Casper – several flushing methods for hydraulic systems

For the system flushing after the hydraulic system is assembled, it is necessary for the newly put into use hydraulic system, and any luck mentality and give up cleaning will bring fatal damage to the equipment. After strict flushing, it can reduce and avoid failures in system commissioning and early operation, shorten the commissioning cycle of the system, and reduce unnecessary losses. However, contamination control of the system is an ongoing process that cannot be done once and for all, and it is also necessary to regularly monitor the condition of the oil during the operation of the system and control the contaminants to ensure that they are within the allowable cleanliness range of the system.

Casper – several flushing methods for hydraulic systems

2. Circulating flushing device

The circulating flushing device generally adopts an independent high-flow high-pressure flushing device or a working pumping station of the system to carry out the circulating flushing operation of the pipeline. The output flow of the independent high-flow high-pressure washing device is generally more than 1000 liters/min, which should be composed of 3-4 high-pressure pumps and 1 low-pressure pump, according to the parameters of the metallurgical hydraulic system, the high-pressure pump (31.5MPa) flow configuration is 250 liters/min, 160 liters/min, 100 liters/min, 63 liters/min and the low-pressure pump (2.5MPa) 400-600 liters/min can be composed of different flushing pressure flow needs.

The output pipe interface of the circulating flushing device should not only enable the output flow of all flushing pumps to flush one flushing circuit at the same time, but also form multiple independent flushing circuits at the same time.

The use of the working pumping station of the system itself to carry out the circulating flushing operation of the pipeline is also more and more widely used and recognized, the use of the working pumping station to the system pipeline flushing is a reliable method to achieve the quality of flushing efficiently and quickly and has more advantages, which is manifested in saving valuable time and construction period, saving a large number of temporary piping materials, and the formal electrical protection of the working pumping station itself and the circulating cooling in the system, the internal circulation filtration function can be used to make the system flushing effect of the pipeline better and faster.

3. Steps of circulating flushing

Circulating flushing is generally divided into the flushing of the main pipeline from the hydraulic pump station to the control valve frame and the flushing from the control valve frame to the cylinder and the oil motor branch pipeline. According to the requirements of pipeline flushing accuracy, it is divided into coarse flushing of intermediate pipelines and fine flushing of all pipelines.

The flushing connection circuit from the hydraulic power station to the main pipe of the control frame is relatively simple, and only needs to be connected at the end of the main pipe.

The flushing of the control valve frame to the cylinder and oil motor branch pipes is relatively complex. Sometimes it is necessary to make a lot of temporary flushing piping to form a flushing circuit, and it is necessary to pay attention to some of the factors that should be considered when flushing in series and parallel as mentioned above.

For hydraulic system flushing with CASAPPA synchronous motors, the following steps can be followed:

Before installing sensitive components (such as servo valves, etc.), the pipes and non-contaminant insensitive components are assembled first, and the ends of the pipes are tightly sealed.

Replace the sensitive components with jumper wires, connect the hydraulic circuits, fill them with liquid and pressurize them, and rinse them until the specified cleanliness is achieved.

The flushing circuit should be chosen to skip the sensitive element and reduce flow resistance as much as possible. Flushing should avoid dirty oil through the pipe that has been flushed clean, for more complex systems, you can choose the circuit to flush from the branch to the main pipeline, and then separate the branch from the main pipeline, and then flush the main pipeline, on the oil return road of the flushing circuit, install an oil filter or a filter, due to more impurities in the early stage of flushing, generally use 80 mesh filter, and use more than 150 mesh filter screen in the later stage of flushing.

In order to improve the flushing effect, the hydraulic pump in the flushing process is better to intermittent movement, and its intermittent time is generally 10-30 minutes, and the flushing effect can be detected during this intermittent time. During the flushing process, in order to facilitate the detachment of the attachment on the inner wall of the pipe, the pipe can be gently tapped with a non-metallic hammer such as a wooden rod or rubber mace, which can be knocked continuously or intermittently.

The choice of flushing medium is usually the actual use of hydraulic oil or test oil. Avoid the use of alcohol, vapor, etc., to prevent corrosion of hydraulic components, pipes, oil tanks and seals.

The amount of flushing liquid is generally 60%-70% of the working capacity of the oil tank, and the flushing time is not too long, generally 2-4 hours, and not more than 10 hours in special cases. The flushing effect is based on the absence of polluting impurities on the circuit filter screen. The flushed hydraulic oil needs to be tested for quality to determine if it can be continued.

Casper – several flushing methods for hydraulic systems

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