Transcontinental Automatic Fin Fan Grease Systems Design, Fabrication, Assembly, and Testing

We received a request from a manufacturer of engineered systems within the chemical industry for the installation of two automatic fin fan grease systems for a chemical complex in the Middle East.

While it seems like a simple request, our team has decades of experience and knows that no project — no matter how quick or simple — is without its challenges. Here's how our team prepared for a smooth project and delivered an exceptional experience to this customer.

The Challenges

The project included a very specific scope of supply as well as specific documentation requirements for the site including an Installation & Operations Manual, BOM, Material Test Reports, Electrical certifications, wiring diagrams, GA drawings, and Assembly and Operating Test Reports. Plus, with their location in the Middle East, this unique system design, fabrication, assembly, and testing would need to be completed using drawings, emails, and phone conversations instead of in-person meetings and site visits.

The Solution

This customer’s automatic fin fan system required a level of rugged design to handle an often severe operating environment. And because the placement was well above grade, all components had to be constructed to be lifted in place at elevation. 

Stainless steel divider block assemblies, distribution tubing and compression fittings, air-operated grease pumps with process switches, and customized programmable controllers were all packaged neatly in stainless steel enclosures mounted to hot-dipped galvanized mounting stands with isolators.

The final result was one that could most definitely withstand even the most severe conditions of the operating environment.

Key Outcomes

Throughout the entirety of the project, our team kept in very close communication with the manufacturer and end-user — opting to over-communicate for the sake of utmost clarity. This clear and consistent communication made the process as seamless as we have experienced, even though we’re located halfway across the globe from our customer.

Before sending the equipment off to our customer, the systems were operationally witness-tested and certified. Stamped with our seal of approval, the equipment was then shrink-wrapped, crated, marked, and shipped – all on time and on budget.

Lessons Learned

We exist to take care of customers. To solve problems, to react and respond promptly, and to do the dirty work others might avoid. 

That’s why looking back at our project performance is of utmost importance to us.

In this situation, the client’s willingness to offer plot plans, engineered structural drawings, and open dialogue made the process of design, fabrication, and build out nearly as simple as it would have been if the client were located right next door.

With our team never having seen the actual site of placement, the completely custom lubrication system was designed, fabricated, and installed to a T, proving that overcoming challenges ultimately makes us stronger assets for our customers.

Experiencing a Similar Challenge?

None of this work is done in a vacuum. Experienced internal resources, great manufacturers,  and quality fabricator relationships allow us the advantage of producing custom lubrication solutions to our customers — regardless of the application or operating environment.

If you are in need of automatic fin fan grease systems or similar systems, we have a solution for you. Learn more about our automatic lubrication system solutions by contacting our team here. Or you can email us at info@spitzer-assoc.com or call us at 713-937-8977.

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Failed Oil Mist Lubrication System

When a Petrochemical customer in SE Louisiana called with an old/obsolete oil mist generator in an alarm condition, BSA offered a solid option to upgrade the entire primary generator at a fraction of the cost of a full generator replacement – retain the existing SS generator enclosure and all air, oil refill and oil mist supply piping.

Challenges

• The generator was found in alarm condition and all controls ceased to function properly – automatic refill, air and oil heaters, and pressure switches

• Budget sensitivity

Key Outcomes

• Provided a new oil mist retrofit panel to include all the primary generator operating components – built and tested at our facility in Houston

• Delivered, installed, commissioned, and completely operational on-site in just a few hours

• Minimized field installation problems – existing generator cabinet and all piping remained undisturbed.

• And best of all, we were able to meet the client’s tight turnaround and budgetary constraints.

Lessons Learned

There is always a solution to the problem and the answer is not always full replacement. The customer came to us with a significant challenge, and we delivered. Upgrading lubrication systems utilizing all new components with functional improvements should always be considered along with replacement. We take our responsibility with the clients’ funds and operating specifications seriously.

Experiencing a similar challenge? Contact our team by calling 713-937-8977.

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Pump Lube Oil Reservoir Upgrade for a Petrochemical Customer

When a customer within the Petrochemical industry in Louisiana needed to upgrade their lube oil reservoir on a positive displacement pump, they enlisted the BSA team for support.

Here's how the BSA team provided a stellar solution for the customer's challenges.

The Challenges

The existing pump’s oil reservoir capacity was too small to accommodate a larger set of duplex filters that were installed on the pump skid. This created low lube oil pressure alarms whenever the customer was swapping filters, which tripped the pump.

The client had no dimensional drawings on the reservoir or the flange connection at the pump. To ensure the fit on the new larger reservoir would match up perfectly, we made a site visit and took all the critical dimensional measurements ourselves.

Every time this tripped the pump, the Petrochemical customer experienced unscheduled downtime and a loss of production. Upon inspecting the current reservoir, our team noticed it hung from the bottom of the outboard bearing housing with a right-angle shaft driven lube pump extending down into the reservoir. In other words, fitting a new reservoir to the pump end would prove challenging. To do so properly, our team would need to overcome several challenges:

1. Increase the reservoir capacity within the limited available space. The reservoir could not extend to the right or increase in height; it could only extend to the left side of the outboard bearing housing.

2. The cantilever design of the new reservoir would need to be supported off the pump base due to the additional weight of increased oil capacity.

3. We would need to minimize piping connection changes from the original design, to assist with field installation – all without dimensional drawings.

4. And we’d need to do it all within two weeks.

The Solution

We started by increasing the original 4.5-gallon capacity to 10.1-gallons for increased production and efficiency. And we duplicated the pump flange and piping connections of the old reservoir to minimize field installation problems. But we didn’t stop there. We also:

• Fabricated four threaded support brackets for adjustable legs

• Added a liquid level gauge with a thermometer

• Added a new drain connection with a crystal clear Luneta Tritan low point bowl assembly, that provides visual indication of any wear debris in the reservoir.

Everything was constructed from 304SS material – a significant improvement from the existing material of construction. We not only increased the pump’s capacity, but we also improved the pump’s design with viewable temp and fluid level indication and added a low-point drain and contaminate-indicating sight glass. And we did all of this with some photos from a site visit – no design drawings to fabricate from.

And that two-week timeline challenge? We only needed 10 working days.

