How does multi-stage filtration work in the hydraulic flushing system?

The Neometrix hydraulic flushing system uses multi-stage filtration to progressively remove contaminants of varying sizes from hydraulic fluid: booster-line filters at 10, 6, and 3 microns, a pressure-line filter at 3 microns, and a return-line filter at 10 microns, plus a 40-micron breather filter on the reservoir. Differential pressure / clogging indicators on each stage let operators monitor filter health and ensure timely replacement.

NMX‑HFR‑140 / Rev 01 / NAS 1638 · ISO 4406 · MIL-STD / Noida · India 2026 · Product Page

NMX-HFR-140

Turbulent‑flow flushing to NAS 6 clean.

Skid-mounted, dual-pump hydraulic flushing rig for defence, aerospace, oil & gas and industrial hydraulic systems. Multi-stage filtration down to 3 microns, up to 140 LPM at 350 bar, and a 600‑litre SS-304 reservoir — engineered to remove contaminants and verify cleanliness before a new system is ever put into service.

Request proposal Filtration system

Hydraulic Flushing Rig by Neometrix — skid-mounted multi-stage filtration system for defence, aerospace and industrial hydraulic systems

Fig · 01 Complete flushing-rig assembly — electrical & mechanical control panels, pump bay below

Qualification testing supported to:

DEF STAN STANAG MIL-SPEC

Max.Flow

140LPM

Max.Pressure

350bar

Reservoir

600L

Cleanliness

NAS6

Cooling

21.5kW

Overview

Contamination is the enemy of every hydraulic system.

Particles, moisture and sludge left behind after fabrication and installation are one of the leading causes of premature wear and failure in hydraulic circuits. Flushing a new system properly — before it is ever put into service — is what stands between a smooth commissioning and an expensive early breakdown.

Hydraulic Flushing Rig assembly with electrical and mechanical control panels for defence and industrial hydraulic circuits

Fig · 02 Control panel detail — pressure & temperature DROs, pump start/stop, emergency stop

The Hydraulic Flushing Rig by Neometrix is an advanced industrial system designed for thorough cleaning and maintenance of hydraulic pipelines and systems. It removes contaminants to ensure optimal equipment performance and longevity, using multi-stage filtration, a high-capacity reservoir, advanced control panels, and an integrated cooling circuit to meet stringent cleanliness standards.

The rig creates high flow combined with high pressure, generating a turbulent flow in the pipework under test — the mechanism that actually dislodges contamination from pipe walls and internal surfaces, rather than simply passing fluid through at low velocity. That makes it suitable for defence, aerospace, power plants, oil & gas, and heavy machinery applications alike.

By flushing a new hydraulic system before bringing it into operation, expensive breakdowns are avoided.

Its robust skid-mounted construction, safety interlocks, and user-friendly control panels make it a reliable solution for critical hydraulic applications — portable enough for field use, and rugged enough for continuous workshop duty.

Architecture

A dual‑pump circuit, built to purge.

A variable-displacement main pump and a fixed-displacement booster pump work in tandem — the booster establishes high-volume turbulent flow, the main pump holds working pressure — while multi-stage filtration and an air-cooled circuit keep the fluid clean and within its temperature window throughout the flushing cycle.

Sub · 01

Main Variable Pump

Variable displacement pump, 71 cc/rev, 350 bar max. working pressure — up to 140 LPM at reduced pressure, 35 LPM at max. pressure. Driven by a 30 kW three-phase induction motor.

Sub · 02

Booster Pump

Fixed displacement pump delivering up to 200 LPM at 10 bar, driven by a 5.5 kW three-phase induction motor — establishes the high-volume turbulent flow that dislodges contamination.

Sub · 03

Multi-Stage Filtration

Booster-line filters at 10, 6 and 3 microns, a 3-micron pressure-line filter, a 10-micron return-line filter, and a 40-micron reservoir breather — each with clogging indicators.

Sub · 04

Cooling & Monitoring

Air-cooled circuit (2 HP fan motor, 21.5 kW cooling capacity at 140 LPM) holds fluid below 60°C, monitored through microcontroller-based digital readouts (DRO).

Filtration System

Six filter stages, 3 microns and finer.

