ZERO HOUR
Zero Hour Certified Cooling System Program – Comprehensive Executive Summary
The Zero Hour Certified Cooling System Program by Ultimate Chemicals is a performance-driven protocol designed to restore industrial engine cooling systems to 'Zero Hour'—the moment of factory-fresh cleanliness, function, and reliability. This program integrates advanced diagnostics, targeted chemical flushes, and seasonal optimization to prevent overheating, lower emissions, and extend engine life.
Step 1: External Cleaning
The process begins with external cleaning using CC300 Cooler Cleaner and B.A.D. (Bad Ass Degreaser). CC300 removes built-up dirt, dust, and debris from fin-fan coolers, while B.A.D. is applied to clean the entire engine skid and surrounding surfaces. A single millimeter of dirt on radiator fins can reduce efficiency by over 10%. Keeping the exterior clean maximizes ambient heat dissipation.
Step 2: Enhanced Diagnostic Insight
The Enhanced Coolant Analysis (ECA), developed in partnership with Lab One, provides a forensic-level look into the condition of the coolant. This includes tracking silicate dropout, pH levels, rust particles, and other contaminants. Results from ECA determine which Royal Flush treatment to deploy, based on contamination type. Quarterly testing is recommended and aligns with Gas Machinery Research Council (GMRC) best practices.
Step 3: Targeted Chemical Flush (The Royal Flush Program)
The Royal Flush Program is a series of specialized flushes, each represented by a card in the spade family, formulated to treat specific types of internal cooling system contamination:
• HDF – Heavy Duty Flush (Ace of Spades): Dissolves burnt glycol ('The Black Death').
• PMF – Preventive Maintenance Flush (King of Spades): For routine system maintenance and moderate fouling.
• PO4 Fix – Phosphate Flush (Queen of Spades): Eliminates phosphate buildup from improper cleaning agents and rust.
• RRF – Rust Removal Flush (Jack of Spades): Dissolves internal rust, restoring flow and efficiency.
• OCF – Oil Contamination Flush (Ten of Spades): Cleans emulsified oil-coolant contamination after a breach.
Step 4: System Refill and CRI - Corrosion Rust Inhibitor
After flushing, the system is filled with clean water or a 50/50 coolant mix. In cold weather environments, CRI (Corrosion Rust Inhibitor) is added to the mix to maintain a 99% rust-free environment and prevent corrosion-related failures.
Step 5: Seasonal Optimization with CoolAint Summerize
CoolAint Summerize is a non-glycol coolant alternative designed for hot weather performance. It reduces outlet temperatures by up to 20° Fahrenheit, lowers emissions, and prevents unit derating in the summer. It contains rust inhibitors and cleaning properties that keep the system performing at peak levels, especially in non-freezing climates.
The Outcome: Zero Hour Certification
Once a system has gone through the full program—external cleaning, analysis, flush treatment, refill with rust inhibitors, and seasonal optimization—it is considered Zero Hour Certified. This status signifies that the system has been restored to peak heat transfer performance, emissions are minimized, and the engine is protected against derating and thermal damage.
Why It Matters
Engines that operate with compromised cooling systems are more likely to overheat, reduce output, and fail prematurely. With regulatory pressure to reduce emissions and push more gas through midstream operations, maintaining an efficient cooling system is no longer optional—it’s a competitive advantage. The Zero Hour Certified Cooling System Program is your insurance against unplanned downtime, derating, and compliance issues.
“ZERO HOUR” in industrial engine maintenance refers to the condition of a system or component being fully restored to its original, factory-like performance specifications. This concept is inspired by aviation and military terminology, where “zero hour” signifies a complete reset or overhaul to ensure the equipment operates as if it were brand new.
1. Cleanliness: All contaminants such as rust, scale, oil residues, and burnt glycol are completely removed.
2. Efficiency: The cooling system is functioning at optimal heat transfer efficiency, free from blockages or inhibitors that reduce performance.
3. System Integrity: Any worn or damaged parts are replaced or repaired, ensuring that the system is structurally sound.
4. Chemical Balance: The coolant chemistry is perfectly balanced, with proper pH, inhibitor levels, and no harmful contaminants.
5. Preventive Readiness: Proactive measures are in place to maintain ZERO HOUR conditions, reducing the risk of future breakdowns or inefficiencies.
