2015

SPECIAL EDITION

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aulic partner for steel process

The Bright World of Metals

PIPING

PICKLING

FLUSHING

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ENGINEERING & CONSULTANCY

PRODUCTION & ASSEMBLY

SERVICE & SITE APPLICATION

• Engineering• Consultancy• Sales Team• Design Office• Optimisation

• Piping Arrangement• Supervising

• Service• Maintenance• Piping &Tubing İn site• Chemical Cleaning İn Line• Flushing

• Cutting / Preparation Area• Welding• Assembly Hole• Painting

• Testing Room• Warehouse• Quality Control & Delivery

• Method of Statement P&P&F Process• Supplying Material Management

• Spare Part• Project & Risk Management

• Inspection• Testing• Certification• Health & Safety• Erection

• Service after Start-up• Condition Monitoring• Oil Analyzing• Diagnostic Test Kit

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PIPING

FLUSHING

PICKLING

• Piping System Managements• Design Principles• Material Supplying and Certifications• Welding Pipe Systems• Non-welding Pipe & Tubing Systems

• Fabrication & Erection• Inspection and Testing• Certification of welders• Welding Procedure with main Contractor• Health & Safety

• Preparation Closed Loop Circulations for Pickling• Health & Safety• Chemical Products to Be Use for Pipe Pickling Operations• Pickling Procedure for in Line Pickling• Pickling Circuit Test Pressure• Washing With Water

• Acid Washing (Hydrochloric Acid Treatment)• Passivation• pH Value and Visual Control of Pipe Surfaces• Drying• Piping System Preconditioning• Line Conservation

• Site Conditions• System Preparations• Purpose of Flushing• Activities Before Flushing• Securing Area

• Flushing Equipments• Flushing Fluid• Flushing Velocity and Temperature• Flushing Performans• Acceptance of Cleanliness NAS/ISO

• System Cleanliness• Oil Analyzing• After Flushing

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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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PIPE CUTTING MACHINES

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.

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PIPING PROJECT MANAGEMENT

• Time Schedule of Work

• Project Reviews (Customer)

• Dedicated Project Manager

• Materials selection & suplly

• Bill of Materials

• Isometrik Drawings

• Layout Instalation

FULL PAPER WORKS

• Certification of All Welder

• Welding Procedures of Main Contractor’s Project

• Materials Certificate

• Consumables Certificate

• Ndt Reports

• Risk Assessment

• Method Of Statement

HEALTH & SAFETY

• Internal/External Risk Assessments

• On site Risk Assessments

• Procedures & Documents

• Onsite Deployment Assessments & Procedures

PIPING

We are an internationally functioninghydraulic complete solution supplying company

with worldwide services and quality.

Fabrication of hydraulic piping system on siteFabrication of hydraulic piping system on site

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PIPING

PIPING

PIPING

PIPING PIPING

FITTINGS AND FLANGESPIPING SYSTEM DESIGN

Hydraulic systems are designed according to a working pressure that the required forces and torq are achieved. Hydraulic system are generaly designed much more approxiamately than 15-20 % the working pressure. All components should be selected to meet the maxiumum system pressure.

At the same time all design parameters have to be selected specifically for each the system and the customers’ requirements, rules, regulations and certifications.

SELECTION OF PIPE SIZEThe inner diameter and wall thickness of the pipes are determination of correct pipe size. The inner diameter selected according to on allowed pressure losses or on flow velocity. The wall thickness is selected according to on the required pressure rating.

PIPE AND TUBE MATERIALS

The recommended pipe and tube materials to be used in hydraulic applications are as follows:

FLOW VELOCITY

d = inner diameter of the pipe [mm]Qmax = maximum flow rate [Lpm]v = flow velocity [m/s]The Reynolds number can be determination of flow type inside of pipe.

• Laminar flow Re < 2300• Turbulent flow Re > 4000The critical Reynolds number should be Rekr for typical hydraulic pipe flow is 2500.

