Pressure Test - Flushing - Pickling - Passivation Hyd-Cw-Gr

Download as pdf or txt
Download as pdf or txt
You are on page 1of 12

PROCEDURE PRESSURE Document n.

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 1 of 12

6.4 PRESSURE TEST - FLUSHING - PICKLING - PASSIVATION

6.5.1 General
The order how to make these operations it will be as follow:
• Initial flushing just to remove the bigger parts from the system
• Pressure test during this operation possible leakage can be discovered and must
be removed (reweld some parts or opening flange to change gasket,
etc.)
• Flushing to remove all dirty, scale, chippings, etc.
• Pickling where required (according to the kind of fluid)
• Passivation where required (according to the kind of fluid)
Circuit preparation
The circuit where the activities are performed is modified compared to the intended circuit design in
order to concentrate the activities on individual circuit parts.
The changes are made through the application of tubular pipe connection constructed ad hoc or
hoses in order to bypass the machines and then directly connect the delivery and return piping.
During the above operation all sensible equipments / instruments (orifice plates, flow meter
elements, control valves and safety valves, etc.) shall be removed and replaced with mock-ups
(plugs) or by pass until the end of these operations.
On the contrary, if the equipments / instruments are provided with insulating valves, it will be
enough to shut-off those manual valves upstream and downstream the equipments / instruments in
order to avoid any damages to the equipments / instruments themselves.
A list shall be prepared and be part of the flush & test procedure.
This procedure specifies the method of cleaning and passivation of internal surface of carbon steel
piping based on use of chemical components to be added in water, prior to taking in service for the
first time after installation / fabrication.
Certain equipment and piping must be chemically cleaned to remove mill scale, dirt, greases used
as rust preventatives, and other foreign materials that could result in operating and maintenance
problems, excessive wear and damage to reciprocating of equipments and corrosion due to the
reaction of scale with the process environment.
Chemical cleaning will generally be done after completion of unit construction. If connection is
flanged the cleaning is done prior to completion of construction and the cleaned equipment must
be protected from atmospheric exposure and entry of any outside debris or dirt otherwise the
cleaning shall be done after completion of unit construction.

6.5.2 Pressure test


The purpose of field testing is to reveal the occurrence of faults in the laying procedure, for
example, joints incorrectly installed, or pipes damaged and general in order to be sure of integrity
of pipelines and must be done before commissioning.
The procedures for each type of system or method are described Danieli standard STD 2.8.102
"NDT" LEAK TESTING "LT.
The max pressure test is definite in “Lines list” document.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 2 of 12

6.5.3 Flushing
All pipes before commissioning must be flushed. There are many flushing methods. Below we
report the most common that can be easily applied on site:

6.5.3.1 Air Blow


This method shall be used to clean and verify cleanliness of small bore pipe for compressed air
(including instrument air) where video inspection is impossible or inadequate due to pipe
dimension or configuration (less than 1 inch).
Blow pipe with clean and dry compressed air. Use sufficient volume of air to create a high velocity
stream in the pipe. If air is supplied from compressors, they shall be equipped with moisture
separators, oil separators, traps, and/or filters, as required to ensure that the air is clean and dry.
During air blowing all section shall be properly hammering air in order to eliminate scales, rust,
dust, and foreign materials inside of pipes.

6.5.3.2 Pressurized air shock blowing


This method shall be used to clean pipes for compressed air (including instrument air) with a
diameter between 1 "and 2.1 / 2".
The pressure fluctuations will create a high velocity stream in the pipe so it will be necessary to
open quickly the valves and close again when pressure drop down to create turbulences inside
pipe.
Valves shall be installed at end of each line to make flushing.
The air shocking pressure shall never exceed the working pressure of the system and shall never
be more than 8 bar. Safety precaution shall be taken when this method is used.
This method may also be used when there are problems removing trapped liquid in the circuit.
During air blowing all section shall be properly hammering air in order to eliminate scales, rust,
dust, and foreign materials inside of pipes.

