SA er ducnghecily SURFACE SAE 2os0 INTERNATIONAL? VEHICLE “ocammenwa Dive, Werenaie PADEO™’ INFORMATION |e 199500 REPORT ‘Submited for recognition as an American Netonal Standerd FLUID POWER PIPING CLEANING PROCESS 1. Scope 4.1 The procedures and guidelines detailed in this SAE Information Report provide various techniques and processes to properly clean fluid power piping prior to assembly and operation. 1.1.1 There are two recommended processes, pickling and flushing. Each procedure will remove particulate contaminates if properly applied. 1.2 Field of Application 1.2.1. The process of conductor cleaning is applicable to hydraulic, lubrication, and pneumatic fluid power systems. 1.2.2 The conductor fabrication process of welding, brazing, heating, machining, and washing of tubing and pipes, ‘causes contaminates to collect on the inside diameter of the conductor. 1.2.8 If these contaminants are not properly removed and anticorrosive measures taken, permanent conductor damage may rocult. 1.2.4 Conductor cleaning and inspection must be done prior to system installation and assembly to remove any contaminants. 1.2.5 Proper conductor cleaning after assembly also assures that the system contamination level meets or exceeds acceptable operating parameters prior to system start up. 4.2.6 Hydraulic and lubrication systems require a cleanliness leve! which should meet cleanliness levels established by ANSV(NFPA/IIC)T2.24.4 1.2.7 This document should parallel O.£.M. and manufacturer procedures and standards to remove conductor ‘associated contaminants prior to equipment assembly. ‘SAE Technical Sardar Board Puls provid at hs pot Is pubtshed by SAE to sevance esate oftacncalanc ergeeenng ‘dances. The uso of his opts erly volta, ands appleby and sutabiy for ny arouse. incu any patent ingame eng terete, he sls aspensbiy oth we SAE reviews each etna part atleast evry ho yar at whch time maybe rete, revised or cancel. SAE inves your writen comments and suanestons, Cony 1995 Soca of Autometve Eranoes, ‘igh oserved Printed in USA.—_—_—_—— | SAE J2254 Issued SEP95 2. References 2.1 Applicable Documents—The following publications form a part of this specification to the extent specified herein. 2.1.1 ANSI PuBLicaTIoN—Available from ANSI, 11 West 42nd Street, New York, NY 10036-8002 ANSI(NFPAJJIC) T.2.24.1—Hydraulic Fluid Power—Systems standard for stationary industrial machinery 2.1.2 ASTM PuBLicaTion—Available from ASTM, 1916 Race Street, Philadelphia, PA 19103-1187 ASTM D 4174—Standard Practice for Cleaning, Flushing, and Purification of Petroleum Fluid Hydraulic ‘Systems 2.4.3 ISO PusuicaTiON—Avallable from ANSI, 11 West 42nd Street, New York, NY 10036-8002. 1SO 4406—Hiydraulic fluid power—Flulds—Method for coding level of contamination by solid particles 22 Other Applicable Reference Sources Parker Hannifin Corporation - Tube Fitings Division The Rexroth Corporation - Industrial Hydraulics Diviston Vickers Incomorated 2 Terms and De ions 28.1 Fi Power piping consists primarily of pine, tubing, hoses, and fittings. 2.3.2 Pickling will remove any contamination from pipes or tubing, especially corrosion, scale, slag and weld ‘patter. The pickling process is typically an acidic solution which chemically “allacks" and loosens contaminate particles. 2.3.8 Flushing will remove dirt and other loose particle contaminates. The flushing solution does not chemically “allack" contaminant particles. The flushing process may no: remove all contaminants. If contaminants are still present, the pickling process should be performed. 3. Pickling and Passivating 34 General 3.1.1. The pickting process should be used after any hot bending, brazing, silver soldering, or welding without anti- slag gas. 3.1.2. Passivating the piping after pickling protects the piping against rust for a limited time. 3.1.3 Stainless steel pipe also requires pickling after welding. 3.1.4 Black pipe may be purchased pre-pickled. The use of only pre-pickled pipe eliminates the possibilty of inventory stock mix-up and may eliminate the need for future pickling depending upon the application. 