When running hydraulic systems in harsh or extreme conditions, you need to be sure that all the components are up to the job. Extreme conditions for hydraulics include anything from outer space, the deep sea, and harsh industrial environments. All of these fields rely on hydraulics to control and power often very complex systems that are up against elements not encountered in everyday life. In these challenging environments, hydraulic systems must perform flawlessly under intense pressure.
Key Considerations for Hydraulic Systems in Extreme Conditions
Depending on the application of the hydraulic system, you will likely need different levels of durability to make the components manage in those environments. Listed below are the factors that need to be considered.
Corrosive Conditions: Salt Water Environments
One of the harshest environments that we need to consider when it comes to hydraulic equipment is corrosion, particularly in marine and subsea applications. Saltwater can be extremely corrosive, so we need to ensure components are made with corrosion-resistant materials. Without proper protection, hydraulic components can quickly degrade, and this could lead to system failures. Making hydraulic components more resilient to contamination and less maintenance makes the system run longer.
Deep-Sea Challenges
Another challenge that goes hand in hand with marine environments is subsea operations. The deep sea represents one of the most hostile environments for hydraulic systems. At depths of several thousand metres, the pressure is immense – often more than 400 times that at sea level. To handle this, hydraulic components must often be customised or pressure-compensated.
At depths down to 305 metres (1,000 feet), components operate primarily in corrosive saltwater, but with manageable pressure, so they’re easier to handle. Sea life also needs to be considered when designing systems exposed directly to the water.
At depths between 300 and 1,800 metres, water pressure becomes a more serious issue, increasing by about 1 bar every 10 metres. By 5,000 metres, the pressure reaches 500 bar, so all work at these depths is done using remote-controlled robots like ROVs and AUVs. The components used here need special designs to withstand the high pressure. These deep-sea operations are often far from shore, and this makes them more challenging.
Harsh Materials
The presence of harsh materials should also be considered. Certain harsh industrial environments can make hydraulic components more prone to blockages. Take sawmills, for example – sawdust, sap, and wood chips can clog hydraulic systems. This can lead to system malfunctions. Seals and other components need to withstand this.
High Temperatures
High temperatures are another crucial factor to consider. A high-performance car, for example, might need hydraulic components to be very small, yet still be able to handle extreme heat and still operate with high dynamic responses, through a 12 V power supply.
Hydraulic pumps naturally generate heat during operation, but this heat should not exceed 180 °F (82 °C). When temperatures go over this threshold, the system can get damaged. It could cause seals to fail, leading to leaks and clogging in the system. It can also speed up the oxidation of hydraulic fluids, creating sludge and varnish that clog lines and valves. Additionally, heat makes the oil thinner, which reduces lubrication and increases wear. To prevent this, it’s important to use the right fluids and keep the system clean. Adding cooling systems could also be an option to manage the heat.
Low Temperatures
Aerospace environments pose the opposite challenge, with hydraulic systems often exposed to very low temperatures. This has a huge impact on the viscosity of the hydraulic fluid that a hydraulic system needs to move. Oil moves like tar once below a certain temperature. This increased viscosity strains the system and could lead to cavitation and reduced seal performance. Low temperatures also make seals brittle, which can lead to cracking or shrinking. To keep the system working in these conditions, it’s important to use special low-temperature fluids or add heating elements to keep the fluid at the right viscosity.
Extreme Vibration
Harsh industrial environments will often expose hydraulic systems to very high vibrations, leaving them at risk of excessive wear and tear, fatigue, and loss of performance. Components need to be sturdy and manufactured with the strongest materials to be able to withstand this.
How to Get Around These Challenges With Domin’s Technology
At Domin, we are renowned for our ability to adapt our valve technology to fit the precise demands of any condition. Our cutting-edge hydraulic solutions have been selected for ground-breaking projects around the world, from high-performance marine, to aerospace, and industrial manufacturing.
While our standard valves already set the benchmark for innovation, we take pride in collaborating closely with our customers to tailor our class-leading technology to the specific requirements of any application, no matter how extreme the conditions.
