The Key to Max Performance & Longevity: Seasonal Hydraulic System Maintenance
See how seasonal changes affect hydraulic systems and find out how to keep your system in top shape year-round
Hydraulic systems are the backbone of many industrial processes such as generating the power necessary to operate machinery efficiently or as a part of the manufacturing process to produce an end product. However, like any complex system, they require maintenance to ensure optimal performance and longevity.
A critical aspect of system maintenance that is often overlooked is actually how seasons can affect machine performance. Just as we prepare our homes and vehicles for the change in weather, it’s essential to tune up hydraulic systems to withstand the unique challenges each season brings.
In this blog, we’ll discuss the following:
- Risks Posed by Neglected Hydraulic Systems
- 5 Hydraulic System Maintenance Practices
- Season Specific Recommended Maintenance (Checklist)
- Best Practice: Predictive Maintenance
Let’s dive deep and get into what happens when maintenance isn’t a top priority.
Risks Posed by Neglected Hydraulic Systems
Most manufacturers work their hydraulic systems to their fullest capacity to meet productivity demands. And as time passes, wear and tear will affect performance.
While it’s common knowledge that a maintenance program should be implemented, sometimes it’s not always known how crucial it is to operations or what is the true value of a maintenance program.
Let’s discuss the risks posed from neglect:
Spikes in Unplanned Downtime
To put it simply, unexpected breakdowns rack up costly interruptions to production schedules.
According to a 2023 published report by Siemens found that on average, unplanned downtime can cost companies between $39,000 to $2M per hour, with the higher end in Automotive.
The same report also found it’s costing manufacturers at least 50% more today than it did in the period 2019-2020 due to inflation and production lines running at higher capacities.
Diminished Performance
Hydraulic systems operate in various conditions, ranging from extreme temperatures to demanding workloads. Without taking a proactive approach to implementing predictive maintenance to recalibrate systems under those conditions, hydraulic system performance suffers.
Shortened Lifespan
In addition to diminished performance, hydraulic systems may experience premature component failures from wear and tear, leading to either earlier-than-expected replacements or costly repairs.
Higher Repair Costs
Taking the fall-off-the-wheels approach of neglecting maintenance, will always result in frequent breakdowns, resulting in expensive repairs or replacing a hydraulic power unit in addition to a loss on the initial ROI.
Environmental Impact
Depending on where the hydraulic system is located, hydraulic fluid leaks and spills could have an environmental consequences such as contaminating soil, waterways and ground water.
Loss of Productivity
Repairs and downtime aren’t the only costs that accrue – the loss of productivity also impacts the bottom line. The decrease in throughput affects profitability and competitiveness in the market because there’s not enough product for the demand.
Safety Hazards
Faulty hydraulic systems pose safety risks to operators and personnel. Sudden failures, leaks or malfunctions can lead to accidents, injuries or damages to equipment and property.
For these reasons above, manufacturers need to prioritize maintenance to mitigate risks and help run more efficient operations.
Let’s discuss the five maintenance practices that will be the foundation of an operator’s maintenance program.
5 Hydraulic System Maintenance Practices
There are generally 5 maintenance practices that should be done on hydraulic systems by operators in order to maximize the system’s performance:
- Visual Inspections – One of the most basic but important practices is to visually inspect hoses & fittings, seals and reservoirs to identify any signs of wear & tear, leaks, damage and corrosion.
- Fluid Analysis – Test hydraulic fluids for viscosity, contamination and chemical composition and compare the results to the manufacturer’s specifications in addition to replacing fluids as recommended.
- Temperature Control – Implement measures to regulate and monitor hydraulic fluid temperatures by installing coolers, heaters and/or insulation.
- Filter Replacement – Prevent contaminants from entering the system and causing damage to components by replacing hydraulic filters including cleaning or replacing breathers and strainers to prevent debris from entering the system.
- Training – Administer proper hydraulic training to Operators and Maintenance Personnel on hydraulic system operations, maintenance procedures and safety protocols to minimize the risk of errors and accidents plus ensure the system runs efficiently including hose & fitting training.
Creating a maintenance plan to ensure the hydraulic system runs on optimal performance and creating safety measures will reduce unplanned downtime and boost productivity.