Key Outcomes

This project was a significant success for our customer. Because of the BSA team’s expertise, we were able to provide various added benefits to the customer, including:

• More than doubled pump capacity

• Minimized field installation problems

• A way for the customer to easily identify any wear debris and check the fluid level in the reservoir without needing to take apart the pump

• Resumed operations in a tight turnaround

Lessons Learned

We exist to take care of customers. To solve problems, to react and respond promptly, and to do the dirty work others might avoid. From system design all the way down to installation and field-level support, we support our customers every step of the way.

That’s why looking back at our project performance is of utmost importance to us. We strongly believe there is always a solution to the problem. The customer came to us with a slew of challenges, but that did not deter us from providing a solution for every one of their concerns and requests.

We answered by saying, “We are on it!” and were able to provide an exceptional experience to a new customer.

Experiencing a Similar Challenge?

If you have issues or concerns about the functionality of your pumps, we have a solution for you. Contact our team by calling 713-937-8977.

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Custom Oil Supply Tanks for Remote Access to Bulk Lubricant Storage

The Bill Spitzer & Associates team can custom design and build your bulk oil storage tanks to meet the demands of your specific application.

Typically used for remote access to bulk stored lubricants, this service is best suited for automatic lubrication systems, remote reservoir refill, and servicing cooling tower gearboxes.

Completely designed and fitted to your specifications.

All BSA-built tanks are specifically designed and fitted to mitigate moisture ingress into stored fluid and prevent leakage and spillage. 

For example, the sloped horizontal tanks have bulk fill-points, lifting lugs, low-point drains, sediment sight glasses, and shielded level gauges with integral valves.

No matter the design, BSA tanks are always hand-welded and leak tested — not sheet metal tanks — so you know they’ll last decades in even the most challenging environments.

Best of all, they’re proven to help you maintain a contaminate-free oil supply — a critical feature for preserving the equipment your tanks serve.

Looking for a custom oil supply tank for your equipment?

Each oil supply tank by Bill Spitzer & Associates is completely customized and sized for application. 

Custom design options include:

• 11-gauge Galvanized CS or SS construction

• With or without containment pans

• Immersion heaters

• Input/Output filtration

• Partitioned tanks for multiple lubricants

• Air-operated or Electric-powered supply pumps

• Single or Double supply pumps

• Desiccant breathers or Nitrogen/Oil Mist purge assemblies

• Over-pressure protection for supplied equipment

• On-Board Transfer Pumps for filling Bulk Storage Tank from drums or totes

Give us a call or send us an email today to discuss more about our custom design work. Truly, the only limitation is your imagination!

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Frac Market and Well Service Industry Solutions - Frac Pump Packing Lube Systems

Serving the Well Service Industry

As lubrication system specialists, we know the critical importance of specifying, designing, and installing lubrication systems that fit the applications’ demands.

That’s why we keep a variety of quality parts stocked for immediate delivery, including SKF Lincoln, Alemite, Lubrication Scientifics, and more.

Our ability to specify the correct packing lube system for frac pumps can alleviate environmental issues, improve up-time, efficiency, and performance, cut costs on lubricant spending, and make it easier for mechanics to perform pump maintenance.

One such instance was a project for a pressure pumping company running 10 fleets of frac pumps in the Eagle Ford.

The Challenge

Our client was experiencing field performance issues throughout their frac fleet with their packing lubrication system. Specifically, the previous system was designed to discontinue flow of lubricant to the fluid end upon failure of one packing point.

As the fracking industry evolved and the hours of operation increased, the maintenance time of the systems also increased proportionately.

Furthermore, the customer struggled with frequent refilling of their small reservoir. This limitation created risk of introducing contamination into the reservoirs and concern of safety hazards with operators in the Red Zone. The goal was to improve system reliability and design that would enhance packing life and up-time performance, while reducing the number of human touches. 

The Solution

We advocated for a large (60-lb. capacity) single line parallel system with exceptional performance in harsh environments. The system included a filtration system on the reservoir lubricant fill port to combat contamination. Lube rates were engineered for increased efficiency by delivering smaller, precise shots of lubricant, more frequently.

We commenced a 365-day field test of our Spitzer FlowMaster II Packing Lube System for this client. We had four systems pumping from the “dirty” side of the manifold serving in numerous Zipper Frac’s throughout the year.

Key Outcomes

• Increased average packing life from 50 to 130 stages

• Expanded the reservoir capacity of the system by 87%

• Decreased the frequency in refill of the reservoir from once every shift to every five days

• Mitigated contamination through filtration, resulting in zero component failures over the year

• Achieved the return on investment in less than one year, based solely on packing life 
  

Field and Engineering Support Services

Beyond providing automated lubrication systems we also provide field and engineering support services.

At BSA, we believe in a comprehensive approach to customer service. Many companies will be happy to sell you a product. They will take your order, ship it to you, and say thanks for the business. We can certainly do that for you. But we always look to do more.

We’re primed to support every stage of your frac pump’s lifespan, including:

• Problem diagnosis and recommendations

• System design to fit your exact needs at the right price

• Reliable inventory and rapid response times

• Installation services via highly qualified and experienced technicians

• Supervision and commissioning to ensure flawless operation of our systems

• Repairs and preventative maintenance as needed

• Support and unmatched customer service

We also provide lubricant consumption analysis to determine current use and see where we can improve consumption rates. This includes assisting in the transition of a packing grease to a packing oil.

We’re Committed to Our Frac Market Customers

Why are we the right choice for your frac market needs?

Our variety of solutions and services promises the highest quality products, unmatched customer service, and comprehensive maintenance of your pumps.

This includes:

• Qualified and experienced field technicians that will get your lubrication system repaired or replaced following best practice installation standards

• Fabrication capabilities

• Custom control packages designed to bring innovative technology to our lubrication system offering

• High-quality lubricants available for frac pump fluid ends

If you’re in the frac market, we have the right solution for whatever need arises. Contact our team by calling 713-937-8977.

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Portable Oil Charge Cart Solutions for High-Volume/High-Pressure Fluid Delivery

Our team works alongside various customers and manufacturers to provide portable oil charge carts for servicing sealing systems on process pumps. This service supports many industries across the world, including oil and gas, refinery, petrochemical and chemical, and pump and compressor operators, as they work to transfer buffer and barrier fluids into sealing systems.

