Cooper-Bessemer Reciprocating Compressor Decontamination and Oil Flush
Overview
Frontline executed a turnkey decontamination and high-velocity oil flushing process on a Cooper-Bessemer reciprocating compressor train and associated lube-oil systems on site. Work included off-line decontamination, crankcase cleaning, sequential flushing of the heat exchanger and system piping with FF-2020. Operations were performed in continuous shifts to minimize downtime and meet site objectives under schedule constraints.
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:
Perform high-velocity fluid flushing to eliminate system contamination.
Crank Case & System Decontamination
Ensure that any remaining fluids meet OEM cleanliness specifications. Execute crank case and system decontamination to remove any contamination build-up.
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
The team implemented a sequential, high-velocity flushing methodology: set up temporary flow loops to bypass the compressor internals (except the insulated internal distribution header), circulated low-viscosity FF-2020 to mobilize contaminants, conducted controlled proving screen runs to assess particulate release, performed crankcase cleanout. Cleanliness was validated with API 614 screen ratings and ISO 4406 practices, all under a composite-rate, turnkey delivery model.
Process
Crank Case Decontamination (Initial): Initial cleaning and flushing of the crank case to remove major contaminants and construction debris.
High-Velocity Oil Flush: Pressurized oil flushing throughout the lubrication system using flushing fluid to remove finer particulates and contaminants.
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 asset is now better positioned to operate at optimum efficiency and reduce the risk of downstream issues.
Clean Screens & Particle Count
The final particle count for the asset was well below 16/14/11, meeting and exceeding the customer’s requirements.
Conclusion
The comprehensive execution of this high-velocity fluid flushing and system decontamination project met and exceeded all specified requirements, successfully mitigating any potential contamination-related reliability risks. The coordinated efforts of Frontline Global Services and stakeholders ensured a safe, timely, and highly effective completion of the project.
