Does filtration factor into your planned equipment maintenance? It should.
The oil and gas industry relies heavily on machinery and equipment to operate at peak performance and that equipment is highly prone to corrosion and degradation. Filtration removes the contaminants and particulates from the fluids and gases used in various stages of production.
However, proper filtration for these machines is often overlooked, leading to unexpected equipment failure and costly downtime.
An hour of downtime in the oil and gas industry can reach nearly $500k. (Siemens Research)
Protecting Equipment Used in Oil and Gas Applications
The oil and gas industry uses a wide range of sophisticated (and expensive) industrial equipment for exploration, extraction, processing, transportation and refining. A few examples of key equipment and their applications that rely heavily on filtration for efficient and safe operation include:
- Drilling equipment such as drilling rigs, degassers and sand pumps.
- Production equipment such as separators, compressors, well cleanouts and pumps.
- Processing equipment such as heat exchangers, reactors and cooling treatments.
- Refinery equipment, mechanical cleaners or decokers, catalyst hydrocrackers, and desulfurization skids, used to convert crude oil into gasoline, diesel and petrochemicals.
- Transportation equipment like pipelines, tankers, trucks and railcars.
- Environment management equipment like flare systems and water treatment systems.
Filtration is less critical but still important for storage, safety and monitoring equipment, and measurement and control systems. Challenging conditions like harsh chemicals, high pressures, vibrations, extreme or fluctuating temperatures, and corrosive elements like salt water, sand and wind put your equipment to the test.
Repeated exposure to these conditions contributes to accelerated wear and tear on machinery, frequent breakdowns and reduced equipment lifespan. When these high-dollar machines go offline, every minute of lost production can equal thousands of dollars.
The Importance of Filters in Oil and Gas Applications
Most equipment breakdowns are blamed on a bad seal or worn-out part, but that overlooks one crucial aspect — the quality of fluids and gases used throughout the systems.
Inadequate filtration limits equipment lifespan and performance while adding to maintenance and repair costs. When contaminants find their way into your system, the consequences can include:
- Increased wear and tear
- Clogged components
- Flow restrictions
- Release of hazardous substances
- Corrosion
- Seal damage
- Overheating
- Component failure
- End product contamination
Beyond operational costs, inadequate filtration creates long-term issues — environmental impacts and legal and regulatory risks — that can haunt your business for years.
Proper filtration captures the solid particles, debris and abrasive substances that cause mechanical wear, corrosion and damage to your key components.
Approximately 75% of all equipment failures can be traced to contaminated hydraulic oil. (Machinery Lubrication)
Hydraulic Fluid Filters
Hydraulic fluid is the lifeblood of your machines and operations, transmitting mechanical power throughout your systems. If the hydraulic fluid isn’t clean, it can wear out critical components and cause irreparable damage to the equipment.
The first step? Choosing a high-quality hydraulic fluid designed for the application. The second? Choosing proper filtration systems that remove contaminants, corrosive components, solid particles, debris and abrasive materials that may sneak into your hydraulic fluid. Blockages or contamination in the hydraulic fluid can cause systems to lock up or component failure.
Filtration systems are your first line of defense against contaminants in your hydraulic assembly. Maintaining hydraulic fluid quality is essential to a healthy hydraulic system.
>> Preventing Premature Failure of Hydraulic Systems in Oil and Gas: Key Strategies for Reliability
Lubrication Filters
Lubrication filters are necessary to remove contaminants like dirt, metal, carbon or other particulates from engine oil, especially in demanding oil and gas activities. Without proper filtration, your system risks excessive wear and tear on critical components like bearings and gears. Lube filtration extends the life of your oil, reduces friction on moving parts, dissipates heat and increases machine uptime.
Compressed Air Filters
Pneumatic systems require quality air filters to remove dirt, particulates, moisture and oil from your air supply. Clean, dry air ensures longevity in your pneumatic systems and prevents equipment damage, product contamination, rust and unnecessary downtime. Contaminated air also contributes to health and safety risks over time, particularly respiratory issues or injury from air tools locking up due to rusted components.
