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SPECIAL EDITION

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• Engineering • Piping Arrangement • Spare Part

• Consultancy • Supervising • Project & Risk Management
• Sales Team • Method of Statement P&P&F Process
• Design Office • Supplying Material Management
• Optimisation
ENGINEERING & CONSULTANCY

• Cutting / Preparation Area • Testing Room

• Welding • Warehouse
• Assembly Hole • Quality Control & Delivery
• Painting
PRODUCTION & ASSEMBLY

• Service • Inspection • Service after Start-up

• Maintenance • Testing • Condition Monitoring
• Piping &Tubing İn site • Certification • Oil Analyzing
• Chemical Cleaning İn Line • Health & Safety • Diagnostic Test Kit
2 • Flushing • Erection 3
SERVICE & SITE APPLICATION
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• Piping System Managements • Fabrication & Erection

• Design Principles • Inspection and Testing
• Material Supplying and Certifications • Certification of welders
• Welding Pipe Systems • Welding Procedure with main Contractor
• Non-welding Pipe & Tubing Systems • Health & Safety
PIPING

• Preparation Closed Loop Circulations for Pickling • Acid Washing (Hydrochloric Acid Treatment)
• Health & Safety • Passivation
• Chemical Products to Be Use for Pipe Pickling Operations • pH Value and Visual Control of Pipe Surfaces
• Pickling Procedure for in Line Pickling • Drying
• Pickling Circuit Test Pressure • Piping System Preconditioning
PICKLING • Washing With Water • Line Conservation

• Site Conditions • Flushing Equipments • System Cleanliness

• System Preparations • Flushing Fluid • Oil Analyzing
• Purpose of Flushing • Flushing Velocity and Temperature • After Flushing
• Activities Before Flushing • Flushing Performans
• Securing Area • Acceptance of Cleanliness NAS/ISO
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FLUSHING
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Complete Hydraulic Solutions offers hydraulic systems (including integrated hydraulic

power unit, valve stands, accumulator stands, high quality and robust cylinders) designed,
manufactured, tested and site application (piping, pickling and flushing) of which is done
by Hidroproser for electric arc furnaces, secondary metallurgical facilities and Rolling Mills.

PIPE CUTTING MACHINES BENDING TOOLS PICKLING UNIT FLUSHING UNIT

MOBILE ASSEMBLY MACHINES COLD TUBE FORMING CHEMICAL MATERIALS LOOP MATERIALS

WELDING EQUIPMENTS HOSE CRIMPING CHEMICAL ANALYZING OIL ANALYZING

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 PIPING

Fabrication of hydraulic
piping system on site

PIPING PROJECT MANAGEMENT FULL PAPER WORKS HEALTH & SAFETY

• Time Schedule of Work • Certification of All Welder • Internal/External Risk Assessments

We are an internationally functioning • Project Reviews (Customer) • Welding Procedures of Main • On site Risk Assessments

hydraulic complete solution supplying company • Dedicated Project Manager

Contractor’s Project
• Materials Certificate
• Procedures & Documents

with worldwide services and quality. • Materials selection & suplly

• Bill of Materials
• Consumables Certificate
• Onsite Deployment Assessments &
Procedures
• Ndt Reports
• Isometrik Drawings
• Risk Assessment
• Layout Instalation
• Method Of Statement

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 PIPING PIPING

PIPING SYSTEM DESIGN FLOW VELOCITY FITTINGS AND FLANGES

Hydraulic systems are designed according to a d= 4 . Qmax Q=V*A

working pressure that the required forces and ∏.v PIPING
torq are achieved. Hydraulic system are generaly d = inner diameter of the pipe [mm]
Qmax = maximum flow rate [Lpm] Steel Type Tensile Strength Yield Point Ductile Yield Condition
designed much more approxiamately than 15-20
% the working pressure. All components should v = flow velocity [m/s]
be selected to meet the maxiumum system The Reynolds number can be determination of EN10220
490 N/mm² (St52.3) 345 N/mm² (St52.3) 20% min. (St52.3)
Seamless non-alloy steel
pressure. flow type inside of pipe. (st52-3 acc.to DIN2448) tubes for pressure purposes

