4 Types of Oil Flushes and When You Should

Use Them
Larry B. Jordan

There are many ways to define what constitutes

an oil flush. Whether you are discussing oil flushing with contractors, equipment manufacturers
or maintenance personnel, it is important to use the same terminology to prevent confusion. This
article breaks down oil flushing into four distinct categories and includes when each action is
appropriate.

Circulation Filtration
This process can take place when the system is in production and running the system pumps in
their normal flow pattern. It typically involves external filtration circulating on the reservoir.
Many maintenance personnel call this an oil flush due to achieving a cleanliness level below the
normal or manufacturer's operating specifications.

This process is appropriate when performing annual maintenance that is limited in scope and
time, i.e., reservoir cleaning, filter/lubricant changing (if same type), etc. Do not use this process
if the outage includes pipe breaks or opening of the bearing housings. A third-party laboratory or
field kits can be used to verify the particle count and determine completion.

Rinse/Purge
This process is utilized when filling the system with a neutral fluid or new charge of oil. The
steps include draining the system, refilling the reservoir to the minimum circulation level and
using system pumps circulating in the normal flow path.

Generally, this procedure is employed when making a wholesale lubricant change during a
conversion or displacing detergents or cleaners used during varnish mitigation. The cleanliness
level is often verified with only the particle count. If performing varnish mitigation, you may
also involve a third-party lab or field test kits.

System Flush
A system flush is just as it sounds. This type of flush takes place when utilizing the "system
pumps." It requires the installation of bypasses (jumper hoses) around all critical components,
such as bearings and control valves, as well as the removal of all orifice plates and blinding of
accumulators or any items that could be damaged by flushing. Inspection screens or media are
used to verify cleanliness along with particle counts.

This process can be employed for light maintenance work, i.e., changing of a temperature-
control valve or for non-critical systems such as redundant boiler feed pumps. Avoid this process
if the unit is critical and can become the controlling factor of a deadline during a turnaround.
Keep in mind that using system pumps to flush out foreign material will take longer than
utilizing an external pump to increase flow.

High-Velocity Oil Flush

Many people believe high velocity occurs once you achieve turbulent flow. Turbulent flow
occurs at high Reynolds numbers and is dominated by inertial forces, which tend to produce
chaotic eddies, vortices and other flow instabilities. In layman's terms, the oil rapidly changes
directions and bounces through the pipe's internals. This assists in breaking off material on the
walls and top sides of the pipe's interior.

If the right velocity is not achieved, the oil moves through in a laminar patstern (a straight line),
following the path of least resistance and leaving behind material that can damage your system.
A Reynolds number of 4,000 is the minimum flow rate that can cause your fluid to become
violent or "turbulent" inside the piping. However, in 99 percent of the cases, this is not enough
turbulence to pick up and remove particulate.

When performing a high-velocity oil flush, target a minimum of two to three times the normal
system flow rate and, if possible, aim for a Reynolds number of 20,000. Multiple Reynolds
calculator apps and websites are available. When in doubt, run your numbers through one of
these tools to verify the flow rate.

The high-velocity oil flushing process includes bypassing system pumps and utilizing an external
unit. Like the system flush, it involves the installation of bypasses (jumper hoses) around all
critical components, such as bearings and control valves, as well as the removal of all orifice
plates and blinding of accumulators or any items that could be damaged by flushing.

Inspection screens or media are used along with particle counts to verify cleanliness. This
process should be used during all major maintenance procedures, system failures or when large
amounts of foreign material have been introduced.

11 Simple Steps for Flushing a Hydraulic

System
Noria Corporation

I was recently asked about a procedure for

flushing hydraulic systems in order to change from one type of fluid to another. Among the ideas
mentioned involved using brake cleaner, diesel fuel or some type of acid cleaning.

However, brake cleaner includes a number of chemicals such as acetone and tetrachloroethylene.
These solvents are known to cause problems for nitrile, neoprene, millable polyurethane and
silicone seals. Ethylene-propylene (EPDM) seals have a very poor petroleum oil and solvent
resistance, and are not recommended for exposure to aromatic hydrocarbons or diesel oil.

Therefore, depending on the types of O-rings and seals in your hydraulic system, the solvents
used in brake cleaner and diesel fuel can dry out or damage your system’s O-rings. There is also
the issue of compatibility with the new type of fluid that has been chosen.
In his article for Machinery Lubrication titled “Cleaning and Flushing Basics for Hydraulic
Systems and Similar Machines,” Tom Odden outlines the procedure for thoroughly cleaning a
hydraulic system. This would be the only “one-size-fits-all” solution and an example of best
practices. It involves mechanical and chemical cleaning of both the components and the system.

of lubrication professionals say mechanical

28% cleaning is the flushing method used most

frequently at their plant, according to a recent
poll at machinerylubrication.com

Of course, not everyone is going to do a complete teardown along with a chemical and
mechanical cleaning of each component and the system each time a fluid changeover is
performed. So let’s examine what should be done at the bare minimum to clean a hydraulic
system.

Step 1
While the fluid is at operating temperature, completely drain the system, paying attention to the
reservoir, all lines, cylinders, accumulators, filter housings or any area of fluid accumulation.
Also, replace the filters.

Step 2
With a lint-free rag, clean the reservoir of all sludge and deposits. Make sure the entire reservoir
is free of any soft or loosened paint.

