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NewsOUR LATEST UPDATES

Woodward UG-25

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UG-8 & 3161 Woodward Governor Retrofit Program

Is your Woodward governor ready for replacement?For the next few months, asset owners will receive a s

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Safety Gear 3

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Installation of State of the Art Test Facility at PM Control

FPES and PM Control have been this week furthering and deepening our progressive and exciting partnership. Two

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ProjectsOUR WORK

1-Bricks

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Revolutionising the Brick Recycling Industry with World First Technology

FPES (Excel Hydraulics) was engaged by The Brick Pit, to lead the design and development of the hydraulic automat

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2-TBMs

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Keeping The TBM’s Operational – North West Raillink

Project: North West Rail Link Customer: Thiess John Holland Dragados (TJHD) Challenge: Keeping The Tunnel B

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In our last article, we wrote about the importance

In our last article, we wrote about the importance of following proper procedures when re-starting a hydraulic system after carrying out maintenance work - to avoid premature failures. Today I want to clarify another myth, that causes a lot of hydraulic problems - and even failures ...

Myth #5. All oil returning to the hydraulic reservoir should be filtered.

True. With one VERY important exception:

The case drains of hydraulic piston pumps and motors. Connecting case drain lines to return filters can cause excessive case pressure, which has a number of damaging effects.

High case pressure results in excessive load on the lip of the shad seal. This causes the seal lip to wear a groove in the shad, which eventually results in a leaking shad seal.

The effect of high case pressure on in-line piston pumps is the same as excessive vacuum at the pump inlet. Both conditions put the piston ball and slipper-pad socket in tension during intake.

In severe cases this can result in buckling of the piston retaining plate and/or separation of the bronze slipper from the piston, causing major failure.

Under certain conditions, high case pressure can cause the pistons of radial piston motors to be lifted off the cam during outlet. When this happens, the pistons are hammered back onto the cam during inlet, destroying the motor.

For the reasons described above, conventional depth filters are generally NOT recommended on case drain lines.

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Last time we explained how to add oil to a hydraul

Last time we explained how to add oil to a hydraulic system - without the dirt.

Today we want to clear up another popular misconception, about the installation of hydraulic components ...

Myth #4. Because oil circulates through hydraulic components in operation, no special attention is required during installation beyond bolting the component on and connecting its hoses.

Nothing could be further from the truth, as this example illustrates:

In the past, we've conducted failure analysis on a hydraulic motor that was the subject of a warranty claim. The motor had failed after only 500 hours in service, some 7,000 hours short of its expected service life.

Inspection revealed that the motor's bearings had failed through inadequate lubrication, as a result of the hydraulic motor being started with insufficient oil in its case (housing).

After this motor was installed, its case should have been filled with clean hydraulic oil prior to start-up. Starting a piston-type motor or pump without doing so, is similar to starting an internal combustion engine with no oil in the crankcase premature failure is pretty much guaranteed.

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Last time around, we corrected a popular misbelief

Last time around, we corrected a popular misbelief about the cause of cylinder creep. A lot of people struggle with this one because it's the exact opposite of what they've been conditioned to believe.

Ready for another.?

Myth #3. New hydraulic oil is clean hydraulic oil.

New hydraulic oil straight from the drum, has a typical cleanliness level of ISO 4406 23/21/18.

Now that number may not mean a lot to you, but it's four cleanliness code levels below that considered ideal for high pressure, high-performance hydraulic system.

Looking at it another way, a 25 GPM pump operating continuously in hydraulic oil at 23/21/18 will circulate 3,500 pounds of dirt to the hydraulic system's components each year.

To add hydraulic oil, and not dirt, always filter new oil prior to use in a hydraulic system.

This can be accomplished by pumping the oil into the hydraulic reservoir through the system's return filter. The easiest way to do this is to install a tee in the return line and attach a quick connector to the branch of this tee.

Attach the other half of the quick-connector to the discharge hose of a drum pump.

When hydraulic oil needs to be added to the reservoir, the drum pump is coupled to the return line and the oil is pumped into the reservoir through the return filter.

