Details

Overview
The Mobile Hydraulic Flushing Rig is a sophisticated, skid-mounted system designed to flush and decontaminate hydraulic pipelines, actuators, and power units. It uses controlled high-velocity turbulent flow, multi-stage filtration, thermal regulation, and real-time monitoring to achieve required fluid cleanliness levels—typically NAS 1638 Class 6 or better (ISO 4406 16/14/11). This ensures optimal protection of mission-critical hydraulic systems from wear, malfunction, and early failure due to contamination. Ideal for aerospace, defense, manufacturing, power generation, and mobile machinery, the rig is engineered to meet the most demanding hydraulic flushing requirements. Whether used for initial commissioning, post-maintenance cleaning, or routine service, it guarantees fast, repeatable, and
certifiable flushing results.

Key Applications
• Aerospace & Defense: Flushing flight control systems, servo-valves, and hydraulic actuation lines in aircraft, tanks, and UAVs.
• Industrial Machinery: Cleaning hydraulic presses, injection molding machines, forging lines, and rolling mills.
• Rail & Metro Systems: Flushing brake control systems, bogie suspension hydraulics, and traction control actuators.
• Marine & Offshore: Flushing steering gear, ballast control circuits, and subsea hydraulic lines—DNV or ATEX configurations available.
• Mobile Equipment: On-site servicing of excavators, cranes, backhoes, and heavy agricultural
or construction machinery.

Functional Design
Contaminants like metal shavings, seal residues, dust, and water are flushed out using high-pressure
fluid passed through a series of progressively finer filters. The rig ensures:
• Turbulent flow (Re > 3000) for mechanical dislodgement of particles
• Multi-stage filtration (up to 3 μm) to capture contaminants
• Temperature control for optimal viscosity and flushing efficiency
• Instrumentation & alarms for operational safety and feedback
• Quick-disconnect couplings for fast, leak-free connection to systems

Technical Specifications
  

    

      
Parameter
      
Specification
    
    

      
Reservoir Capacity
      
600 L, stainless steel (SS-304), baffled, with level gauge and low/high switches
    
    

      
Booster Pump
      
Fixed displacement, 200 LPM @ 10 bar, 5.5 kW motor
    
    

      
Main Flushing Pump
      
Axial piston, variable displacement: 35 LPM @ 350 bar → 140 LPM @ 30 bar, 30 kW
    
    

      
Filtration Stages
      
Booster: 10 µm → 6 µm → 3 µm; Pressure line: 3 µm; Return line: 10 µm
    
    

      
Filter Features
      
Clog indicators, bypass valves, magnetic pre-filter (optional)
    
    

      
Cooling System
      
21.5 kW air-cooled heat exchanger, rated for 140 LPM, max outlet temp 60 °C
    
    

      
Flow Meter
      
0–140 LPM, digital, 4–20 mA output, optional RS-485/USB logging
    
    

      
Temperature Measurement
      
RTD or thermocouple, 4–20 mA transmitter with digital readout
    
    

      
Pressure Gauges/Transmitters
      
Booster, supply, and return lines; 0–400 bar range, 4–20 mA output
    
    

      
Electrical Supply
      
3-phase, 415 V AC, 50 Hz, IP55 control panel with MCBs and motor starters
    
    

      
Safety Features
      
E-stop, low-level shutdown, over-temperature cut-off, filter-clog alarms
    
    

      
Connections
      
1″ BSP or optional QCDC (Quick Disconnect Couplings)
    
    

      
Frame Dimensions
      
Approx. 2200 × 1500 × 1800 mm (L × W × H), forklift-compatible skid frame
    
    

      
Dry/Wet Weight
      
Approx. 1500 kg dry, 2100 kg filled
    
  

Control & Automation Options
Standard Manual Panel
• Toggle switches for pump operation
• Digital and analog gauges for flow, pressure, and temperature
• Emergency stop and fault indicators

PLC-Based HMI (Optional)
• Programmable flushing sequences
• Real-time data display with touchscreen
• Automatic shutdown on fault
• Particle counter integration with cleanliness monitoring
• Remote diagnostics (Ethernet/Modbus/USB)

Operation Workflow
1. Connect the supply and return hoses using QCDC fittings
2. Fill & prime using the booster pump; ensure filters are clean
3. Start the main pump, adjust pressure/flow using the unloading and needle valves
4. Monitor parameters via digital displays—flow, pressure, and temperature
5. Flush until required cleanliness level is achieved (verified by sample or particle counter)
6. Shutdown using standard operating procedures; log flushing results if data logging is
enabled

Advantages
• High Turbulence ensures even hidden debris is flushed
• Fine Filtration removes harmful particles down to 3 μm or finer
• Temperature Regulation ensures fluid properties remain optimal
• Digital Instrumentation provides real-time control and records
• Robust Construction suited for industrial or military use
• Customizable Build allows integration of optional sensors, heaters, and PLCs
• Low Maintenance with visual checks and standardized filter elements

Optional Add-Ons
• Electric pre-heater for fluid (up to 60–80 °C)
• Explosion-proof (ATEX Zone 2) variant
• Integrated particle counter (NAS/ISO display)
• Diesel-powered portable rig for field operations
• Magnetic filter stages for ferrous debris
• Customized filter micron ratings and tank sizes
• Stainless steel control panel (IP66) for harsh environments

Certifications & Standards
• CE compliant per Machinery Directive 2006/42/EC
• NAS 1638, ISO 4406, SAE AS4059 particle cleanliness levels
• IP55-rated control enclosure
• Electrical components per IEC/IS standards
• ATEX Zone 2, DNV/Offshore lifting frame options available

Use Case Highlights
• Defense Establishments: Flushing high-pressure test rigs and electrohydraulic servo systems before deployment
• Aerospace OEMs: Pre-delivery cleaning of actuator and reservoir assemblies for helicopters and aircraft
• Railways: Maintenance of bogie and pantograph hydraulic systems during overhaul cycles
• Steel Plants & Refineries: Pipeline flushing after welding, before commissioning of hydraulic control systems
• Mobile Equipment Service Yards: On-site hydraulic flushing for fleet maintenance of heavy equipment

Conclusion
The Mobile Hydraulic Flushing Rig is an essential quality assurance and maintenance tool for any organization relying on high-performance hydraulic systems. Designed for rugged environments and available in fully automated or manually operated configurations, it offers unmatched performance, reliability, and adaptability. Backed by Neometrix’s engineering expertise, these rigs are available with extensive customization, field support, and certification options to meet global industrial, defense, and aerospace standards.