What an What an Expert SaysSaysAbout Machinery PreservationAbout Machinery Preservation

““ . . . failures of machinery within . . . failures of machinery within days of initial commissioning, were days of initial commissioning, were reduced by factors of factors of 7:1 and higher and higher at locations which applied oil mist at locations which applied oil mist preservation techniques.preservation techniques.””

“Many times equipment arrives at the plant site long before it is ready to be installed at its permanent location”

Heinz P. BlochHeinz P. BlochMachinery ConsultantConsultant

What an What an Expert SaysSaysAbout Machinery PreservationAbout Machinery Preservation

Heinz P. BlochHeinz P. BlochMachinery ConsultantConsultant

““Unless the equipment is Unless the equipment is properly preserved, scheduled properly preserved, scheduled commissioning dates may be commissioning dates may be jeopardized and the risk of jeopardized and the risk of failure is measurably failure is measurably increased.increased.””

““The quality of machinery The quality of machinery preservation during prepreservation during pre--erection storage or longerection storage or long--term term deactivation will have a deactivation will have a measurable effect on machinery measurable effect on machinery infant mortality at the startup of infant mortality at the startup of a plant or process unit.a plant or process unit.””

Machinery Preservation YardMachinery Preservation YardLubriMistLubriMist ®® Oil MistOil Mist

Crated

Uncrated

Aerial View of Oil Mist Preservation Yard in Thailand…Designed and Operated by LSC.

Air SupplyPackageAir SupplyAir SupplyPackagePackage

Oil MistOil MistHeaderHeader

LubriMistLubriMist ®

PRESERVATION SYSTEM LAYOUTPRESERVATION SYSTEM LAYOUT

Oil MistOil MistGenerator(s)Generator(s)

Air SupplyAir SupplyPackagePackage

Three Generator SystemCompressed Air PackageCapacity for 800 Machines

All Types of Equipment are Stored and Preserved

Equipment Arrives At Job Site In A Number of Different WaysEquipment Arrives At Job Site In A Number of Different Ways……But without Protection From The Weather and Elements,But without Protection From The Weather and Elements,

ItIt’’s very Likely To Fail At Starts very Likely To Fail At Start--up or Shortly After.up or Shortly After.

Machinery Preservation WithMachinery Preservation WithLubriMistLubriMist ®® Oil MistOil Mist

Large Electric Motors

Crated Equipment Small Pumps & Motors

Vertical Equipment

A continuous flow of oil mist protects the bearings.No need to rotate equipment by hand.

Equipment Can Be Stored/Preserved for Months/Years! With Minimal Man Power.

Equipment in Crates Need not be Opened up for Inspection or Rotation.

Beneficial PointsBeneficial PointsOil Mist Preservation YardsOil Mist Preservation Yards

•• The mist preservation yards are easily expanded The mist preservation yards are easily expanded and contracted to accommodate the movement of and contracted to accommodate the movement of machinery.machinery.

•• Provides clean form of preservation as there are Provides clean form of preservation as there are no spills and the amount of oil used is precisely no spills and the amount of oil used is precisely controlled.controlled.

•• Equipment is ready for immediate connection to Equipment is ready for immediate connection to the process plant oil mist systems.the process plant oil mist systems.

Advantages of Machinery Preservation Advantages of Machinery Preservation with Oil Mistwith Oil Mist

•• No need to disassemble machinery. No need to disassemble machinery.

•• Not necessary to fill cavities with liters Not necessary to fill cavities with liters of special and costly preservative fluids.of special and costly preservative fluids.

•• Since preservation is achieved with Since preservation is achieved with turbine oil there is no need to clean and turbine oil there is no need to clean and remove preservative coatings.remove preservative coatings.

LubriMistLubriMist ®® Preservation Packaging KitsPreservation Packaging KitsDesigned For Wooden CratesDesigned For Wooden Crates

MistMistInletInlet

MistMistOutletOutlet

LubriMistLubriMist ®® Preservation Packaging KitsPreservation Packaging Kits

Designed For Wooden CratesDesigned For Wooden Crates

Recessed Construction Allows For Stacking of CratesRecessed Construction Allows For Stacking of Cratesand Avoids Breakage.and Avoids Breakage.

