Water Contamination in Hydraulic Systems
Water is a major enemy of hydraulic systems, causing a variety of problems. Here’s a breakdown of its sources, consequences, and what to do if you suspect contamination:
(a) Sources of Water Contamination:
- Condensation: Moisture in the air can condense inside the system, especially during temperature fluctuations.
- Leaking Seals: Worn or damaged seals around pistons, rods, or reservoirs can allow water to enter.
- Breather Contamination: Breather filters are designed to prevent dust and moisture, but malfunctioning or clogged filters can let water in.
- Coolant Leaks: If a heat exchanger leaks coolant (often water-based) into the hydraulic fluid, it can cause contamination.
- Improper Maintenance Practices: Leaving the system open during maintenance or using contaminated refilling fluids can introduce water.
(b) Consequences of Water Contamination:
- Corrosion: Water reacts with metal components, leading to rust and accelerated wear.
- Cavitation: Water vapor bubbles can form and collapse under pressure, damaging pump components.
- Reduced Lubricity: Water weakens the lubricating film of the hydraulic fluid, increasing friction and wear.
- Sludge Formation: Water and contaminants can mix, forming sludge that clogs filters and restricts flow.
- Freezing: In cold environments, water can freeze and damage components.
- Reduced Efficiency: All these problems combine to decrease overall system efficiency and performance.
(c) Actions to Take if Water Contamination is Suspected:
- Fluid Analysis: Perform a test to determine the water content in the hydraulic fluid.
- Visual Inspection: Look for a milky appearance in the fluid, which can indicate water contamination.
- Identify the Source: Investigate potential entry points for water to locate the source of the problem.
- System Flushing: If water contamination is confirmed, the system needs to be flushed with clean fluid to remove the water.
- Filter Replacement: Change all filters in the system to remove any trapped water.
- Seal Repair/Replacement: Replace any worn or damaged seals that might be allowing water ingress.
- Dehydration Process: In severe cases, specialized dehydration equipment may be required to remove large amounts of water.
- Preventive Maintenance: Implement a regular maintenance schedule that includes fluid analysis, filter changes, and inspection for potential leaks.
By taking these steps promptly, you can minimize the damage caused by water contamination and ensure the smooth operation of your hydraulic system.