When a customer on the Gulf Coast contacted us about their need for a pair of oil charge carts to service the seal support systems on their process pumps, the BSA team was able to deliver a solution that checked all their boxes.

The Challenge

This customer wanted a larger reservoir constructed from stainless steel and a hand-operated pump that could deliver a higher volume of fluid per stroke than can typically be found in commercially-available support equipment.

We often hear from customers that commercially-available oil charge carts cause a slew of headaches—from long lead times to a lack of customizable design features to high prices. 

As seals in these process pumps leak, the seal support systems need to be refilled. The application could demand a refill cart to perform the refilling operation in a low or high pressurized environment. This means that the oil charge cart must be highly portable, robustly built, dependable and customizable to the application—all without breaking the bank.

The Solution

Our solution was to provide a portable cart that would offer all those things, designed and built to accommodate various application requirements, regardless of the operating environment. The BSA team was, once again, able to deliver a custom and cost-effective solution that will provide years of reliable service for our customer.

Key Outcomes

In the end, this particular customer received a portable oil charge cart with:

• Rapid delivery with higher delivery volume

• Stainless steel construction with larger reservoir capacity

• Recognizing the need of a readily deliverable solution with a rugged design that’s customizable for each application, led to a new generation of product focused on the component design fitting the application demands; not the fitting the application to whatever is traditionally available.

A true success on all fronts and another opportunity for BSA to be the solution provider - laser focused on designing an answer that satisfies the application requirements and not just “checks most of the boxes”.

Experiencing a Similar Challenge?

The BSA team provides our customers oil charge carts available with the following options:

• Stainless steel oil reservoir construction

• Coated carbon steel reservoir construction

• Custom and maneuverable fifth-wheel-style mobile cart

• Oil retention lip on perimeter of fifth-wheel cart deck designed to contain the entire volume of the reservoir

• Two-wheel hand truck cart

• Discharge hose racks

• Discharge and/or air supply hose reel assemblies

• Manual pumps (various pressures)

• Air-operated pumps (various pressures)

• Air-operated pumps with manual override operation (various pressures)

• On-board filtration for filling cart reservoir

• Reservoir cleanout/access covers

• Discharge fluid filtration

• Pressure gauges, fluid level gauges (Tritan sight glasses), and drain port

• Private labeling available

If you have a need for oil charge carts or other pump support equipment, we have a solution for you. Contact our team by calling 713-937-8977.

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Oil Mist Generator Panel Retrofit for the Refining Industry

On a recent project for a customer within the Refining industry in Baytown, the BSA team was able to preserve an aging oil mist generator through a panel retrofit that respected the customer’s needs, expectations, and budgetary constraints.

Here’s how the BSA team provided a stellar solution for the customer’s challenges:

The Challenges
This Refining customer came to us with an Alemite AMOT oil mist generator that had been in operation for over 20 years.

History tells us that as these generators age, they create risky operating environments for lubricated equipment if not addressed in a timely manner.

Specific challenges that often result from aging generators—and that this customer was experiencing—include:

• Faulty nuisance alarms that condition personnel to ignore the issue at hand

• Little to no available support from the manufacturer

• Difficulty sourcing and fitting replacement components

The Solution
Our answer to the challenge was to implement a proven design of a complete replacement panel and control system fitted into the existing Alemite AMOT oil mist generator.

The replacement panel and control system retrofit were completed at a fraction of the cost of a brand-new oil mist generator.

On top of that, the drop-in replacement oil mist panel comes pre-wired, fitted, and tested, minimizing much of the field installation effort required. The total field installation time and commissioning of the system took place over just four hours! A significant success since the customer was able to experience no downtime.

With these solutions in place, the BSA team was able to eliminate the headaches of nuisance alarm conditions and help the customer avoid the ongoing expenses of replacing individual components within the oil mist generator as it continued to age.

Key Outcomes
This project was a significant success for our customer. Because of the BSA team’s expertise, we were able to provide various added benefits to the customer, including:

• A short four-hour timeline for field installation and commissioning of the system

• No disruption in supplying oil mist to lubricated equipment during replacement

• No temporary oil mist generators needed

• No piping work required between the generator and the oil mist supply header

• Minimal labor investment compared to a full generator replacement
  

Lessons Learned
We exist to take care of customers. To solve problems, to react and respond promptly, and to do the dirty work others might avoid. From system design all the way down to installation and field-level support, we support our customers every step of the way.

That’s why looking back at our project performance is of utmost importance to us.

We’re proud that our team took the time to develop a more cost-effective solution for this customer rather than jumping to what might be considered an easy-fix solution like completely replacing the aging oil mist generator.

Experiencing a Similar Challenge?
If you have issues or concerns about the reliability of your own oil mist generator, we have a solution for you. Contact our team here or by calling 713-937-8977.

For a downloadable copy of this post, click here.

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Oil Mist Preservation Systems for Process Equipment

Properly storing and preserving process equipment presents significant difficulties during normal plant operations but can be especially troublesome during new construction projects.

During the new construction phase, rotating and reciprocating machinery is often purchased well in advance of actual equipment placement. Depending on the size and scope of the project, this can mean long-term on-site equipment storage – perhaps even years.

Stored machinery can be adversely affected by the normal thermal cycle as ambient temperature rises and falls. This can result in exposing critical components to environmental moisture and dirt as the equipment “breathes.” Normal industry practices for appropriate storage of idle equipment can be found in many articles, journals and API documents; these illustrate methods to mitigate this source of premature failure during start-up.

 Conventional methods of stored equipment preservation routinely involve:

• Filling with lubricant containing varying amount/types of rust-preventive properties

• Fogging interior cavities of bearing housings, stuffing boxes, gear cases, etc., and sealing tightly

• Bimonthly rotation of pumps, motors, compressors, fin fans, blowers, etc.

• Dry Nitrogen purge assemblies

• Coating exposed machined surfaces with rust-preventive lubricant

• Periodic inspection of external and internal surfaces
  

One alternative solution to consider for long-term preservation is temporary oil mist lubrication systems. In warm, humid, coastal environments oil mist lubrication can be the best method of protection against contaminates ingression.

American Petroleum Institute’s (API) Document 686:
API 686 3.2.1: Covers the application criteria for using an oil mist preservation system for long term storage of equipment or when dust or dampness is excessive.

