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Tool Box Talk - How to Stop Hydraulic Leaks and Why

Very few organizations pay attention to hydraulic leaks and how they can impact production capacity, asset reliability, and reactivity when a mitigation strategy is in place.

This Tool Box Talk may help you take that next step.

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Tool Box Talk - How to Stop Hydraulic Leaks and Why

  1. 1. Tool Box Talk – How to Stop Hydraulic  Leaks and Why "When fluid is under pressure and leaks it can pull a vacuum thus allowing contamination to be introduced into system components causing partial and total functional failure" General Rules That Should Be Followed  These tips are not an option if you want to stop Hydraulic failures "Remember 10 microns is smaller than the size of a white blood cell" 1. Always add hydraulic fluid that has been filtered to the micron rating allowed for any component in the system. 2. When installing a new hose to replace a leaking one, change all fittings and hose at the same time and torque fittings. 3. When a hydraulic hose has wear it is a maintenance issue and needs to be solved with one of the following: a. Rerouting of hoses b. Protecting hoses using hose covers for reduce abrasive caused by hoses rubbing against other hoses or other items. 4. Ensure maintenance techs are trained in and use effective procedures. 5. Only a small portion of maintenance techs should possess the knowledge of troubleshooting hydraulics systems, unless a troubleshooting guide is developed and taught to everyone; however, anyone who touches a hydraulic system, from adding oil to changing hose, must be trained to a specification and standard. Here are some of the areas they must be trained on: a. Hydraulic Fluid Contamination Methods b. Proper Installation of Hydraulic Fluid c. Storage of Hydraulic Fluid d. Micron Level Required for Equipment e. Proper Installation of Hydraulic Hose – this is based on the hose and fitting manufacturers f. If required: Proper Manufacture of a Hydraulic Hose NOTE: One Micron is so small one cannot see it. Most hydraulic systems today must maintain their fluid at less than 10 micron absolute. 25 microns is the size of a white blood cell . Warning:  Intermix/Interchange with Other  Manufacturers’ Components practices could create system failure, partial and total functional failure. This practice can be dangerous. Leak‐tight seals that will  withstand high pressure, vibration, vacuum, and  temperature changes depend on close tolerances and  consistent, exacting quality control in conjunction with  good design principles. The critical interaction of precision  parts is essential for reliability and safety.   – The Swagelok Company Hydraulic Hose Most Common Failure Modes  Wear – Pump Failure due to Contamination Leakage  –  Caused by no one using the torque wrench causing contamination to be pulled in to the systems because of vacuum. "Oil Leaking out, Contamination coming in" • Leakage of hydraulic fluid from hydraulic fittings o Not following hose fitting or hose manufacturer’s recommended installation best practices o Fittings may even need to be torqued or the use of a gage may be required • Leakage of hydraulic fluid hoses based on wear, o Hoses are not routed most effectively or protected using a protective sleeve Safety is an issue with oil on the floor could cause someone to fall. Do not just clean up the Spill, "Eliminate the Root Cause if the Spill" Questions? send your questions to rsmith@worldclassmaintenance.org For a more detail article on "Maintenance of Hydraulic Systems" go to: https://bit.ly/3kUbQsZ

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