At the same time all design parameters have to

be selected specifically for each the system and • Laminar flow Re < 2300 PIPING BUTT WELDING METHOD
the customers’ requirements, rules, regulations • Turbulent flow Re > 4000
and certifications. The critical Reynolds number should be Rekr for 250 Bar 315 Bar 400 Bar
typical hydraulic pipe flow is 2500.
Outside Wall Outside Wall Outside Wall
SELECTION OF PIPE SIZE Nominal
MECHANICAL DESIGN Size
Diameter Thickness Diameter Thickness Diameter Thickness
The inner diameter and wall thickness of the pipes (mm) (mm) (mm) (mm) (mm) (mm)
are determination of correct pipe size. The inner • Pipe & Tube Material
diameter selected according to on allowed • Connection System: Welding, Fittings, Flanges DN 25 33,7 4,5 - - 42,4 8,8
pressure losses or on flow velocity. The wall • Pipe Supports
thickness is selected according to on the required DN 32 42,4 5,6 48,3 8 48,3 8,8
pressure rating.
DN 40 60,3 8 60 10 60,3 11

FLUID (OIL) VELOCITIES DN 50 76,1 10 76,1 12,5 76,1 14,2

Suction lines ≤ 1 m/sn
Recommended oil velocities to be utilized for Pressure lines ≤ 5 m/s. DN 65 88,9 12,5 88,9 14,2 101,6 20
initial pipe sizing in suction and pressure lines Return lines ≤ 3 m/s.
can be DN 80 101,6 14,2 114,3 20 133 25

DN 100 139,7 20 152,5 28 152,4 30

DN 125 168,3 22 177,8 30 219,1 45

PIPE AND TUBE MATERIALS DN 150 193,7 25 219,1 38 - -

The recommended pipe and tube materials to be used in hydraulic applications are as follows:
PIPING BUTT WELDING METHOD
Stainless
Standard PIPING Carbon
Austenitic Acid-proof SERIE 3000 PSI SERIE 6000 PSI
EN 10 027 E235 E355 - - -
DIN 1630 St 37.4 St 52.4 - - - Outside Wall Outside Wall
Nominal
Diameter Thickness Diameter Thickness
DIN 1629 St 35 St 52 - - - Size
(mm) (mm) (mm) (mm)
Material N. (EN) 1.0380 1.0580 1.4307 1.4571 1.4404
ASTM/SAE A53Gr. A A252Gr. 3
DN 25 33,7 4 33,7 5
X2 CrNi 18 X6 CrNiMoTi X2 CrNiMo
Alloy Steel (EN) - -
11 17 12 2 17 13 2 DN 32 42,4 4 42,4 6,3
AISI - - 304L 316Ti 316L
DN 40 48,3 4 48,3 7,1
TUBING
DN 50 60,3 4,5 60,3 8
Steel Type Tensile Strength Yield Point Ductile yield Condition
Fine grain E235N acc.to Seamless, cold drawn, normal annealed, DN 65 76,1 4,5 76,1 10
EN10305-4 (St.37.4 acc.to 340 N/mm² 235 N/mm² 25 % min DIN EN 10305-1 and 4 Phosphated and
DIN 1630/DIN2391) oiled DN 80 88,9 5 88,9 12,5
250 Bar 315 Bar 400 Bar DN 100 114,3 3,6 - -
Outside Wall Outside Wall Outside Wall
Diameter Thickness Diameter Thickness Diameter Thickness DN 125 139,7 4,5 - -
(mm) (mm) (mm) (mm) (mm) (mm)
8 1 8 1,5 8 1,5
PIPING SOCKET WELDING METHOD
10 1 10 1,5 10 2
12 1,5 12 1,5 - - SERIE 3000 PSI SERIE 6000 PSI
16 2 16 2 16 3
Outside Wall Outside Wall
18 2 18 2,5 - - Nominal
Diameter Thickness Diameter Thickness
20 2 20 2,5 20 4 Size
(mm) (mm) (mm) (mm)
22 2,5 - - - -
25 2,5 25 4 25 4,5 DN 25 33,7 4 33,7 5
28 3 - - - -
DN 32 42,4 4 42,4 6,3
30 3 30 4 30 5
35 3 - - - - DN 40 48,3 4 48,3 7,1
38 4 38 5 - -
DN 50 60,3 4,5 60,3 8
42 4 - - - -

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 PIPING PIPING

MATERIAL SUPPLYING TUBES

HIDPROSER supply tube and pipe, connectors; byte tipe fittings, weld fittings, square flanges, SAE
flanges, made Carbon Steel or Stainless Steel as well according to the DIN or ISO Standards.

