Borger Texas Air Compressor Decontamination

Overview

Frontline Global Services, Inc. was contracted by a company in Borger, Texas, USA to carry out a major asset equipment decontamination project. The core objective was to address lubrication system contamination within a 1101MJ Auxiliary Process Air Compressor’s lubrication system prior to startup. Frontline provided a full turnkey execution covering system decontamination, high-velocity oil flushing, reservoir cleaning, fluid purification, and a startup run-in procedure. The project had an estimated completion window of 72 hours.

Project Objectives

• Safety and Efficiency: Efficiently minimize equipment downtime while ensuring all operations are conducted safely, protecting personnel and equipment.

• Perform High-Velocity Oil Flushing: Use Shell Turbo T46 oil to ensure all contaminants are flushed out from the lube system lines and components.

• Purify Existing System Fluids: Ensure that any remaining fluids meet OEM cleanliness specifications.

• Cleanliness Standards: Achieve a final particle count of 16/14/11 or better, per industry standards (API 614), and ensure clean screens free of particulates.

Methodology

Frontline’s methodology included a structured, engineered approach beginning with pre-project planning site visits and collaboration. The project emphasized health, safety, and environmental protocols (HS&E), system inspections, and tagging. Execution involved flushing and dislodging contaminants, purifying fluids, and validating system cleanliness through ISO and API standards. A turnkey model ensured Frontline managed everything from mobilization to final validation, with the option to include a run-in procedure using slip-stream filtration to verify system readiness post-installation

Process

1. Reservoir Decontamination (Initial): Initial cleaning and flushing of the reservoir to remove major contaminants and construction debris.

2. High-Velocity Oil Flush: Pressurized oil flushing throughout the lubrication system using Shell Turbo T46 to remove finer particulates and contaminants.

3. Reservoir Decontamination (Final): Secondary flushing and inspection to ensure the reservoir meets required cleanliness specifications.

4. Fluid Purification Process: Circulate and filter existing or newly added fluids to ensure they meet ISO 16/14/11 or better.

5. Slip-Stream Start-Up Run-In Process: Post-cleaning run-in using slip-stream filtration to validate the lubrication system during operational testing, ensuring compliance with API 614. ISO 4406 screening to ensure final piping cleanliness criteria.

Notable Project Moments

Critical Contamination Left by Previous Contractor

Upon inspection, significant metallic and particulate debris was discovered in the system, contradicting the prior contractor's claim of a completed flush. This posed a serious risk of catastrophic bearing failure on startup. Frontline identified and corrected this, ensuring asset reliability.

High Wind Conditions and Emergency Plant Shutdown

During the job, the site experienced sustained 50 mph wind gusts, prompting the team to seal and wrap all equipment to prevent contamination. A nearby transformer explosion triggered a fire that consumed 350 acres and forced an emergency evacuation. The Frontline crew executed a rapid, safe shutdown protocol, secured all gear, and resumed work once it was safe to return—demonstrating exceptional safety compliance and contingency management.

Project Summary

Efficient & Safe

Timely execution, proven methodology, and delivery of a thoroughly cleaned and tested system satisfied our customer’s operational and cleanliness standards, all done in a safe and fast manner.

Increased Equipment Reliability

By removing built-up contaminants, the assets are now better positioned to operate at optimum efficiency and reduce the risk of downstream issues.

Clean Screens & Particle Counts

The final particle counts for the assets were below 16/14/11, meeting and exceeding the customer’s requirements.

Conclusion

This technically demanding project highlighted Frontline Global Services’ expertise in system decontamination and response under duress. Starting from a severely compromised asset, the team delivered industry-compliant results, validated by final screen inspections and ISO particle count. The client was extremely satisfied with the outcome and expressed intent to re-engage Frontline for future critical maintenance windows. The operation exemplifies a commitment to safety, technical excellence, and reliability in adverse conditions.