1、Designation: D 6439 05An American National StandardStandard Guide forCleaning, Flushing, and Purification of Steam, Gas, andHydroelectric Turbine Lubrication Systems1This standard is issued under the fixed designation D 6439; the number immediately following the designation indicates the year oforig
2、inal adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.INTRODUCTIONOptimum turbine system reliability requires a well designed lu
3、bricating system 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 specification
4、s and that corrective 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 af
5、ter manufacturing 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 prio
6、r to startup. 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 a
7、re generated or ingressedduring 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 re
8、furbishing of 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, inst
9、aller, and turbine 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
10、 practices, and 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
11、and small lubri-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
12、.5 This standard 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.2. Referenced Documents2.1
13、ASTM Standards:2D 445 Test Method for Kinematic Viscosity of Transparentand Opaque Liquids (the Calculation of Dynamic Viscos-ity)D 664 Test Method forAcid Number of Petroleum Productsby Potentiometric Titration1This guide is under the jurisdiction of ASTM Committee D02 on PetroleumProducts and Lubr
14、icants and is the direct responsibility of Subcommittee D02.0C.01on Turbine Oil Monitoring, Problems, and Systems.Current edition approved April 1, 2005. Published April 2005. Originallyapproved in 1999. Last previous edition approved in 1999 as D 6439 99.2For referenced ASTM standards, visit the AS
15、TM 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 of this standard.Copyright ASTM International, 100 Barr
16、 Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.D 974 Test Method for Acid and Base Number by Color-Indicator TitrationD 2272 Test Method for Oxidation Stability of Steam Tur-bine Oils by Rotating Pressure VesselD 4241 Practice for Design of Gas Turbine Generator Lu-brica
17、ting Oil SystemsD 4248 Practice for Design of Steam Turbine Generator OilSystemsD 4378 Practice for In-Service Monitoring of Mineral Tur-bine Oils for Steam and Gas TurbinesD 4898 Test Method for Insoluble Contamination of Hy-draulic Fluid by Gravimetric AnalysisD 6304 Test Method for Determination
18、of Water in Petro-leum Products, Lubricating Oils, and Additives by Coulo-metric Karl Fisher TitrationD 6810 Test Method for Measurement of Hindered Phe-nolic Antioxidant Content in HL Turbine Oils by LinearSweep VoltammetryD 6971 Test Method for Measurement of Hindered Phe-nolic and Aromatic Amine
19、Antioxidant Content in Non-Zinc Turbine Oils by Linear Sweep VoltammetryF311 Practice for ProcessingAerospace Liquid Samples forParticulate Contamination Analysis Using Membrane Fil-tersF 312 Test Methods for Microscopical Sizing and CountingParticles from Aerospace Fluids on Membrane Filters2.2 ISO
20、 Standards:3ISO 3722 Hydraulic Fluid PowerFluid SampleContainersQualifying and Controlling 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 Cont
21、amination by Solid ParticlesISO 4572 Hydraulic Fluid PowerFiltersMulti-passMethod for Evaluating Filtration Performance2.3 API Standard:4API 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
22、 adsorption, nthe removal of contaminants from oilby adhesion 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 centrifugation, nthe use of centrifugal force toseparate contaminants from oils. Contaminants su
23、ch as waterand particulate are generally more dense than the oil andmigrate to the outside of the centrifuge because of centrifugalforce.3.1.3 cleaning, nthe direct removal of contaminant fromany part of the system, generally with the system shut down.Cleaning can include removal of contaminant by s
24、hoveling,sweeping, wiping, or displacing with clean, dry compressed air.3.1.4 coalescence, nthe process of passing oil with freewater through a fiber sheet, generally in a cartridge form, tocause smaller drops of water to join to form larger ones that canbe more easily removed from the oil.3.1.5 coa
25、lescer, na device that uses coalescence to sepa-rate water from oil. A coalescer generally consists of acoalescing cartridge(s) and a hydrophobic barrier that hinderswater from passing out with the oil. It may also contain a filterlocated upstream or downstream, or both, of the coalescingcartridge(s
26、).3.1.6 filter, na device containing a screen or fiber depthmedium that removes particles from oil by physically trappingthem in or on the screen or mesh.3.1.7 flushing, ncirculation of liquid through the lubrica-tion system or a component, when the turbine is not operating,to remove contaminant.3.1
27、.8 oxidation, na chemical 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.3.1.9 pure oil, nhomogeneous lubricating oil contai
28、ningstable additives and free of soluble or insoluble contaminantsof concentrations that exceed the lubrication system specifica-tions.3.1.10 purification, vremoval of a contaminant present inthe oil through a separation process.4. Significance and Use4.1 This guide is intended to aid the equipment
29、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.4.3 Clean lubrication systems result from
30、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. Theinstallation, cleaning, and flushing of the equipment
31、 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 guidelines for discussion with prospectivecontract
32、ors.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 suspended)contaminants. A more detailed disc
33、ussion of these types ofcontaminants is given in Appendix X1.5.2 Contamination control is the complete program ofobtaining and maintaining a clean lubricant and lubrication3Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036.4Available from Ameri
34、can Petroleum Institute, 1220 L St. NW, Washington, DC20005-8197.D6439052system. This includes proper construction and maintenancepractices, appropriate purification equipment, and regularmonitoring of contaminants. The contamination control pro-gram must be capable of identifying and measuring cont
35、ami-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 their manufa
36、cturersspecifications. 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 potential for sl
37、udge andvarnish creation as a normal consequence of oxidation reac-tions.5.3 Contamination control considerations must begin withsystem design and continue through the manufacture, installa-tion, flushing, operation, and maintenance of the system.5.4 Design of the system must consider component con-
38、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 PracticesD 4248
39、 and D 4241 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 is di
40、scussed 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 maintenance
41、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 Install
42、ing 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 parties.6.1.2 Examples of Essential Precautions
43、 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 properlycleaned and preserved.6.1.2.3 All possible locations for the entrance of dirt (pipeends) must be durably covered and secured for storage pr
44、ior 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, especia
45、lly if the storage is to be for a long duration.6.1.2.6 Inspection immediately prior to installation must bethorough, and the pipe must be cleaned if excessive rust or dirtis discovered.6.1.2.7 Continuous monitoring of conditions during thecomplete turbine installation must take place to ensure that
46、cleanliness related tasks are being accomplished. Dirt shouldnot be introduced into the pipes and equipment.6.1.2.8 Great care must be taken to prevent contaminantentry during any modifications.6.1.2.9 The work area must be kept clean.6.1.2.10 This list is not complete, but it does illustrate thatth
47、e manufacturer, the shipper, the operator, and the installationcontractor are all responsible for ensuring that no contaminantsenter the lubrication system. These efforts to prevent theentrance of dirt will make the flushing procedure easier, safer,and shorter, and thus less costly.6.2 On-Site Conta
48、mination Control:6.2.1 General:6.2.1.1 All components that are fabricated and assembled ata manufacturers facility and received as a unit for installationin the system are defined as preassembled components.6.2.1.2 The preassembled components should be inspectedupon receipt to determine condition an
49、d degree of protection.All seals and caps intended to exclude moisture and dirt shouldbe checked for integrity and replaced as required. If the initialor a subsequent inspection discloses dirt or rusting, the itemshould be immediately cleaned, represerved, and sealed, asrequired. Because of the variety of equipment and materials,details for each case cannot be given here. For painted (coated)components, the coating should be inspected for integrity andrenewed as necessary. All components should be checked toensure that all tape and temporary supports or restraints
