BFPA/P9

GUIDELINES
FOR THE FLUSHING
OF HYDRAULIC
SYSTEMS

BFPA

Representing Hydraulic
& Pneumati<j_wtfJ tj,ies

BFPA/P9

GUIDELINES
FOR THE FLUSHING OF
HYDRAULIC SYSTEMS

Issue 2

Addendum

The publication mentioned throughout this document titled BFPA/P54 -Guidelines

for the Comparison of Particle Counters and Counting Systems for the Assessment of
Solid Particles in Liquid should be BFPA/P55.

July 2004
BFPA/P9

FOREWORD

The first issue of this document was originally published in May 1978 as
AHEM/9 and was prepared by Technical Committee El - Contamination
Control. At that time, members from the following companies were
represented on Committee El under the Chairmanship of Mr N Way of Pall
Europe Ltd:
Automotive
Products Ltd BHRA
Dowty Hydraulic
Units Ltd Fairey
Filtration Ltd
Fawcett Engineering
Institution of Plant
Engineers Lucas
Industrial Equipment
Ltd National Coal
Board

NEL
Pacific Scientific International
Inc. Pall Europe Ltd
Plessey
Hydraulics
Sperry Vickers
Group TellTale Filters Ltd
Y-ARD Ltd

It has now been completely revised by Technical Committee El:

Chairma
n:
Membe
rs:

Mr N
Way Mr
R Baker*
Mr
M
Fairhurst
Mr
B
Goodwin
Mr C D
Hart
Dr T M
Hunt* Mr
K Martin
Mr S J
Purser
Mr R T
Roderick Mr
J A Smith
Dr D G
Tilley Mr
M J Wates
Mr P J
Wilson

Pall Europe
Ltd Howden
Wade Ltd
BHR Group
Ltd Parker
Hannifin plc
Fawcett Christie Hydraulics
Ltd Lindley Flowtech Ltd
Parker Schrader Bellows
Division Vickers Systems Ltd
Flupac Ltd
Pacific Scientific
Ltd University of
Bath Norgren
Martonair Ltd
UCC International
Ltd

* Members of special working group who, along with M

Griffin of Norson Power Ltd, I Burniston of Pall Europe Ltd,
and A Whitehouse of Marioff Services Ltd, prepared the draft
for the Committee's approval.
These Guidelines are intended to reflect the opinion of the Association only
and a User should also consider manufacturers' instructions before using any
particular product. Whilst the Association has taken all reasonable care to

ensure the accuracy of these Guidelines, no liability or responsibility in

negligence or otherwise whatsoever shall be accepted by the Association, its
members, servants or agents as to the content or interpretation of these
Guidelines.
No part of this publication may be photocopied or otherwise reproduced
without the prior permission in writing of the Association. BFPA Guideline
documents are regularly reviewed and readers are advised to check the
validity by contacting the Association at the address given below.
British Fluid Power Association, Cheriton House, Cromwell Park, Chipping
Norton, OX7 5SR. Tel: 01608 647900. Fax: 01608 647919. E-Mail:
enquiries@bfpa.co.uk Website: http://www.BFPA.co.uk
BFPA 1992

BFPA/P9

TABLE OF CONTENTS

Subject

Page

1.0

Introduction

2.0

Decision Balance for Flushing

3.0

Condition of Components

4.0

Condition of Steel Pipes

5.0

Site Conditions and Storage

6.0

Flushing Fluids

7.0

Minimum Flushing Procedures Using the System Pump

8.0

Use of Specialist Flushing Equipment

9.0

Flushing of Operating Systems

10.0

References

Appendix 1

Appendix. 2

Figure 1

12

GUIDELINES FOR THE FLUSHING OF

HYDRAULIC SYSTEMS
1.0

INTRODUCTION
The aim of flushing is to remove contamination from the inside of pipes and
components which is inherent or may be introduced during system assembly. This is
accomplished by passing fluid through the system usually at a velocity much higher
than that during normal operation.
Flushing is a procedure which is vital to the satisfactory operation and life of a
hydraulic system. Omission or curtailment of flushing will inevitably lead to rapid
wear of components, malfunction and breakdowns.
The range of types of hydraulic system is very diverse, both in size and complexity.
This document provides guidance applicable to all systems. Careful judgement must
be exercised in modifying or supplementing the procedure outlined here to a
particular installation.
It is the responsibility of the system designer to specify the required cleanliness
standard and the checking procedure to be adopted.