9.1.5 The use of a professional pickling service ie recommended.SAE J2254 Issued SEPOS, 8.1.6 Pickling process techniques vary, but lwo basic methods exist, bath and circulation pickling. Each pickling process involves saveral steps which nead to be performed correctly. 8.1.7 Protective coatings or coarse contamination (i.e., steel chips, severe rust, etc.) should be removed prior to ‘any machining or pickling process. 8.1.8 Protective coatings can be removed through the use of degreasing agents. The degreasing process may be lassified as hot or cold. The processes vary due to the degreasing agents involved. 3.1.9 If degreasing is performed “in house" all manufacturer's safety precautions, practices, and procedures must be followed. 3.1.10 Removal of coarse contaminants and protective coatings can be accomplished by sandblasting 3.1.11 The sand-biasting process itself creates additional contamination within the piping. This additional contamination can normally be removed with a properly applied pickling process, 3.1.12 Care must be taken in long piping runs, especially those with bends and high spots where the pickling solution may not completely remove the contaminants. 3.1.13 TWo bath type pickling processes are available, multi-bath and single-bath, 3.1.14 Mult-bath pickling involves several immersion steps, whare as the single-bath process minimizes material handling. 9.1.15 The advantage to muiti-bath over single-bath is time. Multibath pickling may require 2 to 3 h as compared to as many as 8 h to remove equivalent contami ingle-bath application. Both methods satisfactorily remove particulate contaminants from piping and tubing, 3.2 Pickling Methods 8.2.4. MULTF-BATH PICKLING 3.2.1.7 Mulibath pickling is the process normally used when there are large quantities of piping involved. 2.2.1.2 Pickling facilities will degrease the pipe or tubing and immerse the piping in an acid bath. This acid bath typically is a solution consisting of a 20 fo 30% pure hydrochloric acid, 8.2.1.3 Depending on the contamination (.0., weld slag etc.) the piping will typically remain in tho eolution for about 2h. 3.2.1.4 The piping is then rinsed in a water bath to minimize transteral of the acidic solution into the neutralization phase, 3.2.1.5 To neutralize the acid, the piping is are placed in a bath of caustic soda and heated to about 70 °C. 2.2.2 SINGLE-BATH PIOKUNG. 3.2.2.1 Single-bath pickling incorporates all the previously mentioned mult-bath steps into one process. This ‘method of pickling is usually done tor small scale applications.SAE J2254 Issued SEP9S 8.28 CIRCULATION PICKLING 3.2.3.1 Circulation pickling is similar to a flushing process in that the pickling solution is circulated through the Piping system. This process requires isolation of the piping and tubing from the other fluid power components. 3.2.3.2 If fluid power components (including nonmetallic conductors, hoses, O-rings, ete.) are not isolated during Circulation pickling, severe system damage to the fluid power system will occur. 2.2.3.8 Ciroulation pickling is not recommended, the preferred mettiod is to design the conductor system to allow individual lengths of conductors to be disassembled and bath pickled 23.4 Bath pickling allows visual inspection of individual sections and provides a method of monitoring the Pickling process for effectiveness. 3.3 Post Pickle Cleaning 3.8.1. Cleaning the “pickled piping, once completely dry, is accomplished by fushing the conductor with mineral ol. This prevents corrosion during storage and fabrication. 3.3.2 The oil used must be compatible with the fluid power operating system. The lubricating flushing fluid must be €s clean as the operating system cleanliness parameters. 3.3.3 If contaminated or incompatible fluid is used to flush or lubricate the piping, the entire fluid power operating system will be contaminated, 8.8.4 The piping once pickled and lubricsted must bo proporly sealed and stored in @ dry location. Proper sloraye wil eliminate the possibility of moisture condensation or airborne contaminatas collecting on the inside diamator of the piping. 