Temporary oil mist lubrication systems can be the solution to significantly reducing or eliminating the high percentage of premature machinery failures at start up, due to corrosion. The concept is as simple as it is cost effective in the role of stored equipment preservation.

The basic oil mist preservation system consists of:

• 1 to 3.6-gallon oil mist generator

• Regulated instrument air or nitrogen supply

• PVC distribution piping and nylon tubing

• Reclassifiers, sight glasses, pipe fittings and compression fittings

• Collection pots for fluid oil

When desired, the oil mist preservation system can be more robust, adding features commonly found with plant configured oil mist systems that lubricate equipment in operating units. These additional features can include:

• Oil heaters

• Oil auto-refill systems

• Air heaters

• Pressure switches

• Alarms and system status lights

• Galvanized distribution piping, fittings, and SS tubing

• Automatic drain legs

• SS collection boxes for fluid oil

The principle of the oil mist preservation system is simple – a low-pressure stream of air laden with suspended ~2 micron oil droplets is delivered to machinery through the distribution piping and tubing. It is critical to vent the equipment properly, as to allow a slight positive pressure and prevent atmospheric contaminates from entering the equipment. The oil mist will quickly coat all the machine’s internal surfaces with a film of lubricant, preventing corrosion.

The oil mist preservation system is easily adjusted to accommodate adding and subtracting machines to the system, as the project moves through its phases of construction. Oil mist preservation systems have been adopted all over the world for the biggest projects. But because of its inherent affordability, portability and adaptability, it should not be over looked as a preservation system for even the smallest of projects. Oil mist preservation is also a very cost-effective method of protecting machinery for decommissioning purposes as well as stand-by redundant spares stored indefinitely.

CASE STUDY - Automatic Grease System for Concrete Batch Plant

Location: Dallas, TX
Date: September 2021
Application: Ready-Mix
Client:  Independent Dry Batch Ready-Mix Concrete Producer in North Texas

Key Outcomes:

• Developed a custom lubrication design to improve bearing and gate maintenance

• Lowered grease consumption about 44%

• Enables a safer working environment to meet OSHA regulations

• $4,000 In estimated annual labor savings

Bill Spitzer & Associates delivered a modern way to simplify concrete plant grease lubrication, increase personnel safety, and achieved ROI between 2 to 3 months.

Overview:

Besides water, concrete is the most consumed and used product in the world and is manufactured in several ways with various types of equipment.  All the required manufacturing equipment requires lubrication to assure the concrete is mixed and transported to specification and location.

Site Facility Situation:

The client wanted to discover safer methods to lubricate their ready-mix concrete plant and decrease maintenance costs.  As a result, Bill Spitzer & Associates (BSA) visited the site and quickly designed an automatic grease system that would save time and improve safety.  The 12 volt 8L pump operates every 2 hours with a calculated delivery of lubricant to the 28 points on the batch plant.  The grease reservoir is large enough to enable a full week (5-7 days) of production before refilling is needed.  BSA installed the entire system within 10 hours, with 2 technicians, around the organizations operation schedule.  Everything went according to plan and will install similar lubrication systems on the other plants.  Additionally, BSA will develop auto-lube systems for the ready-mix trucks 24 lubrication points.      

Bill Spitzer & Associates (BSA) can create customized systems to fit the client’s needs, obstacles, or specifications for any concrete manufacturing plant.  The customized approach enables BSA to provide a turnkey solution for design, installation, commission, and preventative maintenance.

Bill Spitzer & Associates Automatic Concrete Plant Grease System & Service:

• Diagnosis, System Design, Installation, Commissioning, and Preventative Maintenance

• Review application requirements, operating conditions, location, and access by on-site walkdown of the facility

• Determine the most reliable method of delivering grease to bearings and the metering devices, supply and distribution piping/tubing, and lubrication rates

  • Motor driven pumps, pneumatic pumps, & manual pumps

  • Divider blocks or injectors

  • Pressure switches & gauges, cycle switches, controllers, custom panels, & tubing recommendations

• Field matter experts install grease system and provide commissioning, start-up, and training

• Overview of preventative maintenance plan that fits the needs of the system and customer

• Ideal for Ready-Mix, Precast, Prestress, Drycast, Central Mix, Paver, Block, and Pipe Plants

 BSA Automatic Grease System:

• Quicklube Motor Driven Grease Pump

• Divider Block, Divider Valves, Proximity Switch, and Adapters

• Stainless Steel Tubing, Fittings, and Gauges

• 16 lb. Reservoir

• Low Level and Gault Indication

• 1/8” Hose and Reusable Hose Ends

• Guarding Accessories

• On-Site Installation and Commissioning

  • Available to install during business hours, after hours, Saturdays, and Sundays

 Results:

• 28 Points of lubrication

• 2 Total planned installation days

• 0 Change orders & on-time installation

• ROI was achieved between 2 to 3 months

• $4,000 Estimated annual labor savings

• Lowered grease consumption about 44%

• Enabled a safer working environment to meet OSHA regulations

BSA BRIEF - Reduced Packing and Cylinder Lube Rates on Two, Four (4) Throw Hydrogen Process Compressors

Refinery primary compressors typically operate uninterrupted from 3 to 5 years and are only down during a unit turnaround or a non-routine maintenance event. During a turnaround inspection on two, four (4) throw hydrogen compressors at a gulf coast refinery, the refinery’s machine reliability group observed and noted that excess oil was found in compressor valves, downstream bottles, and the process. Additionally, a major concern for the process industry is the carryover of too much oil downstream can affect and contaminate catalyst beds. The machine reliability group assigned to the operating unit contacted Bill Spitzer & Associates for help to analyze circumstances that can affect over lubrication. These discussions led to the following key action steps.

• Determine current lube rates of OEM equipment

  • Specific to the machine’s cylinder and packing points

  • Based on refinery operating conditions and operating process

• Evaluate the OEM supplied divider block system

  • Formulate a recommendation if re-sizing the existing packing and cylinder lubrication system would be required

Planning: The refinery communicated with the compressor OEM for input and a recommendation on lube rates. As subject matter experts, Bill Spitzer and Associates’ would evaluate the existing lube system design to ensure they are sized appropriately and in line with the OEM’s lube rate recommendation.

