Hydraulic Equipment Repairs and Maintenance for the Energy Industry
The energy industry needs hydraulic equipment to install and maintain O&G pipelines – which are a critical part of every energy company’s operation. It’s also a tough job that places intense stress on hydraulic equipment systems.
Expert hydraulic maintenance and the occasional repairs can offset that wear and tear and keep your hydraulic equipment in the field. That includes your hydraulic pumps, hydraulic cylinders and hydraulic spreaders.
Hydraulic Pump Maintenance for the Energy Industry
Your hydraulic pumps are responsible for delivering fluid power to hydraulic jacks, rams, cylinders and spreaders. The pumps are the heart of any hydraulic system, and if they are showing any troubling signs of problems – unusual operating sounds, loss of power delivery, overheating, etc. – follow up with a reputable hydraulic equipment technician.
To minimize the risk of downtime-causing failures, the following preventative maintenance routines should be on the schedule:
- Check hydraulic fluid levels and quality – Inadequate hydraulic fluid levels can cause issues with flow and aerate the fluid, which itself can lead to serious internal wear problems.
To avoid hydraulic fluid-related issues, check fluid levels before operation and, if necessary, fill the hydraulic pump’s reservoir, but carefully. Pour the fluid slowly and do not contact the lip of the fluid container with anything else, as this may introduce contaminants.
At least once a month, take a hydraulic fluid sample from a test point connected to the system – choose a test point near the hydraulic pump’s outflow to determine whether contamination is circulating through the reservoir.
Visually inspect this sample for any signs of sediment. Every few months, send a hydraulic fluid sample to a lab for chemical analysis. This will detect any sediment invisible to the naked eye and provide advance warning of contamination issues.
- Inspect for any hydraulic fluid leaks – A drop in flow can often be attributed to a hydraulic fluid leak. Some of these leaks are external, others are internal.
External hydraulic fluid leaks are obviously easier to spot, as you may see the fluid pooling around your hydraulic equipment or running off it. Note that hydraulic fluid may pool away from the actual leak. If you spot fluid, clean the hydraulic pump and shut it down until a hydraulic equipment expert has a chance to inspect the system.
A common sign of internal leaks is power loss. If your hydraulic cylinders or spreaders aren’t stroking smoothly and fully, it could be due to an internal leak and bypass in your hydraulic system. Dropping hydraulic fluid levels may also indicate an internal leak.
You can isolate an internal hydraulic fluid leak by installing flow meters in line and determining where the fluid isn’t flowing like it should.
- Clean thoroughly, clean often – Contamination is the leading cause of hydraulic system failures, and while there’s no surefire way to keep it out completely, cleaning the hydraulic pump’s body, drive shaft, connections and fluid reservoir can keep contamination at bay for as long as possible.
Wipe down all external surfaces with a cloth or brush and clean the inside of the fluid reservoir with a lint-free cloth. You may use a mild solvent to break down contaminants but be careful with this. Some solvents can damage the seals.
Hydraulic Cylinder Maintenance for the Energy Industry
Hydraulic cylinders and actuators convert fluid power from the pump into linear force. It’s a stressful process that causes significant wear and tear, but preventative maintenance can help mitigate this and includes:
● Inspecting the hydraulic cylinders seals – The seals are always a weak spot in any hydraulic system and that’s also the case with hydraulic cylinders. There are several seals inside every hydraulic cylinder, including the wiper, rod, piston and buffer seals, and if they fail, it can cause severe internal leaks or allow contaminants to rapidly enter the system.
Every few months, when it’s time for a full equipment inspection, check the seals to verify that they are in good condition.
● Inspect the piston rod for signs of wear – The piston rod takes on most of the load when stroking and therefore takes on a lot of wear. During a full hydraulic cylinder inspection, take a close look at the rod and check for any clear signs of damage. Pitting, scoring and signs of corrosion may necessitate rod replacement.
● Clean and lubricate the piston rod – Consistent cleaning is also important for keeping contamination out of your hydraulic cylinder. The piston rod requires the most attention and should be cleaned with a mild solvent to remove any old lubricant. Once cleaned, reapply fresh lubricant to the cylinder rod to protect it.
Hydraulic Spreader Maintenance for the Energy Industry
Like hydraulic cylinders, hydraulic spreaders apply intense forces during operation. Generally, they are used to open up flanges to give maintenance personnel access during pipeline maintenance. To keep your hydraulic spreads in usable condition, the following maintenance routines are recommended:
- Cleaning the spreader following operation – Hydraulic spreaders are easy to keep clean, but it’s important to be consistent with it, as contamination is also a threat to spreaders. Wipe the hydraulic spreader down after use and verify there is no fluid present on the spreader body or arms.
- Tightening all hardware – Fastening hardware and connections can jar loose during repeated operation. Make sure these are torqued prior to spreading to ensure stability during use.
- Pressurizing and inspecting the hydraulic spreader – The best way to spot emerging problems with your hydraulic spreaders is to pressurize them and note how they perform. If they handle roughly or can’t come up to full capacity, these are clear signs of impending failure.
It is also important to occasionally inspect the hydraulic spreader’s arms and body for any signs of wear or damage. Dents, cracks, fractures, scoring and pitting can all affect how the spreader performs and should be addressed by a hydraulic equipment expert.
A Hydraulic Equipment Expert Can Help Energy Companies Optimize Their Hydraulic Assets
Hydraulic pumps, cylinders and spreaders provide energy businesses with excellent reliability and value when they’re properly maintained. Otherwise, they will be prone to sudden, extended failures.
This can have devastating consequences on your operations and your organization’s profitability.
Partnering with a hydraulic equipment technician will minimize this risk, with preventative and responsive maintenance that will extend your equipment’s life and optimize its performance.