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Hydraulic System Pre-Start-Up Commissioning Guide

Hydraulic System Pre-Start-Up Commissioning Guide


Hydraulic System Pre-Start-Up Commissioning Guide

In order for a hydraulic system to work healthily and safely, some checks must be made before commissioning. The following steps allow you to complete this process without any problems.

Checks to be Done Before Commissioning

  1. Cleaning Condition:
  • Is the hydraulic tank completely cleaned?
  • Are the pipelines properly laid and cleaned?
  • If your system has a servo or proportional valve, filtration and flushing should be applied until the pipes reach the desired cleaning level.
  1. Mechanical Controls:
  • Are all fasteners and flanges firmly assembled?
  • Is the piping correctly connected according to the hydraulic circuit diagram?
  1. If Accumulator (Hydraulic Battery):
  • Is the battery filled with nitrogen (Nitrogen) in accordance with the project values?
  • Make sure that the oil side of the system  is depressurized during nitrogen filling  .
  • Has the prefill pressure (p₀) reached the value indicated in the circuit diagram?
  • Labeling the gas pressure value on the battery and adding it to the circuit diagram makes it easier to make comparisons in the future.

Note: Only Nitrogen (Nitrogen) gas should be used.

  1. Pump-Motor Compatibility:
  • Are the motor and pump properly coupled?
  • Are the shaft axes aligned and the coupling settings set properly?
  1. Filtration Controls:
  • Are filters installed in accordance with the filter ratings specified in the circuit diagram?
  • Is the installation direction of the filters correct?
  • Is there enough hydraulic oil added to the tank?
  • The oil must be filled into the tank, not directly, but by passing it through the filter.
  • The filling filter used must be as fine as the most sensitive filter in the system.

Start-up Steps

  1. Loosen all pressure relief and reducing valves. (Excl. TÜV regulated valves)
  2. Open the suction valve of the pump.
  3. If necessary, fill the pump housing with oil via the lekage line. In this way, you avoid dry running.
  4. Check the pump rotation direction by running the main motor briefly. Is it turning in the right direction?
  5. If there is a pilot pump in the system, test it in a similar way.
  6. According to the circuit diagram, gradually increase the pressure setting of the main safety valve.
  7. Operate the system and observe for oil leaks. If there is a leak, stop the system and tighten after the pressure has been completely relieved.
  8. If there is a variable flow pressure regulated pump, make sure that the safety valve setting is 15%–20% higher than the pressure setting on the pump.
  9. Listen to the sound coming from the pump. If you hear an unusual sound, stop the system.
  10. After the actuators have worked, check the oil level in the tank again.

Performing these steps carefully will both extend the life of the system and prevent possible malfunctions. Remember, proper commissioning is the basis for the healthy operation of a system.