THE SOLUTION TO OBSOLESENCE
Businesses in oil and gas are challenged to identify ways to increase profit margins without significant capital investments. Industry leaders are turning to efficient and environmentally-beneficial technologies to gain momentum in increasingly competitive markets. The industry is subject to a global technological revolution; the mentality that reactive maintenance is adequate to maintain reliable equipment and efficient operations is no longer accepted.
To meet the challenges of profit loss as a direct result of unplanned maintenance and equipment failure, the oil servicing sector is focussed on preventative, predictive and proactive maintenance programs to meet best reliability practices. The most integral component to cost-effective operations in the oil servicing sector are Total Level Cleanliness programs for critical systems on oil servicing equipment.
RELIABILITY EQUATED TO PROFITABILITY
RELIABILITY EQUATED TO PROFITABILITY
The probability of equipment to function without failure, when operated correctly, for a given period of time under stated conditions.
The loss or reduction in performance of a piece of equipment that causes a loss or reduction in the ability of the equipment to meet consumer demand.
Mathematically, reliability is the probability of any production-interrupting failure occurring over a given future time interval.
CONTROL COST WITH TOTAL FLUID CLEANLINESS PROGRAMS
1. Extend life of critical systems
Protect critical systems against wear contamination (<1µ) to prevent equipment failure and component replacement.
2. Reduction in wasted materials and supplies
Investing in industry-leading, reusable filtration offers an alternative to disposable depth-media filtration and ultimately a reduction or elimination of filter elements. Each filter produces 5-10 percent fluid loss which carries additional costs of fluid replacement and associated labour.
3. Extend fluid life
Contaminated fluids are the source of component wear which is the source of equipment failure. Employing quality filtration prevents frequent wholesale oil disposal and replacement.
4. Reduction in downtime and lost production
Employing a reliability program centered around quality filtration reduces the costs associated with complete oil changes, system failures, and labour intensive maintenance. Predicting then preventing unplanned maintenance ultimately adds to every business’ bottom line.
OEI MAGNETIC FILTRATION
One Eye Industries designs and manufactures reusable magnetic filtration systems as the solution to inefficient and costly operations.
The patented design allows for effective filtration of wear contamination <1 micron providing on average 2.5x fluid, system, component ultimately equipment life longevity.
Conventional filtration’s inability to meet the cleanliness requirements for system protection is the primary source of equipment failure, unplanned maintenance and downtime.
OEI TECHNOLOGY BENEFITS
Extended life of critical operating systems
Reduction in downtime and lost production
Extended fluid life
Reduction in waste materials and supplies
⇒ Cleanable and reusable for 17+ years with minimal consumables.
⇒ Effective predictive maintenance tool because of the ability to capture and analyze contamination to determine system component failure.
⇒ Filtration capability exceeds ISO fluid cleanliness standards.
⇒ High dirt holding capacity allowing for longer service intervals.
Hydraulic Open Loop Fluid
Hydraulic Closed Loop Fluid
Hydraulic Tank Return Fluid
COMPARING FILTRATION METHODS
Variables to consider:
- Filter Costs
- Fluid Costs
- Labour Costs
- Disposal Costs
- Standard Service Intervals
- Expected Extended Service Intervals
- OEI: 2.5x based on case histories
Conventional Filtration – OEI Magnetic Filtration
This analysis is based on equipment and maintenance data from Ranglar Manufacturing to demonstrate the annual maintenance cost savings of OEI Magnetic Filtration.
Equipment: ISX15 with a 4700 OFS
|Annual Service Costs with:|
|Conventional Media Filters||$ 43,377.93|
|OEI Magnetic Filter Costs – with Initial Investment||$ 46,200.00|
|OEI Magnetic Filter Costs – after Installation||$ 9,126.50|
|OEI Magnetic Filter Costs with Ranglar Manufacturing CMS||$ 6,357.21|
|Annual Costs Savings with:|
|OEI Magnetic Filters||$ 34,251.43|
|OEI Magnetic Filter and Ranglar Manufacturing CMS||$ 37,020.72|
- These costs reflect filter and fluid replacement; they do not reflect the additional savings associated reduced parts replacement and downtime.
- These costs are based on the extension of service intervals with OEI Magnetic Filtration and Ranglar Manufacturing CMS based on historical average experience.
AVERAGE EXTENTION OF INTERVALS
OEI Magnetic Filtration
- Fluid and component replacement: 2.5 x
- Service Intervals: 2.5x
OEI Magnetic Filtration & Ranglar Manufacturing CMS
- Fluid and component replacement: 3.5 x
- Service Intervals: 3.5x
Cost analysis of system components repair, replacement
- Repairs are general and subject to internal damage – these are estimates based on historical data.
- Filter changeouts are grouped, the number of filters is dependent on system design.
- Shop rates differ from shop to shop, data listed is based on average oilfield and truck shops.
|Hydraulic Components||Repair||Replace||Rate Total|
|Main Drive Pump – CTU||$6,500.00||$27,000.00||$5,750.00|
|Typical charge pump||$400.00||$2,200.00||$920.00|
|Typical servo valve||$200.00||$1,250.00||$690.00|
|Standard HP Filter (each)||NA||$750.00||$115.00|
|Standard LP or return filter (each)||NA||$250.00||$115.00|
|Standard charge filter (each)||NA||$400.00||$115.00|
|Directional Control Valve||$500.00||$6,500.00||$4,600.00|
|Hydraulic system flush due to failure||$5,000.00||$5,000.00||$13,800.00|
Main Drive Pump – CTU
Typical charge pump
Typical servo valve
Standard HP Filter (each)
Standard LP or return filter (each)
Standard charge filter (each)
Directional Control Valve
Hydraulic system flush due to failure