Hydraulic Pump Stop Operated by itself after a certain hours

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 =)

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:

• 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..=)

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:

• 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.