Creating and implementing a productivity strategy takes time and commitment. It involves setting clear goals and mapping out SMART tasks with a timeline for completion. Hydraulics are small in size but mighty in force, transmitting powerful hydraulic energy via pipes and flexible hoses.
Safety
Hydraulic equipment is designed to move heavy weights with force without mechanical gears. This is accomplished using hydraulic pressure created through a simple equation: Force / Area. Aside from their superior power, hydraulic systems offer additional safety features that can help reduce the risk of injury. For example, hydraulics are often used in machinery that operates under high temperatures. Traditional mineral oil poses a fire threat in this environment, so many steel mills Ashland KY, utilize fire-resistant hydraulic fluid. In addition, adherence to lockout procedures is a crucial component of safe machine operation and maintenance. Properly depressurizing a system before replacing a fitting or hose prevents the sudden release of hydraulic energy that could cause injury. This practice also minimizes the likelihood of an explosion inside a cylinder or accumulator.
Reliability
Hydraulic systems offer a unique power density, making them an ideal choice for steel production. Hydraulic system components can also multi-task accurately, unlike mechanical gears or levers that must operate independently. Roller adjusting cylinders are good examples of this, capable of high forces and precise control accuracies that make them useful for many steel mill tasks. Fire risk is a major concern in a steel mill environment, particularly with mineral oil hydraulic fluids. This hydraulic system is susceptible to ignition from extreme heat and requires a special flame-retardant liquid to reduce the fire risk. Steer skid loaders are another example of a hydraulic industrial system that uses the same fire-resistant fluid to prevent fires and other hazards. Hydraulic systems are small power sources with tremendous force, so they must be treated like any other energy source in the workplace, with appropriate safety procedures and training to ensure they are used safely.
Efficiency
Unlike manual gears, pulleys and levers, hydraulic systems convert mechanical power into fluid-based energy to move machines. This energy is transferred to actuators and motors, then back to a reservoir where it’s filtered, re-pumped and ready to be used again. This cycle of work and return is called a hydraulic circuit. Hydraulic systems operate in hot environments and must perform reliably without contributing to fire hazards like leaking oil or cylinder failures. Water-based hydraulic systems offer obvious fire resistance and a cost advantage over traditional mineral oil. The water-based hydraulic fluid consists of 10 parts water and one part synthetic additive, which means fewer gallons are needed for the same amount of work, and the non-toxic, biodegradable solution costs less to store and transport. Leaking hydraulic equipment, hoses and valves pose safety risks for workers who may come into contact with the fluid media, which can be toxic or poisonous if ingested. It’s also combustible, so flammability precautions and safe storage tanks are required. As a hazard source, hydraulic power must be controlled and tagged out for maintenance like any other hazard, per OSHA’s Lockout/Tagout standards.
Maintenance
The equipment a steel company spends money on requires consistent maintenance to prevent breakdowns that lead to downtime and lost productivity. Maintenance technicians clear clogs and corrosion and repair or replace worn-out parts.
All mechanical systems degrade and fail eventually. But when they fail, they can transfer stress to other parts that become more likely to fail. Keeping hydraulic systems at peak performance reduces failure rates. Hydraulic systems are popular in large industrial settings because they create movement and force with little energy. However, that small amount of energy can still do great harm if it’s not properly controlled, so it’s important to have a robust safety program and lockout/tagout training for any machine containing hydraulic energy. Hydraulic systems include a diesel engine that motorizes a pump to pressurize hydraulic oil. Then, a series of tubes or flexible hoses connect the pump to other components. Some designs include accumulators and reservoirs to store hydraulic oil.
