DANSK STANDARD

The Danish Standards Association

DS 2396
1 edition Approved: 1998-03-11

Ship and marine technology Hydraulic oil pipe systems Guidance for grades of cleanliness and flushing

DS 2396:1998

Descriptors
Ship technology, hydraulic oil pipe systems, and pipe cleaning

National foreword
This publication is approved as a Danish standard. This standard is based on (CNEQ) Danish Shipbuilding Standard DVS 08004:1996. The technical content of this standard is identical to DVS 08004:1996. Sections 0, 1 and 2 are additions to the Danish standard.

DS 2396:1998

List of Contents
0 1 2 3 4 5 6 7 8 9 10 11 12 Introduction Subject area .. Normative references .. Recommended pipe cleaning levels ..... Level of cleanliness . Assembly and installation of pipe system Blow-through/pull-through of pipe system Description of coupling Leakage test .. Filling of oil . Shock testing/pressure testing ... Flushing of yard produced pipe system.. Start-up of system Bibliography . 5 5 5 5 6 6 6 6 7 7 7 7 14 16

Annex A (informative)

DS 2396:1998

Foreword
The series of Danish standards covering DS 2395 Ship and marine technology Lubricating oil pipe systems Guidance for grades of cleanliness and flushing Ship and marine technology Hydraulic oil pipe systems Guidance for grades of cleanliness and flushing Ship and marine technology Hydraulic oil pipe systems Guidance for assembling and flushing Ship and marine technology Sampling from lubricating oil and hydraulic oil pipe systems Guidance for sampling of representative samples for determination of degree of cleanliness and for solid particle contamination

DS 2396

DS 2397

DS 2398

deals with issues relating to cleaning, extraction of fluid samples, and levels of cleanliness of lubricating and hydraulic oil systems for combustion engines with auxiliaries at first start-up and after repair. This series of Danish standards provides an explanation and implementation of the international standards of the ISO 4548 series concerning oil filters and oil filter systems for internal combustion engines. The ISO 4548 series has been developed within the framework of ISO/TC 70, Internal combustion engines. The measurement methods, measuring units, coding, terminology, etc. of this series of Danish standards are in conformance with the respective ISO standards for fluid power systems. A work group under The Danish Shipbuilders Standardization Committee (DVS) has developed this series of Danish standards.

DS 2396:1998

0 Introduction
The cleaning of pipes and components in hydraulic oil pipe systems is essential for the trouble-free operation of hydraulic systems. The purpose of the cleaning process is partly to remove installation dirt, partly to check that the piping and the hydraulic system have been adequately cleaned. The cleaning process of a system is considered being a scavenge process when Re 3000 and a flushing process when Re 3000. This standard presupposes that the pipe sections of the hydraulic system have been cleaned partly by pickling, and partly by mechanical cleaning (as set out in DVS 05009 and DVS 05013). It is furthermore assumed that both dynamic and static components from system suppliers are adequately clean on delivery (see section 4). The specifications given in this standard are supplementary only and do not replace the guidelines specified by the various manufacturers. The manufacturers guidelines, where available, must primarily be followed.

1 Subject area
This standard specifies pipe cleaning and cleaning levels of hydraulic oil pipe systems. The standard indicates methods and equipment for the practical execution of the cleaning of specific parts of hydraulic systems with appurtenant components.

2 Normative references
ISO 3448 ISO 4021 ISO 4402 ISO 4406 ISO 4572 Industrial liquid lubricants ISO viscosity classification Hydraulic fluid power Particulate contamination analysis Extraction of fluid samples from lines of an operating system Hydraulic fluid power Calibration of liquid automatic particle-count instruments Method using Air Cleaner Fine Test Dust contaminant Hydraulic fluid power Fluids Methods for coding level of contamination by solid particles Hydraulic fluid power Filters Multi-pass method for evaluating filtration performance

3 Recommended pipe cleaning levels

During/after prefabrication of piping and fittings and any subsequent internal surface treatment. 3.1 Pipe cleaning levels during/after prefabrication a. Steel pipes (black) and pipes of other material qualities showing oxide scales as a result of heating or welding. After welding together of prefabricated pipes and fittings, these should be cleaned internally to level 3 in accordance with DVS 05010. Either chemical cleaning (alkaline cleaning and pickling see DVS 05011) or mechanical blow cleaning (see DVS 05012) to achieve a cleanliness corresponding should follow this to Sa2.5 (see DVS 05008). Steel shot should not be used because of the risk of adhesion by magnetism and rust seizure. Instead, the use of Cu slag is recommended. Sealing faces should be protected during the blow cleaning. b. Precision steel pipes and pipes of other material qualities, which are delivered and remain free of oxide scale (no heating or welding). It is recommended that after cutting and careful deburring of pipes and fittings that are joined without being subjected to prior heating or welding processes, e.g. by means of clamping rings, these should be cleaned either chemically (using an alkaline cleaning process see DVS 05011), blown through with pressurized air, or by pulling through lint-free cloths.