Recommendations: The OEM recommended a lube rate reduction near 25% and Bill Spitzer & Associates advised minor changes to the current OEM distribution block design.

Actions Taken: The refinery decided to implement the lube rate reduction from the OEM’s recommendations immediately.

Project Take-a-way: Monitoring, recording, and documenting compressor lubrication rates makes practical and financial sense for all compressor users: refinery, gas transmission station, or gas processing locations. This proactive service by Bill Spitzer & Associates can have measurable benefits, enhanced ma-chine reliability, reduction in operating costs, and improve the environment.

Results:

• Lowered lube consumption over 25% on both compressors

• Saved over 450 gallons per year in lubricant consumption

• Achieved over $5,500 in annual lubricant savings

• Reduced the downstream process impact by lubricant being introduced

• Met OEM lube recommendations

• Improved machine reliability

• Decreased lubricant consumption impacts

The final system cycle time goal was about 30 seconds on both machines, effectively reducing the lube rate almost 30%.

BSA BRIEF - BSA Increases Grouting Efficiencies Saving Client Time and Money

Date: July to September 2021

Location: Gulf Coast Texas Petrochemical Facility

Escoweld 7505E/7530 Epoxy Grout: 3-Component and highly flowable epoxy grout.  This epoxy grout can be pumped and has one of the lowest thermal expansion rates of 14.6 x 10-6.  For this project, compressive strengths surpassed 15,000 psi.

On-Site Technical Grouting Guidance:

A Bill Spitzer & Associates (BSA) subject matter expert was on-site to supervise the mixing and placing of Escoweld epoxy grout. Additionally, reviewed the site for compliance with API 686, ACI 351, and facility specifications. Hot temperatures were a concern; however, those were avoided by tenting and cooling the equipment system environment and grout. After one day, BSA realized wasted time in the grout mixing and placing process. A new procedure was introduced and followed to increase the efficiency and show the value of BSA on-site guidance for the contractor.  

 Bill Spitzer & Associates Values Provided

• Escalated hourly units placed by 30%

• Saved 98.1 hours of labor

• Advised new grouting procedure

  • Broadened schedule flexibility

  • Created economical & efficient solutions

  • Reinforced jobsite safety & ergonomics

 BSA On-Site Aspects:

• Total Project - 609 ft3 or 254 units

• Manpower - 9 men / bucket pouring

• Initial Output - 16.8 ft3 per hour

• BSA Modified Output - 24 ft3 per hour

• 7.2 ft3 Efficiency Improvement

• Total Time Saved - 98.1 hours

CASE STUDY - Automatic & Manual Grease systems for 22 Fin Fans in 5 Separate Units

CASE STUDY - Food Oven Chain Lubrication System to Eliminate $6,000 per Hour of Downtime

CASE STUDY - Emergency Chain Lubrication System Installation Over a Weekend Saves Client Downtime, Overtime, and Shutdown

CLICK HERE TO SEE PDF OF CASE STUDY

Date: May 2021
Location: McKinney, TX
Lubrication System: Lincoln 24v P203 Quicklub® 
Application: Material Handling Chain
Equipment: Machinex Chain Belt Conveyor

Client: A provider of solid waste collection, transfer, recycling, and disposal services in various markets of USA and Canada.  The company is committed to improving the environment for the future of society where we all live, work, and serve.  The organization is making enormous efforts towards alternative technologies to reduce landfill disposal, lower greenhouse gas emissions, and foster biofuels. 

Key Outcomes:

• Proposed & Customized Quicklub System

• Quickly Responded to an Emergency Service Need

• Prevented Costs of Shutting Down the Facility and Production

  • $17,150 per day or $70 per ton of facility downtime

The Problem:  Bill Spitzer & Associates was called to design and recommend a lubrication system for a material handling chain belt conveyor at a recycling facility.  The planned downtime was 1 week and the crew had Wednesday to Friday to install the lubrication system.  Unfortunately, the hired crew ran out of time and the client needed a solution ASAP.  Bill Spitzer & Associates responded quickly, rearrange schedules, and worked over the weekend to prevent downtime, overtime, and shutdown.  Not only did the BSA Sales Manager & Service Technicians finish under budget and on time, they commissioned the lubrication system and taught operations how to perform routine maintenance to lower costs and prevent future issues with the chain belt conveyor.  

Proposed & Installed Quicklub® P203 Lubrication System

• System design for one network

• Quicklub P203 Pump 

  • 4 lb. Reservoir

  • 24 volt

• SSV 6 divider block to feed chain

• Lubrication oil brushes

• 1/8” Supply Lines

• 1/4” Feed Lines

• Customized mounting brackets

• Supplied necessary fittings & adapters

  • Adapters, ferrules, tees, couplings, fittings, screws, and valves

• Filled reservoir with required lubricant

• Weekend installation by certified technicians and sales manager

  • Required scissor lift to install system 50’ to 75’ in height

• On-site training of system for maintenance

Bill Spitzer & Associates eliminated the risk of over $70 per ton of downtime from a failed contractor schedule for the customer.  We saved the client over $17,150 per day in shutdown operation costs.

Packing and Cylinder Lubrication System Advancements on Reciprocating Compressors

Are you experiencing premature wear or failure of compressor parts, i.e., rings, packing or excessive oil consumption, or phantom no-flow shut down issues? If so, these symptoms can be attributed to poor divider block system performance, typically due to the system design, wear, and/or age.  Or,  if you are just looking to “bounce off” a lubrication problem with a subject matter expert at BSA, we invite you to contact us. We can help to review, explore, and analyze your divider block system design and drawing…….and this initial review comes at no cost to you.  We are confident we can recommend improvements to your divider block lubrication system that impact performance, reliability, and production that will save you money.

Bill Spitzer & Associates has over 40 years of experience in lubrication system applications, ranging from design, installation, preventative maintenance service to root cause analysis.  We are also pleased to announce being recently appointed a Patton Divider Block Systems distributor. With our knowledge, experience and field service capability, along with Patton’s innovative and patented product offering, our team now offers the industry an expanded array of cost effective solutions and services, unmatched in the market.   

