
Hydraulic equipment and systems are composed of multiple intricate components that make them vulnerable to several opportunities for errors.
Regardless of whether mistakes are related to filters, or the type of hydraulic fluid selected, they can have a negative impact on operations.
Errors in judgement and poor decision making can have serious consequences including hiking costs, reducing productivity, increased maintenance, mechanical downtime and accelerated wear and tear on system parts.
To help hydraulic equipment users avoid such issues, here we outline some of the common pitfalls that can occur and their effects.
Utilising the wrong hydraulic fluid
Perhaps the most commonplace hydraulic equipment error is employing the wrong type of hydraulic fluids.
Built for purpose, hydraulic oils perform multiple roles in systems. They lubricate equipment while preventing corrosion and oxidation, but also transfer power.
It is critical that users deploy a hydraulic fluid that has appropriate viscosity, to prevent issues from increased friction and high operating temperatures that lead to system damage and total failure. The incorrect oil in play can also result in greater power use, at the considerable cost to a company.
Operators must read the original equipment manufacturer (OEM) recommendations, but should also carry out research of their own, supported by an expert consultation to find the best product for the hydraulic system in their care. Checking hydraulic fluid viscosity index is also crucial.
When the viscosity of a hydraulic fluid solution is too high, several potential problems raise their head. Premature wear is the first issue, as the high viscosity fluid does not lubricate the hydraulic system components adequately.
Furthermore, when parts aren’t lubricated sufficiently due to excessive fluid viscosity, more friction is present. This forces the hydraulic system to demand more power to carry out its role effectively. In turn, system efficiency is greatly reduced, and operations lose time and incur higher running costs.
A hydraulic oil with a viscosity that is too low can also result in multiple problems. Ultimately, contamination will occur, which cuts system efficiency and accelerates wear.
Furthermore, components lack proper protection during system operations. This will inevitably lead to exaggerated wear and in worst cases result in vital components, like pumps and motors failing long before their projected lifespan.
Incorrect hydraulic fluid changes
Just when users should change over hydraulic fluid is a crucial decision, but a prevalent mistake is to action changes at an inappropriate time. This can increase the threat of contamination but also result in higher costs for companies.
Changes typically occur when the hydraulic fluid’s base oil starts to break down, or when its additives become depleted. However, no fixed interval exists at which such situations happen. Users must therefore base it on analysis of the fluid’s condition and hours of service.
When hydraulic oil is well-maintained, it can have a long lifespan that extends even beyond manufacturer recommendations laid out in system manuals.
Prematurely changing over hydraulic fluids is both wasteful and uneconomical. However, changing hydraulic fluids too late is also a mistake that can compromise the functionality and life expectancy of equipment.
Oil analysis is a valuable tool to work out when a fluid’s additive package has become depleted. Water, excessive heat and contaminants are common reasons for oil becoming premature. To mitigate deterioration and extend change intervals, operators must monitor particulate levels, excessive oxidation, water saturation levels, system heat and additive depletion.
Filter changes
Similar to the issue regarding oil changes, fluid filters removed and replaced at the incorrect times is another common error.
When filter changes are unnecessary, they are wasteful. This is because the filter’s full capacity has not yet been used, costing operations more money. Perhaps more importantly, when filters are not changed frequently enough, this negligence can inflict harm on hydraulic equipment, as the fluid circulating will soon become contaminated.
When oil filters are not changed in time, clogging will commonly occur. This results in hydraulic fluid bypass, where oils can circumnavigate the filter in which they can’t freely pass through.
With nothing now stopping unwanted contaminants and particles from entering the hydraulic system, this can lead to prolonged negative consequences.
Dangerous contaminants can wear and degrade parts of the hydraulic equipment, lowering system efficiency and, in extreme cases, cause total system failure.
To avoid this unwanted and expensive mistake, the best practices are to monitor both drops in system pressure and flow restriction. These actions can prevent slow or unpredictable operations occurring by accurately determining when a filter change is imperative.
Fitting filters in the incorrect place
Hydraulic equipment filters have an important job to perform, but not all locations for filters represent a safe place. As a result, users should be aware that fitting a filter in the wrong place can have serious consequences.
Hydraulic fluid filters are designed to protect systems, but to safeguard components efficiently, operators should avoid two sites within the system. These include pump inlets but also drain lines from the dedicated housings for motors and piston pumps.
Placing filters by pump inlets is not necessary, as the system reservoir is unlikely to be contaminated. Furthermore, adding filters can restrict intake. This restriction inhibits the pumping chambers from becoming full and can decrease the active service life of the pumps, gear pumps and piston motors.
Filters fitted at drain lines running from a motor or piston pump can also lead to issues, but ultimately, the same consequences of reduced life expectancy and system failure will occur.
Poor placement of filters is an expensive error to make, as operations will need to spend substantial sums on repairs and replacement parts while covering the cost of operational downtime and loss of output.
Operating equipment at high temperatures
Hydraulic equipment operators will typically cease operating engines that start overheating. However, continuing operations under such circumstances is a serious mistake.
When a system reaches temperatures that are too high, equipment components within will begin to break down.
Operating a system that is overheated is often fatal for the usability of equipment. As the system temperature rises, the hydraulic oil’s viscosity starts to decrease, and the fluid cannot supply sufficient lubrication. As a result, metal components make contact with other metal components, causing contamination and wear, and harming the hydraulic system’s overall functionality.
Hydraulic systems use cooling circuit components to effectively dissipate heat. However, when heat in the system exceeds the safe minimum service temperature, (typically around 82°C), parts like hoses and seals can fail before their time, and system oil deteriorates far faster.
When a system overheats, it usually indicates problems occurring that require immediate attention from operators. A severe mistake is to ignore overheating equipment, as it will not only inflict damage, but mean that users have overlooked other issues happening in the hydraulic system that require attention.
Inadequate education of operators
Equipment operators must understand that hydraulic components don’t self-prime or self-lubricate.
When operators don’t properly prepare and follow all necessary steps before they start the hydraulic equipment, there is a serious risk of harm that can impact system function and efficiency, costing companies both money and time.
Just being aware of risks isn’t enough if operators don’t remember to act. Educate your operators to carry out checks when filling pump housings with hydraulic fluids and to open intake isolation valves, as these are vital steps that require completion. They can ensure equipment is fully functional and prevent damage while maintaining the best system performance possible.
It’s understood that expertise with hydraulic equipment and identifying potential issues that arise comes with quality training and years’ worth of experience. Hydraulic equipment maintenance practices are always evolving, so companies must ensure their team’s knowledge and skills are always current. Participating in seminars, reading the latest training materials and encouraging operators to do the same is essential.
To conclude, remember that understanding these potential errors and the long-lasting negative impact they can have on your operation is key to avoiding them.