Palo Pinto EHC Decontamination

Overview

Frontline Global Services Inc was contracted by a company in Palo Pinto, TX to perform a comprehensive hydraulic system decontamination project on their Westinghouse Steam-Driven Turbine Generator Package, specifically focusing on the EHC (Electrohydraulic Control) System with a 200 USG reservoir capacity. The project encompassed multiple specialized processes including offline system decontamination, high-velocity oil flushing using Fyrquel EHC Fluid, reservoir cleaning and decontamination, fluid purification, and a startup run-in procedure. With a target cleanliness specification of ISO 16/14/11 or better, the turnkey execution was planned for completion within a 3.5-day (84-hour) timeline, demonstrating Frontlines commitment to efficient and thorough system maintenance while ensuring optimal performance and reliability of the equipment.

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 Fyrquel EHC Fluid 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 with personnel. 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 Fyrquel EHC Fluid 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

Custom Made Fittings

The project experienced delays due to the need for a custom-made fitting that was essential for completing the system setup. Sourcing this specific component required additional lead time, as it was not readily available through standard suppliers. Despite proactive efforts to expedite the process, the delay impacted the overall project timeline. To account for this, appropriate credits were provided to the client as a gesture of goodwill and transparency.

Extended HVFU Scope

At the customer’s request, an additional three days were allocated to perform a High-Velocity Oil Flush on the Lube Oil Reservoir Tank for Unit 3. While progress was made, the system did not reach target particle count levels due to constraints in the customer’s budget and available time. The extension allowed for improved cleanliness, but full completion to specification was ultimately limited by these factors.

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

The project demonstrated exemplary technical execution with validated results through screen inspections and ISO particle counts. The client's satisfaction was evident in their recommendation for future work, and particularly in their appreciation of the team's clean work practices. Throughout the project, the team maintained high standards of safety and technical excellence while meeting all required specifications.