A leading manufacturer of large-diameter steel pipes for the oil and gas sector sought to enhance the efficiency of their water treatment system. The company employs a cold-forming expansion process to shape steel pipes, during which WEDOLiTTM expander oil with easy-splitting (ES) technology is used to lubricate metal-to-metal contact. At the same time, this latest generation, mineral oil-based expander oil facilitates the separation of oil from water with minimal chemical input. WEDOLiT expander oil technology is generally known for its efficiency in reducing the amount of chemicals needed to support the process. Despite the advanced properties of WEDOLiT ES technology, the manufacturer experienced excessive consumption of splitting additives, signaling inefficiencies in their water treatment process.
The Challenge
A high consumption of splitting additives observed by the tube manufacturer prompted WEDOLiT experts to conduct a detailed investigation. The goal was to optimize oil-water separation, reduce additive usage, and enable water recovery for post-expansion cleaning operations, ensuring both cost reduction and environmental sustainability.
The Master Fluid Approach
Master Fluid Solutions collaborated closely with the pipe manufacturer to address the challenge through a combined offering of high-performance lubricants, additives and technical support services:
System Assessment and Process Review:
A Master Fluid Solutions expert, together with a water treatment plant engineer, conducted an on-site evaluation of the existing oil-water separation system. The team analyzed the dosing system, additive compatibility, and separation efficiency to identify areas for improvement.
Tailored Jar Testing and Dosage Optimization:
Jar tests were performed to determine the optimal combination and concentration of splitting additives required to maximize oil separation with WEDOLiT ES technology. Based on test results, precise adjustments to the pump rates and additive dosing levels were implemented to achieve effective separation at the lowest chemical input.
System Upgrade and Automation:
Obsolete dosing pumps were replaced with a modern variable-speed dosing system with signal output, ensuring accurate and responsive chemical dosing. A new control panel with data logging and cloud connectivity was recommended to install, enabling real-time monitoring and remote access to critical system parameters.
Operator Training:
On-site training was provided to the company’s technical staff on performing jar tests and interpreting results, empowering the team to monitor and fine-tune additive usage independently.
The Technical Profile
The technical solution in place is a combined approach of high-performance lubricant and process optimization – it delivered multiple operational benefits:...
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