Beneficial PointsBeneficial PointsOil Mist Preservation YardsOil Mist Preservation Yards

•• The mist preservation yards are easily expanded and contracted The mist preservation yards are easily expanded and contracted to accommodate the movement of machinery.to accommodate the movement of machinery.

•• Provides clean form of preservation as there are no spills and Provides clean form of preservation as there are no spills and the amount of oil used is precisely controlled.the amount of oil used is precisely controlled.

•• Equipment is ready for immediate connection to the process Equipment is ready for immediate connection to the process plant oil mistplant oil mist systems.systems.

Advantages with Oil Mist PreservationAdvantages with Oil Mist Preservation

•• No need to disassemble machinery. No need to disassemble machinery.

•• Not necessary to fill cavities with liters of special and costlyNot necessary to fill cavities with liters of special and costlypreservative fluids.preservative fluids.

•• Since preservation is achieved with turbine oil there is no needSince preservation is achieved with turbine oil there is no needto clean and remove preservative coatings.to clean and remove preservative coatings.

OIL MIST PRESERVATIONREDUCES START-UP FAILURES

NOTE: A Good Preservation Program During Construction Would Have Reduced Number of Failures (12) Due to Infant Mortality.

10 Unnecessary Repairs x’s $15k Average Cost Each = $150k

0 1 2 3 4 5 6 7 8 9 10 Years

50

40

30

20

10

0 BE

AR

ING

FA

ILU

RE

S P

ER

YE

AR

LubriMist ®® Preservation SystemPreservation System

Preservation Manifold• Mounts into mist header• Metering orifice machined into

the manifold; no separate reclassifiers or points required

• 8 connection points

Preservation ManifoldPreservation Manifold•• Mounts into mist headerMounts into mist header•• Metering orifice machined into Metering orifice machined into

the manifold; no separate the manifold; no separate reclassifiers or points requiredreclassifiers or points required

•• 8 connection points8 connection points

•• Oil mist generator(s); basic unitsOil mist generator(s); basic unitswith minimum monitoring and controls.with minimum monitoring and controls.

•• Source of compressed air.Source of compressed air.•• Oil supply typically from a drumOil supply typically from a drum

with cover and air driven pump.with cover and air driven pump.•• Post mounted distribution header;Post mounted distribution header;

22”” galvanized.galvanized.•• LubriMistLubriMist®® preservation manifoldspreservation manifolds

with integral reclassifiers.with integral reclassifiers.•• Plastic tubing and fittings to connectPlastic tubing and fittings to connect

equipment to the mist header.equipment to the mist header.

Preservation of EquipmentPreservation of Equipmentin Full Wooden Cratesin Full Wooden Crates

LubriMistLubriMist ®® Preservation Packaging Kits in Place.Preservation Packaging Kits in Place.

MistInletMistMistInletInlet

MistOutletMistMistOutletOutlet

•• Many clients want to leave machinery in the wooden Many clients want to leave machinery in the wooden shipping crate for protection at job site.shipping crate for protection at job site.

•• LSC designed the Preservation Packaging Kit to meet this LSC designed the Preservation Packaging Kit to meet this need and adapt equipment to oil mist preservation.need and adapt equipment to oil mist preservation.

•• Especially effective with materials shipped overseas.Especially effective with materials shipped overseas.

Storage of Crated MachineryStorage of Crated Machinery

Overview of Storage YardOverview of Storage Yard

Equipment Stored without CratesEquipment Stored without Crates

PlasticPlasticTubingTubing

Pump PackagePump PackagePreserved with Oil MistPreserved with Oil Mist

PlasticPlasticTubingTubing

Equipment Stored without CratesEquipment Stored without Crates

Operation of Storage YardOperation of Storage Yard

•• Equipment received at project site and directed to the Equipment received at project site and directed to the storage yard.storage yard.

