Download pdf - Maintenance of Hydraulic Systems

Copyright 2013 GPAllied©

Maintenance of Hydraulic Systems

Presented by: Ricky Smith, CMRP March 2013


“Maintenance”

• To Maintain • Preserve, and Protect from Degradation


“Reliability”

To meet the functional requirements of the end user – Pressure – Flow


Dr. Deming:

“Your system is perfectly designed to give you the results you are getting.”

4

Conveyor Hydraulic System MTBF


Reliability – Production and Maintenance

One Team – Same Goal


Hydraulic System Failures

“It isn’t what you know that will kill you, it is what you don’t know that will”


#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?


• 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

#2 - Root Cause of Hydraulic Failures


Eliminate the Probability of a Hydraulic Failure


Known Best Maintenance Practices “Hydraulics”


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


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!


PdM of Hydraulics Systems (Best Practices) • Expectations of PdM for Hydraulic System?

– Early detection of a Defect

“Early Detection is Key to Success”

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Oil Analysis - Failure Modes Detected, (Best Practices)

• Component Failure Modes – Compromised Seal – Bearing Fault – Internal Pump Failure – Seal Damage – Valve Damage – Zinc Anodes End of Life

• Lubricant Failure Modes – Oxidation – Nitration – Additive Depletion – Soot Loading – Viscosity Change – Poor Handling Practices – Water

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Root Causes of Bearing Failure on Hydraulics

Source: IDCON, Maintenance Technology, SKF, Noria


Micron Comparison


Vibration Analysis, (Best Practices)


Ultrasound (Best Practices)

• Cylinder Bypassing • Valve Functioning


Proactive Maintenance (Best Practices)


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


Equipment Modification (Best Practices)

“Contamination Control”

“Hydraulic Fluid Sample Port” Not an option

Filter Pump


Questions/Comments?

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