DS 2396:1998

3.2 Surface treatment In order to maintain the above-mentioned cleanliness of pipes and fittings until their mounting on board, it is recommended to treat internal and external surfaces at the ends of the pipes and fittings with a suitable oil product (see DVS 05009, section 5, item 2.c). The applied oil product should not change the properties of the flushing or system oil. 3.3 Storage of prefabricated pipes and fittings Cleaned and surface-treated prefabricated pipes and fittings should be blanked-off and stored in accordance with DVS 05009, section 6.

4 Level of cleanliness for pre-tested components and oils forming part of the system.
Component suppliers must be able to specify (or inform of) the level of cleanliness of the components delivered. This applies to suppliers of dynamic as well as static components. The SAE-J1227 indicates methods according to which evaluation and documentation of the level of cleanliness can be carried out. In addition to information regarding the level of cleanliness at the time of delivery, it is recommended that the yard and the system supplier agree in advance on the necessary level of cleanliness of the system oil and the cleaned system to achieve a long and reliable operation.

5 Assembly and installation of pipe system

In connection with assembly and installation of the pipe system, it is important to avoid any welding, brazing soldering or heating of the pipes (oxide scales). If this cannot be avoided then the pipes in question must be cleaned and protected again (repair). In particular, it is important to remove soldering materials. Protection covers should be removed as late in the installation process as possible. Preventing dirt from the installation process from entering the pipe system is crucial, e.g. PFE sealing fluids and tape should be applied with great care.

6 Blow-through and pull-through of the system

Before connecting the pipe system to machines, panels, pump stations, etc., all pipes should be blown through with dry pressurized air and/or N2. If this is not possible because of the pipe dimension then pulling through clean lint-free cloths should clean the pipes. The purpose of this is to remove loose dirt in the most efficient way and, at the same time, ensure that the pipes are dry internally (N2 eliminates condensed water internally in the pipes).

7 Description of coupling
In the design phase, at the structuring of the hydraulic diagram, it is important to consider carefully how the complete system can be flushed in practical terms (including grouping). 7.1 When grouping of the pipe system, the following should be observed: a. Dead areas are unacceptable during flushing (change the coupling points). b. Circuits should always be connected in series. c. Relevant coupling options (connection of uniform pipe diameters should be aimed for in order to avoid too large pressure losses). 7.2 The following should furthermore be taken into consideration: a. Components that may hinder a high flow velocity, or which may be ruined by a high flow velocity, should be by-passed. b. Built-in filter elements must be removed before flushing. c. Pump stations, assembled units and sub-components that have not been pre-tested must be flushed separately in case they are not delivered in a cleaned condition. This also applies to pipe systems where space conditions on board do not allow flushing of the pipe systems installed. d. It is important that sampling of oil during the actual flushing is carried out in a way that ensures a representative sample. Reference is therefore made to ISO 4021, which sets out the sampling from a dynamic system. See also DVS 08006.

DS 2396:1998

8 Leakage test
Before the filling of the flushing oil, the leak-tightness of the system can checked in the following ways: a. Connect the pipe system (by-pass/blank-off of components). b. Put the system under pressure in accordance with the directions of the Danish Working Environment Inspectorate using clean, dry pressurised air or N2, and perform external testing with soapy water or duration (loss of pressure). c. After filling of the flushing oil, the leak-tightness of the system can be tested by means of shock or pressure testing.

9 Filling of oil
a. As to the choice of oil type and quality, see section 11, item c. b. Connect the pipe system (by-pass of components). c. Clean the tank/sump in the portable pump station and the power pack to a cleaning level corresponding to the cleaning level of the components supplied to the system, see section 4. d. Fill oil onto the system by pumping the oil through a filter during the actual filling process until the tank/sump is full. The filter must be capable of filtering the oil to minimum two ISO-codes below the cleanliness specified for the system. Care should be taken that air bubbles do not enter the system in connection with the filling operation and, if necessary, the system should be topped-up and vented.