Step 3
Flush the system with a lower viscosity fluid that is similar to the fluid to be used. A Reynolds
number between 2,000 and 4,000 should be selected to achieve enough turbulence to remove
particles from the lines. Stroke valves frequently to ensure they are thoroughly flushed. The fluid
should be filtered and the flushing should continue until reaching one level beyond the system’s
target cleanliness levels. For example, if the target is ISO 15/13/11, continue to flush the system
until ISO 14/12/10 is reached.

Step 4
Drain the flushing fluid as hot and as quickly as possible. Replace the filters and inspect/clean
the reservoir again.
Step 5
Fill the system to approximately 75 percent with the fluid to be used. Bleed/vent the pump. If the
pump has a pressure relief or bypass, it should be wide open. Run the pump for 15 seconds, then
stop and let it sit for 45 seconds. Repeat this procedure a few times to prime the pump.

Step 6
Run the pump for a minute with the bypass or pressure relief open. Stop the pump and let it sit
for a minute. Close the bypass and permit the pump to operate loaded for no more than five
minutes. Allow the relief valve to lift to confirm that it is flushed as well. Do not operate the
actuators at this time. Stop the pump and let the system sit for about five minutes.

Step 7
Start the pump and operate the actuators one at a time, allowing fluid to return to the reservoir
before moving to the next actuator. After operating the final actuator, shut down the system.
Keep an eye on the fluid level in the reservoir. If the level drops below 25 percent, add fluid and
fill to 50 percent.

Step 8
Refill the reservoir to 75 percent and run the system in five-minute intervals. At each shutdown,
bleed the air from the system. Pay close attention to the system sounds to determine if the pump
is cavitating.

Step 9
Run the system for 30 minutes to bring it to normal operating temperature. Shut down the system
and replace the filters. Inspect the reservoir for obvious signs of cross-contamination. If any
indication of cross-contamination is present, drain and flush the system again.

Step 10
After six hours of operation, shut down the system, replace the filters and sample and test the
fluid.

Step 11
The sampling frequency should be increased until you are confident that the system fluid is
stable.

Flushing Tactics
There are a lot of different ways to flush out a machine. You want to match the flushing method
to the flushing condition. Following are common tactics for accomplishing this:

Drawdown Filtration/Separation — Contaminants or insoluble suspensions removed by

filtration or separation technologies at normal flow rates.

High Turbulence, High Fluid Velocity, Low Oil Viscosity — Flushing is enhanced by high
turbulence flushing conditions by lower flush oil viscosity and increasing oil flow rates.

High Flush Oil Temperature — This reduces viscosity, increases turbulence and increases oil
solvency. Temperatures in the range of 175 to 195 degrees F are generally targeted.

Cycling Flush Oil Temperature — Using heat exchangers and coolers to change temperature
during flushing across a 100 degree F range helps dislodge crusty surface deposits.

Pulsating Flush Oil Flow — Rapidly changing flow rates by pulsation help dislodge
contaminants from nooks and crannies.

Pneumatic Vibrators and Hammers — Used to break loose debris from pipe walls and
connectors.

Sparge Flush — Air or nitrogen is bubbled into the flush fluid to improve cleaning
effectiveness.

Reverse Flush Oil Flow — By changing fluid flow direction, some contaminants and surface
deposits can be dislodged and washed away.
Wand Flush Tool — Used for wet sumps, gearboxes and reservoirs with access hatches and
clean-out ports. A wand on the end of a flushing hose is used to direct high-velocity oil flow to
loosen deposits or for picking up bottom sediment.

Charged Particle (Electrostatic) Separators — Some suppliers have demonstrated success at

removing varnish from machine surfaces and stripping out submicron soft contaminants that can
contribute to varnish and sludge.

Solvent/Detergent Flush Fluid — Various solvents and detergents have been used with
different degrees of success, including mineral spirits, diesel fuel, motor oils and
detergent/dispersant packages.

Chemical Cleaning — These are chemically active compounds, typically caustics and acids,
used to aid in the removal of organic sludge and oxide deposits.

Mechanical Cleaning — This involves the use of scrapers, brushes and abrasives, typically used
with solvents and other chemicals, to remove hard adherent surface deposits.

Some adherent machine deposits require tactics that are more aggressive than a high-velocity
flush, so you must match the flushing tactic and strategy to the problem you are trying to resolve
with the flush. Once you understand the problem within the machine that needs to be cleaned,
you can then select the appropriate flushing tactic to remedy it. This issue was described in Jim
Fitch’s three-part series on flushing for Machinery Lubrication, which can be read at
www.machinerylubrication.com/Read/609/oil-flush,
www.machinerylubrication.com/Read/634/oil-flushing-tactics and
www.machinerylubrication.com/Read/657/flushing-oil.

At this point, it should be obvious that a fluid changeout is not just a drain-and-fill operation.
Care must be taken to confirm that the system is as clean as possible prior to introducing the new
fluid. Most changeover procedures suggest that some of the old fluid will need to be either
drained off the bottom or skimmed off the top of the reservoir after a period of time.

Just because the changeover has been completed does not mean that you are “out of the woods.”
Your system will need to be closely monitored for a while to make certain that the flushing was
thorough. Taking the time to verify that the system is fully flushed and purged of the old fluid
prior to introducing the new fluid will go a long way toward ensuring a healthier hydraulic
system.