6.5.3.3 Water Flush


This method shall be used to clean pipes for water lines, which shall be flushed using fresh water
having chloride content less than 50 ppm for the final flush. (Note: domestic water generally
contains less than 2 ppm chlorides).
Water shall be generally pumped using the installed pumping stations protected by the existing
suction strainers, or temporary (movable) station even protected by suction strainers. Water lines,
which are not directly connected to pumping systems, shall be temporarily connected to other
installed water pumping systems or to movable pumping units.
The water tanks shall be carefully cleaned from any foreign matter before and after flushing
activities.
Since effectiveness of cleaning is proportional to the quantity of circulated water, then during
flushing all available pumps shall be kept in operation.
After flushing and before cleaning, all by passes, temporary strainers and any other provision used
for flushing purposes shall be removed.
As a general rule, flushing must be carried out immediately prior to commissioning activities. It is
important to avoid both to maintain standstill water in pipelines and to drain it out, leaving humidity
inside.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 3 of 12

The water used for flushing shall therefore be drained and just replaced by the water of the quality
specified by the cleaning (pickling) & passivation process, and the lime must then be
commissioned.
In case of water seal, these shall be inspected and if necessary cleaned before to put water inside.

6.5.3.4 Requirements
• Fresh water for filling and flushing for circuits should be done until water qualities within the
acceptable limits.
• Manpower to:
- Remove all manometers on pumping station and main line
- Remove flow transmitter on pipe lines
- Remove basket filters
- Isolate the automatic make up valves installed on the main headers: close the interception
valves and open the by-pass valves.
• Install all necessary temporarily loops and bypass piping for flushing / draining.
• Install blinds and suitably sized drain where necessary especially at the lowest part.
• Checklist to facilitate valve line-ups as required for each major flush path.

General for flushing the following shall be excluded or removed from the circuits by closing the
valve:
• All manometers on pumping station and main line
• Flow transmitter on pipe lines (only if orifices are used)
• Basket filters: remove the baskets.
• Automatic make up valves installed on the main headers: close the interception valves and
open the by-pass valves.

Objective
• To reduce the interference caused by dirt, grit and sand (debris) in the subsequent process of
removal of foul and mill scale.
• To limit the demand of cleaning chemicals this would otherwise be lost through adsorption on
the fouling deposits and other contaminants.
• To curtail the time required to achieve desired water quality at the end of the pre-cleaning
process, i.e. oil, grease and mill scale removal.

CW/CWR - QW/QWR – KW/KWR

Product Dosage ppm Duration Control Frequency of Analysis


− Turbidity (TSS)**
N/A N/A Variable* Every 2 Hrs.
− T. Iron **
* The duration is variable as it is related to the results of the analyzes
** As per technical specification
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 4 of 12

6.6 OPEN CIRCUIT (CW / CWR)


6.6.1 Pickling
Once water quality has been achieved in terms of turbidity at the end of flashing, all bleed of points
will be shut, and Stage II of the pre-cleaning process will be commenced. The next stages consist
of process as mentioned below.

6.6.2 Requirements
• All Necessary Chemicals
• Forklift for shifting the chemicals
• Manpower for shifting, handling and adding of chemicals.
• Ensure that adequate supply of good make up water is available during the cleaning
passivation period.
• Pit / tank where to discharge the cleaning solution should be ready to accept the cleaning
solution once the Iron level has been stabilized

6.6.3 Procedure
Stage 1
The cleaning process mentioned will be carried out merely adding the recommended level dosage
of Hydrex – 5208 cleaning chemicals based on Organic acid, with dispersant and re-circulated
the water minimum period of 24 hours. This period may be extended depends on the stabilization
of total iron level in the re-circulating water. During this cleaning the pH, turbidity, total iron cleaner
residual will be monitored at intervals of every hour.
Note: The stabilization of the iron level in the re-circulating water will be the indication of
completion of the cleaning process and will be the basis for the cutoff point.
Product Dosage ppm /Qty. Duration Control Frequency of Analysis
- pH, Every 1 Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- Treatment Reserve
200 ppm min

Provision of 2 days is being made for the Stage II cleaning process, however the cut off point for
this process is the stabilization of iron level in the re-circulating water.
Stage 2
Once the iron level has been stabilized in the in the re-circulating water its indication of completion
for the cleaning process stage 1, the system will start “balanced bleed (water is drained, ideally
from the lowest point in the system and simultaneously refilled by the make water while
recirculation continuous to be maintained) until the iron level reached at the point of less than 2.0
ppm while the pH at ideal level.
Then the system is ready to be drained completely and arrange to commence mechanical cleaning
for CW cooling water basin, clean all the strainers and open the loose leg areas for mechanical
cleaning as well. After the mechanical cleaning has been completed it is required to fill the system
immediately by good quality of make-up water for the preparation of passivation stage.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 5 of 12

Remarks:
All the by-pass line for the on line equipments and instrument can be removed, put in on line and
adjusts the water level as required.