Every litre of fluid passes through a staged sequence of filters before it is considered clean — coarse elements catch bulk debris first, progressively finer elements strip out micron-level particles, and clogging indicators tell the operator exactly when an element needs replacing.

FS · 01 | Booster Line

Stage 1 — 10 Micron

First-stage element on the booster line, removing bulk contamination before fluid reaches the finer stages.

Coarse Stage · Visual Clogging Indicator

FS · 02 | Booster Line

Stage 2 — 6 Micron

Second-stage booster-line element, progressively reducing particle size ahead of final filtration.

Intermediate Stage

FS · 03 | Booster Line

Stage 3 — 3 Micron

Final booster-line stage, capturing fine particulate before the flow enters the pressure circuit.

Fine Stage · Electrical Clogging Indicator

FS · 04 | Pressure Line

Pressure Line Filter — 3 Micron

Guards downstream equipment and the test circuit from any contamination generated within the pump and pressure line itself.

Downstream Protection

FS · 05 | Return Line

Return Line Filter — 10 Micron

Filters fluid as it returns from the system under flush, before it re-enters the reservoir for recirculation.

Recirculation Protection

FS · 06 | Reservoir

Breather Filter — 40 Micron

Filters air drawn into the SS-304 reservoir as fluid level changes, preventing airborne contaminants from re-entering the system.

Reservoir Protection

Hydraulic Flushing Rig control panel and pump bay showing multi-stage filtration circuit and gauges

Fig · 03 Pump bay detail — main variable-displacement pump, booster pump, and pipework routing beneath the control panels

Control & Reservoir

Instrumented for real-time traceability.

An electrical panel and a mechanical panel give the operator direct control over the flushing cycle, while a corrosion-resistant SS-304 reservoir keeps the working fluid conditioned between passes.

Hydraulic Flushing Rig electrical and mechanical control panel with pressure gauges, DRO displays and pump switches

Fig · 04 Electrical panel — pressure, temperature, flow, oil-level and clogging indicators, with independent booster / main pump start-stop

The electrical panel carries indicators for pressure, temperature, flow, oil level, operating hours and clogging status, an emergency stop switch, and independent start / stop controls for the booster and main pumps. The mechanical panel adds pressure gauges for the booster, supply and return lines, plus needle valves for precise flow and pressure adjustment.

Microcontroller-based digital readouts (DRO) display real-time pressure, temperature and flow data with high accuracy, letting operators confirm cleanliness progress without relying on analogue gauges alone.

The reservoir is built in corrosion-resistant SS-304 stainless steel with a 600-litre capacity, and includes a level indicator, a temperature gauge, and a 40-micron breather filter to keep the fluid uncontaminated during operation. The whole rig sits on a welded steel skid frame with forklift slots and lifting hooks, making it straightforward to transport and position even in confined industrial spaces.

Watch

The rig in operation.

A walk-through of the Hydraulic Flushing Rig running a live flushing cycle — pump start-up, control panel operation, and the turbulent flow circuit at work.

What you'll see

Booster and main pump start-up sequence on the control panel
Live pressure, temperature and flow readouts during a flushing pass
Turbulent-flow circulation through the instrumented pipework
Multi-stage filtration housings and clogging indicators in context

For a guided in-person demonstration or factory acceptance test at our Noida facility, get in touch through the proposal request below.

Gallery

The rig, on the shop floor.

The complete assembly and control-panel detail — photographed at the Neometrix workshop.

Hydraulic Flushing Rig — complete assembly, electrical and mechanical control panels, pump bay below

Hydraulic Flushing Rig — angled view of control panel and pump enclosure

Hydraulic Flushing Rig — front view showing pressure gauges and DRO displays

Hydraulic Flushing Rig — angled view of electrical and mechanical control panels

Downloads

Catalog & GA drawings.

General catalog and general-arrangement drawings for the Hydraulic Flushing Rig, ready for your engineering and procurement teams.

Specifications

Full technical parameters.

Key system parameters for the standard NMX-HFR-140 configuration. Custom flow rates, filtration stages and mobility configurations are available on request.

