1、Designation: D6439 11 (Reapproved 2017)Standard 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
2、 or, in the case of 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 syst
3、em and use of a goodlubricant 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 cor
4、rective action is 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 manufactur
5、ing or rebuilding.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.
6、Ongoingpurification 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 o
7、r carried induring operation, and by malfunctions that occur during operation or contaminants that are introducedduring overhaul, or both.1. Scope1.1 This guide covers types of contaminants, oil purificationdevices, contamination monitoring, contamination control dur-ing building or refurbishing of
8、turbine systems, 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 tur
9、bine operator in 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, an
10、d operating conditions.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 lubr
11、i-cation systems. 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 standa
12、rd does not purport 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.1.6 This international standard was devel
13、oped in accor-dance with internationally recognized principles on standard-ization established in the Decision on Principles for theDevelopment of International Standards, Guides and Recom-mendations issued by the World Trade Organization TechnicalBarriers to Trade (TBT) Committee.2. Referenced Docu
14、ments2.1 ASTM Standards:21This guide is under the jurisdiction of ASTM Committee D02 on PetroleumProducts, Liquid Fuels, and Lubricants and is the direct responsibility of Subcom-mittee D02.C0.01 on Turbine Oil Monitoring, Problems and Systems.Current edition approved May 1, 2017. Published July 201
15、7. Originally approvedin 1999. Last previous edition approved in 2011 as D6439 11. DOI: 10.1520/D6439-11R17.2For 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 stan
16、dards Document Summary page onthe ASTM website.*A Summary of Changes section appears at the end of this standardCopyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United StatesThis international standard was developed in accordance with internationall
17、y recognized principles on standardization established in the Decision on Principles for theDevelopment of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.1D445 Test Method for Kinematic Viscosity of Transparentan
18、d 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 TitrationD2272 Test Method for Oxidation Stability of Steam Tur-bine Oils by Rotating Pressure VesselD
19、4241 Practice for Design of Gas Turbine Generator Lubri-cating Oil Systems (Withdrawn 2008)3D4248 Practice for Design of Steam Turbine Generator OilSystems (Withdrawn 2008)3D4378 Practice for In-Service Monitoring of Mineral Tur-bine Oils for Steam, Gas, and Combined Cycle TurbinesD4898 Test Method
20、for Insoluble Contamination of Hydrau-lic Fluids by Gravimetric AnalysisD6304 Test Method for Determination of Water in Petro-leum Products, Lubricating Oils, and Additives by Cou-lometric Karl Fischer TitrationD6810 Test Method for Measurement of Hindered PhenolicAntioxidant Content in Non-Zinc Tur
21、bine Oils by LinearSweep VoltammetryD6971 Test Method for Measurement of Hindered Phenolicand Aromatic Amine Antioxidant Content in Non-zincTurbine Oils by Linear Sweep VoltammetryD7155 Practice for Evaluating Compatibility of Mixtures ofTurbine Lubricating OilsD7546 Test Method for Determination of
22、 Moisture in Newand In-Service Lubricating Oils and Additives by RelativeHumidity SensorD7647 Test Method for Automatic Particle Counting ofLubricating and Hydraulic Fluids Using Dilution Tech-niques to Eliminate the Contribution of Water and Inter-fering Soft Particles by Light ExtinctionF311 Pract
23、ice for Processing Aerospace Liquid Samples forParticulate Contamination Analysis Using Membrane Fil-tersF312 Test Methods for Microscopical Sizing and CountingParticles from Aerospace Fluids on Membrane Filters2.2 ISO Standards:4ISO 3722 Hydraulic Fluid PowerFluid SampleContainersQualifying and Con
24、trolling Cleaning Meth-odsISO 4021 Hydraulic Fluid PowerParticulate Contamina-tion AnalysisExtraction of Fluid Samples from Lines ofan Operating System.ISO 4406 Hydraulic Fluid PowerFluidsMethod forCoding Level of Contamination by Solid ParticlesISO 4572 Hydraulic Fluid PowerFiltersMulti-passMethod
25、for Evaluating Filtration Performance2.3 API Standard:5API 614 Lubrication, Shaft-Sealing, and Control-Oil Sys-tems for Special 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
26、 extremely thin layer ofmolecules to a fixed solid. The solid can be a fiber, a finepowder, or porous particles.3.1.2 centrifugation, nuse of centrifugal force to separatecontaminants from oils. Contaminants such as water andparticulate are generally more dense than the oil and migrate tothe outside
27、 of the centrifuge because of centrifugal force.3.1.3 cleaning, vdirect removal of contaminant from anypart of the system, generally with the system shut down oroffline. Cleaning can include removal of contaminant byshoveling, sweeping, squeegee, vacuuming, wiping, displacingwith clean, dry compress
28、ed air and can be done with the aid ofcleaning solutions.3.1.4 cleaning solution, nfluid used to aid in the removalof sludge and particulate matter in a system. Cleaning solutionsmay be classified as chemical cleaners, solvent cleaners, or oilsoluble cleaners.3.1.5 coalescence, nprocess of passing o
