ASTM D6439-11(2017)
(Guide)Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication Systems
Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and Hydroelectric Turbine Lubrication Systems
SIGNIFICANCE AND USE
4.1 This guide is intended to aid the equipment manufacturer, installer, and turbine operator in coordinating their efforts to obtain and maintain clean lubrication and control systems.
4.2 The flushing and cleaning philosophies stated in this guide are applicable to both large and small lubrication systems.
4.3 Clean lubrication systems result from proper system design and good planning, execution, and communication by all involved during commissioning. No phase of these procedures should be undertaken without a thorough understanding of the possible effects of improper system preparation. The installation, cleaning, and flushing of the equipment should not be entrusted to persons lacking in experience.
4.4 Because of the knowledge and specialized equipment that is required, the operator may wish to employ an outside specialist contractor for the system flushing. Review of this guide can provide guidelines for discussion with prospective contractors.
SCOPE
1.1 This guide covers types of contaminants, oil purification devices, contamination monitoring, contamination control during building or refurbishing of turbine systems, lubrication system flushing, and maintenance of pure lubrication oil.
1.2 To obtain maximum operating life and reliability, or lubricants and system, it is vital that the turbine lubrication system has pure oil. This guide is intended to aid the equipment manufacturer, installer, and turbine operator in coordinating their efforts to obtain and maintain clean lubrication and control systems. These systems may be on land or marine turbine generators and propulsion and mechanical drive equipment. This guide is generalized due to variations in the type of equipment, builder's practices, and operating conditions.
1.3 This guide primarily addresses petroleum based lubricating oil. For systems using nonpetroleum based fluids, this guide may not be appropriate. For nonpetroleum products, consult the equipment and fluid manufacturers.
1.4 This guide is applicable to both large and small lubrication systems. Some equipment specified herein, however, may not be appropriate for all systems. Moreover, in situations where specific guidelines and procedures are provided by the equipment manufacturer, such procedures should take precedence over the recommendations of this guide.
1.5 This standard does not purport to address the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
General Information
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Designation: D6439 − 11 (Reapproved 2017)
Standard Guide for
Cleaning, Flushing, and Purification of Steam, Gas, and
Hydroelectric Turbine Lubrication Systems
This standard is issued under the fixed designation D6439; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
Optimum turbine system reliability requires a well designed lubricating system and use of a good
lubricant that is free of contaminants. Achieving this requires use of proper purification methods to
ensure that the oil is free of detrimental contaminants. In addition, it requires an ongoing monitoring
program to ensure that the oil quality is within specifications and that corrective action is taken to
minimize contaminant generation and ingression. The benefits of purification of an operating
lubrication system can be significantly reduced if the lubricating systems are not initially cleaned to
a level that will prevent component damage on initial start up after 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 these
processes, it is necessary to flush and purify the system to remove them prior to startup. Ongoing
purification is required to maintain pure oil during operation. In new systems, the emphasis is on the
removal of contaminants introduced during manufacture, storage, field fabrication, and installation. In
operational systems, the emphasis is on the removal of contaminants that are generated or carried in
during operation, and by malfunctions that occur during operation or contaminants that are introduced
during overhaul, or both.
1. Scope 1.4 This guide is applicable to both large and small lubri-
cation systems. Some equipment specified herein, however,
1.1 This guide covers types of contaminants, oil purification
may not be appropriate for all systems. Moreover, in situations
devices, contamination monitoring, contamination control dur-
where specific guidelines and procedures are provided by the
ing building or refurbishing of turbine systems, lubrication
equipment manufacturer, such procedures should take prece-
system flushing, and maintenance of pure lubrication oil.
dence over the recommendations of this guide.
1.2 To obtain maximum operating life and reliability, or
1.5 This standard does not purport to address the safety
lubricants and system, it is vital that the turbine lubrication
concerns, if any, associated with its use. It is the responsibility
system has pure oil. This guide is intended to aid the equipment
of the user of this standard to establish appropriate safety and
manufacturer, installer, and turbine operator in coordinating
health practices and determine the applicability of regulatory
their efforts to obtain and maintain clean lubrication and
limitations prior to use.
control systems. These systems may be on land or marine
1.6 This international standard was developed in accor-
turbine generators and propulsion and mechanical drive equip-
dance with internationally recognized principles on standard-
ment. This guide is generalized due to variations in the type of
ization established in the Decision on Principles for the
equipment, builder’s practices, and operating conditions.
