There was a day, when you've got the problem, which you should not run from it, but face it wisely.
Ok2..back to the topic. Once I've face a problem with one of my offline circulation filtration pump units. This pump unit normally is operated to be used to top-up the oil quantity inside the tank when it reach at the low level and also to keep the oil inside the tank circulating through the filtration system once the whole system stop from operation.
Problem:
The pump is turned on. After around an hour, the pump was found stopped without anyone switching it off. The pump's motor is considered tripped. Try to switch it on back and keep on monitoring for next hours. The problem since repeated.
Action:
Change the filter element with new spare. Switch on back the pump and wallao.....the pump smoothly operated for continuous 8 hours.
Findings:
The filter element has clogged. Why clogged hydraulic filter element resulting tripping pump's motor. Electrical motor has certain setting on the Amps value. This Amps value act like the pressure relief valve for hydraulic system. It protects the motor from burnt, same like the pressure relief valve protecting the hydraulic system from sudden pressure peak. This amp has the connection on the load of the motor take. The clogged filter increase more blockage which will resulting higher pressure inside the pipe/line. When the pressure increased, it will also increased the work rate for the motor. Higher load will be resulting higher amp. When the amp reached to the safety limit of the motor, it will automatically cut off the supply in order to protect the motor from burn.
Case closed =)
Wednesday, December 14, 2011
Tuesday, June 14, 2011
Hydraulic Power Pack Producing Loud Sound
Problem:
During operation, the power pack producing super loud noise. Even though the location of the power pack is under the cellar, but the sound can be heard till top of floor and even miles away...
During the inspection time, the power pack was shut down. Try to restart the power pack. At first minutes, the sound of the pump is normal and acceptable. Then suddenly it starts to make a lot of noise + vibration. OMG! Is the pump gonna blow? LOL...Worst case, the vibration from the power pack causing the valve stand to vibrate. And one of the pipe joint fitting get loose and causing the hydraulic oil spreading all around. Yeah baby..it's shower time...lololololol...
Action:
During operation, the power pack producing super loud noise. Even though the location of the power pack is under the cellar, but the sound can be heard till top of floor and even miles away...
During the inspection time, the power pack was shut down. Try to restart the power pack. At first minutes, the sound of the pump is normal and acceptable. Then suddenly it starts to make a lot of noise + vibration. OMG! Is the pump gonna blow? LOL...Worst case, the vibration from the power pack causing the valve stand to vibrate. And one of the pipe joint fitting get loose and causing the hydraulic oil spreading all around. Yeah baby..it's shower time...lololololol...
Action:
- Check the condition for any loosen bolts on both of hydraulic pump and electrical motor base. Loosen bolts is one of the typical reason why pumps producing high noise. Result, everything is tighten enough...
- Check the coupling for any defect parts. OMG!. The coupling is in good condition...
- Remove the hydraulic pump from its location. Dismantle it into the pieces. Post-mortem it. Suspected the bearing was out-of-date. The defect bearing can also resulting the pump producing loud noise. The bearing is in good condition. Take out the vane cartridge. Dismantling all the vane blade together with the springs. Check for any scratch and broken springs. Pheww..everything is in good condition...
- Last thing, check the suction filter condition. OMG!..The filter is clogged like hell. No wonder the pump is producing a lot of noise and vibration...Why? Because the clogged filter will block some of the oil flow into the pump. Once the pump did not sucking the adequate amount of oil, the air bubbles will be produced and pump will start to suck oil and air bubbles. This situation can cause aireation to the hydraulic pump.
Conclusion:
Clogged suction filter can resulting excessive vibration and noise the hydraulic pump....
CASE CLOSED..=)
Saturday, April 16, 2011
Fundamental Hydraulics: Basic Hydraulic Filtration System
When you dealing with hydraulic system, you are also dealing with a high cleanliness oil requirement. Why oil cleanliness is very important in hydraulic system?
First of all, most of hydraulic system valve (such as pressure relief valve, directional valve and others) are design with a very precise and small clearance. Oil cleanliness is very crucial to ensure that the component will not be premature fail, wear and tear. Failing to comply with the cleanliness requirement, your system will having so much problem.
