Executive Summary

Miniamc Systems successfully executed an essential internal tank cleaning and online oil filtration project at the , Torrent Power site in Surat, achieving the targeted NAS 5 oil cleanliness level with safety incidents and full compliance with client-defined requirements.

The project involved handling 28,000 liters of lubricating oil from a 40 KL tank, removal of accumulated sludge and contaminants, and continuous online filtration under confined-space and high-safety conditions. Using Minimac’s Contamination Removal Skid (FS-50-2S-H-V) and the MLC-LVDH-50-2S system, the job was completed on schedule and formally accepted by the client.

Introduction

Minimac Systems is a specialized engineering solutions provider focused on oil contamination control, lubrication system reliability, tank cleaning, and online filtration services for critical industrial assets. The company supports power plants, OEMs, and EPCs in improving equipment life, operational safety, and maintenance efficiency.

This case study highlights Minimac’s capability to deliver technically precise, safety-intensive, and result-driven oil cleanliness solutions for power-sector applications.

Client Profile

• Industry: Power Generation
• Project Location: Torrent Power, Akhakhol, Surat, Gujarat
• Tank Capacity: 40 KL
• Oil Volume Processed: 28,000 Liters
• Project Type: Internal Tank Cleaning & Online Oil Filtration.
• Executed By: Minimac Systems Pvt. Ltd.
• Project Status: Successfully Completed.

The Challenge

Before MINIMAC’s engagement, the lubricating oil tank exhibited:

• Accumulation of sludge and settled contaminants.
• Degraded oil cleanliness beyond acceptable NAS limits.
• Presence of moisture that could accelerate oil degradation.
• High safety sensitivity due to confined space entry and live plant conditions.

The client required:

• Restoration of oil cleanliness to NAS 5 (NAS 1638).
• Moisture levels below 500 PPM.
• Safe execution with zero incidents.
• Minimal disruption to ongoing operations.

Failure to address these issues posed a risk to equipment reliability, asset life, and plant availability.

The Solution

Minimac Systems designed and executed a structured, safety-driven solution, aligned with approved method statements and international safety standards.

Scope of Work Executed

• Oil transfer from the main tank to a temporary tank.
• Complete tank isolation using Lockout–Tagout (LOTO).
• Internal tank cleaning and removal of sludge and residues.
• Collection, handling, and statutory disposal of waste.
• Re-transfer of oil to the main tank.
• Continuous online filtration until target cleanliness is achieved.
• Final inspection and client handover.

Equipment Deployed

• Contamination Removal Skid: FS-50-2S-H-V.
• Online Filtration System: MLC-LVDH-50-2S.

Execution & Safety Compliance

The project was executed under strict safety governance, including:

• Work Permit System and daily Job Safety Analysis (JSA).
• Confined Space Entry Procedures.
• Continuous gas monitoring.
• The standby rescue team is deployed at the site.
• Mandatory PPE compliance.
• Daily toolbox talks.

All activities were carried out in compliance with:

• OHSAS 18001:2007 – Occupational Health & Safety.
• ISO 14001:2015 – Environmental Management Systems.

Results Achieved

Performance Metrics

Additional Project Details

• Oil Cleanliness Standard: All measurements and acceptance criteria were evaluated as per the NAS 1638 standard.
• Tank Capacity: Internal tank cleaning was carried out on a 40 KL lubricating oil tank.
• Safety Performance: The entire project was executed with zero safety incidents and zero reportable cases.
• Project Duration: The work was successfully completed within the planned schedule, from 22 January 2026 to 03 February 2026.

Outcome Summary

• Oil cleanliness restored to NAS 5, exceeding acceptance criteria
• Moisture content was reduced well below the specified limits
• Tank handed over in ready-to-use condition
• Zero accidents and zero reportable incidents
• No safety violations observed
• Minimal impact on client operations

All results were verified, inspected, and formally accepted by power industries. A Work Completion Certificate was issued confirming satisfactory execution.

Conclusion

This project demonstrates Minimac Systems’ ability to execute complex, safety-critical tank cleaning and online filtration projects for the power sector. The successful achievement of NAS 5 oil cleanliness, combined with disciplined safety execution and environmental compliance, reinforces Minimac’s position as a trusted partner for OEMs, EPCs, and power utilities.

Minimac Systems continues to deliver measurable improvements in oil quality, equipment reliability, and operational confidence across critical industrial applications.