Optimize lubricant application in industrial turbines

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SRP (Salt River Project), a public power utility in the United States, provides reliable and affordable electricity and water to over two million people in central Arizona. As part of its commitment to sustainable operations, SRP recognized the need to address the issue of premature oil degradation in its combined-cycle power plants. Traditional oil management practices involved frequent oil changes, which not only incurred significant costs but also contributed to environmental pollution through the production, transportation, and disposal of new lubricating oil. This case study took place at SRP’s Mesquite Power plant in Arlington, Arizona. It is a 1250MW combined cycle power plant.

SRP partnered with Fluitec to implement the Fill4Life™ program, a comprehensive solution that enables a "fill for life" strategy for lubricants. This approach involves:

1. Contaminant Removal

   Fluitec's technology filters out harmful particles, water, and other contaminants that contribute to oil degradation.

2. Component Replenishment

   Essential additives and solubilizers are replenished to maintain the lubricant's optimal performance and protective properties.

3. Continuous Monitoring

   Online and offline oil analysis is conducted to monitor lubricant health and identify potential issues before they escalate.

By continuously maintaining and optimizing the condition of the lubricant, the program eliminates the need for frequent oil changes, extending the lifespan of lubricants and reducing waste.

Sustainability impact

Climate

Targeted emissions sources

Scope 1: This initiative directly targets emissions from SRP's power generation operations.

Decarbonization impact

By extending the lifespan of turbine oil beyond 300% of the industry standard, SRP has avoided the production, transportation, and disposal of over 50,000 gallons (~ 190,000 liters) of oil per decade per turbine. This has resulted in a significant reduction of approximately 150 tons of CO2e (carbon dioxide equivalent) emissions per year per turbine.

Nature

There are approximately 200 million gallons of used oil in the US that are improperly disposed of each year. SRP’s efforts ensure that none of their used turbine oils contribute to this total.

Business impact

Benefits

The implementation of the program has yielded substantial financial benefits for SRP’s Mesquite Power. By optimizing oil life and preventing associated costs with oil changes, Mesquite Power realizes over $275,000 per year in OPEX savings (Operating Expenses) and over 150 tons per year in CO2e emissions. Furthermore, less human interaction with their turbine oil translates to a safer working environment for their employees.

Costs

Investment costs are lower than the cost of one oil change, so savings are realized immediately.

Typical business profile

This solution is applicable to any industrial facility operating small to large machinery that relies on lubricating oil and hydraulics. Power generation plants, general manufacturing, chemical plants and other industries with similar equipment can benefit from this technology. The savings realized in this case study are similar to any other power plant in the world operating with steam or gas turbines.

Approach

1. Assessment: Fluitec conducted a comprehensive oil analysis to assess the condition of SRP's turbine oil and determine the feasibility of implementing the Fill4Life™ program

2. Implementation: Fluitec installed the necessary filtration, oil rebalancing additives and monitoring equipment, tailored a maintenance plan for SRP's specific needs, and provided training to SRP personnel on the operation and maintenance of the system

3. Monitoring and Maintenance: SRP, with ongoing support from Fluitec, continues to monitor the oil condition through routine analysis, ensuring the continued effectiveness of the Fill4Life™ program and proactively addressing any potential issues

Stakeholders involved

• Project Leads: Operations and Maintenance team at SRP, the solution provider’s technical experts

• Company Functions: Operations, Maintenance, Engineering

• Main Provider: Fluitec

Key parameters to consider

• Oil Condition: A comprehensive oil analysis is essential to determine the suitability of the Fill4Life™ program and establish a baseline for monitoring progress

• Equipment Compatibility: Ensure that the Fill4Life™ technology is compatible with the specific lubricants and equipment used in the facility

• Operational Conditions: Consider the operating environment and contamination levels, which can impact the effectiveness of the program

Implementation and operations tips

• Early Adoption: Implement the Fill4Life™ program early in the equipment's lifecycle to maximize the potential benefits in terms of oil life extension and cost savings

• Regular Monitoring: Adhere to the recommended oil analysis schedule to proactively identify and address any potential issues

• Partnership: Foster a close working relationship with the solution provider to leverage their expertise and optimize the results of the program