HYUNDAI ‘S.Page | T. Page INDUSTRIES CO.LTD. 1 14 PLAN HISTORY ENGINE ALL HYUNDALMAN BBW MESSRS. z RULE 5 SHIP NO. a ENG. No. e TITLE : GUIDANCE OF OIL FLUSHING FOR MAIN ENGINE (14 _ SHEETS WITH COVER) DRAWN: DESIGN CHECK APRD DESCRIPTION R [ ‘ deshin sea BLA | Temporary filter added: 4 20747230 | BOTI220 | BOiT 1220 |_ 180 4408 wct714 Weert of ES | SES | FOR APPROVAL o Sa A INDIAN FijGg poze ' HEAVY INDUSTRIES CO.,LTD. WA | vane 4 wicimeny omson Ny) A14-275132-6 ENGINE DEsiGw orFice ELS fal) Eine are/\HYUNDAI PAGE 2 ofa HEAVY INDUSTRIES COLD. DOC. NO.AT4-275132.6 CONTENTS 4. General (the purpose of oil flushing) 2. Lube Oil System Flushing Procedure (MLO,PCO,T/C) ... 3. Cylinder Lube Oil System Flushing Procedure 4. Fuel Oil System Flushing Procedure 5. Kinds of by-pass Blind Flange 6. Inspection and criterion of Oil flushing. 7. Important Points of Oil Flushing. 8. Others (ISO 4406 and NAS 1638) HSeF-K210-c004(R0) ENGINE & MACHINERY DIVISION Adar X 297M LA/A\HYUNDAI PACE Solis. HEAVY INDUSTRIES CO,L7D. 75132-6 4. GENERAL To protect the engine components, it is very important that the main lube oil system and fuel oil system are carefully flushed before the engine is started-up. The purpose of flushing is to ensure satisfactory operation of the lube oil, hydraulic oil and fuel oil systems by removing foreign matters which might be collected inside of the Pipe lines during in service. Before mounting, all pipes and tanks should be ground inside to smooth out welds and remove welding spatter. This emphasizes the importance of using pipe connections with flanges so that all welds can also be inspected from inside the piping. After grinding and welding, all pipes should be acid-cleaned and neutralized. When filling the tanks, let all oil pass through a filter to ensure that all impurities from the supplier's storage tanks and filling line are removed. The external system such as lube oil and fuel oil are to be checked for cleanliness by means of check bags and recommended particle counting, before such systems are connected to the main engine. In addition, the check bag is to be installed in a by-pass after the filter, drained off into the oil sump tank and fuel oil service tank. 2. Lube Oil System Flushing Procedure(MLO, PCO, T/CLO) 2-4) The purpose of the flushing The purpose of the flushing procedure is to remove particles during circulation of the oil but by-passing the bearings, which should be thoroughly protected against the entrance of dirt until the lube oil system and lube oil are found to be in an acceptably clean condition 2-2) Flushing of external piping in the ship(MC/-C, ME/-C TYPE) (Engine Room : Ship Yard pipe oil flushing Procedure) Fig. 1 om HoH 2-3) Increasing the filter fineness After the first 24 hours of flushing by means of the standard 40ym filter basket. In addition, additional 10-25ym filter material can be inserted inside the filter basket. HSEF-K210-c0044R0) ENGINE & MACHINERY DIVISION ‘naz 0m X 287mm)/\HYUNDAI PAGE 4 af 4 ae TORIES CORETE DOG. NO.At™.275133.6 additionally, a by-pass filter unit with sufficient capacity and approx. 6-10um fineness can be used sump to sump to reduce the total flushing time and ensure better flushing results. during the first 1 hours of flushing By-pass filter(Emergency strainer), the temporary (40ym) filter with magnetic element can be used instead of stainless steel element to have a good flushing effect, 2-4) Running of purifiers and system cleanness Running the purifiers is vital for a good result of the flushing. The purifiers remove a large number of particles from the contaminated oil. This reduces the load on the filters. Starting the flushing with a clean lubricating oil 2-5) Oil tank cleaning Remove all build-in contaminants such as slag, visible impurities, and spatters from the oil tank and ship pipe installations. 