Hydraulic System Installation, Commissioning And Maintenance

Technical Preparations Before Installation

1) Preparation and Familiarization with Technical Materials

Gather and study all necessary documents, including:

· Hydraulic system schematics.

· Electrical schematics.

· Pipeline layout drawings.

· Lists of hydraulic components, auxiliary parts, and fittings.

· Relevant component catalogs and specifications.

These materials should be complete to allow engineering personnel to understand and study the specific requirements in detail.

2) Material Preparation

Verify the quantity and quality of hydraulic components according to the hydraulic system diagram and parts list.

· Conduct a thorough inspection of pressure gauges to ensure they meet quality standards.

· Confirm the calibration date of each pressure gauge, and recalibrate gauges with outdated inspection records to guarantee accuracy.

3) Quality Inspection

Hydraulic components are prone to contamination and corrosion during transportation or storage. Extended storage times may lead to seal aging, causing loss of sealing performance. Some components may have poor performance due to subpar manufacturing or assembly. A strict quality inspection is therefore necessary.

A) Inspection of Hydraulic Components

1. Ensure all hydraulic components match the part numbers and specifications on the component list.

2. Verify the storage duration and environment of each component. Inspect the condition of internal seals for aging, and perform cleaning, replacement, or performance testing as needed.

3. Check that adjustment screws, handwheels, and lock nuts on each hydraulic component are intact and undamaged.

4. Ensure the surface quality of any attached seals meets standards; replace any defective seals.

5. Plate-mounted components should have defect-free connection surfaces. The machining accuracy of seal groove dimensions must meet relevant standards.

6. Threaded ports on tube-connected components must be free of damage or loose threads.

7. Mounting surfaces of base plates for modular valves must be smooth and free from defects. Threads should also be intact.

8. Remove plugs from oil ports and inspect the cleanliness of the internal components.

9. Inspect the solenoid cores and external quality of solenoid valves. Do not use components showing defects.

10. Verify that all accessories attached to hydraulic components are complete.

B) Inspection of Hydraulic Auxiliary Components

1. The oil tank must meet specified quality requirements, and all accessories should be intact. Ensure the interior of the tank is free of rust and thoroughly cleaned before filling with oil.

2. Filter models and specifications must conform to design requirements. Verify filter element precision, confirm there are no defects, and inspect threaded connections for damage. Accessories must be complete.

3. Inspect all seals for surface quality, and check the storage duration. Do not use seals with defects or those stored beyond their recommended period.

4. Accumulators must meet quality standards and include all required accessories. Inspect the storage duration of accumulators, and perform strict quality checks on those stored for extended periods. Do not use accumulators that fail to meet technical specifications or usage requirements.

B) Inspection of Hydraulic Auxiliary Components

1. Oil Tank
The oil tank must meet the specified quality requirements, and all accessories must be intact. The interior of the tank must be free of rust and thoroughly cleaned before adding oil.

2. Oil Filter
The model and specifications of the filter must comply with design requirements. Verify the filter element's precision level, ensure it has no defects, and confirm that threaded connections are undamaged. All accompanying accessories must be complete.

3. Seals
The surface quality of all seals must meet the required standards. Check the storage duration of the seals. Do not use seals with defects or those stored beyond their recommended period.

4. Accumulator
The accumulator must meet quality standards and include all required accessories. Check the storage duration of accumulators, and strictly inspect those stored for extended periods. Do not use accumulators that fail to meet technical specifications or usage requirements.

5. Air Filter
Air filters are used to filter dust from the air and must not create excessive airflow resistance to maintain atmospheric pressure inside the tank. The air filter must have sufficient air-passing capacity.

C) Inspection of Pipes and Fittings

The pressure rating of pipe fittings must meet design requirements.

a) Pipes
The material, diameter, wall thickness, model, and quality of fittings must comply with design specifications. Do not use pipes with the following defects:

1. Corrosion or significant discoloration on the inner or outer surfaces.

2. Surface cracks or scratches exceeding 10% of the pipe wall thickness.

3. Small holes in the pipe wall.

4. Dents on the pipe surface exceeding 10% of the pipe diameter.

b) Bent Pipes
Bent pipes must not be used if the following defects are present:

1. Irregular or jagged curves on the inner or outer surfaces of the bend.

2. Ovality of the bend exceeding 10%.

3. The minimum outer diameter at the flattened bend is less than 70% of the original pipe's outer diameter.

c) Fittings
Fittings must be free of defects. Do not use fittings with the following issues:

1. Scratches, burrs, or damaged threads on the fitting body or nut.

2. Poor machining accuracy on joint surfaces that fails to meet technical requirements.

3. Loose or stuck threads between the fitting body and nut.

4. Incorrect groove dimensions or machining precision for seal installation.

d) Hoses and Connectors
Do not use hoses or connectors with the following defects:

1. Surface damage or signs of aging on the hose.

2. Corrosion on the connector body.

3. Scratches, burrs, damaged threads, or loose/stuck fittings.

e) Flanges
Do not use flanges with the following defects:

1. Air holes, cracks, burrs, or radial grooves on the sealing surface.

2. Incorrect dimensions or machining precision of the sealing groove that do not meet design requirements.

3. Defects on metal sealing gaskets for the flange. The gasket material's hardness must be lower than that of the flange.