Objective
The objective of the flushing process (Stage 2) is to flush the system off the Material/deposits
dislodged during the cleaning process (Stage II) and prepare the surface to receive the passivated
film in the subsequent process of passivation.

6.6.4 Passivation
Stage 3
Once water quality has been achieved in terms of turbidity at the end of stage 1, all bleed of points
will be shut and Stage II of the pre-cleaning process will be commenced. The next stage consist of
process as mentioned below
Product Dosage ppm Qty. (Kg) Duration Control Frequency of Analysis
2 - 5 days* - pH, Every Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- - -

Procedure:
In order to control the proliferation of bacteria in the re-circulating water and prevent it from
interfering with the passivation proves, a non-oxidizing biocide will be added based on the system
volume at the start up to the passivation process.
The pH, turbidity, iron and treatment reserve will be monitored during this stage to determine the
progress of the passivation process.

Notes:
• Passivation level of corrosion inhibitor will be maintained in the system until the treatment
reserve stabilizes. Any drop in the treatment reserve will be made up by fresh addition of
corrosion inhibitor.
• Most of the passivation is achieved in the first 3 – 4 hours after addition of the corrosion
inhibitor. However, in order to ensure the integrity and uniformity of the protective film
passivation level of the corrosion inhibitor will be maintained for the subsequent 2 - 5 days.
• There will be no deliberate discharge of the water from the system during and after this
passivation stage.
• Once the passivation is complete, lower treatment reserves as per the normal operation will be
maintained by allowing the treatment reserve to fall gradually. (This is not a necessity and will
be dictated by the system requirement of fresh make up water).
• It is ideal to maintain the circulation after passivation process is complete to ensure availability
of adequate level of corrosion inhibitor to maintain the uniformity and integrity of the
passivation film.
• There should be no interruption of the treatment programmed after completion of this stage in
order to maintain the passivation film layer.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 6 of 12

The objective of the passivation process is to promote the rapid formation of the protective and
passivation film on the metal surface.

6.6.5 Initial Filling of Normal Treatment


Stage 4
At the end of passivation process (Stage 3) the system will allow to meet the normal water
parameters by means of balance flushing and add the corrosion inhibitor and biocide as per the
dosage rate and maintain the system under circulation with desired control limits and monitoring.

6.7 CLOSED CIRCUIT (QW / QWR)


6.1.1 Pickling
Once water quality has been achieved in terms of turbidity at the end of flushing, all bleed of points
will be shut and Stage II of the pre-cleaning process will be commenced. The next stages consist
of process as mentioned below.

6.1.2 Requirements
• All Necessary Chemicals
• Forklift for shifting the chemicals
• Manpower for shifting, handling and adding of chemicals.
• Ensure that adequate supply of good make up water is available during the cleaning
passivation period.
• Pit /tank where to discharge the cleaning solution should be ready to accept the cleaning
solution once the Iron level has been stabilized

6.1.3 Procedure
Stage 1
The cleaning process mentioned will be carried out merely adding the recommended level dosage
of Hydrex – 5208 cleaning chemicals based on Organic acid, with dispersant and re-circulated
the water minimum period of 24 hours. This period may be extended depends on the stabilization
of total iron level in the re-circulating water. During this cleaning the pH, turbidity, total iron cleaner
residual will be monitored at intervals of every hour.
Note: The stabilization of the iron level in the re-circulating water will be the indication of
completion of the cleaning process and will be the basis for the cutoff point.
Dosage ppm
Product Duration Control Frequency of Analysis
/Qty.
- pH, Every 1 Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- Treatment
Reserve 200 ppm
min

Provision of 2 days is being made for the Stage II cleaning process, however the cut off point for
this process is the stabilization of iron level in the re-circulating water.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 7 of 12

Objective
The objective of this process is to render the metal surface free of scale, foulants and other
deposits and thus the rapid formation of the uniform passivating film of corrosion inhibitor in the
subsequent process of passivation.
Stage 2
Once the iron level has been stabilized in the re-circulating water its indication of completion for the
cleaning process stage III, the system will start “balanced bleed until the iron level reached at the
point of less than 1.0 ppm and the pH at ideal level prior to drain closed loop (QW) tank and
commence mechanical cleaning accordingly and refill immediately for preparation of the
next stage.
Remarks:
All the by-pass line for the on line equipments and instrument can be removed, put in on line and
adjusts the water level as required.

