Astm D6439 11

Designation: D6439 − 11
Standard Guide for

Cleaning, Flushing, and Purification of Steam, Gas, and
Hydroelectric Turbine Lubrication Systems1
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-
1.1 This guide covers types of contaminants, oil purification cation systems. Some equipment specified herein, however,
devices, contamination monitoring, contamination control dur- may not be appropriate for all systems. Moreover, in situations
ing building or refurbishing of turbine systems, lubrication where specific guidelines and procedures are provided by the
system flushing, and maintenance of pure lubrication oil. equipment manufacturer, such procedures should take prece-
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
turbine generators and propulsion and mechanical drive equip-
2. Referenced Documents
ment. This guide is generalized due to variations in the type of
equipment, builder’s practices, and operating conditions. 2.1 ASTM Standards:2
D445 Test Method for Kinematic Viscosity of Transparent
1.3 This guide primarily addresses petroleum based lubri-
and Opaque Liquids (and Calculation of Dynamic Viscos-
cating oil. For systems using nonpetroleum based fluids, this
ity)
guide may not be appropriate. For nonpetroleum products,
D664 Test Method for Acid Number of Petroleum Products
consult the equipment and fluid manufacturers.
by Potentiometric Titration
1
This guide is under the jurisdiction of ASTM Committee D02 on Petroleum
Products and Lubricants and is the direct responsibility of Subcommittee D02.C0.01
2
on Turbine Oil Monitoring, Problems and Systems. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved May 1, 2011. Published July 2011. Originally approved contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
in 1999. Last previous edition approved in 2005 as D6439–05. DOI: 10.1520/ Standards volume information, refer to the standard’s Document Summary page on
D6439-11. 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
Copyright by ASTM Int'l (all rights reserved); 1

D6439 − 11
D974 Test Method for Acid and Base Number by Color- 3.1.1 adsorption, n—removal of contaminants from oil by
Indicator Titration adhesion of the contaminant in an extremely thin layer of
D2272 Test Method for Oxidation Stability of Steam Tur- 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-
3.1.2 centrifugation, n—use of centrifugal force to separate
cating Oil Systems (Withdrawn 2008)3
contaminants from oils. Contaminants such as water and
D4248 Practice for Design of Steam Turbine Generator Oil
particulate are generally more dense than the oil and migrate to
Systems (Withdrawn 2008)3
the outside of the centrifuge because of centrifugal force.
D4378 Practice for In-Service Monitoring of Mineral Tur-
bine Oils for Steam and Gas 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
Turbine Oils by Linear Sweep Voltammetry 3.1.5 coalescence, n—process of passing oil with free water
D7155 Practice for Evaluating Compatibility of Mixtures of through a fiber sheet, generally in a cartridge form, to cause
Turbine Lubricating Oils smaller drops of water to join to form larger ones that can be
D7546 Test Method for Determination of Moisture in New more easily removed from the oil.
and In-Service Lubricating Oils and Additives by Relative 3.1.6 coalescer, n—device that uses coalescence to separate
Humidity Sensor water from oil. A coalescer generally consists of a coalescing
D7647 Test Method for Automatic Particle Counting of cartridge(s) and a hydrophobic barrier that hinders water from
Lubricating and Hydraulic Fluids Using Dilution Tech- passing out with the oil. It may also contain a filter located
niques to Eliminate the Contribution of Water and Inter- upstream or downstream, or both, of the coalescing car-
fering Soft Particles by Light Extinction tridge(s).
F311 Practice for Processing Aerospace Liquid Samples for
Particulate Contamination Analysis Using Membrane Fil- 3.1.7 displacement flush, n—system flush using on-board
ters turbine pumps designed to remove unwanted materials from
F312 Test Methods for Microscopical Sizing and Counting installation or repair.
Particles from Aerospace Fluids on Membrane Filters 3.1.8 displacement oil, n—oil used to remove either a lighter
2.2 ISO Standards:4 grade flush oil or an oil that is highly contaminated with oil
ISO 3722 Hydraulic Fluid Power—Fluid Sample soluble material.
Containers—Qualifying and Controlling Cleaning Meth-
ods 3.1.9 filter, n—device containing a screen or fiber depth
ISO 4021 Hydraulic Fluid Power—Particulate Contamina- medium that removes particles from oil by physically trapping
tion Analysis—Extraction of Fluid Samples from Lines of them in or on the screen or mesh.
an Operating System. 3.1.10 flushing, v—circulation of liquid through the lubrica-
ISO 4406 Hydraulic Fluid Power—Fluids—Method for tion system or a component, when the turbine is not operating,
Coding Level of Contamination by Solid Particles to remove contaminant.
ISO 4572 Hydraulic Fluid Power—Filters—Multi-pass
3.1.11 high-pressure water flush, n—use of high-pressure
Method for Evaluating Filtration Performance
water to remove heavy rust or fouling from lube system
2.3 API Standard:5 internals.
API 614 Lubrication, Shaft-Sealing, and Control-Oil Sys-
tems for Special Purpose Applications 3.1.12 high-velocity flush, n—system flush using external
pumps that generate three to four times normal operating
3. Terminology system velocities and a Reynolds number over 4000.
3.1 Definitions of Terms Specific to This Standard: 3.1.13 operating oil, n—specific charge or chemistry of oil
to be used as the final fill oil after the flush.
3
The last approved version of this historical standard is referenced on 3.1.14 oxidation, n—chemical reaction of a lubricant at
www.astm.org.
4
elevated temperatures between dissolved atmospheric oxygen
Available from American National Standards Institute (ANSI), 25 W. 43rd St.,
and the base oil. Oxidation reaction will be accelerated by the
4th Floor, New York, NY 10036.
5
Available from American Petroleum Institute, 1220 L St. NW, Washington, DC presence of oxidation accelerators such as metallic contami-
20005-8197. nants and water.

D6439 − 11
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 system design and continue through the manufacture, installa-
of concentrations that exceed the lubrication system specifica- tion, flushing, operation, and maintenance of the system.
tions. 5.4 Design of the system must consider component con-
3.1.16 purification, v—removal of a contaminant present in taminant sensitivity and provide points for sampling oil and
the oil through a separation process. methods for controlling contaminants. Contamination monitor-
3.1.17 sacrificial flush oil, n—charge of oil that is used in ing is discussed in Appendix X2 and contamination control
the flushing process and not used as the final operating oil. methods in Appendix X3. Inclusion of filtration in steam and
3.1.18 surface active flush, n—system flush with the use of gas turbine lubrication systems is discussed in Practices D4248
surface active cleaners to remove varnish and sludge. and D4241 respectively.
5.5 The manufacturer must minimize the amount of built-in
4. Significance and Use contaminant by minimizing ingression and by flushing com-
4.1 This guide is intended to aid the equipment manufac- ponents to achieve target cleanliness levels in the finished
turer, installer, and turbine operator in coordinating their efforts component.
to obtain and maintain clean lubrication and control systems. 5.6 Contamination control during installation and major
4.2 The flushing and cleaning philosophies stated in this maintenance of turbine systems is discussed in Section 6.
guide are applicable to both large and small lubrication 5.7 Proper heating is critical during flushing and routine
systems. operation to minimize oil degradation. Heating is discussed in
4.3 Clean lubrication systems result from proper system Appendix X4.
design and good planning, execution, and communication by 5.8 Removal of contamination by flushing is discussed in
all involved during commissioning. No phase of these proce- Section 7.
dures should be undertaken without a thorough understanding
of the possible effects of improper system preparation. The 5.9 Contamination control in operational systems and dur-
installation, cleaning, and flushing of the equipment should not ing routine maintenance is discussed in Section 8. Properly
be entrusted to persons lacking in experience. designed systems can normally control water and insoluble
contaminants in operational systems. If, however, it is neces-
4.4 Because of the knowledge and specialized equipment sary to remove soluble contaminants other than water, an oil
that is required, the operator may wish to employ an outside change and also possibly a flush may be required.
specialist contractor for the system flushing. Review of this
guide can provide guidelines for discussion with prospective
6. Contamination Control When Installing and
contractors.
Refurbishing Turbine Systems
5. Contamination Control Overview 6.1 General:
5.1 Lubrication systems can become contaminated from a 6.1.1 Exclusion or removal of contaminant, or both, in
variety of sources. The main focus of this guide is on the manufacturing or refurbishing, or both, are necessary for a
minimization, monitoring, and control of contaminants: water subsequent successful flush and can be achieved only by the
and both soluble and insoluble (stationary and suspended) cooperation and diligence of many parties.
contaminants. A more detailed discussion of these types of 6.1.2 Examples of Essential Precautions to Exclude or
contaminants is given in Appendix X1. Remove Contaminant, or Both:
6.1.2.1 The system should be designed to allow successful
5.2 Contamination control is the complete program of
cleaning.
obtaining and maintaining a clean lubricant and lubrication
system. This includes proper construction and maintenance 6.1.2.2 The pipe and other equipment must be properly
practices, appropriate purification equipment, and regular cleaned and preserved.
monitoring of contaminants. The contamination control pro- 6.1.2.3 All possible locations for the entrance of dirt (pipe
gram must be capable of identifying and measuring contami- ends) must be durably covered and secured for storage prior to
nants and controlling them at, or preferably below, component shipment and loading. Shipment and unloading must take place
tolerances. In particular, the sensitivity of bearings, gears, without damage to these covers.
seals, and proportional and servo valves should be reviewed. 6.1.2.4 Inspection of pipe at the turbine site must be
As described in X2.7.1, cleanliness levels for various system thorough to discover any damage or open covers and to have
components are generally established by their manufacturers’ them repaired.
specifications. These and recommendations of the fluid manu- 6.1.2.5 Storage prior to installation must be in a sheltered
facturer must be considered when employing contamination location, especially if the storage is to be for a long duration.
control systems. In addition, there are insoluble contaminants 6.1.2.6 Inspection immediately prior to installation must be
(oxidation precursors) that are below machine tolerances, but thorough, and the pipe must be cleaned if excessive rust or dirt
as their volume amasses they create a potential for sludge and is discovered.
varnish creation as a normal consequence of oxidation reac- 6.1.2.7 Continuous monitoring of conditions during the
tions. complete turbine installation must take place to ensure that

