3 Ways to Detect Cavitation Wear in

Hydraulic Systems

"We think cavitation wear may be occurring in

our hydraulic system but don't know for sure. Is there a way to determine this?"

Cavitation can be determined by three easy means of detection: abnormal noise, high fluid
temperature and slow operation.

Abnormal noise can be caused by two sources: aeration and cavitation. Aeration is the more
alarming of the two. Sometimes referred to as hammering, it occurs when air is entrained
in the system. Large air bubbles compress and decompress, resulting in a "banging" noise. In
severe cases, this can lead to the failure of piping and equipment. It may also be confirmed
by foaming and erratic operation of actuators.

In the case of cavitation, the absolute pressure falls below the vapor pressure of the fluid,
creating vapor cavities. These cavities will implode, which produces a knocking sound. This
can be identified with vibration sensors or acoustical analysis equipment. At times, this may
even be loud enough to be heard. The source of this noise is actually the implosion and
subsequent micro-jet impinging on the surfaces of the system. Imagine a very small water
jet cutting on the system surfaces. This constant impingement sounds similar to a growling
or rattling in the system.

High fluid temperature is the result of the compression of air and other entrained gases in
the fluid, or when the fluid moves from a high-pressure to low-pressure area without
performing useful work. This takes place when the fluid leaks past internal seals in a
piston/cylinder arrangement or when there is an improperly adjusted relief valve.

If the heat is not dissipated, it can have an effect on the viscosity of the fluid, which impacts
the lubrication of the system and components as well as causes other problems that increase
the likelihood of further cavitation. Research has shown that the higher the viscosity, the
lesser the impact and likelihood of cavitation. The inverse of this is also true; as the viscosity
decreases, the likelihood of damage from cavitation increases.

Slow operation and longer cycle times are usually the first indication that there is a problem.
Remember that the operation of the system is based on flow. If there is a loss of speed in
your actuators, there is likely a loss of flow somewhere in the system. This is generally
caused by leakage, such as from a ruptured hose, blown seals, leaking fittings, etc. These
are fairly obvious and easy to correct.

Internal leakage is much more difficult to identify but not impossible. When fluid moves from
a high-pressure to low-pressure zone without doing work, heat is generated. This can be
determined with infrared thermometers, sometimes in conjunction with flow meters.

In short, noise, temperature and cycle times are good indicators of cavitation in your
hydraulic systems. As with everything else, early detection is the best way to prevent
equipment failure and subsequent downtime. Be proactive and look for these indicators.
Failure to do so can have a huge impact on the bottom line.

Best Way to Check an Oil's Sludge

Formation Tendency

"What is the best way to check the sludge formation

tendency of a new hydraulic fluid?"

ASTM D2070 is a test method that's "designed primarily to evaluate the thermal stability of
hydrocarbon-based hydraulic oils, although oxidation may occur during the test." This
oxidation may result in sludge, which is measured and recorded in milligrams per 100
milliliters.

This description of D2070 could lead you to believe that the test will provide an adequate
indication of the sludge formation tendency of a mineral-based fluid. However, you must also
consider the scope of ASTM D4310, which states, "This test method covers and is used to
evaluate the tendency of inhibited mineral oil based steam turbine lubricants and mineral oil
based anti-wear hydraulic oils to corrode copper catalyst metal and to form sludge during
oxidation in the presence of oxygen, water, and copper and iron metals at an elevated
temperature. The test method is also used for testing circulating oils having a specific gravity
less than that of water and containing rust and oxidation inhibitors." This test is specifically
designed to quantify the sludge formation tendency of a mineral-based steam turbine oil or
hydraulic fluid.

It should be noted that although D2070 will give an indication of the sludge content due to
oxidation of the copper and steel rods, it is more of an acknowledgement of the sludge as a
byproduct rather than a test specifically for sludge. On the other hand, D4310 is exclusively a
test for the measurement of the sludge formation and corrosion tendency of a mineral-based
turbine or anti-wear hydraulic fluid.

It would be easy to confuse these two tests, as they are seemingly quite similar. However,
the D4310 standard is more of an involved test procedure than D2070, which uses copper
and steel rods in combination with heat. D4310 utilizes copper and steel coils in combination
with water and heat to oxidize the oil for the purpose of forming sludge.

Procedure "A" of ASTM D4310 requires the determination and report of the weight of the
sludge and the total amount of copper in the oil, water and sludge phases. Procedure "B" of
ASTM D4310 involves the sludge determination only.

Keep in mind that while the D2070 test method can lead to the formation of sludge, the
D4310 test procedure will result in sludge formation. Although the two tests may seem
similar, they are examining two different properties of a mineral-based fluid.

9 Factors for Selecting Oil Seals

We just discovered that one of the seals on our pumping

system is leaking. Do you have any ideas as to what could have caused this, and can you
offer some advice for selecting a good seal?

