Hydrocarbon Processing - June 2022 - 33

Special Focus Process Optimization
J. HANNON, ExxonMobil Fuels and Lubricants,
Allentown, New Jersey
Advanced cleaner technology:
Leveraging tailored solutions for reliability goals
Operators at refineries, petrochemical plants and power generation
companies are under constant pressure to reduce maintenance
and operational costs, boost productivity, minimize risk
of unplanned outages and maximize time between overhaul periods.
As a result, many oils used in commercial settings are engineered
to provide extended performance in severe conditions,
with the goal of keeping critical assets online. However, non-oil
related events (e.g., localized hot spots) can still lead to significant
problems associated with oil oxidation, which impedes
overall oil performance, protection and reliability.
In response, advanced oil-soluble cleaner technology has
emerged as a promising solution to address these issues and
to provide operators with peace of mind when it comes to reliability.
However, taking advantage of this technology is not as
simple as applying an oil-soluble cleaner product every time
there seems to be an equipment issue. Operators should be informed
about the full potential of the technology itself, and how
it should be leveraged for their unique operational goals.
Leveraging advanced cleaner technology to improve
reliability and cut costs. Advanced oil-soluble cleaner technology
can help address many issues that hinder equipment reliability,
but it is important for operators to understand the differentiation
between the solutions available to them.
For example, some of the products on the market for issues
like high bearing temperatures and deposit buildup only offer
temporary fixes, with the potential for additional problems
down the line, including anything from risk of severe deposit
buildup and phase separation to accelerated degradation and
potential incompatibilities that impact foam and demulsibility.
While most oil-soluble cleaners can help with conversions
between oil changes and offer some aid in troubleshooting unplanned
threats to equipment reliability, few are able to accomplish
both effectively, while mitigating the risk of future issues
and even extending the life of the current system oil.
When it comes to identifying a solution that is both seamless
and highly effective for long-term operation, this is where
a product's technology becomes effective. For example, the author's
company's proprietary oil-soluble cleanera
technologyb
, which enables it to be a high-performing solution
designed for power generation and petrochemical equipment.
For example, the product is engineered to be compatible with
stands out from
other oil-soluble cleaners on the market based on its technologyenabled
benefits. The oil-soluble cleanera
is based on proprietary
most API Group 1-4 lubricants and hydraulic oils, so it has no
adverse impact on in-service oils. Therefore, it can used as a
leave-in cleaning solution during oil changes and systems facing
issues like high bearing temperatures and varnish buildup without
requiring those systems to be taken offline. The proprietary
oil-soluble cleaner can also help with oil life extension, allowing
operators to have the protection they need to mitigate future issues
with performance. Additionally, it can be used in these scenarios
at a much lower concentration that most competitors, with
only 3%-5% of total oil volume typically added to these systems.
Advanced oil-soluble cleaners continue to show proven success
in helping companies across various industries avoid operational
shutdowns, improve oil performance, and prevent future
and reoccurring issues. However, it is important that operators
pay close attention to long-term performance to avoid causing
problems beyond the immediate issue. Technical experts can assist
in implementing an effective condition monitoring program
to monitor long-term performance.
The proprietary oil-soluble cleaner has led to cost savings, as
well as helped avoid potential equipment shutdowns by assisting
in conversions, troubleshooting ongoing issues and extending
current oil life. For example, a refinery was replacing oils and
wanted a clean system for the new charge. The author's company's
engineering team and reliable industrial group recommended
a varnish flush with the proprietary oil-soluble cleanera
in lieu of a traditional flushing method, which led to savings of
$104,000 on two turbine fills. In another instance, a company
in the petrochemicals industry had high-speed cryogenic compressors
with frequent bearing temperature spikes that were
stabilized within 30 min of the technology being added to the
system. Another plant was able to extend compressor oil service
life to 3 yr with the use of the proprietary oil-soluble cleaner to
mitigate prior varnish issues.
Preventing downtime in critical moments and planning.
Sometimes, operators must quickly troubleshoot an issue to
prevent critical equipment downtime and avoid a major shutdown
that could cost the company millions of dollars. While a
rapid fix in these moments is crucial to prevent high costs, it is
also important for operators to plan and mitigate the need for
aggressive, short-term solutions down the line-resulting in
more savings for the operation over time.
For example, the product solutions used should also extend
equipment performance and reliability. In addition, operators
Hydrocarbon Processing | JUNE 2022 33
Hydrocarbon Processing - June 2022

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