D6439 − 11
cleanliness related tasks are being accomplished. Dirt should 6.2.2.2 Once the rust preventative is removed, the ferrous
not be introduced into the pipes and equipment. surfaces are subject to rust unless care is taken to keep all
6.1.2.8 Great care must be taken to prevent contaminant surfaces oil-wetted. Corrosion of unwetted surfaces can be
entry during any modifications. minimized by the use of vapor space inhibited oils to the
6.1.2.9 The work area must be kept clean. maximum extent possible. The general procedure for the use of
6.1.2.10 This list is not complete, but it does illustrate that the vapor space inhibited oils is as follows:
the manufacturer, the shipper, the operator, and the installation (1) Wet all surfaces with vapor space inhibited oils after
contractor are all responsible for ensuring that no contaminants cleaning.
enter the lubrication system. These efforts to prevent the (2) Do not drain; add sufficient oil to provide a reservoir of
entrance of dirt will make the flushing procedure easier, safer, the oil in the assembly.
and shorter, and thus less costly. (3) Seal the component to prevent loss of vapor phase
protection and intrusion of contaminants.
6.2 On-Site Contamination Control:
6.2.2.3 These vapor space inhibited oils may be fully
6.2.1 General: compatible with regular lubricating oils and flushing oils, and
6.2.1.1 All components that are fabricated and assembled at draining or removal may not be necessary. Compatibility
a manufacturer’s facility and received as a unit for installation testing in accordance with Practice D7155 is recommended to
in the system are defined as preassembled components. confirm compatibility. In addition, it has been shown that these
6.2.1.2 The preassembled components should be inspected oils may provide some residual protection to the system and
upon receipt to determine condition and degree of protection. minimize corrosion after the oils have been drained or dis-
All seals and caps intended to exclude moisture and dirt should placed.
be checked for integrity and replaced as required. If the initial 6.2.2.4 The vapor space inhibited oils are available in a
or a subsequent inspection discloses dirt or rusting, the item range of viscosities. However, if an oil of significantly higher
should be immediately cleaned, represerved, and sealed, as viscosity than the flushing oil is used, draining of the as-
required. Because of the variety of equipment and materials, sembled system to limit the amount of the higher viscosity to
details for each case cannot be given here. For painted (coated) 10 % is recommended to prevent significantly increasing the
components, the coating should be inspected for integrity and viscosity of the flushing oil.
renewed as necessary. All components should be checked to
ensure that all tape and temporary supports or restraints have 6.2.3 Gear Assemblies:
been removed. 6.2.3.1 When shipping gears, additional braces and tapes
6.2.1.3 Undercover storage is recommended. Monthly in- are frequently used to prevent movement of the elements and
spections are recommended, and corrective steps must be taken damage to the teeth and bearings. Upon receipt of the as-
when necessary. Care must be taken during inspections to sembled gears at the installation point, an inspection should be
minimize disturbance of equipment protection. conducted with the gear manufacturer’s representative to
determine whether any damage has occurred during shipment.
6.2.2 Corrosion Protection:
At this time the gears should be thoroughly inspected for
6.2.2.1 The application of various types of rust preventives
contamination, and if any is found, the manufacturer’s recom-
is required to protect uncoated ferrous surfaces from corrosion
mendation should be followed for proper represervation. Peri-
during the storage and installation phases. Most preservatives
odic inspections, careful to minimize vapor space inhibition
today are oil soluble, and special procedures, such as hydraulic
loss, should be made to ensure that proper preservation is
lancing, are often used to preserve gear cases, sumps, and
maintained until the gear assembly is placed into regular
tanks. The preservative compounds can normally be removed
operation. Upon installation, all temporary restraints, including
by flushing the system with regular lubrication oil or oil
tape, must be removed.
solvent, although hand cleaning of some components is also
employed. If possible, however, the flush oil, operating oil, and 6.2.3.2 Speed reducers are normally shipped with a thin
preservative should be compatible to preclude foaming, the coating of preservatives applied to all internal machined
formation of emulsions, precipitates or the breakdown of surfaces that are in contact with lubrication oil, such as gear
lubrication oil additives. A system flush (displacement flush) teeth, bearings, journals, interior housing surfaces, and oil
with a sacrificial flush oil is often recommended to minimize piping. The preservative is oil soluble and is normally removed
operating oil contamination which could result in reduced by the flushing program. Gear cases, protected by vapor space
performance. Product compatibility of the flush oil should be inhibited lubricating oil, should be inspected upon receipt for
confirmed in accordance with Practice D7155 testing. Caution integrity of seals. Damaged seals should be replaced immedi-
should be exercised in this regard. Compatibilities and limita- ately. If the oil has been lost, the gear case and the gears should
tions may generally be obtained from the oil suppliers. It is be pressure sprayed through the inspection openings with
strongly recommended that preservative oil removal and pre- filtered vapor space inhibited oil or rust preventive oil at 55 to
servative oil solubility in, and compatibility with, all subse- 57°C (130 to 135°F). Starting at the top of the case, the gear
quent oils, including the system oil, be reviewed at every step case and the gears should be thoroughly flushed down. After
of subsequent processes. Review with the equipment manufac- flushing, the oil level recommended by the gear manufacturer
turer may also be beneficial. All oils added, including preser- should be reestablished and the unit sealed.
vative oils, should be filtered as discussed in 7.6. 6.2.4 Valves, Strainer, and Coolers:

D6439 − 11
6.2.4.1 Valves, strainers, and coolers, when received from 7.2.1.1 For a unit that is field assembled, keeping the
the manufacturer, should be inspected to determine if there is lubrication and hydraulic control system piping clean enough
contamination. If there is evidence of a hard film protective so that flushing is not necessary is economically and practically
coating or contamination, the unit should be dismantled and all impossible. Thus, it is generally recognized that an oil flush
the parts thoroughly cleaned with filtered petroleum solvent. In must take place after the piping has been installed and just
all cases, use clean, lintless cloths (not waste cloths), a before the turbine and its driven equipment go into operation.
squeegee, or a vacuum cleaner. The success of this oil flush, however, depends to a large
6.2.4.2 Internal surfaces that cannot be reached should be degree on the success of the efforts to keep dirt out initially and
flushed with an oil soluble cleaner or filtered petroleum the proper conduct of the flush. A successful flush means that
solvent. Alkaline or acid cleaners should not be used. clean pipe and system components are obtained in a minimum
of time and with a minimum of effort.
NOTE 1—Petroleum solvents are flammable; care must be taken to
prevent fires. Precautions must also be taken to ensure that workers do not 7.2.1.2 The cleaning and flushing of both new and used
inhale fumes from the solvent or come into contact with liquid solvents for systems are accomplished by essentially the same procedure.
prolonged periods. Filters can generate electric charges. Proper electrical In the new systems, the emphasis is on the removal of
connection of all equipment prior to transferring fluids or starting flushing
is required.
contaminants introduced during the manufacture, storage, sys-
tem temporary rust protection, field fabrication, and installa-
6.2.4.3 After internal surfaces have been cleaned, they tion. In used systems, the emphasis is on removal of contami-
should be sealed or put into service as soon as possible. If the nants that are generated during operation or are introduced to
internal surfaces cannot be effectively sealed or put into the system during overhaul.
service, they must be thoroughly air dried and coated imme-
7.2.1.3 A displacement flush utilizes a displacement flush
diately by spraying them with filtered and compatible rust
oil of the same chemistry as the operating oil. System pumps
preventive oil. After all surfaces have been coated, the equip-
and flow channels are utilized to circulate the displacement
ment should be reassembled and all openings capped. This rust
flush oil. Side stream filtration is recommended to improve
preventative coating may require removal with flush oil prior to
flush effectiveness.
equipment use.
6.2.5 Sumps and Tanks—Sumps, reservoirs, or tanks should 7.2.2 High-Velocity Flush—For new systems and systems
be completely drained and thoroughly inspected. If present, with service hours that may not require surface active cleaning
rust, mill scale, weld spatter, loose paint, and so forth, should and will benefit from enhanced flushing compared to displace-
be manually removed. A coating of rust-preventive oil, or a ment flushing. High-velocity flushing provides improved
vapor space inhibitor oil, should be applied, and all openings cleaning of typically non-wetted surface areas like the lube oil
should be sealed. This rust preventative coating may require return header.
removal with flush oil. Repainting is not recommended. 7.2.2.1 The primary requirement for a successful oil flush is
6.2.6 Bearings—It is important that bearings be installed by a high oil velocity at least three to four times normal system
qualified personnel. Extreme care should be taken to prevent velocity, and a Reynolds number over 4000 within the system.
accidental contamination of, or damage to, the bearings and Wherever possible, turbulent flow should be achieved in
journals. Bearing surfaces should be protected by rust- system pipes. Bearing jumpers are installed to elevate bearing
preventive oil that is readily soluble in flushing oil or vapor supply and return flow rates and protect bearing surfaces from
space inhibitor oil. All openings should be sealed. contaminants. System headers may be isolated to increase
6.2.7 Control Devices—Installation and contamination pro- pipeline velocity. The use of outside pumps is typically
tection for oil-wetted control devices should be handled as required to achieve this flow.
carefully as that for bearings. Extreme care must also be taken 7.2.3 Surface Active Cleaner—Flushing for in-service sys-
to prevent accidental contamination of the associated piping tems with varnish or sludge that require a cleaning solution for
during installation. effective deposit removal.
6.2.8 Pumps—Prior to assembly and installation, pumps 7.2.3.1 Some turbine and associated hydraulic systems may
should be inspected for the presence of hard film coatings or require a surface active flush to clean inaccessible internal
contaminants. If any are present, the pumps should be thor- surfaces of varnish. The term varnish is being used to include
oughly cleaned, coated with rust-preventive or vapor-space all internal deposits, including sludge. Flushing with a surface
inhibitor oil, and sealed. active cleaner is typically reserved for gas turbines with
combined hydraulic and turbine oil reservoirs. Minor levels of
7. Flushing oil soluble cleaners or solvent cleaners may impact operating
oil demulsibility, required in steam turbine operation. A sub-
7.1 If the equipment manufacturer has supplied detailed
sequent displacement flush shall be conducted to effectively
flushing procedures, they should take precedence over these
remove the surface active cleaning agent. Both the surface
recommendations.
active flushing fluid and the following displacement flush fluid
7.2 Flushing Methods: should not be reused as they may impact the performance of
7.2.1 Displacement Flush—For new systems and systems the final system operating oil. Hydraulic system flushing can be
with service hours that do not typically require surface active improved with the use of flushing blocks that are used to
cleaning or the improved cleaning of a high-velocity flush. bypass the system servo valves.