Development of International Standards, Guides and Recom-
1.3 This guide primarily addresses petroleum based lubri-
mendations issued by the World Trade Organization Technical
cating oil. For systems using nonpetroleum based fluids, this
Barriers to Trade (TBT) Committee.
guide may not be appropriate. For nonpetroleum products,
2. Referenced Documents
consult the equipment and fluid manufacturers.
2.1 ASTM Standards:
This guide is under the jurisdiction of ASTM Committee D02 on Petroleum
Products, Liquid Fuels, and Lubricants and is the direct responsibility of Subcom-
mittee D02.C0.01 on Turbine Oil Monitoring, Problems and Systems. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved May 1, 2017. Published July 2017. Originally approved contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
in 1999. Last previous edition approved in 2011 as D6439 – 11. DOI: 10.1520/ Standards volume information, refer to the standard’s Document Summary page on
D6439-11R17. the ASTM website.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D6439 − 11 (2017)
D445 Test Method for Kinematic Viscosity of Transparent 2.3 API Standard:
API 614 Lubrication, Shaft-Sealing, and Control-Oil Sys-
and Opaque Liquids (and Calculation of Dynamic Viscos-
tems for Special Purpose Applications
ity)
D664 Test Method for Acid Number of Petroleum Products
3. Terminology
by Potentiometric Titration
D974 Test Method for Acid and Base Number by Color- 3.1 Definitions of Terms Specific to This Standard:
Indicator Titration 3.1.1 adsorption, n—removal of contaminants from oil by
D2272 Test Method for Oxidation Stability of Steam Tur- adhesion of the contaminant in an extremely thin layer of
molecules to a fixed solid. The solid can be a fiber, a fine
bine Oils by Rotating Pressure Vessel
powder, or porous particles.
D4241 Practice for Design of Gas Turbine Generator Lubri-
cating Oil Systems (Withdrawn 2008)
3.1.2 centrifugation, n—use of centrifugal force to separate
D4248 Practice for Design of Steam Turbine Generator Oil
contaminants from oils. Contaminants such as water and
Systems (Withdrawn 2008) particulate are generally more dense than the oil and migrate to
D4378 Practice for In-Service Monitoring of Mineral Tur- the outside of the centrifuge because of centrifugal force.
bine Oils for Steam, Gas, and Combined Cycle Turbines
3.1.3 cleaning, v—direct removal of contaminant from any
D4898 Test Method for Insoluble Contamination of Hydrau-
part of the system, generally with the system shut down or
lic Fluids by Gravimetric Analysis
offline. Cleaning can include removal of contaminant by
D6304 Test Method for Determination of Water in Petro-
shoveling, sweeping, squeegee, vacuuming, wiping, displacing
leum Products, Lubricating Oils, and Additives by Cou-
with clean, dry compressed air and can be done with the aid of
lometric Karl Fischer Titration
cleaning solutions.
D6810 Test Method for Measurement of Hindered Phenolic
3.1.4 cleaning solution, n—fluid used to aid in the removal
Antioxidant Content in Non-Zinc Turbine Oils by Linear
of sludge and particulate matter in a system. Cleaning solutions
Sweep Voltammetry
may be classified as chemical cleaners, solvent cleaners, or oil
D6971 Test Method for Measurement of Hindered Phenolic
soluble cleaners.
and Aromatic Amine Antioxidant Content in Non-zinc
3.1.5 coalescence, n—process of passing oil with free water
Turbine Oils by Linear Sweep Voltammetry
through a fiber sheet, generally in a cartridge form, to cause
D7155 Practice for Evaluating Compatibility of Mixtures of
smaller drops of water to join to form larger ones that can be
Turbine Lubricating Oils
more easily removed from the oil.