For more information on the levels of cleanliness required for reliable operation, refer
to table 3 in BFPA/P5 - Guidelines to Contamination Control in Hydraulic Fluid
Power, and for information on possible methods to check the cleanliness levels, refer
to BFPA/P54* - Guidelines for the Comparison of Particle Counters and Counting
Systems for the Assessment of Solid Particles in Liquid.
2.0

DECISION BALANCE FOR FLUSHING

The amount of care and effort that is put into flushing has to be decided upon on an
individual basis. For example, a sub-sea actuator system for North Sea oil is a simple
hydraulic system, but because it has to be right first time every time, every effort is
put into ensuring maximum cleanliness. On the other hand, a small company that
occasionally produces a small economically priced power pack for a non-critical
application may have only the most elementary precautions taken. Set out below are
some general recommendations on the selection of the level of flushing required for
various categories, each level implies that the lower ones are also covered where
appropriate.
Typical Applications

Operations Carried Out

Level 1 Very dirt tolerant systems

w i th severe bu dget
limitations (small power
packs)

Component suppliers asked to

maximise cleanliness and ensure
build of equipment is as clean as
their facilities will allow.

Level 2 Average systems where

OEM has sufficient quality
system to implement control
within manufacture process

Cleanliness standard instituted for

machinery.

Level 3 Average systems where

OEM has quality system to
control suppliers

Component supplier required to

meet cleanliness specification.

Under preparation

-1-

Typical Applications

Operations Carried Out

Level

Flow through sensitive components

avoided during start-up.

4 Moderately sensitive
systems and where high
production rate requires
minimum time for flushing
(mobile plant, moderate
size power packs)

Level 5 Systems with very sensitive

components such as servo
valves (injection
moulding/tensile
testing
machines)

3. 0

Sensitive components replaced with

flushing blocks during flushing
operation.

Level 6 Large systems requiring

high levels of reliability
(turbine controls, off-shore
systems)

Sub-systems flushed individually

and checked for cleanliness before
total assembly of system.

Level 7 Absol u
te
required
systems)

Clean Room conditions required for

components and systems.

perfor m
ance (eg.
satellite

CONDITION OF COMPONENTS
All components and hoses must be supplied ready for assembly into the system in
pre cleaned condition, and all openings sealed. Temporary sealing devices, plugs, etc.
should only be removed immediately prior to assembly. In addition, and where
applicable, the component may be inhibited with a preservative oil. For more
information on methods of assessing the cleanliness of components, refer to
BFPA/P48
- Guidelines to the cleanliness of hydraulic fluid power components.

3.1

Coolers
These should be received from manufacturers in the clean condition, if not,
contact the manufacturers.
3.2

Reservoirs
Unless supplied in the clean condition, the reservoir should be cleaned by
grinding with mechanical grinders, steel wire brush or other suitable cleaning devices
to remove rust, mill scale, welding splatter, greases, dirt and other foreign matter such
as joint and gasket compounds. If adequate safety precautions are adhered to,
petroleum solvents may be used for cleaning and degreasing reservoir surfaces. Toxic
or highly flammable solvents such as carbon tetrachloride or benzene must not be
used for cleaning. The surface must be wiped with clean lintless cloth (not waste).
Putty or other suitable compounds may be used to pick up all loose dirt and metallic
particles from corners and the base of the reservoir. After thorough inspection of all
parts of the reservoir and re-cleaning where necessary, all openings should be sealed.
If the internal surfaces are to be left untreated, the reservoir should be coated with a
rust preventative oil readily soluble in the flushing oil and then closed and sealed.
Care should be taken to see that no water or foreign material is trapped in low
pockets, inaccessible corners or horizontal surfaces.
In systems where the reservoir is integral with the machine, it should be cleaned and
protected as above before installation.

