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GB/T 25133-2010 (GB/T25133-2010)

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GB/T 25133-2010: PDF in English (GBT 25133-2010)

GB/T 25133-2010
Hydraulic fluid power systems.Assembled systems.Methods of cleaning lines by flushing
ICS 23.100.40
J20
National Standards of People's Republic of China
Hydraulic system assembly pipeline flushing method
(ISO 23309.2007, IDT)
Released on.2010-09-26
2011-02-01 implementation
General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China
China National Standardization Administration issued
Foreword
This standard is equivalent to ISO 23309.2007 "Hydraulic Transmission System Assembly Pipeline Flushing Method" (English version).
This standard is equivalent to translation ISO 23309.2007.
For ease of use, this standard has the following editorial changes.
--- Change "this International Standard" to "this standard";
--- Replace the comma "," as a decimal point with the decimal symbol ".";
--- Remove the preface to international standards;
--- Replace the corresponding international standards with national standards.
Appendix A of this standard is an informative annex.
This standard was proposed by the China Machinery Industry Federation.
This standard is under the jurisdiction of the National Hydraulic and Pneumatic Standardization Technical Committee (SAC/TC3).
This standard was drafted. Liming Hydraulic Co., Ltd., Beijing University of Chemical Technology, China Shipbuilding Industry Corporation 707 Institute
(Jiujiang), Aviation Industry Corporation Filtration and Separation Machinery Product Quality Supervision and Inspection Center.
The main drafters of this standard. Ye Ping, Li Fangjun, Zheng Yuan, Gao Yuanan, Huang Huiwen, Lu Hongnan.
introduction
In hydraulic drive systems, power is transferred and controlled by means of pressurized liquid in a closed circuit.
The initial cleanliness level of the hydraulic system will affect the performance and service life of the system. If the system is not removed during manufacturing and assembly
The resulting particulate contaminants, which circulate in the system and destroy system components. In order to reduce the probability of such damage, liquids and liquids
The inner surface of the press system needs to be filtered and rinsed to the specified cleanliness level.
Flushing the piping of the hydraulic system is one way to remove particulate contaminants from the system, but it is not the only way.
Hydraulic system assembly pipeline flushing method
1 Scope
This standard specifies methods for flushing solid particulate contaminants in hydraulic system piping. These contaminants may be in the system of new hydraulic systems.
It is brought in during the manufacturing process or during the repair and modification of the existing system.
This standard supplements, but does not replace, the requirements of system suppliers and users, especially when their requirements are more stringent than those specified in this standard.
This standard does not apply to the following situations.
a) Chemical cleaning and pickling of hydraulic fittings.
b) Cleaning of the main components of the system (see GB /Z 19848-2005).
The cleanliness level inspection of the system assembly is carried out in accordance with GB /Z 20423.
2 Normative references
The terms in the following documents become the terms of this standard by reference to this standard. All dated references, followed by all
Modifications (not including errata content) or revisions do not apply to this standard, however, parties to agreements based on this standard are encouraged to study
Is it possible to use the latest version of these files? For undated references, the latest edition applies to this standard.
GB/T 17446 fluid drive system and component terminology (GB/T 17446-1998, idtISO 5598. 1985)
GB/T 17489 Hydraulic particle contamination analysis Extract liquid samples from working system pipelines (GB/T 17489-1998, idtISO 4021.
1992)
GB /Z 19848-2005 Guidelines for the achievement and control of cleanliness of hydraulic components from manufacture to installation (ISO /T R10949.2002,
IDT)
GB /Z 20423 Hydraulic system assembly cleanliness inspection (GB /Z 20423-2006, ISO /T S16431.2002, IDT)
3 Terms and definitions
The terms and definitions established in GB/T 17446 and the following are applicable to this standard.
3.1
Flushing
The process of cleaning the hydraulic piping system, including the rinsing medium circulating in the hydraulic system piping to remove, transport and filter in processing and assembly
And particulate contaminants entering the system during maintenance.
3.2
External flushing outflushing
The process of freeing a sufficient volume of flushing media from the blind end of the pipe to an open vessel or bucket to remove contaminants therefrom.
3.3
Visual cleanliness visiblecleanliness
The surface cleanliness of the identification can be directly visually observed without magnification.
3.4
Clean work area cleanworkarea
Work area where no debris or particles are produced during work.
Note. Activities such as welding, shovel, cutting, grinding or burning can produce debris or particles and are therefore not allowed in the cleaning work area.
4 cleanliness level
The primary purpose of rinsing is to achieve a system or component cleanliness level as required by the user or supplier. For unspecified cleanliness levels
For the case, see the selection guide in Appendix A.
5 Flushing of the pipeline in the hydraulic system
5.1 Influencing factors
In order to achieve a satisfactory cleanliness level for the hydraulic system piping, the following influencing factors need to be considered.
a) Select components that have been cleaned in accordance with GB /Z 19848-2005;
b) the initial cleanliness of the mating line;
c) using a suitable flushing procedure;
d) Select a filter with a suitable filter to ensure that the required cleanliness level is achieved within the allowed time period;
e) Establish a turbulent state to remove and transport particles to the filter.
