HOW IS FLUSHING DONE IN THE HYDRAULIC SYSTEM?

WHAT IS FLUSHING IN A HYDRAULIC SYSTEM?

It is the cleaning process of the hydraulic lines that have been completed, if the welding process has been done, after the pickling process, if the welding process has been done, or after the end of the assembly if socket connections are used, the hydraulic oil is circulated in the pipes by creating turbulence.

In order to circulate the oil in a closed volume and clean the particles, the oil must create friction in the pipe.

The friction of the oil in the pipe occurs when the oil flow changes from laminar flow to turbulent flow. The flow variation depends on the viscosity of the oil, the pipe diameter and the Reynolds' number. When Reynold's number is 2320 and above, the flow is turbulent. The flow rate varies in direct proportion to the Reynolds' number.

The washing process is carried out in two stages:

In the first stage, a unit of the required size is adapted to the system from the outside and oil cleaning is brought to the desired norms.

In the second stage, cleaning is done using the pump and tank in the system. In the second cleaning process, the tank of the system will be filled with oil, so the tank must be cleaned meticulously. The point to be considered in this cleaning process is that the oil to be used in the cleaning process is system oil and the materials to be cleaned are non-particle-free.

Washing is very important in hydraulic systems, as the biggest factor in the smooth operation of the system is the cleanliness of the system. We can explain this concept of cleanliness by the fact that a person's hair is 90 microns, the smallest particle that the best eye can see is 40 microns, and the hydraulic system is 20 microns, and even 10 microns or more in systems with proportional valves. The vibration we will create by hitting the pipes with a soft hammer during the washing process will positively affect the cleaning. In addition, it is necessary to change the direction of flow periodically. We need to heat the oil to reduce the oil viscosity. In order to heat the oil, heaters that will not burn the oil locally are needed in the washing system.

Heat will be released by the resistance created by the oil that we circulate with turbulent flow in the pipes. If a cooler is needed in the system, the cooler is adapted so that it does not exceed the temperature (60 °C (140 F) determined according to the washing procedure).

DETERMINATION OF OIL PARAMETERS

The fact that the oil to be used for washing is the oil to be used in the operation of the system will ensure that we do not have problems later.

The recommended operating range of ISO VG 46 mineral oil is between -10 °C and 80 °C. In the washing process, flushing is envisaged with an optimum oil temperature of 60 °C, taking into account the minimum viscosity in this oil working range. Thus, we determine the oil viscosity as 22 mm²/sec.

FILLING THE LINES WITH OIL

The washing unit will be adapted to the system and the entire line will be filled with oil.

One liter of oil holds 0.09 liters of molten air at atmospheric pressure. The air in the form of bubbles is very dangerous for the system. Excessive noise causes difficulties in power generation and control as a result of increased system elasticity, making control impossible, especially in systems with servo valves. In addition, the presence of air in the form of bubbles in the fluid also damages the sealing elements.

For this reason, at the beginning of the washing process, all lines will be filled with oil, and the flow will continue until the oil comes out to provide air exit at the highest points in all lines. The duration of this process will vary with the size of the pipes and the pump flow rates of the washing circuit.

PRESSURE TEST

Before the washing process begins, a pressure test is applied to ensure that all lines are suitable for operation and that no modifications can be made after the washing process. Since the main pressure line and the return line will be connected to each other in the washing process, the system is locked at 20 bar by closing the rotation of the washing unit after the system is deaerated. The system is examined for 20 minutes to see if there are leaks. Subsequently, the pressure is gradually increased up to the design pressure and the pressure test is completed by waiting for 20 minutes at the design pressure.

PREPARING THE SYSTEM FOR WASHING

Since the pressure line and the return line will be connected to each other in the system, the lines directly connected to the return line will be blinded and oil leakage will be prevented. These lines will be kept closed unless they have their own cleaning process.

SECOND STAGE IN WASHING SYSTEM

After cleaning the system with the washing unit, the main tank in the system is filled with oil. All pumps are activated and oil is sent to the system through the main tank at lower pressure. After the desired values are reached in the washing process, the washing circuits are removed and the system is brought to the operating position. In the meantime, disassembly and assembly operations must be done meticulously.

POLLUTION CONTROL

In the system, the filter elements in the return line in the washing circuit will be made by using 20 microns at first, then 10 microns, 5 microns and 3 microns at the last stage.

For the measurement of pollution in the system, particles can be counted with an electronic pollution measuring device. Direct connection can be made with minimes connection on the lines.

A written report is obtained with the measurements made with this device.

