1、Designation: D6439 11Standard Guide forCleaning, Flushing, and Purification of Steam, Gas, andHydroelectric Turbine Lubrication Systems1This standard is issued under the fixed designation D6439; the number immediately following the designation indicates the year oforiginal adoption or, in the case o
2、f revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.INTRODUCTIONOptimum turbine system reliability requires a well designed lubricating system and use of a go
3、odlubricant that is free of contaminants. Achieving this requires use of proper purification methods toensure that the oil is free of detrimental contaminants. In addition, it requires an ongoing monitoringprogram to ensure that the oil quality is within specifications and that corrective action is
4、taken tominimize contaminant generation and ingression. The benefits of purification of an operatinglubrication system can be significantly reduced if the lubricating systems are not initially cleaned toa level that will prevent component damage on initial start up after manufacturing or rebuilding.
5、Care and thorough cleaning are required to minimize and remove contaminants during fabrication,rebuilding, or installation, or combination thereof. Because contaminants will remain from theseprocesses, it is necessary to flush and purify the system to remove them prior to startup. Ongoingpurificatio
6、n is required to maintain pure oil during operation. In new systems, the emphasis is on theremoval of contaminants introduced during manufacture, storage, field fabrication, and installation. Inoperational systems, the emphasis is on the removal of contaminants that are generated or carried induring
7、 operation, and by malfunctions that occur during operation or contaminants that are introducedduring overhaul, or both.1. Scope*1.1 This guide covers types of contaminants, oil purificationdevices, contamination monitoring, contamination control dur-ing building or refurbishing of turbine systems,
8、lubricationsystem flushing, and maintenance of pure lubrication oil.1.2 To obtain maximum operating life and reliability, orlubricants and system, it is vital that the turbine lubricationsystem has pure oil. This guide is intended to aid the equipmentmanufacturer, installer, and turbine operator in
9、coordinatingtheir efforts to obtain and maintain clean lubrication andcontrol systems. These systems may be on land or marineturbine generators and propulsion and mechanical drive equip-ment. This guide is generalized due to variations in the type ofequipment, builders practices, and operating condi
10、tions.1.3 This guide primarily addresses petroleum based lubri-cating oil. For systems using nonpetroleum based fluids, thisguide may not be appropriate. For nonpetroleum products,consult the equipment and fluid manufacturers.1.4 This guide is applicable to both large and small lubri-cation systems.
11、 Some equipment specified herein, however,may not be appropriate for all systems. Moreover, in situationswhere specific guidelines and procedures are provided by theequipment manufacturer, such procedures should take prece-dence over the recommendations of this guide.1.5 This standard does not purpo
12、rt to address the safetyconcerns, if any, associated with its use. It is the responsibilityof the user of this standard to establish appropriate safety andhealth practices and determine the applicability of regulatorylimitations prior to use.2. Referenced Documents2.1 ASTM Standards:2D445 Test Metho
13、d for Kinematic Viscosity of Transparentand Opaque Liquids (and Calculation of Dynamic Viscos-ity)D664 Test Method for Acid Number of Petroleum Productsby Potentiometric TitrationD974 Test Method for Acid and Base Number by Color-Indicator Titration1This guide is under the jurisdiction of ASTM Commi
14、ttee D02 on PetroleumProducts and Lubricants and is the direct responsibility of Subcommittee D02.C0.01on Turbine Oil Monitoring, Problems and Systems.Current edition approved May 1, 2011. Published July 2011. Originally approvedin 1999. Last previous edition approved in 2005 as D643905. DOI: 10.152
15、0/D6439-11.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.1*A Summary of Changes section appears at the end
16、of this standard.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.D2272 Test Method for Oxidation Stability of Steam Tur-bine Oils by Rotating Pressure VesselD4241 Practice for Design of Gas Turbine Generator Lu-bricating Oil Systems3D
17、4248 Practice for Design of Steam Turbine Generator OilSystems3D4378 Practice for In-Service Monitoring of Mineral Tur-bine Oils for Steam and Gas TurbinesD4898 Test Method for Insoluble Contamination of Hy-draulic Fluids by Gravimetric AnalysisD6304 Test Method for Determination of Water in Petro-l