2-6) Lube oil flow velocity and temperature If necessary to obtain a satisfactory flow, it is recommended to circulate the lube oil through the system with both lube oil pumps operating at their max. capacity, but not higher than the max. capacity of the filters. The flushing oil flow should reach a minimum of Reynold Number 3000 in order to have sufficient turbulence in the piping, Al pumps, piping, filters and other equipment should all be included in the flushing process. The lube oil should be heated to 60-65 degrees C to ensure that all inside rust protection of pipes and engine parts is removed, which can normally be achieved by heating up the water side of the lube oil cooler or heater. Formula for calculating the Reynold Number: R, Reynold Number = YX2 ¥ 1000 V" average flow valocity (m/s) v Vv kinematic viscosity (eSt) D pipe inner diameter (mm) 2-7) Running of purifiers and system cleanness It is recommended that the lube oil purifiers are running sump-to sump during the Whole flushing period in order to improve the cleanliness. Running the purifiers is vital for a good result of the flushing. The purifiers remove a large number of particles from the contaminated oil. This reduces the load on the filters. Starting the flushing with a clean lubricating oil 2.8) Use of flushing equipment For filling and topping up, use always a filter cartridge with a filtration ability of Beta 6= 200. For flushing, use of a with a filter minimum filtration ability of B,= 75 is recommended, Filtration ability of minimum B,.= 75 is needed. Use of additional filters, “off-line” filters, for flushing filter with a minimum filtration ability of Bs= 75 is recommended, filtration ability of minimum Byo= 75 is needed. Use of ME-fiter for flushing is recommended. Back-flushing oil must be returned to a separate back-flushing tank and then back to the main tank via a Beta6=200 filter cartridge. 2-9) Flushing of external piping in the ship In order to ensure that dirt from external pipe lines is removed by the filters and HSEF-K210.co04(R0) ENGINE & MACHINERY DIVISION ‘Aazi0me x 257mm)A PAGE: 5 of 14 HYUNDAI Reno Aes centrifuges, and not passed on to the engine, itis recommended to perform the flushing in the following steps: - Flushing by the temporary flushing pump or onboard system pump. - Temporary drain pipe is to be installed by the rubber hose to the sump tank. ~ For drain line to sump tank, itis to be provided the drain pipe and flange in advance. ~ Flushing oil is to be heated to 60-65'C to increase the flushing effect. - Flushing oll can be used temporary filter or by-pass filter(emergency strainer) equipped with magnetic element or wrapped temporary element at first 12 hours for primary flushing, ~ After 12 hours, will be open and operate the main auto filter (40m). - Min. 12 hours of secondary final flushing will be performed after 12 hours of primary flushing. ~ Check filter and sampling every 6" hours and flushing conditions will be recorded ~ Continue flushing of external piping until all visible dirt has been removed and reached ISO 4406 x¥/19/15. ~ Oil cleanliness to be confirmed by the check bag of 50um filter gauze. = Until NAS 10 grade accepted by shipyard QM or/and owner, repeat oil flushing ‘And flushing for piping is to be completed & the log is to be recorded 2-10) Flushing of external and engine internal piping in the ship. (Ship yard + Engine side pipe flushing Procedure : (MC/-C, ME/-C TYPE)) Fig. 2 vig woo ston > smn tan In order to ensure that dirt from external pipe and engine lines is removed by the filters and passed on to the engine, it is recommended to perform the flushing in the following steps: ~ Before external and internal engine pipe flushing, the