System Type	Hydraulic Flushing Rig — Multi-Stage Filtration, Turbulent-Flow Cleaning System
Model Reference	NMX-HFR-140
Working Fluid	Hydraulic oil
Cleanliness Level Achieved	NAS 6 · Verified to ISO 4406 / NAS 1638 methods
Max. Operating Pressure	350 bar (350 kgf/cm²)
Main Pump	Variable displacement, 71 cc/rev · up to 140 LPM at reduced pressure, 35 LPM at max. pressure
Booster Pump	Fixed displacement · up to 200 LPM at 10 bar
Drive Motors	30 kW (main pump) + 5.5 kW (booster pump) · three-phase induction motors
Filtration — Booster Line	3-stage: 10 / 6 / 3 micron elements, visual & electrical clogging indicators
Filtration — Pressure Line	3 micron element
Filtration — Return Line	10 micron element
Breather Filter	40 micron, fitted to reservoir
Reservoir	SS-304 stainless steel, 600 L capacity · level & temperature indicators
Fluid Temperature Range	Max. 60°C, maintained by the air-cooled cooling circuit
Cooling System	Air-cooled, 2 HP fan motor · 21.5 kW cooling capacity at 140 LPM
Overall Dimensions (L×W×H)	1500 × 1100 × 1400 mm
Weight	~1100 kg
Electrical Supply	3-phase, 37.5 kW connected load, 50 Hz
Control & Monitoring	Electrical panel (pressure / temp / flow / oil-level / hour-meter / clogging indicators, E-stop) · mechanical panel (gauges & needle valves) · microcontroller-based DRO
Frame	Welded steel skid with forklift slots and lifting hooks · portable / skid-mounted
Safety Features	Emergency stop · low oil-level cut-off · over-temperature protection · pressure relief & unloading valves
Compliance	NAS 1638 · ISO 4406 · MIL-STD & customer-specified defence / aerospace requirements

Applications

Where it runs.

Defence, aerospace, oil & gas, power generation and heavy engineering — anywhere a hydraulic system needs to be verified clean before it goes into service.

A · 01Pre-commissioning flushing of new hydraulic pipelines and systems

A · 02Defence hydraulic system cleaning and cleanliness certification

A · 03Aerospace and aviation hydraulic circuit flushing

A · 04Oil & gas hydraulic system contamination control

A · 05Power plant turbine and cooling-circuit hydraulic maintenance

A · 06Heavy machinery and industrial equipment maintenance

A · 07Automotive and railway hydraulic system servicing

A · 08Precision equipment flushing ahead of critical operation

A · 09Field and workshop hydraulic system maintenance

A · 10Quality-assurance sampling and particle-count verification before handover

In Depth

The complete technical read.

Engineering narrative for maintenance engineers, QA managers and procurement teams who want the complete picture before specifying a flushing programme.

Why hydraulic flushing matters

The Hydraulic Flushing Rig is an advanced, industrial-grade system designed to meet the rigorous demands of hydraulic system cleaning and maintenance. It provides a robust and efficient solution for flushing pipelines and hydraulic systems by eliminating contaminants that may cause damage, inefficiency, or premature equipment failure. Engineered with precision, the rig ensures compliance with NAS, ISO, and MIL-STD cleanliness standards, making it suitable for aerospace, automotive, defence, energy, and heavy-machinery applications.

State-of-the-art flushing process

The rig employs a high-turbulence flow mechanism to dislodge and carry contaminants out of the hydraulic system. Continuous fluid recirculation with integrated filtration ensures consistent, measurable cleanliness levels, verified through NAS / ISO cleanliness codes at micrometer-level precision.

Sophisticated multi-stage filtration

Booster line filters at 10, 6 and 3 microns, a pressure-line filter at 3 microns, and a return-line filter at 10 microns.
Each filter has visual and electrical clogging indicators to notify the operator when replacement is required.
Eliminates even the finest contaminants, protecting downstream equipment.

High-capacity hydraulic reservoir

Constructed from corrosion-resistant SS-304 stainless steel with a 600-litre capacity. Features a level indicator, temperature gauge, and a 40-micron breather filter to keep fluid uncontaminated during operation.

Dual motor pumping system

Variable Displacement Pump

Maximum working pressure: 350 bar.
Displacement: 71 cc/rev.
Flow capacity: up to 140 LPM at reduced pressure, 35 LPM at maximum pressure.