Hidroproser engineering team offers expert consultation to the customer’s project requirements
with determination the best-suited solutions for piping systems. Hidroproser provides all necessary
equipments and consumable materials according to standards and specifications.

DIN FITTINGS TUBES CLAMPS

WELD FITTINGS CUSTOM PRODUCTS

SAE FLANGES / BUTT WELD END / SOCKET WELD END DN FLANGES

SQUARE FLANGES / BUTT WELD END ADOPTERS / HOSE

VALVES FILTER ELEMENTS / OIL / COLLECTORS

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Special Instruction for
Pickling in Site PICKLING

• General
• Preparation Closed Loop Circulations for pickling
• Health & Safety
• Chemical Products to be use for Pipe Pickling Operations
• Pickling İn Line
• Pickling Procedure for İn Line Pickling
• Pickling Circuit Test Pressure with Water or Compressed Air
• Washing by means of water
Hidroproser prepared and applied procedures and • Acid Washing (Hydrochloric Acid treatment)
technical specifications for chemical cleaning process • Passivation
are removed from potential risks in the field. The pickling • pH Value and Visual Control of Pipe Surfaces
activities are caried out expert, experienced and qualified • Drying
team by HIDROPROSER. • Piping System Preconditioning
• Line Conservation
 PICKLING PICKLING

RECIRCULATION PROCESS PICKLING PROCEDURE FOR IN LINE PICKLING

CLOOSED LOOP Purpose of the acid washing is to solubilize
CIRCULATION the oxide layer present against the inside
FLUSHING DISPOSAL walls of the piping. When the previous
WITH OIL TANK alkaline washing and water washing is
PRESSURE TEST concluded, the circuit will be filled by water
adding following reagents:

NEUTRALIZATION HCL (33 % Acid) for pickling

DRYING TANK pH 7 DEGREASING Inhibütor for pickling
Amonium Bi Florür for pickling

WATER CLEANING Pickling concentrated will be added up until to have the solution reaching a pH value equal to 1-2.
By the way, acid washing duration will not be less than 4 hours.

The following analys will be randomly performed during the pickling phase; Acid Content pH control
PASIVATION NEUTRALIZATION PICKLING will be sufficient.
pH 9 - 10 pH 7 pH 1 - 2
PASSIVATION
Purpose of the passivation phase is to create
PREPARATION CLOOSED LOOP CIRCULATIONS FOR PICKLING a protective layer on the inside walls of the
piping, protecting them from oxidation.
HIDROPROSER is identify and arrange of all the necessary (to by pass components such as valves This passivating solution will be kept in
and cylinders) temporary fittings and blind flanges, for the pickling circuit preparation. The pickling circulation for 2 (four) hours keeping the
operation will be include interconnecting piping of Hydraulic system, Gress and Lubrication oil for temperature steady.
carbon steel welded lines. The stainless steel lines can only apply de-greasing process.

HIDROPROSER provide an operating sequence of how propose to pickling the system.

VISUAL CHECKING INSIDE OF PIPE SURFACE
After the finishing passivation step randomly It will be a visual check inside of the piping surface
condition removing the flanged joints

The system schematic, showing where connections for pickling equipment will be installed.
Information on how the system is to be interconnected to form a continuous loop will be shown
on these drawings. Prefabricated loops will be precleaned and followed every stage of process.
All valves, manifolds, cylinders, system pumps and system reservoir will be bypassed during pickling
and capped to prevent entry of dirt.
DRYING
Nitrogen will be inserted to empty the circuit as soon as possible the passivation phase is concluded,
opening all drains with a low nitrogen flow and eventually, opening flanges connection in order to
drain the solution as much as possible.

