ASTM D6439-99

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
An American National Standard
Designation: D 6439 – 99
Standard Guide for
Cleaning, Flushing, and Purification of Steam, Gas, and
Hydroelectric Turbine Lubrication Systems
This standard is issued under the fixed designation D 6439; 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 (e) 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 during
operation and by malfunctions that occur during operation or contaminants that are introduced during
overhaul, or both.
1. Scope may not be appropriate for all systems. Moreover, in situations
where specific guidelines and procedures are provided by the
1.1 Toobtainmaximumoperatingreliabilityandcomponent
equipment manufacturer, such procedures should take prece-
life, it is vital that the turbine lubrication system has pure oil.
dence over the recommendations of this guide.
This guide is intended to aid the equipment manufacturer,
1.5 This standard does not purport to address the safety
installer, and turbine operator in coordinating their efforts to
concerns, if any, associated with its use. It is the responsibility
obtain and maintain clean lubrication and control systems.
of the user of this standard to establish appropriate safety and
Thesesystemsmaybeonlandormarineturbinegeneratorsand
health practices and determine the applicability of regulatory
propulsion and mechanical drive equipment. This guide is
limitations prior to use.
generalized due to variations in the type of equipment, build-
er’s practices, and operating conditions.
2. Referenced Documents
1.2 This guide covers types of contaminants, oil purification
2.1 ASTM Standards:
devices, contamination monitoring, contamination control dur-
D 95 Test Method for Water in Petroleum Products and
ing building or refurbishing of turbine systems, lubrication
Bituminous Materials by Distillation
system flushing, and maintenance of pure lubrication oil.
D 445 Test Method for Kinematic Viscosity of Transparent
1.3 This guide primarily addresses petroleum based lubri-
and Opaque Liquids (the Calculation of Dynamic Viscos-
cating oil. For systems using nonpetroleum based fluids, this
ity)
guide may not be appropriate. For nonpetroleum products,
D 664 TestMethodforAcidNumberofPetroleumProducts
consult the equipment and fluid manufacturers.
by Potentiometric Titration
1.4 This guide is applicable to both large and small lubri-
D 974 Test Method for Acid and Base Number by Color-
cation systems. Some equipment specified herein, however,
Indicator Titration
This test method is under the jurisdiction of ASTM Committee D-2 on
Petroleum Products and Lubricants and is the direct responsibility of Subcommittee
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
D02.0C.01 on Turbine Oil Systems.
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Current edition approved Aug. 10, 1999. Published September 1999.
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
D6439–99
D 1533 Test Method for Water in Insulating Liquids by 3.1.5 coalescer, n—a device that uses coalescence to sepa-
Coulometric Karl Fischer Titration rate water from oil. A coalescer generally consists of a
D 1744 Test Method for Water in Liquid Petroleum Prod- coalescing cartridge(s) and a hydrophobic barrier that hinders
ucts by Karl Fischer Reagent water from passing out with the oil. It may also contain a filter
D 2272 Test Method for Water in Insulating Liquids by located upstream or downstream, or both, of the coalescing
Coulometric Karl Fischer Titration cartridge(s).
D 4241 Practice for Design of Gas Turbine Generator Lu- 3.1.6 filter, n—adevicecontainingascreenorfibermatthat
bricating Oil Systems removesparticlesfromoilbyphysicallytrappingtheminoron
D 4248 Practice for Design of SteamTurbine Generator Oil the screen or mesh.
Systems 3.1.7 flushing, n—circulation of liquid through the lubrica-
D 4378 Practice for In-Service Monitoring of Mineral Tur- tion system or a component, when the turbine is not operating,
bine Oils for Steam and Gas Turbines to remove contaminant.