•• Records and documentation kept for each crate:Records and documentation kept for each crate:-- Arrival date documented.Arrival date documented.-- Initial inspection reports prepared.Initial inspection reports prepared.-- Location in the yard noted.Location in the yard noted.-- Oil mist applied to the package.Oil mist applied to the package.-- Flow of oil mist verified.Flow of oil mist verified.

Continued:Continued:

Operation of Storage YardOperation of Storage Yard• Equipment maintained and inspected

while in the yard.

• Mist systems kept fully operational.

• When crates leave the storage yard, departuredate and condition noted.

•• Equipment maintained and inspectedEquipment maintained and inspectedwhile in the yard.while in the yard.

•• Mist systems kept fully operational.Mist systems kept fully operational.

•• When crates leave the storage yard, departureWhen crates leave the storage yard, departuredate and condition noted.date and condition noted.

Continued:Continued:

•• Storage yard erected and made operational.Storage yard erected and made operational.•• Installation of the permanent mist systemsInstallation of the permanent mist systems

is carried out in two phases. is carried out in two phases.

Phase I -- Begins following erection of major pipe racks.Begins following erection of major pipe racks.•• Mist generators are set in place.Mist generators are set in place.•• Distribution and return header pipe is erected.Distribution and return header pipe is erected.•• Preservation manifolds mounted in header.Preservation manifolds mounted in header.•• Mist generator is placed in service.Mist generator is placed in service.

-- Compressed air source needed, not electrical power.Compressed air source needed, not electrical power.

Integration of Storage and Operating Mist Systems

Integration of Storage and Operating Mist Systems

continued:continued:

Phase IPhase I

•• As equipment foundations are completed, machinery As equipment foundations are completed, machinery is moved from the storage yard, removed from crates is moved from the storage yard, removed from crates and placed on the foundation.and placed on the foundation.

•• Temporary plastic tubing is run from the preservation Temporary plastic tubing is run from the preservation manifold to the equipment cavities to be preserved.manifold to the equipment cavities to be preserved.

-- No more than three days without oil mist.No more than three days without oil mist.•• During completion of construction the equipment During completion of construction the equipment

continuously receives mist and is routinely inspected.continuously receives mist and is routinely inspected.

IntegrationIntegration

•• Begins after all process piping has been installed Begins after all process piping has been installed and equipment permanently setand equipment permanently setin place.in place.

•• All utilities are connected to central oil mist console All utilities are connected to central oil mist console and oil supply/demisting vessel.and oil supply/demisting vessel.

•• Temporary plastic tubing and preservation manifolds Temporary plastic tubing and preservation manifolds are removed.are removed.

•• Permanent supply and return drops are installed.Permanent supply and return drops are installed.

Phase II

continued:continued:

IntegrationIntegration•• Proper size reclassifiers are installed in mist Proper size reclassifiers are installed in mist

manifolds and SS tubing is connected.manifolds and SS tubing is connected.•• Collection containers and drain lines installed along Collection containers and drain lines installed along

with return to collection header.with return to collection header.•• Mist is applied to the machine.Mist is applied to the machine.•• Full system commissioned.Full system commissioned.•• Operator training conducted.Operator training conducted.

Note: Oil mist preservation yard generators and Oil mist preservation yard generators and distribution piping can be used for storage of spare distribution piping can be used for storage of spare machinery, gear boxes, turbine rotors and other machinery, gear boxes, turbine rotors and other equipment as part of the store house.equipment as part of the store house.

Users of Oil Mist PreservationUsers of Oil Mist Preservation•• ExxonExxon•• ShellShell•• TexacoTexaco•• CaltexCaltex•• EquistarEquistar

Special Note: The Next Edition of API Special Note: The Next Edition of API Specifications will Include A Section on Mist Specifications will Include A Section on Mist Preservation; Preservation;

APIAPI--686; Recommended Practices686; Recommended PracticesSection 5.19.4Section 5.19.4