Maintenance of Hydraulic Systems

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Hydraulic Systems are very delicate systems, if contamination enters the systems failure will occur in the form of partial functional failure or total functional failure.

Training, education, and standardization is the only path to success. It is all about the "Failure Modes" and their causes.

This short assortment of slides provides recommended actions to solve these problems at the end.

Good Luck and God Speed.

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Maintenance of Hydraulic Systems

  1. 1. Maintenance of Hydraulic SystemsPresented by: Ricky Smith, CMRPMarch 2013 Copyright 2013 GPAllied©
  2. 2. “Maintenance” • To Maintain • Preserve, and Protect from Degradation Copyright 2013 GPAllied©
  3. 3. “Reliability” To meet the functional requirements of the end user – Pressure – Flow Copyright 2013 GPAllied©
  4. 4. Dr. Deming: “Your system is perfectly designed to give you the results you are getting.” Conveyor Hydraulic System MTBF 4 Copyright 2013 GPAllied©
  5. 5. Reliability – Production and Maintenance One Team – Same Goal Copyright 2013 GPAllied©
  6. 6. Hydraulic System Failures“It isn’t what you know that will kill you, it is what you don’t know that will” Copyright 2013 GPAllied©
  7. 7. #1 – “How Failures Occur in Hydraulics Systems” • Introduction of Contamination into the System – Valve stop functioning (Servo, Proportional, Direction, etc.) – System Pressure Fluctuating (dirt, silicon, water, etc.) – Low Pump Flow – Others? • Causes of Contamination – Hydraulic Fluid Introduced to the system – Changing Hydraulic Filters – Cleaning the inside of a Hydraulic Reservoir – Installation of new component (ie. Valve, Pump, etc.) – Hydraulic fitting leak – Heat Exchanger Replacement – Hyr – Others? Copyright 2013 GPAllied©
  8. 8. #2 - Root Cause of Hydraulic Failures • Lack of Knowledge – Basic Hydraulic Knowledge – Contamination Control – Hydraulic Maintenance Best Practices – Air Breather? • Inaccurate PM Procedures – Replace Hydraulic Filters? – Inspect Heat Exchanger? – Check for Leaks? • No Repeatable, Corrective Procedures with Specifications and Standards Copyright 2013 GPAllied©
  9. 9. Eliminate the Probability of a Hydraulic Failure Copyright 2013 GPAllied©
  10. 10. Known Best Maintenance Practices “Hydraulics” Copyright 2013 GPAllied©
  11. 11. Known Best Maintenance Practices/Hydraulics • Contamination Control is #1 – 25 Microns is the size of a white blood cell • 10 Microns? – Filter Oil in at all times with an External Filter Pump • Replace filter before use – Handle all hydraulic work as if it were Heart Surgery • Replacement of any component is Critical Work – Servo Valve – Directional Control Valve – Hydraulic Pump – Hydraulic Hoses • Some Components must be Prepped before Installation – Hydraulic Hoses – New Hydraulic Fluid Copyright 2013 GPAllied©
  12. 12. PM of a Hydraulic System (Best Practices) • What is Preventive Maintenance? – Clean (operator care) – Inspect (sensory, quantitative) (maintenance, operator care) – Adjust (maintenance) – Replenish (maintenance) – Rebuild (maintenance) – Replace (maintenance) • What are the expectations of Preventive Maintenance? – Failure Mitigation or Elimination! Copyright 2013 GPAllied©
  13. 13. PdM of Hydraulics Systems (Best Practices)• Expectations of PdM for Hydraulic System? – Early detection of a Defect “Early Detection is Key to Success” Copyright 2013 GPAllied©
  14. 14. Oil Analysis - Failure Modes Detected, (Best Practices) • Component Failure Modes • Lubricant Failure Modes – Compromised Seal – Oxidation – Bearing Fault – Nitration – Internal Pump Failure – Additive Depletion – Seal Damage – Soot Loading – Valve Damage – Viscosity Change – Zinc Anodes End of Life – Poor Handling Practices – Water Page O - 14 Copyright 2013 GPAllied©
  15. 15. Root Causes of Bearing Failure on Hydraulics Page O - 15 Source: IDCON, Maintenance Technology, SKF, Noria Copyright 2013 GPAllied©
  16. 16. Micron Comparison Copyright 2013 GPAllied©
  17. 17. Vibration Analysis, (Best Practices) Copyright 2013 GPAllied©
  18. 18. Ultrasound (Best Practices) • Cylinder Bypassing • Valve Functioning Copyright 2013 GPAllied©
  19. 19. Proactive Maintenance (Best Practices) Copyright 2013 GPAllied©
  20. 20. What is Required? (Best Practices) • Culture Change (current level of thinking must change) • Contamination Control is #1 • Develop an Effective PM/PdM Program for Hydraulic Systems – Maintenance Strategy Adjustment – Failure Modes/Causes – Failure Mitigation or Elimination • Education – Contamination Control (100%) – Hydraulics 101 “The Fundamentals”(shift and key personnel) – Maintaining Hydraulic Systems (shift and key personnel) – Troubleshooting Hydraulic Systems (shift and key personnel) • Measure Hydraulic System Reliability (MTBF) • Hydraulic System Modification – Next slide Copyright 2013 GPAllied©
  21. 21. Equipment Modification (Best Practices) “Contamination Control” “Hydraulic Fluid Sample Port” Not an option Copyright 2013 GPAllied© Filter Pump
  22. 22. Questions/Comments? www.maintenancephoenix.com rsmith@gpallied.com Copyright 2013 GPAllied©

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