Over the past few years, significant resources have been allocated to enhance flushing techniques for hydraulic and lubrication systems. This investment has generated a wealth of knowledge, reflected in numerous articles, international standards, and procedures on the topic. However, despite these advancements, a considerable gap persists between the theoretical understanding and practical application in Automotive Lift Repair Tampa Florida hydraulic and lube oil systems.
While many well-crafted papers address flushing technology, this discussion will focus on methodical practices and specific procedures. The insights shared come from Mator AS, a Norwegian offshore company with extensive experience in oil and gas drilling and production platforms in the North Sea, as well as larger land-based production facilities and smaller hydraulic and lube oil systems.
When to Flush an Automotive Lift Repair Tampa Florida System
The approach to flushing differs significantly between newly fabricated systems and those already in service due to varying procedural methods and practical constraints. Flushing can be a time-intensive process, and estimating the required time can be challenging. Often, due to system design limitations, only about one-third of the total time is spent on the flushing itself, while the remaining two-thirds is devoted to mobilizing flushing equipment, disassembling sensitive components, assembling bypass lines, connecting flushing hoses, pre-cleaning the flushing fluid, and filling and heating the system. Efficient and well-executed flushing practices can yield substantial returns on investment.
The Fabrication Stage
Flushing should be integrated into the lifelong maintenance program right from the design phase, but this is rarely done. Systems often lack dedicated flushing connection ports, air-bleed ports, and pre-mounted bypass loops. Additionally, subcontractors need to adhere to proper flushing procedures and documentation requirements for subsystems.
Consequently, the final flushing of complex Automotive Lift Repair Tampa Florida systems often poses management challenges, leading to increased costs and delays. Shortcuts may seem appealing but can postpone rather than resolve issues.
To transition from traditional flushing practices to best practices, consider the following steps:
1. Develop a Detailed Flushing Procedure: Include it in all supplier bids and contracts. Reassess if standards from organizations like API, ASTM, or ISO can support your requirements. Specify documentation templates to ensure traceability, which is crucial for liability insurance.
2. Incorporate Flushing Documentation into Quality Assurance: Make flushing documentation an essential aspect of acceptance checks within your quality assurance program.
3. Control the Integration of Subsystems: Prevent cross-contamination by systematically managing how subsystems connect to the main system. Document all results as part of the flushing procedure.
4. Establish Standards for Flushing Connectors: Include dimensions and placement in the engineering contractor’s design handbook.
5. Specify Sampling Points for Monitoring: Define these points for both flushing and in-service conditions.
6. Appoint a Technical Specialist: This individual will oversee and approve flushing procedures and manage any deviations from the standard processes, independent of technical and commercial departments.
Verification routines should be implemented each time a subsystem connects to the main system. Integrating these recommendations into the overall plan will foster confidence and reduce costly rework at the project’s conclusion.
Flushing Strategies for Automotive Lift Repair Tampa Florida Systems in Service
1. Post-Breakdown or Repair Cleaning:
– In a well-designed system, contaminants from pump or motor failures should be contained by in-line filters, requiring flushing of only the affected areas.
– If contaminants are spread throughout the system, a complete flush is necessary.
– During routine maintenance, minimize external contamination by using proper coverings until the system is sealed.
2. Flushing After Modifications: Follow the same approach as for new systems.
3. Proactive Flushing: In older systems, contaminants can accumulate in the reservoir and piping due to low fluid velocity and inadequate filtration. Periodic proactive flushing can be more cost-effective than a major upgrade or modification.
General Cleaning and Flushing Requirements
Ensure all new components meet cleanliness requirements. New cleaning and hot oil flushing should occur after any changes or assemblies.
Flushing Strategy Tips
– Connect circuits in series.
– Isolate sensitive Automotive Lift Repair Tampa Florida components from high fluid velocities or contaminants during flushing.
– Ensure that components, including manifolds and pumps, are delivered clean or flushed separately if not.
Component Cleanliness Level
Components connected post-flushing should meet or exceed the main system’s cleanliness standards. Suppliers should provide cleanliness certificates, and if unavailable, the system assembler must clean according to specified procedures.
System Cleaning Preparation
For mechanical tube cleaning, precision steel tubes should undergo chemical cleaning and hot oil flushing. Welded tubes should be mechanically cleaned using a plastic pig.
Chemical Cleaning and Hot Oil Flushing
Each circuit should achieve specified fluid velocities and pressures to avoid settling particles. Chemical cleaning follows a multi-phase process involving degreasing, pickling, neutralizing, preservation, and drying, utilizing environmentally friendly chemicals.
Minimum Process Equipment Required
The pickling unit must include a reservoir, pump, filter, and heating system, with fluid velocities around 3 m/sec preferred. Adequate drying facilities are crucial to ensure no contamination remains.
Process Control
To validate effective chemical cleaning, document key parameters such as pH, temperature, chemical volume, flow rate, and more.
Flushing Fluids
Flushing fluids must be compatible with normal operation fluids, typically achieving a viscosity of 10-15 cSt at 40°C for effective turbulent flow.
Turbulent Flow, Fluid Velocity, Temperature, and Pressure
A minimum Reynolds number of 4,000 is essential to ensure turbulent flow for effective cleaning. System pressure should be maintained at 3 to 5 bar downstream from the flushing circuit.
Cleaning Components
Automotive Lift Repair Tampa Florida Reservoirs are particularly challenging to flush and often require manual cleaning. Other components should also be cleaned in separate loops, ensuring full movement during flushing for thorough cleaning.
Minimum Flushing Time
Once cleanliness is confirmed, continue flushing for at least an additional 30 minutes to remove stubborn particles.
Verify Flushing Results
Each flushing loop should be unique and traceable, with complete documentation of all relevant parameters. Third-party verification may be required to confirm cleanliness.
Flushing Skid
Adapt the flushing procedure to the specific rig conditions, ensuring the filter system is effective for both solid and moisture removal. Avoid using original system filters for flushing, as they do not meet cleanliness requirements.
Although flushing can be resource-intensive, it is essential for effective Automotive Lift Repair Tampa Florida system operation, particularly after construction or component failure, and should be part of routine maintenance. A well-designed system facilitates more efficient flushing, optimizing the overall process for reliability and performance.