4. 0

CONDITION OF STEEL PIPES

Particular attention should be given to piping, which should be free from scale, rust,
flux, etc. Piping not in the clean condition should either be rejected and replaced or
cleaned before assembly. Thorough cleaning before assembly may not be possible in
-2-

the case of very large pipes so that these will require special attention during flushing
to attain the required standard of cleanliness.
Before installation, and after all fabrication has been completed, all pipes and
fittings, unless supplied in the clean condition should be treated as follows:
All accessible welds on pipes and fittings must be inspected for the presence
of welding beads. If beads are found they should be ground off before the
cleaning procedure is undertaken.
All fabricated steel pipes and flange fittings should be blown with steam or
air to remove loose scale, welding beads, dirt or sand. They should then be
immediately submerged and washed in a hot alkaline solution, prepared and
used in accordance with recommended practices. During this operation all
dirt, paint and grease is removed from the metal thereby preparing the pipe
and fittings for pickling. The parts, with the exception of the valves, should
then be pickled by any one of the standard pickling processes in order to
remove mill scale from the metal. It is extremely important that all traces of
pickling materials are removed by water washing or other suitable means so
that subsequent contamination of the oil with the acidic products cannot
occur.
After thoroughly drying the pipe with dry air, it should be coated with a
suitable rust preventative oil which will be readily soluble in, and hence
removed by, the flushing oil.
Finally, all the openings should be closed to prevent the entry of foreign
material and excessive moisture.

5. 0

SITE CONDITIONS AND STORAGE

In most cases, hydraulic systems are not assembled in clean room conditions. Care
must, therefore, be exercised during system assembly to minimise the ingress of
contamination, since in the majority of cases, site conditions cannot be controlled. It
is essential to avoid areas in the proximity of welding, grinding, air cleaning and any
other contaminant generating activities. Piping and components awaiting assembly
should be stored in a dry place or at least elevated and covered, with all ports and
openings sealed.

6. 0

FLUSHING FLUIDS
Although special flushing fluids, with good solvency power, inhibitors and de
watering properties are available, the majority of flushing operations take place with
the system hydraulic fluid for reasons of cost. If the intended system fluid has too
high a viscosity to achieve the required turbulent flow, then a lower viscosity
classification (BS 4231) of the same oil can be used.
Should special flushing fluids be specified, then it is essential to ensure that they are
compatible with all the components in the system, particularly elastomers in seals
and hoses. Thorough draining of flushing oil will be required with the additional
possible requirement of a displacement oil to be charged into the system immediately
after removal of the flushing oil. Delay may result in rusting of the newly cleaned
smfaces.

7. 0

MINIMUM FLUSHING PROCEDURES USING THE SYSTEM PUMP

Procedures needed will vary greatly and this section covers the minimum procedure
required for simpler systems.
Ideally, flushing should be accomplished by passing fluid through the system at a
velocity which is much higher than that occurring in normal operation. This
requirement, however, necessitates the use of a separate pumping system.
Additionally

some systems, particularly those using a fire-resistant fluid, may involve the use of a
special flushing fluid which must be compatible with the fluid ultimately to be used.
Recommended procedures for the use of separate pumping systems and flushing
fluids are described in paragraphs 8.0 and 6.0 respectively.
If due precautions are taken, many systems can be adequately flushed using the
system pump, and the procedures outlined below:

Fill the system with clean fluid, preferably by pumping it into the reservoir
though a filter.
After starting the pump, ensure that it is properly primed and that the outlet
pressure is low.
As the system fills, the level of fluid in the reservoir will drop, and filling
should continue until the level of fluid in the reservoir is stable. This is
particularly relevant when the system contains relatively large volumes in the
pipework and cylinders.
The direction of flow through all parts of the system should be changed as often
as possible, but extreme care must be exercised to ensure that damage is not
caused by operating equipment out of sequence.
To ensure that the system is flushed as quickly and efficiently as possible, both
fluid velocity and temperature should be as high as conveniently possible.
All filter condition indicators should be monitored continuously, and any
heavily loaded filter elements replaced before the element starts to bypass.
At reasonable intervals fluid samples should be taken and the contaminant level
measured, for example, after initial start-up and then after 10, 50 and 100
theoretical recirculations.
Flushing should continue until the sample indicates that the specified level of
cleanliness has been achieved.
Any temporary equipment should now be removed and the complete system
reconnected. When the system is re-started, additional fluid may be required to
fill actuators that have been bridged out during the initial flushing.
Reconnecting components such as cylinders which have been bridged out
during preliminary flushing can introduce further contamination into the system,
so the flushing process should be continued until the specified fluid cleanliness
level is again reached.
The equipment should subsequently be monitored in its working environment to verify
that the filter element rating is satisfactory. If the required cleanliness level cannot be
achieved in a reasonable period, it may indicate that the filters designed to maintain the
general system cleanliness level need to be fitted with finer elements. In any case, it is
prudent to change all replaceable elements at the end of a flushing period and examine,
and if necessary clean any strainers. Finally, the system should be run again for a short
period to remove any air which might have been introduced during the filter element
change, and the reservoir fluid level re-checked.

8. 0

USE OF A SPECIALIST FLUSHING EQUIPMENT

8.1

System Preparation
Only the simplest system can be flushed in one operation. In the majority of
systems they should be divided into sections or loops, the sections being flushed in

turn. Pump stations and valve manifolds may be flushed separately from the piping
system unless they have been supplied in the clean condition.
System components which may present a restriction to the flow or which may be
damaged by the high flushing flow should be bypassed by suitable make-up pieces.
These components, which may have been flushed on assembly, include reservoirs,
pumps, motors, dead-end components such as cylinders, servo valves, flow regulators
and other valves containing small orifices. Filters may be left in place but with their
elements removed.
It is preferable that air bleeds should be fitted to all high points in the system to
ensure filling of pipes and components.
Drain points should be fitted to every low point in the system and to dead-ends to
assist in the removal of contaminants. Dead-ends should be avoided as far as possible
or bridged with make-up pieces.
Flushing connections should be fitted to each loop in the system. The connections
should be large enough to pass the flushing flow at a low pressure drop.

8.2

Flushing Equipment
The flushing rig should comprise pumps, reservoirs, heaters, coolers, filters,
return line sampling points and hose connections.
The pumps, sized to cater for the required flow range, should incorporate adjustable
relief valves to be set at a pressure above that required to pass the full pump flow
through the system to be flushed. The required pump flow capacity is defined in the
next section.
The reservoir should have a capacity at least equal to three times the pump delivery
per minute and preferably of greater capacity than the system to be flushed.
The heaters/coolers should be capable of controlling the flushing fluid temperature.
Where electrical heaters are used, it is recommended that the oil supplier be consulted
to determine the heat input requirements. Failure to select the appropriate heating
arrangements could result in damage to the oil.
The filters should incorporate clogging indicators, preferably incorporating an
audible alarm. If the filter elements are not able to withstand the full system pressure
as differential pressure, then it is desirable to have an automatic filter bypass valve to
prevent the bursting of blocked elements. This valve should not commence to open
before indication, either visual or, preferably, audible is given. The filter size should
be selected to pass the specified pump delivery at a low pressure drop, depending
upon type and should have a generous dirt-holding capacity. The degree of filtration
should normally be of a finer grade than that to be used in the final system.

8 . 3 Flushing Velocity and Temperature

To ensure that the system is flushed as quickly and efficiently as possible,
both fluid velocity and temperature should be as high as conveniently possible. A
reasonable temperature limit for mineral oils is 60C, and for water-in-oil emulsions
and water-glycols it is 50C. Higher temperatures are acceptable for silicone and
some other synthetic hydraulic fluids.
The fluid velocity should exceed the rated velocity of the system and the flow
condition should be in the turbulent region at all points in the system. Turbulent flow
is considered to be attained when the flow in litres/min is greater than 0.189 ud
where d = pipe bore (mm) and u = viscosity (cST). The derivation of this formula is
given in Appendix 1.