10 Shock testing/pressure testing

a. Connect the pipe system (by-pass of components). Ensure 100% filling of the system. b. Pressurise the pipe system up to the relevant testing pressure, and relieved it again by opening the relief valve on the pump station. Repeat this min. 25 times, unless otherwise specified.

11 Flushing of yard produced pipe system

a.1 Connection, etc. Connect the pipe system (by-pass/blank-off of components). Best use of a vibrator would be to vibrate over a broad frequency range. It would be appropriate to change the flow direction a couple of times during the flushing period. Moreover, the directions specified in item b to e must be followed. a.2 Special pump units Experience achieved with using a hydraulic accumulator and a pulsation valve sending pressure/flow pulsations through the pipes is very good in connection with cleaning of pipes. In a pipe system with a small internal diameter in which a turbulent flow can be difficult to achieve, i.a. due to a large pressure drop, special gas/oil units can be used which fill the entire pipe system with gas and oil loads and which are subsequently compressed. The loads are released and the gas pockets expand, resulting in a turbulent oil flow. b. Flushing filters b.1 Filter capacity The permanent filters of the systems should not/cannot always be used for the cleaning of flushing oil in connection with flushing. Instead, special flushing filters designed to increase the filter capacity to a predetermined extent during flushing can be used together with the portable pump station. It is advisable to place the filters on both the pressure line and the return line in order to reduce the total flushing time. The choice of filter capacity should be made with the aim of achieving an acceptable service life for the filter element. The service life is, all other things being equal, determined by the filters contamination capacity. It is difficult to determine the desired contamination capacity and, also, to be informed by the manufacturers of the relevant contamination capacity. For this reason, the flow capacity for 1/min. is often used as the basis for achieving an acceptable service lifetime. The filter capacity Q1* (1/min.) = K1 x current capacity Q2 (1/min.). in that K1 normally varies from 2.5 to 3.5 for flushing filters. A high K1 value is chosen for high-pressure systems. For low-pressure systems, a low value is chosen. Q2 is shown in Table 2.

DS 2396:1998

*Choose a filter element which in a cleaned condition is capable of handling the oil amount Q1 at a pressure drop p of 0.3 bar, according to the manufacturers specifications. Flushing filter elements must be exchanged when the max. p for a contaminated filter is reached during flushing (this is read from a p pressure gauge or from a contamination indicator, if fitted). The contamination indicator must be of a type that gives a signal before the by-pass valve opens. As in practice it is impossible to calculate and obtain different filter capacities for varying flushing operations, the individual yards are encouraged, on the above basis and their own parameters, to calculate and use one or more standard filters that can be used within specific limits. Proposed calculation: Q1 = Re x v x x d x 15000 x K1 (1/min.). For Re, v and d: see item d.2. Since Re can be set at e.g. 3000 and v can also be kept constant by standardising the flushing oil quality and temperature, only d and K1 are variable. Since d is small, where K1 is largest (high pressure systems), and vice versa (low pressure systems), the individual yard may thus standardise their way to a flushing filter capacity which is adequate for all general tasks at the yard. b.2 Filter Filtration characteristics and achievable level of cleanliness The filtration characteristics of the flushing filters should be chosen on the basis of the cleanliness level required by the system supplier, the ACL (Allowable Cleanliness Level) for the system in question. The ACL specifies an acceptable contamination level, which is consistent with the contamination tolerance for the most sensitive system components and the desired service life. If the ACL is not informed, standard classifications according to NAS 1638 or ISO 4406 may serve as a guideline for the choice of the filter fineness, see Table 1. For relations between filtration characteristics and flushing time, see item e.1. x mentioned in Table 1 below is defined in the following way: x = number of particles added x m number of particles emitted x m
Pressure Flushing unit at start-up ISO 4406 >160 bar > 160 bar > 160 bar > 160 bar > 160 bar > 160 bar > 160 bar < 160 bar < 160 bar < 160 bar < 160 bar < 160 bar 15/13/10 15/13/10 16/14/11 16/14/11 17/15/12 17/15/12 17/15/12 17/15/12 17/15/12 18/16/13 18/16/13 18/16/13 NAS 1638 4 4 5 5 6 6 6 6 6 7 7 7 Cleanliness on delivery after test run ISO 4406 16/14/11 16/14/11 17/15/12 17/15/12 18/16/13 18/16/13 18/16/13 18/16/13 18/16/13 19/17/14 19/17/14 21/17/14 NAS 1638 5 5 6 6 7 7 7 7 7 8 8 8 Max. allowable contamination ISO 4406 18/16/13 18/16/13 20/17/14 20/17/14 21/18/15 21/18/15 21/18/15 21/18/15 21/18/15 21/18/15 21/18/15 22/19/16 NAS 1638 7 7 8 8 9 9 9 9 9 9 9 10 Typical filter service requirement B x 75 3-5 m 3-5 m 5-10 m 5-10 m 5-10 m 5-10 m 5-10 m 5-10 m 5-10 m 10-20 m 10-20 m 10-20 m