D6439 − 11
7.2.4 High-pressure water flush for systems with service numbered blanks. The numbered blanks must be removed from
hours that have developed significant rust or fouling to the the system and accounted for on a checklist at the end of the
extent that less aggressive flushing methods are ineffective. flushing period.
High-pressure water is locally directed at fouled areas. Special 7.4.3 Despite all efforts, some particles large enough to
care must be taken to remove all flush water at the completion damage pumps may remain. In all systems, installing tempo-
of this flush. rary strainers of 80 to 100 mesh on the suction side of the
7.2.5 General Flushing Method Guidance: lubrication oil or flush pumps, or both, is recommended. In
7.2.5.1 It may not be practical to flush through certain addition, install temporary fine mesh strainers on the discharge
systems or devices that are assembled, cleaned, and sealed in side of gravity and pressure systems. Fine screens of 100 mesh
the factory before shipment. Such equipment should be care- or finer should be installed at the inlet of all feed lines to the
fully protected against intrusion of contaminants, and in this bearing pedestal. They should also be installed on the inlet
flushing procedure, such equipment should be blanked off or
headers of gear sets. Lintless bags, if available, may be used
bypassed until other systems are clean.
temporarily on the inside of the existing lubricating oil system
7.2.5.2 Even for assemblies that can be flushed through
strainers during the flushing period. Magnetic separating ele-
freely, the prescribed flushing procedure may not have the
ments may be installed in the existing lubricating oil system
ability to flush out any and all conceivable kinds of contami-
strainers. Customary marine practice is to install these in the
nants. Much adverse experience testifies to this. Therefore, it is
duplex strainers on the discharge side.
clear that great care should be exercised during the entire
system installation to prevent unnecessary impurities from 7.4.4 Whenever possible, use of full flow filters during the
entering the oil systems that cannot be easily removed by flush is recommended. Auxiliary filters may be used to provide
flushing. Such contamination, when dislodged by turbine higher filtered oil flow rates and finer filtration. All purification
vibration or system operational effects, could cause problems systems should be ready for operation as soon as the flushing
in subsequent operations. oil is installed. It is generally desirable to purify the reservoir,
7.2.5.3 The knowledge that a system flush will be per- pump, and purification systems before beginning to flush the
formed before startup should not be allowed to lead to the rest of the unit. This has the advantage of providing clean oil
misconception that contaminants entering the oil system are to other parts of the system. In addition, when purified oil is
not harmful because “they will all be removed by the flush.” used for flushing, the increased contaminant observed in the oil
7.3 General Guidelines for Flushing of Operational Systems when additional sections are flushed gives some measure of
to Remove Contaminant: flush effectiveness. If necessary, pipes and valves for recircu-
7.3.1 Guidelines for when to remove used oil or flush an lation to the reservoir should be installed. If this piping is
operational system to reduce contaminant, or both, are given in temporary, valves at the reservoir and purification device
8.5. should be provided to allow removal of the temporary piping.
7.3.2 The remainder of Section 7 should be reviewed and 7.4.5 Frequently, sampling points installed for monitoring
the applicable sections decided upon, after consultation of the oil cleanliness during routine operation are not adequate to
equipment user with the appropriate suppliers, based on the monitor the cleanliness of components and the progress of the
condition of the system and used oil. flush. Sampling points must be installed as necessary, as
7.3.3 Sea water contamination requires special procedures. described in X2.2.2. If the lubricating oil heater has not been
After removal of excess salt water, corrosion inhibitors spe- installed, or if it is inadequate, heat may be supplied to the
cifically developed for this type of contamination might be flushing oil in several ways. The best method is to pass hot
used in the system. water through the cooler; this can be generated by bubbling
7.4 Preparation of System for Flushing: low-pressure steam through the water somewhere outside the
7.4.1 Prior to the flushing operation, all accessible areas of cooler. The cooler must be vented to the atmosphere to prevent
the lubricating oil system should be thoroughly inspected. If pressure build up. Low pressure steam may also be used;
significant contaminant is encountered, it should be manually however, the cooler should be checked against the manufac-
removed. Final inspection for welding splatter or materials that turer’s recommendation. Great care must be taken to ensure
may break loose and contaminate the system with metallic that not over 34 kPa (5 psig) steam is admitted to the cooler so
particles should be made. If found they should be completely that the cooler is not damaged and the flushing oil is not
removed. overheated. Electrical heaters may also be used. The cautions
7.4.2 Any temporary humidity control devices (vacuum outlined in Appendix X4 must be observed to avoid overheat-
dehydrators, coalescing filters) placed in the system must be ing the oil.
removed. The state of cleanliness of the system at this time is 7.4.6 A lance attached to a clean hose should be used for hot
always questionable, and therefore, all lubricating oil mani- oil spraying of gearing or other hard to reach areas. It can be
folds and leads to bearings must be blanked off as closely as attached to the cooler (currently being used as a heater) or an
possible to the parts they serve. For high-velocity flushing, oil pump discharge strainer. For safety, the hose, lance, and any
jumpers may be installed to bypass all bearings, but they other fittings used must be pressure rated for the full flush
should be so installed as to bypass as little of the piping and pump outlet pressure. Precautions must also be taken to protect
flow passages as possible. All other areas in the system that are personnel from the hot oil spray. Extreme fire and spark
not to be flushed should be blanked off with the use of protection precautions must be taken. Even less hazardous

D6439 − 11
lubricants can ignite if heated and sprayed; conventional finer filters as the system operating or flushing filters. In
mineral oils may form explosive mixtures under such condi- addition, in the flushing process, it is generally advisable to
tions. filter the oil between transfers. This allows single pass filtration
7.5 Selection of Flushing Oil: that prevents the purified oil from mixing with the contami-
7.5.1 The oil selected for flushing of the system can be nated oil. Filtration of oils while warm will improve element
either the system operating oil or flushing oil that is compatible life. Filter ratings on transfers to holding tanks can vary with
with the operating oil and of similar viscosity. The selection of oil temperature and oil contaminant levels. The reservoir
the type of flushing oil to be used should be based on the should be filled to the minimum operating level to ensure that
judgment of experienced personnel after thorough inspection the system lubricating oil pump(s) are always submerged and
of the lubricating oil system. Residual flush oil may impact operate properly.
system operating oil performance. To minimize oil contamina- 7.7 Flushing Procedure:
tion, delivery should only be made in clean containers with 7.7.1 Elevated oil temperature, oil temperature cycling and
clean or flushed hoses, pumps and manifolds. For large vibration contribute to the success of an oil flush. Hammering
quantities, use of stainless steel or aluminum tank trucks or or vibration at pertinent points will promote loosening of solids
tank cars and cleanliness certification are required. in the system. Once solids are loosened, they will settle by
7.5.2 System Operating Oil—In applications where an ex- gravity in the main oil tank, eventually be caught by temporary
isting unit is being flushed, the previous turbine lubricating oil screens, or removed by filtration.
may be used as flushing oil or subsequently as the operating 7.7.2 Monitoring of Contaminant During Flushing:
oil, or both. In this case, the oil has been stored in a storage 7.7.2.1 Monitoring of contaminant, especially particulate, is
tank. When the system operating oil is used for flushing, it commonly performed during the flush and is strongly recom-
should not be used for operation unless it has been tested and mended. These analyses ensure that clean oil is being used for
shown to be suitable for system operation following flushing. the flush and provide the best measure of the flush’s progress.
This precaution is necessary because oil-soluble contaminants 7.7.2.2 The analyses for particulate may be performed on
picked up during the flush may be incompatible with system site using a particle count method or field analysis of contami-
components or cause foaming, emulsification or reduced oxi- nant from a sample drawn through an analysis membrane as
dation resistance, or combination thereof. discussed in X2.5.2 or performed in a laboratory as discussed
7.5.3 Flushing Oil Selection: in X2.6. If the analysis is performed on site, the person
7.5.3.1 Any operator who uses a flushing oil assumes performing the analysis should be completely familiar with the
responsibility to ensure its mechanical and chemical compat- operation and limitations of the apparatus. If the analyses are to
ibility with the entire lubricating oil system and all turbine be performed by a laboratory, the schedule must be established
equipment exposed to this oil, including, but not limited to: before the flush commences to provide timely results.
(1) All components of the lubrication and flushing systems. 7.7.2.3 Flushing decisions based on sample cleanliness
(2) Final charge of lubricating oil. should only be made by personnel familiar with both the flush
(3) Permanent or temporary flushing hose lining at tem- dynamics and the significance of the sample cleanliness. For
peratures up to 88°C (190°F), including those to boiler water system components, some manufacturers will require full flow
feed pump turbine systems. analysis for large particles, typically larger than 125 µm. This
(4) Rust preventive paints used in pedestal and guard generally entails filtering all return oil through strainers of the
piping. appropriate mesh. If required, these analyses should be per-
(5) Preservatives used to protect pipes during shipping, formed with the appropriate throughput and by personnel
storage, and installation that normally may not be removed familiar with the procedure.
prior to flushing. 7.7.3 Maintenance of Purification Apparatus During
(6) Residual oil impact on performance of system operat- Flushing—Experience in flushing lubricating oil systems has
ing oil. shown that almost all of the foreign matter is collected in the
7.5.4 Surface Active Cleaner Selection—Varnish removal is filters or temporary strainers during the first few hours of
greatly accelerated with the use of cleaners but there can be flushing. During this time, whenever a noticeable increase in
negative impact from cleaner residue on the system operating the pressure drop across the strainers is observed, the strainers
oil and equipment components. Cleaners are segmented as should be cleaned and bags renewed. This may occur as
follows: frequently as 15 min intervals. The lubrication oil contamina-
7.5.4.1 Oil Soluble Cleaners—Typically naphthenic based tion control devices must be inspected and cleaned frequently.
with detergents, dispersants, and corrosion inhibitors. Auxiliary filters, when used, should be operated within the
7.5.4.2 Solvent Cleaners—Typically hydrocarbon-based pressure drop limits as specified by the manufacturer.
like alkylated benzene. 7.7.4 Startup—If appropriate, the lubricating oil pump(s)
7.5.4.3 Water-based chemical cleaners are not recom- should be started. Oil circulation in the reservoir should be
mended as the water and chemical residue can cause significant begun and purification started. The oil should be gradually
damage to the system operating oil and equipment compo- heated to 65 to 71°C (150 to 170°F) by use of the purifier oil
nents. heater and, if necessary, by methods described in 7.4.5.
7.6 Supplying Flushing Oil to Reservoir—When filling the Circulation and purification should be continued as long as it is
turbine lubricating system, oil should be filtered with as fine or necessary to flush the system. When heating the oil, the