8.4

Flushing Procedures
New fluid is often dirty by the standards required for hydraulic systems,
therefore, with the system prepared as described in Section 4, the flushing rig should
be filled through a fine filter (3m absolute).
It is advantageous to re-circulate the fluid with the flushing rig until the cleanliness
level matches or exceeds the required standard.
Having connected the flushing unit to the system, circulate the fluid and bleed the
system to remove trapped air. Heat the fluid to the temperature given in paragraph
8.3.
As explained in paragraph 8.3, turbulent flow and high velocities are essential for
effective flushing operations. These conditions may be enhanced by introducing
vibration of the pipe work by mechanical or other means, for example, pneumatic
hammers fitted with pipe saddles. This has the effect of loosening contaminant
adhering to the pipe particularly at formed bends and weld areas. Techniques such as
flow pulsing and gas injection are also sometimes used. With all of the above
procedures, great care must be exercised in their application.
During the flushing operation, the cleanliness level should be monitored on a regular
basis. The condition of the filter element should be monitored using the filter
clogging indicator or differential pressure readings and the element changed as
required.
It is an advantage to reverse the flow through the system by interchanging the supply
and return lines to the flushing rig. Care must be exercised where low and high
pressure lines are being flushed simultaneously to avoid over pressurisation of low
pressure lines.
Continue the flushing operation until two consecutive samples within the required
cleanliness level are obtained.
If the system comprises several loops, each individual loop must be flushed to the
required cleanliness level before changeover to the next loop.

Cleanliness levels are established by assessment of fluid samples using qualitative

and quantitative methods. For certification to international standards, a quantitative
method must be adopted, preferably by particle counting.
When all individual loops have been flushed to the required cleanliness level, all
temporary hoses, flanges and fittings should be removed and the system pipework
and components reinstated.
After system reinstatement it is desirable, where possible, to install a temporary filter
in the system for the commissioning period to safeguard the established cleanliness
level.
Should the system require topping up after the flushing operation, it is essential that
the fluid is transferred through a fine filter, as new oil may not be sufficiently clean.
8.5

System Final Oil

A full charge of new hydraulic oil should be installed in the system as soon as
possible. This charge should be introduced through a fine filter. The oil should then
be circulated and the equipment operated so that the cleaned surfaces will be properly
protected.
9.0

FLUSHING OF OPERATING SYSTEMS

In the event of a major component failure, complete system overhaul or severe
contamination by water or sea water, it may be necessary to conduct a flushing
operation before re-commissioning the system.

Only by a complete inspection of the system and analysis of the oil can the necessity for
flushing be determined.
Sea water contamination requires a very special procedure for handling. After removal
of excess salt water, corrosion inhibitors specifically developed for this type of
contamination must be used in the system. Careful cleaning procedures must be
followed to obtain a satisfactory condition in the hydraulic system. Following this the
whole of the flushing procedure should be followed.

10 . 0 REFERENCES
BFPA/PS:1991
BFPAIP48
BFPA/P54*
BS4231

Under preparation

Guidelines to Contamination Control in Hydraulic Fluid Power

Guidelines to the Cleanliness of Hydraulic Fluid Power
Components
Guidelines for the Comparison of Particle Counters and Counting
Systems for the Assessment of Solid Particles in Liquids
Viscosity Grades of Industrial Liquid Lubricants

APPENDIX 1
The flow condition in a pipe or hose can be assessed using Reynolds Number as follows:

=
=
=
=

where: Re

v
d

'\)

Reynolds Number
mean flow velocity in mis
pipe internal diameter in mm
kinematic viscosity of fluid in cSt

