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OIL, GAS & ENERGY
RAISING AWARENESS OF MACHINE ISSUES Andrew Powles,
managing director, FPE Seals, a provider of piston rings for various sectors including oil and gas, offers expert insight into where many operational challenges arise, and how to deal with them
ithin the oil and gas sector, machinery and equipment running efficiently and safely is crucial for businesses to succeed. But like all industries, the machinery in use is no stranger to issues and faults, which can lead to downtime, hits to efficiency, and increased safety concerns. In fact, the cost of unplanned downtime in the sector has been calculated to be as much as $38 million (£30 million) annually for offshore organisations.
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businesses to make informed decisions about the interventions and spending around repairs and replacement.
Fluid issues and other contaminations
Being aware of common machine issues helps detect and identify problems, allowing for prompt maintenance or replacement to ensure smooth processes.
Corrosion and wear
The environments the oil and gas sector operates within can be extremely harsh, often because of exposure to corrosive chemicals or high temperatures. The continuous use of machines may result in various damages, such as harm to the body and housing, as well as to the more intricate and significant components like pipes, valves, and pumps. If not checked, these machines may leak, break down, or pose huge hazards to worker safety.
Misalignment from vibration Machines in use can vibrate and become misaligned, particularly pumps, compressors, and turbines. This can lead to premature wear, bearing failures, and damage to the structure of the equipment, especially if they sustain extreme vibration and misalignment. From the moment of installation, proper alignment and balancing set up the machinery for a much longer lifespan and more efficient running. Similarly, regular vibration analysis and predictive maintenance can be used to identify potential vibration issues, allowing
38 APRIL 2024 | PROCESS & CONTROL
A common issue that occurs within lubricants and hydraulic fluids used in the sector is contamination that can occur due to water, dirt, and other debris. These can inhibit the performance of the equipment as well as its reliability, which happens due to the wear caused by abrasion, as well as clogging filters and sensitive components getting damaged.
Due to the small size of these contaminants, it’s important to set out control measures that can catch them at every level. This includes stringent filtration systems, regular analysis of the fluids, and appropriate storage practices. Proper cleanliness and preservation, as well as only using the highest quality fluids and lubricants available, will maintain the integrity and performance of the equipment.
Electrics and instrument failure The electricals and instrumentation within control systems, sensors, and monitors experiencing issues can be hugely impactful. Anything from moisture ingress to power surges can affect how reliable the equipment is, throwing its accuracy into question.
This is another area where maintenance schedules are adhered to, and monitoring the condition of the equipment is hugely important to prevent potential failures that can lead to interruption and subsequent
machine downtime.
Compliance with environmental regulations
In the oil and gas industry, adhering to environmental guidelines and regulations is crucial. The UK government has extensive legislation around offshore oil and gas, which is a matter of legal requirement. Any equipment malfunctions, leaks, or emissions from these operations can result in the release of contaminants into the environment. Such incidents can not only violate regulations but also adversely affect a company's reputation for a long time. Having the appropriate detection systems in place can greatly reduce environmental risks while keeping businesses compliant with regulations. This can also serve as an opportunity to educate the wider workforce on the impact practices can have, thus encouraging them to get more involved in moving away from harmful processes and focusing on sustainability.
Machinery issues are inevitable no matter the industry, but with the right plans in place, they can be manageable and prevent downtime. This is why investing in preventive processes like maintenance, advanced technologies, and workforce training can improve efficiency and safety. Sources:
https://www.maxgrip.com/resource/article-the-cost- of-unplanned-downtime/
https://www.gov.uk/guidance/oil-and-gas-offshore- environmental-legislation
FPE Seals
www.fpeseals.com
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