Lubricants are the lifeblood of machinery, and every decision, from selection, purchase, storage, dispensing, and health management, plays a critical role in ensuring the reliable operation of essential machines. A minor oversight can lead to significant downtime, production losses, and costly repairs.
Recently, a major oil and gas company in the Middle East learned a lesson when a seemingly routine task resulted in an unplanned shutdown of a critical turbo-compressor, leading to a significant loss of production for five days.
What caused this costly shutdown? A simple activity of topping up new lubricant oil.
The Incident
It all began when the maintenance staff topped up the oil reservoir of their turbo-compressor with eight drums of what was believed to be ISO VG 46 turbine oil, freshly received from a well-known and trusted lubricant supplier.
The used oil in the reservoir was of the same oil brand, so there shouldn’t be a compatibility issue. This oil is standard for turbo-compressors, designed to perform under the high-speed, low-load conditions these machines typically operate in. The new oil drums were correctly labeled, and there was no initial reason for concern.
However, almost immediately after the oil top-up, the plant operator noticed a strange and troubling issue: frequent choking of the oil filter elements in the inline oil filtration system.
The filter elements were immediately replaced. However, the problem persisted, leading to the replacement of six sets of filter elements within a short period. Despite these repeated replacements, the issue remained unresolved, and the company was at the risk of depleting its entire stock of oil filter elements.
The Investigation: Uncovering the Truth
Faced with a potentially critical situation, the company launched an urgent investigation. The clogged filter elements were sent to a lab for filter analysis for quality assurance, and oil samples were taken from the oil reservoir and new oil drums and sent to a lab for detailed analysis. The findings were both surprising and alarming.
Despite the oil drums being labeled as ISO VG 46 turbine oil, further analysis revealed that they contained ISO 460 gear oil—a completely different product with vastly different characteristics.
ISO VG 46 turbine oil is a low-viscosity oil specifically engineered for the precise needs of turbo-compressors. On the other hand, ISO 460 gear oil is a high-viscosity lubricant designed for heavy-duty, high-load applications, such as in industrial gearboxes with entirely different additive packages, including EP additives.
Significant differences exist between these two types of oils, and using them interchangeably or getting them mixed accidentally is a sure recipe for disaster.
The higher viscosity of the ISO 460 gear oil was the root cause of the filter element clogging. The inline filtration system, designed for the much thinner ISO VG 46 oil, couldn’t cope with the thicker, more viscous gear oil. The filters were overwhelmed, leading to repeated clogging and the need for constant replacements.
The Resolution: A Painful but Necessary Shutdown
Once the root cause of the problem was identified, the company had no choice but to shut down the turbo-compressor entirely to prevent any catastrophic damage to the machinery. The company then urgently involved the oil supplier that arranged a fresh batch of new turbine oil ISO VG 46, ensuring its quality met specifications.
The labor-intensive process of draining the incorrect mixture of turbine and gear oil was conducted. After thoroughly flushing the system, it was refilled with the correct ISO VG 46 turbine oil. This process was time-consuming and expensive, resulting in significant operational downtime and financial loss.
Lessons Learned: The Importance of Vigilance in Lubricant Management
This incident raised a powerful reminder of the critical importance of thorough verification and testing of lubricants before use. Since rotating machinery reliability is significant in any industry, even a small mistake in lubricant specification can have major consequences.
Onsite Testing of Lubricants
One of the most critical lessons from this incident is the necessity of onsite testing of newly received lubricants. Even when dealing with reputable suppliers, verifying that the product inside the drum matches the specifications on the label is essential.
Simple onsite tests, such as viscosity checks, moisture content, and particle count, can quickly confirm whether the lubricant is appropriate for its intended application.
Developing Robust Receiving Procedures
Companies should develop and implement robust procedures for receiving lubricants. These procedures should include steps for verifying the product specifications, conducting oil sampling and testing, and ensuring that the supplier provides all relevant documentation, such as certificates of analysis and conformity.
Supplier Communication and Accountability
Clear communication with suppliers is crucial. Companies should insist on receiving a certificate of conformity with every shipment, which confirms that the product meets the required specifications. This ensures accountability and provides a traceable record in the event of any issues.
Regular Training for Staff
Ensuring that staff are regularly trained on the importance of lubricant verification and the potential consequences of using incorrect lubricants is vital. This training should be a part of the company’s overall reliability and maintenance strategy.
The High Cost of Small Mistakes
Attention to detail is crucial in fast-paced sectors such as the oil and gas industry, where unscheduled downtime would lead to significant financial implications. The incident at this Middle Eastern oil and gas company underscores the importance of lubricant Onsite verification in maintaining operational reliability.
By implementing robust receiving procedures, onsite testing, and clear communication with suppliers, companies can prevent similar incidents and ensure that their machinery continues to operate smoothly and efficiently.
Ultimately, this costly lesson highlights a simple truth: even the tiny details matter in industrial operations. Ensuring the right lubricant is used every time is not just good practice; it’s essential for maintaining the reliability and trouble-free performance of critical machinery.
