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Customer SAVE
REAL Services' customers are engaged in
producing crude petroleum and natural gas; extracting oil from oil sands and oil shale; producing natural gasoline and cycle condensate; and refining of hydrocarbon liquids from coal processing of plastics & polymers.

Types of activities included are catalytic conversion, pressurization and general processing & refining of oil and gas well operation and maintenance.   Refinery maintenance plans include Ferrography and Oil Analysis; provided by REAL Services along with our exclusive SAVE REPORT which provided Return On Investment and Cost Justification of your PM Program.

Petroleum Refining - Compressor

Case Study # 111

Although the equipment particle concentration (EPC) of 3,046 is well within the historic mean for this equipment,  analysis of equipment particle size, shape and composition indicate spalling of the babbitt material, from Refinery NTSG compressor.  The equipment was rated CRITICAL.

Recommendation:  Schedule equipment for maintenance action. Inspection for abnormal bearing wear mode in progress and damage to journal (sleeve) bearing.

   

Equipment Particle Analysis (EPA) shows 130 micrometer (um) white non-ferrous (Babbitting Alloy) Severe Sliding Wear particles.  Analysis also shows the presence of 55um Copper Alloy (including Brass & Bronze) Severe Sliding wear particles.   These particle are of sufficient size to cause a metal to metal interference with the close tolerances of this film boundary  lubrication of this equipment.

 

 

 

 

Heat treatment of these 130um white non-ferrous metal particles confirm their composition of babbitting alloy.  Evidence from the equipment particle profile indicate pitting and spalling of the babbitt layer of the sleeve or journal bearing. 

   

Upon opening of NTSG Compressor, three-(3) of the five-(5) sets of  sleeve or journal bearings show pitting and spalling.  Significant secondary damage was avoided resulting in the  saving of the crankshaft in this reciprocating compressor.

CUSTOMER ESTIMATED COST SAVINGS:

Original Component Savings:                          210,000
Secondary Damage Savings:                           72,000
Down Time Min./Production hrs. Savings:                 0
RUSH Shipping Cost Savings:                                   0
Parts & Inventory Warehouse Savings:                      0
Overtime Repair Savings:                                            0     
                                 Total SAVINGS:   $ 282,000

 

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