18、eum Products, Lubricating Oils, and Additives by Coulo-metric Karl Fischer TitrationD6810 Test Method for Measurement of Hindered PhenolicAntioxidant Content in Non-Zinc Turbine Oils by LinearSweep VoltammetryD6971 Test Method for Measurement of Hindered Phenolicand Aromatic Amine Antioxidant Conten
19、t in Non-zincTurbine Oils by Linear Sweep VoltammetryD7155 Practice for Evaluating Compatibility of Mixtures ofTurbine Lubricating OilsD7546 Test Method for Determination of Moisture in Newand In-Service Lubricating Oils and Additives by RelativeHumidity SensorD7647 Test Method for Automatic Particl
20、e Counting ofLubricating and Hydraulic Fluids Using Dilution Tech-niques to Eliminate the Contribution of Water and Inter-fering Soft Particles by Light ExtinctionF311 Practice for Processing Aerospace Liquid Samples forParticulate Contamination Analysis Using Membrane Fil-tersF312 Test Methods for
21、Microscopical Sizing and CountingParticles from Aerospace Fluids on Membrane Filters2.2 ISO Standards:4ISO 3722 Hydraulic Fluid PowerFluid SampleContainersQualifying and Controlling Cleaning Meth-odsISO 4021 Hydraulic Fluid PowerParticulate Contamina-tion AnalysisExtraction of Fluid Samples from Lin
22、es ofan Operating System.ISO 4406 Hydraulic Fluid PowerFluidsMethod forCoding Level of Contamination by Solid ParticlesISO 4572 Hydraulic Fluid PowerFiltersMulti-passMethod for Evaluating Filtration Performance2.3 API Standard:5API 614 Lubrication, Shaft-Sealing, and Control-Oil Sys-tems for Special
23、 Purpose Applications3. Terminology3.1 Definitions of Terms Specific to This Standard:3.1.1 adsorption, nremoval of contaminants from oil byadhesion of the contaminant in an extremely thin layer ofmolecules to a fixed solid. The solid can be a fiber, a finepowder, or porous particles.3.1.2 centrifug
24、ation, nuse of centrifugal force to separatecontaminants from oils. Contaminants such as water andparticulate are generally more dense than the oil and migrate tothe outside of the centrifuge because of centrifugal force.3.1.3 cleaning, vdirect removal of contaminant from anypart of the system, gene
25、rally with the system shut down oroffline. Cleaning can include removal of contaminant byshoveling, sweeping, squeegee, vacuuming, wiping, displacingwith clean, dry compressed air and can be done with the aid ofcleaning solutions.3.1.4 cleaning solution, nfluid used to aid in the removalof sludge an
26、d particulate matter in a system. Cleaning solutionsmay be classified as chemical cleaners, solvent cleaners, or oilsoluble cleaners.3.1.5 coalescence, nprocess of passing oil with free waterthrough a fiber sheet, generally in a cartridge form, to causesmaller drops of water to join to form larger o
27、nes that can bemore easily removed from the oil.3.1.6 coalescer, ndevice that uses coalescence to separatewater from oil. A coalescer generally consists of a coalescingcartridge(s) and a hydrophobic barrier that hinders water frompassing out with the oil. It may also contain a filter locatedupstream
28、 or downstream, or both, of the coalescing car-tridge(s).3.1.7 displacement flush, nsystem flush using on-boardturbine pumps designed to remove unwanted materials frominstallation or repair.3.1.8 displacement oil, noil used to remove either alighter grade flush oil or an oil that is highly contamina
29、ted withoil soluble material.3.1.9 filter, ndevice containing a screen or fiber depthmedium that removes particles from oil by physically trappingthem in or on the screen or mesh.3.1.10 flushing, vcirculation of liquid through the lubri-cation system or a component, when the turbine is notoperating,
30、 to remove contaminant.3.1.11 high-pressure water flush, nuse of high-pressurewater to remove heavy rust or fouling from lube systeminternals.3.1.12 high-velocity flush, nsystem flush using externalpumps that generate three to four times normal operatingsystem velocities and a Reynolds number over 4
31、000.3.1.13 operating oil, nspecific charge or chemistry of oilto be used as the final fill oil after the flush.3.1.14 oxidation, nchemical reaction of a lubricant atelevated temperatures between dissolved atmospheric oxygenand the base oil. Oxidation reaction will be accelerated by thepresence of ox
32、idation accelerators such as metallic contami-nants and water.3.1.15 pure oil, nhomogeneous lubricating oil containingstable additives and free of soluble or insoluble contaminantsof concentrations that exceed the lubrication system specifica-tions.3.1.16 purification, vremoval of a contaminant pres
33、ent inthe oil through a separation process.3Withdrawn. The last approved version of this historical standard is referencedon www.astm.org.4Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036.5Available from American Petroleum Institute, 1220 L St
34、. NW, Washington, DC20005-8197.D6439 1123.1.17 sacrificial flush oil, ncharge of oil that is used inthe flushing process and not used as the final operating oil.3.1.18 surface active flush, nsystem flush with the use ofsurface active cleaners to remove varnish and sludge.4. Significance and Use4.1 T