Secondly, to avoid high maintenance cost. Trust me, hydraulic system parts mostly are not cheap. When premature failure, wear and tear happen, the maintenance cost can shoot up to twice, thrice and more than that.
To ensure the oil cleanliness is always within specs, a good filtration system is needed. Basically, for the common hydraulic system, the filtration system will be consists of:
Of cause, the more complicated and critical your hydraulic system, the more filtration system need to be put.
Circulation Filtration System.
The main function of the circulation filtration system is to keep the hydraulic system clean. The oil will be continuously circulated by the pump while the system is in operation. Normally, the circulation system use vane pump or gear pump to circulate the oil. The pressure normally not exceeded 6 bar. The standard filter element rating is around 13 micron.
Pressure Line / Supply Line Filtration System.
This filtration system normally is attached to the main pump. The main purpose is to filter the oil before delivered into the system (valves, cylinders,hydraulic motors). It plays major roles to protect our hydraulic system components. Common practice for the location of the filter are either located in hydraulic main pump suction line or in hydraulic main pump pressure line (some people call discharge line or delivery line). The advantage for putting the filter in suction line is we can give extra protection to the pump since the oil is filtered before it enter into the pump. The disadvantage of this practice is it can cause cavitation and damage our pump internal components if not been replaced on time once clogged. Why? Because once the filter clogged, the flow rate of the oil will be decreased and causing the air bubbles created. These bubbles will hit the internal parts of the pump and burst. The energy produced during bursting will make the pump internal parts wear and tear faster. The advantage of putting the filter in pressure line is the risk for your pump cavitation due to clogged filter element is eliminated. The disadvantages are your pump did not have any extra protection and need filter element that can resist high pressure. Normally the filter element rating are around 6 to 10 micron.
Return Line filtration system.
Return line filtration system acts like the last defender for our oil reservoir. It located at the end of the hydraulic system loop. During designing and installation stage, it is a compulsory that all the oil needed to return back to tank must go through this filtration system. Failing to do so, you will be facing problem to control the oil cleanliness. The main function is to trap any dirt from wear and tear hydraulic component inside the system to enter the reservoir back. The filter element for this system will normally clogged faster than other two filtration system. Therefore, the frequency of changing is much more higher. It is crucial to ensure the clogged filter element is replaced on time. Normally the filter element rating is 20 micron.
Filtration system plays big role in hydraulic system. The finest rating for the filter element, the more you need to spend for the cost. However, this system is still needed and the cost consumption is one we need to face it in order to keep our hydraulic system in clean and smooth condition.
First of all, most of hydraulic system valve (such as pressure relief valve, directional valve and others) are design with a very precise and small clearance. Oil cleanliness is very crucial to ensure that the component will not be premature fail, wear and tear. Failing to comply with the cleanliness requirement, your system will having so much problem.
Secondly, to avoid high maintenance cost. Trust me, hydraulic system parts mostly are not cheap. When premature failure, wear and tear happen, the maintenance cost can shoot up to twice, thrice and more than that.
To ensure the oil cleanliness is always within specs, a good filtration system is needed. Basically, for the common hydraulic system, the filtration system will be consists of:
- Circulation Filtration System
- Pressure Line/ Supply Line Filtration System
- Return Line Filtration System
Of cause, the more complicated and critical your hydraulic system, the more filtration system need to be put.
Circulation Filtration System.
The main function of the circulation filtration system is to keep the hydraulic system clean. The oil will be continuously circulated by the pump while the system is in operation. Normally, the circulation system use vane pump or gear pump to circulate the oil. The pressure normally not exceeded 6 bar. The standard filter element rating is around 13 micron.
Pressure Line / Supply Line Filtration System.
This filtration system normally is attached to the main pump. The main purpose is to filter the oil before delivered into the system (valves, cylinders,hydraulic motors). It plays major roles to protect our hydraulic system components. Common practice for the location of the filter are either located in hydraulic main pump suction line or in hydraulic main pump pressure line (some people call discharge line or delivery line). The advantage for putting the filter in suction line is we can give extra protection to the pump since the oil is filtered before it enter into the pump. The disadvantage of this practice is it can cause cavitation and damage our pump internal components if not been replaced on time once clogged. Why? Because once the filter clogged, the flow rate of the oil will be decreased and causing the air bubbles created. These bubbles will hit the internal parts of the pump and burst. The energy produced during bursting will make the pump internal parts wear and tear faster. The advantage of putting the filter in pressure line is the risk for your pump cavitation due to clogged filter element is eliminated. The disadvantages are your pump did not have any extra protection and need filter element that can resist high pressure. Normally the filter element rating are around 6 to 10 micron.
