In the oil and gas industry, maintaining machinery is a critical aspect of operations. However, the traditional method of manual lubrication often comes with a plethora of hidden costs that can significantly impact productivity and profitability. These costs include labour expenses, downtime, and the potential for equipment damage due to human error. In this blog post, we will delve into the hidden costs of manual lubrication and explore why automation is becoming the future for oil and gas operations.
The Hidden Costs of Manual Lubrication
Manual lubrication may seem like a straightforward process, but it is riddled with inefficiencies and high costs. Let's break down the costs associated with manual lubrication for a large motor on a fluid pump, which is a common application in the oil and gas industry.
Cost of Manual Lubrication: For a large motor on a fluid pump, the yearly cost of manual lubrication can be significant. This includes the cost of labour, lubricants, and potential downtime during the lubrication process.
Downtime and Labor Costs: Downtime costs can be substantial, especially for critical equipment like fluid pumps. Labour costs for manual lubrication can also add up quickly, considering the frequency of lubrication required for such equipment.
Impact on Efficiency and Costs: Manual lubrication tasks can lead to operational inefficiencies and higher labour costs, with global manufacturing companies losing 20-30% of their productive capacity due to such inefficiencies.
The Pitfalls of Manual Lubrication
Manual lubrication poses several significant disadvantages, including:
Inefficient Processes: Manual lubrication systems are no guarantee for the right amount of lubricant at the right time and in the right place. This leads to serious risks for industrial applications where optimal lubrication is necessary to ensure efficient processes and minimal downtime and maintenance costs.
Increased Downtime: The ongoing need for manual lubrication can result in significant downtime. This not only affects production but also incurs additional costs related to lost productivity and potential machine damage.
Automation Benefits
Automating lubrication can significantly reduce these hidden costs and improve overall efficiency. Here are some key benefits:
Reduced Labor Costs: Automating lubrication can reduce labour costs, as 5% of labour costs are typically attributed to lubrication activities. Skilled maintenance technicians can be freed to perform more analytical tasks.
Improved Safety: Automation technologies such as IoT, RPA, and intelligent automation can enhance safety, accuracy, and efficiency, reducing safety risks and jobsite injuries.
Enhanced Efficiency: Automation in the oil and gas industry can reduce data interpretation time and cost by 50-60% and engineering hours by up to 70%.
Oil and Gas Industry Automation
Automation is not just about reducing costs; it's also about enhancing the overall performance of machinery. In the oil and gas industry, automation can:
Optimize Bearing Performance: By ensuring optimal lubrication, automatic lubrication systems can extend equipment lifespan, reduce the need for repairs, and minimize downtime.
Streamline Supply Chains: Automation technologies can streamline supply chains by reducing the need for frequent manual interventions, thereby improving inventory management and reducing waste.
Single-Point Lubricators in Action
For applications like large motors on fluid pumps, single-point lubricators can be particularly effective. These devices automatically dispense precise amounts of lubricant at regular intervals, ensuring consistent and optimal lubrication. Here's how they benefit such applications:
Consistent Lubrication: Single-point lubricators provide a steady, measured flow of lubricant, preventing over- or under-lubrication that can occur with manual methods.
Reduced Contamination: By maintaining a sealed lubrication system, these devices minimize the risk of contaminants entering the bearing, which is crucial in dusty or humid environments often found in oil and gas operations.
Extended Maintenance Intervals: With automated lubrication, maintenance teams can extend the time between manual checks, reducing labour costs and minimizing the need for equipment shutdowns.
Criticality Analysis
A thorough criticality analysis of assets helps determine the impact of failures on production costs, maintenance costs, environmental impact, and personnel safety. Critical assets are often the first targets for automatic lubrication.
Conclusion
The hidden costs of manual lubrication are substantial and can significantly impact the profitability of oil and gas operations. By automating lubrication processes, industries can reduce labour costs, improve safety, enhance efficiency, and optimize bearing performance. As the industry continues to evolve, automation is becoming increasingly essential for maintaining high levels of productivity and minimizing downtime.
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FAQ
- What are the hidden costs of manual lubrication in oil and gas operations?
- The hidden costs include labour expenses, downtime, and potential equipment damage due to human error. For large motors on fluid pumps, these costs can be substantial due to the critical nature of the equipment.
- How does automation reduce labor costs in lubrication?
- Automation reduces labor costs by freeing skilled maintenance technicians to perform more analytical tasks, thereby reducing the time spent on manual lubrication activities.
- What are the benefits of automated lubrication systems in oil and gas operations?
- The benefits include reduced downtime, improved safety, enhanced efficiency, and optimized bearing performance. Automation also reduces data interpretation time and engineering hours.
- How does automation improve safety in oil and gas operations?
- Automation technologies such as IoT, RPA, and intelligent automation enhance safety by reducing safety risks and jobsite injuries. These systems ensure that the right amount of lubricant is applied at the right time, minimizing the risk of equipment failure.
- What is the impact of manual lubrication on production time in oil and gas operations?
- Manual lubrication can lead to operational inefficiencies and higher labor costs, resulting in a 20-30% loss of productive capacity.
- How do automated grease point maintenance systems reduce re-lubrication costs in oil and gas operations?
- Automated grease point maintenance systems reduce re-lubrication costs by ensuring consistent and optimal lubrication, thereby extending equipment lifespan and minimizing the need for repairs.
