics (transportation, recycling /discarding) incur costs.
Better Maintenance Planning
Relying heavily on lab results for oil sample testing and not using real-time oil condition monitoring delays issue identification and resolution.
A Higher Level Of Customer Satisfaction
The absence of a real-time monitoring solution for lube oil health.
Environmental Impact of Low-Quality Oil
Poor quality lubeoil as well as regular oil replacement have a negative impact on the environment.
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