As well as filtering the oil, spills are avoided and the ingress of external contamination is prevented.

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In our last blog, we explored the myth about pump

In our last blog, we explored the myth about pump suction strainers - they do more harm than good. And installing them to 'protect' the pump is a contradiction because they can actually destroy it.

Myth #2. Creep in a double-acting cylinder is caused by a leaking piston seal.

A popular misbelief about hydraulic cylinders is that if the piston seal is leaking, the cylinder can creep down.

The fact is if the piston seal is completely removed from a double-acting cylinder, the cylinder is completely filled with oil and the ports are plugged, the cylinder will hold its load indefinitely - unless the rod-seal leaks.

What happens under these conditions - due to the unequal volume on either side of the piston, is fluid pressure equalizes and the cylinder becomes hydraulically locked. Once this occurs, the only way the cylinder can move is if fluid escapes from the cylinder via the rod seal or its ports.

If you grasp the theory at work here, you'll probably realize there are a couple of exceptions. The first is a double-rod cylinder - where volume is equal on both sides of the piston.

And the second is when a load is hanging on a double-acting cylinder. In this arrangement, the volume of pressurized fluid on the rod side can be accommodated on the piston side. In this case, a vacuum will develop on the piston side and depending on the weight of the load, this may eventually result in equilibrium that arrests further creep.

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Over the next few blogs, we're going to explore fi

Over the next few blogs, we're going to explore five popular myths.

Now, you may believe one or more of these to be true. So what I have to say will likely challenge your thinking on these issues. But all I ask is you keep an open mind.

Here we go...

Myth #1. Hydraulic pump inlet lines must have a strainer.

A pump inlet or suction strainer is a 140 micron, mesh screen which is screwed onto the pump intake penetration inside the hydraulic reservoir.

These stainers increase the chances of cavitation occurring in the intake line and subsequent damage to, and failure of the hydraulic pump. Piston-type pumps are particularly vulnerable.

If the reservoir starts out clean and all fluid returning to the reservoir is filtered, inlet strainers are not required since the hydraulic fluid will not contain particles large enough to be captured by a coarse mesh screen.

The main argument for installing suction strainers is to protect the pump from debris that enter the reservoir as a result of careless maintenance practices.

Fact is, nuts, bolts, tools and similar debris pose minimal threat to the pump in a properly designed reservoir, where the pump intake is located a minimum of four inches off the bottom.

When you consider the damage that vacuum-induced cavitation can cause to a hydraulic pump, NOT installing a suction strainer is definitely the lesser of two evils.

We generally recommend removing and discarding all filters fitted to pump intake lines. But you don't have to take our word for it.

If in doubt, consult the hydraulic pump OEM.

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Previously, we've wrote about the tangible, bottom

Previously, we've wrote about the tangible, bottom-line benefits of maintaining hydraulic plumbing to eliminate leaks.

Ideally, this begins with connector selection.

NPT is the least reliable type of connector for high-pressure hydraulic systems because the thread itself provides a leak path. The threads are deformed when tightened and as a result, any subsequent loosening or tightening increases the potential for leaks.

Replacing pipe thread connections with soft seal connections such as UNO or BSPP greatly improves 'no-leak' reliability.

In the case of hoses, manufacturers estimate that 80% of hose failures are attributable to external physical damage through stretching, kinking, crushing or abrasion of the hose.

To prevent hose damage, ensure all clamps are kept secure, pay careful attention to routing whenever a replacement hose is installed and if necessary, apply inexpensive polyethylene spiral wrap to protect hoses from abrasion.

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In our last post, I wrote about what we consider t

In our last post, I wrote about what we consider to be THE MOST important component of every hydraulic system - the oil, and the importance of taking care of it.

One of these is to control contamination. Studies have shown that it costs 10 times more to extract contaminants
from hydraulic fluid than it does to exclude them in the first place.