D6439 − 11
guidelines given in Appendix X4 should be followed to avoid evidence of contaminants appears in the strainers, bags, or
overheating the oil. Purification of the reservoir should con- auxiliary filters or from oil analysis, oil circulation to these
tinue until the oil reaches the desired cleanliness level as gears should be stopped. If practical, representative bearings
determined by taking a reservoir sample or sample immedi- should be inspected and their condition should be used as a
ately upstream of a purification device as discussed in Appen- guide to whether further flushing is necessary. Bearing inspec-
dix X2. tion may not, however, be practical or recommended, espe-
7.7.5 Flushing times of 12 h to as much as several days may cially in packaged gas turbine systems.
be necessary to reach the desired level of cleanliness. Periodic 7.7.11 Flushing of Turbine Main Bearings and Sumps:
sampling and analysis, as discussed in 7.7.2, is recommended 7.7.11.1 The turbine main bearings will be one of the most
to monitor the progress of the flush. Throughout the flushing sensitive components to particulate that moves through the
period, the oil in the system should be maintained at 65 to 71°C system as a result of a flush. The turbine manufacturer’s
(150 to 170°F), except when rotating the equipment. This guidelines for flushing turbine bearings areas (bearings or
temperature is necessary to maintain fluidity of the flushing oil bearing sumps, or both) should be used whenever available.
in the system and to dissolve oil soluble materials and to aid in When not available, the following should be considered.
loosening adherent particles. General practice is to allow the 7.7.11.2 Bearing areas should be flushed with clean fluid
oil temperature to drop 28 to 32°C (50 to 60°F) for 2 to 3 h only. This may be accomplished either by isolating the bearing
during flushing to allow for pipe contraction. This procedure areas and flushing all upstream components, including valves
aids in removing any scale that may be on the pipe. and piping, to a specified cleanliness level and then redirecting
7.7.6 Flushing of Coolers—Each lubricating oil cooler the flow of clean fluid through the bearing area or by placing
should be cleaned separately to provide maximum oil velocity a screen or bag filter immediately upstream of the bearing area
in the cooler to optimize contaminant removal. to ensure that particulate freed within the system does not flow
7.7.7 Flushing of Gravity Tanks—If there is more than one through the bearing.
gravity tank in a gravity system, circulation of the flushing oil 7.7.11.3 Monitoring fluid cleanliness at the first accessible
should be alternated through each of the gravity tanks for a location downstream of the bearing area being flushed gives
minimum of 12 h or more for each tank. the most reliable indication of bearing cleanliness. Some
7.7.8 Flushing of Lubricating and Auxiliary Pumps—Each manufacturers may require full flow monitoring of the fluid
lubricating oil pump and auxiliary pump should be used during coming from these areas for relatively large particles using
the flushing period. screens. Experience indicates that if these are used, screens and
7.7.9 Flushing of Piping—During the early phases of the analysis procedures should be designed to eliminate the influ-
flushing period, the piping, particularly at joints and flanges, ence of environmental contaminant that could unnecessarily
should be vibrated or hammered to dislodge any scale or weld prolong the flush.
splatter that may have adhered to the surface. The absence of 7.7.12 Flushing Procedures Specific to Surface Active
contaminants, such as lint, welding beads, or other extraneous Flushing:
matter, on strainers or bags and accessible parts of the system 7.7.12.1 Confirm in-service oils suitability for use as to
indicates that the system is clean. The final decision to flush support surface active cleaner and insoluble system contami-
additional parts of the system, however, should be based on nants. In-service oil solubility and contaminant testing, like
cleanliness criteria specified by the equipment manufacturer or ultra-centrifuge or membrane patch colorimetry, may be suit-
established prior to the flush. After these criteria have been able. The surface active cleaner shall be added in concentra-
met, other parts of the lubricating oil system should then be tions and circulated based oil suppler recommendations. Side
flushed by removing blanks and jumpers. stream filtration is recommended, during the flush. Flushing
7.7.10 Flushing of Gears: may be considered complete based on time and or system
7.7.10.1 At this point in the flush, if the unit being flushed before and after test coupon cleanliness. A test coupon is an
is a geared unit, the gear case should be opened and sprayed area or part of the lubrication system that has deposit formation
with oil cooled to 55 to 60°C (130 to 140°F). All accessible (varnish/sludge) that can be used for validation during the
points, including the upper surfaces of the casing, should be surface active flush using photo or boroscope documentation.
included. This flushing should be done through the inspection 7.7.12.2 At the flush completion the flush oil, containing
openings on the gear housing. The gears should be jacked surface active cleaners, should be completely drained. Particu-
progressively to new positions to permit thorough cleaning. lar attention should be paid to low point draining. A subsequent
Jacking should not be continuous and should not be done if the flush oil should be used to remove cleaner residue that may
oil temperature is in excess of 60°C (140°F). Upon completion impact the performance of the final fill operating oil. At the
of the flushing by hose, the inspection covers should be secured completion of this flush the oil should be drained and the
and oil circulation continued, while gradually heating the oil to system prepared for confined space entry cleaning.
65 to 71°C (150 to 170°F). The flushing procedure should be 7.7.13 Flushing Procedures Specific to High-Velocity Flush-
continued until the entire system is thoroughly cleaned. At this ing:
point, a representative sample should be taken for verification 7.7.13.1 Bearing and hydraulic section jumpers are required
of cleanliness. to provide for increased flow rate or three to four time nominal
7.7.10.2 All oil strainers adjacent to gear oil spray nozzles lube oil header flow rates to obtain a minimum Reynolds
should be examined and cleaned as necessary. When no number of 4000. External pumping done through isolated

D6439 − 11
turbine sections offers elevated flush velocities. Turbine sec- supplier on compatibility with the system oil. Confirm com-
tions are isolated and flushed in sequences that provide for patibility with Practice D7155. During this period, the system
optimum system cleaning. (Warning—Fluid temperature may should be inspected frequently for signs of corrosion, particu-
increase due to internal friction. It is recommended to monitor larly the upper portions of the gear case where the newly
and appropriately control the temperature within safe operating charged oil has not come into contact with the case and gear
levels.) surfaces. It is in this region that moisture will condense into
7.7.14 Terminating the Flush—When all contaminated sec- droplets of water and start the corrosion process and contami-
tions of the system have been flushed and sample evaluations nate the new oil. If corrosion is taking place, it can be
indicate that operating cleanliness requirements for all compo- minimized by hand lancing these portions of the housing.
nents have been met, including any manufacturer or user Corrosion on the gear teeth can be prevented by rotating the
cleanliness requirements, terminate the flush. bull gear a turn and a quarter every week with the lubrication
7.8 Draining of Oil Used for Flushing—If the oil is to be oil system operating, thereby coating all of the teeth with a new
drained when the flushing procedure is complete, it should be protective film of oil. Cold oil, approximately 38°C (100°F),
drained as soon as practical and safe. Allowing the oil to cool should be used for this purpose and when hand lancing to
will leave more contamination in the system than if drained obtain best adhesion.
while it is still hot. Oil lines should be opened at the lowest 7.11 New Oil Charge—A full charge of new turbine oil
points and the oil allowed to drain. Breaking of flanges and the should be installed in the system as soon as possible. This
use of a vacuum will improved drain effectiveness. The oil charge should be introduced through filters, purified and
should then be removed from sumps, tanks, and coolers. The certified as clean before circulating.
sump and all tanks and accessible surfaces should be manually
cleaned with lint-free rags to remove all traces of residual 8. Contamination Control In Operational Units
contamination and as much oil as possible. The flushing oil,
after purification, may be used for flushing another installation, 8.1 Contamination Control During Operation—
after it has been determined that the product is free of Contamination control systems should be in operation as long
contaminants and still contains solvency and rust inhibiting as the lubricating oil system is in service. These systems should
properties. After the flushing oil has been drained and surfaces maintain oil purity at levels discussed in X2.7. Additional
cleaned, the lubricating oil system should be again thoroughly guidelines for contamination monitoring in operating systems
inspected for evidences of contamination. The system should are given in Practice D4378. The oil contamination levels and
then be completely rechecked to determine if it is secure for the operation of all purification devices should be constantly
operation. monitored to ensure that they are performing adequately and to
determine the need for maintenance. In addition, all openings
7.9 Displacement Oil—If very light oil is used for flushing, from the system to the atmosphere, such as breather vents,
or if there are quantities of special flushing oil left in the should be regarded as sources of contaminant. Whenever
system, displacement oil must be used. Another reason for the practical, these should be provided with particle and moisture
use of displacement oil is to remove flushing oil or cleaners, or control devices. When making inspections or working on or
both, that are highly contaminated with oil soluble materials. A around a turbine, care must be taken to prevent contaminants
displacement flush is also recommended when changing the from entering the lubrication system. When extraneous work
type of oil in a system. Displacement oil should be compatible that may generate contaminants is being performed in the
with and approximately the same viscosity as the operating vicinity of the lubrication system, precautions should be taken
charge to be installed. To minimize the impact of the displace- to ensure that system components are not exposed and all
ment flush oil on the operating oil it is recommended that these access points closed or protected, prior to beginning the work.
oils be of the same chemistry. Strainers and filter housings and
other large vessels should be drained, strainers cleaned, and all 8.2 Contamination Control During Oil Transfer:
filter elements replaced. Pump the displacement oil into the 8.2.1 There are several reasons why oil may be transferred
system as soon as possible. The circulating pumps and turning out of all or part of the lubrication system. These include
or jacking gear, if present, should be started, the oil heated to preparation for repair of a system component, system overhaul,
60 to 70°C (140 to 160°F), and circulated for a minimum of or replacement because the oil no longer meets specifications.
two h with purification. Circulation of the oil should be In the first two cases, the oil will probably be returned to the
continued for 12 to 24 h or until inspection of the strainers and system, while in the third case, it will probably be discarded.
filter bags shows no evidence of contaminants. The displace- 8.2.2 If the oil is to be retained, it should be transferred to a
ment oil should be drained while warm to improve flow. Low clean container. Before transferring the lubricant, inspect the
points and isolated areas should be drained or vacuumed clean. storage tank for particulate and water and clean if necessary.
7.10 Interim Corrosion Protection —With respect to corro- Residues from previous fills are contaminants and should be
sion, one of the most critical times for a lubricating oil system removed if practical.
is the long idle period that may exist between flushing and 8.2.3 When the oil is being transferred from the system, care
regular operation. Proper scheduling of the flushing operation should be taken to remove all the oil. Heaters, coolers, and
will minimize this idle period. The use of oil with a vapor space purification devices can contain large amounts of oil that
inhibitor will protect the system from corrosion by condensa- contain contaminants. In addition, this prevents inadvertent
tion. If a corrosion inhibitor is used, consult with the oil spillage later.