D 4898 Test Method for Insoluble Contamination of Hy-
3.1.8 pure oil, n—homogeneous lubricating oil containing
draulic Fluid by Gravimetric Analysis stable additives and free of soluble or insoluble contaminants
F 311 PracticeforProcessingAerospaceLiquidSamplesfor
of concentrations that exceed the lubrication system specifica-
Particulate Contamination Analysis Using Membrane Fil-
tions.
ters
3.1.9 purification, v—removalofacontaminantfromtheoil
F 312 Test Methods for Microscopical Sizing and Counting
by passing it through a mechanical device or chemical adsor-
Particles from Aerospace Fluids on Membrane Filters
bent.
2.2 ISO Standards:
ISO 3722 Hydraulic Fluid Power—Fluid Sample
4. Significance and Use
Containers—Qualifying and Controlling Cleaning Meth-
4.1 This guide is intended to aid the equipment manufac-
ods
turer,installer,andturbineoperatorincoordinatingtheirefforts
ISO 4021 Hydraulic Fluid Power—Particulate Contamina-
to obtain and maintain clean lubrication and control systems.
tionAnalysis—Extraction of Fluid Samples from Lines of
4.2 The flushing and cleaning philosophies stated in this
an Operating System.
guide are applicable to both large and small lubrication
ISO 4406 Hydraulic Fluid Power—Fluids—Method for
systems.
Coding Level of Contamination by Solid Particles
4.3 Clean lubrication systems result from proper system
ISO 4572 Hydraulic Fluid Power—Filters—Multi-pass
design and good planning, execution, and communication by
Method for Evaluating Filtration Performance
all involved during commissioning. No phase of these proce-
2.3 API Standard:
dures should be undertaken without a thorough understanding
API 614 Lubrication, Shaft-Sealing, and Control-Oil Sys-
of the possible effects of improper system preparation. The
tems for Special Purpose Applications
installation, cleaning, and flushing of the equipment should not
be entrusted to persons lacking in experience.
3. Terminology
4.4 Because of the knowledge and specialized equipment
3.1 Definitions of Terms Specific to This Standard:
that is required, the operator may wish to employ an outside
3.1.1 adsorption, n—the removal of contaminants from oil
specialist contractor for the system flushing. Review of this
by adhesion of the contaminant in an extremely thin layer of
guide can provide guidelines for discussion with prospective
molecules to a fixed solid. The solid can be a fiber, a fine
contractors.
powder, or porous particles.
3.1.2 centrifugation, n—the use of centrifugal force to
5. Contamination Control Overview
separate contaminants from oils. Contaminants such as water
5.1 Lubrication systems can become contaminated from a
and particulate are generally more dense than the oil and
variety of sources. The main focus of this guide is on the
migrate to the outside of the centrifuge because of centrifugal
minimization, monitoring, and control of contaminants: water
force.
and both soluble and insoluble (stationary and suspended)
3.1.3 cleaning, n—the direct removal of contaminant from
contaminants. A more detailed discussion of these types of
any part of the system, generally with the system shut down.
contaminants is given in Appendix X1.
Cleaning can include removal of contaminant by shoveling,
5.2 Contamination control is the complete program of
sweeping,wiping,ordisplacingwithclean,drycompressedair.
obtaining and maintaining a clean lubricant and lubrication
3.1.4 coalescence, n—the process of passing oil with free
system. This includes proper construction and maintenance
water through a fiber sheet, generally in a cartridge form, to
practices, appropriate purification equipment, and regular
causesmallerdropsofwatertojointoformlargeronesthatcan
monitoring of contaminants. The contamination control pro-
be more easily removed from the oil.
gram must be capable of identifying and measuring contami-
nants and controlling them at, or preferably below, component
Withdrawn.
tolerances. In particular, the sensitivity of bearings, gears,
4 nd th
Available from American National Standards Institute, 11 W 42 Street, 13
seals, and proportional and servo valves should be reviewed.
Floor, New York, NY 10036.
As described in X2.7.1, cleanliness levels for various system
Available fromAmerican Petroleum Institute, 1220 LSt. NW,Washington, DC
20005-8197. components are generally established by their manufacturers’
D6439–99
specifications. These and recommendations of the fluid manu- 6.1.2.7 Continuous monitoring of conditions during the
facturer must be considered when employing contamination complete turbine installation must take place to ensure that
control systems. cleanliness related tasks are being accomplished. Dirt should
not be introduced into the pipes and equipment.
