How can you improve hydraulic system reliability and efficiency?

Hydraulic systems are essential for the operation of various aircraft components, such as landing gear, brakes, flaps, and flight controls. They provide high power and precise control with minimal weight and space. However, they also pose some challenges for reliability and efficiency, such as fluid contamination, leakage, pressure loss, and heat generation. In this article, you will learn some tips and best practices to improve your hydraulic system performance and reduce maintenance costs.

1 Choose the right fluid

The type and quality of the hydraulic fluid can have a significant impact on the system reliability and efficiency. You should choose a fluid that meets the specifications and requirements of your aircraft manufacturer and the hydraulic components. The fluid should have the appropriate viscosity, lubricity, corrosion resistance, thermal stability, and compatibility with seals and hoses. You should also monitor the fluid condition regularly and replace it when necessary to prevent contamination, degradation, or oxidation.

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Arun Arora

DY. G.M ENGINEERING at AIR INDIA LIMITED (Retd)
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Always use hydraulic fluid as recommended by the Manufacturer. Fluid checking and replacement be done as per Maintenance manual guidelines with proper flushing of lines. Proper Rig and sealed fluid cans to be used.

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2 Maintain the filters and seals

The filters and seals are critical components to prevent contamination and leakage in the hydraulic system. You should inspect them regularly and replace them according to the recommended intervals or whenever they show signs of wear, damage, or clogging. You should also ensure that the filters and seals are compatible with the hydraulic fluid and the operating temperature and pressure. By maintaining the filters and seals, you can extend the life of the hydraulic components, improve the fluid quality, and reduce the risk of system failure.

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Arun Arora

DY. G.M ENGINEERING at AIR INDIA LIMITED (Retd)
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Use right part number of Filter and Seals. Be vigilant on Filter pop out button. Do not reuse filters unless recommended maintenance manual. Do not reuse seals.

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3 Optimize the piping and fittings

The piping and fittings are the conduits that transport the hydraulic fluid from the pump to the actuators and back to the reservoir. You should optimize the piping and fittings design and installation to improve the hydraulic system reliability and efficiency. You should use the appropriate size, material, and shape of the piping and fittings to minimize pressure loss, friction, turbulence, and vibration. You should also avoid unnecessary bends, joints, or restrictions that can cause flow resistance or leakage. Additionally, you should secure the piping and fittings properly to prevent damage or loosening due to vibration or thermal expansion.

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Rajat Pandey

Marine, Shipbuilding & Defense Consultant | Past - L&T, Reliance Naval | Ex- Indian Navy
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Pipe internal surface smoothness plays a vital role. Flow resistance, Temperature rise, debris generation, hydraulic fluid contamination etc is mostly due poor surface of pipe internals. We must work on it to have a healthy Hydraulic system. Internal coating, Electropolishing are some of the solutions.

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Arun Arora

DY. G.M ENGINEERING at AIR INDIA LIMITED (Retd)
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Hydraulic pipelines should be made of material as specified by the manufacturer. Lines should be properly pressure tested. Lines to be checked for Cleating and chaffing periodically. Flexible hoses to be installed properly without twist or kink. All nuts to be corrected torqued as specified in manual.

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4 Monitor the pressure and temperature

The pressure and temperature are key parameters that affect the hydraulic system performance and efficiency. You should monitor them regularly and adjust them as needed to suit the operating conditions and the hydraulic components. You should avoid excessive or insufficient pressure that can cause system instability, component wear, or fluid cavitation. You should also avoid excessive or insufficient temperature that can cause fluid degradation, viscosity changes, or seal failure. You can use pressure regulators, relief valves, accumulators, coolers, or heaters to control the pressure and temperature of the hydraulic system.

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Rajat Pandey

Marine, Shipbuilding & Defense Consultant | Past - L&T, Reliance Naval | Ex- Indian Navy
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Temperature and Pressure of a system at various points are good indicator of system health in a given state of operation. Variation in these parameters needs to be analyzed. Solution to rise of temperature does not lie in providing extra cooling. We must analyze as to why temperature has risen up else the extra cooling is not going to help at the problem point of temperature rise.

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Arun Arora

DY. G.M ENGINEERING at AIR INDIA LIMITED (Retd)
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Pressure and Temperature to be monitored either in cockpit warning or during periodic checks. Also ensure proper fluid level.

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5 Perform preventive maintenance

Preventive maintenance is essential to improve the hydraulic system reliability and efficiency. You should perform preventive maintenance according to the manufacturer's recommendations and the system condition. You should check the hydraulic system for any signs of leakage, contamination, wear, damage, or malfunction. You should also clean, lubricate, and test the hydraulic components regularly. By performing preventive maintenance, you can detect and correct any problems before they become serious, reduce downtime, and enhance safety.

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Arun Arora

DY. G.M ENGINEERING at AIR INDIA LIMITED (Retd)
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Perform periodic checks as per manufacture . Frequent inspections at areas more susceptible to leak or damage as per your experience.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you improve hydraulic system reliability and efficiency?

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1 Choose the right fluid

2 Maintain the filters and seals

3 Optimize the piping and fittings

4 Monitor the pressure and temperature

5 Perform preventive maintenance

6 Here’s what else to consider

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