D7546 Test Method for Determination of Moisture in New
3.1.6 coalescer, n—device that uses coalescence to separate
and In-Service Lubricating Oils and Additives by Relative
water from oil. A coalescer generally consists of a coalescing
Humidity Sensor
cartridge(s) and a hydrophobic barrier that hinders water from
D7647 Test Method for Automatic Particle Counting of
passing out with the oil. It may also contain a filter located
Lubricating and Hydraulic Fluids Using Dilution Tech-
upstream or downstream, or both, of the coalescing car-
niques to Eliminate the Contribution of Water and Inter-
tridge(s).
fering Soft Particles by Light Extinction
3.1.7 displacement flush, n—system flush using on-board
F311 Practice for Processing Aerospace Liquid Samples for
turbine pumps designed to remove unwanted materials from
Particulate Contamination Analysis Using Membrane Fil-
installation or repair.
ters
3.1.8 displacement oil, n—oil used to remove either a lighter
F312 Test Methods for Microscopical Sizing and Counting
grade flush oil or an oil that is highly contaminated with oil
Particles from Aerospace Fluids on Membrane Filters
soluble material.
2.2 ISO Standards:
3.1.9 filter, n—device containing a screen or fiber depth
ISO 3722 Hydraulic Fluid Power—Fluid Sample
medium that removes particles from oil by physically trapping
Containers—Qualifying and Controlling Cleaning Meth-
them in or on the screen or mesh.
ods
3.1.10 flushing, v—circulation of liquid through the lubrica-
ISO 4021 Hydraulic Fluid Power—Particulate Contamina-
tion system or a component, when the turbine is not operating,
tion Analysis—Extraction of Fluid Samples from Lines of
to remove contaminant.
an Operating System.
3.1.11 high-pressure water flush, n—use of high-pressure
ISO 4406 Hydraulic Fluid Power—Fluids—Method for
water to remove heavy rust or fouling from lube system
Coding Level of Contamination by Solid Particles
internals.
ISO 4572 Hydraulic Fluid Power—Filters—Multi-pass
Method for Evaluating Filtration Performance 3.1.12 high-velocity flush, n—system flush using external
pumps that generate three to four times normal operating
system velocities and a Reynolds number over 4000.
The last approved version of this historical standard is referenced on
www.astm.org.
4 5
Available from American National Standards Institute (ANSI), 25 W. 43rd St., Available from American Petroleum Institute (API), 1220 L. St., NW,
4th Floor, New York, NY 10036, http://www.ansi.org. Washington, DC 20005-4070, http://www.api.org.
D6439 − 11 (2017)
3.1.13 operating oil, n—specific charge or chemistry of oil components are generally established by their manufacturers’
to be used as the final fill oil after the flush. specifications. These and recommendations of the fluid manu-
facturer must be considered when employing contamination
3.1.14 oxidation, n—chemical reaction of a lubricant at
control systems. In addition, there are insoluble contaminants
elevated temperatures between dissolved atmospheric oxygen
(oxidation precursors) that are below machine tolerances, but
and the base oil. Oxidation reaction will be accelerated by the
as their volume amasses they create a potential for sludge and
presence of oxidation accelerators such as metallic contami-
varnish creation as a normal consequence of oxidation reac-
nants and water.
tions.
3.1.15 pure oil, n—homogeneous lubricating oil containing
5.3 Contamination control considerations must begin with
stable additives and free of soluble or insoluble contaminants
of concentrations that exceed the lubrication system specifica- system design and continue through the manufacture,
installation, flushing, operation, and maintenance of the sys-
tions.
tem.
3.1.16 purification, v—removal of a contaminant present in
the oil through a separation process.
5.4 Design of the system must consider component con-
3.1.17 sacrificial flush oil, n—charge of oil that is used in taminant sensitivity and provide points for sampling oil and
the flushing process and not used as the final operating oil. methods for controlling contaminants. Contamination monitor-
ing is discussed in Appendix X2 and contamination control
3.1.18 surface active flush, n—system flush with the use of
methods in Appendix X3. Inclusion of filtration in steam and
surface active cleaners to remove varnish and sludge.
gas turbine lubrication systems is discussed in Practices D4248
4. Significance and Use and D4241 respectively.
4.1 This guide is intended to aid the equipment
5.5 The manufacturer must minimize the amount of built-in
manufacturer, installer, and turbine operator in coordinating
contaminant by minimizing ingression and by flushing com-
their efforts to obtain and maintain clean lubrication and
ponents to achieve target cleanliness levels in the finished
control systems.
component.
4.2 The flushing and cleaning philosophies stated in this
5.6 Contamination control during installation and major
guide are applicable to both large and small lubrication
maintenance of turbine systems is discussed in Section 6.
systems.