Three common points of contaminant ingression are:

1. Reservoir breather.

Standard filler-cap breathers fitted to the majority of hydraulic reservoirs are not effective in preventing ingression of airborne contaminants. All air entering the reservoir should be adequately filtered. In damp environments (e.g. marine applications, tropical climates) desiccant breathers are essential to prevent the ingression of airborne moisture.

2. Cylinders.

Worn or damaged rod-wiper seals and pitted or gouged cylinder rods give dust and other contaminants an easy path into the system. Fitting rod protectors (bellows) to cylinders operating in abrasive or corrosive environments can extend rod and wiper seal life and provides an extra barrier to the ingression of contaminants via the cylinder rod.

3. Plumbing.

Where fluid leaks out, contamination can get in. The immediate rectification of hydraulic system leaks not only minimises the cost of clean-up, disposal and replacement fluid, it also saves the hidden cost of removing ingested contaminants.

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Here are four quick tips for you to get the most o

Here are four quick tips for you to get the most out of THE most important component of every hydraulic system - the oil:

1. Don't change the oil - filter it.

Water or particle contamination rarely necessitates an oil change - unless the contamination has resulted in additive depletion or base oil degradation. These contaminants can be removed from the hydraulic fluid by filtration.

2. Eliminate particle contamination to reduce breakdowns...

Research has shown that maintaining fluid cleanliness at ISO 4406 16/14/11 will result in a tenfold increase in the average time between breakdowns when compared with a fluid cleanliness level of 24/22/19. This is based on the findings of a three-year study of 117 mobile and industrial hydraulic machines to determine the correlation between fluid cleanliness and breakdown frequency.

3. ...And extend fluid life.

Particle contamination reduces the service life of hydraulic oil by stripping additives and promoting oxidation. Additives attach to particles, which are then removed by the filters or settle at the bottom of the reservoir. Wear metal caused by particle abrasion is a catalyst for fluid oxidation.

4. Keep it cool.

Elevated operating temperatures increase the rate at which the oil oxidises and this decreases its service life. By-products of the oil oxidation process - varnish and sludge, can cause reliability issues such as valve spool stiction and filter clogging.

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Measured Success in Filtration - Valmet Valmet, a

Measured Success in Filtration - Valmet

Valmet, a global leader in the global pulp, paper and energy industries, is responsible for the maintenance of the Orora-B9 paper machine in Matraville, Sydney. The plant was installed in 2012 and a recent contamination issue led to FPES - Fluid Power Engineering Solutions (Excel Hydraulics) being invited to take our exclusive FluidCare Technology™ service to their site.

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Design, Manufacture & Commission Specialised Lidli

Design, Manufacture & Commission Specialised Lidlifter – Intermodal Solutions Group

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CIMC Group in China is the largest manufacturer of steel shipping containers in the world and it supplies customers from a wide range of industries. They employ 5,000 people who produce 500 containers each day at their expansive facility in the Jiangshu province. One of CIMC’s customers, Intermodal Solution (ISG), was commissioned by a mine in South America which required a very specific type of container and this is what led to FPES - Fluid Power Engineering Solutions (Excel Hydraulics) being invited to design-manufacture-install-commission a new hydraulic lid lifting unit for ISG.

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The North West Rail Link is Australia’s biggest

The North West Rail Link is Australia’s biggest public transport infrastructure project. Four tunnel boring machines (TBM’s) are digging 15 kilometres of twin tunnels which will be the longest rail tunnels in the nation. The route includes eight new railway stations which will link the northwest of Sydney to the north shore.

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FPES (Excel Hydraulics) was called on to resolve a lengthy period of major issues with the TBM’s pumps and valves continually being clogged by contaminants.

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FPES (Excel Hydraulics) was engaged by The Brick P

FPES (Excel Hydraulics) was engaged by The Brick Pit, to lead the design and development of the hydraulic automation and intelligent control systems for a new prototype brick cleaning machine. Throughout this time-intensive 18month product development process, FPES has collaborated closely with The Brick Pit owner, Keith Carqueville and a team of experts.

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With the first prototype now in full-scale operation, see attached case study pdf, the project continues with successful design and integration of an inclusive dust collection system to complete this exciting engineered solution.

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