bearings are by-passed by blanking off the branch pipes to the main bearings in the crankcase, the bearings and spray nozzles in the chain box, the thrust bearing and crosshead bearings, axial and torsional vibration damper, moment compensators and turbocharger bearings as the following diagram (referred table 1). ~ Temporary drain pipe or the rubber hose is to be removed from connected to the WseF-210-c004(R0) ENGINE & MACHINERY DIVISION ‘(240mm X 257mvan PAGE : 6 of 14 HYUNDAI DOC NO RE sump tank ~ External pipe after filter to engine connection pipe is to be inspected the inside of pipes free of dirties. - The end pipe(adjustable pipe) is to be carried out air blowing pipe inside to clean - After thorough inspection, mount the end pipe to the main engine. - Flushing by the temporary flushing pump or onboard system pump. - Flushing oll is to be heated to 60-65C to increase the flushing effect. ~ Min, 48 hours of Auto-filter(40um) flushing for MC/MC-C engine and ME/ME-C’s Auto-filter(4Qum) and ME fiter(6um) flushing will be performed the external and internal engine pipe flushing (referred Fig 3) - Check filter and sampling every 6” hours and flushing conditions will be recorded. ~ Continue flushing of piping for MC/MC-C engine until all visible dirt has been removed and reached ISO 4406 xx/19/15 and ME/ME-C is |SO 4406 xx/19/15 before ME filter : 6m) and ISO 4406 20/16/13(after ME filte - Oil cleanliness to be confirmed by the check bag of 50m filter gauze. - Until NAS 10 grade(MC/MC-C) and NAS 8 grade(ME/ME-C) accepted by shipyard QM or/and owner, repeat oil flushing and flushing for piping is to be completed & the log is to be recorded. © Before ME filter(6um) : ISO 4406 ¥/19/15(NAS 1638 code10) © After ME filter(6um) : ISO 4406 xx/16/13(NAS 1638 code8) Fig. 3: ME Oil flushing procedure : ship yard and engine pipe diagram. Moin engine ps, HU ME fiter(oym) — Backfusting iter om ME filter ME syslam on engine Auto-ackwasting ‘iter 40u) lubrication of pumps lubrication oi) tent © Temporary Filter(subplate filter) for ME engines In order to protect the most vital parts in the ME engines hydraulics, namely the proportional valves, subplate filters can be installed between the FIVA main valve and pilot valve, and between the pumps and their control valve. HSEF-K210-c004R0) ENGINE & MACHINERY DIVISION ‘A240 X 257m 3PAGE : 7 of 14 DOG. NO. AT4-275132-8 If the filter is used during shop test and sea trial the ISO 4406 cleanliness level can be reduced to code xx/17/14, The filter has a indicator which show when the pressure drop across it reachers 6 bar. When the indicator is red the filter will still be usable but the filter cartridge should be changed at first opportunity. Normally the indicator will determine the life time of the filter cartridge. On a few engine types the space on the HCU do not allow the indicator to be installed, on these the below guide line can be used. The calculated life time of a filter cartridge used at the pump, at oil cleanliness level ISO 4406 Code xx/17/14 is 14 hours. In practice we recommend exchange after 1 shop test or 1 sea trial. | iter with toois on proportional valve on hydra ump Proportional vave Peat Hyeroute pure The calculated life time of a filter cartridge used at the FIVA vlave, at oil cleanliness level ISO 4406 Code xx/17/14 is 193 hours. In practice we recommend exchange after 10 sea trials. Filter with tools on FIVA valve Pater vahe FIVAVaNe soeues NSEF-x210-c004(R0) ENGINE & MACHINERY DIVISION ‘Adon X 2870) EAPAGE : 8 of 14 RIN BOSRG ATE ~ Diagram for Temporary Filer(subplate filter) application of ME engine sin engine eh Me titr¢Gym)—Backtatin er ACU Wome ite Oil Cleanliness ISO xx/17/44 ‘uto-backwastiog fies 404m) Iworleation of puree lubrication of tent - Table 1 : Location of