Objective
The objective of the flushing process (Stage 2) is to flush the system off the material/deposits
disludged during the cleaning process (Stage 1) and prepare the surface to receive the passivating
film in the subsequent process of passivation.

6.1.4 Passivation
Stage 3
Once water quality has been achieved in terms of the iron Level at least < 1.0ppm passivation is
ready to add as per the dosage rate of 5000 ppm of Hydrex - 2510. Then after an hour circulation
Hydrex – 7310 at dosage rate of 100ppm should be added.
Product Dosage ppm Qty. (Kg) Duration Control Frequency of Analysis
2 - 5 days - pH, Every Hr.
- Turbidity (FTU),
- TSS,
- Total Iron
- - -

Procedure:
In order to control the proliferation of bacteria in closed re-circulating water and prevent it from
interfering with the passivation proves, a non-oxidising biocide will be added based on the system
volume at the start up to the passivation process.

The pH, turbidity, iron and treatment reserve will be monitored during this stage to
determine the progress of the passivation process.

Objective:
The objective of the passivation process is to promote the rapid formation of the protective and
passivation film on the metal surface.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 8 of 12

6.1.5 Initial Filling of Normal Treatment


Stage 4
At the end of passivation process (Stage IV) the system will allow to meet the normal water
parameters by means of balance flushing and add the corrosion inhibitor and biocide as per the
dosage rate and maintain the system under circulation with desired control limits and monitoring.

6.8 PICKLING – FLUSHING – PRESSURE TEST (HYDRAULIC AND GREASE)


6.8.1 General note
In case of discrepancies, Danieli General Specification GS-H-01; GS-H-02; GS-P-01 will prevail.

6.8.2 Pipe pickling in tanks


Generally speaking, pickling will be carried out according to the following operating cycle:
1. mechanically clean the pipes (with brushes, compressed air, wooden mallets, etc...) to
eliminate any foreign matter or considerable scaling
2. clean by immersion in tanks containing strongly alkaline or similar solution suitable to
removing grease, oil from the pipes surface
3. wash under running water
4. protect the threadings or other parts in order not to be attacked by the pickling bath with
grease or other acid-resistant means
5. pickle by immersion in tanks containing acid solution
6. the duration of these operation will depend on the solution concentration and on the
cleanliness of the surfaces, which must be free of scales, calamine and oxide
7. during pickling, frequently move the prefabricated sections and fittings to assist the acid
action on the surfaces and to remove any gas bubbles which could prevent the solution
from coming into complete contact with the metal
8. the neutralization treatment shall be carried out with a proper alkaline or similar solution.
This treatment requires particular care because any acid solution residue would continue
their corrosive action
9. the passivation treatment shall be carried out with a proper passivation solution. This
treatment prevents rust formation after neutralization
10. apply the spray protection, suited to the flushing fluid, on the inner surfaces of the pipings.
This type of spray protection prevent internal rust protection and it is soluble in the flushing
fluid
11. seal the pipes ends with suitable visible (not transparent) plugs.

6.8.3 Pipe pickling on site


Generally speaking, pickling will be carried out according to the following operating cycle:
1. prepare the circuit so as to link the delivery lines to the return ones, by-passing all the
equipment, valves and users.
2. disassemble those pipe parts which cannot be included in the pickling closed circuit for
specific system reasons. These disassembled pipes shall be connected together in
separate, provisional circuits.
3. pickle with chemical solutions circulating in the pipes by means of a special central unit in
compliance with the following operating cycle:
- degreasing with an alkaline or similar solution;
- washing with running water;
- pickling with an acid solution;
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 9 of 12

- neutralization with an alkaline solution;