D6439 − 11
8.2.4 Purification of the oil during transfer or temporary surface, releasing either chips or pigment particles. It may be
storage is also recommended if analyses indicate it is required. more advantageous to clean the surface and allow the inhibitors
If the entire system is drained, contractors with large portable in the oil to protect the surface. Cleaning by flushing with oil
purification apparatus may be employed to purify the oil. These after wiping and hand cleaning is recommended. The same
contractors should be able to provide a certificate of analysis general procedures given for cleaning systems in the preceding
indicating the fluid meets the established cleanliness criteria. sections should be followed. Chemical cleaning is not recom-
On completion of system repairs, the oil should be returned in mended. Such chemicals could cause serious degradation of
the same manner as indicated for new oil in 7.11. the operating oil and could damage system components. The
8.3 Contamination Control During Repairs: use of hot water or steam could result in rusted surfaces and is
8.3.1 The discussions in this section and the following not recommended.
section are pertinent for repairs that intrude into the lubrication 8.5 Flushing:
system but where a full system flush will not be performed.
8.5.1 Except under unusual circumstances, such as after
Guidelines for deciding whether to perform a full system flush,
major repairs or overhaul, an operational lubrication system
including that for removing oil-borne contamination system-
should not be flushed. Only by a complete inspection of the
wide, are given in 8.5.
system and analysis of the oil can the necessity for flushing be
8.3.2 Whenever maintenance or repair is performed on a
determined.
part of the lubrication system or a lubricated component, care
should be taken to prevent contamination. 8.5.2 The condition of the oil and the system should both be
8.3.3 Major Precautions to Prevent Contamination During taken into consideration when deciding whether to flush the
Repairs: system following repairs. The presence of soluble contami-
8.3.3.1 Cover/close the area being worked on to prevent nants that can not be removed by purification and the degra-
ingression of abrasives, weld slag, and dust. dation of the oil’s additives or base stock may be reasons for
8.3.3.2 Use clean, lintless wipes. flushing the entire system. Laboratory analyses of the used oil
8.3.3.3 Inspect each space before access is limited to ensure should be performed if these types of oil degradation are
that all wipes, cords, tapes, tools, and other materials have been suspected. Consultation with the oil supplier is recommended.
removed. 8.5.3 The condition of the system, however, is generally
8.3.3.4 Use only clean, oil compatible cleaners and preser- more significant. It is of particular importance to consider the
vatives. Remove as much cleaner as possible, if used. sensitivity of the section being repaired to contaminant and the
8.3.3.5 Take any steps necessary to prevent rust and other sections of the system that would be directly exposed to
corrosion. contaminant from this system. Without full flow purification,
8.3.3.6 Install gears bearings and seals properly to prevent for example, some of the contaminant from this component
future wear, which will generate wear particles when operat- will probably reach other components before it can be removed
ing. by settling or side-stream purification. The cleanliness level of
8.3.3.7 For components that are particularly sensitive to replacement parts, the types of built-in contaminants, and the
particulate, order replacement parts that have appropriate type of contaminants introduced in the repair work (abrasive
cleanliness standards. grit, weld slag, fibers, solvents, and so forth) should also be
8.3.3.8 Do not use untested coatings to protect bearing considered. If a full flush will not be done, consideration
surfaces during rotor handling. should be given to flushing the component and the pipes
8.3.3.9 For a more thorough discussion, a review of Section connected to it with heated, filtered operating oil. Monitoring
6 is recommended. of the cleanliness of the flush oil during this flush is recom-
mended. Details on flushing individual components are given
8.4 System Cleaning and Coating—After draining, all ac-
in 7.7.6-7.7.11.
cessible parts of the system should be cleaned using the
appropriate method(s), followed by wiping with lint-free ma- 8.5.4 If, after consideration of the factors above, the opera-
terial. Particular attention should be given to reservoirs, where tor and lubricant supplier agree that a full flush is required, the
most deposits are usually found. Deposits accumulated during appropriate flushing procedure in Section 7 should be used.
service should be examined to determine the source, and steps
taken to eliminate the cause. If it is necessary to repair or recoat 9. Keywords
surfaces, they should be thoroughly cleaned before being 9.1 centrifugation; cleanliness; coalescence; contamination;
recoated with an oil compatible durable coating. Caution dehydration; filtration; flushing; purification; turbine
should be employed if using a coating that may come off the lubrication

D6439 − 11
APPENDIXES
(Nonmandatory Information)
X1. WATER, OIL SOLUBLE CONTAMINANTS OTHER THAN WATER, AND OIL INSOLUBLE CONTAMINANTS
X1.1 Water X1.1.5 The circulation in most lubrication systems today is

such that there is little settling. For leaks and some solids
X1.1.1 Water is present in oil in solution and possibly also
ingression, the operation of the purifier or contamination
in the free or emulsified form. Ingression of salt water will also
control device, if present, is usually sufficient to remove
result in the deposition of salts if the water is evaporated. All
contaminants.
free and emulsified water and any salts should be removed
from turbine lubrication before placing the turbine in opera- X1.1.6 In the case of severe salt water contamination, where
tion. the water is accompanied by a substantial quantity of salts, it
may be necessary to remove the operating oil and clean and
X1.1.2 Water can exist in solution at varying concentrations flush the lubricating systems.
depending on the compounding of the oil, the temperature, and
so forth. For example, oil may hold 50 ppm of water at 21°C X1.2 Oil Soluble Contaminants Other than Water
(70°F) and 250 ppm at 71°C (160°F). In general, under normal X1.2.1 Soluble contaminants in lubricating or control sys-
operating conditions, dissolved water has no significant ad- tems may include gases, fuel oils, cleaning chemicals, solvents,
verse effect on lubricating properties of the oil and does not most rust preventatives, lubricants incompatible with system
cause significant corrosion in these systems. Dissolved water components, flushing oils, extraneous oils, gasket sealant,
has, however, been reported to cause bearing damage. In degradation by-products, and assembly lubricants. Oil soluble
addition, when oil passes through a cooler, some water may contaminants may change the oil viscosity, alter the flash point,
come out of solution and become free water in the form of change the color, result in sludge and varnish deposits, initiate
droplets. Free water can have adverse effects on the lubricating additive-water interaction (which can cause emulsification,
properties of the oil and cause other system problems. possible additive loss, instability, and impaired purification
X1.1.3 Many contaminants inhibit the separation of free equipment performance, foaming, and air entrainment), and
water from the oil by forming a stable emulsion. In turbine oils, accelerate oxidation. If a soluble contaminant is present, the oil
the emulsion may impair oil circulation, interfere with lubri- supplier and the equipment manufacturer should be consulted
cation, and adversely affect contamination control equipment. regarding the advisability of continued use of the oil or
Emulsions may be prevented by removing water. If water can replacing it with a new charge. Most of these contaminants
not be eliminated, it is recommended that methods for control- cannot be removed by conventional oil contamination control
ling emulsions be discussed with the equipment or oil supplier. equipment, although there is some evidence that degradation
If severe emulsification with water occurs, it may be desirable by-products such as acids can be removed through some ion
to raise the oil temperature to around 82°C (180°F) to facilitate exchange technologies in API Group II and III lubricants.
breaking of the emulsion to form larger drops of free water. Gases and some light solvents can also be removed by vacuum
The guidelines given in Appendix X4 should be followed to dehydration methods. Normally, a new charge of oil is required
to correct the problem.
avoid overheating the oil.
X1.1.4 Water contamination can be classified as either fresh X1.3 Oil Insoluble Contaminants
or seawater, as encountered in land or marine systems. Fresh X1.3.1 Insoluble contaminants normally encountered are
water may enter the lubricating system through turbine gland metallic and nonmetallic materials of all types and sizes,
seals, in moist air through improperly located or improperly including fibers, airborne solids, sand, soaps, and some rust
protected vents, or both, and through leaks in coolers and steam preventatives. These contaminants are often the result of
heaters. Seawater, in marine lubrication systems, enters inappropriate or careless manufacturing, shipping, storage,
through leaks in coolers, faulty manhole gaskets, faulty sump installation, operation, or maintenance practices. Some of the
tank seals and improperly located vents. Sea and brackish effects of solid contamination are abrasive wear of bearings
water may also present a problem when used as a coolant in and seals, faulty control functioning, plugged oil lines, reduced
land based units. Even fresh water from leaking coolers may oil stability, sludge and varnish formation, reduced filter
contain significant amounts of solids or materials that may element life, increased foaming tendency, stabilized water-oil
react with oil additives. Water contamination in lubricating and emulsions, and accelerated oxidation by the catalytic effect of
control oils tends to: promote oil oxidation, reduce oil stability, metal particles. Harmful insolubles may exist in the lubrication
promote sludge and varnish, promote foaming, form emul- oil system as stationary or suspended matter. Normal operation
sions, promote rusting and corrosion, reduce additive concen- causes insoluble contaminants. Evaluating particle concentra-
tration, adversely affect lubricating properties, alter oil viscos- tion, type and build-up rate can indicate possible system
ity, reduce filter element life and may cause bacterial growth. problems. Particle counting however, usually does not indicate