5.3 Contamination control considerations must begin with
6.1.2.8 Great care must be taken to prevent contaminant
system design and continue through the manufacture, installa-
tion, flushing, operation, and maintenance of the system. entry during any modifications.
6.1.2.9 The work area must be kept clean.
5.4 Design of the system must consider component con-
6.1.2.10 This list is not complete, but it does illustrate that
taminant sensitivity and provide points for sampling oil and
the manufacturer, the shipper, the operator, and the installation
methods for controlling contaminants. Contamination monitor-
contractorareallresponsibleforensuringthatnocontaminants
ing is discussed in Appendix X2 and contamination control
enter the lubrication system. These efforts to prevent the
methods in Appendix X3. Inclusion of filtration in steam and
entrance of dirt will make the flushing procedure easier, safer,
gas turbine lubrication systems is discussed in Practices
and shorter, and thus less costly.
D 4248 and D 4241 respectively.
6.2 On-Site Contamination Control:
5.5 The manufacturer must minimize the amount of built-in
6.2.1 General:
contaminant by minimizing ingression and by flushing com-
ponents to achieve target cleanliness levels in the finished 6.2.1.1 All components that are fabricated and assembled at
component. a manufacturer’s facility and received as a unit for installation
in the system are defined as preassembled components.
5.6 Contamination control during installation and major
6.2.1.2 The preassembled components should be inspected
maintenance of turbine systems is discussed in Section 6.
upon receipt to determine condition and degree of protection.
5.7 Proper heating is critical during flushing and routine
All seals and caps intended to exclude moisture and dirt should
operation to minimize oil degradation. Heating is discussed in
be checked for integrity and replaced as required. If the initial
Appendix X4.
or a subsequent inspection discloses dirt or rusting, the item
5.8 Removal of contamination by flushing is discussed in
should be immediately cleaned, represerved, and sealed, as
Section 7.
required. Because of the variety of equipment and materials,
5.9 Contamination control in operational systems and dur-
details for each case cannot be given here. For painted (coated)
ing routine maintenance is discussed in Section 8. Properly
components, the coating should be inspected for integrity and
designed systems can normally control water and insoluble
renewed as necessary. All components should be checked to
contaminants in operational systems. If, however, it is neces-
ensure that all tape and temporary supports or restraints have
sary to remove soluble contaminants other than water, an oil
been removed.
change and also possibly a flush may be required.
6.2.1.3 Under-cover storage is recommended. Monthly in-
spectionsarerecommended,andcorrectivestepsmustbetaken
6. Contamination Control When Installing and
when necessary. Care must be taken during inspections to
Refurbishing Turbine Systems
minimize disturbance of equipment protection.
6.1 General:
6.2.2 Corrosion Protection:
6.1.1 Exclusion or removal of contaminant, or both, in
6.2.2.1 The application of various types of rust preventives
manufacturing or refurbishing, or both, are necessary for a
is required to protect uncoated ferrous surfaces from corrosion
subsequent successful flush and can be achieved only by the
during the storage and installation phases. Most preservatives
cooperation and diligence of many parties.
today are oil soluble, and special procedures, such as hydraulic
lancing, are often used to preserve gear cases, sumps, and
6.1.2 Examples of Essential Precautions to Exclude or
tanks. The preservative compounds can normally be removed
Remove Contaminant, or Both:
by flushing the system with regular lubrication oil or oil
6.1.2.1 The system should be designed to allow successful
solvent, although hand cleaning of some components is also
cleaning.
employed.Ifpossible,however,theflushoil,operatingoil,and
6.1.2.2 The pipe and other equipment must be properly
preservative should be compatible to preclude foaming, the
cleaned and preserved.
formation of emulsions, or the breakdown of lubrication oil
6.1.2.3 All possible locations for the entrance of dirt (pipe
additive
...