Your pump’s efficiency and system pressure subtly diminish long before you notice anything wrong. With the cost of downtime rising, reactive hydraulic systems maintenance is no longer an option in many industries. Fluid analysis data lets you avoid costly component damage.
Why Fluid Analysis Data Acts as an Early Warning System
Every fluid and pump has different requirements, so there’s no one-size-fits-all schedule for changing hydraulic oil. Everything from your working conditions to your equipment’s age can impact the timeline. However, as you know, accuracy is vital. If you act too soon, you waste oil and money, but if you wait too long, you risk mechanical damage and inefficient operations.
Even a single skewed property can have potentially catastrophic effects. For instance, a 20% reduction in viscosity can increase the internal leakage rate by 25%. Whether the problem manifests as overheating, high-pitched whining or erratic operation, your system pressure and efficiency will diminish.
There are countless causes of hydraulic pump damage, but you can almost always find the origin by checking your fluid. While cracked components, clogged filters and worn seals are standard, contaminants are the leading culprit.
Faulty wiper seals are the most prevalent source. However, foreign particles in the environment or the internal components that shed microscopic metal debris can introduce contaminants. Either way, approximately seven in 10 hydraulic system failures stem from fluid impurities, which can severely damage the piston rod or seal surface.
Hydraulic fluid analysis data covers viscosity, changes in acidity, particle count, metal contamination, additive depletion and water contamination to determine cleanliness, chemical properties and resistance to flow. You can use it as an early warning system for pumps. Most laboratories will assess everything from color to oxidation characteristics.
How It Improves Hydraulic Systems Maintenance
Countless industries rely on hydraulic systems for their superior durability and reliability. They are significantly more affordable and dependable than diesel or air brake alternatives because they have fewer components, making them easier for you to upkeep and service.
However, suppliers and original equipment manufacturers are responsible for informing their customers about hydraulic fluid testing. Ensuring optimal performance and equipment lifespan is essential for preserving brand reputation because it impacts how consumers perceive their products.
Luckily, a fluid analysis is straightforward and cost-effective. A laboratory will test your sample using advanced tests like spectroscopy — a nondestructive technique that determines chemical composition using light. They will also conduct physical and visual evaluations to assess the oil’s cleanliness and material properties.
Of course, you benefit, too. You can identify early signs of wear and damage, since fluid analysis enables preventive hydraulic systems maintenance. The 2024 True Cost of Downtime report found that one hour of unplanned downtime can cost over $600 per second, depending on the industry, so this change could save you thousands annually.
Mitigating wear can extend your pump’s longevity, enhance its performance and lower hydraulic systems maintenance expenses. Moreover, site safety improves when operators don’t have to contend with erratic operation or low system pressure. Whether you own or rent equipment, testing provides peace of mind.
Monitoring Your Pump’s Health Using Hydraulic Fluid Testing
Collecting fluid analysis data through proactive testing enables preventive hydraulic systems maintenance, enabling you to mitigate unplanned downtime and optimize pump health with minimal investments. The savings achieved by proactively addressing problems typically offset the cost of sending a sample to a laboratory.