The relationship between flow velocity, flow rate and internal diameter is given by:
V = 21.2 Q
ud2
where:

hence,
Re

flow rate in L/min

2.12 x 104 _Q_

ud

To have complete confidence that turbulent flow is occuring, Reynolds Number Re must be
greater than 4000, ie.
2.12 x 104 _Q_ > 4000
ud
The flow rate required to achieve this condition can be determined as follows:
Q > 0.189 ud

APPENDIX 2
EXAMPLES OF LEVELS
OF FLUSHING
A 2 . 1 Level 1 Example
Flushing method for simple systems
Type of Equipment
Small individual hydraulic power pack design to service coal shute deflector cylinders
in power station.
System is 120 litre capacity, ISO 46 grade mineral oil.
Pump is 30 litre/min, 150 bar maximum pressure, external gear type, valves
are solenoid operated, 200 micron suction strainer, filler breather, 25 micron
return line filter.

Company Operation
Small company employing five persons, main business is as the distributor of hydraulic
components, repair service and builder of five to ten small power packs per year.

Cleanliness and Flushing Operations

1

The pump, valves, filters, hoses and fittings are purchased from component
manufacturers and are normally received in capped condition, no extra cleaning
being carried out.

ii The reservoir is fabricated on-site, and the area is curtained off from the
assembly area to minimise contamination. Welds are ground by hand to remove
slag and weld spatter. Prior to assembly the reservoir is vacuumed and wiped
with a dry lint free rag, followed by a wipe with a clean oil soaked rag.
ill

Pipe sections are cut, formed, de-burred and cleaned using an air gun purge.

1v Having assembled the system, the oil is transferred from the barrel to the
system using a filling trolley with a 10 micron filter in the supply line.
v

Prior to starting the system, the relief valve is wound completely open to allow
the pump to start without any appreciable back pressure.

v1

After 20 minutes, the relief valve is closed to gradually increase system pressure
to 150 bar; this, with leak and function tests, takes a further one hour 40
minutes.

vii

The return line filter is fitted with a new filter element, and the unit is shipped to
the customer.

A 2.2 Level 4 Example

Flushing method for high production systems

Type of Equipment
Backhoe excavator vehicle hydraulics.
System volume is 90 litres, ISO 32 grade mineral oil
Pump is internal gear 120 litres/minute, 220 bar maximum pressure.
System has ten cylinder functions controlled by a mixture of mechanical and
solenoid valves, 120 m suction strainer, 12 m absolute return line filter, positive
pressure reservoir filler cap and air blast heat exchanger.

Company Operations
The company produces 50 of the above model per day, (amongst other lower volume
models) employs 2,000 people and has considerable quality control and quality
assurance capabilities. Laboratory facilities exist with technicians skilled in
contamination analysis. Company has total quality management structure (TQM).

Cleanliness and Flushing Operations

i

All incoming components are purchased to a cleanliness specification that

controls the number of particles allowed at various sizes. The control on
reservoirs is tighter than for other components because it is the largest
contributor of contaminant to the system as a whole. Nearly all component
suppliers now have laboratory facilities to check the level of contamination
achieved. Manufacturer carries out quality audits on all suppliers and checks
cleanliness of components supplied on a statistical basis. All components are
capped and sealed to prevent ingress of contaminant.

Production plant is designed so that fabrication and machining operations occur

in a separate part of the plant to where the assembly line is situated.

iii Assembly operators are trained in hygienic assembly of components. Caps and
seals are only removed immediately before assembly.
IV

The hydraulic system is complete four minutes before the end of the
production line. At this point, it is filled with hydraulic fluid, from a
dispenser with a 6 m absolute filter in the supply line, and the return line
filter is fitted with a 6 m absolute element.

The engine is started with the hydraulic system in the open circuit position and
the engine set to run at full speed. None of the system functions are operated
in this critical first four minutes, to enable the system to purge the largest
proportion of contaminants on to the return line filter, thus the most sensitive
components (steering valve and pilot operated check valves) are exposed to
flow only after the majority of the system has had this primary flush.

