1、 Reference number ISO 28520:2009(E) ISO 2009INTERNATIONAL STANDARD ISO 28520 First edition 2009-02-15 Ships and marine technology Lubricating oil systems Guidance for grades of cleanliness and flushing Navires et technologie maritime Circuits dhuile de graissage Guide relatif aux degrs de propret et
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6、er ISO at the address below or ISOs member body in the country of the requester. ISO copyright office Case postale 56 CH-1211 Geneva 20 Tel. + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyrightiso.org Web www.iso.org Published in Switzerland ii ISO 2009 All rights reservedISO 28520:2009(E) ISO 2
7、009 All rights reserved iii Contents Page Foreword iv 1 Scope . 1 2 Normative references . 1 3 Terms and definitions. 1 4 Recommended degrees of pipe cleaning. 2 4.1 Degrees of pipe cleaning during/after prefabrication. 2 4.2 Inside surface treatment 2 5 Cleaning of system components 2 5.1 Pumps, va
8、lves, filters, oil coolers, etc 3 5.2 Engine crankcase . 3 5.3 Gearbox . 3 5.4 Tanks 6 5.5 Special comments 6 6 Flushing . 6 6.1 Flushing practice (2-stroke engine) 6 6.2 4-stroke engines (practical execution) . 12 6.3 Flushing execution . 12 6.4 Flushing practice (turbines and turbo generators) . 1
9、3 7 Approval of flushing. 13 ISO 28520:2009(E) iv ISO 2009 All rights reservedForeword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through IS
10、O technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates c
11、losely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is to prepare International Standards. D
12、raft International Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this do
13、cument may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights. ISO 28520 was prepared by Technical Committee ISO/TC 8, Ships and marine technology, Subcommittee SC 3, Piping and machinery. INTERNATIONAL STANDARD ISO 28520:2009(E) ISO 2009
14、 All rights reserved 1 Ships and marine technology Lubricating oil systems Guidance for grades of cleanliness and flushing 1 Scope This International Standard provides guidance for flushing of lubricating oil systems, and grading of the resultant cleanliness. The flushing process is twofold: to remo
15、ve dirt from the erection and installation, and to demonstrate that the pipes and the system as a whole is sufficiently clean. Crankcase and, where applicable, gearbox etc. are cleaned separately before flushing, and requirements relating to this are also specified in this International Standard. Si
16、milar considerations apply to the system tank and other components of the system. For this International Standard, the cleaning process is considered as “washing through” when the Reynolds number, R e , is u 3 000, and “flushing” when the R eW 3 000. NOTE If available, any original equipment manufac
17、turer requirements for flushing take precedence over the requirements outlined in this International Standard. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated reference
18、s, the latest edition of the referenced document (including any amendments) applies. ISO 4406, Hydraulic fluid power Fluids Method for coding the level of contamination by solid particles ISO 8501-1, Preparation of steel substrates before application of paints and related products Visual assessment
19、of surface cleanliness Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings ISO 28521 1) , Ships and marine technology Hydraulic oil systems Guidance for grades of cleanliness and flushing 3 Terms and definitions F
20、or the purposes of this document, the following terms and definitions apply. 1) To be published. ISO 28520:2009(E) 2 ISO 2009 All rights reserved3.1 main engine ME prime mover used for propulsion of the vessel or to drive a ships generator 3.2 turbocharger TC centrifugal blower driven by exhaust-gas
