28 March, 2024

The importance of fluid sampling and preventative maintenance in hydraulic hose systems

13 April, 2017

Regarding spectrometric analysis, results are obtained by a rotating disk electrode (ROE) spectrometer and reported in PPM. Some 20 different wear metals and additives are analysed to help determine the condition of the fluid. The spectrometric test is limited to identifying particles below 5-7 µm in size. Base line (new) fluid samples should be sent in for each different fluid to be analysed, which will be used to determine their status.

Of course, obtaining a fluid sample for analysis involves important steps to make sure a representative sample is collected. Erroneous sampling procedures will merely serve to disguise the true nature of system cleanliness levels. ParkerStore uses established and proven methodology for systems with and without a sampling valve.

Fluid sampling should be deployed as part of scheduled preventative maintenance programme as only this will help avoid expensive emergency repairs, downtime and safety risks for workers. The primary goal of preventative maintenance is to pinpoint weak system components before failure occurs. Such an approach delivers many potential benefits beyond system efficiency, including greater uptime, reduced repair costs, more effective use of maintenance staff and better control of spares inventory.

Safety first

Probably the most important aspect of any preventative maintenance programme is safety. With operating pressures as high as 700 bar, there are many potential dangers, not least pinholes, leaks, bursts, hose cracks, twisted hoses, cover blisters, bulges, soft spots, coupling blow-offs, whipping hoses and charged accumulators. Failures can have numerous consequences relating to fire risks and impact on mechanical and electrical equipment. With this in mind, the implementation of regular inspection intervals during routine operation, particularly in regard to factors such as operating temperature and pressure, is pivotal in ensuring that hydraulic systems run safely. Other giveaways include pools of accumulated fluid, low reservoir levels and greasy/dirty hoses.

The ability to troubleshoot is also paramount in the rapid resolution of issues before they become catastrophic failures. For example, an abraded hose should be re-routed to avoid rubbing on other hoses or abrasive sources. Where it cannot be re-routed, a suitable sleeve or pad should be fitted. Other factors such as excessive hose flexing should also be avoided to keep the hose from exceeding its minimum bend radius, thus avoiding bursts, while O-rings need to be checked to make sure that they have not degraded as a result of heat or temperature incompatibility.

Clearly, hoses that have become old, worn or damaged can present a danger to personnel and the environment, which makes regular inspection vital. As a result, daily inspection routines as part of a preventative maintenance programme might involve checking for damage to hose covers, hose hardness or stiffness, colour changes, squashed or kinked hoses, and fluid seepage. Maintenance personnel can check for fluid seepage by pushing at the base of the coupling with their thumb. Further maintenance routines conducted as part of a regular equipment shutdown, say once a quarter, could include hydrostatic pressure testing, for example.

There are of course many simple measures that can be taken to help maximise hose life and ensure worker safety. For instance, the maximum rated pressure of the hose should never be exceeded. Furthermore, hoses should never be over-bent or pulled by their couplings, while lifting a large diameter hose by its middle, with the ends dangling, can damage internal reinforcement at the support point.

Effective hose cleaning is also vital. The use of cleaning solutions, flushing or immersing in a cleaning bath, or steam cleaning, can all prove useful in prolonging hose life.

Summary

Ultimately, modern hydraulic hose systems must be backed by a reputable preventive maintenance programme, such as those offered by ParkerStore. Sure enough, selecting the correct hose is important, but the best practice approach to maximising hose life, minimising unwanted downtime and ensuring the safety of workers, is being proactive in the inspection, maintainence and troubleshooting of hose systems.

www.parker.com




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