PIPING SYSTEM RECONDITIONNING

All temporary piping connection will be reconditioned as soon as the above here describe operations,
and/or flushing phase has been completed. Particular care will be taken to avoid piping contamination
during such phase.

Time frame between the chemical treatment and further flushing operation or circuit start up with
final fluid, shall be as short as possible to prevent oxidation of inner piping walls. This never achievable
and the whole circut shall be kept under a preservation state.

The most suitable preservation state is achievable keeping the whole circuit under a low nitrogen
pressure after drying phase and up until the system will be started up.

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 FLUSHING

Hidroproser guarantees all work undertaken

to comply with all relevant requirements of the
customer’s specification; certification and
documentation will be provided on completion.
 FLUSHING
SYSTEM PREPARATION
Only the simplest system can be flushed in one operation. In the majority of systems, they
should be divided into sections or loops, the sections being flushed in turn. The separate
loops should be arranged onsite using jumper leads, make-up pieces etc. to give the least
number of flushing circuits possible to ensure a continuous circulation of oil with no dead-
ends returning to the flushing rig reservoir.
The installation of several bleeding points on the highest points of each line should be
pressure tested in order to purge air out of the installation. With this operation, pressure
stabilization time will reduce significantly.
PURPOSE OF FLUSHING
After fabrication (and installation) and pressure testing of piping systems, it may be necessary
to clean the piping system to remove all particles and contamination from inside the pipes
and components. The aim of flushing is to remove any contamination by passing fluid through
the system at velocity much higher than during normal operation, but based on calculations
of Reynolds numbers.
All components ready for assembly into the system should be in a clean condition, inhibited
with preservation oil and all openings sealed. All piping must be free from scale, rust, flux,
etc., otherwise is will be rejected and replaced, or cleaned prior to assembly. Any contamination
that may have been introduced in transit or during system assembly, and may be harmful
to equipment connected to it, must be removed. Flushing is often performed immediately
after pressure testing. Some of the following conditions may therefore have been set up
during pressure testing but are repeated for completeness and added safety.
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FLUSHING
ACTIVITIES BEFORE FLUSHING
These may include:
• Description of the system, number, test pack, gauge, pump, flange specifications, etc.
• Pre-fabrication acceptance details
• Scope of test and support drawings
• Risk assessments and method statements
• Contamination assessments
• Relevant regulatory for the type of application and the PPE requirements, e.g. reference
to stipulations in the contract, company Handbook, etc.
• Customer Health & Safety regulations
• Main contractor regulations
FLUSHING EQUIPMENT
Check that the flushing rig which consists of pumps, reservoir, filters, thermometer, particle
counter, hose connections, is in a clean condition throughout. All terminations should be
connected with adjacent pipe work to provide a continuous loop.
Check that the adjustable relief valves are set at a pressure above that required to pass the
full pump flow through the system which is to be flushed. The filters may be of disposable
element type. The filters should incorporate clogging indicators. The filter size should be
selected to pass the specified pump delivery at a low-pressure drop. Select a filter size to
meet the requirements of the system to be flushed. It should have a generous dirt holding
capacity.
Temperature gauge and pressure gauge should be calibrated and calibration record submitted
prior to start flushing. Flushing oil should be specified according to system demands.
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 FLUSHING FLUSHING

