Overview
A major petrochemical plant in China replaced the lubricant in an Ingersoll Rand compressor on its second air separation unit. Despite flushing the system, deposits in low-flow zones and high-surface-area piping dissolved into the fresh PAO oil, causing increasing shaft vibrations. Fluitec’s partner Finta advised adding 5% DECON, which immediately stabilized the vibration trend.
Months later, another lubricant changeout—this time without flushing—triggered sawtooth vibration patterns and a forced shutdown. A second 5% DECON treatment quickly reduced vibrations to stable levels. The plant avoided repeated shutdowns and achieved a 4,347% ROI.
Problem
In China, a major petrochemical plant had a scheduled lubricant replacement where they changed the oil on the compressor in their second air separation unit. During this time, they also performed conventional flushing of the system before filling it with a new fully synthetic PAO based oil. However, after 3 days, they noticed abnormal secondary shaft vibrations which continued to intensify. Upon inspection, they realized that some deposits which were lodged in hard-to-reach places such as; low-level zones, high-surface-area piping, and oil coolers were dissolved by the new oil and transported throughout the system to the critical components (bearings / journals) leading to the increase in vibrations.
Solution
Fluitec’s partner, Finta advised the customer to add 5% DECON to the system.
Results
Immediately, the shaft vibrations stabilized and the upward trend was reversed. A couple months later, the plant was scheduled to perform another lubricant changeout (retaining the same OEM brand of lubricant as previously used which is 70% polyglycol and 30% jet-oil type polyol-ester). This time, the power plant did not flush the system and instead filled the system with the new oil. Within 10 days, sawtooth vibration patterns emerged which culminated in a forced shutdown a few weeks later. 5% DECON was added and the vibrations were reduced to stable levels.