Return Line filtration system.
Return line filtration system acts like the last defender for our oil reservoir. It located at the end of the hydraulic system loop. During designing and installation stage, it is a compulsory that all the oil needed to return back to tank must go through this filtration system. Failing to do so, you will be facing problem to control the oil cleanliness. The main function is to trap any dirt from wear and tear hydraulic component inside the system to enter the reservoir back. The filter element for this system will normally clogged faster than other two filtration system. Therefore, the frequency of changing is much more higher. It is crucial to ensure the clogged filter element is replaced on time. Normally the filter element rating is 20 micron.
Filtration system plays big role in hydraulic system. The finest rating for the filter element, the more you need to spend for the cost. However, this system is still needed and the cost consumption is one we need to face it in order to keep our hydraulic system in clean and smooth condition.
Tuesday, November 2, 2010
Maintenance Philosophy
Philosophy in maintenance? huh! Really? What is the maintenance philosophy?
(Drum Roll ...........................................)
Well, neither these philosophy are consider official nor not yet it can be implement into the Maintenance Area. Hydraulic system consists of wide area such as design, analysis, maintenance and many more. Hence the maintenance of hydraulic system is one of the most crucial part to ensure the systems are at optimum condition anytime anywhere.
Ok. BAck to thefuture topic. What is the maintenance philosophy? (actually this is the philosophy created and faith by the writer...LOL)
There are threestooges major area. SMT.
What the heck is this SMT? Ok2...SMT are:
(drum Rolllllllllllllllllllllllll ...............)
Yeah! These 3 item is related each other and is effecting each other. However, let go deeper into this topic...
To me, the most important thing among these item are Spare Parts. Why? Because parts are the 'things' that ensuring our machine, system or whatever operate!
Example:
Imagine a lifting machine which is used to lift...... let say a box from lower level to higher place. As for the hydraulic system, normally the system will consists of hydraulic cylinder (for lifting purpose), hydraulic pump, hydraulic hoses and hydraulic control valves. These are the must-have-item in a hydraulic system to operate it.
Good maintenance practice must ensure all the parts at least have one unit to ensure any breakdown occur can be rectify in a minimum time. Let say, in worst case, the hydraulic pump did not have any spare and suddenly breakdown occur, WTF! The hydraulic system will be totally halt! The hydraulic pump is the heart of the hydraulic system! Without it fluid can't be distributed in the system....
How to seek for emergency remedy? Is there any ways to operate the system while waiting the new pump from the manufacturers/suppliers? Anything that can act like the hydraulic pump?
Heck! The answer is NO! That's why the Spare Parts is at the First Place!!
It's useless to have adequate manpower and tools without spare part(personal thought)
Number two, manpower. To execute maintenance activity, manpower is needed. Either while executing preventive, reactive or proactive maintenance (these maintenance topic will be discussed in next time), we still need the manpower. Adequate manpower will ensuring the task is carried out proper way and time.
Example:
Take above lifting machine as the sample. Same situation; the broken pump. This time the maintenance team has the spare parts and adequate, proper tools. But at the time situation take place there are only two technician in-charge out of three person in-charge during normal operation. The activity still can be carried out but it will consume a little bit more time (and increasing the machine downtime). However the situation is less worse than having no spare parts during breakdown!
But, adequate manpower is very important in maintenance activity in order to ensure the activity is smooth and tip-top!
Thechosen last one, tools. Tools are important because use to remove, open, detach, attach and many more activity which is relevant. Proper and adequate tools in maintenance lead to the good time and cost management!
Example:
Still the same lifting machine with the same broken pump. This time the maintenance team is having enough spare parts and manpower are all attending(luckily there are no member suddenly need to meet the doctor and take medical leave during the breakdown occur..LOL!). They need to replace the broken pump with the new pump. While doing the activity suddenly the wrench which is needed to open the M30 size MIA (missing in action..LOL!). How can they open the bolt? What they need to do?