Season Specific Recommended Maintenance (Checklist)
Different seasons can pose particular problems for hydraulic systems. So in addition to conducting regular maintenance on an annual basis as a bare minimum practice, it may also be worthwhile to incorporate the following seasonal maintenance practices:
Spring Maintenance
- Check Fluid Conditions – Fluctuating temperatures can add stress on systems. Monitor the hydraulic fluid viscosity and adjust accordingly for optimal performance
- Inspect Fluid Reservoirs – Humidity can elevate the risk of moisture contamination in hydraulic fluid, which can lead to corrosion and component damage.
Check fluid reservoirs for water accumulation and take steps to remove any moisture to prevent those issues.
Summer Maintenance
- Monitor Fluid Temperatures – The rise in temperatures can lead to overheating of hydraulic fluid, which reduces its effectiveness and potentially damages system components.
Equip hydraulic systems with adequate cooling mechanisms, such as heat exchangers or fans to maintain ideal operating temperatures.
- Examine Seals & Hoses – Heat and UV exposure can accelerate the deterioration of seals and hoses. Check all seals and hoses for cracking, swelling or degradation and replace them to prevent leaks and maintain system integrity.
Fall Maintenance
- Observe Fluid Conditions – Falling temperatures cause fluid to thicken, which affects flow characteristics and system performance. Consider using cold-weather hydraulic fluids or adjust fluid viscosity to ensure smooth operations in colder conditions.
- Discard Debris Accumulation – Outdoor hydraulic systems can accumulate leaves and debris from fall foliage.
Regularly clear out and inspect systems to remove any obstructions that could cause damage or hinder operations.
Winter Maintenance
- Take Cold Weather Precautions – Extreme cold tends to thicken hydraulic fluid, which increases the risk of a system failure.
Safeguard equipment by installing heaters or using winter-grade hydraulic fluids to protect the hydraulic system from freezing temperatures.
- Snow & Ice Removal – Snow and ice buildup can become a problem to hydraulic systems in outdoor installations.
Clearing snow and ice from access points and equipment to ensure safe operation and prevent damage to the system.
By addressing these seasonal considerations in addition to a regular maintenance plan, it will ensure a hydraulic system’s maximum performance.
However, the smart choice would be to implement best maintenance practices, which in this case would be to consider starting a predictive maintenance plan.
Best Practice: Predictive Maintenance
In the past decade, there have been proponents for preventative or predictive maintenance, debating on which plan is better.
Each maintenance plan has its own sets of pros and cons however, in this day and age of data, which allows us to make more intelligent business decisions, one plan leads the pack: Predictive Maintenance.
Although Preventative Maintenance has its own set of pros such as a simpler implementation, scheduled inspections to address the potential issue before catastrophic failures and lower dependency on data, Predictive Maintenance seems to have the edge:
Predictive Maintenance Plan Advantages
- Minimizes Downtime – Predictive Maintenance (PM) uses data analytics and sensors, like Parker’s SensoNODETM Sensors, to anticipate potential equipment failures.
Repairs can be scheduled during planned downtime to minimize costly disruptions to operations. - Cost Savings – Since PM identifies potential issues earlier on, it allows hydraulic system operators to address problems before they escalate into larger, more costly issues.
Avoiding major breakdowns and extending hydraulic components’ lifespan lead to significant cost savings over time. - Increased Safety – Hydraulic systems operate under high pressure, which could potentially pose safety risks and/or accidents if not properly maintained.
By analyzing data from sensors and proactively addressing issues before they grow into massive headaches, PM will reduce the risk of accidents and malfunctions, leading to improved workplace safety. - Optimized Maintenance Scheduled – PM only focuses on maintenance tasks that are based on real-time actual equipment conditions, not just on a fixed schedule.
Resources will be allocated more efficiently, which reduces unnecessary maintenance activities, reduces energy consumption and boosts overall productivity. - Data-Driven Insights – The sensors and monitoring devices on hydraulic systems for a PM Plan generate a large volume of data, which is leveraged to identify patterns, trends and potential failures.
These insights provide operators with information that optimizes maintenance plans and resource allocation.
Although a Preventative Maintenance strategy for hydraulic systems has its own place in the manufacturing world, a Predictive Maintenance Plan is considered a best practice. It leverages data to help operators make smarter decisions, optimize productivity and run efficient operations while reducing costs.
In Conclusion
Simply put, implementing any maintenance plan for a hydraulic system will always be a smart move.
Whichever strategy is selected, maintenance is vital to getting the maximum performance out of a hydraulic system and extend the equipment’s lifespan.
Whether you have questions or need help with selecting sensors or monitoring devices to implement a Predictive Maintenance plan, PHI is here to help.
Contact us at hydraulics@phionline.com or call 201-791-3400 to request a quote.
