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Hydraulic oil pollution and hazards
Oil contamination can occur in several ways, and it's crucial to understand how water, impurities, and air can enter the system.
First, water can mix with oil through various pathways. One common source is condensation inside the fuel tank due to temperature fluctuations. When warm air cools, moisture forms as droplets on the tank cover. Another cause is damage to seals or cracks in cooling systems, allowing water to leak into the oil. Additionally, damp air entering through the hydraulic cylinder rod seal can condense into water droplets. Lastly, human handling or exposure of the oil to moist environments can also introduce water into the system.
The presence of water in oil can be very harmful. When water mixes with hydraulic oil, it can cause emulsification, making the oil appear cloudy or milky. If the oil has poor anti-emulsification properties, the water may not separate, leading to long-term cloudiness. This contaminated oil can cause internal rusting of hydraulic components, reduce lubrication efficiency, and increase wear. Rust particles can circulate throughout the system, causing more damage. Water can also react with additives in the oil, forming sludge and other contaminants that speed up oil degradation. In addition, sulfur and chlorine in the water can produce acids, increasing abrasive wear and accelerating oxidation. These contaminants act as catalysts for further deterioration, potentially clogging components and causing system malfunctions. At low temperatures, water can freeze into ice particles, which can block small passages in control valves.
Second, oil can become contaminated with solid particles. These particles often come from manufacturing processes, wear during operation, or external sources like dust or dirt. The effects of these impurities are significant. They can damage pumps and motors by causing jams or increasing wear when they get lodged in critical areas. Particles can also harm hydraulic cylinders by wearing down pistons, rods, and seals, leading to leakage and reduced performance. In valves, particulates can cause sticking or blockages, resulting in improper function. Moreover, contaminants can promote bacterial growth, accelerating oil aging and leading to foul odors and further pollution. This cycle can lead to blocked filters, increased friction, and even failure of sensitive components like servo valves.
Third, air can enter the hydraulic system through loose connections, exposed oil surfaces, or faulty seals. When oil is low in the tank, circulation increases, making it harder to remove air bubbles. Air typically enters as small bubbles (0.05–0.5 mm in diameter), which can significantly affect the oil’s volumetric elasticity and viscosity. As pressure rises, some air dissolves, but much remains in the gas phase. Excessive air reduces the oil’s ability to transmit pressure effectively, leading to slower response times, unstable movement, and increased noise. It can also cause cavitation, higher power consumption, and faster oil oxidation. Overall, air contamination compromises the performance and reliability of the entire hydraulic system.