The Cost of Contaminated Hydraulic Fluid

Hydraulic equipment operates under higher pressures and tighter tolerances than ever before. As such, the purity of hydraulic fluid becomes paramount. Contamination in hydraulic fluid jeopardizes equipment performance and poses the risk of clogs and damage to critical components.

Effectively managing contamination levels optimizes equipment longevity by minimizing wear and tear and reducing the frequency of fluid replacement. Also importantly, adhering to federal and local regulations on hydraulic fluid disposal ensures environmental responsibility and mitigates disposal costs. Here, we discuss the multifaceted costs associated with hydraulic fluid contamination, shedding light on its implications and the need for a proactive approach.

Types of Hydraulic Fluid Contamination

Contaminated hydraulic fluid poses a grave threat to the efficiency and durability of your equipment, potentially resulting in substantial costs for your company. The nature of the damage varies depending on the type of contamination, but its consequences are universally detrimental.  

Jammed Components

Typically, fluid contamination begins with mechanical components becoming jammed, setting off a chain reaction of deteriorating conditions. As jammed equipment introduces new contaminants into the system, the situation worsens rapidly, exacerbating the damage and compromising equipment functionality.

Water Infiltration

Infiltration of water or particulates into the hydraulic system leads to the formation of insoluble sludges and solid precipitates, obstructing vital components such as pumps, nozzles, and jets. Solid particles act as abrasive agents, generating a grinding paste within the machinery, accelerating erosion and wear on delicate surfaces.

Tight Clearances 

With its tighter clearances, modern equipment is especially vulnerable to even the tiniest particulates, given that some machines operate with oil thicknesses as minimal as 5-10 microns. Contaminants exceeding this size disrupt the lubricating properties of the oil, exacerbating the damage and necessitating costly repairs.

The Result of Contaminated Hydraulic Fluid

Regardless of the specific contamination type, any form of hydraulic fluid contamination results in diminished performance and increases the risk of expensive repairs. In severe cases, contamination can even lead to catastrophic equipment failure, severely impacting operations and finances. While wear-and-tear is an inevitable aspect of equipment operation, effective management of hydraulic fluid contamination is essential to prevent issues from spiraling out of control and prolong the overall lifespan of your machinery.

Investing in proactive contamination control measures safeguards your equipment and saves your company significant time and money in the long run. Prioritizing maintenance and adherence to contamination control protocols is paramount for preserving equipment integrity and optimizing operational efficiency.

The Cost of Contaminated Hydraulic Fluid

Contaminated hydraulic oil poses many risks to your valuable equipment and overall operational efficiency. The potential consequences extend beyond the immediate financial burdens of repairing or replacing expensive machinery. Downtime resulting from idle workers and diminished productivity compounds the costs associated with contaminated fluid.

Foremost among the risks is the vulnerability of the system’s central component: the pump. As the heart of your hydraulic setup, the pump is often the first point of failure when contamination occurs. The expenses involved in replacing a damaged pump, along with contaminated hoses and filters, far outweigh the costs associated with proactive measures such as equipment shutdowns for cleaning and repairs. Implementing rigorous maintenance practices and strict protocols for introducing fluid into the system is crucial to averting potential catastrophes.

Detecting Contaminated Hydraulic Damage

The initial indication of hydraulic fluid contamination damage typically manifests in pump malfunction. Scoring on the internal components caused by circulating contaminants is another early warning sign. Recognizing that contaminants behave differently depending on the oil’s temperature dynamics is essential. While warm oil facilitates the continuous circulation of contamination particles, cooling the oil during equipment shutdown allows debris to settle, with contaminants adhering to surfaces.

Various symptoms may emerge depending on the type of contamination present. Unusual noises, sticky valves, or sluggish machine performance are all potential indicators of impending trouble. Vigilantly observing these early signs empowers proactive intervention to address the issue before contaminated fluid inflicts severe damage. 

By promptly identifying and addressing contamination issues, you can safeguard equipment integrity and mitigate the risk of costly repairs and downtime.

Avoiding Contaminated Hydraulic Fluid

Hydraulic fluid contamination stems from two primary sources: internal and external factors. Internal contamination arises from equipment’s everyday wear and tear during operation, where friction produces particulate matter and rubber seals degrade over time. While inevitable, this can be managed through regular maintenance and filters. Additionally, contamination may occur during manufacturing or servicing, necessitating the flushing of hydraulic fluid in newly purchased or serviced machines.

On the other hand, external contamination originates from outside the system and can include air, water, and chemicals. Preventing external contamination involves keeping hydraulic fluid containers tightly sealed and stored in controlled environments to avoid exposure to moisture and debris. Regularly flushing containers helps prevent the introduction of microscopic particulates into fresh hydraulic fluid. 

It’s crucial to use high-quality hydraulic fluid recommended by the manufacturer to ensure compatibility and avoid damage. Leaks from damaged seals can also allow contaminants to enter the system, highlighting the importance of prompt repair. While older equipment may tolerate contamination better due to lower pressure and greater clearances, newer equipment operates at higher pressures and finer tolerances, demanding cleaner hydraulic fluid for optimal performance and longevity. 

Prioritizing proper maintenance and contamination control measures ensures equipment longevity and superior performance in the long term.

Discover How Delta Can Support You

At Delta Hydraulics, we recognize the paramount importance of maintaining the purity and dependability of your hydraulic fluid. Effectively controlling hydraulic fluid contamination is pivotal for ensuring optimal operation and longevity of your equipment. Additionally, contamination escalates the frequency of necessary fluid changes, contributing to significant disposal costs.

Should your hydraulic system need maintenance, don’t hesitate to contact us today! Our team stands ready to deliver the expertise and attention your equipment demands, empowering you with the necessary skills to uphold a clean, pure, and worry-free hydraulic system.