- washing with running water;
- neutralization and passivation;
IMPORTANT: if after the pickling last phase and after emptying the circuit the system is not ready
for flushing, pressurize the inner part of the pipes with inert gas (e.g. Nitrogen, Helium), in order to
avoid any corrosive action on the system.
The maximum time between Pickling and Flushing to avoid the system pressurization with inert
gas is 3 hours.
6.8.4 Chemical products to be used for pipes pickling operations
There are many methods to perform the pickling operation; the simplest method recommended is,
however, to use ready products, such as BETONA or RIDEC 154.
These products do not require any preparation or particular knowledge for their use, as they offer
the advantage of performing the pickling in a single operation.
If these products are not available, it is recommended to have the pipes pickled by a specialized
company, anyway taking care that, after the inhibited acid solution, passivation must be duly
performed; the following products (or similar) to perform the pickling and neutralization/passivation
of pipes are suggested:
• P3RST at 50°C for degreasing
• Lutensol-ON79-BASF (chemically pure) 5  7 % for degreasing
• HCl (5  7 % at 20  40 °C) for pickling;
• HF (2 % at 20  40 °C) for pickling;
• H2SO4 (15  18 % at 45  50 °C) for pickling;
• C6H8O7 (0.3  0.4 %) for pickling;
• (NH4)HF2 (1 %) for pickling;
• (CH2)6N4 (3%) for pickling;
• NaOH (55 kg/m3) for neutralization
• NH3OH (0.9 %) for passivation
• NaNO2 (0.3  0.4 %) for passivation
The product concentrations depend however on the proposed method.

6.8.5 Flushing circuit


After study of actual system to be flushed, the Contractor has to supply a marked copy of the
system schematic, showing where connections for flushing equipment will be installed.
Also to be shown on this drawing is information on how the system is to be interconnected to form
a continuous loop. Prefabricated loops must be pre-cleaned.
All potential trouble spots where dirt may accumulate are to be identified for special attention.
All valves, manifolds, cylinders, system pumps and system reservoir must be bypassed during
flushing and capped to prevent entry of dirt.
The design of the flushing circuit must include provision for reversal of flow.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 10 of 12

Contractor must supply a flushing pump; system pumps are not to be used. Pump flow must be
high enough to create turbulent flow in every part of circuit during the cleaning phase. This level is
to be determined by the following formula, assuming Reynolds Number (Re) to be greater than
10.000 (minimum fluid velocity, 4,5 m/sec):
Q
where: Re= ( v) 21·300
Q = flow (lpm) D
d = pipe ID (mm)
ν = kinematics viscosity of the fluid (cSt)

The pump will most likely not be able to maintain the turbulent flow during the fluid flush phase.
Flow can be maximized by circuit isolation during this phase.
Sampling ports must be provided to permit samples to be taken ahead of filters when flushing in
either direction (fluid sampling containers according to ISO 3722).
Because of danger and flaking, no rubber hoses are to be used for bypass during flushing.
Where flushing all piping in series is not practical because of pressure drop, temporary manifolds
may be installed with isolation valves to form parallel circuits. However, the turbulent flow velocity
discussed in item 5, above, must be maintained.
Filters must be provided with means to detect “dirty” conditions; these filters must not have bypass
valves inside them.
Isolation valves must be provided so that filters can be changed without disturbing flow.
To facilitate the choice of the flushing pumps to use, we list the capacity referring to the various
internal diameters of pipes assuming the Re > 10.000, fluid velocity > 4,5 m/sec and fluid viscosity
= 30 cSt.

Pipe ID Viscosit Density Minimum Fluid Pressure drop Fluid velocity


Re
(mm) y (cSt) (kg/m³) flow (lpm) (bar/m) (m/sec)
10 30 900 150 10.615 16,16 31,85
15 30 900 220 10.379 4,60 20,76
20 30 900 300 10.615 2,02 15,92
25 30 900 360 10.190 0,96 12,23
30 30 900 450 10.615 0,60 10,62
40 30 900 580 10.261 0,24 7,70
50 30 900 750 10.615 0,13 6,37
65 30 900 950 10.342 0,06 4,77
80 30 900 1.400 12.384 0.04 4,64
100 30 900 2.200 15.568 0,03 4,67
125 30 900 3.500 110.814 0,02 4,76
150 30 900 5.000 23.588 0,02 4,72

6.8.6 Flushing activities


A flushing program is generally more effective if starts with clean piping components.
We stress the necessity, therefore, to use only “cold-draw pipes” without any internal slang and
free from rust, preferably with a high degree of internal cleanness. The flushing fluid capacity to
remove particles from the internal surfaces of piping is in proportion to the quantity of energy
available as a result of the fluid-pipe surface friction.
During flushing, every welded joint must be hammered with a ball peen hammer for 30 sec. during
each phase of the schedule, including reverse flow. Hammer in the direction of flow.
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 11 of 12

Though vibrators may be used on low spots where dirt tends to accumulate, hammering is
preferred. In addition, starting and stopping flow by sudden opening and closing of valves is a good
assist.
Reverse flow is required during pickling, passivation and flushing phases, when the hammering is
to be repeated in direction of flow.
The particles removed by the flushing should be caught with a filter with a high “β ratio”. We
consider fundamental that filters of major companies makers are employed and also we do not
recommend the use of low finesse filters followed by high finesse filters, as this is not economically
convenient.
During flushing, contractor is to inspect lines frequently and to stop flushing immediately if a leak
occurs. Flushing fluid must be kept out of customer’s sewers.
After system has been drained of all fluids, system is to be purged whit dry nitrogen.