The energy production environment poses many challenges to equipment life. MCE can help.
We carry filtration solutions specifically designed for different oil and gas operation applications, including rigs, fracking and refineries. Set your team up for more effective maintenance plans, decreased downtime and less drain on your bottom line. We can help you:
- Extend the lifespan of expensive equipment
- Achieve operation efficiency and performance
- Meet stringent regulations
- Improve employee safety
- Enhance environmental sustainability
Recommended Filter Types for Oil and Gas Processes
At MCE, we have a full range of Parker filtration solutions for every need, including filters for hydraulic and lubrication, compressed air and gas, process fluids and dust collection. Let’s talk about a brief selection of filters for midstream and upstream oil and gas operations and why they should be on your radar.
These filters are involved in purifying fluids or gases during production, transportation, or processing.
Coalescing Filters
Purpose: Remove liquid aerosols (e.g., water, oil) and fine particulate matter from gas streams.
Design: Use tightly packed fiber media to coalesce small droplets into larger ones, which are then removed by gravity. Often combined with particulate pre-filters to extend the life of the Coalescing Filters.
Applications:
- Separation of water and oil from natural gas.
- Gas dehydration in refineries and natural gas processing plants.
- Protection of compressors, turbines, and other equipment from moisture.
Key Feature: High separation efficiency for submicron aerosols.
Example: Parker Balston High-Efficiency Coalescing Filters remove 99.99% of oil, water and particulate aerosols as small as 0.01 microns and are suitable for high-flow applications with minimal pressure drop. Parker's proprietary Zander technology ensures efficient separation of liquids and particulates even in harsh environments.
Activated Carbon Filters
Purpose: Remove contaminants like hydrocarbons, odors, and other organic impurities.
Design: Contain granular activated carbon with a high surface area for adsorption of contaminants. Often combined with particulate pre-filters to reduce the load and extend the life of the carbon media.
Applications:
- Gas purification in natural gas processing and petrochemical plants.
- Removal of volatile organic compounds (VOCs) and other liquid hydrocarbons in refineries.
- Used in gas treatment processes to meet quality standards.
Key Feature: Effective removal of trace contaminants and odors.
Example: Parker AC Series Activated Carbon Filters are designed to work in conjunction with coalescing filters for optimal performance in the demanding environments of oil and gas. Achieves up to 99.9999% efficiency in removing oil vapors and odors.
Particulate Filters
Purpose: Remove solid contaminants (e.g., dirt, sand, rust, debris) from fluids or gases.
Design: Typically made with mesh screens, pleated paper, or synthetic materials to trap particles. Available in varying micron ratings and media configurations, to target specific contaminant particle sizes in various forms.
Applications:
- Hydraulic systems to protect pumps, valves and actuators.
- Refinery process applications to remove contaminants from production products to meet standards and customer expectations.
- Pipeline operations to ensure clean fluid & gas flow.
- Pre-filtration for coalescing or activated carbon filters.
Key Feature: High dirt-holding capacity to extend operational life.
Example: Parker Hannifin Filters: High-performance replacement filters for hydraulic, process, and compressed air systems. Provides reliable filtration for equipment in harsh conditions, such as drilling rigs and fracking equipment.
Multi-Stage Filtration Systems
Purpose: Provide comprehensive contaminant removal using a combination of filter types.
Design: Integrates multiple filter stages, such as particulate, coalescing and absorptive filters. Configurable to handle diverse contaminant profiles.
Applications:
- Comprehensive gas and liquid filtering for both midstream and upstream operations.
- Sour gas treatment and refinery processes with high contamination loads.
- Offshore platforms for multiphase fluid separation.
Key Feature: Tailored solutions for specific operational needs.
