Why do Hydraulic System Leaks?

Leaking is an inherent problem in a hydraulic system. It is very essential to combat the problem of hydraulic plumbing leaks so as to achieve the maximum efficiency and reliability of performance of a hydraulic system. In order to maintain a leak-free system, it is necessary to check for the possible causes of leaks which should be properly repaired or upgraded using proper hydraulic seals and other materials.

Main Reasons for Hydraulic System Leaks

Pipe Threads
Almost all hydraulic machines, systems used in the industry today are using threaded pipes, which are considered to be unreliable for high-pressure fluids. This is because the thread itself is the cause of a leak path. The threaded pipes are deformed when tightened, and hence with movement like tightening or loosening lead to an increase in the chances for leaks. To achieve leak-free performance, it is better that hydraulic system should not use pipe thread connections and these should be replaced with soft seal connections. Working under above normal temperatures
A slight change in temperature leading to a high temperature situation can permanently damage all the seals in an entire hydraulic system. This can result into many leaks. Moreover if the hydraulic system is operated for long hours in the above normal temperature, it can also lead to leaks. That is why when seals are replaced, it is necessary to see that the system temperature is brought under control. This is done by considering the generation and dissipation of heat or by installing a heat exchanger before replacing seals. At the same time, it is also necessary to replace all hardened seals.

Vibration
In a hydraulic system, fluid power is used to exert power and force into the system. This is also applied to provide actuator movement. This results into vibration, which can badly affect the torque on plumbing connections. In such cases, metal fatigue is produced. The root cause of the vibration should be addressed if possible. The best way to handle this problem is to properly secure the equipment to the floor. Proper design, and supporting of plumbing lines will help in achieving leak-free service, even in the most severe applications. You can install a well-secured junction block between a moving hose and a pipe or tube. It is also necessary that there should be vibration dampening clamps in rigid lines.

Improper Torque on Fittings
All metal-to-metal connections are sensitive to excessive torque. In most cases, there is no proper torque loading on fittings. Torque loading requires using the correct torque setting. Tubing and fittings are easily damaged if the metal faces are cold-worked against each other. This leads to flared tubing. Cold forming tends to cause metal to become less elastic and thereby the problem of leaking arises.

Improper Installation and Maintenance
This is one of the main cause for hydraulic system leakage. It is a common thing in most hydraulic systems, tube bending and fabrication is not done in a proper way. And hence you do not get properly supported and aligned connections. Misalignment causes strain on the tubing, which can lead to leakage.