8.3.5 An external protective coating, depending on future use, may be implemented al this time. 4. Flushing 4.4 General 4.1.1 The flushing of fluid power piping will remove dirt and contamination associated with the fabrication process ofa system. 4.1.2 Flushing of conductors prior to system start-up will eliminate unnecessary contamination from damaging the system. 4:1.8 Following basic guidelines and good housekeeping practices during fabrication will expedite contamination removal during the flushing process, 4.1.4 Flushing involves circulating fluid through the piping at high velocities. The fast-flowing fluid carries the ‘contaminant particles through the fluid, 4.4.5 Filtering systems must be incorporated in the system to contain the contaminants. 4.1.6 The duration and intensity of flushing depend on the criginal contamination level, volume of the piping system, velocity of the flushing fluid, and the efficioney of the fitere. a‘SAE J2254 Issued SEPOS 44.7 The flushing process must proceed unl the flushing fluid's contaminant level is less than normal system ‘operating cleanliness parameters. 4.1.8 ltems, such as pumps, valves or any other devices that may be damaged during the flushing process must be bypassed or Isolated. 4.1.9 Separate flushing systems including pumps, heaters, and filters should be temporarily installed. Venting valves at high points and drains at low points may be installed to provide proper fluid flow paths during flushing. 4.4.40 Temporary alteration of the normal fluid power piping eystem may be roquired to provide adequate flow rates through all parts of the piping network. 4.1.11 The flushing procedure will remove the necessary contaminates only it flow paths with adequate velocities are provided, 4.1.12 The size of the system to be flushed and the capacity of the flushing equipment will determine if a fluid ‘power system will need to be isolated into several subsystems. 4.1.13 The system design must incorporate access ports for this flushing process. 4.1.14 Flushing velocity and fluid temperature should be higher than normal operating parameters. 4.1.45 The recommended flow velocity should be at least twice that of the normal operating system. The flow must be turbulent flow and may be described by Equation 1. Qzo1t-ved (Ea) where: Q = Volumetric flow, Limin d= Inside diameter of pipe, mm v = Viscosity, mm?/s 4.1.16 The recommended operating temperature of the flushing system for mineral oils is 60 °C. 4.1.17 Water-in-oil emulsions and water-glycol based fluid systems should be flushed at 50 °C. 4.1.18 The type of flushing fluid used must be compatible with the normal system operating fluid to be used in the system. 4.1.19 If the flushing fluid is not compatible with the seals or any other component in the system, major system damage wil result 4.1.20 A lower viscosity, less expensive fluid may be used, consultation with the original equipment manufacturer ‘or fluid supplier is recommended. 4.1.21 The filters selected must be capable of ftering the fluid efficiently and have enough contaminant holding capacity to minimize filter element replacement.SAE J2254 Issued SEP95 4.2 Flushing Process 4.2.1 Filtration of the flushing fluid prior to flushing is recommended. The fluid entering the system should be as. clean as the flushing cleanliness target goal. 4.2.2 The fluid should be heated to the required flushing temperature. 4.2.3 Provide proper flow paths for the system to be flushed (Le., vents and drains). 4.2.4 Isolate sections of the system if necessary. 4.2.5 Flush the system, 4.2.6 Monitor the conditions of the fiters and replace the elements as required. 4.2.7 Reverse direction of tushing tlow path, 4.2.8 Flushing should be continued until the flushing fluid meets or exceeds the taroeted cleanliness level. Fluid samples should be analyzed or a reliable particle counter be used to monitor fluid cleanliness. 4.2.0 Discontinue the flushing process, drain the flushing fluid, and remove all residual flushing fluid paying particular attention to low areas of the fluid power system. 