21、 turbines and used to supercharge an engine 3.3 lubricating oil LO petroleum product designed to reduce friction and heat between moving parts in internal combustion engines 3.4 Reynolds number R edimensionless ratio of the internal flow forces to the viscous forces within a fluid NOTE An indicator
22、of the flow characteristics (laminar or turbulent) of a moving fluid. 4 Recommended degrees of pipe cleaning This clause specifies the recommended degrees of pipe cleaning during and after prefabrication for pipes or parts, possibly followed by inside surface treatment. To ensure the best possible c
23、onditions for flushing, individual prefabricated parts should be made and cleaned, before erection on-board. 4.1 Degrees of pipe cleaning during/after prefabrication Concerning prefabrication of pipes and parts, it is recommended that these are completely cleaned inside, which means that all welds a
24、ssociated with the welding of pipe sections and pipe branches should be smooth and free of slag, welding spatter, burns and porosities. Fillet welds on flanges should be smooth and finely grounded and should also be free of roundings as these can damage part of the joint faces. Concerning possible s
25、ubsequent chemical acid-cleaning or mechanical blast-cleaning, the degree of cleaning should correspond to Sa 2 1/2 as specified in ISO 8501-1. Steel sand should not be used for shot blasting, due to the risk of adhesion by magnetism or rusting; copper (Cu) slag should be used instead. Sealing surfa
26、ces are to be mechanically well protected during shot blasting. 4.2 Inside surface treatment In order to maintain the above-mentioned degree of cleaning before erection on-board, it is recommended that the inside of the pipes be treated with an appropriate oil product. Painting the inside with appro
27、priate paint is sometimes prescribed by various manufacturers, and any such requirements should be followed. 5 Cleaning of system components Shot blasting, grinding, painting and welding should not be executed in the near vicinity during cleaning operations on the items listed in 5.1 to 5.4. ISO 285
28、20:2009(E) ISO 2009 All rights reserved 3 5.1 Pumps, valves, filters, oil coolers, etc. System oil requirements shall be requested from suppliers of these auxiliaries. 5.2 Engine crankcase When engines (especially large engines) are delivered without cleaned and sealed lubricating oil systems, inclu
29、ding the crankcase, the crankcase shall be cleaned before flushing. This can be done as follows. a) Blank-offs are placed on each oil drain to the engine mainframe. Starting at the top of one cylinder block at a time, the inside of the crankcase is washed down with oil to remove rough particles. Dur
30、ing this task the engine crankshaft is turned at regular intervals so that chains, chain wheels, and the crankshaft are washed down and cleaned. b) A thin, non-drying oil, is recommended (about SAE 10 to 30 cSt), the remainder of which is compatible with the system oil, which can dissolve the rust-p
31、revention product which the engine has been coated with when delivered. System oil (SAE 30 90 cSt or SAE 40 175 cSt) may be employed instead, provided the oil is heated to 55 C to 60 C. In practice, 200 l to 400 l per cylinder have proven to be sufficient, with the same quantity used for camshaft dr
32、ive. When the camshaft drive is cleaned, the thrust bearing cover is removed, if possible, and the thrust bearing is washed down. Furthermore, the thrust-bearing ahead and astern thrust-pads are taken out for wiping if possible. Ensure that the flash point of the oil is not too low (danger of fire).
