Choosing the right lubrication in the offshore industry is typically based on considerations such as performance and reliability, but this does not have to come at the expense of the environment.
For any piece of industrial machinery to run smoothly, lubrication is a key consideration. In the offshore industry, where equipment may be stranded more than 100 miles from the shore, maximum efficiency is essential, so lubrication treatment must be carefully selected to ensure reliable performance. Where spares and replacement parts may be days away, ensuring that everything is fully functional is critical to the bottom line.
Offshore operators must also carefully consider the environmental effects of the lubricant they choose. Though demand for oil has never been greater, the pressure facing companies extracting hydrocarbons from the ground is challenging in the current environmental climate. A surge in environment-related legislation in mature production zones like the North Sea has added to the complexity of offshore production. This trend is likely to continue in the North Sea and other oil-producing parts of the world.
However, operators still must weigh reliability in their lubrication decisions. The use of an environmentally responsible product that does not at least meet conventional product performance may actually be detrimental to the environment in the long-term. If one accepts a shorter service life than from conventional oil, it may reduce the immediate impact of a spillage but may increase the overall amount of oil consumed along with its attendant packaging, shipping, storage and disposal costs-all at a cost to the environment.
If the alternative fluid is more aggressive toward elastomers than mineral oil, there is actually an increased risk of a spill or leak from the seals. It is a difficult and complex balancing act between environmental responsibility and reliability that operators must perform.
Environmentally Responsible Lubricants
Fortunately, new environmentally responsible lubricants have been subjected to rigorous test programs to ensure product life, component life and system reliability are not compromised by the need for better environmental performance.
It is not only the normal aspects of lubricant performance under consideration. Other things to consider include the compatibility of the environmental alternatives with existing components and standard oils, which ensures the conversion process is simple and straightforward with no attendant risks arising from the change.
Hydraulic Oils
Hydraulics are among the most vulnerable systems on board a platform with high pressures, high flow rates and flexible hoses contributing to the possibility of a significant spill occurring at some time. New environmentally responsible hydraulic oils have been formulated to be stable in service, so they do not oxidize (combine with air) or hydrolyze (break down when wet) more than the traditional stable mineral oils. This means the service life can be expected to be at least as long as that of current lubricants.
Base Oils
New environmentally responsible base oils are compatible with the same range of elastomers used for mineral oils, so changeover is easy with no seal replacements required. Overall, the risk of a spill or leak is maintained at a low level, and the impact of any spill is reduced.
Open Gear Lubricants
Open gear lubricants used for doping the legs of jack-up drill rigs are an example of deliberately introducing the lubricant into the marine environment. The grease is applied onto wet steel, squeezed between gear teeth and is expected to stay in place on the leg when it is jacked down into the sea. Apart from selecting components with low toxicity, low tendency to bioaccumulate and good biodegradability, the main performance criteria is staying in place-it cannot have low environmental impact if it washes immediately into the sea.
A new open gear lubricant meets the demanding requirements for load carrying capability, adhesiveness and resistance to water wash-off. It was taken into the North Sea and evaluated during rig moves, where it was proven to perform as well as conventional leg dopes, was easy to apply with no stringing and provided a clean, safe working environment.
Conclusion
The emergence of more environmentally responsible lubricant products for the offshore industry offers a new solution at a time of mounting legislation. With the oil industry moving into increasingly challenging locations, such as the Arctic, the industry is expected to face ongoing environmental questions. The selection of new, more environmentally aware products may help in these instances. These products will only prove their value if they are robust enough to deliver the same-or better-performance as conventional lubricants, while reducing industry impact on the planet.
The result of their failure can be unexpected downtime, higher maintenance costs or even personnel safety risks. In the worst cases, human lives may be at stake. It is time to stop treating grease as some simple substance that just needs to be pumped into machines at some random frequency and then hoping for the best. Machine greasing must be a systematic and carefully planned process to ensure safe operation of assets and to achieve maximum equipment life.
The result of their failure can be unexpected downtime, higher maintenance costs or even personnel safety risks. In the worst cases, human lives may be at stake. It is time to stop treating grease as some simple substance that just needs to be pumped into machines at some random frequency and then hoping for the best. Machine greasing must be a systematic and carefully planned process to ensure safe operation of assets and to achieve maximum equipment life.
