$238,000 Saved in Three Months
GLOBAL ENERGY COMPANY SAVES $238,000 IN FIRST THREE MONTHS WITH CARE RELIABILITY SERVICES
Our client, a Calgary-based company focused on conventional oil and gas exploration and production, has assets spread over a wide geographic area in Alberta and British Columbia. In addition to a number of producing wells, the company operates compressor stations and gas plants, with ambient temperatures ranging from -40°C to +40°C on a 24-hour, 365-day-per-year basis. They operate a diverse fleet of close to 400 reciprocating and rotary screw compressors, with a mix of electric motor and gas engine drivers.
The oil and gas industry in Canada has been influenced by lower prices, ample supply, and increased competition in key markets. These pressures have resulted in the need to optimize maintenance and operating budgets while maintaining a high level of equipment availability.
With 2400 samples being collected per year, the company’s maintenance leaders were overwhelmed by the large volume of analysis results, and opportunities to protect equipment from catastrophic failures were being missed. Even with a large number of warnings being produced, few maintenance activities were being done in a timely fashion.
The company turned to Fluid Life’s Condition Assessment & Reliability Evaluation (CARE) program for a solution.
In September of 2015, Fluid Life’s Reliability Specialists started working closely with the company’s maintenance leaders. Fluid Life’s team worked to identify the root causes of the significant number of notifications and warnings being issued and was able to identify the following impending equipment failures:
- A critical propane refrigeration screw compressor was being lubricated by the wrong lubricant, one that wouldn’t readily separate from the process gas. Fluid Life’s Reliability Specialists worked with the client’s maintenance leaders and their lubricant vendor to specify the correct lubricant and to develop an appropriate changeover procedure.
- High levels of copper found during routine oil analysis prompted a Fluid Life Reliability Specialist to alert the client. The source of the wear was identified and repairs were completed.
Other opportunities for improvement were identified, including:
- Entering equipment and lubricant hours and maintenance events into mylab™ (Fluid Life’s online software solution),
- Focusing maintenance efforts on critical issues, to helping frontline staff feel less overwhelmed and more engaged with and in control of their oil analysis program.
By implementing Fluid Life’s CARE program, we have created a sustainable and controlled oil analysis program. Working with our client, we have helped them achieve the following:
- Reduced focus on non-critical issues: This process has reduced the volume of corrective actions that are identified, helping front-line staff feel less overwhelmed and frustrated.
- An increase in average response time: In the first month, the average response time was 17 days. In the second month, the average time was reduced to seven days, then to six days by the third month.
- Though the program has only been in effect for approximately 90 days, the client has confirmed maintenance savings of over $238,000, for a return on investment of 1,592%. As the program continues to mature, significantly more savings are expected.
Client: Oil & Gas
Service: CARE Service