The importance of cleanliness in the oil & gas sector

03 January, 2020

Also, with big data and the growing use of cloud-based solutions, Webb explained that remote and on-site monitoring can be undertaken, bringing additional benefits of convenience and cost savings. “The use of data and data analytics will continue to be a key industry focus with regard to cleanliness monitoring,” Webb said. “Pall and other filtration companies see the importance of making it easier for equipment users to both maintain the filter element and monitor the service fluids that pass through them as effectively as possible. They’ll do this by offering effective monitoring solutions that are able to harness the benefits of machine learning and the Internet of Things.”

Education

According to Geoff Grant, CMP product manager at MP Filtri, the main challenges for particle counters and condition monitoring equipment within the onshore and offshore oil & gas sector is education. “It is important to understand the reasons why all fluids and operating systems have to be cleaned to suitable levels. This is to prevent damage to hydraulic components and contamination of tooling and equipment when connecting them to topside and subsea,” he said.

So, what are some of the key functionality must-haves to look for in particle counters to best ensure maximum efficiency and reading accuracy? “Be aware of the fluids you are analysing and use the correct type of particle counter suitable for those fluids, seal material and wetted parts compatibility (i.e., synthetic, water or mineral oil-based),” said Grant. “Also, be vigilant not to cross-contaminate these fluids.”

He added that it is also important to ensure they are flushed and cleaned with the appropriate fluid so as not to affect the readings of the particle counter or monitor they are using. Grant also stressed users should know and use the correct international standards appropriate to today’s technology and equipment. “Most standards were written many years ago and I feel the levels of cleanliness required today for the majority hydraulic components and systems are not stringent enough,” he remarked, adding that the market has seen an increase in component sensitivity, operating at higher pressures & faster speeds.

Meeting different challenges

Because of the variations among oil wells and what they produce, each well poses different challenges. For instance, Wright explained that if chemicals are put into the water stream they could cause polymerisation and blocks filters. “In the case of condensate filtration and dewatering, waxes may be present. This makes accurate sizing critical in order to ensure you are not sizing the filtration system based purely on hydraulic flow rate.”

Barnett pointed out that there might also be financial constraints at play. When the oil price dropped below US$50 per barrel in 2016 Hydac was asked to reduce price of its filters by 20%. “To achieve this, we designed a budget filter where features were removed and changes in the grade of stainless steel which is a little cheaper but still highly anticorrosive,” he said. “Thus, we created a larger range, one with all the features such as bowl drain and one known as a budgetary filter housing to give a price saving.”

Satisfying regulatory requirements

Safety compliance is also a non-negotiable when it comes to oil & gas applications. As Barnett explained, previously just ATEX was asked for. This then progressed to IECEX and then North American standard UL. “Hydac therefore supplies an electrical clogging indicator suitable for hazardous areas that has triple approval,” he said. “There is a lot of work taking place in the background that customers do not see such as the design and updating of technical files to comply to updated Standards and regulations, along with quality assurance. Hydac pressure-tests every stainless-steel filter that leaves our production facilities. 100% have to be good; we cannot afford a defective filter reaching a customer – especially when it comes to subsea applications.”

Maintenance

And what of ongoing service and support for filtration solutions in the oil & gas sector? Webb pointed out that demand is high for greater ease of service and filter products’ maintenance. “For example, Pall’s hydraulic and lube oil filters now feature a top service cap that can simply be unscrewed to ease service, rather than having to remove the complete element bowl. Users also benefit on space because this design can be put in situ in an environment that is easier to handle and safer for operators to maintain, therefore reducing the risk of workplace injury.”

So, for a wide range of applications within the particularly challenging oil and gas sector, effective filtration systems are a non-negotiable.