A GE Turbine system and Main Lube Oil Tank (MLOT) needed a thorough cleaning and contaminate removal to improve bearing life and protect the turbines critical parts. A lube oil flush, side-stream filtration, mechanical pipe cleaning, and varnish removal process performed, achieved an ISO particle count better than 15/14/10.
RIG performed oil reconditioning and tank cleaning on a 3000-Ton Press on location at an extrusion plant. The 48-hour cleaning process removed debris and returned ISO contamination to acceptable levels on a tight timeline.
The RIG team successfully removed varnish from a refinery’s centrifugal compressor lube oil system, achieving changing the MPC from >40 to 1. High velocity flushing combined with side streaming filtration an chemical cleaning. We were contracted to provide services on the compressor lube oil system during the turnaround. The services performed included:
- Varnish mitigation flush with Step One Cleaner
- Purge / particle contamination flush with virgin oil
- Side stream filtration of final fill oil
Managed Reliability Program, Oil Analysis, and Side Stream Filtration for Injection Molding Manufacturer
RIG developed and implemented a turnkey ISO cleanliness program that increased the reliability of critical hydraulic systems for a global plastic mold injection company. The program managed 28 re-circulation hydraulic systems located in a single department of the manufacturing plant. These systems actuated sensitive valves and cylinders, with proportional directional valves being the most critical components.
The plant was experiencing issues with several electrically operated valves sticking in the closed position ever year requiring them to be rebuilt. Operating pressures of the valves were below 3000 psi. The target ISO 4406:99 cleanliness code for these systems was 17/15/11. The cleanliness program reduced maintenance, oil, and filter costs as well as prolonged the life of critical hydraulic equipment by exceeding the target cleanliness level on all 28 hydraulic systems.
A previous flushing provider left a flange slip screen in place during a turbine flush. The screen in front of the turbines T5 bearing starved the bearing of oil and caused $1.2 million dollars in damage. RIG’s plant reliability experts were called to find the source of the issue and help repair the damage while ensuring the system and oil lubricants were clean.
RIG recently completed a project for a major petroleum refinery on a process compressor. The lube oil system for the compressor had never been cleaned in over 30 years of service and would benefit greatly from RIG’s services. The unit was down for a major maintenance outage which created the perfect opportunity to address the ISO cleanliness of the oil and oil system. RIG custom engineered and performed a successful reservoir and chemical cleaning coupled with a high velocity hot oil flush (HVOF) to return the system to acceptable ISO and API cleanliness specifications. In order to meet the needs of both the Reliability and Estimator stakeholders, the job was submitted with a not to exceed bid.
This case study presents a detailed overview of 11 high velocity hot oil flushes performed by RIG at a customer’s new production facility.
A multitude of contamination opportunities existed during the installation and fabrication processes of the lubrication equipment and piping. This study highlights the contamination consistently seen in lubrication systems after initial installation and the effectiveness of RIG’s high velocity hot oil flush services at removing the contamination.
RIG recently completed a project for a major power plant by performing an electrohydraulic control (EHC) fluid change and flush. It was imperative that RIG met and exceeded the customer’s expectation and fulfilled their equipment reliability and budget needs.
A major chlorine manufacturer reached out after a failed attempt to perform an on board cleaning of the piping powerhouse on a steam turbine and power pack. The customer had previously attempted to perform an on-board cleaning of the piping unsuccessfully.
The dated piping design and configuration necessitated using the customer’s reservoir as well as an external reservoir to perform the chemical clean and HVOF. The following case study outlines the various stages of the chemical cleaning and HVOF including the periodic screen inspections until API 614 pipe cleanliness standards were successfully met.
RIG developed and implemented a turnkey ISO cleanliness program that increased the reliability of critical hydraulic systems for a global tire manufacturer. The program managed 63 re-circulation hydraulic systems located in a single department of the manufacturing plant. . ISO cleanliness program reduced maintenance, oil, and filter costs as well as prolonged the life of critical hydraulic equipment by exceeding target cleanliness levels on all 63 hydraulic systems