No worries, with a little bit of creativity, experience, skills and determination the first aid kit can be made. One way is to fabricate wrench-look-alike-yet-functioning temporarily from other materials(let say mild steel plate). Once completed, the job can be finished (yet is still consuming more time). However, this scenario can be worst as having no spare parts if the activity need some sort of special equipment/tools.
By right, these three factors need to be closely monitored in order to achieve good maintenance practice. Sometime luck can be with us, and sometime they don't.
However, if you are feeling the luck is not with you, you can have the Lucky Strike Cigar...........(ok..that's a joke actually....ok...fine..it's not funny)
Till we meet again. Buh-bye!
(Drum Roll ...........................................)
Well, neither these philosophy are consider official nor not yet it can be implement into the Maintenance Area. Hydraulic system consists of wide area such as design, analysis, maintenance and many more. Hence the maintenance of hydraulic system is one of the most crucial part to ensure the systems are at optimum condition anytime anywhere.
Ok. BAck to the
There are three
What the heck is this SMT? Ok2...SMT are:
(drum Rolllllllllllllllllllllllll ...............)
Spare Parts
Manpower
Tools
Yeah! These 3 item is related each other and is effecting each other. However, let go deeper into this topic...
To me, the most important thing among these item are Spare Parts. Why? Because parts are the 'things' that ensuring our machine, system or whatever operate!
Example:
Imagine a lifting machine which is used to lift...... let say a box from lower level to higher place. As for the hydraulic system, normally the system will consists of hydraulic cylinder (for lifting purpose), hydraulic pump, hydraulic hoses and hydraulic control valves. These are the must-have-item in a hydraulic system to operate it.
Good maintenance practice must ensure all the parts at least have one unit to ensure any breakdown occur can be rectify in a minimum time. Let say, in worst case, the hydraulic pump did not have any spare and suddenly breakdown occur, WTF! The hydraulic system will be totally halt! The hydraulic pump is the heart of the hydraulic system! Without it fluid can't be distributed in the system....
How to seek for emergency remedy? Is there any ways to operate the system while waiting the new pump from the manufacturers/suppliers? Anything that can act like the hydraulic pump?
Heck! The answer is NO! That's why the Spare Parts is at the First Place!!
It's useless to have adequate manpower and tools without spare part(personal thought)
Number two, manpower. To execute maintenance activity, manpower is needed. Either while executing preventive, reactive or proactive maintenance (these maintenance topic will be discussed in next time), we still need the manpower. Adequate manpower will ensuring the task is carried out proper way and time.
Example:
Take above lifting machine as the sample. Same situation; the broken pump. This time the maintenance team has the spare parts and adequate, proper tools. But at the time situation take place there are only two technician in-charge out of three person in-charge during normal operation. The activity still can be carried out but it will consume a little bit more time (and increasing the machine downtime). However the situation is less worse than having no spare parts during breakdown!
But, adequate manpower is very important in maintenance activity in order to ensure the activity is smooth and tip-top!
The
Example:
Still the same lifting machine with the same broken pump. This time the maintenance team is having enough spare parts and manpower are all attending(luckily there are no member suddenly need to meet the doctor and take medical leave during the breakdown occur..LOL!). They need to replace the broken pump with the new pump. While doing the activity suddenly the wrench which is needed to open the M30 size MIA (missing in action..LOL!). How can they open the bolt? What they need to do?
No worries, with a little bit of creativity, experience, skills and determination the first aid kit can be made. One way is to fabricate wrench-look-alike-yet-functioning temporarily from other materials(let say mild steel plate). Once completed, the job can be finished (yet is still consuming more time). However, this scenario can be worst as having no spare parts if the activity need some sort of special equipment/tools.
By right, these three factors need to be closely monitored in order to achieve good maintenance practice. Sometime luck can be with us, and sometime they don't.
However, if you are feeling the luck is not with you, you can have the Lucky Strike Cigar...........(ok..that's a joke actually....ok...fine..it's not funny)
Till we meet again. Buh-bye!
