A procedure for lube oil flushing

Published on: April 30, 2020

TMI Staff & Contributors
Flushing with lube oil is carried out to remove dirt from the system by loosening it from the
inside of the system or by dissolving it in the flushing oil. Dirt which is picked up by the flushing
oil will be caught in the fine mesh installed in the return line and can be removed.

This article contains an excerpt from the paper, “Save your Centrifugal Machinery during
Commissioning” by Arun Kumar and Mohit Sabharwal of HPCL- Mittal Energy Ltd at the 2018
Asia Turbomachinery & Pump Symposia.

Before charging the lube oil inside the tank, it is important to ensure that the lube oil tank & run
down tank are thoroughly cleaned. All loose foreign material such as scale, sand,weld splatter
particles and cutting chips shall be removed. The inside of the interconnecting piping should be
wire brushed where accessible. Thereafter, the interconnecting piping shall be thoroughly cleaned
before installation by air or steam blowing.

Lube Oil piping is to be connected and for initial flushing temporary bypass piping is to be
connected for bearing housings and Seal Oil supply. The scheme is to be validated by the
machinery OEM. Orifices, probes and other flow restrictions must be removed for cleaning and
flushing to obtain optimum velocities. All removed items shall be tagged and properly store for
reinstallation. All the pressure gauges except lube oil pump discharge pressure gauge, pressure
switches and instrument connections shall be isolated. All the PSVs shall be removed and
blinded during the flushing.

Ensure Motor power connection is provided and, that the auxiliary and emergency oil pumps are
ready for use to circulate lube oil. The entire lube oil circuit is divided into different
circuits/loops so as to make the flushing more effective. Flushing of successive loops shall be
started after the completion of flushing of preceding loop. Fill the tank with enough oil (up to
min. level shown on the level gauge) i.e., up to the level such that the pump suction is fully
immersed during flushing. Note that after starting the flushing oil, the level will drop inside the
tank so make-up oil arrangement should be ready. Ensure that the lube oil tank heater is
commissioned and maintains the temperature between 60-70 deg C.

Advertisement
Make temporary hose connections / jump overs across the bearing housing as per the identified
scheme connecting the supply lines to return header with fine mesh (100 mesh plain weave,
stainless steel) in-between. Install fine mesh (100 mesh plain weave, stainless steel) in the lube
oil return line just before the tank as identified in the scheme. In the first circulation, filter
elements should not be installed. Once the clarity of lube oil improves, filter elements should be
installed properly seated in the filter housing. Ensure filter element commissioning spares are
available. At the time of lube oil flushing through bearing, the dry gas seal should not be in place
but if it is already installed then a nitrogen/Instrument air purge shall be provided as a separation
gas at design pressure.

Sufficient venting of the oil cooler & filters shall be done while taking inline to ensure no air
pockets is left. Once the filter element is installed, periodically check the pressure drop across
the oil filter. When the pressure drop becomes too high (As per OEM recommendation) change
over to the clean filter element. Remove and replace the dirty filter element.
Initially fine wire mesh should be checked after ½ hr. of circulation for accumulation of
dirt/corrosion products. Carry out the flushing of lube oil piping through the fine mesh into the
return header for 12 hours for each loop. Periodically strike the piping in an attempt to loosen any
foreign material. Vary the oil temperature during the flushing process from hot to cold and vice
versa a number of times. Stop the lube oil pump after 12 hours of circulation, allow for oil to
drain back in to the tank and check the fine mesh for collected particles. Repeat flushing till no
particles are observed visibly and no grittiness in felt by touch. The system shall be considered to
be clean when the return line mesh found to be free from any foreign particles.

A Centrifuge/online cleaning system shall be used for cleaning the lube oil in the reservoir during
flushing. On the completion of the flushing, lube oil sample shall be taken from the reservoir
bottom and checked for water content and dirt contamination. Depending on the results oil shall
be conditioned or replaced with fresh oil.

6 Steps for Successful Oil Flushing

Larry B. Jordan

Proper oil flushing of rotating equipment tends

to be an afterthought. Whether it is commissioning or maintenance involving end users,
construction groups or manufacturers, oil flushing tends to be thought of as a "just do it" item.
The only time it becomes a priority is when a system fails, and then it is all about getting back on
line quickly and not so much about planning. Fortunately, there is a better way. The following six
steps are intended to help you achieve a more successful high-velocity oil flush.

Step 1: Realization and Understanding

Realizing that most commissioning groups and maintenance personnel are not oil flushing experts
is the first step. Understanding that there are subject-matter experts available is step 1A. This step
can be tricky. Not all flushing companies are equal. I have had the privilege of working for the
same organization for 24 years.
We started as a couple of individuals in a two-bay garage and grew to a global corporation, which
is to say that size doesn't always matter. We used the same principles in our early years that are
still employed today. In fact, many of the larger companies tend to focus more on chemical
cleaning and perform oil flushing as a requirement to receive a contract. This leads to step 2.
Step 2: Research
Any reputable oil flushing company will be able to provide references and case studies, so ask for
them and follow up. Review documents, make phone calls and visit the flushing contractor's
facility if possible. How a company's facility is maintained can say a lot about how it will execute
in the field. How does the contractor handle equipment maintenance? How is product cross-
contamination prevented?
What does the facility's safety plan look like? Don't just rely on a salesman telling you, "We got
this." Finding out later that you were the guinea pig and that the company had never flushed your
type of unit before can result in costly delays or damage to your system.

