Hydraulic Reliability Assessments

Serving Industry Through Training, Troubleshooting and Reliability Since….

The only preventive maintenance and reliability procedures that most plants perform is to change the filters regularly and to check the oil level. When the machine fails, there is little or no information about the system to refer to when troubleshooting. Our consultant will first perform a customized Reliability Assessment on each of your in plant machines. You will receive a Reliability Report on each system with recommendations for immediately improving the system operation, shock, heat, leakage, speeds, etc. You will also be provided with a Reliability and Preventive Maintenance Schedule that can be used to check the condition of the system on a regular basis, reducing un-scheduled downtime. The recorded information will also provide a valuable reference for troubleshooting if a failure of the machine should occur. Digital analog and infra-red pictures will be included throughout the report to identify the reliability test points in the system. The Assessment will be conducted while the machine is operating and will include the following:

  • Testing of the pump(s) to determine if the proper volume is being delivered to the system. By making this test regularly the pump can be replaced on a down day and not when it fails and interrupts production.
  • Checking the accumulators to make sure they are properly pre-charged which is necessary to achieve the desired speed to maintain production.
  • On any given hydraulic system, there should be some lines that are hot (above 130 degrees), warm (100-130 degrees), and cool or at ambient temperature. By checking the temperature of these lines on a regular basis a component failure can be found before the system fails completely.
  • One of the main issues in a hydraulic system is leakage. One drop of oil that drips once per second will lose 405 gallons a year. If leakage is occurring there is a reason for it. Our consultant will identify the cause of the leak and recommend the necessary fix to prevent it from occurring in the future.
  • One of the biggest problems in systems today is that the pressures are out of adjustment which causes excessive force, heat, leakage and wasted electrical energy. Our consultant will identify any pressure setting issues and many times correct them during the assessment.
  • Check to verify that the pipe and tubing clamps are properly spaced and are of the proper type.
  • Make sure that the hoses are properly installed to prevent premature failure and oil loss.
  • Check the condition of the filters if a visual or electrical indicator is available.
  • Verify that the air and water heat exchangers are operating properly to reduce the oil temperature to an acceptable level. If the oil temperature is above 140oF then oil will start breaking down causing sludge and varnish in the system.
  • Check the condition and micron rating of the breather cap and recommend a maintenance schedule.
  • Sound checks to determine pump cavitation, aeration or valves bypassing in the system.

Schedule a Reliability Assessment at your plant today for a full report on the condition and recommended improvements for your systems. Then by using the customized Reliability and P.M. Schedule downtime, parts cost and oil loss will be reduced.

 

 

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GPM Hydraulic Consulting, Inc.

 

Address: 797 Ridge Road Monroe, Ga 30655

Phone: (770) 267-3787

GPM Hydraulic Consulting, Inc.

Hydraulic Training – Troubleshooting – Reliability