6.8.7 System tank cleaning


Access cover is removed, and the inside is swabbed with lint-free cloth.
If reservoir is large enough for a person to enter, contractor’s worker must wear clean white paper
coveralls and white paper boots for manual wiping of inside with lint-free cloth. Safety precautions
for entering closed space must be observed.
Access cover and gasket are to be reinstalled and checked later for leaks.

6.8.8 Final approval


Final samples, to be sent to an outside lab, must be analysed according to ISO 3938. Report must
be in ISO 4406 code format (expanding the code to three ranges correlating to 2μm, 5μm and
15μm).
Minimum three samples for each loop circuit may be taken at any time after flushing begins with
system fluid and after welded connections have been hammered during this part of the schedule. If
clean enough, sample may be drawn for transport to outside lab. This sample is to be drawn by
DANIELI Centro Combustion personnel. Short time-turnaround is a must.
While test results are awaited, flushing is to continue. If sample turnaround is longer than 4 hrs
DANIELI Centro Combustion may waive testing by outside lab and agree to use of field test kit or
field portable contaminated monitor and related reports (min. three reports for each loop circuit).
If sample results are within specifications (see item 5, below), flushing may stop and system can
be drained. The Contractor will dispose of this contaminated fluid.
The target cleanliness level for systems must be:
CONTAMINATION LEVEL- FILTER ABSOLUTE
TYPE OF SYSTEM ISO 4406-(TARGET) FINENESS SUGGESTED
2μm-5μm-15μm (βx ≥ 100)
Hydraulic systems with servo-valves 13/11/9 1÷2
Hydraulic systems without servo-valves 15/13/11 3÷5
Lubrication for oil film bearings 18/16/14 5÷10

CONTAMINATION LEVEL- FILTER ABSOLUTE


TYPE OF SYSTEM ISO 4406-(TARGED) FINENESS SUGGESTED
2μm-5μm-15μm (βx ≥ 100)
Conventional lubrication systems 21/19/16 10÷15
Air-oil lubrication systems 15/13/11 3÷5
Centralized grease lubrication systems 18/16/14 5÷10
PROCEDURE PRESSURE Document n.:

DANIELI Centro Combustion S.p.A. TEST – FLUSHING – xxxx


PICKLING - PASSIVATION Page 12 of 12

6.8.9 System filling with final fluid


After flushing is completed, all system components are to be reconnected after contractor’s
equipment has been removed.
In the case of flushing in which is used the same working fluid, this must be checked by the fluid
Manufacturer before the filling on the following characteristics: viscosity, acidity (T.A.N./S.A.N.) and
water content. In case of these values are not into the range of new product, the Contractor must
recondition or change the fluid.
Before proceeding to fill-up the system, make sure that the fluid corresponds exactly to the
requirements of the design.
All fluids on the market, with no exception, even the new ones and those contained in sealed
container, are not perfectly clean. They should, therefore, be filtered.
Filling must always be done through the appropriated external filter which has a better degree of
absolute filtration as the ones mounted on the system.
Be extremely careful of any accidental introduction of pollutants, dust, rags and various objects.
Test perfect sealing and perfect functionality of the air filters mounted on the vents which permit
the intake and emission of air as the level of the fluid rises and drops in the tank.
Never mix fluids of different types or makes.

6.8.10 Pressure test and final cleanliness control


The hydraulic seal test will have to be carried out at a pulsating pressure 1.2/1.5 times more than
the operating pressure for at least one hour whit the installed equipment in order to check the
proper circuit connections and valves sealing.
Each cylinder should be cycled at least five times, and all hydraulic motors operated for five min.
Fluid samples should then be analysed to assure that no dirt was introduced during the
reconnection process. On the contrary, flushing activities must be repeated under Contractor’s cost
and responsibility. For test procedure see STD 2.8.102

You might also like