Step 3: Planning
Generally, the only time planning is avoided is during a system failure. Then it becomes all hands
on deck to get the unit back up and producing. My philosophy is a little different. If you are an
owner or end user, the planning stage should take place while your systems are running and
everything is quiet.
The process begins with the creation of a customized plan for your unit. This plan should include
written procedures, materials to bypass critical equipment, items the site supplies, items the
contractor will supply, detailed steps, safety requirements, and most importantly the criteria used
to execute the oil flush and deem the system clean.
The cleanliness criteria will depend on many factors, such as if the unit is being flushed for
commissioning. If so, the manufacturer will supply cleanliness requirements to meet the
warranty. When in doubt, refer to API 614 for general-purpose lube oil systems or ASTM
D6439-99 (Standard Guide for Cleaning, Flushing, and Purification of Steam, Gas, and
Hydroelectric Turbine Lubrication Systems).
These standards should be used as the minimum criteria, but it is always best to customize your
plan for the individual system using the manufacturer's recommended specifications.
Additional items to consider include deviations to procedures, safety data sheets, a spill
prevention plan, emergency contact phone numbers and signature lines for approving the
procedure.

Step 4: Verification
Whether you are performing the oil flush yourself or hiring a contractor, several things must be
verified first. Develop a checklist and run through it prior to staging for the flush. Check for any
foreign material that may contaminate your system, such as different lubricants or rusty fittings.
Ask your contractor for foreign-material exclusion plans and confirm that all materials are
adequate with pressure testing records for temporary hoses, certificates of calibration for testing
equipment, flow charts for temporary pumps and maintenance procedures. Reputable contractors
should be able to provide these documents and walk you through their standard operating
procedures.
Step 5: Execution and Delays
To help your oil flush be a success and avoid undue headaches, it is important to be wary of
certain issues, such as the system's coolers. Coolers have the potential to hold dirt, decrease flow
and cause delays. If possible, coolers should be pulled and cleaned separately. If time does not
allow this, flush as a separate circuit to reduce the possibility of the coolers becoming a dirt trap.
When performing an oil flush, remember that it is about flow and not pressure. Fluid will become
turbulent at a Reynolds number of 4000, which takes into account flow, temperature and
viscosity. However, while the fluid becomes turbulent at this rate, it is not always adequate to
pick up and carry foreign materials out of the system.
This can lead to a lot of confusion, as the system will appear clean as you flush it, but then
starting and stopping the pump will free debris and send it into your inspection media. Most
successful oil flushes utilize targeting flow at two to three times the normal flow rate of the
system's pumps. This requires external temporary pumps or running primary and redundant
pumps if performing the oil flush yourself.
Regardless of the system's size, it is recommended to have at least a 24-hour "course" flush at a
high flow prior to inserting the inspection media. Once the initial 24-hour flush is completed, the
inspection media should be inserted at the farthest point from the filter. Run the system for one
hour and then review the inspection media.
This can tell you if the course flush should continue or if the system is ready for the inspection
phase. When performing an oil flush on larger systems, consider extending the initial course flush
to 48-72 hours. Shutting down to look at a dirty screen will only delay the process, and the
downtime can add up quickly.
Poor decision-making and not having the right people involved can delay an oil flush longer than
any of the items listed above. Identifying the decision-maker for all parties on the front end can
eliminate many delays. More than 90 percent of oil flushing today runs 24 hours a day and seven
days a week, so having decision-makers available at the right time can save days with some oil
flushes.

Step 6: Documentation
In addition to written procedures, be sure to document all aspects of the oil flush. Keeping logs of
the temperature, flow, pressure, filter life and work activity will be vital in determining if the
flush is on schedule or if something has changed.
At the end of the oil flush, these records, procedures and any photos can be compiled into a
complete document, which will be helpful if flushing the unit again in the future. This will also
can come in handy when justifying the current or future oil flushing.
In conclusion, it usually is not one item that turns a three- or four-day oil flush into two to three
weeks. In most cases, it is a combination of little events. Always start with a good plan and verify
that it is being followed. Be adaptable and willing to course correct as needed (but document the
changes). Build in contingencies and plan, plan and plan. Good luck in making your next oil flush
a successful one.
About the Author
Larry Jordan has worked with industrial lubricants for 29 years and is a subject-matter expert in
high-velocity oil flushing and oil conditioning. Larry is currently a senior services technical
adviser at Reliable Industrial Group. For more of Larry's oil flushing tips and advice, contact
him via LinkedIn at: https://www.linkedin.com/in/larry-jordan-10b25456/.