The path to lubrication excellence can be difficult to navigate. It begins when individuals and organizations become aware of the importance of their lubrication program, its impact on productivity and its direct effect on the bottom line. Once this enlightenment has occurred, comprehensive training in best practices is acquired and the organization can consider what the lubrication program should be and where they wish to take it.
The path to lubrication excellence can be difficult to navigate. It begins when individuals and organizations become aware of the importance of their lubrication program, its impact on productivity and its direct effect on the bottom line. Once this enlightenment has occurred, comprehensive training in best practices is acquired and the organization can consider what the lubrication program should be and where they wish to take it.
One of the best ways to achieve fault-free operation of paper machines is to ensure the proper lubricant is applied to the frictional surfaces. Most paper machines have hundreds, if not thousands, of lube points that require periodic application of oil or grease. There are bearings, gears, couplings, journals, cylinders and valves which must all receive the correct lubricant to survive the rigors of the paper-making process.
One of the best ways to achieve fault-free operation of paper machines is to ensure the proper lubricant is applied to the frictional surfaces. Most paper machines have hundreds, if not thousands, of lube points that require periodic application of oil or grease. There are bearings, gears, couplings, journals, cylinders and valves which must all receive the correct lubricant to survive the rigors of the paper-making process.
There are different thoughts of what constitutes a "world class lubrication program." It is our belief that a world class lubrication program consists of researching, documenting and implementing the best lubrication practices and regulatory requirements as defined by the leaders in the lubrication and reliability industry (Noria, SMRP, ICML, etc.) as well as regulatory agencies (OSHA, EPA). We have determined that for most programs, best practices can be summarized into the following categories:
There are different thoughts of what constitutes a "world class lubrication program." It is our belief that a world class lubrication program consists of researching, documenting and implementing the best lubrication practices and regulatory requirements as defined by the leaders in the lubrication and reliability industry (Noria, SMRP, ICML, etc.) as well as regulatory agencies (OSHA, EPA). We have determined that for most programs, best practices can be summarized into the following categories:
So what is going wrong with the lubricant and bearings in our pumps? We do not get a service life any where near those numbers. It turns out that most bearings fail prematurely for only two reasons: High heat that caused the lubricant to "varnish" and then form "coke" that will introduce solids into the lubricant, and contamination of the lubricant by water, moisture, and solids.
So what is going wrong with the lubricant and bearings in our pumps? We do not get a service life any where near those numbers. It turns out that most bearings fail prematurely for only two reasons: High heat that caused the lubricant to "varnish" and then form "coke" that will introduce solids into the lubricant, and contamination of the lubricant by water, moisture, and solids.
Improper bearing lubrication or re-lubrication accounts for up to 40 to 50 percent of machine failures. By eliminating lubrication from machinery, OEMs can minimize the costs and risks associated with maintenance for the end user. At the same time, costs related to the proper disposal of oil can be eliminated and the initial expenditure for ancillary components and processes (grease lines, zerks, manifolds, etc.) can be decreased.
Improper bearing lubrication or re-lubrication accounts for up to 40 to 50 percent of machine failures. By eliminating lubrication from machinery, OEMs can minimize the costs and risks associated with maintenance for the end user. At the same time, costs related to the proper disposal of oil can be eliminated and the initial expenditure for ancillary components and processes (grease lines, zerks, manifolds, etc.) can be decreased.
Following this meeting, a professional consultant visited Schmid to determine if the right oil and lubricants were being utilized to meet maintenance goals. After much testing and analysis, the consultant determined that the oils in use were not as high quality as the company originally thought. With hard work and determined mechanics, every piece of equipment and every truck was changed over to the new brand of oil and the company seemed to have fewer lubrication related problems. Still, large amounts of money were poured into repairs and the desired results were not fully achieved.
Following this meeting, a professional consultant visited Schmid to determine if the right oil and lubricants were being utilized to meet maintenance goals. After much testing and analysis, the consultant determined that the oils in use were not as high quality as the company originally thought. With hard work and determined mechanics, every piece of equipment and every truck was changed over to the new brand of oil and the company seemed to have fewer lubrication related problems. Still, large amounts of money were poured into repairs and the desired results were not fully achieved.
