Optimizing Produced Water Cooler (PWC) Cleaning Through Long-Term Partnership and Continuous Improvement

At a glance

In a SAGD produced water cooling system, Guardian’s BrightShield process helped streamline cleaning, improve safety, and cut chemical use by 50%. After optimizing the program from three products to two, total cleaning costs dropped by an additional 13.4%, with reduced inventory, simpler application, and lower on-site exposure.

Key metrics

OVER 50% LESS CHEMICAL PER CLEANING

13.4% COST REDUCTION

FURTHER SAVINGS FROM 2-PRODUCT SOLUTION

FEWER WASHES PER BARREL

WASHES PER MBD CUT NEARLY IN HALF

Why produced water cooler cleaning is a recurring cost in SAGD

In SAGD operations, produced water comes back to surface hot and carries oil, solids and dissolved minerals. Produced water coolers bring that water down in temperature before treatment. Over time, the coolers foul and have to be chemically cleaned.

Each cleaning event uses chemical, labour and time, and it repeats all year. A program that needs several products, frequent cleanings and a large on-site inventory adds cost and exposure every cycle.

This SAGD facility had a three-product cleaning program and an unreliable supplier. It needed dependable supply first, then a simpler program that used less chemical without losing cleaning performance.

Challenges

Unreliable supply from their previous vendor left this SAGD facility at risk. Their produced water cooler (PWC) cleaning program was also overly complex, requiring three products, frequent cleanings, and high on-site inventory. This led to higher costs, increased labour, and safety risks.

Solutions

Guardian ensured dependable supply from day one, then focused on simplifying the program. Over five years, we helped cut chemical use per cleaning by 50% and reduced cleaning frequency nearly in half. Later, we streamlined the program to a two-product solution using our BrightShield™ Process improving efficiency without sacrificing performance.

Results

Through a long-term focus on performance and continuous improvement, the BrightShield™ program delivered measurable gains in cost, safety, and efficiency:

50% less chemical per cleaning event after optimizing the original 3-product program
Additional 16.7% chemical reduction and 13.4% savings in chemical costs achieved after streamlining to a 2-product solution
Cleaning frequency was nearly cut in half compared to pre-Guardian levels, reducing downtime, labour, and equipment wear.
Simplified application process, with less on-site inventory and improved safety
8+ year partnership, built on continuous improvement and operational reliability

Data

Frequently asked questions

How much did chemical use per cleaning drop?

By 50% over the first five years. After moving to a two-product BrightShield program, chemical use fell a further 16.7% and chemical cost a further 13.4%.

Did cleaning frequency change?

Yes. It was cut nearly in half compared with levels before Guardian’s involvement.

How long has the program been running?

More than 8 years.

What else improved?

The application process is simpler, with less inventory on site and less exposure for workers.