check bag and blank flanges Location of check bag and blank flanges Blanking off pipes: 1. Main bearing by-pass blanks 2. Crosshead bearings by-pass blanks 3. Blank-off bearings and spray nozzles at main chain otveton Blank-off thrust bearing Blank-off or by-pass axial vibration damper Blankoff torsional vibration damper Blank-off forward moment compensator chain drive /Mononieter e Blank-off or by-pass turbocharger 8. —_Blank-of hydraulic chain tghtener et IT 1G, “aut ome ge i Fixe hase 2-9) Guide of flushing in relation to the engine delivery condition ~ When the engine is delivered in several parts, flushing of engine at ship yard is needed. And the oil flushing should be carried out in accordance with 2-9 and 2-40 procedure. - When the engine is delivered assembled in one parts, flushing of main engine at ship yard can be avoided but, Flushing of ship yard installations (pipe lines) is needed seF-xz10-c004(R0) ENGINE & MACHINERY DIVISION ‘Aa zi0men X 287m)/\HYUNDAI PAGE 9 of 14 NEAVY INDUSTRIES O,LTD. DOG. NO.ATA-275732-5 ‘Guido to System Contamination Control Shipyard Filing of shipyard installations. rp (Use of aditional iter recommended) Ene delivery comple Ee hing ovoid Ey clewing eoed 3. Cylinder Lube Oil System Flushing Procedure. (Mechanical and Alpha lubricator system) - Before connection to engine internal pipe, ship yard pipe line should be arranged to cylinder lube oil tank by temporary rubber hose. ~ Flushing oil is to be heated to 60-65'C to increase the flushing effect. - Flushing should be circulated to cylinder lube oil tank of the external pipe flushing. min. 12 hours as below piping diagram. (referred to Fig.4). ~ After 12 hours, it is to be checked the flushing condition by the check bag. = Continue flushing of piping until all visible dirt has been removed. ~ After flushing, by-pass piece or rubber hose is to be removed and connected to the engine intemal pipe. Fig. 4 HSEF-210-c004(R0) ENGINE & MACHINERY DIVISION ‘(240mm X 287mm}/\HYUNI PAGE : 10 of 14 HEAVY INDUSTRIES 1 DOG. NO. A142751325 4. Fuel Oil System Flushing Procedure The flushing procedure is intended for use on engines where all fuel system piping has been fitted and sealed by the engine builder before delivery. For engines delivered with fuel system piping to be fitted on site, all pipes should be thoroughly cleaned and inspected before assembly. In order to ensure that dirt from external pipe lines and in the fuel oil tank is removed by the filters and centrifuges, and not passed on to the engine, it is recommended to perform the flushing in the following steps: © Thorough cleaning of fuel oil tank before filling up © Flushing of external piping ~ Air vibrator should be installed on the pipe line. In addition, a portable vibrator or hammer should be used on the outside of the pipes during the flushing period in order to loosen any impurities in the piping system. ~ The small pipes can be used by hammering during the oil flushing, ~ To effective oil flushing, temporary filter can be installed on ship yard pipe line. ~ MIE fuel oil inlet and outlet port's make the bypass loop with temporary filter and the other isolation position will be blinded by blind flange on the main engine external Positions to avoid entrance of dirt in the pipe line. ~ The duration of flushing by Auto-filter(S0um)will be min. 48 hours, but the flushing time can be controlled the degree of impurities on check filter condition ~ After flushing, the filters and service tank should be opened for inspection and manual cleaning, if necessary. Oil Flushing is carried out continuously until all visible dirt has been removed and to be checked for cleanliness. (referred to Fig.5). Fig. 5 — Main engine pipe — Ship yas pipe ——. Fleable hove 5. Kinds of by-pass Blind Flange. HSEF-K210:C004(Ro) ENGINE & MACHINERY DIVISION ‘M(2t0mm X 257mm) 2APAGE : 11 of 14 ABYUNDAI BOS NO RESETS - Main bearing : by-pipe blind flange * Main Bearings Ragtt(0) Bad(x) ad{x)-Nowelig} - Piston cooling oil line : by-pass blind flange * P.C.0/ Cross head Bearings Right 0) Bad(x) Bad(x}~Toolow ue 6. Inspection and Criterion of Oil Flushing. 