Examples of ship installations Stabiliser with servo valves Steering gear with variable pumps Gantry crane with proportional valves High-pressure winch with aut. tension Hydraulic valve systems Azimuth systems Ramps, gates and doors Proportional remote winch control Variable propeller systems with servo valves Variable propeller systems without servo valves Bow and stern thruster Low-pressure winches and cranes

In general: Find the component, which has the finest level of cleanliness. For instance, a proportional valve typically has a cleanliness requirement of code 18/16/13. In order to maintain a proper cleanliness, the service requirement will be 17/15/12, and for the flushing unit it will be 16/14/11.

Table 1

DS 2396:1998

Examples of particle counting Suck 100 ml oil through an automatic particle-count instrument. Plot the number of particles > 2 m, > 5 m and > 15 m on the code chart. 1408400 365200 33800 > > 2 m is in classification range 21 5 m is in classification range 19

> 15 m is in classification range 16

The ISO cleanliness code is thus 21/19/16. Almost the same method is applied for NAS 1638 classification, except for the fact that only one code number is normally used, in this case NAS cleanliness code 10. For particle sizes between 2 and 5 m and a quantity of 2 x 106, there will be a large uncertainty in the counting result, whereas counting results concerning > 5 m and > 15 m are quite reliable. Results
Counting method: Particle size m Number of particles per 100 ml BDS class Recommended max. NAS class Recommended max. 10 HIAC/ROYCO laser diode according to ISO 4402 and 4406 >2 1408400 >5 365200 > 10 98600 >15 33800 > 30 7600 > 50 1510 > 100 80

Measured water content: Recommended max.: Number of fibres: Comments:

Date : __________________

Signature: __________________________________

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DS 2396:1998

Most filter manufacturers use the x relationship, but other classes to illustrate filtration characteristics. International standardisation is available in this area, see ISO 4572. Nominal Rating and Absolute Rating are examples of other classes. For instance, 10 m abs. should in practice correspond to 10 > 75. The guiding value should be between 75-200. The use of filters with a value higher than 75 is recommended, as higher values shorten the total flushing time. The relationship between system types, filters and level of cleanliness. Please note that if the oil used for the flushing (e.g. system oil) becomes dark and/or blurred after the flushing, then a chemical analysis should be performed to clarify the cause (e.g. oxidation or contamination with water). Normally, the oil is unfit for use if: a. viscosity has changed more than 15%, b. water content exceeds 0.05 per cent by weight, c. neutralisation number is higher than 1.2 mg KOH/g. This applies irrespective of whether the particle counting shows satisfactory results. c. Flushing oil Either system oil or a special flushing oil can be used for flushing. By using the latter, it can be ensured through supplier contacts that the flushing oil is compatible with the system oil and that it does not attack the system components (especially gaskets). When system oil is used, there is a risk that water may occur in the oil after flushing. If this is the case, the water should be removed. Equipment for checking for water in the oil is often available on board newbuildings. Special flushing oils have i.a. a cleaning effect on sticky particles without attacking sealing materials, and without having insufficient properties in regard to lubricate corrosion protection, etc. The flushing oil should, especially when flushing without having adequate possibilities for heating the oil (hard frost), have a relatively low kinetic viscosity, e.g. about 15 cSt at 40 C ~ISO VG 32 (ISO 3448 Viscosity Classification), and have a relatively high specific weight. The flushing oil must be able to meet the requirements of the system supplier. Zinc Additive Oil can be used if the pump (bearings) is designed for it. However, this type of oil can, especially if it is contaminated with water, form breakdown products that may block fine filters. The flushing oil is filled through a filter according to the same guidelines and filtration requirements, etc. which apply to the filling of system oil, see section 12, item c. d. Flushing oil temperatures and flow velocities, etc. d.1 Temperature Heating of the flushing oil will promote the removal of hard-packed installation dirt on the pipe walls, etc. In addition, the viscosity will be reduced, which is beneficial for the achievement of a turbulent flow (see item d.2). However, it should be observed that the flushing oils: a. viscosity must be kept at or higher than 10 cSt out of consideration for the pump in the flushing rig, b. temperature must be kept below 60 C to prevent oxidation of the oil. However, if the oil becomes unfit for use after being used for flushing, an increase of the oil temperature is acceptable, but not higher than to max. 80 C. Quick heating of the oil can be achieved by means of the overflow valve. And with the right flow volume during the actual flushing, it is normally possible to maintain the flushing oils temperature. At low ambient temperatures and, in particular, at high wind speeds, it may become necessary to: a. supplement the heating with a heating element (max. 1 watt/cm2 for stagnant oil and max. 1.5 watt/cm2 for circulating oil, b. cover pipes with tarpaulins or similar. d.2 Flow velocities and capacities The most effective flushing is achieved when the flow velocity is relatively high and/or the viscosity is relatively low, so that a turbulent flow is created in the pipe system during the flushing. Turbulent flows occur when Reynolds figure Re =