VI

At the end of the production line, the steering wheel is fitted as the last
operation, and the vehicle is driven out of the factory for a 40 minute hot
function test where all circuits are exercised to full cylinder travel for a
minimum of ten operations each.

vn The 6 m absolute return line filter element is left in the machine until the first
service at 50 hours, when it is exchanged for the standard 12 m absolute
element.

viii

Machines are sampled and checked that they meet the contamination standard
according to a statistical sampling programme.

A 2. 3 Level 6 Example
Flushing method for large offshore hydraulic piping systems
The following example details the necessary flushing requirements on a typical platform
drillfloor hydraulic piping system on a module prior to float-out.
The system consists of two main piping assemblies:
the high pressure supply lines to the various drillfloor equipment packages
the corresponding low pressure return lines from the above equipment.
Flushing operations are necessary for a number of reasons:
the critical nature of the equipment is such that should any failure occur during
normal operations, drilling and production activities on the platform are severely
disrupted
the relative costs of repair or replacement of key components in the systems
would be prohibitive due to the "inaccessibility" of the offshore installation.
These costs can be as much as 2 or 3 times that of similar work conducted
onshore.
Therefore, by conducting a comprehensive flushing programme, the potential for
occurrence of such failures is subsequently reduced.
In order to achieve the optimum results from the flushing operation, certain criteria
must be satisfied.
Referring to Figure 1, it is noticeable that in both the high pressure and return lines,
there are a number of branch lines serving various equipment packages. As a single
flushing flow path is required to control the conditions in the pipework, it will be
necessary to address this system as a number of individual flushing operations for
both the supply and return lines.
In this case, however, the line sizes are relatively close in diameter, i.e. supply 38 mm
and return 50 mm. This will facilitate the utilisation of both lines during any single
flushing operation.
It must be noted, however, that where the diameter of the lines vary greatly, e.g.
supply 25 mm and return 75 mm, then the required minimum flow rate for the 75 mm
line would be too great for the 25 mm line and would result in an unacceptable pressure
drop. In this case, the lines should be kept separate.
Having established various flushing flow paths, attention must be turned to the
flow/velocity requirements. Calculations for both the Reynolds Number and Velocity
must be done and from these, the required flow rates determined.
In this type of piping system, it is not always possible to place the flushing rig in the
ideal position, i.e. as close to the piping inlet as possible. It may be required to use
long hose assemblies of up to 40 metres in length to connect the flushing rig to the
piping system. In this case, it is important to include these hoses in the calculations
as the pressure drop will be affected.

-11-

BFPAIP9

When the above criteria are met, the flushing operation can commence. Details of
individual flow paths are shown in Figure 1. Where reverse flow flushing is adopted,
itmust be noted that if, as in this particular example, a pressure line is linked to a
return line, the application of directing the flow up the return line, can lead to over
pressurisation of that line. Therefore, reverse flow flushing can only be adopted where
the line design pressures allow.
During the flushing operation, monitoring of the cleanliness level can be done as
described in paragraph 8.4. When the required cleanliness level is achieved, the
flushing operation is stopped and the system pipework reinstated.
In most applications, and where practicable, the fluid should be left in the line to
prevent ingress of contamination prior to the commissioning of the complete
system. However, in this case, i.e. offshore installation, weight is a critical factor
and, therefore, it will be necessary to drain the system as much as possible. In
doing so, care must be taken when reinstating pipework. All open connections
should be sealed positively with blank flanges, etc. and not with tape.

Due to the complexity of this type of system, it is imperative to adhere to the

relevant calculation results, and that great care is taken in establishing the correct
sequence of flow paths to achieve optimum results during flushing. If this is not
done, the end result would be that the fluid in the pipework is cleaned to the
required specification but the pipework itself is not. Consequently, the remaining
contamination in the pipework may subsequently be released into the system
during the commissioning perjod, causing component failure at a critical time
resulting in very costly remedial work.

TEMP HOSE

LOOP

-1'"'

(FLUSH 2)

1,0

TE SEr'll
(FLUSH 3)

V'

/
C)

-12 -