HYDRAULIC SYSTEM MAINTENANCE

Typical Maintenance Approaches include

 Reactive Maintenance
 Preventive Maintenance
 Predictive Maintenance

Reactive Maintenance

This is the Least Efficient Method because, plant personnel take Corrective Action only after some
type of Breakdown has Already Occurred.

In Process Industry , allowing Failures to happen means that Consequences and Costs of Failure
will be Greatly Magnified due to Lost Production associated with having Equipment Out of
Service .

Preventive Maintenance

With this Approach , end user tries to Prevent Failures by Scheduling Regular interventions on
equipment to

 Repair
 Replace
 Rebuild Equipment or Components .

The Timing for these Interventions might be based on Vendor Recommendations or Past History.
This is Better than a Reactive Approach because it Cuts Down on the On Line Failures, but it does
Involve Higher level of Maintenance Activity, and some Work may be Done Unnecessarily on
Equipment that was Still in Good Condition.

Predictive Maintenance

Predict Failure and Schedule Corrective Action Before it can Occur . This is a little like "Just In
Time Maintenance" there is No Wasted Effort since the interventions are based on Impending
Failure.

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The Predictions are the Difficult Part of this Approach and are based upon the Combination of
Nondestructive Examination and Past History. This is the Most Cost Efficient means of
Addressing Maintenance concerns to these 3 Traditional Maintenance Techniques.

HYDRAULIC SYSTEM MAINTENANCE

Many hydraulic systems are designed without any consideration being given to the maintenance
of the system once it is in use. Frequently the prime requirement is minimum initial cost without
thought of the running and maintenance costs. Consequently it is possible that:

 The filtration in the system will be inadequate.

 There will be a lack of test points.
 There will be no facilities for monitoring wear.
 Valves and other components will be mounted in inaccessible positions.
 It may be necessary to empty the oil reservoir before certain components can be examined
or replaced.

EQUIPMENT AND PRACTICES WHICH BENEFIT MAINTENANCE

i. Good housekeeping practice

 System filtration and cleanliness
 Test points and testing
 Condition monitoring of components and fluid
 Component wear
 Component position
 Records and information
ii. Fluid storage and handling
 Storage
 Handling
 Remember The benefit of good clean storage can be completely nullified if the
fluid becomes contaminated in transit from the drum to the machine
iii. Installation and commissioning of hydraulic systems
 Power pack installation
 Filling the system

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  Initial starting and commissioning
iv. Routine maintenance
 Operator tasks (to be undertaken during operation of plant)
 Periodic maintenance (weekly or monthly etc., dependent upon
 operating conditions
 Annual maintenance

TROUBLE SHOOTING IN HYDRAULIC SYSTEMS

a) Test equipment
b) General rules for hydraulic maintenance engineers
c) The concept of logical fault finding

In far too many instances, the method of fault finding in hydraulic systems is by trial and error.
The maintenance engineer removes components in a random manner and replaces them with new
ones hoping to cure the fault. This can be a very time consuming and expensive exercise, and can
indeed introduce additional faults into the system. Every time a joint is broken, contaminants are
introduced.

Using a simple logical fault finding technique can considerably reduce down time and case the
task of the maintenance engineer To use this technique, it is essential to have the following

 A good understanding of the function of all the hydraulic components in the system
 A complete and up to date circuit diagram
 A parts list showing full part number and manufacturer of each component
 An operational schedule giving details of sequence of operations, cylinder speeds motor
speeds, setting pressure of relief valves, pressure reducing valves etc

Test equipment

Ideally every user of hydraulically operated machines should have the following equipment
available to the maintenance engineer:

 A flow meter
 Test gauges
 A hydraulic test unit

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  A contamination measuring device

General rules for hydraulic maintenance engineers

 Before working on a machine check the effect on interlocked parts or machines.