W xd v

x 1000 is larger than 3000

For Re > 3000, the flow will always be turbulent. In order to achieve a thinner laminar boundary against the inner pipe wall, recommendations of Re 4000 may be found in various literature.

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DS 2396:1998

Moreover, flushing should be performed with higher Re than what the system will be subjected to during operation at normal service viscosity and max. oil flow. Experience has shown that the flow velocity during flushing should be twice the normal service speed, but always turbulent. W = average flow velocity (m/sec.), d = internal pipe diameter, v = kinematic viscosity in cSt. Example: For flushing of a pipe system with d = 0.40 mm (48.3 x 4) a special flushing oil with v = 27 cSt should be used at a temperature of 50 C. Search for the necessary capacity Q2 in l/min. System oil viscosity: ISO VG 68. Calculation: W=

R xv e d

x 1000 (m/sec.) thus the necessary capacity

Q2 = d x v x Re x x 10-3 for Re = 3000, d (mm) and v cSt gives Q2 = d x v x 0.1414 Q2 = 40 x 27 x 0.1414 = 152.7 ~ 153 l/min. If the system oil (v = 43 cSt at 50 C) had been used for flushing, it would be Q2 ~ 244 (l/min.). If the system oil had only been heated to 40 C (which is not recommendable, see item d.1), it would be Q2 ~ 385 l/min. The viscosity of the flushing oil is therefore highly important in determining the necessary capacity. For determining the necessary capacity, see Table 2. d.3 Pressure drop in pipes To achieve the desired flow velocity, especially in pipes with a small internal diameter, it may become necessary to have a higher pressure available during flushing.
W 2

Pressure drop p = d = mm w = m/sec.

d x 0.1959 = bar/m

d.4 Values for achievement of turbulent flow Necessary oil capacity Q, flow velocity w or pressure drop dp to achieve Re = 3000.
Internal pipe diameter d in mm 4 5 6 7 Q in [l/min.] w in [m/sec.] dp in[bar/m] Q in [l/min.] w in [m/sec.] dp in[bar/m] Q in [l/min.] w in [m/sec.] dp in[bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] 10 6 7.50 2.76 7 6.00 1.41 8 5.00 0.82 10 4.29 0.51 15 8 11.25 6.20 11 9.00 3.17 13 7.50 1.84 15 6.43 1.16 20 11 15.00 11.02 14 12.00 5.64 17 10.00 3.27 20 8.57 2.06
Kinematic viscosity v in cSt at flushing oil temperature