35、his guide is intended to aid the equipment manufac-turer, installer, and turbine operator in coordinating their effortsto obtain and maintain clean lubrication and control systems.4.2 The flushing and cleaning philosophies stated in thisguide are applicable to both large and small lubricationsystems
36、.4.3 Clean lubrication systems result from proper systemdesign and good planning, execution, and communication byall involved during commissioning. No phase of these proce-dures should be undertaken without a thorough understandingof the possible effects of improper system preparation. Theinstallati
37、on, cleaning, and flushing of the equipment should notbe entrusted to persons lacking in experience.4.4 Because of the knowledge and specialized equipmentthat is required, the operator may wish to employ an outsidespecialist contractor for the system flushing. Review of thisguide can provide guideli
38、nes for discussion with prospectivecontractors.5. Contamination Control Overview5.1 Lubrication systems can become contaminated from avariety of sources. The main focus of this guide is on theminimization, monitoring, and control of contaminants: waterand both soluble and insoluble (stationary and s
39、uspended)contaminants. A more detailed discussion of these types ofcontaminants is given in Appendix X1.5.2 Contamination control is the complete program ofobtaining and maintaining a clean lubricant and lubricationsystem. This includes proper construction and maintenancepractices, appropriate purif
40、ication equipment, and regularmonitoring of contaminants. The contamination control pro-gram must be capable of identifying and measuring contami-nants and controlling them at, or preferably below, componenttolerances. In particular, the sensitivity of bearings, gears,seals, and proportional and ser
41、vo valves should be reviewed.As described in X2.7.1, cleanliness levels for various systemcomponents are generally established by their manufacturersspecifications. These and recommendations of the fluid manu-facturer must be considered when employing contaminationcontrol systems. In addition, there
42、 are insoluble contaminants(oxidation precursors) that are below machine tolerances, butas their volume amasses they create a potential for sludge andvarnish creation as a normal consequence of oxidation reac-tions.5.3 Contamination control considerations must begin withsystem design and continue th
43、rough the manufacture, installa-tion, flushing, operation, and maintenance of the system.5.4 Design of the system must consider component con-taminant sensitivity and provide points for sampling oil andmethods for controlling contaminants. Contamination monitor-ing is discussed in Appendix X2 and co
44、ntamination controlmethods in Appendix X3. Inclusion of filtration in steam andgas turbine lubrication systems is discussed in Practices D4248and D4241 respectively.5.5 The manufacturer must minimize the amount of built-incontaminant by minimizing ingression and by flushing com-ponents to achieve ta
45、rget cleanliness levels in the finishedcomponent.5.6 Contamination control during installation and majormaintenance of turbine systems is discussed in Section 6.5.7 Proper heating is critical during flushing and routineoperation to minimize oil degradation. Heating is discussed inAppendix X4.5.8 Rem
46、oval of contamination by flushing is discussed inSection 7.5.9 Contamination control in operational systems and dur-ing routine maintenance is discussed in Section 8. Properlydesigned systems can normally control water and insolublecontaminants in operational systems. If, however, it is neces-sary t
47、o remove soluble contaminants other than water, an oilchange and also possibly a flush may be required.6. Contamination Control When Installing andRefurbishing Turbine Systems6.1 General:6.1.1 Exclusion or removal of contaminant, or both, inmanufacturing or refurbishing, or both, are necessary for a
48、subsequent successful flush and can be achieved only by thecooperation and diligence of many parties.6.1.2 Examples of Essential Precautions to Exclude orRemove Contaminant, or Both:6.1.2.1 The system should be designed to allow successfulcleaning.6.1.2.2 The pipe and other equipment must be properl
49、ycleaned and preserved.6.1.2.3 All possible locations for the entrance of dirt (pipeends) must be durably covered and secured for storage prior toshipment and loading. Shipment and unloading must take placewithout damage to these covers.6.1.2.4 Inspection of pipe at the turbine site must bethorough to discover any damage or open covers and to havethem repaired.6.1.2.5 Storage prior to installation must be in a shelteredlocation, especially if the storage is to be for a long duration.6.1.2.6 Inspection immediately prior to installation must bethorough, and
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