FLUSHING FLUID CLEANLINESS LEVEL CORRELATION TABLE

Particles per Milliliter (ISO 11171 um �c�) SAE
The flushing fluid must be compatible with the fluid specified for the system and with system Code to NAS 1638
materials, especially the seals. In all cases the appropriate technical and regulatory standards Seviyesi
ISO4406: 1999 >2 Microns >5 Microns >15 Microns (1964)
will apply to the fluid selection, including supplier specifications, e.g. in the use of synthetic (1963)
hydraulic oils. 23/21/18 80,000 20,000 2,500 12 -
22/20/18 40,000 10,000 2,500 - -
The recommended flushing fluid is normally the same grade as the working fluid.
22/20/17 40,000 10,000 1,300 11 -
22/20/16 40,000 10,000 640 - -
FLUSHING VELOCITY AND TEMPERATURE 21/19/16 20,000 5,000 640 10 -
20/18/15 10,000 2,500 320 9 6
To ensure that the system is flushed as quickly and efficiently as possible, both fluid velocity
19/17/14 5,000 1,300 160 8 5
and temperature should be as high as conveniently possible. Heat oil during work to 55 ºC
~ 60 ºC for VG32 oil. The temperature shall be measured in the reservoir. Temperature shall 18/16/13 2,500 640 80 7 4
not exceed 62 ºC. The flushing flow is calculated and based upon achieving turbulent flow. 17/15/12 1,300 320 40 6 3
This is achieved when Reynolds number is greater than 4000.
16/14/12 640 160 40 - -
Flow = Re x ID x Vsc 16/14/11 640 160 20 5 2
21220 15/13/10 320 80 10 4 1
Re = Reynolds number 14/12/9 160 40 5 3 0
ID = Inside diameter of largest pipe to be flushed
Vsc = Oil viscosity at flushing temperature 13/11/8 80 20 2,5 2 -
NB Re of 4000 minimum is preferred. 12/10/8 40 10 2,5 - -
12/10/7 40 10 1,3 1 -
A reasonable temperature limit for mineral oils is 60 ºC, for water-in-oil emulsions and
water-glycols it is 50 ºC. Higher temperatures are acceptable for silicone and some other 12/10/6 40 10 ,64 - -
synthetic hydraulic fluids.

FLUSHING PERFORMANCE CLEANLINESS LEVEL FOR COMPONENTS

With the system prepared, fill the system by feeding the flushing fluid to the flushing rig so High Pressure Very High Pressure
Low/Medium Pressure
that the fluid is filtered before entering the system. New fluid is often dirty by hydraulic 2000 to 2999 psi 3000 psi and over
standards. Circulate the flushing fluid. Under 2000 psi
(low/medium with (high pressure with
(moderate conditions)
severe conditions) severe conditions)
Thermal shock
During the flushing, the oil temperature will be oscillated but if fluid temperature exceeds ISO Target Micron ISO Target Micron ISO Target Micron
Pumps
62 ºC it shall not be re-used. Levels Ratings Levels Ratings Levels Ratings

Hydraulic shock Fixed Gear or Fixed Vane 20/18/15 20 19/17/14 10 18/16/13 5

The system may be hydraulically shocked by shutting down valves to interrupt the flow.
Fixed Piston 19/17/14 10 18/16/13 5 17/15/12 3
Mechanical shock Variable Vane 18/16/13 5 17/15/12 3 - -
Vibrator or rubber hammer can be used on the horizontal section and corners of the line to
apply hammering effect on the pipe. Variable Piston 18/16/13 5 17/15/12 3 16/14/11 3
Valves
Check Valve 20/18/15 20 20/18/15 20 19/17/14 10
Directional (selenoid) 20/18/15 20 19/17/14 10 18/16/13 5

Standard Flow Control 20/18/15 20 19/17/14 10 18/16/13 5

Cartridge Valve 19/17/14 10 18/16/13 5 17/15/12 3

Proportional Valve 17/15/12 3 17/15/12 3 16/14/11 3
Servo Valve 16/14/11 3 16/14/11 3 15/13/10 3
Actuators

Cylinders, Vane Motors,

20/18/15 20 19/17/14 10 18/16/13 5
Gear Motors
Piston Motors,
19/17/14 10 18/16/13 5 17/15/12 3
Swash Plate Motors
Hydrostatic Drives 16/15/12 3 16/14/11 3 15/13/10 3
Test Stands 15/13/10 3 15/13/10 3 15/13/10 3

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REFERENCES

SOLUTION PARTNERS

Istanbul Head Office İzmir Factory Moscow Sales Office

+90 216 527 92 00 +90 232 375 43 30 00 7 926 304 19 34
+90 216 527 92 02 +90 232 375 43 31 info@hidroproject.com
Bayraktar Bulvarı No:57 10006/1 Sk. No:35 A.O.S.B Moscow City / RUSSIA
Pk:34775 Şerifali, İstanbul / Turkey Pk:35620 Çiğli, İzmir / Turkey

www.completehydraulicsolutions.com

The Bright World of Metals