MECHANICAL DESIGN• Pipe & Tube Material• Connection System: Welding, Fittings, Flanges• Pipe Supports

PIPING

Steel Type Tensile Strength Yield Point Ductile Yield Condition

EN10220(st52-3 acc.to DIN2448) 490 N/mm² (St52.3) 345 N/mm² (St52.3) 20% min. (St52.3) Seamless non-alloy steel

tubes for pressure purposes

TUBINGSteel Type Tensile Strength Yield Point Ductile yield Condition

Fine grain E235N acc.to EN10305-4 (St.37.4 acc.to

DIN 1630/DIN2391)340 N/mm² 235 N/mm² 25 % min

Seamless, cold drawn, normal annealed, DIN EN 10305-1 and 4 Phosphated and

oiled

BUTT WELDING METHOD

250 Bar 315 Bar 400 Bar

NominalSize

OutsideDiameter

(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)

DN 25 33,7 4,5 - - 42,4 8,8

DN 32 42,4 5,6 48,3 8 48,3 8,8

DN 40 60,3 8 60 10 60,3 11

DN 50 76,1 10 76,1 12,5 76,1 14,2

DN 65 88,9 12,5 88,9 14,2 101,6 20

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

DN 150 193,7 25 219,1 38 - -

Q = V * Ad = 4 . Qmax

∏ . v

FLUID (OIL) VELOCITIESRecommended oil velocities to be utilized for initial pipe sizing in suction and pressure lines can be

250 Bar 315 Bar 400 BarOutside

Diameter(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)8 1 8 1,5 8 1,5

10 1 10 1,5 10 212 1,5 12 1,5 - -16 2 16 2 16 318 2 18 2,5 - -20 2 20 2,5 20 422 2,5 - - - -25 2,5 25 4 25 4,528 3 - - - -30 3 30 4 30 535 3 - - - -38 4 38 5 - -42 4 - - - -

PIPINGStandard CarbonStainless

Austenitic Acid-proofEN 10 027 E235 E355 - - -

DIN 1630 St 37.4 St 52.4 - - -

DIN 1629 St 35 St 52 - - -Material N. (EN) 1.0380 1.0580 1.4307 1.4571 1.4404ASTM/SAE A53Gr. A A252Gr. 3

Alloy Steel (EN) - - X2 CrNi 1811

X6 CrNiMoTi17 12 2

X2 CrNiMo17 13 2

AISI - - 304L 316Ti 316L

BUTT WELDING METHOD

SERIE 3000 PSI SERIE 6000 PSI

NominalSize

OutsideDiameter

(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)

DN 25 33,7 4 33,7 5

DN 32 42,4 4 42,4 6,3

DN 40 48,3 4 48,3 7,1

DN 50 60,3 4,5 60,3 8

DN 65 76,1 4,5 76,1 10

DN 80 88,9 5 88,9 12,5

DN 100 114,3 3,6 - -

DN 125 139,7 4,5 - -

SOCKET WELDING METHOD

SERIE 3000 PSI SERIE 6000 PSI

NominalSize

OutsideDiameter

(mm)

WallThickness

(mm)

OutsideDiameter

(mm)

WallThickness

(mm)

DN 25 33,7 4 33,7 5

DN 32 42,4 4 42,4 6,3

DN 40 48,3 4 48,3 7,1

DN 50 60,3 4,5 60,3 8

Suction lines ≤ 1 m/snPressure lines ≤ 5 m/s.Return lines ≤ 3 m/s.

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PIPING PIPING

MATERIAL SUPPLYING

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.

WELD FITTINGS

DIN FITTINGS

SAE FLANGES / BUTT WELD END / SOCKET WELD END

SQUARE FLANGES / BUTT WELD END

VALVES

TUBES

TUBES CLAMPS

CUSTOM PRODUCTS

DN FLANGES

ADOPTERS / HOSE

FILTER ELEMENTS / OIL / COLLECTORS

PICKLINGSpecial Instruction for Pickling in Site

• 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• Acid Washing (Hydrochloric Acid treatment)• Passivation • pH Value and Visual Control of Pipe Surfaces • Drying• Piping System Preconditioning• Line Conservation

Hidroproser prepared and applied procedures and technical specifications for chemical cleaning process are removed from potential risks in the field. The pickling activities are caried out expert, experienced and qualified team by HIDROPROSER.

Special Instruction for Pickling in Site

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PICKLING PICKLING

PREPARATION CLOOSED LOOP CIRCULATIONS FOR PICKLING

HIDROPROSER is identify and arrange of all the necessary (to by pass components such as valves and cylinders) temporary fittings and blind flanges, for the pickling circuit preparation. The pickling operation will be include interconnecting piping of Hydraulic system, Gress and Lubrication oil for 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.

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.

PICKLING PROCEDURE FOR IN LINE PICKLING

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 will be sufficient.

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

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.