The main causes of external lubricant leakage from pumping systems, hydraulic machines,
gearcases and sumps are the wrong selection, improper application, poor installation and
inadequate maintenance practices that are applied to sealing systems. These problems can
be overcome through a better understanding of the types of sealing materials available,
redefined selection procedures and the consistent application of sound replacement and
maintenance practices.

A number of variables must be considered when selecting oil seals. There are nine factors
that designers and maintenance engineers must evaluate when oil seals are specified:
Shaft Speed

The maximum allowable shaft speed is a function of the shaft finish, runout, housing bore
and shaft concentricity, type of fluid being sealed and the type of oil seal material.

Temperature

The temperature range of the mechanism in which the seal is installed must not exceed the
temperature range of the seal elastomer.

Pressure

Most conventional oil seals are designed only to withstand very low-pressure applications
(about 8 psi or less). If additional internal pressure is present or anticipated, pressure relief
is necessary.

Shaft Hardness

Longer seal life can be expected with shafts having a Rockwell (RC) hardness of 30 or more.
When exposed to abrasive contamination, the hardness should be increased to RC 60.

Shaft Surface Finish

Most effective sealing is obtained with optimum shaft surface finishes. The sealing efficiency
is affected by the direction of the finish tool marks and the spiral lead. Best sealing results
are obtained with polished or ground shafts with concentric (no spiral lead) finish marks. If
you must use shafts with spiral finish leads, they should lead toward the fluid when the shaft
rotates.

Concentricity

When the bore and shaft centers are misaligned, seal life will be shortened because the wear
will be concentrated on one side of the sealing lip.

Shaft and Bore Tolerances

The best seal performance is achieved when close shaft and bore tolerances are present.
Other factors include shaft eccentricity, end play and vibration.

Runout

Runout must be kept to a minimum. Movement of the center of rotation is usually caused by
bearing wobble or shaft whip. When coupled with misalignment, this problem is compounded.
Contrary to popular belief and common practice, the installation of flexible couplings cannot
correct or compensate for misalignment.

Lubricant

Seals perform much better and longer when they are continuously lubricated with an oil that
has the correct viscosity for the application and that is compatible with the seal lip elastomer
material. The consideration of seal incompatibility, particularly with certain additives and
some synthetic lubricants, should not be ignored, but unfortunately very often is.

Causes of Hydraulic Pump Failures

"What could be the reason for a hydraulic pump failure

and how can we prevent such failures in the future?"

A hydraulic pump failure can be caused by a number of factors. There are several different
types of pumps available on the market, and each can have its own specific failure mode. Of
course, certain failure modes are common to all types of pumps. Some of these failures can
be caused by poor system design, using low-quality fluids and/or poor contamination control.

The best way to prevent future failures is to ensure that you are using quality hydraulic
fluids. Keep in mind that the fluid is the single most important component of a hydraulic
system, so always use high-quality hydraulic fluids with the correct viscosity.

Hydraulic fluids should also be kept clean, cool and dry. This is highly important. One of the
ways you can do this is through quality filtration. Filters should be selected only if they
achieve the target cleanliness levels that have been set for the fluid in the system. Also, use
quality filters in locations that assure the required protection and upgrade the filters when
necessary.

In addition, consider the possibility of using offline filters, because the cost of removing dirt
is often much less in an offline mode than trying to do everything in a pressure-line filter
location on the hydraulic system.

It is estimated that between 70 to 80 percent of hydraulic system failures are from

contamination, with particle contamination making up the largest portion. Therefore, it is
best practice to regularly perform oil analysis with particle counts.

Remember, the hydraulic pump is generally the most expensive component on a hydraulic
system. It has the highest reliability risk, the highest contaminant sensitivity risk and the
ability to cause chain-reaction failures. In other words, when the pump starts to fail, it starts
to kick out debris into a debris field downstream of the pump. If there is not a good filter
downstream, this debris moves on to other components like valves and actuators, and can
lead to damage in those components as well.

Be wary of quick-fix solutions like switching to costly synthetics and expensive filtration
systems. Instead, provide solutions to the problems that exist. It is critical to set the proper
cleanliness and dryness targets and to develop contamination control procedures that will
allow you to meet those targets. By doing so, you should greatly reduce and possibly
eliminate your pump failures.

10 Hydraulic Reliability Checks You

Probably Aren't Making

When most people think of preventive maintenance and

reliability procedures for a hydraulic system, regularly changing filters and checking the oil
level are the only things considered. When the machine fails, there is often very little
information about the system to refer to when troubleshooting. However, proper reliability
checks should be done with the system running under normal operating conditions. These
checks are vital for preventing equipment failures and downtime.

