Executive Summary

Overview:

During commissioning, a Kochi defence-sector facility was dealing with serious contamination issues in its hydraulic systems. The system did not meet the necessary cleanliness standards despite numerous attempts at flushing. Using its High Velocity Flushing (HVF) solution, Minimac Systems successfully removed embedded and loose contaminants.

Key Metrics:

• Achieved NAS 1638 Class 6 cleanliness.
• Systems were successfully cleaned up to 100 mesh.
• Reduced commissioning delays and risk of premature component failure.

Introduction

About Minimac Systems:

Minimac Systems offers advanced solutions for oil flushing, filtration, and contamination control for critical industrial applications across the defence, power, and heavy engineering sectors.

Client Profile:

• Sector: Defence
• Location: Kochi, Kerala, India
• Application: Commissioning hydraulic systems for equipment that is essential to the mission.
• Operational Requirement: Extremely high oil cleanliness to meet defence-grade reliability, safety, and performance standards across critical systems.

The Challenges

Problem Statement:

During system commissioning, the client encountered severe oil contamination issues. Conventional flushing methods were unable to remove fine and adhered particles from the hydraulic lines, posing a serious risk to system reliability.

Impact of the Problem:

• Failure to achieve the required NAS 1638 cleanliness levels
• Risk of valve sticking, pump wear, and system malfunction
• Potential delays in commissioning and operational readiness
• Increased concern from engineers due to defence compliance requirements

Engineering Analysis & Observations

Detailed oil and particle analysis revealed:

• Contamination levels exceeding acceptable limits.
• Presence of particles larger than 100 mesh.
• The cleanliness requirement is defined by the NAS 1638 standards.
• The engineering team concluded that standard flushing velocity was insufficient to dislodge embedded contaminants from pipe walls and bends.

The Solution

Minimac Systems’ Approach:

Minimac Systems deployed its High Velocity Oil Flushing Systems methodology, designed specifically for critical systems where standard flushing fails.

Solution Highlights:

• High flow rates are required to achieve turbulent flow.
• Mechanical removal of loose and embedded contaminants.
• Continuous monitoring of cleanliness levels.
• Controlled flushing cycles to protect system components.

Product & Technology Used:

• High-Velocity Oil Flushing System.
• Advanced filtration and monitoring tools.
• Cleanliness validation as per NAS 1638 standards.

Results

Quantitative Outcomes:

Qualitative Outcomes:

• Improved confidence among client engineers.
• Reduced risk of early component failure.
• Enhanced system reliability and lifecycle performance.

Conclusion

Summary of Benefits:

This case study demonstrates how Minimac Systems' High Velocity Oil Flushing effectively resolves severe contamination challenges in the defense sector's hydraulic systems. By achieving NAS 1638 Class 6 cleanliness, the client ensured operational reliability, compliance, and long-term system protection.

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