Kotech KDP-34/10 Oil-Free Compressor Supports Chemical Cleaning in Saudi Arabia’s Oil & Gas Sector
A pipeline service company in Saudi Arabia needed oil-free air for chemical cleaning and pre-commissioning. Their existing oil-lubricated compressors risked oil vapor contamination that could fail Saudi Aramco inspection. Kotech deployed a KDP-34/10 100% oil-free compressor delivering ISO 8573-1 Class 0 air. The unit ran at 34 m³/min with 99.5% uptime over 90 days. The chemical cleaning passed inspection on the first attempt.
Customer Pain Points
The client was contracted to perform chemical cleaning and pre-commissioning on a newly constructed oil and gas pipeline. The cleaning process required compressed air to drive pigs through the pipeline, circulating chemical solutions to remove mill scale, weld slag, and construction debris. After cleaning, compressed air was also used for blow-drying the line to meet pre-commissioning acceptance standards.
The client's existing oil-lubricated portable compressors, even with multi-stage filtration, carried a persistent risk of oil vapor and condensate contamination in the compressed air supply. Trace oil mixing with chemical cleaning agents would reduce their effectiveness or leave an oily film on the pipe's internal surface, causing the entire cleaning campaign to fail. Oil or moisture left behind after blow-drying would result in failure of the final inspection by Saudi Aramco, requiring costly rework and project delays. Additionally, oil contamination could cause pig seals to swell and get stuck inside the pipeline, creating a serious operational hazard. The client needed a truly 100% oil-free, dry, and clean compressed air source.
Solutions
Kotech deployed a single KDP-34/10 100% oil-free diesel portable rotary screw air compressor for this project. The unit features dry-running oil-free compression technology, with no oil introduced into the compression chamber. The output air is third-party certified to ISO 8573-1 Class 0 standard, guaranteeing zero detectable oil in any form.
The compressor delivers 34 m³/min (1,200 CFM) at 10 bar working pressure, providing the high-volume, high-pressure air required for chemical cleaning and pipeline blow-drying. Powered by a Cummins diesel engine and equipped with a high-ambient cooling package, the unit operates reliably in Saudi summer temperatures exceeding 45°C. The trailer-mounted chassis enables easy relocation between pipeline sections as the cleaning campaign progresses.
Kotech engineers managed on-site commissioning, pipeline connections, and integration with the client's pig launcher/receiver systems, ensuring stable operation throughout the 90-day cleaning cycle.
Implementation Steps
- On-site survey and technical assessment to confirm ISO 8573-1 Class 0 air purity requirements, flow rate, and pressure specifications
- Customized KDP-34/10 oil-free unit configuration with high-ambient cooling package; factory performance testing and shipment
- Equipment arrived at Eastern Province site; unboxing and trailer chassis inspection completed
- On-site piping connections and integration with chemical cleaning circulation system and pig launcher/receiver units
- Full system commissioning and air purity validation to confirm Class 0 compliance
- Units put into operation for chemical cleaning and pipeline blow-drying; 90 consecutive days of continuous operation
- Operator training provided on oil-free compressor routine maintenance and troubleshooting procedures
Customer results
Products Used in This Case
FAQ (Frequently Asked Questions)
Why is oil-free air critical for chemical cleaning in pipelines?
Oil in the compressed air can contaminate chemical cleaning agents, making them ineffective. It can also leave an oily film on the pipe's internal surface, which can cause the final pre-commissioning inspection to fail. Additionally, oil can damage the seals on cleaning pigs, causing them to become stuck inside the pipeline
What makes Kotech's KDP-34/10 compressor an "oil-free" compressor?
The KDP-34/10 used in this project features Kotech's dry-running, oil-free screw technology. This design means no oil is ever introduced into the compression chamber. This is different from oil-injected compressors that require complex filtration to try to remove oil from the air output, making Kotech's solution a true 100% oil-free guarantee, certified to ISO 8573-1 Class 0 standards
How did the KDP-34/10 handle the extreme heat in Saudi Arabia?
Kotech's KDP series compressors are rated for a maximum ambient temperature of 50°C. The unit deployed in Saudi Arabia was configured with a high-ambient cooling package, including an oversized radiator and heavy-duty cooling fans, which ensured reliable operation even during the hottest parts of the day.
Besides chemical cleaning, what other oil & gas applications benefit from oil-free compressors?
Oil-free compressors are also used in the oil & gas industry for instrument air systems, which need clean, dry air to control pneumatic valves without fail. They are also essential for gas processing and any application where air comes into contact with sensitive catalysts or final products