Walk into a modern manufacturing facility and the deep, rhythmic pulse of machines working in harmony will impress and amaze you. Poetry in motion, churning output in well-drilled unison. Hydraulic presses power into motion, actuators respond on cue, and control systems maintain the flow of production with great precision. It runs like clockwork; but often it’s the things you don’t see, or hear, that carry the most telling signs of irregular system health.
To illustrate this, consider this example, based on real-world conditions in a heavy-duty hydraulic operation. A fabrication plant outside Johannesburg began noticing subtle changes in one of the primary hydraulic presses. This press was central to forming structural steel components, and was vital to truck chassis assembly. While it was still functional, something felt wrong. There were slight delays in the stroke return and movements that lacked their usual sharpness. Most plant workers wouldn’t have noticed, but to seasoned operators familiar with the machine’s behaviour, the change was noticeable.
This press depended on electrohydraulic control valves for rapid response and overall precision. It is often overlooked that these components are very vulverable to miniscule levels of ingress and contamination. Tiny particles, invisible to the naked eye, can erode valve surfaces, damage seals or jam intricate internal spools. Contamination rarely announces itself with a bang, it slowly impedes performance.
Fortunately, the system in question had comprehensive filtration and ongoing monitoring in place. A high-pressure inline filter was installed operating just downstream of the pump, working in tandem with a return-line filter equipped with clogging indicators. Additionally, a contamination monitor was installed on an offline kidney filter, offering real-time ISO 4406 cleanliness readings. These control features were incorporated into the system design based on recommendations by Hydrasales, a long-standing advocate for clean and reliable hydraulic systems.
The contamination monitor recorded a steady rise in particles, particularly in the 4 μm and 6 μm range. Shortly after the return filter’s clogging indicator turned red, maintenance acted swiftly, replacing the filter and inspecting the filter media. The results revealed fine metallic debris, filings. Further inspection traced the contamination to internal wear along the barrel wall of a hydraulic cylinder, caused by thinning guide rings and a damaged piston seal. A potentially catastrophic failure was averted by timely intervention.
This was before a breakdown and was an early warning and a powerful reminder of the value of proactive system monitoring. Filtration doesn’t only involve removing contaminants, it protects performance. This protection begins with appropriate component placement. High-pressure inline filters, positioned immediately after the pump, act as the first line of defence, trapping harmful particles before they reach sensitive equipment. Most modern systems operate under extreme pressure and high flow rates. Only filters designed for such demands can deliver the requisite performance output without compromising efficiency.
Protection doesn’t stop there. Suction filters shield pumps from coarse contaminants during startup. Return-line filters ensure the fluid returning to the tank is clean. Tank-mounted breathers can prevent moisture and airborne particles from entering the reservoir. Together, they can contribute to a layered strategy for total fluid cleanliness.
Even the best filter is only effective if you know when it needs replacing, and that’s where monitoring tools, such as clogging indicators and real-time contamination monitors, are essential. They provide insight into system performance by tracking fluid condition. This empowers maintenance teams to act before issues become emergencies.
At Hydrasales, our approach to fluid cleanliness is built on prevention, not reaction. Our filtration and monitoring solutions include:
• High-pressure inline filters for core system protection
• Return and suction filters for complete loop filtration
• Tank-mounted breathers and accessories to protect from external contaminants
• Contamination monitors and clogging indicators for real-time maintenance insights
• A comprehensive range of absolute filter elements needed for optimum efficiency
We team up with our customers to supply components and help them build clean and efficient systems that last. No matter if you’re working with mobile equipment, industrial installations, or just getting a feel for it, listening to your hydraulic system can make all the difference.
| Tel: | +27 11 392 3736 |
| Email: | [email protected] |
| www: | www.hydrasales.co.za |
| Articles: | More information and articles about Hydrasales |
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