Purpose of the acid washing is to solubilize the oxide layer present against the inside walls of the piping. When the previous alkaline washing and water washing is concluded, the circuit will be filled by water adding following reagents:

HCL (33 % Acid) for picklingInhibütor for picklingAmonium Bi Florür for pickling

PASSIVATION

Purpose of the passivation phase is to create a protective layer on the inside walls of the piping, protecting them from oxidation. This passivating solution will be kept in circulation for 2 (four) hours keeping the temperature steady.

RECIRCULATION PROCESS

CLOOSED LOOPCIRCULATION

PRESSURE TEST

DEGREASINGNEUTRALIZATION

TANK pH 7DRYING

FLUSHINGWITH OIL

DISPOSALTANK

WATER CLEANING

PICKLINGpH 1 - 2

NEUTRALIZATIONpH 7

PASIVATIONpH 9 - 10

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.

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FLUSHING 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.

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

CLEANLINESS LEVEL CORRELATION TABLE

Code toISO4406: 1999

Particles per Milliliter (ISO 11171 um �c�) NAS 1638(1964)

SAESeviyesi(1963)>2 Microns >5 Microns >15 Microns

23/21/18 80,000 20,000 2,500 12 -22/20/18 40,000 10,000 2,500 - -22/20/17 40,000 10,000 1,300 11 -22/20/16 40,000 10,000 640 - -21/19/16 20,000 5,000 640 10 -20/18/15 10,000 2,500 320 9 619/17/14 5,000 1,300 160 8 518/16/13 2,500 640 80 7 417/15/12 1,300 320 40 6 316/14/12 640 160 40 - -16/14/11 640 160 20 5 215/13/10 320 80 10 4 114/12/9 160 40 5 3 013/11/8 80 20 2,5 2 -12/10/8 40 10 2,5 - -12/10/7 40 10 1,3 1 -12/10/6 40 10 ,64 - -

CLEANLINESS LEVEL FOR COMPONENTS

Low/Medium PressureUnder 2000 psi

(moderate conditions)

High Pressure2000 to 2999 psi

(low/medium with severe conditions)

Very High Pressure3000 psi and over

(high pressure with severe conditions)

Pumps ISO TargetLevels

Micron Ratings

ISO TargetLevels

Micron Ratings

ISO TargetLevels

Micron Ratings

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

Fixed Piston 19/17/14 10 18/16/13 5 17/15/12 3

Variable Vane 18/16/13 5 17/15/12 3 - -

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,Gear Motors 20/18/15 20 19/17/14 10 18/16/13 5

Piston Motors,Swash Plate Motors 19/17/14 10 18/16/13 5 17/15/12 3

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

FLUSHING FLUID

The flushing fluid must be compatible with the fluid specified for the system and with system materials, especially the seals. In all cases the appropriate technical and regulatory standards will apply to the fluid selection, including supplier specifications, e.g. in the use of synthetic hydraulic oils.

The recommended flushing fluid is normally the same grade as the working fluid.

FLUSHING VELOCITY AND TEMPERATURE

To ensure that the system is flushed as quickly and efficiently as possible, both fluid velocity 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 not exceed 62 ºC. The flushing flow is calculated and based upon achieving turbulent flow. This is achieved when Reynolds number is greater than 4000.

Flow = Re x ID x Vsc21220Re = Reynolds numberID = Inside diameter of largest pipe to be flushedVsc = Oil viscosity at flushing temperatureNB Re of 4000 minimum is preferred.

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 synthetic hydraulic fluids.

FLUSHING PERFORMANCE

With the system prepared, fill the system by feeding the flushing fluid to the flushing rig so that the fluid is filtered before entering the system. New fluid is often dirty by hydraulic standards. Circulate the flushing fluid.

Thermal shockDuring the flushing, the oil temperature will be oscillated but if fluid temperature exceeds 62 ºC it shall not be re-used.

Hydraulic shockThe system may be hydraulically shocked by shutting down valves to interrupt the flow.

Mechanical shockVibrator or rubber hammer can be used on the horizontal section and corners of the line to apply hammering effect on the pipe.

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Istanbul Head Office+90 216 527 92 00+90 216 527 92 02Bayraktar Bulvarı No:57Pk:34775 Şerifali, İstanbul / Turkey

İzmir Factory+90 232 375 43 30+90 232 375 43 3110006/1 Sk. No:35 A.O.S.BPk:35620 Çiğli, İzmir / Turkey

Moscow Sales Office00 7 926 304 19 34info@hidroproject.comMoscow City / RUSSIA

REFERENCES

SOLUTION PARTNERS

The Bright World of Metals