Asset Type
Downstream natural gas compressor station
Location
Rabab Harweel On-Plot, Oman
Client
Petroleum Development Oman (PDO)
Project Phase
Pre-commissioning
System Diameter
4"–6" (150# ANSI)
Objective
Achieve API 614 / NAS / ISO 4406 cleanliness standards prior to commissioning
Outcome
Achieved NAS 6 cleanliness per MAN Energy OEM specification
PDO’s Rabab Harweel Integrated Project is designed to handle a complex mix of sour and sweet gas, condensate, and large production volumes. With new compressors ready for commissioning, the reliability of the lube oil system was a critical path activity. Any contamination in the lube oil piping could compromise compressor performance, cause premature wear, or delay start-up - each scenario carrying significant operational and financial impact. PDO needed a partner capable of delivering a high-velocity oil flush (HVOF) that met stringent API 614 and OEM cleanliness requirements, while also ensuring safety, efficiency, and zero schedule slippage.
The Hydratight Middle East engineering team mobilized from planning through execution with a right-first-time approach:
1. Detailed Pre-Job Engineering
A full walk-down and engineering review identified every connection point in advance. A tailored process and procedure document was developed, including a complete list of pre-engineered jumpers and connection spools.
This preparation ensured the crew arrived with everything required for a safe and uninterrupted operation.
2. Purpose-Built Flushing Technology
Hydratight deployed its customized high-velocity flushing skid, designed specifically for rapid mobilization and controlled flushing performance. The integrated skid included:
- Lube oil tank
- Multi-stage filtration
- Heater
- Reverse-flow manifold
- Forced fin-fan cooler
- Capacity for flushing systems up to 12" diameter
The system generated turbulent flow to lift and carry debris, while the reverse-flow manifold increased agitation to remove contamination more effectively. Thermal input ensured sub-surface contaminants were released from pipe walls.
3. Controlled Flushing Process
Flushing was performed across the 4" and 6" lube oil piping runs leading to and from the cooler, demister vent line, and short pipe sections. Although a new cooler was included, no pickling was required.
Periodic screen inspections were conducted throughout the HVOF process, with cleanliness levels monitored against:
- API 614
- NAS / ISO 4406
- MAN Energy OEM requirements
The flushing operation was completed safely, efficiently, and without delay. Hydratight delivered:
surpassing OEM requirements
due to pre-engineered components and a fully integrated skid
ensuring the compressor train could be commissioned with confidence
with recognized industry standards for cleanliness and asset protection
If you need specialist flushing, commissioning, or integrity services that keep your project on schedule, let’s talk. Hydratight’s engineered solutions help ensure your assets are clean, compliant, and ready for safe operation.