Products

• Replacement parts in stock, including box lubricators for the most common frames

• Patton ALB-1 Gearbox adapts to: Ariel 1 & 2, Worthington Cub, Super Cub, White Superior, Chicago Pneumatic, Dresser Rand, and Gemini

• Off machine or standalone lubrication system packages, specifically designed to pre-lubricate cylinder and packing components prior to machine start up

• Form, fit, and functional replacements for other brands, CPI©, Graco-Trabon©, & DropsA©

• All products are in stock and ready for immediate delivery

 Services

• Experienced service technicians, who can quickly and effectively analyze, troubleshoot existing systems

• Onsite audits available designed to improve and validate system reliability and to eliminate costs due to over lubrication

• Complete turnkey system installation and preventative maintenance services

• Onsite or virtual training available

 BSA’s Divider Block System “Tips of the Day”

• Always be sure to purge all air from the system after any maintenance performed

• Contamination is the leading cause of lubricator pump failure, it is highly recommended to incorporate both low and high pressure filtration

• We recommend using SS filter elements rather than the traditional bronze elements in certain gas service, the bronze will corrode and will eventually cause system clogging and eventual system failure

• If you’re using a typical pump to point lubricator pump with a sight glass, we recommend periodic pressure testing of the pumps to ensure the drops in the sight glass are equal to the volume is being delivered to the application point

CASE STUDY - Cold Weather Epoxy Grouting Three 752hp Pumps with Rain and High Wind Gusts

Client: A Fortune 500 global manufacturer of transportation fuels, other petrochemical products, renewables, and power.  This publicly traded company employs over 10,000 people and was founded over 40 years ago. 

Overview: Bill Spitzer & Associates (BSA) was selected for epoxy grout at the facility for all rotating and reciprocating machinery for a capital project expansion. As subject matter experts, BSA was needed to manage the epoxy grouting procedure because of technical aptitude and experience for cold weather circumstances. Additionally, almost 1” of precipitation occurred the day before grouting that created some site specific considerations. Generally, epoxy grouting temperatures should range between 55°F to 95°F without the concerns for proper polymerization and exothermic reaction of the epoxy technology to thermoset.

Location: Southern Louisiana
Date: January 2021
Grout: Escoweld 7505E/7530
Size: 184 units or 405ft3
Equipment: API Centrifugal
Avg Lock in Pour Depth: 2.5”
Avg Fill Pour Depth: 8”
Avg Cap Pour Depth: 4”
Avg Concrete Temp: 74°F
Avg Low Tent Ambient: 76°F
Avg High Tent Ambient: 87°F
Avg Low Ambient: 47°F
Avg High Ambient: 61°F
Max Wind Gusts: 18 mph
Avg Dew Point: 44°F
Avg Resin Temp: 59°F
Avg Aggregate Temp: 52°F
Avg Mixed Epoxy Grout Temp: 60°F

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Cold Weather Key Decision-Making & On-Site Guidance:

• Overall Constructability

• Flowability to Temperature Reactivity

• Epoxy Grout Viscosity to Flow Effectiveness

• Proper heating of equipment, grout, and environments

• Verification of concrete preparation, formwork rigidity & leak prevention, anchor bolt protection, clean & dry contact surfaces, proper jack bolts, expansion joints, grout conditioning, and adequate manpower
  

3-Day On-Site Technical Guidance:

• Crew had been previously trained at the site for cohesive grout team capabilities

• Discovered a leak in hooch that allowed water into the grouting area

  • Used heat, fans, & rags to evaporate & soak up water and moisture

• Found missing bond prevention measures on the 3 pumps leveling screws

  • Reapplied antiseize

• Secured constructability

• Advised and instructed how to prep, mix, pour, and protect epoxy grout in cold weather

• Analyzed and monitored project parameters, temperatures, wetness, and obstacles

• Constantly calculated units needed to finish pours to be pulled from heated hooch

• Supervised grouting process and sequencing

• Implemented appropriate post-condition procedures for epoxy gout

• Prevented overrun costs of a 4th day of grouting by beneficial project management
  

Escoweld® 7505/7530 Epoxy Grout:

• 3-Component, 100% Solids, & Versatile Epoxy Grout

• Meets or exceeds American Concrete Institute (ACI) 351, American Petroleum Institute (API) 686, & Process Industry Practices (PIP) STS03601 specifications

• Excellent bondability to itself without surface preparation

• Similar Coefficient of Linear Thermal Expansion as Steel and Concrete

  • Steel: 14.6 x 6.1-6 / °F at 32°F to 140°F

  • Concrete: 5.9 x 10-6 /°F at 32°F to 140°F

  • Escoweld®: 14.6 x 10-6 / °F at 32°F to 140°F

  • PIP STS03601 Maximum: 30 x 10-6 / °F at 32°F to 140°F

  • ASTM C827/C827M, with accordance to ASTM C531

• 2.4 ft3 (68 L) Unit Coverage or Yield

• 2 Hour Pot Life at 77°F (25°C)
  

Epoxy Grout & at or Below 50°F (10°C):

• The rate of build of glass transition temperatures (Tg) will be significantly slowed

• One study showed that based on Arrhenius Law, a thermosetting bisphenol epoxy system has shown a 30% reduction in elastic modulus and strength

• Might be from a decrease in plasticization

• Recovery could occur if dryness, time, and temperatures are appropriate for the specific circumstance

(Development of physical and mechanical properties of cold-curing structural adhesive in a wet bridge environment: Savvilotidou, Vassilopoulos, Frigione, & Keller, 2017)

Solution:

Bill Spitzer & Associates (BSA) created a customized process for efficiently pouring Escoweld® 7505/7530 over three days. The uniquely technical aspects of cold weather epoxy grouting can be solved with BSA differentiated proficiency and aptitude. Furthermore, BSA advances engineers, owners, and contractors to become more profitable, timely, and productive. BSA operates a client first mentality or specialization. BSA also provided initial on-site contractor training and continues to administer instruction for the remaining schedule of the project and new labor. BSA is with the client every step of the way to prevent minor mistakes creating major issues.

CASE STUDY - Reduction of Packing and Cylinder Lube Rates on Hydrogen Compressor

Project:

Bill Spitzer & Associates collaborated with a Gulf Coast refinery to reduce packing and cylinder lube rates on two, four (4) throw hydrogen process compressors.