6-1) Flushing cleanliness for Lube oil and Fuel oil flushing Item 104406 Code | NAS 1638 1 | Lube oil system ot 95 10 2 | Cylinder Oil system = 5 3. | TIC Oilsystem “ = 4 | ME Hydraulic ol system xt 6/13 8 5. | Fuel oil system “ = HSEF-K210-coD4(Ro) ENGINE & MACHINERY DIVISION ‘(a tomm x 287m) 3.4/\HYUNDAI HEAVY INDUSTRIES CO, LTO. PAGE: 12 of 14_ DOC. NO.A14-2781326 6-2) Flushing medium and classification of the inspection Inspector inipection, Item Medium | Working Applied Owner | am | wim | visual | Particle 1 | Lube oil system oO oO ° oO ME System oil 2 | cyt oil system ° 6 panes 3] TiC oilsystem | TIC System oil tustg ° a we 4 [RETSea [we sytem ot o [0 o | o | sem 5 | Fueloil system | MDO. ° ° 6-3) Flushing check sheet. The ship yard QM inspector and Engine maker engineer should be approved by owner of the oil flushing condition after finishing the oil flushing for pipe line between ship yard and engine side by means of below check sheet. ‘FLUSHING CHECK Se ide Waa ese SEES MAIL Ruse BE ra ‘eM pue TET 06 BALE bug SHOR HALO BH DEMS 2 eso EE 8 EHR LATOR ES Hale z, Important Points of Oil Flushing. 7-1) Ship yard pipes must be clean inside of pipe before installing the connection pipe(end pipe/adjustable piece) between yard external and engine internal pipe. 7-2) Correct installation of by-pass blank for main lube oil and piston cooling oil line to avoid the damages of bearings during oil flushing. 7-3) Check the pipe inside before dismantling by-pass blanks. 7-4) Check the yard's pipe pieces (pipe inside) between engine connection pipe and filter outlet pipe after auto-fiter as shown below diagram, HseF-xz10-co04R0) ENGINE & MACHINERY DIVISION ‘230mm X 297mm 2HPAGE : 13 of 14 Uo Tenn: 6 - Boe 1. Fon: ni 0 7-5) Check the telescopic pipe between outside and inside together with guide show after lifting 300mm of telescopic pipe as below picture. In addition, Protection cover for crosshead is to be carried out before oil flushing and inspect the particles after oil flushing. © Major check points - Telescopic pipe - Cross-head covering ~ 300mm lifting for inspection of pipe 7-6) Check main bearing point which is connected lube oll inlet pipe to avoid the entrance of any dirt particles after removing the by-pass blank to protect the main bearings after oil flushing “@ Major check points - Each oylinder main lube oil inlet pipe inside (inspect the inside of pipe after dismantling pipe) - Each cylinder bearing inside - Thrust bearing inside NSEF-K210-c004(R0) ENGINE & MACHINERY DIVISION ‘AN zI tram X 257mm) 8APAGE : 14 of 14 DOC. NO. At42751326 8. Others (ISO 4406 and NAS 1638). 8-1) Filtration Requirement ISO 4408, Code x x/19/15 and 16/13 Number or Farucles Per 100 a Up toand neta Range Number Taare than | 23 4900000) 8000000. 21 ‘0000002000900 cI "250000. ‘nna 17 168000 130000 15 18000 32000 13 ‘2000 u00 1000 2000 250. 509 Minimum requirement ofcleeniness lve - Wain Lube Ol System rl 180 4406, Code xx/19/15 ‘Ths eoperas aga mre ae tte ics on 2010" 2S ns epee» H macabre imum equrement of clerinesslvel~ME Hydraulic System NZ 180 4408, Code x«/18/13 Trscregert masini! nee pees cen en 2310964 [Pena Name pct» Veto 1D"WE nse 8-2) NAS 1638 Contamination Classes [Maximum Particles! 100mL in specified size range jum] 25-50 4 3 7 32 3 7 7126 7425 _| 253 72850_| 606 3700] 1072 71400_[_2025 722800[ 4050, 45600 [8100 ‘91200 | 162007 782400 | 32400, SEF-x210-C004R0) ENGINE & MACHINERY DIVISION ‘Adame x 297m