Booster Pump

Fixed displacement pump with a maximum flow of 200 LPM at a pressure of 10 bar.

Both pumps are driven by high-efficiency three-phase induction motors (5.5 kW and 30 kW), ensuring continuous-duty performance.

Advanced monitoring and control panels

Electrical panel: indicators for pressure, temperature, flow, oil level, operating hours, and clogging status, plus an emergency stop switch and independent start/stop controls for booster and main pumps.
Mechanical panel: pressure gauges for booster, supply, and return lines, and needle valves for precise flow and pressure adjustment.
DRO systems: microcontroller-based digital readouts display real-time pressure, temperature, and flow data with high accuracy.

Integrated cooling system

An air-cooled system with a 2 HP motor keeps the hydraulic fluid below 60°C even under heavy-duty operation, with a cooling performance of 21.5 kW at 140 LPM for optimal temperature management during extended runs.

Robust and portable design

Built on a welded skid frame of reinforced steel with forklift slots and lifting hooks for easy transportation. Compact dimensions (1500 × 1100 × 1400 mm, ~1100 kg) make it suitable for deployment in confined industrial spaces.

Safety and reliability

Interlocks including emergency stop push-buttons, low oil-level cut-off switches, and over-temperature protection.
Pressure relief and unloading valves safeguard the system against overpressure conditions.
Automatic shutdown protocols activate when faults are detected, protecting both the rig and the operator.

Applications

Pipeline cleaning — ensures hydraulic pipes are free of contaminants post-installation or maintenance.
Industrial equipment maintenance — maintains cleanliness in hydraulic systems used in heavy machinery and manufacturing plants.
Precision equipment flushing — guarantees contamination-free operation in aerospace and defence systems.
Power plant maintenance — suitable for hydraulic circuits in turbines and cooling systems.

Included tools and accessories

Comprehensive spanner and Allen key sets for system assembly and maintenance.
Full-scale hydraulic and electrical circuit diagrams for troubleshooting and training.
Sampling ports and QCDC (Quick Connect-Disconnect Couplings) for fluid testing.

Why choose Neometrix's Hydraulic Flushing Rig

Reliability	Engineered for long-term durability with corrosion-resistant materials and industrial-grade components.
Performance	High flow and pressure capacities ensure fast, thorough flushing for demanding applications.
Ease of use	User-friendly interface with labeled controls and indicators.
Support	Detailed operation manuals, troubleshooting guides, and warranty coverage.

Enhance hydraulic system cleanliness and performance by integrating this rig with our Hydraulic Power Pack 230 LPM 210 Bar, which delivers the high-flow, high-pressure hydraulic energy required for effective flushing and contamination removal in demanding applications.

For aerospace-grade servicing and fluid-charging operations, the Universal Hydraulic Charging Rig complements this system by enabling precise filling, topping, and conditioning of hydraulic systems after flushing.

In field or on-site maintenance scenarios, our Mobile Hydraulic Flushing Rig provides flexibility and portability, allowing efficient flushing and cleaning of hydraulic circuits directly at operational locations.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is a Hydraulic Flushing Rig and why is it important?

A hydraulic flushing rig is a specialized hydraulic flushing system designed to clean internal surfaces of pipelines, hydraulic circuits, and components by circulating fluid at controlled flow rates and pressures. It is critical because contamination such as particles, moisture, and sludge can severely impact system efficiency, cause premature wear, and lead to catastrophic failures in high-performance systems. The Neometrix Hydraulic Flushing Rig ensures removal of contaminants through high-velocity turbulent flow, helping achieve required cleanliness standards before commissioning.

Q · 02 What cleanliness standards does the Neometrix Hydraulic Flushing Rig meet?

The rig is designed to meet stringent hydraulic flushing cleanliness standards such as ISO 4406, NAS 1638, and customer-specific defence and aerospace requirements, achieving an NAS 6 cleanliness level on the standard configuration. Cleanliness is monitored using particle counters and sampling ports, ensuring compliance before system handover.

Q · 03 How does multi-stage filtration work in this hydraulic flushing system?

