Reduce expensive hydraulic system downtime [image] Learn more about our oil flushing container workshops

Reduce expensive hydraulic system downtime

As the cost of sophisticated, high pressure systems continues to rise, proactive maintenance is imperative to maximise the system service life and minimise operating costs. The single most important preventive maintenance procedure is regular oil sampling and analysis. Over 96% of all hydraulic failures can be traced directly to oil that has been improperly cared for.

As long as the oil has not lost viscosity and has not been damaged by overheating, it can normally be reused by flushing the system. When the oil is just drained from the reservoir and the system replenished, several gallons of old oil and residues are left in the lines and components.

As new clean oil is introduced, it mixes with the old oil, absorbing the contaminants, circulating them through the system again to cause further damage. Flushing the system is the only way to remove these potentially damaging residues as part of the maintenance regime.

At Rolls-Royce, we recommend the following process to reduce expensive downtime:

  1. Clean the hydraulic system properly
  2. Keep the system clean
  3. Monitor the hydraulic fluid
  4. Maintaining cleanliness levelsAll flushing system units are based on ISO containers and are designed to operate virtually anywhere.

Strategically located at hubs around the world, we aim to service our customers globally by working around your vessel’s schedule.

Keeping your hydraulic system clean

1.  Flushing cleans the system properly

As the cost of sophisticated, high pressure systems continues to rise, proactive maintenance is imperative to maximise the system service life and minimise operating costs.

Always flush a new or a rebuilt hydraulic system, filter the oil up to the required NAS level or ISO code. Rolls-Royce provides this service and will inspect and verify that the system, the hydraulic piping, storage tanks and filling routines meet the required standards.

Our flushing units are hired out with a trained technician, as no matter how good the machine, it is only as good as the man operating it. We provide a full flushing report and plus documentation to customer specification.

2. Keeping your system clean

Once the system has been fully flushed, always fill the tank with oil, filtered to the manufacturer’s standards. New equipment, hoses, pipework must never be installed without checking they have been properly cleaned.

The Rolls-Royce flushing unit supplies the filtered oil and a variety of filter units, custom made or in stock filter trolleys can be made available.

  • Filters for our units in stock
  • High-pressure hydraulic work

3.  Monitoring your hydraulic fluid

Rolls-Royce can monitor your hydraulic fluid for you and optimise your maintenance intervals. Hydraulic equipment not in regular use must be checked for bacteria growth before connecting to a hydraulic circuit.

Our periodic oil sampling allows for early discovery of:

  • Water contents
  • Lubricant quality
  • Contamination level

4.  Maintaining cleanliness levels

Do you know what standard of system cleanliness you have? A trained Rolls-Royce technician can find signs of component wear through oil analysis.

The investment in a proactive approach will quickly be recovered through improved performance and reduced operating costs. Vendors including Hägglunds, Rexroth, Danfoss, Parker and Poclain Hydraulics have the same NAS/ISO standard for oil cleanliness. ISO code 17/15/12 or better. (NAS1638 6 or better)

Regular flushing is your assurance of system cleanliness

Cleanliness Level Correction Table

This chart illustrates why operating with hydraulic oil at a cleanliness level below ISO code 17/15/12 can have a significant impact on system performance.

From experience we have found that the quality of new oil can vary. Typically we see ISO code 22/20/17 or NAS 1638 11. Only by flushing as part of the maintenance routine can system cleanliness be assured.

Three sizes of flushing unit are available:

Benefits of the service

  • Increased equipment life - Regular flushing of the system significantly reduces the potential for system failure due to oil contamination, as old oil and residues left in the lines and system, as the reservoir is drained, cannot be easily re moved in another way.

  • Reduced expensive downtime - Using one of our high performance flushing units and trained technician is quick and efficient, helping to minimise downtime.

  • Optimised maintenance intervals - Regular oil sampling and analysis provides an effective, preventive maintenance programme.

  • Reduced maintenance costs & improved productivity - The cost of new oil is saved as it can be recovered, filtered and reused after flushing. Clean oil ensures consistent machine performance with reduced down time.

  • Consistent quality and safety - All units are equipped with inline laser particle counters & oil sampling, and have level/ pressure monitoring with automatic shutdown on adjustable set values.