Inspecting the Filter Bypass Valve

Most hydraulic filter assemblies have a bypass check valve to prevent damage in the event
the element becomes plugged with contamination. This valve will open whenever the
differential pressure across the filter reaches the spring rating of the valve (usually 25 to 90
pounds per square inch, depending on the filter design). When these valves fail, they
normally fail in the open condition due to contamination or mechanical malfunction. When
this occurs, the oil will bypass the element without being filtered. This will lead to premature
failure of the downstream components.

In many cases, this valve can be removed from the housing and inspected for wear and
contamination. Consult the filter manufacturer's documentation for the specific location of
this valve and the proper removal and inspection procedures. This valve should be inspected
periodically when the filter assembly is being serviced.

Hose Condition

Leakage is one of the biggest problems in a hydraulic system. Proper hose assembly and
replacement of defective hoses is one of the best ways to reduce leakage and prevent
unnecessary downtime. Hoses should be inspected regularly for leakage and deterioration.
Hoses that show wear on the outer jackets or leakage at the hose ends should be replaced as
soon as possible. A hose that has "blisters" indicates a failure of the inner lining of the hose,
allowing the oil to leak through the metal braid and collect under the outer jacket.

Hose Length

Whenever possible, hose length should not exceed 4-6 feet. Excessive hose length will
increase the possibility of the hose rubbing against other hoses, a catwalk or a beam. This
will lead to premature hose failure. In addition, when a pressure spike occurs in the system,
the hose can absorb some of the shock. When this occurs, the hose length can change
slightly. The hose should be made long enough so that it has a slight bend to absorb these
shock spikes.

Hose Routing

Where possible, hoses should be routed in a way that prevents them from rubbing against
each other. This will prevent premature failure of the outer jacket of the hose. In the event it
is not possible to route hoses to prevent rubbing, protective sleeves should be used. Several
types of sleeves are commercially available for this purpose. Sleeves can also be made by
cutting an old hose to length and slitting it lengthwise. The sleeve can be placed over the
hose at the rub point. Plastic cable ties should also be used to fasten the hoses together. This
prevents relative movement of the hoses at the rub points.

Check for Proper Clamping

Proper hydraulic pipe clamps should be used. Conduit clamps are generally not acceptable for
hydraulic lines due to the vibration and pressure spikes inherent in a hydraulic system.
Clamps should be inspected regularly for loose mounting bolts. Broken clamps should be
replaced. In addition, clamps should be properly spaced. A good rule of thumb is to space
clamps approximately 5-8 feet apart and within 6 inches from where the pipe terminates.

Breather Cap Maintenance and Inspection

Breather caps are some of the most neglected items in a hydraulic system, but keep in mind
that a breather cap is a filter. The reservoir oil level constantly changes as cylinders extend
and retract, and the breather cap (filter) is the first line of defense against contamination. To
prevent contamination from entering the reservoir from the outside, a proper breather filter
of the appropriate micron rating should be used. Several manufacturers offer breather filters
in the 3-micron range that also remove water from the air by using desiccant materials. The
desiccant will change color when saturated with moisture. These filter assemblies will pay for
themselves many times over when changed on a regular basis.

Measuring Drive Motor Current Draw

The amount of power required to drive a hydraulic pump is dependent on the system
pressure and flow. As the pump wears, the internal bypassing increases due to increased
internal clearances. This results in decreased pump output. With the pump delivering less
flow to the system, the power required to drive the pump will decrease proportionally.
Therefore, the drive motor current draw will decrease. A record should be made of the
current draw when the system is relatively new to establish a baseline reference.

Temperature Checks

As system components wear, the internal clearances increase. This leads to increased
bypassing. Whenever this bypassing occurs, heat is generated. This heat does no useful work
in the system; therefore, energy is wasted. By using an infrared camera or some other type
of heat-detecting device, this bypassing can be found. Bear in mind that heat is generated
whenever a pressure drop occurs, so localized heat will always occur in any device that
meters flow, such as a flow control or proportional valve. Making regular inlet and outlet oil
temperature checks on heat exchangers will give an indication of the overall heat
exchanger's efficiency.

Sound Checks

Regular sound checks should be made, especially with hydraulic pumps. Cavitation occurs
whenever the pump cannot get the total amount of oil it is calling for at the suction port. This
will produce a steady, high-pitched whining sound. If not corrected, the pump will deliver a
reduced output until it destroys itself. The most common cause of cavitation is a plugged
suction strainer. It may also be caused by excessive oil viscosity (low temperature) or
excessive drive motor revolutions per minute (RPM). Aeration occurs whenever outside air
enters the suction port of the pump. It will produce a more erratic sound. Causes of aeration
include an air leak in the suction line, low fluid level or a bad shaft seal on a fixed
displacement pump.

Pressure Checks

Pressure checks should be made regularly. This will give an indication of the condition of
several components in the system, such as accumulators and various pressure control
valves. If the pressure drops more than 200 pounds per square inch (PSI) while the
actuators are moving, this may indicate a problem. A record should be made of these
pressures when the system is operating normally to establish a baseline reference.