5.7 Proper heating is critical during flushing and routine
4.3 Clean lubrication systems result from proper system
operation to minimize oil degradation. Heating is discussed in
design and good planning, execution, and communication by
Appendix X4.
all involved during commissioning. No phase of these proce-
dures should be undertaken without a thorough understanding 5.8 Removal of contamination by flushing is discussed in
Section 7.
of the possible effects of improper system preparation. The
installation, cleaning, and flushing of the equipment should not
5.9 Contamination control in operational systems and dur-
be entrusted to persons lacking in experience.
ing routine maintenance is discussed in Section 8. Properly
4.4 Because of the knowledge and specialized equipment
designed systems can normally control water and insoluble
that is required, the operator may wish to employ an outside
contaminants in operational systems. If, however, it is neces-
specialist contractor for the system flushing. Review of this
sary to remove soluble contaminants other than water, an oil
guide can provide guidelines for discussion with prospective
change and also possibly a flush may be required.
contractors.
6. Contamination Control When Installing and
5. Contamination Control Overview
Refurbishing Turbine Systems
5.1 Lubrication systems can become contaminated from a
6.1 General:
variety of sources. The main focus of this guide is on the
6.1.1 Exclusion or removal of contaminant, or both, in
minimization, monitoring, and control of contaminants: water
manufacturing or refurbishing, or both, are necessary for a
and both soluble and insoluble (stationary and suspended)
subsequent successful flush and can be achieved only by the
contaminants. A more detailed discussion of these types of
cooperation and diligence of many parties.
contaminants is given in Appendix X1.
6.1.2 Examples of Essential Precautions to Exclude or
5.2 Contamination control is the complete program of
Remove Contaminant, or Both:
obtaining and maintaining a clean lubricant and lubrication
6.1.2.1 The system should be designed to allow successful
system. This includes proper construction and maintenance
clean
...
This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: D6439 − 11 D6439 − 11 (Reapproved 2017)
Standard Guide for
Cleaning, Flushing, and Purification of Steam, Gas, and
Hydroelectric Turbine Lubrication Systems
This standard is issued under the fixed designation D6439; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
INTRODUCTION
Optimum turbine system reliability requires a well designed lubricating system and use of a good
lubricant that is free of contaminants. Achieving this requires use of proper purification methods to
ensure that the oil is free of detrimental contaminants. In addition, it requires an ongoing monitoring
program to ensure that the oil quality is within specifications and that corrective action is taken to
minimize contaminant generation and ingression. The benefits of purification of an operating
lubrication system can be significantly reduced if the lubricating systems are not initially cleaned to
a level that will prevent component damage on initial start up after 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 these
processes, it is necessary to flush and purify the system to remove them prior to startup. Ongoing
purification is required to maintain pure oil during operation. In new systems, the emphasis is on the
removal of contaminants introduced during manufacture, storage, field fabrication, and installation. In
operational systems, the emphasis is on the removal of contaminants that are generated or carried in
during operation, and by malfunctions that occur during operation or contaminants that are introduced
during overhaul, or both.
1. Scope*Scope
1.1 This guide covers types of contaminants, oil purification devices, contamination monitoring, contamination control during
building or refurbishing of turbine systems, lubrication system flushing, and maintenance of pure lubrication oil.
1.2 To obtain maximum operating life and reliability, or lubricants and system, it is vital that the turbine lubrication system has
pure oil. This guide is intended to aid the equipment manufacturer, installer, and turbine operator in coordinating their efforts to
obtain and maintain clean lubrication and control systems. These systems may be on land or marine turbine generators and
propulsion and mechanical drive equipment. This guide is generalized due to variations in the type of equipment, builder’s
practices, and operating conditions.
1.3 This guide primarily addresses petroleum based lubricating oil. For systems using nonpetroleum based fluids, this guide may
not be appropriate. For nonpetroleum products, consult the equipment and fluid manufacturers.
1.4 This guide is applicable to both large and small lubrication systems. Some equipment specified herein, however, may not
be appropriate for all systems. Moreover, in situations where specific guidelines and procedures are provided by the equipment
manufacturer, such procedures should take precedence over the recommendations of this guide.
1.5 This standard does not purport to address the safety concerns, if any, associated with its use. It is the responsibility of the
user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations
prior to use.
1.6 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
This guide is under the jurisdiction of ASTM Committee D02 on Petroleum Products Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Subcommittee D02.C0.01 on Turbine Oil Monitoring, Problems and Systems.