Situation Overview:

Refinery primary compressors typically operate uninterrupted from 3 to 5 years and are only down during a unit turnaround or a non-routine maintenance event.  During a turnaround inspection on two, four (4) throw hydrogen compressors at a gulf coast refinery, the refinery’s machine reliability group observed and noted that excess oil was found in compressor valves, downstream bottles, and the process. Additionally, a major concern for the process industry is the carryover of too much oil downstream can affect and contaminate catalyst beds.  

The machine reliability group assigned to the operating unit contacted Bill Spitzer & Associates for help to analyze circumstances that can affect over lubrication.  These discussions led to the following key action steps:

1. Determine current lube rates of OEM equipment

   1. Specific to the machine’s cylinder and packing points

   2. Based on refinery operating conditions and operating process

2. Evaluate the OEM supplied divider block system

   1. Formulate a recommendation if re-sizing the existing packing and cylinder lubrication system would be required

Planning:

The refinery communicated with the compressor OEM for input and a recommendation on lube rates. As subject matter experts, Bill Spitzer and Associates’ would evaluate the existing lube system design to ensure they are sized appropriately and in line with the OEM’s lube rate recommendation.

Recommendations:

The OEM recommended a lube rate reduction near 25% and Bill Spitzer & Associates advised minor changes to the current OEM distribution block design.

Actions Taken:

The refinery decided to implement the lube rate reduction from the OEM’s recommendations immediately. A Management of Change (MOC) was created and the field change was implemented quickly. Due to the operating demands of the units, the system re-design would be reviewed later. Under the direction of the machine reliability group and over a six-month period, Bill Spitzer & Associates’ technicians coordinated with the plant to reduce the rates systematically over a series of months to minimize “shock” to the compressors.

Results:

The final system cycle time goal was about 30 seconds on both machines, affectively reducing the lube rate almost 30%.

The refinery realized the following benefits and savings by lowering lube rates to the two primary compressors:

• Lowered lube consumption over 25% on both compressors

• Saved over 450 gallons per year in lubricant consumption

• Achieved over $5,500 in annual lubricant savings

• Reduced the downstream process impact by lubricant being introduced

• Met OEM lube recommendations

• Improved machine reliability

• Decreased lubricant consumption impacts

• Lessened environmental footprint

Project Takeaway:

Monitoring, recording, and documenting compressor lubrication rates makes practical and financial sense for all compressor users: refinery, gas transmission station, or gas processing locations. This proactive service by Bill Spitzer & Associates can have measurable benefits, enhanced machine reliability, reduction in operating costs, and improve the environment.

CASE STUDY - Automatic Oil Mist System for the Petrochemical Industry

Location: Beaumont, TX
Date: June 2018
Product: Alemite - SKF
Application: Petrochemical - CHD2 Unit

Client:

Major publicly traded company that explores and produces oil and gas globally. Additionally, the organization works through upstream, chemical, and downstream business units. The customer has over 20,000 operated wells, 70,000 employees, and 20 billion oil-equivalent barrels in reserves.

Overview:

Oil mist lubrication began in the United States around the early 1900s.  Originally, it was used in the steel industry and made its way into the refining, petrochemical, and paper markets.  Our client was dealing with computer atomization and redundant sensor issues, which had been trending since the 1990s for the oil mist market.  Oil mist is a straightforward process made by combining instrument air, or nitrogen, with oil through a venturi nozzle. The system will make mist while these three components are present and operating properly.  Some reoccurring settings and ancillary component problems with the customer were air heater, oil heater, alarms, and automatic oil refill that has a high and low setting.  Our client wanted to eliminate the overly technical alarming capabilities that signaled regulated air flow, mist density, and oil refill speed.  For this circumstance, the equipment had antiquated components with parts that the manufacturer no longer provided.  Moreover, the constant triggering of alarms was a nuisance and caused employees to ignore the constant signals from faulty components.

Site Facility Situation:

Refinery coker converts residual crude oil from distillation units into automotive fuel feedstocks and petroleum coke, which may be substituted for coal.  Hydrotreaters eliminates hydrogen sulfide from automotive fuels and feedstocks to comply with USA environmental laws.  The sulfur recovery units pull sulfur from hydrogen sulfide taken away by the hydrotreaters.

BSA Oil Mist System & Service: Diagnosis, System Design, Installation, Commissioning, and Preventative Maintenance

• Reviewal of application, measurements, and on-site walkdown of facility

• Analysis of proper oil mist console, bulk oil storage tanks, piping, reclassifiers and oil mist collection

• Field matter experts install oil mist system in the field

• Oil mist generator, supply header, drop lines, feed lines, connections, drain lines, collection container, and drain legs

• Overview of preventative maintenance plan that fits the needs of the system and customer

Recommendations and Implementations:

• Verified and measured the sizing of the new cabinet by performing a walkdown of the unit and reviewing all bearing sizes

• Reviewed and analyzed piping diagrams for new equipment system

• Installed the Alemite EM oil mist cabinet in close proximity to the existing operating unit

• Pre-Fabricated and modularized piping for a seamless transfer

• Commissioned the new system

• Confirmed operational success and performance

• Provided new system orientation and training for all operations and preventative maintenance personnel

  • Included walkdown details, troubleshooting scenarios, alarm notification instructions, plot plans, & field notes

• Proposed stocked parts, preventative maintenance plans, and lubrication rates

BSA EM Oil Mist Equipment:

• Customizable & 6 Standard Sizes

• NEMA 4x SS Enclosure

• Filter/Regulator with Pressure Gauge

• 5 gal SS Oil Reservoir

• Oil Level Sight-Glass

• Oil Heater & Thermostat

• Oil Temperature Gauge

• Oil Level Float Switch

• Automatic Oil Refill Capability

• Hi-Lo Mist Pressure Switch

• Mist Pressure Gauge

• Mist Pressure Alarm

• LED Status Alarm Lights

• LED System Parameter Indicator Lights

• Air Heater

• Backup Mist Generator

• Cabinet Cooling System

• Bulk Oil Storage Tank

• Oil Collection Containers

• Pure & Purge Mist Kits

Results:

• No loss in operations or production from the ease of installation

  • The CHD2 Unit can affect the hydrogen process, which can cost over $1 million in unproductivity and downtown expenses

• Highly experienced service department was able to install the cabinet in under 2 hours

• Elimination of nuisance and frequent alarms that were plaguing the unit and operations

• Trained personnel on the new oil mist system, which reduced expenses associated with simple service repairs, downtime, expenses, and maintenance calls

• Estimated $17,000 annual cost decrease from less call outs

• Standardized the control panel for easy access

CASE STUDY - Additional 6,000 HP Compressor Packages Grouted By Pumping

Client:

One of the largest diversified corporations in the world, with businesses in insurance, energy, hospitality, and packaging industries. Additionally, they are traded on the NYSE over 35 years. The customer has 15 offshore drilling rigs, over 13,000 miles of gas pipelines, over 400 miles of NGL pipelines, and underground gas storage capacity of over 200 billion ft3.

