Solving oil & Gas lubrication inconsistencies
Often frac packing oil application is inconsistent and does not remain where it is applied and needed. This can lead to the overconsumption of lubricant and unnecessary costs.
Industrial Autolube’s Frac Pump Packing lubrication systems use an electric pump that dispenses ¼ the amount of lubricant compared to standard oil systems. This amount of lube remains consistent as our systems use a series progressive divider valve to proportion the same amount of lubricant to each packing cavity regardless of the pressure differential. This ensures the majority of the lubricant will not go to the point of least resistance. Our standard manifold systems can starve certain packings which extends the overall life of the packings on the pump.
Another issue faced with frac packing is over pressurizing packings. This causes them to be driven into the plungers and burns them out. By preventing the pressure from building up, this prolongs the packings’ life.
Industrial Autolube has designed a return relief assembly so if any packing starts to overload with grease and the pressure rises above 1500 psi, the system will allow the grease that would have been sent to that packing to be vented back to the pump. This would then cause the pressure switch to trigger and signal the programmable logic controller (PLC) or controller to slow the pump temporarily to allow the grease to be consumed and reduce the packing cavity pressure.
Unique wireline lubrication solutions
Industrial Autolube has created a unique solution to a common wireline lubrication problem. Rubber plugs installed in the wellhead wear down because of the wire passing through it. By applying a small amount of oil as it passes through the seal, our systems are able to reduce the friction being generated and dramatically improve the life of the plugs.
The applicator we designed is lined with a felt material that is kept saturated with oil. As the wireline goes through the applicator at speeds of up to 900 feet per minute, it picks up enough oil to let the line slide through the plug smoothly and freely.
Increasing blender auger bearing longevity through lubrication
Blenders are used to auger sand into bins for mixing with water and other chemicals. The sand is abrasive and is dumped in around the bearings at the bottom of the augers. This sand will tear out the seals of the bearings quickly reducing their lifespans. To remedy this our lubrication systems have a direct line down to the bearings and will dispense grease to flush the sand away from the seals. The grease used to lubricate the bearings is minimal, so the remaining 8-12x more grease dispensed is utilized to flush debris from the bearings.
Our systems have taken bearing failures from as many as 20 sets per year to zero and improved the longevity of the bearings by a factor of six.