Example: PECO Multi-Stage Systems, available through Parker Hannifin, are designed for high-volume gas and liquid processing. Modular design allows systems to be tailored to specific operational requirements, such as flow rates, pressure levels, and contaminant types. Built with materials like stainless steel, carbon steel, or alloys for corrosion resistance and durability in harsh environments and can handle high pressures and temperatures typical of oil and gas operations.
Specialty Hydrogen Sulfide & Carbon Dioxide Filters
Purpose: Target carbon Dioxide, hydrogen sulfide and other sulfur compounds for removal from gas or liquid streams.
Design: Incorporate chemical scavenger media or specialized adsorbents to neutralize H₂S. May include high-temperature materials for extreme environments.
Applications:
- Protecting hoses and fittings from corrosion.
- Installed within the gas treatment systems in natural gas processing to remove carbon dioxide & hydrogen sulfide from sour gas, converting it into sweet gas suitable for commercial use.
- Used in refinery operations in desulfurization units to reduce sulfur content in fuels and raw materials.
Key Feature: Designed to handle highly corrosive environments.
Example: Parker PCO2-AC Series hydrogen sulfide Adsorber Filters uses advanced adsorption technology to neutralize corrosive agents effectively. Parker PEACH and Pleated liquid filters used to control solid particulates and removed undesirable liquids from amine and glycol streams most commonly used in large applications. Enhances efficiency by preventing the release of adsorbed hydrogen sulfide back into the system. Filter housings are made from corrosion-resistant materials such as stainless steel or coated carbon steel. Capable of withstanding high pressures and temperatures typical in oil and gas environments.
Recommended Filters for Oil and Gas Industry Equipment
These filters protect critical components of hydraulic, pneumatic, or mechanical systems from contaminants. They are designed to protect specific machinery (e.g., hydraulic filters on pumps, particulate filters on engines) and typically focus on preventing mechanical wear and tear.
High-Pressure Hydraulic Fluid Filters
Purpose: Protecting pumps, actuators, and valves in hydraulic systems on drilling rigs and fracking equipment when filtering contaminants under extreme pressure.
Design: Constructed with reinforced metal housing to handle pressures exceeding 6,000 PSI. Media options include cellulose, synthetic or wire mesh.
Applications: Hydraulic systems on drilling rigs, fracking equipment and subsea operations.
Key Feature: Durability under extreme pressure and vibration.
Example: Parker H Series High-Pressure Hydraulic Filters designed to operate at pressures up to 6,000 PSI (414 bar). Suitable for extreme hydraulic applications in demanding environments. Uses Parker’s Microglass III filter media for efficient contaminant removal and comes in a variety of micron ratings, ranging from 2 to 20 microns. Equipped with a built-in bypass valve to protect the system during filter clogs, ensuring uninterrupted flow.
Cartridge Filters
Purpose: Economical filtration for bulk solids and liquids.
Design: Cartridge filters: Cylindrical filters made with pleated or depth media.
Applications:
- General-purpose filtration for low-pressure systems.
- Protection for cooling systems, lubricants, and fuel lines in equipment.
Key Feature: Simple design and easy replacement.
Example: Parker Fulflo® Filter Cartridges support a wide range of fluid applications, from low-viscosity liquids to aggressive chemicals. Designed with large surface areas to maximize contaminant retention and extend service life. Reduces the frequency of cartridge changes, improving efficiency and reducing downtime.
MCE Filtration Products and Services for Oil and Gas Industry
MCE helps oil and gas customers with consultative support on a full range of filtration solutions and industrial and MRO supplies.
Prevent contamination and ensure the highest level of performance using proper filtration products that meet your specific operational requirements. At MCE, we carry a complete line of Parker filtration solutions designed to maximize machine uptime, reduce maintenance costs and extend equipment life by preventing system contamination. Product lines include:
- Filtrations systems
- Filter Cartridges
- Filters
- Stainless steel tubing
- Compression fittings
- Needle valves
We offer onsite services and consulting expertise, plus inventory management programs to ensure you have the right tools and supplies to keep your operation running smoothly.
Contact MCE for industry-leading filtration solutions and support