Oologah High-Velocity Oil Flush

Overview

Frontline Global Services executed a high-velocity oil flush, reservoir decontamination, fluid purification, and final fluid fill on a GE Frame 7FA Combustion Turbine-Driven Generator. The project was initiated to mitigate contamination issues impacting asset reliability. Despite challenges and schedule extension, the project successfully achieved cleanliness standards and restored asset operational integrity.

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

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 utilized proprietary high-velocity flushing equipment and fluid purification technologies, including specialized high-velocity filtration units (HVFU), high-quality stainless double armor guard hoses, and real-time particle counting to meet stringent cleanliness standards. System flushing targeted Reynolds numbers greater than 20,000, achieving API 614 compliant screens and particle counts as per ISO 4406.

Process

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

   
   

2. High-Velocity Oil Flush: Executed flush across all lube, seal, control, and jacking oil lines bypassing the customer's equipment. Targeted Reynolds number >20,000 ensuring turbulent flow conditions.

   
   

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. Final Fluid Fill: System re-inventoried with new, purified ACT SAP7500-25 fluid, meeting OEM standards.

Notable Project Moments

Nearby Train Derailment

Just before wrapping up their work at the power station, the Frontline team encountered an unexpected twist in their project - a Union Pacific train derailment that turned their routine departure into a logistical puzzle. Two empty coal cars had jumped the tracks near Oologah creating an impromptu roadblock. Unfazed, they plotted a back‑road bypass, turning a derailment into just another challenge overcome, and proving that in industrial maintenance, “routine” is simply a synonym for “expect the unexpected.”

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

Frontline Global Services successfully addressed system contamination challenges through meticulous project execution, achieving superior cleanliness standards. This enhanced asset reliability and operational efficiency, positioning the Combustion TurbineGenerator for optimal performance and extended operational lifecycle.