Electro Hydraulic Control Flushes
Below is an in depth description of how important it is to maintain a healthy EHC system and the benefits of allowing Hydra-Lube perform an EHC system flush using a unique customized procedure to fit your needs
To get started let’s talk about why you must be concerned about the condition of your system and what could happen if you have neglected the care and maintenance of the system. I would also like to discuss contamination and what to look for, along with troubleshooting tips on how to locate and isolate the source. This article will have questions and answers on the hazards associated with a poorly maintained system along with solutions to eliminate then. These tips and information are based of the years of experience designing, upgrading, and flushing a wide range of different EHC system controls on both steam and combustion turbine such as GE, Westinghouse, Toshiba, Siemens, Allis Chalmers, Fajitsu, Mitsubishi and Brown Bavarians
Actions needed and how we can help
The first action that needs to be taken to return your system back to a health state is to locate the source of which the contamination has entered the system. The source must then be isolated or eliminated to prevent the chance of it happening again. If there is a case where it cannot be completely eliminated, then an engineered solution must be discussed to reduce the risk of it reoccurring. A plan of action also needs to be in places so that if it repeats itself techniques may be diploid to correct the situation before it worsens or causes a costly forced outage. Therefore, Hydra-Lube and our highly trained knowledgeable team members are here to assist you in all your EHC needs and desire the opportunity to do so. Over the year our team at Hydra-lube devised cost efficient solutions that are performed in a timely manner to return your system back to a healthy state. Guaranteed to increase the reliability and life span of your system. Our goal is to stand by our customers answering any question and assisting them in any way possible maintain a healthy reliable EHC system.
Quick overview of flushing procedure
We have specially designed equipment that if needed capable of performing a full system flush without the risk of damaging a system pump. Each specialized Flushing team will be equipped with a series of either manual flushing valves or jumper hoses to be installed so that flow can manually be directed as needed. In cases where a system has accumulated large amounts of varnish and gel we’ve implemented a procedure using a Chemical or Cleaning Agent that’s added to the either the existing fluid or a carrier fluid depending on the situation. This “cleaning agent flush” is performed by connecting our unique flushing skid capable of flushing at a higher velocity then system pumps. More velocity aids in the removal of baked on varnish and gel as the chemical starts to dissolve or break them down. Prior to this flush all filter where removed so that the contamination that is broken down will be able to return back into the reservoir so that it can be easily cleaned and removed from the system. This first stage of the Cleaning Agent flush is usually run for a minimum of 24 hours while tracking and documenting the progress through oil samples which are analyzed onsite using an annually calibrated laser counting portable oil dialysis machine. Once the oil sample signify the cleaning agent has performed its duties the fluid is drained into labeled waste drums and the reservoir is cleaned, inspected and documented.
The second stage of the flush we call the “Rinse Flush” consisting of a new charge of fluid added to the system along with a set of filters. The filters used for this stage of the flush are provided by Hydra-lube and are only used in our flushing skid which prevents the customer from having to purchase 2 sets of filters and helps save time due to the size and style being used. The rinse flush normally takes anywhere from 8 to 16 hours depending on the size of the unit. Again the progress of this flush will also be tracked through samples. The flush will continue until a clean sample is achieved that is slightly lower than the recommended specification of the oil. The draining and cleaning procedure is the repeated as performed in the first stage.
The final stage or the “Restoration” is the most critical. Our skilled flushing technicians use technique such as peer-checking, Quality control “QC” and Quality assurance “QA” to follow a strict procedure while restoring the system back to operating configuration. Flushing equipment will carefully be removed so that the time of which the system is exposed will be minimal and clean system components are return back onto the system with new Viton O-ring provided by Hydra-Lube. To complete the restoration a new set of filter are installed and the reservoir is filled with a final fill fluid that has been polish throughout the entire flush to insure the cleanliness of the new fluid exceeds recommended specification. Finally, the ultimate test is performed by starting system pumps and pressurizing the system to check for leaks and proper functioning of the system and its components. This final step is the key to insuring the customer has a flawless start up.
Not all systems require a full cleaning agent flush to determine this an evaluation must first be performed which may require an onsite visit from one of our Project Managers. If a system may be returned back to a clean state without taking it off line, we have a variety of different size filtration and water removal systems that can be installed to a system to without affecting its operation.