This standard is essential in industrial maintenance as it minimizes downtime, maximizes system lifespan, and ensures the system operates reliably under demanding conditions.
Ultimate Chemicals’ solutions are designed to help systematically achieve and maintain ZERO HOUR in their cooling systems.
Steps to Achieve a “Zero Hour” Cooling System
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1. Preparation and System Assessment
• 1.1 Inspect the Cooling System
• Identify key problem areas such as rust, oil contamination, burnt glycol, phosphates, or scaling.
• Check for leaks, clogs, or compromised components.
• 1.2 Analyze the Coolant
• Use Enhanced Coolant Analysis (ECA) to assess the current coolant condition and contaminants present.
• Evaluate pH, glycol levels, and particulate contamination.
2. Draining the System
• 2.1 Shut Down the System
• Ensure the system is completely shut down and depressurized for safety.
• 2.2 Drain Existing Coolant
• Completely drain the old coolant from the system, including the reservoir, hoses, and radiators.
• 2.3 Flush Residual Liquids
• Use water or compressed air to remove as much leftover fluid as possible.
3. Initial Flush with HDF (Heavy Duty Flush)
• 3.1 Dissolve Burnt Glycol and Heavy Contaminants
• Use HDF, the Ace of Spades, to target burnt glycol, congealed deposits, and heavy carbon buildup.
• 3.2 Circulate the Flush
• Fill the system with a mixture of HDF and water, and run the system at operating temperature for the recommended time.
• 3.3 Drain and Rinse
• Drain the HDF solution and thoroughly rinse with clean water to remove all dissolved debris.
4. Targeted Flushes
• 4.1 Phosphate Removal with PO4 Fix
• Apply PO4 Fix (Phosphate Fix) to remove phosphate buildup and rust from systems where soaps or degreasers were previously used.
• Follow the same process: circulate, drain, and rinse.
• 4.2 Rust Removal with RRF (Rust Removal Flush)
• Use RRF to eliminate rust and corrosion deposits.
• 4.3 Oil Contamination Flush (OCF)
• If oil contamination is present, use OCF to dissolve and remove it effectively.
5. Preventive Cleaning
• 5.1 Preventive Maintenance Flush (PMF)
• Use PMF, the King of Spades, to remove minor dirt, silicate dropout, and carbon deposits while preventing future buildup.
• This can be included after the targeted flushes for a final cleanup.
6. System Integrity Check
• 6.1 Inspect the System
• Check for any remaining residue or contaminants.
• Inspect all components for wear, damage, or leaks after the cleaning process.
• 6.2 Rinse Thoroughly
• Conduct multiple rinses with clean water to ensure no chemical residue remains.
7. Refill with Fresh Coolant
• 7.1 Select the Right Coolant
• Use CoolAint Summerize (glycol-free coolant substitute) if preparing for hot climates.
• For other systems, refill with the manufacturer-recommended coolant.
• 7.2 Proper Dilution
• Mix coolant with distilled or deionized water as recommended.
• 7.3 Bleed the System
• Eliminate any air pockets by properly bleeding the cooling system.
8. Ongoing Maintenance
• 8.1 Regular Coolant Analysis
• Schedule periodic testing with ECA to monitor coolant quality.
• 8.2 Routine Flushing
• Perform regular flushes with PMF to prevent buildup and maintain performance.
• 8.3 Component Inspections
• Check hoses, radiators, and reservoirs during every maintenance cycle.
9. Documentation and Best Practices
• 9.1 Record the Process
• Document all flushing and cleaning steps for reference in future maintenance.
• 9.2 Train Technicians
• Ensure staff is trained on proper chemical application and handling procedures.
• 9.3 Follow Manufacturer Guidelines
• Always adhere to engine and system manufacturer recommendations.
Summary of Products Needed:
• HDF (Heavy Duty Flush): Burnt glycol and heavy contamination removal.
• PMF (Preventive Maintenance Flush): General preventive cleaning.
• PO4 Fix (Phosphate Fix): Phosphate and rust removal.
• RRF (Rust Removal Flush): Targeted rust cleanup.
• OCF (Oil Contamination Flush): Oil contamination removal.
• CoolAin’t Summerize: Glycol-free coolant substitute.
• ECA (Enhanced Coolant Analysis): Testing and monitoring.
By following these steps, the system will be restored to a “zero hour” condition, ensuring optimal performance and longevity. Let me know if you need detailed instructions for any specific step!