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Hydraulic Flushing Rig

About

Flushing rigs are ideal for troublesome systems or where large amounts of contamination have been introduced to a machine. They are designed to work on any system Machine can be supplied to perform both oil flushing and pressure testing and is ideal for:-
  • When any system does not run properly due to contamination.
  • New plant Installation Prior to Commissioning.
  • System with Performance problems.
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Technical Details

  • Dimension (L,W,H) in mm : 1500/1100/1400
  • Weight : 1100 Kg
  • Working Fluid : Hydraulic Oil
  • Tank Volume : 300 liters
  • Cleanliness level of Oil : NAS 6
  • Pressure Adjustment Range of working fluid in pressure line : Up to 350 Kgf/cm2
  • Max. Pressure of working fluid : 350 Kgf/cm
  • Temperature Range of working fluid : MAX. 60°C
  • Capacity of Pumping station of Rig : MAX. 58 LPM
  • Electric Power supply requirement : 3Ø Power supply, 37.5kW, 50Hz
  • Flushing units are used to clean hydraulic systems.
  • By flushing a new hydraulic system before bringing it into operation, expensive breakdowns are avoided.
  • Flushing system creates a high flow combined with high pressure, which in turn creates a turbulent flow in your hydraulic lines that eliminates contamination.
  • Q1. What is a hydraulic flushing rig used for?
    • Ans- It is used to clean and flush hydraulic systems, pipelines, and components by circulating oil or other cleaning fluids to remove contaminants like particles, sludge, and moisture.
  • Q2. How does the flushing process work?
    • Ans- The rig circulates hydraulic fluid at high velocity and pressure through the system, while multi-stage filters remove contaminants. The process continues until cleanliness standards (e.g., ISO 4406 or NAS 1638) are met.
  • Q3. What industries benefit from a hydraulic flushing rig?
    • Ans- Industries like aviation, marine, oil & gas, construction, and manufacturing use these rigs to maintain hydraulic systems and extend equipment life.
  • Q4. What types of fluids can the rig handle?
    • Ans- The rig is compatible with various fluids, including hydraulic oils, turbine oils, and flushing fluids specified for specific systems.
  • Q5. How do I monitor cleanliness levels?
    • Ans- The system often includes in-line contamination monitors or particle counters that provide real-time cleanliness data according to standards like ISO 4406.
  • Q6. Is the rig portable?
    • Ans- Yes, most rigs are either skid-mounted or have wheels, allowing easy transportation to job sites. Some models are designed for use in confined spaces or remote locations.
  • Q7. What safety features are included?
    • Ans- Safety features typically include pressure relief valves, emergency shut-off systems, and temperature control to prevent overheating.
  • Q8. How often should the filters be replaced?
    • Ans- Filter replacement depends on usage, but they should be changed when pressure drop across the filter exceeds recommended limits or as specified by the manufacturer.
  • Q9. What maintenance does the rig require?
    • Ans- Regular maintenance includes inspecting hoses and connections, checking for leaks, cleaning the tank, and replacing filters. Periodic calibration of sensors and gauges is also essential.
  • Q10. Can the rig be customized for specific needs?
    • Ans- Yes, rigs can be customized based on flow rate, pressure, tank size, and filtration requirements to suit specific applications.
  • Q11. How do I ensure compatibility with my hydraulic system?
    • Ans- Provide details about your hydraulic system's specifications (pressure, flow, fluid type, and cleanliness standards) to the manufacturer for guidance on selecting a suitable rig.
  • Q12. What are the standard cleanliness targets for hydraulic systems?
    • Ans- Typical cleanliness targets are ISO 4406: 18/16/13 or NAS 1638: Class 6, but this varies based on system requirements.

Key Features

  • Cleanliness verification to the appropriate standard.
  • All mild steel construction/Stainless steel construction on demand.
  • All pipes/fittings-SS304.
  • Wide range of pressure and flow combinations.
  • Suitable for water and oil based fluids.
  • Booster pump based close loop filtration and cooling circuit.
  • Water cooling/Air cooling options.

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Details

A Hydraulic Flushing Rig Machine is a critical tool designed for cleaning and flushing hydraulic systems to remove contaminants such as 
dirt, metal particles, and sludge. These rigs ensure optimal performance and longevity of hydraulic systems in industries like construction, aviation, marine, and manufacturing.

Specifications
Parameter Details
Flow Rate 10 - 400 LPM (adjustable depending on the application)
Working Pressure  10 - 400 bar (varies by model)
Tank Capacity 50 - 1,000 liters (depending on system size)
Filtration  Multi-stage filtration system with micron ratings from 3 µm to 25 µm
Control System  PLC or manual control with pressure and flow monitoring
Power Supply  Electric motor (3-phase, 380-440V) or diesel engine for remote sites
Hoses and Connections High-pressure, flexible hoses with quick couplings for easy setup
Filtration Medium Replaceable filter cartridges or mesh filters
Cooling System  Integrated oil cooler to maintain optimal fluid temperature
Mobility  Skid-mounted or wheeled base for portability
Noise Level Below 85 dB (industry-standard for safe operation)
Certifications  ISO 4406, NAS 1638 compliant (contamination levels), CE certified

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