The system uses multi-stage filtration to progressively remove contaminants of varying sizes: booster-line filters at 10, 6 and 3 microns, a pressure-line filter at 3 microns, a return-line filter at 10 microns, and a 40-micron breather filter on the reservoir. Differential-pressure / clogging indicators on each stage let operators monitor filter health and ensure timely replacement.

Q · 04 Is the Hydraulic Flushing Rig suitable for Defence and aerospace applications?

Yes. The rig is engineered for defence and aerospace flushing applications where precision, reliability, and cleanliness are critical, and is capable of handling high-pressure hydraulic circuits used in aircraft, missile systems, and ground support equipment. It can also be customized for field deployment or workshop use.

Q · 05 What is the maximum flow rate and tank capacity?

The standard configuration delivers up to 140 LPM from the variable-displacement main pump (up to 200 LPM from the booster pump) at a maximum working pressure of 350 bar, with a 600-litre SS-304 stainless steel reservoir. High flow rates are essential to dislodge contaminants from pipe walls during turbulent-flow flushing.

Q · 06 How long does a typical hydraulic flushing process take?

Duration depends on system size, contamination level, and the required cleanliness standard, typically ranging from several hours to a few days for complex systems. Continuous monitoring of contamination levels ensures flushing continues only as long as necessary, and multiple cycles may be required for heavily contaminated systems.

Q · 07 Can the rig handle different types of hydraulic fluids?

Yes. The rig is compatible with a wide range of hydraulic fluids, including mineral oils, synthetic fluids, and specialized aerospace-grade hydraulic oils. Component and seal materials are selected to ensure chemical compatibility and safe operation across fluid types.

Q · 08 What control and monitoring features are included?

The rig includes an electrical panel (pressure, temperature, flow, oil-level, operating-hour and clogging indicators, plus an emergency stop) and a mechanical panel (pressure gauges and needle valves for booster, supply and return lines), together with microcontroller-based digital readouts (DRO) for real-time data.

Q · 09 Can the Hydraulic Flushing Rig be customized for specific applications?

Yes, the rig can be fully customized — flow rate, tank capacity, filtration stages, control systems, and mobility configuration can all be tailored to specific industries such as aerospace, defence, or heavy industrial applications.

Q · 10 How does the Hydraulic Flushing Rig improve system reliability?

By removing contaminants that cause wear, blockages, and component failure before a hydraulic system is commissioned, the rig ensures systems start their lifecycle in optimal condition. This reduces the risk of unexpected failures, lowers maintenance costs, and extends equipment life through verified, repeatable cleaning performance.

↗

Other hydraulic systems from Neometrix.

Complementary hydraulic power, charging and flushing systems engineered and manufactured at our Noida facility.

↗ Power Pack

Tell us your flow rate
and cleanliness target.

We size the flushing circuit, propose a filtration configuration, and walk through the acceptance criteria with your engineering team before you commit.

Request proposal +91 7777 876 876

Turbulent‑flow flushing to NAS 6 clean.

Contamination is the enemy of every hydraulic system.

A dual‑pump circuit, built to purge.

Main Variable Pump

Booster Pump

Multi-Stage Filtration

Cooling & Monitoring

Six filter stages, 3 microns and finer.

Stage 1 — 10 Micron

Stage 2 — 6 Micron

Stage 3 — 3 Micron

Pressure Line Filter — 3 Micron

Return Line Filter — 10 Micron

Breather Filter — 40 Micron

Instrumented for real-time traceability.

The rig in operation.

What you'll see

The rig, on the shop floor.

Catalog & GA drawings.

Full technical parameters.

Where it runs.

The complete technical read.

Why hydraulic flushing matters

State-of-the-art flushing process

Sophisticated multi-stage filtration

High-capacity hydraulic reservoir

Dual motor pumping system

Advanced monitoring and control panels

Integrated cooling system

Robust and portable design

Safety and reliability

Applications

Included tools and accessories

Why choose Neometrix's Hydraulic Flushing Rig

Complementary Neometrix systems

Common questions.

Other hydraulic systems from Neometrix.

Hydraulic Power Pack 230 LPM 210 Bar

Universal Hydraulic Charging Rig

Mobile Hydraulic Flushing Rig

Tell us your flow rateand cleanliness target.

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