Oil Analysis

Informative Oil Analysis

Contamination, mixing and oil ageing: Professional oil analyses ensure that problems with the oil are detected at an early stage and rectified before they lead to wear and machine downtimes. The HANSA-FLEX fluid experts carry out their tests either directly on site or in the laboratory, provide their recommendations and implement suitable measures. They can also install oil condition sensors for continuous fluid monitoring.

Systematic oil analyses

Adopt a systematic approach based on comprehensive oil analyses

Determine all the information about the oil

A check of your hydraulic system including a professional oil analysis provides all the important information about your fluid, such as contamination, mixing and ageing. The cleanliness level of the oil is also measured in accordance with ISO 4406. The oil analysis is carried out by an accredited and certified independent laboratory. The HANSA-FLEX fluid experts interpret the results and produce specific recommendations. In this way you can rectify faults exactly before they develop and lead to damage.

Systematic damage detection

When damage occurs, you need to act fast. Experienced HANSA-FLEX fluid and hydraulic experts search for the causes directly on site and immediately carry out a professional oil analysis. The results form the basis for detecting damage to components such as pumps, cylinders, hose lines and filters. The experts then derive the specific measures required to get your system up and running again. We can also plan and manage other jobs to ensure your system runs smoothly in the long term, such as installing filters or cleaning the hydraulics. We also support you in the implementation of preventive maintenance measures.

Comprehensive fluid management

Your oil analysis forms the basis for optimising your system. It indicates possible weak points and helps you to rectify them in good time. The HANSA-FLEX Fluid Service can implement further processes as part of fluid management, in addition to carrying out various measures such as cleaning or drying the hydraulic oil. From determining the timing of oil maintenance processes to deciding on service intervals, from monitoring the results of the measures to employee training: the experienced fluid and hydraulic experts at HANSA-FLEX are always available to answer questions and provide information about fluid management.

Contaminated fluid

These five factors damage hydraulic oil

Contamination with solids

Contamination of the hydraulic oil with solids such as dust or metal or seal particles is one of the most frequent causes of damage. The source of the particles may be unfiltered fresh oil, inadequate filter design, an inadequately filled tank, wear of components or the ingress of dirt particles during assembly. The first step in rectifying this problem is to examine the whole system, including the use of on-site particle counters if necessary. By doing this, you can be absolutely sure of the cause of the damage and take exactly the measures required to prevent the ingress of dirt, such as installing filter systems.

Water contamination

Contamination of the hydraulic oil with water leads to corrosion, cavitation, sludge formation or premature ageing of the oil. Water contamination can be caused by condensation, oil-water coolers, cleaning with steam jets, strong temperature fluctuations, ingress of spray water or defective cylinder seals. To prevent contamination of the hydraulic oil with water, the HANSA-FLEX Fluid Service first carries out an intensive examination of the entire hydraulic system to find the possible causes. The experts then draw up a list of suitable measures, such as the use of drier breathers or vacuum dewatering systems, and implement them if you wish.

Undissolved air

Too little oil in the tank, leaking suction lines to the pump or inadequate deaeration: too much undissolved air in the hydraulic oil can lead to component damage. Hydraulic oil enriched with air tends to age prematurely. There is also the risk that the bubbles in the oil-gas mixture will implode (cavitation) or detonate under too much compression (diesel effect) due to pressure and temperature peaks. From the design of the oil tank to the selection of the right fluid and checking the effectiveness of the deaeration components: the experienced fluid and hydraulic experts from HANSA-FLEX will advise you on how to avoid oxidation, cavitation or micro-diesel effects.

High temperatures and shear

Excessive operating temperatures reduce the performance of the hydraulic oil. The consequences: ineffective additives, accelerated ageing of the oil, formation of acid in the oil and, not least, damage to components. Excessive pressure and temperature peaks lead to overstressing of the fluid. Overstressing tears apart the molecule chains in the oil, which has a negative effect on the flow properties. This can also lead to the additives losing their effect, shorter oil change intervals and increased wear on the components. Monitoring the temperature and pressure, either as part of an oil analysis or using sensors, can be helpful in preventing the harmful effects of high temperatures.

Oil mixing

Mixing different hydraulic oils often leads to a deterioration of their physical properties. Mixing often occurs unintentionally during filling, removing or reinstalling equipment or changing the oil. Even combinations of oils of the same classification can cause swelling of elastomeric components and hydraulic hose lines, foam formation, less effective deaeration or sludge formation in the oil. Mixing hydraulic oils also results in the loss of all rights under the machine manufacturer’s warranty. No oil combination is guaranteed to be 100% trouble-free. For this reason, you should always avoid mixing different oils.

Professional Oil Analyses from Experts

A professional oil analysis from the HANSA-FLEX Fluid Service reveals all the important information contained in your hydraulic oil

Perfect analysis

Oil analyses in the laboratory or on site provide precise information about the condition of the oil and the machine.

 

Reliable fault detection

Faults such as oil mixing, contamination or water in the oil are detected immediately.

 

Oil change timing

The optimum oil change interval is determined individually for each machine or plant.

 

Guaranteed quality

Quality checks after oil changes and fulfilment of warranty services.

 

Keep an eye on your oil with condition monitoring

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  • Current condition analysis and basic planning
  • Determination of limit values to meet hydraulic system requirements
  • Selection and installation of oil condition sensors
  • Configuration and set-up of data transmission paths
  • Evaluation and interpretation of measured values
  • Manufacture and installation of alarm devices etc.