Improving the Efficiency and Longevity of Your Hydraulic Equipment

Costly hydraulic system failures can be prevented without a large capital investment. Proper attention to filtration systems and control of noise and vibration levels can save you money and improve efficiency.

In many old pieces of equipment there are poorly designed filtration systems, or, as in many cases, no filtration system at all. An immediate improvement can be made by replacing an outdated filtration system with today's modern 10 micron to 1 micron filtration systems. The effects of installing such a system can be dramatic, usually reducing hydraulic system failures by as much as 85 percent.

The reason for these large reductions in hydraulic failures is easy to account for. When a hydraulic system is in operation, the oil is moving constantly through pumps, valves, motors, and cylinders. All of these moving parts wear, and as they wear, they release fine particles into the oil, many as small as 0.0002 inches in size. These particles remain suspended in the oil and act as an abrasive throughout the system. This, in turn, releases more abrasive particles, which multiplies the effect and increases the wear rate on all the components in the hydraulic system. The most common results are internal leakage, which reduces the efficiency of motors, pumps, and cylinders; wastes horsepower; and generates excessive heat. All of these factors combine to contribute to the early failure of the system components, many of which can be extremely expensive.

Selecting a Filtration System

When selecting a hydraulic filtration system for your equipment, the following guidelines should be followed.

Systems in daily use should be filtered at 1 micron to minimize maintenance of the system and maximize the life of all the components. If, for example, you are running a baler on a daily basis, the pump should be protected from large contaminants by installing a line strainer between the inlet and the pump. Depending on what degree of protection you require, the oil can then be filtered between the pump and other working components, such as valves and cylinder. The filtration should be a maximum of 10 microns and preferably 1 micron. This ensures maximum protection of these components. Another area where a filter can be installed is in the return line of the baler. This gives you the advantage of operating under minimum pressure, and, with oil in good condition, maintaining a clear system. The disadvantage to using a filter in the return lines is that any contaminant that has entered the system will not be removed until it has passed through all of the system components.

Systems that are used in a backup role, or only used on a part-time basis, may require only a reduced level of protection. This would reduce the cost of the filtration system. However, the maximum filtration level should be set between 25 and 30 microns to ensure safety.

When selecting the filtration system for your machinery, take into consideration the high dust and dirt levels associated with scrap plant operations and be sure to filter the air entering the hydraulic reservoir to compensate for changes in the fluid level.

Proper Maintenance Is Key

As with any working component in a hydraulic system, the filter system requires maintenance. Some key points to remember:

Set up a regular filter inspection and maintenance program.

After changing filters be sure to inspect the elements for tell-tale signs of early system-component failures or failure of the filter, which may require earlier filter replacement.

Never return oil that has leaked from the system back into the system.

Never use a system in which all of the filtration devices are not in place and functioning properly.

Use clean hoses, funnels, and containers when filling the hydraulic reservoir to prevent contamination from entering the oil.

When changing or repairing parts of the system, be sure to keep them clean.

Keep your reserve supply of fresh hydraulic oil tightly covered.

Keeping a proper filtration system in good working order is your best line of defense in preventing early component failures.

Noise Pollution

Another item that can improve the efficiency of your equipment is the proper control of noise and vibration. There are primarily two reasons to control noise and vibration in hydraulic system: one is to protect employees; the other, to protect equipment. Excessive exposure to noise generated above acceptable levels can lead to possible hearing loss and decreased employee efficiency. Employees cannot be exposed to steady sound levels in excess of 115 decibels on the slow scale, which is the A scale (dbA), for any amount of time; and the Occupational Safety and Health Administration has set strict guidelines for permissible noise exposure levels.

Maximum acceptable levels per OSHA 1910.95 are:

90 dbA in an eight-hour period;

92 dbA in a six-hour period;

95 dbA in a four-hour period;

97 dbA in a three-hour period;

100 dbA in a two-hour period;

102 dbA in a one-and-a-half-hour period;

106 dbA in a one-hour period;

110 dbA in a half-hour period;

115 dbA in a quarter-hour or less period; and

over 115 dbA: no acceptable steady sound level period.

Most, if not all, shearing and baling operations either come very close to maximum noise levels or exceed them. For this reason it is very important that every effort be made to control the noise created by these machines by using either administrative or engineering controls. If these fail to lower the noise exposure levels to an acceptable level, then a personal protective program must be effected to reduce exposure. Ear plugs, ear muffs, or other personal equipment must be supplied free of charge to employees at risk. In addition, a regular hearing testing program must also be established to ensure that employees are properly protected.

Engineering controls can be put into place to reduce employee discomfort and also improve longevity of equipment. By ensuring that pump intake lines are properly sized and kept as short as possible, you will reduce noise levels within the pump and virtually eliminate pump cavitation, the primary cause of early pump failure.

The noise generated by fluid flow through the system is proportional to the velocity of the hydraulic fluid through the Pipe. This means that the fluid must flow at a higher velocity through any restrictions to deliver the same number of gallons per minute. This causes increased vibration, which can, over time, fatigue the pipes and cause unnecessary failure.

By adding accumulators to a hydraulic system two things may be accomplished. You can reduce the shock generated in the hydraulic system, reducing noise, and also use the stored energy to help increase the speed and smooth operation of many shears and balers.