5.2 System Design
5.2.1 The design of the hydraulic system should consider the flushing of the system during the design phase. Blind ends that cannot be flushed should be avoided. Such as
If the particulate contaminant has a risk of moving from the blind end to the rest of the system, the blind end should be able to be flushed externally.
5.2.2 Pipes connected for flushing are not allowed to be connected in parallel, and only in series under turbulent conditions are allowed. Hydraulic system
Pipes in the system should also avoid parallel flow paths unless instrumented inspections demonstrate sufficient flow in each parallel flow path.
5.2.3 Current limiting components and components susceptible to damage from high flow rates or particulate contaminants should be capable of being removed from the circuit or bypass. After removing the components
Ensure that the lines are connected to each other for flushing.
5.2.4 The critical position in the system shall be provided with a sampling valve in accordance with GB/T 17489.
5.3 Component cleanliness level
The cleanliness levels of components and components installed in the system should be at least the same or higher than the specified system cleanliness level. Component supply
The supplier shall provide information on the cleanliness level of the components.
5.4 Preservatives
If the component contains a preservative that is incompatible with the system's working medium, use a detergent that is compatible with the system seal and working media.
Wash the components. Detergents are not allowed to affect the sealing of the components.
6 pipeline treatment
6.1 Preparation of piping during manufacturing
Pipe fittings used as hydraulic lines shall be deburred according to the agreement between the manufacturer and the user. Pipe fittings with oxide layer and rust shall be in accordance with
The agreement between the manufacturer and the user is handled.
6.2 Surface treatment
To maintain cleanliness before piping installation, use suitable protective fluids. Anti-corrosion measures are required in the storage process.
6.3 Storage of pipes and joints
Clean and surface treated fittings and fittings should be immediately sealed with a clean lid and stored in a clean, dry place.
7 Hydraulic line installation
7.1 During the installation of hydraulic lines, the pipes should be prevented from being welded, brazed or heated to prevent the formation of oxide layers. If unavoidable
If it is not, the pipeline should be cleaned and protected (see 5.3 of GB /Z 19848-2005).
7.2 Flanges or standard fittings should be used. During the installation process, all protective elements (such as covers) of the piping and components should be as far as possible at the final stage.
The paragraph is removed.
8 Flushing requirements
8.1 General
8.1.1 Pipelines requiring flushing should be identified by special documentation and the level of cleanliness they achieve.
8.1.2 The flushing method should be adapted to the actual conditions. However, to ensure a satisfactory result, the following main criteria should be met.
a) The tank of the flushing equipment should be at least cleaned to the level specified for the cleanliness specified by the system (see Chapter 4);
b) The flushing media injected into the system should be filtered through a suitable filter (see 5.1d). During the process of filling the rinsing medium, it should not be
Air is brought into the system and, if necessary, the system should be filled with flushing media to an overflow condition;
c) The pump of the flushing equipment should be as close as possible to the suction port of the pipeline to minimize the flow loss;
d) The flow and temperature measuring devices should be as close as possible to the return port of the pipeline;
e) The filter should be close to the return port of the line; the suction port can also be used with a filter.
8.2 Clearing inner surface particles
8.2.1 In order to effectively remove particulate contaminants from the hydraulic lines, the flow state of the flushing medium is required to be turbulent. Turbulent flow energy of the medium
Ensure that particulate contaminants in the piping system are removed and filtered through the filter. Should use a flow medium with a Reynolds number (Re) greater than 4000
Wash the system.
Note. If flushing with a fluid with a Reynolds number less than 4000, there may be a laminar flow in the tubing.
8.2.2 Re and required flow (qV) can be calculated using equations (1) and (2).
Re=
21220×qV
υ×d
(1)
qV=d×Re×υ21220
(2)
In the formula.
qV---flow, the unit is liter per minute (L/min);
υ---Motion viscosity, in square millimeters per second (mm2/s);
d---The inner diameter of the pipe, in millimeters (mm).
8.2.3 It may be difficult to obtain a Re greater than 4000. Re increases as the flow rate increases or the viscosity decreases. Lowering the viscosity is
The preferred method of obtaining turbulence. Reducing the viscosity can be achieved by increasing the temperature of the rinsing medium or by using a system working medium of low viscosity grade.
If the temperature of the rinsing medium is increased, the increase in temperature should be limited to ensure that the nature of the rinsing medium does not change or that the system components do not
Be adversely affected. If dedicated flushing media is used, the flushing media should be compatible with the working media the system is intended to use. Preferred party
The system uses a working medium to flush or use the same low viscosity grade media as the system's working media.
8.2.4 In cold environments, the heat of the rinsing medium may be lost. In this case, in order to verify that Re is greater than 4000,
The temperature of the rinse medium should be checked at the lowest point of the estimated system temperature. When the lowest temperature of the measured medium can guarantee Re is greater than 4000
This media is allowed to be flushed only when the manufacturer consults the viscosity and temperature data of the relevant flushing media. In very cold conditions,
The system should be insulated to ensure that the temperature of the rinse medium is above the minimum value that allows Re to be greater than 4000.