Current edition approved May 1, 2011May 1, 2017. Published July 2011July 2017. Originally approved in 1999. Last previous edition approved in 20052011 as
D6439D6439 – 11.–05. DOI: 10.1520/D6439-11.10.1520/D6439-11R17.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D6439 − 11 (2017)
2. Referenced Documents
2.1 ASTM Standards:
D445 Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity)
D664 Test Method for Acid Number of Petroleum Products by Potentiometric Titration
D974 Test Method for Acid and Base Number by Color-Indicator Titration
D2272 Test Method for Oxidation Stability of Steam Turbine Oils by Rotating Pressure Vessel
D4241 Practice for Design of Gas Turbine Generator Lubricating Oil Systems (Withdrawn 2008)
D4248 Practice for Design of Steam Turbine Generator Oil Systems (Withdrawn 2008)
D4378 Practice for In-Service Monitoring of Mineral Turbine Oils for Steam, Gas, and Combined Cycle Turbines
D4898 Test Method for Insoluble Contamination of Hydraulic Fluids by Gravimetric Analysis
D6304 Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl
Fischer Titration
D6810 Test Method for Measurement of Hindered Phenolic Antioxidant Content in Non-Zinc Turbine Oils by Linear Sweep
Voltammetry
D6971 Test Method for Measurement of Hindered Phenolic and Aromatic Amine Antioxidant Content in Non-zinc Turbine Oils
by Linear Sweep Voltammetry
D7155 Practice for Evaluating Compatibility of Mixtures of Turbine Lubricating Oils
D7546 Test Method for Determination of Moisture in New and In-Service Lubricating Oils and Additives by Relative Humidity
Sensor
D7647 Test Method for Automatic Particle Counting of Lubricating and Hydraulic Fluids Using Dilution Techniques to
Eliminate the Contribution of Water and Interfering Soft Particles by Light Extinction
F311 Practice for Processing Aerospace Liquid Samples for Particulate Contamination Analysis Using Membrane Filters
F312 Test Methods for Microscopical Sizing and Counting Particles from Aerospace Fluids on Membrane Filters
2.2 ISO Standards:
ISO 3722 Hydraulic Fluid Power—Fluid Sample Containers—Qualifying and Controlling Cleaning Methods
ISO 4021 Hydraulic Fluid Power—Particulate Contamination Analysis—Extraction of Fluid Samples from Lines of an
Operating System.
ISO 4406 Hydraulic Fluid Power—Fluids—Method for Coding Level of Contamination by Solid Particles
ISO 4572 Hydraulic Fluid Power—Filters—Multi-pass Method for Evaluating Filtration Performance
2.3 API Standard:
API 614 Lubrication, Shaft-Sealing, and Control-Oil Systems for Special Purpose Applications
3. Terminology
3.1 Definitions of Terms Specific to This Standard:
3.1.1 adsorption, n—removal of contaminants from oil by adhesion of the contaminant in an extremely thin layer of molecules
to a fixed solid. The solid can be a fiber, a fine powder, or porous particles.
3.1.2 centrifugation, n—use of centrifugal force to separate contaminants from oils. Contaminants such as water and particulate
are generally more dense than the oil and migrate to the outside of the centrifuge because of centrifugal force.
3.1.3 cleaning, v—direct removal of contaminant from any part of the system, generally with the system shut down or offline.
Cleaning can include removal of contaminant by shoveling, sweeping, squeegee, vacuuming, wiping, displacing with clean, dry
compressed air and can be done with the aid of cleaning solutions.
3.1.4 cleaning solution, n—fluid used to aid in the removal of sludge and particulate matter in a system. Cleaning solutions may
be classified as chemical cleaners, solvent cleaners, or oil soluble cleaners.
3.1.5 coalescence, n—process of passing oil with free water through a fiber sheet, generally in a cartridge form, to cause smaller
drops of water to join to form larger ones that can be more easily removed from the oil.
3.1.6 coalescer, n—device that uses coalescence to separate water from oil. A coalescer generally consists of a coalescing
cartridge(s) and a hydrophobic barrier that hinders water from passing out with the oil. It may also contain a filter located upstream
or downstream, or both, of the coalescing cartridge(s).
3.1.7 displacement flush, n—system flush using on-board turbine pumps designed to remove unwanted materials from
installation or repair.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM Standards
volume information, refer to the standard’s Document Summary page on the ASTM website.