Costly hydraulic system failures can be prevented without a large capital investment. Proper attention to filtration systems and control of noise and vibration levels can save you money and improve efficiency.

In many old pieces of equipment there are poorly designed filtration systems, or, as in many cases, no filtration system at all. An immediate improvement can be made by replacing an outdated filtration system with today's modern 10 micron to 1 micron filtration systems. The effects of installing such a system can be dramatic, usually reducing hydraulic system failures by as much as 85 percent.

The reason for these large reductions in hydraulic failures is easy to account for. When a hydraulic system is in operation, the oil is moving constantly through pumps, valves, motors, and cylinders. All of these moving parts wear, and as they wear, they release fine particles into the oil, many as small as 0.0002 inches in size. These particles remain suspended in the oil and act as an abrasive throughout the system. This, in turn, releases more abrasive particles, which multiplies the effect and increases the wear rate on all the components in the hydraulic system. The most common results are internal leakage, which reduces the efficiency of motors, pumps, and cylinders; wastes horsepower; and generates excessive heat. All of these factors combine to contribute to the early failure of the system components, many of which can be extremely expensive.

Selecting a Filtration System

When selecting a hydraulic filtration system for your equipment, the following guidelines should be followed.

Systems in daily use should be filtered at 1 micron to minimize maintenance of the system and maximize the life of all the components. If, for example, you are running a baler on a daily basis, the pump should be protected from large contaminants by installing a line strainer between the inlet and the pump. Depending on what degree of protection you require, the oil can then be filtered between the pump and other working components, such as valves and cylinder. The filtration should be a maximum of 10 microns and preferably 1 micron. This ensures maximum protection of these components. Another area where a filter can be installed is in the return line of the baler. This gives you the advantage of operating under minimum pressure, and, with oil in good condition, maintaining a clear system. The disadvantage to using a filter in the return lines is that any contaminant that has entered the system will not be removed until it has passed through all of the system components.

Systems that are used in a backup role, or only used on a part-time basis, may require only a reduced level of protection. This would reduce the cost of the filtration system. However, the maximum filtration level should be set between 25 and 30 microns to ensure safety.

When selecting the filtration system for your machinery, take into consideration the high dust and dirt levels associated with scrap plant operations and be sure to filter the air entering the hydraulic reservoir to compensate for changes in the fluid level.

Proper Maintenance Is Key

As with any working component in a hydraulic system, the filter system requires maintenance. Some key points to remember:

Set up a regular filter inspection and maintenance program.

After changing filters be sure to inspect the elements for tell-tale signs of early system-component failures or failure of the filter, which may require earlier filter replacement.

Never return oil that has leaked from the system back into the system.

Never use a system in which all of the filtration devices are not in place and functioning properly.

Use clean hoses, funnels, and containers when filling the hydraulic reservoir to prevent contamination from entering the oil.

When changing or repairing parts of the system, be sure to keep them clean.

Keep your reserve supply of fresh hydraulic oil tightly covered.

Keeping a proper filtration system in good working order is your best line of defense in preventing early component failures.

Noise Pollution

Another item that can improve the efficiency of your equipment is the proper control of noise and vibration. There are primarily two reasons to control noise and vibration in hydraulic system: one is to protect employees; the other, to protect equipment. Excessive exposure to noise generated above acceptable levels can lead to possible hearing loss and decreased employee efficiency. Employees cannot be exposed to steady sound levels in excess of 115 decibels on the slow scale, which is the A scale (dbA), for any amount of time; and the Occupational Safety and Health Administration has set strict guidelines for permissible noise exposure levels.

Maximum acceptable levels per OSHA 1910.95 are:

90 dbA in an eight-hour period;

92 dbA in a six-hour period;

95 dbA in a four-hour period;

97 dbA in a three-hour period;

100 dbA in a two-hour period;

102 dbA in a one-and-a-half-hour period;

106 dbA in a one-hour period;

110 dbA in a half-hour period;

115 dbA in a quarter-hour or less period; and

over 115 dbA: no acceptable steady sound level period.

Most, if not all, shearing and baling operations either come very close to maximum noise levels or exceed them. For this reason it is very important that every effort be made to control the noise created by these machines by using either administrative or engineering controls. If these fail to lower the noise exposure levels to an acceptable level, then a personal protective program must be effected to reduce exposure. Ear plugs, ear muffs, or other personal equipment must be supplied free of charge to employees at risk. In addition, a regular hearing testing program must also be established to ensure that employees are properly protected.

Engineering controls can be put into place to reduce employee discomfort and also improve longevity of equipment. By ensuring that pump intake lines are properly sized and kept as short as possible, you will reduce noise levels within the pump and virtually eliminate pump cavitation, the primary cause of early pump failure.

The noise generated by fluid flow through the system is proportional to the velocity of the hydraulic fluid through the Pipe. This means that the fluid must flow at a higher velocity through any restrictions to deliver the same number of gallons per minute. This causes increased vibration, which can, over time, fatigue the pipes and cause unnecessary failure.

By adding accumulators to a hydraulic system two things may be accomplished. You can reduce the shock generated in the hydraulic system, reducing noise, and also use the stored energy to help increase the speed and smooth operation of many shears and balers.