29、il with free waterthrough a fiber sheet, generally in a cartridge form, to causesmaller drops of water to join to form larger ones 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 coalescingcartr
30、idge(s) and a hydrophobic barrier that hinders water frompassing out with the oil. It may also contain a filter locatedupstream 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 frominstal
31、lation or repair.3.1.8 displacement oil, noil used to remove either a lightergrade flush oil or an oil that is highly contaminated with oilsoluble 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
32、 mesh.3.1.10 flushing, vcirculation of liquid through the lubrica-tion system or a component, when the turbine is not operating,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, nsy
33、stem flush using externalpumps that generate three to four times normal operatingsystem velocities and a Reynolds number over 4000.3The last approved version of this historical standard is referenced onwww.astm.org.4Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floo
34、r, New York, NY 10036, http:/www.ansi.org.5Available from American Petroleum Institute (API), 1220 L. St., NW,Washington, DC 20005-4070, http:/www.api.org.D6439 11 (2017)23.1.13 operating oil, nspecific charge or chemistry of oilto be used as the final fill oil after the flush.3.1.14 oxidation, nche
35、mical reaction of a lubricant atelevated temperatures between dissolved atmospheric oxygenand the base oil. Oxidation reaction will be accelerated by thepresence of oxidation accelerators such as metallic contami-nants and water.3.1.15 pure oil, nhomogeneous lubricating oil containingstable additive
36、s and free of soluble or insoluble contaminantsof concentrations that exceed the lubrication system specifica-tions.3.1.16 purification, vremoval of a contaminant present inthe oil through a separation process.3.1.17 sacrificial flush oil, ncharge of oil that is used inthe flushing process and not u
37、sed 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 This guide is intended to aid the equipmentmanufacturer, installer, and turbine operator in coordinatingtheir efforts to obtain and
38、 maintain clean lubrication andcontrol systems.4.2 The flushing and cleaning philosophies stated in thisguide are applicable to both large and small lubricationsystems.4.3 Clean lubrication systems result from proper systemdesign and good planning, execution, and communication byall involved during
39、commissioning. No phase of these proce-dures should be undertaken without a thorough understandingof the possible effects of improper system preparation. Theinstallation, cleaning, and flushing of the equipment should notbe entrusted to persons lacking in experience.4.4 Because of the knowledge and
40、specialized equipmentthat is required, the operator may wish to employ an outsidespecialist contractor for the system flushing. Review of thisguide can provide guidelines for discussion with prospectivecontractors.5. Contamination Control Overview5.1 Lubrication systems can become contaminated from
41、avariety of sources. The main focus of this guide is on theminimization, monitoring, and control of contaminants: waterand both soluble and insoluble (stationary and suspended)contaminants. A more detailed discussion of these types ofcontaminants is given in Appendix X1.5.2 Contamination control is
42、the complete program ofobtaining and maintaining a clean lubricant and lubricationsystem. This includes proper construction and maintenancepractices, appropriate purification equipment, and regularmonitoring of contaminants. The contamination control pro-gram must be capable of identifying and measu
43、ring contami-nants and controlling them at, or preferably below, componenttolerances. In particular, the sensitivity of bearings, gears,seals, and proportional and servo valves should be reviewed.As described in X2.7.1, cleanliness levels for various systemcomponents are generally established by the
44、ir manufacturersspecifications. These and recommendations of the fluid manu-facturer must be considered when employing contaminationcontrol systems. In addition, there are insoluble contaminants(oxidation precursors) that are below machine tolerances, butas their volume amasses they create a potenti
45、al for sludge andvarnish creation as a normal consequence of oxidation reac-tions.5.3 Contamination control considerations must begin withsystem design and continue through the manufacture,installation, flushing, operation, and maintenance of the sys-tem.5.4 Design of the system must consider compon
46、ent con-taminant sensitivity and provide points for sampling oil andmethods for controlling contaminants. Contamination monitor-ing is discussed in Appendix X2 and contamination controlmethods in Appendix X3. Inclusion of filtration in steam andgas turbine lubrication systems is discussed in Practic
47、es D4248and D4241 respectively.5.5 The manufacturer must minimize the amount of built-incontaminant by minimizing ingression and by flushing com-ponents to achieve target cleanliness levels in the finishedcomponent.5.6 Contamination control during installation and majormaintenance of turbine systems
48、 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 Removal of contamination by flushing is discussed inSection 7.5.9 Contamination control in operational systems and dur-ing routine mainte
49、nance is discussed in Section 8. Properlydesigned systems can normally control water and insolublecontaminants in operational systems. If, however, it is neces-sary to 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 asubsequent successful flush and can be achieved only by thecooperation and diligence of many
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