33、 Some rust prevention oils can influence the foam characteristic of the system oil; this occurrence can be limited in the following way. The work can be partly done from the outside of the crank and shaft casting through various inspection covers. After an appropriate amount of time, allowing for dr
34、ipping and draining, the dirty flush oil and deposited sediments shall be removed from the oil sump. The inside of the engine is then wiped with lint-free and non-frayed cloths, and an inspection is made before the actual flushing is commenced. 5.3 Gearbox If gears are delivered with no cleaned and
35、sealed lubrication oil systems, including pump and pipes, the gears shall be cleaned before flushing. 5.3.1 Sealed gearboxes For sealed gearboxes, external piping, filters and pumps, see 6.3.1. 5.3.2 Non-sealed gearboxes For non-sealed gearboxes (when assembling gearboxes, including external pump, p
36、iping, filters and coolers) see 6.3.2. 5.3.3 Choice of cleanliness level The most impurity-sensitive components in a gearbox are, typically, ball- and roller-bearings. Information concerning required bearing-cleanliness may be obtained from the bearing supplier, but shall in all cases be stated by t
37、he gearbox supplier. To a wide extent, the demand for life cycle and bearing load conditions shall guide the choice of cleanliness level. Bearing manufacturers have developed a bearing-lifetime theory, which among other items includes the influence of impurities on service lifetime based on system l
38、ubrication oil. Figures 1 and 2 show the relationship between size and hardness of impurities, how harmful they are to bearing life, and how important it is to focus on cleanliness. ISO 28520:2009(E) 4 ISO 2009 All rights reservedKey X grain hardness, expressed in Vickers hardness (HV) Y grain size,
39、 expressed in micrometres aHarmless. bHarmful. NOTE In the calculation of these results the following parameters are used: friction coefficient, , 0,1; oil film thickness 0,4 m; hardness of outer track and roller 800 HV. Figure 1 Attrition particles damaging effects with relation to their size and h
40、ardness ISO 28520:2009(E) ISO 2009 All rights reserved 5Key L 50bearing lifetime, expressed in million revolutions X absolute filter fineness, expressed in micrometres Figure 2 Bearing lifetime (L 50 ) as a function of filter fineness Table 1 indicates proposals for the degree of cleanliness for the
41、 various gear types. Gear type, in this context, is a specification that combines and includes such characteristics as speed, load variation and lifetime frequent start-stop. Table 1 Level of cleanliness for the various types of gear Level of cleanliness after approved flushing Level of cleanliness
42、after commissioning trial Max. allowable contamination during service Typical service oil filter Type of gear ISO 4406 ISO 4406 ISO 4406 x 75 1 16/14/11 17/15/12 18/16/13 3-5 m 2 17/15/12 18/16/13 19/17/14 5-10 m 3 18/16/13 19/17/14 20/18/15 5-10 m 4 21/19/16 22/20/17 23/21/19 20-50 m The classifica
43、tion of type of gear (number) is explained as follows. 1) Demand for long service life, high operational reliability, high gear load, rpm ( 3 000), frequent start-stop, such as on ferries with gas turbines on short crossings, and high loaded gear with multiple power take-off (PTO). ISO 28520:2009(E)
44、 6 ISO 2009 All rights reserved2) Medium loaded gear, rare demand for maximum load, gearing where secondary PTO is running idle, such as on big trawlers, gear on ferries where two main engines are coupled to a joint common gear box, integrated gear and controllable pitch propeller (CPP) control syst
45、ems. 3) Same as 2), but with separated gear and CPP control system separated with individual oil supplies. 4) Gear with low rpm/load and low service time. 5.3.4 Instruction manual The instruction manual shall contain requirements for and descriptions of programmed maintenance, which will ensure that
46、 the earlier-stated levels of cleanliness can be maintained. 5.4 Tanks The system tanks shall be internally cleaned for spatter and oxide scales, brushed, vacuum cleaned, and possibly coated according to special prescriptions. Internal tank-surfaces should be washed down before flushing, according t
47、o the same principles stated in 5.2. It is assumed that storage tanks are clean. 5.5 Special comments Pipe and components between the filter and bearings shall be cleaned meticulously for spatter, oxide scales, etc. and the components supplied by the manufacturers and sub-contractors shall be checke
48、d for cleanliness. This applies especially to oil coolers (see Figure 5), if they are placed between filters and the engine. During system filling with flush-oil from the storage tank, the system LO separator or filter shall be operable in order to obtain an initial flush-oil start-off cleanliness l
49、evel of ISO 19/17/14 or better (see ISO 4406). 6 Flushing The aim of the flushing process can be summed up as follows: 6.1 Flushing practice (2-stroke engine) Flushing is divided into a) the flushing of external piping systems (mainly shipyard fabricated piping), and b) the flushing of internal surfaces and piping (mainly engine builder fabricated piping). 6.1.1 First flushing sequence 6.1.1.1 General The first flushing sequence concerns, in principle, all system piping fabricated at the shipyard