8.2.5 Care should be taken when considering the need to reduce the diameter of the hydraulic line to maintain the required Re number, as this may be a flush flow or low
The pressure element has an effect.
8.2.6 Vibration, ultrasonic or changing the direction of flow will help to remove particulate contaminants from the piping system more quickly. However, this is only a contradiction
The flow of fluid supplements, but not the turbulent flow of fluids.
8.2.7 The pressure of the piping system should be monitored to ensure that it does not exceed the maximum working pressure allowed by the system.
8.3 Separation of filters and particles
8.3.1 General requirements
8.3.1.1 The filter used for rinsing determines the final cleanliness level and cleaning time of the system.
8.3.1.2 A filter with a suitable filtration ratio should be used. If a filter with an inappropriate filtration ratio is selected, the specified clearing will not be achieved.
The level of cleanliness or conditions that can be reached with extended rinse time.
Note. The filtration ratio is determined according to GB/T 18853.
8.3.1.3 The filter shall be equipped with a plugging monitoring device (eg differential pressure indicator). If necessary, the filter element should be replaced to ensure that the pressure difference is allowed in the filter element.
Within the scope.
8.3.2 Auxiliary Flushing Filter
8.3.2.1 Additional auxiliary flushing filters may be required during the flushing process in order to.
a) Protect sensitive components from particle intrusion (if used at the suction pipe to protect the pump from contaminants in the fuel tank), it should be considered
The effect of pressure drop;
b) directly filter out the particles released by the component (such as using a return filter to prevent particles from settling in the tank);
c) Reduce the rinsing time.
8.3.2.2 Large flushing filters should be used whenever possible. The minimum flush filter should meet the actual viscosity and maximum flow rate of the flushing media
The maximum pressure drop through the cleaning cartridge does not exceed 5% of the bypass valve or clogging alarm indicator setting.
8.4 Minimum rinse time
8.4.1 The minimum flushing time required depends on the capacity and complexity of the hydraulic system. After rinsing for a short period of time, even flushing
Sampling indicates that the specified solid particle contamination level has been reached and turbulent rinsing should continue.
Note. Continued rinsing increases the likelihood of removing particles adhering to the tube wall.
8.4.2 The recommended minimum rinse time (t) can be calculated using equation (3).
t=20VqV
(3)
In the formula.
qV---flow, the unit is liter per minute (L/min);
V---System volume in liters (L).
9 Final cleanliness test
The final cleanliness level shall be verified in accordance with GB /Z 20423 and shall be documented prior to completion of the flushing operation.
10 Description of the label (citing this standard)
When the manufacturer chooses to comply with this standard, it is recommended to use the following instructions in the test report, product samples and sales documents.
Appendix A
(informative appendix)
System Cleanliness Level Requirements Guide
A.1 System may require high cleanliness applications
When high reliability is a control element or system contains the following components, the system requires high cleanliness.
a) proportional valve or servo valve;
b) small flow flow control valves and pressure reducing valves, especially under conditions of high pressure drop;
c) A motor or pump whose operating state is close to the performance limit.
A.2 System may require medium cleanliness applications
When the component is operated under abnormal conditions agreed by the supplier and the user, and the total running time is relatively controlled, the system shall specify
Cleanliness.
A.3 Guidelines for the level of solid particle contamination in media meeting the high and medium cleanliness requirements of the system
Table A.1 gives guidelines for the level of solid particle contamination in media that meets the high and medium cleanliness requirements of the system.
Table A.1 Guidelines for the level of solid particle contamination in media meeting the requirements for high and medium cleanliness of operating hydraulic systems
System pressure
Liquid cleanliness requirements, expressed in accordance with GB/T 14039
High school
≤16MPa (160bar) 17/15/12 19/17/14
>16MPa (160bar) 16/14/11 18/16/13
references
[1] GB/T 14039 hydraulic transmission oil solid particle pollution level code method (GB/T 14039-2002, ISO 4406.
1999, MOD)
[2] Identification and control of GB/T 17484 hydraulic oil sampling container purification method (GB/T 17484-1998; idtISO 3722.
1976)
[3] GB/T 18853 hydraulic transmission filter to evaluate the filtration performance of the filter multi-pass method (GB/T 18853-2002,
ISO 16889.1999, MOD)
[4] GB/T 18854 Hydraulic Transmission Liquid Automatic Particle Counter Calibration (GB/T 18854-2002, ISO 11171.
1999, MOD)
[5] GB/T 20110 Hydraulic transmission parts and components cleanliness related to contaminant collection, analysis and data reporting
Inspection documents and guidelines (GB/T 20110-2006, ISO 18413.2002, IDT)
[6] ISO 18413 Hydraulicfluidpower-Cleanlinessofpartsandcomponents-Inspection
Documentandprinciplesrelatedtocontaminantcolection,analysisanddatareporting.
[7] BFPA/P9 Guidelinesfortheflushingofhydraulicsystems,BFPA,ChippingNorton,
UK,.1992.
......
 
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.