 Chock up all cylinders and parts which may fall under gravity.
 Isolate electrical supply and lock control cabinet.
 Isolate pump and ensure it cannot be started accidentally
 Bleed fluid to relieve any pressure in system by cracking fittings cover with cloth to prevent
oil spray.
 Particular care must be taken in the case of accumulator circuits.
 Plug all pipe ends and ports of components to keep out contaminants.
 Ensure that components stripped are marked to facilitate correct assembly.
 Wash components in the correct fluid. If in doubt use clean hydraulic Quid as used on the
machine.
 Use torque wrenches for tightening components. Do not over tighten.
 Use extreme care when starting machine for first time after overhaul a pipe left off can
cause a flood of oil; a valve spool reversed may cause a cylinder to fall instead of rise ;
actuators may operate out of sequence.

The concept of logical fault finding

This is a diagnostic technique in which all the symptoms have to be carefully considered so the
fault can be localized to one section of the circuit. If the fault affects all cylinders and motors it
must be something common to them all, i.e a failure in supply either of hydraulic fluid a fault in
the power pack or in the electrical control system. Should the fault be unique to one actuator, start
by considering the components associated with that actuator.

To determine the possible cause of a fault, the exact function and effect of each component
associated with the system must be known. Consider the action of each component in turn, with
respect to the symptoms. Make a note of the component or components which if maladjusted or
malfunctioning could result in all these symptoms.

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When this has been done select the component which can be most easily tested, for example
adjusting flow or pressure settings, manually operating solenoid valves and limit switches. Only
when all the simple tests have been completed should any attempts be made to disconnect
pipework or remove components. Every time a joint is broken, contamination will enter the system
always plug pipes and manifolds when components are removed.

Fault finding procedure:

 initial information
 initial check on machine
 fault diagnosis
 fault finding using functional block diagrams and trouble shooting charts
 tree branching method of fault finding

INITIAL INFORMATION

This is from the machine operator

1. Where and when does fault

(a) On all cylinders and motors.

(b) On one only.

(c) Under all load conditions

2. Type of fault

(a) Complete stoppage.

(b) Reduced speed or thrust

3. How soon did fault

(a) Suddenly ... (breakdown)

(b) Gradually …….. (general)

(c) Periodically ... (intermittent fault)

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4. Unauthorized adjustment

(a) Has someone adjusted the machine?

(b) Has any attempt been made to repair unit?

(c) Has machine recently been modified or repaired?

INITIAL CHECK ON MACHINE

 Check electrical supply is switched on to both power and control circuits

 Check oil level, condition, temperature.
 Check pumps for correct running.
 Check filters.
 Check pressures.
 Check visually for broken or burst pipes, leaks from components.

FAULT DIAGNOSIS

 If fault is localized to part of circuit, only that area need be considered.

 If fault is general to all the circuit the cause must be something common to whole circuit,
e g pump, main relief valve, suction line.
 Initially trace the fault to a particular part of the circuit so that only components in that
part need to be considered.
 Next consider each component and determine which components could cause the fault
Only when possible causes of the fault have been determined should any components be
tested.
 Carry out the easiest tests on suspect components first, i e tests which can be done in situ,
e g manual operation of solenoid valves, pressure settings, low settings, and oil leaks and
damaged pipes.
 If this fails to locate the fault, remove the component most likely to be faulty and check
that first

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Fluid power systems Eng Mpiima Isaac
Fluid power systems Eng Mpiima Isaac
FAULT FINDING USING FUNCTIONAL BLOCK DIAGRAMS AND TROUBLE SHOOTING
CHARTS

 A hydraulic circuit can look very complex to the uninitiated and make fault finding almost
impossible Although it is preferable for maintenance engineers to have a working
knowledge of power hydraulics it is possible by using charts and block diagrams to
simplify trouble shooting
 There is considerable work involved in designing and drawing up the appropriate charts,
so this method may only be viable if a number of similar machines are involved
 The complete system should be broken down into sections which can be considered
individually, for example an actuator or group of actuators and the associated control
valves

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Fluid power systems Eng Mpiima Isaac
TREE BRANCHING METHOD OF FAULT FINDING

This is basically another method of presenting the fault finding chart. It asks a question which has
only two possible answers, 'yes' or 'no'; the answer determines the next step to be taken. It is said
that on average it takes four times as long to locate a fault as it does to rectify it and this technique
helps develop a logical and rapid approach to fault diagnosis.

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Fluid power systems Eng Mpiima Isaac
Fluid power systems Eng Mpiima Isaac