D6439 − 11
the sludge and varnish potential of the fluid, since the insoluble X1.3.2.2 Unless this stationary debris is removed, it may
contaminants responsible for sludge and varnish are typically become dislodged during startup or during system operation.
below 1 µm in size, which is below the detection limits of most These contaminants should be dislodged by high flow rates,
particle counting technologies. vibration, hydraulic lancing, or high-pressure water flushing.
Experience, good judgment, and careful inspection by the
X1.3.2 Stationary Contaminant: installation supervisor must be relied upon to determine when
X1.3.2.1 In new systems, prior to any flushing, most of the such debris has been satisfactorily removed. If a high-pressure
contaminants will be stationary. In a new or refurbished water flush is performed, provisions must be made to ensure
system, contaminants can include abrasive grit, metal filings, that all water has been removed.
weld slag, rust, dirt, and paper and cloth fibers. In operating
X1.3.3 Suspended Contaminants—Both new and in-service
systems, contamination can settle out in parts of the system
oil can contain suspended contaminants. The amount they
where there is no, low, or intermittent flow. These areas can
contain will depend on the extent of prior purification. Con-
include the reservoir, lubricant pipes with low flow rates, dead
taminants suspended in the oil can be from system operation or
end pipes, or pipes with closed valves and bearing cases where
generated during a flush by loosening stationary contaminant
there is low oil flow. There are frequently lubricant pipes that
from pipes, pedestal castings, tank walls, and so forth. Sus-
are not completely full. In these pipes, gravity is the driving
pended debris can be measured, as described in X2.5 and X2.6.
force of the flow and the flow rate and oil levels in the pipe are
To prevent the level of suspended debris from getting beyond
strongly dependent on the oil viscosity, which is a function of
acceptable limits and to prevent contamination of cleaner
temperature. Stationary contaminants in operating systems can
areas, all units should be provided with contamination control
include wear metals, seal debris, rust, dirt, cloth or paper
systems as described in Appendix X3.
debris, and materials generated by various chemical reactions.
Oil that has been exposed to elevated temperatures can form X1.4 Temperature Dependant Contaminants—Some tur-
higher molecular weight degradation products that help to bind bine oil degradation products will transition in and out of
the stationary contaminant together. solution based on oil temperature.
X2. OIL CONDITION MONITORING
X2.1 In operating systems, the lubricating oil should be the results of the analyses, particularly particle counts, is
sampled and evaluated at frequent intervals (see Practice critical to ensure a successful flush. If the flush piping or blanks
D4378) or as recommended by the manufacturer or oil sup- allow, sampling the oil immediately upstream or downstream
plier) during operation. Practice D4378 also recommends daily of the bearing or component that is being flushed and that is
visual inspection for free water. These observations and sample farthest from the oil supply gives the most direct indication of
analyses will serve as a guide to the condition of the oil and the cleanliness of the components being flushed. If the flush
will determine the effectiveness of the oil maintenance pro- bypasses the bearings, or if samples at the bearings cannot be
gram. Data from all inspections and analyses should be obtained, then a return oil sample will give the most direct
recorded, and a log of oil makeup should be maintained. The indication of the cleanliness of the components being flushed.
rate of change in the properties of the oil can be as significant Return oil samples are frequently difficult to obtain because of
as the absolute values. In system flushes, samples should be their location or their low line pressure, or both. If samples can
taken and analyzed at appropriate frequencies to monitor flush not be taken elsewhere, samples are frequently taken from the
progress. A log of all samples taken and the results of all reservoir or immediately upstream of the purification device. In
analyses should also be maintained for flushes. this case, the dilution effect of the reservoir must be consid-
ered, particularly when the reservoir initially contains very
X2.2 Sampling Points pure oil. In general, samples taken downstream of a purifica-
X2.2.1 Location in Operational Systems—The three most tion device, usually a filter, that supplies oil directly to the
common locations for sampling are from the center of the components being flushed indicate the cleanliness of the
reservoir and upstream and downstream of a purification flushing oil, not how much contaminant is being removed from
device. Whenever possible, obtain a sample from a flowing the system. Frequently, samples are taken from several loca-
stream of fluid. A reservoir sample or sample upstream of a tions.
purification device gives information about contaminant enter- X2.2.3 In monitoring operational systems and flushing,
ing or being generated by the system. In a full flow contami- sample locations recommended by the turbine manufacturer
nation control system, a sample downstream of the purification should be given preference.
device reflects the cleanliness of the oil going to the turbine. X2.2.4 Configuration—Samples should be taken from loca-
Because of contaminant settling, the oil sample obtained from tions that are representatives of the oil going to the system.
the reservoir drain valve is not representative of the system oil. Thus, for full flow contamination removal systems, the pre-
Sampling from the drain valve is not recommended. ferred location is downstream of the contamination control
X2.2.2 Additional Sampling Points to Monitor Flush— device. For systems with bypass contamination control or
Selecting the proper sample location and properly interpreting when a sample cannot be taken from a point downstream of a

D6439 − 11
supply pump, a sample may be taken from the center of the may cause false values and may result in needless attempts to correct an
reservoir. Because contaminants can settle, sampling from the apparently contaminated system that is in good condition.
bottom of the reservoir is not recommended. Design sampling X2.4 Manual Inspection
points for obtaining samples from a fluid line following the
X2.4.1 Frequent observations (daily) should be made
principles are outlined in Section 4.1 of ISO 4021. Use ball
through the flow sight glass (bull’s eye) of the oil flow in the
valves with polytetrafluoroethylene (PTFE) seats in sample
lines to or from the various parts of the unit to check changes
points used for taking samples for particulate analysis. As
in the oil conditions. A noticeable change in appearance is an
much as possible, sampling hardware should be placed in
indication of contamination, particularly water, air, or sedi-
protected positions to prevent accidental breakage and loss of
ment. Small samples should be taken periodically in properly
fluid. Samplers for obtaining reservoir samples, particularly
cleaned glass containers and compared visually with new oil
those for particle counts, should follow the principles given in
and previously retained samples. Inspection includes a check
Section 4.2 of ISO 4021.
of cloudiness (free water or gases), sediment, and odor.
X2.3 Oil Sampling Techniques
X2.5 On-Site Analysis
X2.3.1 The taking of several samples in break-resistant, 250
X2.5.1 Commercial test apparatus exists for on-site lubri-
mL (8 oz) glass bottles with screw on caps and plastic liners is
cating oil evaluation. Portable automatic or online particle
preferred. A representative sample must be analyzed. Metal
counters, or both, that have the accuracy of laboratory units are
cans with press-on lids or containers with rubber or ground
available. Relative to an off-site laboratory particle count, they
glass stoppers are not acceptable if particle concentrations are
have the advantage of reduced turnaround time. In addition the
to be evaluated. However, metal cans are acceptable for other
online counter has the advantage that it can be connected
types of testing. Cleanliness in the handling of the sample and
directly to the system, eliminating the possibility of contami-
container is critical. Each container should be cleaned and kept
nation from the environment or sample containers, or both. As
clean. The following is a recommended cleaning procedure for
with all testing and measurement equipment, the manufactur-
used glass sample containers: (1) wash thoroughly in hot water
er’s procedures must be followed. Testing must be carried out
and detergent; (2) rinse with soft, hot tap water; (3) rinse with
by a knowledgeable and experienced individual. Particle
filtered distilled water; (4) rinse with filtered isopropyl alcohol;
counts can provide useful guidance during a flush that the
(5) final rinse with filtered acetone; (6) dry with clean air. Caps
desired level of cleanliness has been reached. During a flush, it
should be isolated from the bottle contents by a liner of clean
may be advisable to have a final laboratory analysis to ensure
plastic that is compatible with the system fluid. Precleaned
that the desired cleanliness has been reached.
bottles may also be obtained from commercial sources. If
particulate concentrations are to be evaluated, it is recom- X2.5.2 There is also equipment available to draw a sample
mended that the cleanliness of selected sample bottles be of oil through an analysis membrane for examination of the
evaluated per ISO 3722 to ensure that they are clean enough so contaminant. The membrane is then rinsed with filtered solvent
as not to contribute significant particulate to the sample. It is and examined with a microscope. This allows a semi-
recommended that the required cleanliness level be set at a quantitative determination of the contaminant concentration
maximum of 10 % of the upper limit of the lowest ISO Code and allows for visual determination of the types of contaminant
likely for each size. present. Use of a clean filter funnel and filtered solvent are
critical to minimize outside contaminant. This method will also
X2.3.2 The collection of samples for evaluating contamina-
give an indication of when a section has been adequately
tion control should be made from a system operating at the
flushed. A sample should also be provided to a lab for a final
rated flow. The sample line should be thoroughly flushed by the
particle count.
oil, passing at least 500 milliliters of fluid or five times the
volume of the sampling line and valve, whichever is greater. X2.5.3 Instruments are commercially available for measur-
Since the flush volume can affect the sample particle concen- ing water and viscosity. These instruments employ a variety of
trations, whatever flush volume is used, it should be used techniques, and the user should be familiar with their limita-
consistently. Without changing the sample valve setting, the tions. These instruments can offer guidance for critical deci-
sample container should be rinsed with the system oil and the sions. Again, however, ongoing sampling and laboratory mea-
oil discarded. When the needed volume has been collected, the surements are recommended.
plastic film and cap should be immediately replaced. The X2.6 Laboratory Analysis
container, with its cover tightened, may be wiped clean on the
outside and then transported promptly to a particle counter or X2.6.1 Samples of lubricating or control oils should be
a lab for analysis. All containers should be properly identified submitted periodically for laboratory analysis during system
with respect to type of product, source, tests required, etc. operation or when a visual inspection indicates an abnormal
Additional guidelines for obtaining samples for particle counts condition. Additional guidelines can be found in Practice
are given in ISO 4021. D4378. Analyses that should be included in the laboratory
evaluation are given in Table X2.1.
X2.3.3 Retained samples should be stored in a cool, dark
place. X2.7 Oil Cleanliness Criteria
NOTE X2.1—Unless the above detailed precautions are followed, X2.7.1 The equipment manufacturer is responsible for es-
contaminant introduced by the sample container or sampling technique tablishing the recommended degree of cleanliness. The turbine