25 14 18.75 17.22 18 15.00 8.82 21 12.50 5.10 25 10.72 3.21

30 17 22.50 24.80 21 18.00 12.70 25 15.00 7.35 30 12.86 4,.3

35 20 26.26 33.76 25 21.00 17.29 30 17.50 10.00 35 15.00 6.30

40 23 30.01 44.09 28 24.00 22.58 34 20.00 13.07 40 17.15 8.23

45 25 33.76 55.81 32 27.01 28.57 38 22.50 16.54 45 19.29 10.41

50 28 37.51 68.90 35 30.01 35.28 42 25.00 20.41 49 21.43 12.86

55 31 41.26 83.37 39 33.01 42.68 47 27.51 24.70 54 23.58 15.56

60 34 45.01 99.21 42 36.01 50.80 51 30.01 29.40 59 25.72 18.57

65 37 48.76 116.44 46 39.01 59.62 55 32.51 34.50 64 27.86 21.73

70 40 52.51 135.04 49 42.01 69.14 59 35.01 40.01 69 30.01 25.20

Table 2
(continues on the next page)

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DS 2396:1998

Internal pipe diameter d in mm 8 10 Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in[bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q i [l/min.] w i [m/sec.] dp i [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] Q in [l/min.] w in [m/sec.] dp in [bar/m] 10 11 3.75 0.34 14 3.00 0.18 11 1.67 0.05 21 2.00 0.05 28 1.50 0.02 35 1.20 0.01 45 0.94 0.01 57 0.75 0.00 71 0.60 0.00 92 0.46 0.00 113 0.38 0.00 141 0.30 0.00 177 0.24 0.00 212 0.20 0.00 247 0.17 0.00 283 0.15 0.00 354 0.12 0.00 424 0.10 0.00 15 17 5.63 0.78 21 4.50 0.40 17 2.50 0.10 32 3.00 0.12 42 2.25 0.05 53 1.80 0.03 68 1.41 0.01 85 1.13 0.01 106 0.90 0.00 138 0.69 0.00 170 0.56 0.00 212 0.45 0.00 265 0.36 0.00 318 0.30 0.00 371 0.26 0.00 424 0.23 0.00 530 0.18 0.00 636 0.15 0.00 20 23 7.50 1.38 28 6.00 0.71 23 3.33 0.18 42 4.00 0.21 57 3.00 0.09 71 2.40 0.05 90 1.88 0.02 113 1.50 0.01 141 1.20 0.01 184 0.92 0.00 226 0.75 0.00 283 0.60 0.00 354 0.48 0.00 424 0.40 0.00 495 0.34 0.00 566 0.30 0.00 707 0.24 0.00 848 0.20 0.00

Kinematic viscosity v in cSt at flushing oil temperature

12 15 20 25

32 40 50 65 80 100 125 150 175 200 250 300

25 28 9.38 2.15 35 7.50 1.10 28 4.17 0.28 53 5.00 0.33 71 3.75 0.14 88 3.00 0.07 113 2.34 0.03 141 1.88 0.02 177 1.50 0.01 230 1.15 0.00 283 0.94 0.00 354 0.75 0.00 442 0.60 0.00 530 0.50 0.00 619 0.43 0.00 707 0.38 0.00 884 0.30 0.00 1061 0.25 0.00

30 34 11.25 3.10 42 9.00 1.59 34 5.00 0.41 64 6.00 0.47 85 4.50 0.20 106 3.60 0.10 136 2.81 0.05 170 2.25 0.02 212 1.80 0.01 276 1.38 0.01 339 1.13 0.00 424 0.90 0.00 530 0.72 0.00 636 0.60 0.00 742 0.51 0.00 848 0.45 0.00 1061 0.36 0.00 1273 0.30 0.00

35 40 13.13 4.22 49 10.50 2.16 40 5.83 0.56 74 7.00 0.64 99 5.25 0.27 124 4.20 0.14 158 3.28 0.07 198 2.63 0.03 247 2.10 0.02 322 1.62 0.01 396 1.31 0.00 495 1.05 0.00 619 0.84 0.00 742 0.70 0.00 866 0.60 0.00 990 0.53 0.00 1237 0.42 0.00 1485 0.35 0.00

40 45 15.00 5.51 57 12.00 2.82 45 6.67 0.73 85 8.00 0.84 113 6.00 0.35 141 4.80 0.18 181 3.75 0.09 226 3.00 0.04 283 2.40 0.02 368 1.85 0.01 452 1.50 0.01 566 1.20 0.00 707 0.96 0.00 848 0.80 0.00 990 0.69 0.00 1131 0.60 0.00 1414 0.48 0.00 1697 0.40 0.00