Monday, November 1, 2010
How To Know Hydraulic Oil Type
In industries, there are various type of hydraulic oil been used. Typically used is mineral oil based. The common codename of this mineral based oil is HLP followed by figures.
An example:
HLP 68
Explanation:
HLP is the type of the hydraulic oil. In this case, it refers to the mineral based oil. The two figures follow represent the viscosity of the oil in normal temperature(around 50-60 degree celcius). If the number is 68, it means that in normal temperature, the oil viscosity is 68 mm square / seconds.
The type will be differs from other countries. Normally, the major consideration is the climate of the country. Usually, in the Europe, the industry will prefer to use HLP 46 whereas the climate is consider as cool. While in Malaysia, most of industry will prefer to use HLP 68 which the climate is much more hotter.
Ok. That's all for this time. Next time I will explained more on this Hydraulic Oil topic. The important of choosing the right hydraulic fluid / oil is very critical. Otherwise, the system will be malfunction. Worst case, all the system will totally damage ( and you will get scolded by your boss for causing more expenses...LOL)
Wednesday, September 22, 2010
Just For Fun (yet informative)
Ok..its been awhile after the last post Don't Pray-Pray With Leaking.
Time constraint is too tight. Work Load is too heavy. Roses are red violet are blue. Lol..just kidding.
For this post, please enjoy the videos posted. Its all about the Hydraulics. Remember Hydraulics, Remember Hydraulic Hubo.blogspot.com.
End.........
Time constraint is too tight. Work Load is too heavy. Roses are red violet are blue. Lol..just kidding.
For this post, please enjoy the videos posted. Its all about the Hydraulics. Remember Hydraulics, Remember Hydraulic Hubo.blogspot.com.
End.........
Tuesday, June 8, 2010
Don't Play-play with leaking!
Alright, since i have limited time, so this post will be super short yet informative!
One of the most common problem in hydraulic system is leaking. Normally took place at piping fittings connection, hydraulic cylinder hose connection fittings, hydraulic cylinder piston (normally called as inner leaking), valve connector, valve stand/block and flange packing.
Why leaking occur?
There are some reasons why leaking can occur but the popular reasons are:
- repetitive high vibration / shock at the piping.
- overheated hydraulic oil in the system.
- high contaminated / residue in the hydraulic oil.
- improper hydraulic system design
Why we must not neglecting leaking?
- high operation costing (hydraulic oil will flowing out from the piping / container through the leaking point. The higher the operation pressure, the faster oil will be drained out)....P/s: high operation cost mean high possibility to be scolded by superior....lol!
- reducing the efficiency of the hydraulic system.
- high possibility to allowed more dust, particle, to enter to the hydraulic system through the leaking point. As the result, your equipment will tear and wear faster than it supposed.
- allowing air to enter into the system which will causing cavitation. High cavitation is very dangerous for hydraulic pump. Eventually, hydraulic pumps must be filled with the hydraulic oil all the time during running. Dry running / air existence in the hydraulic pump will causing the component to damage!
One of the most common problem in hydraulic system is leaking. Normally took place at piping fittings connection, hydraulic cylinder hose connection fittings, hydraulic cylinder piston (normally called as inner leaking), valve connector, valve stand/block and flange packing.
Why leaking occur?
There are some reasons why leaking can occur but the popular reasons are:
- repetitive high vibration / shock at the piping.
- overheated hydraulic oil in the system.
- high contaminated / residue in the hydraulic oil.
- improper hydraulic system design
Why we must not neglecting leaking?
- high operation costing (hydraulic oil will flowing out from the piping / container through the leaking point. The higher the operation pressure, the faster oil will be drained out)....P/s: high operation cost mean high possibility to be scolded by superior....lol!
- reducing the efficiency of the hydraulic system.
- high possibility to allowed more dust, particle, to enter to the hydraulic system through the leaking point. As the result, your equipment will tear and wear faster than it supposed.
- allowing air to enter into the system which will causing cavitation. High cavitation is very dangerous for hydraulic pump. Eventually, hydraulic pumps must be filled with the hydraulic oil all the time during running. Dry running / air existence in the hydraulic pump will causing the component to damage!
So..DON'T 'PRAY-PRAY' WITH LEAKING!
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