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National Power Fluids-The Leading Power Fluid Provider
 
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National Power Fluids
1400 S. Ocean Blvd.
Suite N-902
Boca Raton, FL 33432


Marianne Segal


PH: 720-289-2429
Fax: 877-789-4133
Fluid Replacement  >  Chemical Flush
Chemical Flush

 EHC SYSTEM CHEMICAL FLUSHING PROCEDURE OUTLINE-Fossil Unit

1. Prepare System for Flush
        a. Hydraulic Power Unit
               i. Remove Side Steam Filter Elements (not used during flush)
               ii. Remove Pump Discharge Filters
               iii. Clean Pump Suction Strainer/s
               iv. Remove and Recondition Accumulators (reconditioning can be
                    done concurrent with Flush)
        b. EHC Fluids
               i. Transfer Rinse Fluid from Barrels to Totes
               ii. Transfer Final Operating Fluid from Barrels to Totes
               iii. Continuously Filter Fluid in Totes until needed.
         c. Protective System
               i. Jumper around Trip System Valves
               ii. Remove and recondition Protective System Accumulators (If
                     provided)
         d. Steam Valve Actuators
               i. Remove and recondition hydraulic actuators and jumper hydraulic lines to be flushed or                  install flushing valves on hydraulic actuators in order to flush lines and actuators. Note it is                  highly recommended that the hydraulic actuators be removed and reconditioned during the                  flush and only the pipes be flushed. This insured the actuators are thoroughly cleaned                  following the flush since it is impossible to get high velocity flows through the actuators                  during the flush.

2. Chemical Flush
         a. Start One Hydraulic Power Unit Pump and Check Systems for Leaks
         b. Start Second Hydraulic Power Unit Pump and Check System for
              Leaks
         c. Functionally check system (flushing valves and/or jumpers)
         d. Bring fluid to 130F (Both pumps running for flushing)
         e. Add Flushing Chemistry to existing fluid in Reservoir (Oleylamine-
             1% of reservoir capacity)
         f. Flush each line while maintaining fluid temperature between
               i. 1st cycle = 30 minutes per line
               ii. Remaining cycles = 10 minutes per line
               iii.  Take periodic fluid samples and analyze the fluid (Generally it takes 4 cycles to get all of                       the  gels and varnish dissolved and or dislodged. It may take more cycles). iv. When no                       hard  varnish is observed under the microscope and the particulate counts are no longer                       increasing (generally we see a decrease in particulate counts) the Chemical Flush is                       complete.
3. Preparations for Rinse Flush
         a. Shut down lockout and tagout Hydraulic Power Unit Pumps
         b. Depressurize the system and open and all flushing valves and or jumpers
         c. Drain and thoroughly clean the Hydraulic Power Unit Reservoir using
            non-chlorinated solvent and lint free rags
         d. Drain and clean the Side Stream Filter Housing
         e. Remove and Clean Pump Suction Strainer/s
         f. Install new Pump Discharge Filter elements
         g. Install new Air Breather material
         h. Drain Hydraulic Power Unit Coolers
         i. Drain all low point drains within hydraulic fluid system
         j. Fill Reservoir with new filtered Rinse Fluid

4. Rinse Flush
         a. Start both Hydraulic Power Unit Pumps and Check Systems for Leaks
         b. Bring fluid to 120F.
         c. Flush each line for 10 minutes per cycle while maintaining fluid temperature between           120F-130F.
               i.  Take periodic fluid samples and analyze (Generally it takes 2 cycles
                    to get the system clean or residue left behind during Chemical
                    Flush. It may take more cycles).
               ii. When consistently low particulates are observed under the microscope the Rinse Flush is                    complete.

5. Restoring the Hydraulic Fluid System
         a. Hydraulic Power Unit
               i. Shut down lockout and tagout Hydraulic Power Unit Pumps
               ii. Depressurize the system and open all flushing valves and/or jumpers
               iii. Drain and thoroughly clean the Hydraulic Power Unit Reservoir using non-chlorinated                   solvent and lint free rags
               iv. Drain and clean the Side Stream Filter Housing and install new filter elements
               v. Remove and clean or replace Pump Suction Strainer/s
               vi. Replace Pump Discharge Filters with new filter elements
               vii. Drain Hydraulic Power Unit Coolers
               viii. Drain all low point drains
               ix. Install reconditioned HPU Accumulators
               x. Fill Reservoir with new filtered Final Operating Fluid
         b. Protective System
               i. Remove jumpers assembly and reconnect all lines.
               ii. Install reconditioned or new accumulator is provided
         c. Steam Valve with actuators in place
               i. Replace flushing valves with new or reconditioned servo valves and solenoid valves
               ii. Remove, clean, inspect and reassemble all Dump Valves if equipped
         d. Steam Valves with Actuators removed for refurbishing during flush
               i. Replace jumpers with reconditioned hydraulic actuators. The actuators should have either                reconditioned or new servo valves, solenoid valves and dump valves.

6. Restart of System
         a. Start One Hydraulic Power Unit Pump and check system for leaks
         b. Start Second Hydraulic Power Unit Pump and check system for leaks
         c. Reset turbine controls and check system for leaks
         d. Stroke all steam valves and check system for leaks

EHC SYSTEM INTACT RINSE PROCEDURE OUTLINE-Fossil Unit

1. Prepare System for Rinse
          a. Hydraulic Power Unit
               i. Drain Side Steam Filter housings and remove filter elements (not used during Rinse)
               ii. Replace Pump Discharge Filters with new elements
               iii. Clean Pump Suction Strainer/s
               iv . Drain and thoroughly clean Hydraulic Power Unit Reservoir using  non-chlorinated solvent  and lint free rags.
               v. Drain Hydraulic Power Unit Coolers
               vi. Drain all low point drains within hydraulic fluid system
               vii. Fill Reservoir with new Rinse Fluid

2. Rinse
         a. Start One Hydraulic Power Unit Pump and Check Systems for Leaks
         b. Bring fluid to 110F.
         c. Reset Turbine Control System
         d. Stroke all hydraulic actuator 3-4 times fully opened and closed
         e. Trip Turbine Control System
         f. Shut off first Hydraulic Power Unit Pump and start Second Hydraulic
          Fluid Pump and check for leaks.
         g. Shut down pumps
         h. Depressurize the hydraulic fluid system.

3. Restoring the Hydraulic Fluid System
         a. Hydraulic Power Unit
               i. Drain and thoroughly clean the Hydraulic Power Unit Reservoir using non-chlorinated                    solvent   and lint free rags
               ii. Drain and clean the Side Stream Filter Housing and install new
             filter elements
               iii. Remove and clean or replace Pump Suction Strainer/s
               iv. Replace Pump Discharge Filters with new filter elements
               v. Drain Hydraulic Power Unit Coolers
               vi. Drain all low point drains
               vii. Fill Reservoir with new Final Operating Fluid
4. Restart of System
         a. Start One Hydraulic Power Unit Pump and check system for leaks. Shut
            down pump
         b. Start Second Hydraulic Power Unit Pump and check system for leaks
         c. Reset turbine controls and check system for leaks
         d. Stroke all steam valves and check system for leaks

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