Post on 02-Dec-2014
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Maintenance of Hydraulic Systems
Presented by: Ricky Smith, CMRP March 2013
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“Reliability”
To meet the functional requirements of the end user – Pressure – Flow
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Dr. Deming:
“Your system is perfectly designed to give you the results you are getting.”
4
Conveyor Hydraulic System MTBF
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Hydraulic System Failures
“It isn’t what you know that will kill you, it is what you don’t know that will”
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#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?
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• 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
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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
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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!
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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
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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
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Equipment Modification (Best Practices)
“Contamination Control”
“Hydraulic Fluid Sample Port” Not an option
Filter Pump
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Questions/Comments?
www.maintenancephoenix.com rsmith@gpallied.com