Overview:

From a previous successful project, Bill Spitzer & Associates (BSA) was asked to administer choices for the contractor to be successful in pumping epoxy. Two 6,000 hp compressor packages were required to utilize the engineered pumpable epoxy grout to ease constructability, empower schedule flexibility, maximize effective bearing area, and produce advantageous efficiency. Chockfast® Red HF decreased the total grouting project time (about 50%) and lowered expenses associated with labor and materials (1 mortar mixer versus 4).

Location: Petal, MS
Date: March 2020
Product: Chockfast® Red HF
Size: 100 units or 251 ft³
Skid Dimension: 186” x 378”
Crew Size: 10 installers
Install Time 6 Hours
Low Ambient: 57°F
High Ambient: 79°F
Max Wind Speed: 67 mph
Avg Dew Point: 59°F

Challenges:

• Managing project scheduling targets and goals

• Enhancing constructability

• Evaluating project parameters and difficulties

• Prohibiting overrun costs

• Acclimating to the specific site variables and conditions

• Consulting in the field 

Action Steps:

• Analyzed blueprints

• Investigated formwork

• Reviewed facility constraints

• Recalculated grout supply

• Organized pre-grout meeting

• Supervised grout pumping

• Adapted to cooler climates

• Taught finishing techniques

• Oversaw proper sampling procedures

Cold Weather Grouting:

Although Bill Spitzer & Associates (BSA) operates in warmer climates, BSA has extensive field knowledge to adapt to many circumstances.  For this colder field environment, BSA pre-conditioned the materials 48 hours, pre-conditioned the working environment 12 hours, and post-conditioned the compressor packages 48 hours.  This aided a high effective bearing area (EBA) of 99%, maintained flow rates to meet schedules, and provided predictable installing attributes.  Moreover, the expansion joint spacing was reduce to eliminate the concerns of thermal shocking or cracking. Temperatures should be 65°F - 95°F.  Since it was difficult to have hot water for grout clean up, IXT-59 was the preferred solution to adequately clean tools and equipment.      

Solutions:

Bill Spitzer & Associates (BSA) sold the compressor packager Chockfast® Black previously and later Chockfast® Red HF at the jobsite to provide a monolithic structure between the mechanical and civil engineering practices.  Moreover, Chockfast® Black is an example of how BSA is involved at many supply chain stages to advise clients of reliability applications with grout.  The uniquely specialized concepts of epoxy grouting can be simplified with BSA differentiated expertise.  Also, BSA fosters engineers, owners, and contractors to become more profitable, timely, and productive. BSA operates a client first mindset.

CASE STUDY - Increase Frac Pump Packing Life & Uptime Performance for Top Well Service Provider

Client:

Founded over 100 years ago, this customer has about 50,000 employees in over 80 countries.  For this case, we worked with their Mega-Camp in the Eagle Ford Shale operating 10 Frac Fleets.  

Key Outcomes:

• Delivered smaller and more precise shots of lubrication more frequently

• Increased packing life

• Expanded reservoir capacity

• Minimized refill intervals, human touches, and time in the Red Zone

• Evolved the hydraulic fracturing client to continuous production pumping practice by enlarging the capacity 650%

• Maintained desired performance and reliability with zero component failures over the course of a year

Location: Eagle Ford Shale
Date: Jan. to Dec. 2019
Product: Spitzer FlowMaster Packing Lube System
Reservoir Capacity: 60 lb.
System Driver: 24 VDC Electric Motor
System Type: Centro-Matic 
Application: Reciprocating Plunger Seal Packing on a Trailer Mounted Frac Pump

Overview:

Hydraulic fracturing has evolved into a continuous production situation with rigorous demands on the equipment used and the personnel involved. Our client was experiencing field performance issues throughout their Frac Fleet with their packing lubrication system. Specifically, the previous system was designed to discontinue flow of lubricant to the fluid end upon failure of one packing point. As the fracing industry evolved and the hours of operation increased, the maintenance time of the systems also increased proportionately. Furthermore, the customer struggled with frequent refilling of the small reservoir. This limitation created risk of introducing contamination into the reservoirs and concern of safety hazards with operators in the Red Zone. The goal was to improve system reliability and design that would enhance packing life and uptime performance, while reducing the number of human touches.

Recommendations and Implementations:

• Advocated a large (60 lb. capacity) single line parallel system

• Exceptional performance in harsh and severe environments

• Developed a filtration system on the reservoir lubricant fill port to combat contamination when refilling

• 90% of lube system failures could be attributed to contamination or impurities

• Engineered lubrication rates for increased efficiency

• Delivered smaller, precise shots of lubricant, more frequently

• Installed and commissioned custom systems in three (3) hours per frac pump

• Four (4) frac pumps were equipped with the Spitzer FlowMaster Packing Lube System

• Commenced a 365-day field test of the Spitzer FlowMaster Packing Lube System

• Pumped from the “dirty” side of the frac manifold

• Served in numerous Zipper Fac’s in the Eagle Ford

• Performed frequent system validation checks to monitor success

• Partnership with the client enabled the packing life to be tracked over the course of a year

Results:

• Increased average packing life from 50 to 130 stages on pumps working dirty side of the manifold

• Delivered lubricant more frequently in smaller dosages

• Created independent operating metering valves for continuous lubrication to all points in the system, should blockages occur

• Expanded the reservoir capacity eight (8) times than previous reservoir

• Decreased the frequency in refill from once every shift to every five (5) days

• Mitigated contamination through filtration resulting in zero component failures to date

• Constructed a rugged solution that has lasted over a year in some of the harshest environments

• Achieved the return on investment in less than one year, based solely on packing life