Petrochemical and Refinery

Petrochemical plants depend on a diverse range of equipment, including process fluid systems, process ovens, high-pressure compressors, and ventilation systems. The reliable performance of this equipment is crucial, as any unexpected downtime in a single component could disrupt the entire plant’s operations.
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Hydrocarbon processing industry

In the hydrocarbon processing industry, the reliance on rotating equipment for delivering results surpasses that of any other sector. Whether it’s pumps, compressors, turbines, or gearboxes, ensuring the reliability of this equipment is essential for sustaining a competitive edge. When factoring in the substantial downtime costs, which can exceed $1 million per day for certain units, the demanding outdoor operating conditions, and the extensive turnaround cycles lasting 3-5 years, it presents a considerable challenge.

Pumps function in an environment characterized by dirt and moisture, leading to significant particulate and water contamination. The bearings housed within the pump are crucial oil-lubricated components, and they are highly susceptible to contamination. In the event of pump failure, the crucial function of supplying water to the boiler for steam production, turbine operation, and ultimately electricity generation would be compromised.

Compressors function in an environment prone to dirt and moisture, leading to particle and water contamination. The internal components of the compressor serve as the primary lubricated elements, highlighting the susceptibility of the system to these challenging conditions.
The gearboxes in cooling towers face unique lubrication challenges due to their exposure to an extremely wet environment and limited accessibility without proper configuration. The primary lubricated components are the driving gearbox and water circulation pump bearing housings. In the event of gearbox failure, the cooling tower fan would be unable to expel hot air, leading to operational issues. Similarly, if the water circulation pumps fail, the cooling process would be adversely affected.

Large valves function in a dirt and moisture-prone environment, leading to significant particulate and water contamination. The hydraulic system, responsible for operating these valves, serves as the major lubricated component. In the event of valve failure, it could lead to production losses and potentially compromise safety measures.

Motors are subjected to environmental elements and function in a dirty, wet setting prone to significant particulate and water contamination. Large motors rely on oil-lubricated bearings as their primary lubricated components. In the event of motor failure, it could lead to process disruptions and potential safety hazards due to the critical processes they facilitate.
Small and large gearboxes play a crucial role in driving processes across the refinery, whether through reducers or agitators. These gearboxes operate in a dirty, wet environment prone to substantial particulate and water contamination, with the gears inside serving as the major lubricated component. In the event of gearbox failure, it could lead to process interruptions, improper mixing or agitation, and potential safety risks.
Engines function in a dirty, wet environment susceptible to significant particulate and water contamination. These engines are responsible for providing supplementary power or operating portable pumps or compressors, with their internal components serving as the major lubricated elements. In the event of internal component failure, auxiliary equipment that supports operational processes may cease to function.
Small steam turbines are commonly utilized in lieu of electric motors to power various equipment such as pumps, compressors, and blowers, especially in environments with abundant steam. These turbines operate in harsh conditions characterized by heavy particulate and water contamination. The governor and bearing housings are the major oil-lubricated components, with the governor controlling the steam flow and the bearing housings supporting the turbine. Given the sensitivity of bearings to contamination, the failure of any of these components could lead to production loss and potential safety hazards due to the cessation of equipment operation.

Establishing an optimal lube room within every plant is essential for maintaining lubrication-related supplies and fostering a culture of meticulous oil handling standards. The lube room should be strategically located in an area with minimal particle and dirt presence, facilitating easy temperature control for optimal storage conditions.

Storage and Filtration of New Oil
The lube room serves as a central hub for storing new oil, housing storage drums and drum racks. Prior to use, new oil should undergo filtration, either through storage units equipped with built-in filtration or via the utilization of filter carts to cleanse oil in drums. Furthermore, the storage units should be equipped with desiccant breathers to mitigate moisture ingress.


Organization and Inventory
In addition to new oil storage, the lube room should accommodate transfer pumps, valves, filter carts, portable storage containers, and various lubrication-related supplies such as grease guns, oil cans, unused filters, cleaning materials, and spill absorbents. Careful organization of these supplies is pivotal for efficient inventory management and ease of access.

 

Cultivating a Culture of Excellence
Beyond being a storage space, the lube room serves as a platform for fostering a culture of effective and meticulous oil handling standards within the company. By implementing best practices and maintaining a well-organized lube room, companies can reinforce their commitment to optimal lubrication procedures and maintenance protocols.
In essence, the lube room plays a multifaceted role, not only as a storage and transfer space for oil-related assets but also as a cornerstone for promoting excellence in oil handling practices within the organization.

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