HYDRAULICS Hydraulic systems are at the core of many industries, driving everything from machinery in manufacturing plants to equipment in agriculture. These systems rely on hydraulic fluid, not just for power transfer but also for lubrication. Proper lubrication is essential for the smooth operation of these systems, helping to reduce friction, prevent wear, and ensure the longevity of the components. However, maintaining the fluid’s quality and performance over time is no simple task, and regular fluid maintenance is necessary to keep things running smoothly. At the heart of hydraulic lubrication is the fluid itself, which acts as both a power transmitter and a lubricant for the internal components. Over time, the fluid can degrade due to heat, contamination, or chemical breakdown. This can lead to a reduction in the fluid’s ability to lubricate the system effectively, increasing friction and wear on critical components like pumps, valves, and cylinders. This is why regular checks on the hydraulic fluid are vital to ensure the system is properly lubricated and protected from excessive wear. Contamination One of the most common issues in hydraulic systems is contamination. Dust, dirt, water, and even air can make their way into the fluid, affecting its ability to lubricate the system effectively. Particles in the fluid increase friction between moving parts, leading to excessive wear and sometimes even catastrophic failure. Water contamination, in particular, can cause corrosion in metal parts and degrade the fluid’s lubrication properties. This is why contamination control is an integral part of fluid maintenance. Using high-quality filters, along with regular fluid checks, can help remove contaminants before they cause harm. In some cases, installing water-absorbing filters can prevent water from degrading the fluid or corroding the system’s components. Viscosity is another critical factor in lubrication. Hydraulic fluid needs to maintain the right thickness to effectively lubricate moving parts and transfer power. If the fluid becomes too thick, it won’t flow smoothly through the system, causing excessive pressure and heat. If it’s too thin, it can’t provide an adequate lubricating film, leading to increased wear on components. This is why monitoring the fluid’s viscosity is a key part of lubrication maintenance. If the fluid has become too thick or thin due to age or contamination, it should be replaced or treated to restore its proper consistency. Temperature also plays a significant role in the fluid’s ability to lubricate. As hydraulic systems operate, they generate heat, and high temperatures can cause the fluid to break down faster. This not only affects the fluid’s lubrication properties but can also lead to the formation of harmful deposits or sludge that can block filters and other components. Conversely, if the fluid becomes too cold, it can thicken and flow poorly, putting stress on the system. It’s important to monitor the temperature of the hydraulic system to ensure the fluid stays within its optimal operating range. In many cases, temperature sensors are used to provide real-time data, allowing operators to adjust the system before overheating or underperformance becomes an issue. Water contamination, specifically, is one of the most damaging threats to hydraulic fluid. Even small amounts of water can lead to rust and corrosion, degrading the fluid’s ability to lubricate effectively. It can also cause the fluid to become emulsified, forming a mixture that loses its lubricating properties. Water can enter the system through condensation, faulty seals, or even the atmosphere, so it’s important to regularly check for moisture. Special dewatering systems or water-absorbing filters can help remove any excess water before it causes damage. In addition, performing regular water content testing ensures that the fluid remains in optimal condition. Even with the best maintenance routines, there comes a time when the fluid must be replaced. Over time, hydraulic fluids break down due to oxidation, contamination, and the stresses placed on them. As the fluid degrades, its lubricating properties are compromised, leading to increased friction and wear. Replacing the fluid at the right intervals ensures that the system continues to operate smoothly and that the components are properly lubricated. For some systems, condition-based monitoring is used to assess the exact right time for fluid replacement, based on factors like acidity levels, viscosity, and contamination. Regular fluid replacement Regular fluid replacement goes hand-in-hand with maintaining the filtration system. Filters are essential in removing particles from the fluid and keeping the system free from damaging debris. Clogged filters can reduce the effectiveness of lubrication, and in some cases, they can even cause a complete failure of the system. Checking filters regularly, and replacing them when needed, ensures that contaminants are kept to a minimum and that the fluid continues to lubricate the system effectively. The type of hydraulic fluid used is another consideration that can affect lubrication. Some fluids contain additives, such as anti-wear agents, that help protect against friction and wear in the system. Others may be designed to withstand higher temperatures or have better resistance to contamination. Choosing the right fluid for the specific system and environment can significantly improve performance and reduce maintenance needs. For example, biodegradable fluids are becoming more popular in industries where environmental concerns are a priority, while synthetic oils offer enhanced lubrication in extreme conditions. In the UK, industries are increasingly aware of the importance of hydraulic fluid maintenance, particularly in sectors like manufacturing, construction, and agriculture. Proper lubrication isn’t just about keeping the system running smoothly; it’s about preventing unnecessary wear, reducing downtime, and protecting expensive equipment from failure. A proactive maintenance plan that includes regular fluid checks, contamination control, and timely fluid replacement can save companies significant amounts of money in the long run. To ensure hydraulic systems remain reliable and efficient, operators need to focus on more than just the basic functionality of the machinery. Maintaining the lubrication system through careful fluid management is an investment that pays off in the form of reduced repair costs, fewer breakdowns, and better overall performance. By monitoring fluid quality, controlling contamination, and replacing fluid at the appropriate intervals, businesses can maximise the life of their hydraulic systems and ensure smooth operations for years to come. 26 HYDRAULICS & PNEUMATICS March 2025 www.hpmag.co.uk Optimising lubrication for hydraulic systems Proper hydraulic fluid maintenance ensures performance, efficiency, and longevity. Monitoring condition, controlling contamination, and maintaining lubrication prevent wear, reduce downtime, and extend machinery life. H&P reports.
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