45 51 16.88 6.98 64 13.50 3.57 51 7.50 0.92 95 9.00 1.06 127 6.75 0.45 159 5.40 0.23 204 4.22 0.11 255 3.38 0.06 318 2.70 0.03 414 2.08 0.01 509 1.69 0.01 636 1.35 0.00 795 1.08 0.00 954 0.90 0.00 1114 0.77 0.00 1273 0.68 0.00 1591 0.54 0.00 1909 0.45 0.00

50 57 18.75 8.61 71 15.00 4.41 57 8.33 1.13 106 10.00 1.31 141 7.50 0.55 177 6.00 0.28 226 4.69 0.13 283 3.75 0.07 354 3.00 0.04 460 2.31 0.02 566 1.88 0.01 707 1.50 0.00 884 1.20 0.00 1061 1.00 0.00 1237 0.86 0.00 1414 0.75 0.00 1768 0.60 0.00 2121 0.50 0.00

55 62 20.63 10.42 78 16.50 5.34 62 9.17 1.37 117 11.00 1.58 156 8.25 0.67 194 6.60 0.34 249 5.16 0.16 311 4.13 0.08 389 3.30 0.04 506 2.54 0.02 622 2.06 0.01 778 1.65 0.01 972 1.32 0.00 1167 1.10 0.00 1361 0.94 0.00 1555 0.83 0.00 1944 0.66 0.00 2333 0.55 0.00

60 68 22.50 12.40 85 18.00 6.35 68 10.00 1.63 127 12.00 1.88 170 9.00 0.79 212 7.20 0.41 271 5.63 0.19 339 4.50 0.10 424 3.60 0.05 551 2.77 0.02 679 2.25 0.01 848 1.80 0.01 1061 1.44 0.00 1273 1.20 0.00 1485 1.03 0.00 1697 0.90 0.00 2121 0.72 0.00 2545 0.60 0.00

65 74 24.38 14.55 92 19.50 7.45 74 10.84 1.92 138 13.00 2.21 184 9.75 0.93 230 7.80 0.48 294 6.09 0.23 368 4.88 0.12 460 3.90 0.06 597 3.00 0.03 735 2.44 0.01 919 1.95 0.01 1149 1.56 0.00 1379 1.30 0.00 1608 1.11 0.00 1838 0.98 0.00 2298 0.78 0.00 2757 0.65 0.00

70 79 26.26 16.88 99 21.00 8.64 79 11.67 2.22 148 14.00 2.56 198 10.50 1.08 247 8.40 0.55 317 6.56 0.26 396 5.25 0.14 495 4.20 0.07 643 3.23 0.03 792 2.63 0.02 990 2.10 0.01 1237 1.68 0.00 1485 1.40 0.00 1732 1.20 0.00 1980 1.05 0.00 2475 0.84 0.00 2969 0.70 0.00

Table 2

e. Flushing times and methods for checking of cleanliness level e.1 Flushing times The flushing time is reduced if the temperature and flow velocity are kept relatively high (see Table 2) and also at increased filtration efficiency.

