Mitigating risks of hydraulic equipment breakdowns and unscheduled maintenance: Addressing significant financial and operational setbacks
Hydraulic equipment and diesel-powered machines often operate under demanding conditions, where unexpected breakdowns and unscheduled maintenance can lead to significant financial and operational setbacks.
To mitigate these risks and ensure consistent performance, continuous monitoring of the fluids that power and lubricate these machines is crucial, according to HYDAC South Africa’s Mechatronics Engineer, Izak Lombaard.
Effective fluid monitoring not only safeguards the machinery’s health but also helps prevent costly production delays and operational inefficiencies.
HYDAC’s approach to fluid contamination monitoring is rooted in the understanding that proactive maintenance is key to optimising machine performance and avoiding expensive repairs. By offering a combination of real-time monitoring, comprehensive data analysis, and expert filtration solutions, HYDAC ensures that clients have the tools and knowledge necessary to keep their machinery running at peak efficiency.
Mr Lombaard draws a parallel between machine maintenance and human health: "Just as doctors perform tests and analyse blood samples to diagnose health problems, HYDAC analyses oil samples from machines to assess their condition. However, unlike humans who can recover after medical treatment, machines require constant, proactive monitoring to avoid catastrophic failure.”
A significant challenge, particularly in South Africa, is the lack of expertise in contamination and condition monitoring within plant and mining operations. This field is inherently complex, requiring expertise in both mechanical and electrical systems, as well as a deep understanding of contamination monitoring.
"Many of our customers in South Africa believe their maintenance practices are sufficient until they are asked to provide oil samples for analysis, which often reveals gaps in their approach," Mr Lombaard says.
HYDAC addresses these gaps by offering not only oil sample analysis but comprehensive evaluations of the customer's systems. This includes identifying beneficial and detrimental factors, recommending corrective actions, and advising on strategies to prevent contamination.
"Machines are often neglected without management’s knowledge, highlighting the need for real-time monitoring systems that deliver data through online platforms," Mr Lombaard adds.
Moreover, the use of diesel-powered machinery in South Africa and further afield in Africa underscores the need for sophisticated condition monitoring.
As engine technology advances, especially with Tier 4 and Tier 5 emission standards, maintaining the cleanliness of diesel fluid has become critical to preventing breakdowns. OEM manufacturers specify strict cleanliness standards, including water content limits, necessitating precise and continuous monitoring.
HYDAC offers specialised filtration solutions, including dewatering coalescing filters, to address these challenges.
Traditionally, condition monitoring has been conducted through the analysis of oil samples. This process involves extracting a small amount of oil — typically around 100 ml — and sending it to a laboratory for testing. These tests assess parameters like particle and water content, as well as more complex contaminant analysis.
While effective, this method can be delayed due to the time it takes for sample collection, testing, and reporting. Reports often arrive one to two weeks after the sample is taken, which can hinder timely decision-making, Mr Lombaard highlights.
Furthermore, a common issue with traditional sampling in South Africa and Africa is the lack of skilled personnel equipped to correctly interpret reports. As a result, reports are sometimes stored without being thoroughly reviewed or acted upon.
To alleviate these challenges, HYDAC provides a comprehensive solution.
The company offers customers a clean, precise sampling kit to collect oil samples on-site.
"Traditional sampling methods carry the risk of contamination during the collection process as the container used for sampling may not be clean, compromising accuracy," Mr Lombaard says. "HYDAC's focus on the cleanliness of oil sampling kits and hygienic analysis ensures no contamination can take place."
Once collected, the samples are returned to HYDAC's in-house laboratory in Johannesburg for analysis. The results are then uploaded to the HYDAC Fluid Care portal, where customers can register their machinery and set specific contamination limits, thereby preventing damage and ensuring that equipment remains in optimal condition.
HYDAC's online condition monitoring solutions see sensors installed directly onto equipment, providing real-time data on a variety of parameters such as particle contamination, water saturation, temperature, pressure, flow, and electrical conductivity. These sensors can differentiate between ferrous and non-ferrous particles, which is particularly useful for identifying specific failures in components like bearings or gears.
Real-time monitoring provides immediate feedback, enabling operators to act swiftly when abnormalities are detected. The data can be integrated into a SCADA system, providing operators with easy access to critical information about the system’s condition.
"However, the challenge remains when operators and maintenance personnel lack the expertise to interpret the data and take the necessary corrective actions," Mr Lombaard emphasises.
To further improve accessibility and responsiveness, HYDAC has developed the CMX Cloud solution. This innovative system allows monitoring data to be collected and stored in the cloud, enabling remote access for engineers and maintenance staff.
This is particularly beneficial for companies managing multiple sites, as engineers can monitor all locations in real-time, and receive instant notifications of any detected issues via email or SMS.
The CMX Cloud solution also provides access to historical data, allowing for comprehensive analysis and trend identification. By proactively addressing potential issues, HYDAC helps clients minimise equipment failure, reduce downtime, and resolve concerns such as high particle contamination.
HYDAC’s commitment to excellence goes beyond monitoring and data analysis. The company offers a variety of filtration solutions, including a rental fleet of equipment designed to address issues related to high water content in fluids.
Measuring contamination levels in fluids according to ISO standards, include tests conducted through the Karl Fischer moisture test to determine water content, and analysing the Total Acid Number (TAN) to assess fluid acidity. Varnish tests can also be conducted. Furthermore, HYDAC employs advanced techniques such as high-resolution imaging to analyse oil samples, providing a detailed view of the fluid's condition.
These comprehensive capabilities enable clients to take timely corrective actions, extend equipment lifespan, and make more informed decisions regarding resource allocation.
HYDAC’s commitment to proactive maintenance, coupled with its advanced cloud-based solutions, positions the company as a leader in condition monitoring. By offering real-time data, expert analysis, and specialised filtration solutions, HYDAC helps customers across various industries improve the reliability and longevity of their equipment while reducing operational costs.