D6439 − 11
TABLE X2.1 Laboratory Analyses for Turbine Lubrication Oil X2.7.2 Particulate limits are generally expressed in terms of
NOTE 1—Tests should include some measure of oxidation stability counts or cleanliness codes. During either a manual or auto-
reserve or antioxidant concentration, such as FT-IR, voltametric measure- matic particle count, each particle is assigned to one of several
ments, or Test Methods D2272, D6810, or D6971 to determine remaining size ranges and the total number of particles in each size range
antioxidant life. Consult with the oil supplier when selecting methods and per volume of fluid recorded. The well known ISO 4406
acceptance criteria for oxidation stability reserve or the measurement of
antioxidant concentrations.
method uses a code to reference the number of particles larger
than 4, 6, and 14 µm/mL of oil. ISO 4406 assigns integer values
Characteristic Test Method
Appearance - to denote a range of particles per millilitre whose upper limit
Odor - doubles with each successive number. Manufacturers’ turbine
Viscosity D445 lubrication oil cleanliness recommendations typically vary
Water D6304, D7546
Sediment F311 or D4898 from ISO 16-/14/11 to ISO 18-/16/13.
Acid Number D664, D974
Particle Count F312 or D7647
X2.7.3 It is recommended that the concentration of the
water in a lubricating system be maintained at or below the
saturation level at the lowest temperature in the system. This
prevents water from condensing out of the oil to form free
manufacturer is responsible for assigning cleanliness levels and water that could settle in areas with low flow. It also allows the
sampling and analysis methods. In all cases, the criteria oil to eventually remove free water that might have settled. The
specified by the turbine manufacturer should supersede those saturation level of the oil as a function of temperature should
found in this practice. Recommendations vary depending on be obtained from the oil manufacturer. When non-mineral oil
the configuration of the turbine lubrication and hydraulic such as a phosphate ester fluid is used, the manufacturer’s
systems. recommendations should be followed.
X3. CONTAMINATION CONTROL
X3.1 Methods X3.1.3.1 Centrifugation is a means of removing some in-

X3.1.1 The contamination control system should be capable soluble fluids and solid contaminants from fluids by utilizing
of maintaining particulate matter and water contamination the centrifugal force developed by rotating the fluids at a high
below limits established for the system by the equipment speed. For contaminants suspended in oil, the degree of
manufacturer. The type of system installed, the configuration it separation is dependent upon the flow rate through the centri-
is installed in, flow rate through the purification system, and the fuge, the viscosity of the oil, and the difference in the density
contaminant ingression or generation, or both, rate all affect the of the contaminants and oil. Commercial units are sized to
concentration of the contaminant in oil going to the turbine’s attain a specific level of separation. Clean oil and separated
components. Not all methods described below may be appro- water are continuously discharged automatically by the centri-
priate for all systems. fuge. Sludge and solid contaminants remain in the centrifuge
X3.1.2 Gravity Settling—Gravity settling separates con- bowl and are periodically removed manually or, in a self-
taminants that are heavier than the oil and requires slowly cleaning type centrifuge, automatically. These units may be
flowing or quiescent oil. Gravity settling of water and solids referred to as purifiers or clarifiers.
has generally been supplanted by more active methods of X3.1.3.2 It has been reported that centrifuges can remove
purification, especially for operating systems. It may be em- particles as small as 5 µm or smaller. With favorable conditions
ployed, particularly off-line, as a method for reducing the of low oil viscosity and appropriate throughput, centrifuges
contaminant load on other purification devices. The rate of have been reported to reduce water to less than 0.5 %. Most
separation is dependent on the viscosity of the oil, the size and emulsions can be prevented by the removal of water. It has
specific gravity of the contaminants, and lack of turbulence of been reported that emulsions may be broken in centrifuges.
the oil. Tanks or reservoirs that use gravity settling generally
have a sloped bottom or a sump, or both, for removing X3.1.4 Filtration:
contaminant. Careful control of oil transfer between the turbine X3.1.4.1 Mechanical filters remove solid contaminants by
lubrication reservoir and the settling tank is necessary to ensure passing fluid through restrictions that trap the solid particles.
that the oil level in the reservoir does not go above or below its Depending upon the choice of filter medium, mechanical filters
designed limits. Unless gravity settling tanks are cleaned can remove particles as small as 1 µm. As contaminants are
thoroughly, there is also the possibility of reintroducing con- removed and collected on the filter element, the pressure drop
tamination from previous oil. Free water collected by gravity across the filter increases, ultimately requiring replacement or
separation should be drained periodically to avoid the growth cleaning of the element.
of organic material. This material may accumulate in piping, X3.1.4.2 Instrumentation such as a differential pressure
flow control, or monitoring devices or purification devices and gage should be provided with the filters to enable the operator
reduce lubricating oil flow to critical machine components. to monitor the contamination control system to ensure that it is
X3.1.3 Centrifugation: functioning properly and to signal or indicate the necessity for

D6439 − 11
changing or cleaning the filter elements. This is particularly also said to remove sludge and varnish that has already
important in automated systems. precipitated out of the fluid and formed on the internals of the
X3.1.4.3 Filter Ratings: system. Electrostatic separators are set up on a bypass loop off
(1) The absolute rating represents complete removal of all of the reservoir, and require several passes to clean the fluid.
spherical test contaminants equal to or larger than the absolute The technology requires a nonconducting fluid and its perfor-
particle size rating. In the rating test, a specified volume of a mance is therefore affected with high amounts of water
specified fluid with a specified concentration of spherical contamination. Beta ratios are not useful for determining
contaminant with a defined size distribution is passed through technology performance.
the test filter at a specified temperature and flow rate. The X3.1.7 Charge Agglomeration—A process where sub-
effluent is filtered through an analysis membrane and the micron particles are charged with electrostatic forces and then
membrane inspected. All particles on the membrane must be allowed to agglomerate in size. These sub-micron particles
smaller than the specified rating. agglomerate to sizes that can be removed by conventional
(2) The nominal rating of a screen or filter represents the mechanical filtration.
removal in a circulating system of 98 % of the contaminants
equal to or larger than the nominal rating. For a nominal rating X3.1.8 Coalescence—Purification by coalescence makes
to be meaningful, the test method and contaminant used must use of special fiber cartridges similar to filter elements to
be specified. coalesce small dispersed water droplets to larger ones. The oil
(3) The beta rating represents a ratio of particles of a given is then passed through special hydrophobic barrier screens that
size x (in microns) that enter a filter to those that leave the filter prevent passage of the large water droplets. These then drop to
in a multipass test. The multipass test is performed in accor- the bottom of the coalescer and are removed. Depending on oil
dance with ISO 4572. Filters will have different beta ratings for additive package, throughput, viscosity, and temperature, co-
different particle sizes. Use of beta filter ratings is recom- alescers can provide oil with outlet water concentrations to as
mended over absolute or nominal ratings. low as 100 ppm. Particles trapped in the coalescer cartridges
X3.1.4.4 Screens have a meaningful removal rating only may interfere with coalescence and will reduce cartridge life. It
when evaluated with contaminant comprised solely of spheri- is therefore generally necessary to protect the coalescer by use
cal particles. They have good retention of particles but fairly of a prefilter. Typical solid concentrations should be considered
low dirt capacity because all dirt is collected on the surface. By prior to use of a coalescer system.
comparing the rating of the screens used in the lubricating X3.1.9 Vacuum Dehydration—Vacuum dehydration is a
system during flushing with the allowable contamination level, method by which water is removed from the oil by application
it will be evident that only coarse particles can be retained by of heat or air stripping and vacuum. Wet oil is introduced into
these screens. a chamber with a vacuum of 693 to 870 mm (272 to 340 in.)
X3.1.5 Depth Media Filters—The removal of fine particles of water where it is distributed over a large surface or sprayed
must be done by the bypass or full flow contamination control at temperatures of 38 to 82°C (100 to 180°F). Elevated oil
system, as well as the filters through which the oil is passed temperatures may impact oxidation stability. The water is
when the system is drained and refilled. Filters in these systems removed in the form of a vapor and may be condensed before
are often depth filters; that is, a bed of material (metal, or rejection from the system. Care must be taken that the
organic or inorganic fiber) with narrow irregular passages. combined effect of temperature and vacuum will not remove
Such filters have no meaningful pore size, and even a relatively some of the lower vapor pressure oil components. Depending
coarse depth filter will usually remove a large amount of fine on oil additive package, throughput, viscosity, and temperature,
particles, especially after successive passes (recirculation). vacuum dehydrators can provide oil with outlet water concen-
Depth filters have high dirt capacity due to their relatively large trations to as low as 45 ppm. The oil supplier can provide the
void volumes. Cleaning, however, is difficult, or even impos- necessary information on this point. If salt water is present, an
sible; used cartridges usually have to be replaced with new after filter may be required for the removal of salt crystals.
ones. Vacuum purification equipment frequently also includes a filter
for removing particulate to provide cleaner oil. In addition,
X3.1.6 Electrostatic Separators—Electrostatic separation is
without appropriate filtration, solids may collect in the purifi-
a technology that allows very small insoluble particles to be
cation chamber. For these reasons, typical solids concentrations
collected and removed. Whereas mechanical filters can only
should be considered prior to use of a vacuum purification
remove particles down to 1 mm in size, electrostatic separation
system. Vacuum dehydration also offers the advantage that it
can remove particles as small as 0.01 mm in size. Since the
removes air from the system.
majority of contaminants in turbine oils are under 1 µm in size,
and these contaminants eventually form deposits, electrostatic X3.1.10 Adsorption—Adsorption (surface attraction) purifi-
separation is useful in preventing sludge and varnish. The cation utilizes active-type media, such as Fuller’s Earth, or
technology works by sandwiching dielectric contamination activated alumina to remove oil oxidation products by their
collectors between electrodes. High, direct current voltage is attractive or adherence to the surfaces of these materials.
applied to the oil as it flows through the media, electrically Adsorption agents with highly active surfaces may also remove
charging the insoluble particles. The charged particles are then additives from inhibited oils and alter chemical composition of
attracted to either the anode or cathode, depending upon their the base stock. This method of purification should only be used
charge, and captured in a collector. Electrostatic separators are with agreement and consultation between the user and the