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DS 2396:1998

Figure 2 The x relationships influence on the flushing time and the achievable level of cleanliness
A coarse filter requires (see Figure 2) a long flushing time without achieving a particularly high level of cleanliness. The general guideline is that the higher the x relationship, all other things being equals, the shorter the flushing time. An efficient filter must therefore be chosen in order to reduce the flushing time to an acceptable length. The extra cost of the better filter is outweighed by the saving in flushing time. Thus, the flushing time depends on the available possibilities for promoting the flushing process. However, the flushing must continue until the filter element chosen according to section 11, item 1.b, no longer shows an increasing loss in pressure p (indicated by for instance a contamination indicator), if necessary the filter element is changed. If too much water is present (see section 11. item 1.b.2), the flushing oil should be changed. Next the flushing oils level of cleanliness is checked, which for the system in question must observe the level specified by the system supplier or if such data is not available, determined according to Table 1. e.2 Methods for checking of cleanliness level The cleanliness level achieved by means of the flushing can be established and/or documented in various ways. In the following, selections of methods are described of which method No. 4, perhaps supplemented with method Nos. 1 and 3 is recommended for use at the yards to establish the cleanliness level in connection with the practical execution of the flushing process. The true level of cleanliness of a system is reflected not only by the speed whereby a given level of cleanliness is achieved by flushing, but also by how much the level of cleanliness drops when the flushing filter is disengaged from the circuit. The level at which contamination stabilises itself is called the systems true level of cleanliness. Methods based on evaluation of changes in the pressure: Method 1: Evaluation of p pressure drop across filter By observing the p-pressure gauge in connection with the sequential exchange of the flushing filter element in order to establish when the p level no longer increases in relation to for a new clean element (indicated by e.g. a contamination indicator). it is possible during the flushing to establish when the required level of cleanliness is reached, provided that well-established flushing filters in accordance with section 11, item 1.b. are used. It should again be underlined that the condition for using this method is the correct choice of flushing filter (see section 11. item 1.b). In particular, the filtration characteristics are of great significance (use x see section 11. item 1.b.2). Method 2: Evaluation of pressure rise Same principles as for method 1. However, in this case it is the pressure rise before the filter that forms the basis of the method. These methods are considered to be uncertain because of the varying temperature conditions and consequent changes in viscosity. Methods based on visual comparison and/or particle counting* * Particle counting can be performed automatically (see ISO 4402) or manually (see ASTM F312) by means of various methods. For instance the Technological Institutes, see code No. for suppliers under DVS 08004 in the DVS register, are willing to offer guidance in connection with the acquisition and training in the use of such equipment, or to perform the particle counting on request. For guidance on oil sampling and particle counting, see DVS 08006.

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Method 3: Direct collection method

DS 2396:1998

In connection with the flushing, samples are collected directly, according to further specified rules, by means of a filtration kit. The filtration result can be evaluated visually on board, e.g. by a comparison with the Master Slide. In conclusion visually evaluated samples can be re-checked by means of a particle counting analysis (see the below chart of particle counting samples and results) or a portable particle-count instrument. Method 4: Indirect collection method Flushing oil samples are collected in containers. according to further specified rules. in connection with the flushing process. The samples are sent to a laboratory where they are analysed by means of particle counting (see the below chart of particle counting samples and results). 11.1 Leakage testing When sufficient cleanliness has been achieved for yard manufactured pipe systems, make preparations for pressure testing of the pipe system. The pipes are to be connected and tested for any leakage in accordance with the specification. 11.2 Activation of components a. b. c. With the portable pump station (the flushing rig) still being engaged, the pipe connections are connected in accordance with the plants flow diagram. Any flushing oil is drained off. With the flushing rig pump in neutral position the previously blanked-off or by-passed components can be cautiously activated while slowly increasing the oil flow and pressure to the specified values. Repeat the flushing process in accordance with section 11, item 1, until the specified cleanliness is achieved for the complete system.

12. Start-up of system

a. b. Drain off the flushing oil. It can be reused after cleaning and an analysis showing that the flushing oil still complies with the suppliers specification of additives and viscosity and that the content of water is not too high (see section 11, item 1.b.2). Dismount the portable pump station and engage the systems own pump station. Install filters elements with capacity and characteristics in accordance with the system suppliers specifications or determined in accordance with section 11, item 1.b in the permanent filter units, perhaps with finer filters during initial commissioning. Fill system oil through a filter and/or according to the suppliers directions. The system oil must be filtered to the cleanliness level required by the system (e.g. see Table 1). Unless otherwise indicated, a pump with a filter is recommended. The preferred oil supplier is to be agreed with the owner in question. Vent and top up the system. Adjust the pressure valves to the specified pressures. The system supplier should check the system to the necessary extent. Start and run up the system to the specified working pressure. Test the system performance. In conclusion, oil samples can be extracted for analysis and documentation of the cleanliness level (as mentioned in section 11. item 1.e.2) as a test of the delivered system.

c.

d. e. f. g. h.

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DS 2396:1998

Annex A (Informative)
Bibliography This series of Danish standards make reference to the following DVS standards regarding recommended solutions to relevant problem areas. DVS 05008 DVS 05009 DVS 05010 DVS 05011 DVS 05012 DVS 05013 DVS 10005 Rust, wire brush and sand blasting levels Steel pipes, black, basis for achievement of clean pipes Steel pipes, black, cleaning of prefabricated pipes and fittings after welding together Steel pipes, black, chemical cleaning Steel pipes, black, mechanical blow cleaning Steel pipes, scale free, basis for achievement of clean pipes Components for pipe systems, requirements to cleanliness, transport, etc.