4.2.10 Reconfigure the piping system back to its normal operational state, 4.2.11. During this portion extreme care must be taken to not contaminate the system during reassembly. 4.2.12 The described flushing process is primarily used on new and rebuilt equipment installations and start-ups. 4.2.13 This procedure can aleo be implemented on an existing system that has a contamination level detrimental to the components in the system. 3. Alternate Piping Cleaning Procedure 5.1 An altemate cleaning/flushing procedure which is an acceptable method of cleaning fluid power piping, primarily tubing. 5.2 The following piping cleaning procedure applice toward individual component flushing prior to assombly on a system, 8.3 This procedure was originated because ot the brazing process associated with some types of O-ring face seal tube fitings. 5.4 This procedure is suggested after any brazing of tube fittings on fiuid power systems. The process mechanically loosens the contaminants inside the tube and flushes the contaminants out with high pressure fluid. 5.5 The recommended steps are as follows. 5.5.1 Using stiff stainless stee! wire brush, loosen existing contaminants on the tube inside diameters, reaching as far back towards the tube bend as possible.SAE J2264 Issued SEP9S 5.5.2 After loosening the contaminants on both ends, blow out the loose debris with compressed alr. 5.5.3 Clean |. ofthe tubes on both ends with high pressure water jt (approximately 3500 kPa (500 ps)—similar todo it yourself" car washes). 5.5.4 Immediately after wash, flush the tubes with an ultra-clean solution (filtered to 21/18/14 cleanlinoee por ISO 4406) of 115 g (4 02) of Bemite 136 to 3.785 mL (1 gal) of water. This will clean the tubes, neutralize any acidic residue from the braze cleaner and provide temporary surface protection of up to 4 weeks. 5.5.5 Flushing may be accomplished with either of the two waye described in 6.6.8.1 or 6.6.8.2 bolow: 5.5.5.1 Pump the fluid through the tubes at a velocity of 6.1 mis (20 ft/s) or more for about 30 s. 5.5.5.2 Fill tho tubes about 76% full, cap both onds, and slosh the fluid from end to end vigorously several times before draining it. Repeat the sloshing process (6.5.5.2) one more time. 8.8.6 Alter the clean tush, coat LD. of tubes with a clean rust inhibitor such as WD 40 or SP-350. This is best ‘accomplished by filing the tubes with the fluid and then letting them drain. 5.5.7 It is not necessary to let tubes dry after step 5.5.4, since the rust inhibitors recommended above are water displacing type. 5.5.8 Cap the tube ends if tubes go into storage before putting on the machine. If the tubes are going on the ‘machine, cap the open ends of the tubes to keep humid air or dirt from getting into the cleaned tubes. 5.5.9 The above procedure will completely clean the tubes of all contarninants except for any rust in the bends and middle of the tubes unreachable by the brush. The rust inhibitors will provide protection for up to 6 months of storage. 5.5.10 The preferred method to clean the tubes of all possible corusion is by pickling the tubing assembly as previously described in the pickling section. PREPARED BY THE SAE LUBRICATION COMPONENTS AND SYSTEMS COMMITTEE.42254 SEPOE Rationale—Not applicable. Relationship of SAE Standard to ISO Standard—Not applicable. Application—The procedures and guidelines detailed in this SAE Information Report provide various techniques ‘and processes to properly clean fluid power piping prior to aesembly and operation. There are two recommended processes, pickling and flushing. Each procedure will remove particulate contaminates i properly applied. Reference Section ANSI(NFPAWJIC) T.2.24,1—Hydraulic Fluid Power—Systems standard tor stationary industrial machinery ASTM D 4174—Standard Practice for Cleaning. Flushing, and Purification of Petroleum Fluid Hydraulic Systems 180 4406—Hydraulic fluid power—Fiuids—Method for coding level of contamination by solid particles Parker Hannifin Corporation - Tube Fittings Division ‘The Rexroth Corporation - Industrial Hydraulics Division Vickers Incorporated Developed by the SAE Lubrication Components and Systems Committee