D6439 − 11
lubricant supplier. When fire resistant type fluids such as coalescer with pre-filtration is used, both water and solid
phosphate esters are used, as in hydraulic governor control contaminants are removed.
systems, bypass purification with an adsorption medium may X3.3.3.2 The required capacity of the bypass system will
be used for acid removal. Devices using adsorbents can vary with the rate of contaminant ingression and type, effi-
provide fluids with as low as 10 ppm of water at their outlet. ciency, and capacity of the purification apparatus. The higher
X3.1.11 Resin Based Filter Technologies—Some filtration the efficiency of the purification system, the cleaner the system
technologies utilize a resin matrix that is designed to remove oil will be. For a given efficiency, the higher the purification
oil degradation products that are either in solution or in rate relative to the system volume, the cleaner the system oil
suspension. will be. Higher bypass rates are recommended for dirty
environments, such as coal-fired plants. Recommended bypass
X3.1.12 Vent Protection—Vents should be protected with purification flow rates are typically 10 to 75 % of the system
breather filters. When ingression of atmospheric moisture volume hourly.
would be the primary source of water in a system, a vent drier
may also be used. X3.3.4 Batch Contamination Control:
X3.3.4.1 Batch methods are generally employed for purify-
X3.2 Contamination Control Method Limitations ing oil when it is being transferred between a storage system
and the lubrication system reservoir. To minimize the risk of
X3.2.1 Centrifuges are gravity related, and effectiveness is contamination from outside sources, oil should be transferred
dependent upon particle size, density, and gravitational force directly from a purifier (filter, centrifuge, dehydrator, and so
developed. Mechanical type filters are ineffective for water forth) into the lubrication or hydraulic system. Batch contami-
removal and insoluble contaminants less than 1 µm in size. nation control is not generally used with operating systems
Coalescers are designed primarily for water removal and are because it is labor intensive, may not be able to keep up with
limited by the solid contamination, viscosity, and surfactant in contaminant ingression, and risks contamination from the
the oil. Neither centrifuges or coalescers will remove dissolved holding tank.
water. Electrostatic separators cannot remove moisture and X3.3.4.2 If the oil storage tank is in a cold environment,
have reduced performance in the presence of water contami- heating may be required to obtain a viscosity suitable for
nation. Vacuum dehydrators have low single-pass water re- operation of the pumps and purification system. When heating
moval efficiency and can impact the oils oxidation stability if the oil, the guidelines given in Appendix X4 should be
over exposed to elevated temperatures. Adsorbents can affect followed to avoid overheating.
chemical composition and are generally not recommended.
Thus a combination of devices is often needed. X3.4 Contamination Control System Connections
X3.2.2 To ensure that the oil being used is compatible with
X3.4.1 In designing contamination control system connec-
system filtration, the oil supplier should be consulted before
tions, the following criteria should be considered. The connec-
purification is specified for turbine lubrication and hydraulic
tions should contribute to providing the purest oil practical to
systems. System purification requirements should be included
the turbine, to providing maximum protection against turbine
in the discussion when considering turbine lubrication or
damage due to purification system equipment or piping failure,
hydraulic system oils.
and to maximizing the life of purification cartridges (filter
elements, coalescer elements, or adsorbent cartridges). Con-
X3.3 Contamination Control Configurations nection design variables include the position of the purification
X3.3.1 Contamination control employs one or more of the system inlet and outlet in the turbine lubrication system and the
following configurations to ensure the most efficient removal sizing and configuration of associated tubes, pipes, valves, and
of contaminants. so forth on the purification system.
X3.3.2 Full Flow Contamination Control—The most effec- X3.4.2 Many older turbine lubrication systems were de-
tive means of maintaining clean oil is by full flow treatment signed for gravity settling or deaeration, or both, and as a result
while the oil is being circulated during flushing and subsequent may have a complex system of baffles in the reservoir or
operation of the unit. In this configuration, all fluid being auxiliary settling tanks that should be considered when evalu-
pumped to the system is purified first. Because of the high flow ating purification connection locations. To an increasing extent,
rates involved, this configuration is generally restricted to mechanical devices have taken over the function of removing
filtration. water and solids. In newer systems, the reservoir and purifica-
X3.3.3 Bypass Contamination Control: tion system connections have probably been designed for use
X3.3.3.1 In the bypass mode, also frequently referred to as with mechanical purification and the connections have been
a kidney loop, a portion of the oil is continuously withdrawn optimized.
from the reservoir, the contaminants are removed, and the oil X3.4.3 To avoid introducing contamination when adding oil
then returned to the reservoir. Continuous bypass purification, to the system, it is recommended that a separate connection be
although less effective than full flow, has the advantage that oil provided for filling the system. To avoid contamination with
purification can continue in operation even when the lubricated the wrong oil, it is also recommended that the proper lubrica-
oil equipment has been shut down. Bypass systems are tion oil’s manufacturer, oil name, and viscosity grade be
frequently easier to install for retrofits. When a centrifuge or clearly indicated at this connection. Provision should be made

D6439 − 11
so that oils can be transferred to and from holding tanks and installed immediately downstream of the lubricant pump. In
settling tanks with purification. All purification devices and this case, the effective inlet and outlet of the purification device
associated hardware should be cleaned to levels comparable to are already defined. An oil flow bypass must be provided when
the main turbine lubrication system prior to installation or use. maintenance on the device is required while the turbine is
Clear labeling and good record keeping of the contents of operating. In the case of filters, this is frequently accomplished
transfer vessels will aid in preventing use of the wrong oil. by providing multiple housings that allow one or more to be
X3.4.4 All connections should be appropriately sized to bypassed while the elements are changed.
prevent undue pressure drops at the rated flow of the purifica- X3.4.9 Bypass Purification:
tion device. With all contamination control devices, including
settling tanks, care must be taken to prevent loss of lubricant X3.4.9.1 If a retrofit bypass purification system is being
from the system. All drain valves that lead out of the system installed, it is recommended that the operator review reservoir
should be locked closed when not in use. Any pressure relief drawings and obtain guidance from the turbine manufacturer
valve drains should be piped back to the reservoir. All and manufacturer of the purification device. Both the inlet and
purification device inlets must be low enough in the tank to the outlet should be connected to the reservoir, with no
ensure an adequate oil supply to prevent air entrainment. connection to the main lubrication piping. It is generally
recommended that the inlet and the outlet be placed as far apart
X3.4.5 The pressure rating of pumps supplying the purifi-
as possible in the reservoir; however, possible reduction of
cation devices must be considered. It is generally recom-
deaeration and contaminant removal through settling by flow
mended that all hardware downstream of such a pump be rated
bypass through the device should be considered. As discussed
to the full output pressure of the pump. If that is not practical,
fail safe pressure relief must be provided and all hardware rated in X3.4.7, contaminant settling and device contaminant sensi-
to the relief setting. Wherever practical, valves and other tivity should be considered in determining the level of the
fittings should be designed to be strong enough to resist lubrication system reservoir outlet to the purification system.
breakage by being struck accidentally or being stepped on. For X3.4.9.2 In general, with a bypass system, the higher the
permanent installation of purification devices, pipes are rec- flow through the bypass system, the purer the fluid will be
ommended instead of hoses. going to the turbine. If bypass contamination control is to
X3.4.6 For water removal devices, provision must be made reduce the contamination load on a full flow purification
to allow the water removed from the lubrication oil to be device, such as a pressure line filter, the bypass removal
disposed of in an environmentally acceptable manner. efficiency times the flow rate should be at least equal to, and
preferably several times greater than, the removal efficiency
X3.4.7 If gravity settling is employed as a purification times the flow rate for the full-flow device.
method, it is necessary to have a drain at the bottom of the tank
or tank sump to remove the settled contaminant. It is generally X3.4.10 If portable purification is used, there are several
recommended that the material be drained from the bottom of additional precautions to be observed. All connections on the
the tank or tank sump to a waste oil tank and the waste oil lubrication system and purification device must be clearly
disposed of in an environmentally acceptable manner. The oil labeled. A label on the purification device must indicate current
may also be purified and reused; however, the sensitivity of the contents to avoid cross contamination. All hoses and connec-
purification device to contaminant should be considered. Be- tions must have appropriate pressure ratings. Where connec-
cause fine filters, coalescers, and vacuum dehydrators are tions with valves are used, the valves on the turbine lubrication
relatively sensitive to settled contaminant, particularly sludge system should be locked closed when not in use. Use of a
and surfactants, it is generally not recommended that the drain pressure relief device on the purification device is recom-
be connected to these devices. If oil from a settling tank is to mended should flow be accidentally started to a connection
be purified by one of these devices, the tank outlet to the with a closed valve. When not in use, hoses and valves should
purification device should be above the level where significant be capped to prevent accidental leakage and contaminant
concentrations of settled contaminant would be encountered. ingression. Before connecting to the lubrication system, the
X3.4.8 If the system is being retrofitted with a full-flow purification device should be at least as clean as the lubrication
purification device, it is most likely that this device will be system.

D6439 − 11
X4. HEATING
X4.1 Flushing frequently involves heating the oil, as do maximum watt density for electrical heaters of 2.3 W/cm2 (15
some methods of contamination control. To avoid degradation, W/in.2) for mineral based products. Higher watt densities of up
the lubricant manufacturer should be consulted to assist in to 3.6 W/cm2 (23 W/in.2) have been recommended with
selecting appropriate heating and caution should be exercised adequate circulation to avoid exceeding the allowable heater
in heating the oil. At all times, heating elements must be totally skin temperatures indicated above. Controls should be installed
immersed. An oil level control will provide adequate protec- to maintain these maximum levels.
tion.
X4.3 To heat noncirculating oil, heater skin temperatures
X4.2 In circulating oil systems, maintain heater skin tem-
should be maintained at or below 66°C (150°F). Temperature
peratures below 121°C (250°F) and ensure that oil circulating
monitoring devices should be installed on the heater skin for
pumps are operated during heating. Steam heating pressure
this purpose, and temperature control devices employed.
should be no higher than 34 kPa (5 psig). API 614 specifies a
SUMMARY OF CHANGES
Subcommittee D02.C0.01 has identified the location of selected changes to this standard since the last issue
(D6439–05) that may impact the use of this standard.
(1) Added Practice D7155 and Test Methods D7546 and (4) Revised 8.3.3.8.
D7647 to Section 2, Referenced Documents. (5) Revised Appendix X1.
(2) Added and revised definitions in Section 3, Terminology. (6) Revised Table X2.1.
(3) Extensively revised Sections 6 and 7. (7) Revised Appendix X3.
ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.
This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should
make your views known to the ASTM Committee on Standards, at the address shown below.
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X1.1 Water X1.1.5 The circulation in most lubrication systems today is

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X2. OIL CONDITION MONITORING

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X3. CONTAMINATION CONTROL

X3.1 Methods X3.1.3.1 Centrifugation is a means of removing some in-

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