How to Check System Cleanliness

After an Oil Flush
Nic Schaff

Before any oil flush project, it is important to set a cleanliness goal. Whether it’s a
simple rinse/purge as part of a lubricant change, or a high-velocity oil flush after a
major system failure, at the end of the process, you should be confident that the
target system cleanliness has been achieved.
When we enter the planning phase of a flushing project with a customer, we help you
establish cleanliness targets aligned with your goals and OEM specifications that
meet ISO 4406 or NAS 1638 cleanliness requirements. After the process is
complete, there are several ways to check that these targets have been achieved,
ranging from simple visual inspections to laboratory analysis. Because contaminants
come in a range of sizes and types, it’s important to address both the particles you
can see with the naked eye and those you cannot. Often, the best approach is to use
a combination of methods that provide accurate and reliable results without spending
extra time or money needlessly.
Flange Screens
Generally preferred by oil flushing experts, flange screens (or slip screens) can be placed
between two flanges in place of gasket material. This style of screen allows for the full-flow
particle capture and multiple screens can be layered together.
Screens are a simple indicator of cleanliness. As they are coated with debris, they should be
removed and cleaned to avoid the potential for fluid backup. By the end of a flushing
procedure, screens should be looking clean and free of buildup. Since a screen is a frontline
inspection location, it’s often helpful to add valves on either side of the screen to make it
easy to perform spill-free inspections of your screens.

Example of a screen used in an Industrial Fluid

Maintenance (IFM) high-velocity oil flushing project.

Strainers
Strainers, like filters, are used to remove contaminants as oil passes through them.
Strainers are generally used to capture larger contaminants (40 microns or larger)
but can also be used to check the cleanliness of oil. Because forty microns is
generally the smallest particle size that can be seen by an unaided eye, strainers
retain particles that will be visible to the inspector. There are a few types of strainers
to consider using for inspections:

 Wye Strainers – These strainers employ a cylindrical screen for inspections.

Care should be taken, however, as contamination can drop out into the
screen cover, resulting in a false positive reading.
 Basket Strainers – These strainers are commonly used in oil flushes and
have a sealed bottom that catches materials for inspection.
 Witch’s Hat Strainers – Less commonly used during oil flushes, witch’s hat
strainers are often used in the return header to prevent contaminants from
reaching the reservoir. These strainers are useful for the detection of gross
contamination, but the screens have a tendency to tear.
Portable Particle Counters
One of the most reliable ways to verify the amount of microscopic particles present in oil,
onsite particle counters also provide the benefit of speed. Different types of counters are
better suited for different applications.
Light-refracting counters, for example, work well with turbine and hydraulic fluids but are
often inaccurate when used with darker oils or oils contaminated with moisture.
Pore-blockage counters, on the other hand, do work with dark or moisture-contaminated oils
but are sensitive, requiring special care in terms of handling and calibration.

High-quality particle counters will generally provide data for both the National Aerospace
Standard (NAS) and the International Organization for Standardization (ISO) cleanliness
codes.

Because it relies on light, a light-refracting particle counter can be inaccurate for darker oils or those
contaminated with moisture.

Bag Filters
Cheap and readily available, bag filters can be used like filters, in regards to
inspections. Bag filters are nominal, however, meaning they do not capture all of the
contamination. Additionally, they can present difficulties when inspecting and often
have to be cut open to allow for a particle count.
Laboratory Analysis
Laboratory testing offers the confidence of controlled and certified results. The
downside of lab testing is the amount of time required to receive those results: You
must collect a sample, package and send it, wait for the lab to test it, and then
receive the final results; the process can take several days or even weeks.
Patch Testing

Labs can give highly accurate results, but they are often
too time consuming for verifying system cleanliness after an oil flush.

Patch tests are a quick way to determine particle counts in oil

but are susceptible to human error. IF needed, the results of a patch test can
be supported by further laboratory analysis. A patch test works by submitting a
specific volume of oil to a membrane filter; the sample is pulled through the
membrane with either an electric or manual pump.

The pore structure of the membrane prevents particles above a specific size from
passing through, instead retaining them on the surface. Residual oil is then washed
from the membrane surface with a solvent. Following this process, the membrane is
inspected for discoloration and particle density. The sample can then be compared
to standard patches of known contamination levels, determining the cleanliness of
the oil.

Patch tests are relatively inexpensive, easy to perform in the field, and, unlike optical
particle counting, patch tests allow for the inspection of organic particles, particle
shape, particle color, and edge detail. For that reason, they are one of the primary
methods we use in oil flushing projects.
 Here, a technician is using a patch test kit with a manual pump to perform the test.

How does IFM Verify Cleanliness?

We frequently use a combination of screen inspections and patch tests to verify system
cleanliness during and after a flushing project. In most cases, a cleanliness target of
16/14/11 ISO 4406 has been set, which can be accurately verified by a patch test. In
addition, we provide a comprehensive post-job report within 30 days of project completion
that includes information on cleanliness tests along with all daily reports and related
documentation. Third-party lab analysis is often included with this report including a laser
net-fines and pictures from the patch test.

Whether you are considering flushing for a commissioning project, switching to a new oil, or
addressing a maintenance issue, IFM is here to help

Gek 3256f