The last approved version of this historical standard is referenced on www.astm.org.
Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036.10036, http://www.ansi.org.
Available from American Petroleum Institute, 1220 L St.Institute (API), 1220 L. St., NW, Washington, DC 20005-8197.20005-4070, http://www.api.org.
D6439 − 11 (2017)
3.1.8 displacement oil, n—oil used to remove either a lighter grade flush oil or an oil that is highly contaminated with oil soluble
material.
3.1.9 filter, n—device containing a screen or fiber depth medium that removes particles from oil by physically trapping them
in or on the screen or mesh.
3.1.10 flushing, v—circulation of liquid through the lubrication system or a component, when the turbine is not operating, to
remove contaminant.
3.1.11 high-pressure water flush, n—use of high-pressure water to remove heavy rust or fouling from lube system internals.
3.1.12 high-velocity flush, n—system flush using external pumps that generate three to four times normal operating system
velocities and a Reynolds number over 4000.
3.1.13 operating oil, n—specific charge or chemistry of oil to be used as the final fill oil after the flush.
3.1.14 oxidation, n—chemical reaction of a lubricant at elevated temperatures between dissolved atmospheric oxygen and the
base oil. Oxidation reaction will be accelerated by the presence of oxidation accelerators such as metallic contaminants and water.
3.1.15 pure oil, n—homogeneous lubricating oil containing stable additives and free of soluble or insoluble contaminants of
concentrations that exceed the lubrication system specifications.
3.1.16 purification, v—removal of a contaminant present in the oil through a separation process.
3.1.17 sacrificial flush oil, n—charge of oil that is used in the flushing process and not used as the final operating oil.
3.1.18 surface active flush, n—system flush with the use of surface active cleaners to remove varnish and sludge.
4. Significance and Use
4.1 This guide is intended to aid the equipment manufacturer, installer, and turbine operator in coordinating their efforts to
obtain and maintain clean lubrication and control systems.
4.2 The flushing and cleaning philosophies stated in this guide are applicable to both large and small lubrication systems.
4.3 Clean lubrication systems result from proper system design and good planning, execution, and communication by all
involved during commissioning. No phase of these procedures should be undertaken without a thorough understanding of the
possible effects of improper system preparation. The installation, cleaning, and flushing of the equipment should not be entrusted
to persons lacking in experience.
4.4 Because of the knowledge and specialized equipment that is required, the operator may wish to employ an outside specialist
contractor for the system flushing. Review of this guide can provide guidelines for discussion with prospective contractors.
5. Contamination Control Overview
5.1 Lubrication systems can become contaminated from a variety of sources. The main focus of this guide is on the
minimization, monitoring, and control of contaminants: water and both soluble and insoluble (stationary and suspended)
contaminants. A more detailed discussion of these types of contaminants is given in Appendix X1.
5.2 Contamination control is the complete program of obtaining and maintaining a clean lubricant and lubrication system. This
includes proper construction and maintenance practices, appropriate purification equipment, and regular monitoring of
contaminants. The contamination control program must be capable of identifying and measuring contaminants and controlling
them at, or preferably below, component tolerances. 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 system components are generally
established by their manufacturers’ specifications. These and recommendations of the fluid manufacturer must be considered when
employing contamination control systems. In addition, there are insoluble contaminants (oxidation precursors) that are below
machine tolerances, but as their volume amasses they create a potential for sludge and varnish creation as a normal consequence
of oxidation reactions.
5.3 Contamination control considerations must begin with system design and continue through the manufacture, installation,
flushing, operation, and maintenance of the system.
5.4 Design of the system must consider component contaminant sensitivity and provide points for sampling oil and methods for
controlling contaminants. Contamination monitoring is discussed in Appendix X2 and contamination control methods in Appendix
X3. Inclusion of filtration in steam and gas turbine lubrication systems is discussed in Practices D4248 and D4241 respectively.
5.5 The manufacturer must minimize the amount of built-in contaminant by minimizing ingression and by flushing components
to achieve target cleanliness levels in the finished component.
5.6 Contamination control during installation and major maintenance of turbine systems is discussed in Section 6.
5.7 Proper heating is critical during flushing and routine operation to minimize oil degradation. Heating is discussed in
Appendix X4.
5.8 Removal of contamination by flushing is discussed in Section 7.
D6439 − 11 (2017)
5.9 Contamination control in operati
...
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