Hydraulic systems are prevalent across all automation and heavy industry sectors. Monitoring hydraulic oil condition is fundamental in ensuring reliable equipment operation, and optimum performance levels.
Due to the extensive use and continuous operation of hydraulic systems, every disruption in the cycle means a loss of time and money. Research indicates that up to 80% of hydraulic system failures are due to deficient fluid conditions, and more than 50% of all lost production is due to annual shutdown and unplanned maintenance of hydraulic equipment. Hydraulic system reliability is critical to the production process, therefore streamlining the associated maintenance activity with real-time oil condition monitoring will maximise uptime and profitability.
Hydraulic fluid applications operate under tight tolerances and require routine oil sampling to maintain optimum oil condition. The presence of water and high operating temperatures can degrade lubricant properties and accelerate acid formation, increasing oxidation and reducing lubricity, which will reduce the life of the equipment, and the oil itself. Continued operation with degraded oil will lead to accelerated wear of moving parts and filtration problems resulting in an accumulation of sludge in the tank and pipework, ultimately leading to hydraulic system failure. Despite this, and largely due to inadequate sampling and maintenance practices, hydraulic oil contamination is very common, and equipment reliability is often compromised.
Monitoring the oil provides insight into the actual operating condition and status of the hydraulic equipment. Accurately knowing the condition of oil in real-time enables immediate and precise diagnosis of the overall equipment condition. Filtration performance, new system commissioning, hydraulic component wear, external contamination and the condition of new oils can all be monitored to give an overall picture of machine health, and guide maintenance to maximise uptime and minimise costs.
Tan Delta’s Hydraulic Monitoring Kit uses patented Full Spectrum Holistic technologies to provide real-time continuous analysis of hydraulic oil condition. The kit can be easily retrofitted to existing hydraulic systems and ensures any change in oil condition is instantly detected, accurately measured and clearly reported, allowing operators to reduce lab sampling and save money on maintenance and repairs with an average project return on investment in under 12 months.