It specifies the number of parts with different diameters from 2 microns to 100 microns and accordingly the corresponding NAS and ISO standards.

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We manufacture in many areas under the roof of Hidroman. We manage each product group and production groups separately to increase our service quality. For more information: www.hidroman.com.tr

As Seide Makina A.Ş., we establish Hydraulic Hose Production Lines with Fittings and Twisted Steel Drawn Pipe Production Lines with Fittings. For more information:

www.seidehydraulics.com

www.seidemachine.com

As Heben Makina, we produce mobile construction equipment with hydraulic systems.

As Hydraulic Market, we offer hydraulic equipment and services to our customers via the internet with our online sales platform in Türkiye. For more information: www.hidrolikmarket.com.tr

As Hydraulic Store, we offer hydraulic equipment and services to our customers via the internet with our online sales platform abroad.

As Pneumatic Market, we offer our customers pneumatic equipment and services over the internet with our online sales platform in Türkiye. For more information: www.pnomatikmarket.com

As Ata Hydraulic Cylinder, we manufacture hydraulic cylinders and perform hydraulic cylinder revisions.

As Hydraulic Service, we are not only there for you in case of Hydraulic System Failures and Sudden Stops, but also ensure that your hydraulic system machines operate with more efficiency with our predictive maintenance work. For more information: www.hidrolikservis.com.tr

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Hidroman Makes a Difference with Its Customer-Focused After-Sales Service Approach!

Hidroman, which has a 20-year history in the Hydraulic System sector, offers an after-sales service approach focused on increasing customer satisfaction with maintenance contracts that aim to reduce the operating costs of its customers and increase efficiency.

Hidroman, the innovative brand of the Hydraulic Equipment sector, continues to make a difference with its after-sales services positioned in accordance with the needs of its customers as well as the services it offers before and after sales. Hidroman, which aims to provide uninterrupted and safe services to its customers with its operations throughout Turkey and Europe, defines a perfect customer experience as product reliability and after-sales service reliability.

Hidroman, which has made being with its customers throughout the life of the product in order to create brand loyalty a part of its corporate culture, organizes the services it offers within the scope of After-Sales Services under four main headings as supervision and assembly, commissioning, maintenance-repair and original spare parts supply. Supervision service; It covers consultancy and training services on issues such as efficient hydraulic equipment selection, rules to be considered for correct product installation and connection of the pump with other installation equipment. After the installation of the device, the commissioning service is also carried out by Hidroman’s expert technical staff.

In hydraulic equipment technologies used in many different areas, malfunctions may occur over time due to operating conditions. During the 10-year life of a piece of equipment, the initial investment cost and repair expenses constitute 10-15% of its total cost, while the remaining expenses are due to energy consumption. Hidroman examines all processes from the selection of the hydraulic system to all the equipment on which the hydraulic system will operate, and offers “efficient system solutions that aim to minimize energy consumption”.

In addition, with preventive and protective maintenance agreements, it aims to reduce the risk of failure of the device, extend its life and ensure that the device operates with high efficiency and low energy consumption.

Thanks to the advantages offered by Hidroman with preventive and protective maintenance services, the budget allocated by its customers for maintenance pays for itself in a short time.

In businesses where uninterrupted service is important, Hidroman intervenes in malfunctions in a short time and minimizes damages caused by labor losses. Offering its customers a 10-year original spare part guarantee in the hydraulic systems it sells, Hidroman delivers tested original spare parts from stock in case of malfunction, shortens malfunction periods and eliminates disruptions that may occur during this period.

Hidroman After-Sales Services department stated that they offer annual maintenance services in accordance with the needs of the business. It states that their aim with maintenance services is to increase hydraulic system efficiency, ensure continuous operation of the hydraulic system and to detect, monitor and prevent possible malfunctions in operating equipment and devices by using technological measurement, control, analysis and monitoring devices.

We aim to standardize the service provided by our authorized services by inspecting them at certain intervals. In addition, we follow the calibration processes of our technical equipment in line with quality certificates. We attach importance to communication channels to be established in order to increase customer satisfaction both in sales and service. We are at the service of our customers 24/7 with our competent services that can answer the questions of our customers who buy our products by trusting our brand. In order to measure the customer satisfaction rate, we organize surveys for our customers at certain intervals through our call center. As a result of the feedback we receive, we take action quickly to meet the expectations of our customers. The nature of the products and services in the market is changing rapidly with the effect of the digital transformation we are experiencing due to technological developments. For this reason, we see the development in our products and services as a constantly living process and we continue our improvement and development works without stopping.

HOW IS FLUSHING DONE IN THE HYDRAULIC SYSTEM?